Anomaly occurrences in hydraulic machinery may lead to massive systems shut down, jeopardizing the safety of the machinery and its surrounding human operator(s) and environment, and the severe economic implications succeeding the faults and their associated damage. Hydraulics are mostly placed in ruthless environments, where they are consistently vulnerable to many faults. Hence, not only the machines and their components are prone to anomalies, but also the sensors attached to them, which monitor and report their health and behavioral changes. In this work, a comprehensive applicational analysis of anomalies in hydraulic systems extracted from a hydraulic test rig is thoroughly achieved. Firstly, we provided a combination of a new architecture of LSTM autoencoders and supervised machine and deep learning methodologies to perform two separate stages of fault detection and diagnosis. The two phases are condensed by: the detection phase using the LSTM autoencoder. Followed by the fault diagnosis phase represented by the classification schema. The previously mentioned framework is applied to both component and sensor faults in hydraulic systems, deployed in the form of two in-depth applicational experiments. Moreover, a thorough literature review of the past decade related work for the two stages separately is successfully conducted in this paper.

In this work, a hybrid component Fault Detection and Diagnosis (FDD) approach for industrial sensor systems is established and analyzed, to provide a hybrid schema that combines the advantages and eliminates the drawbacks of both model-based and data-driven methods of diagnosis. Moreover, it shines the light on a new utilization of Random Forest (RF) together with model-based diagnosis, beyond its ordinary data-driven application. RF is trained and hyperparameter tuned using three-fold cross validation over a random grid of parameters using random search, to finally generate diagnostic graphs as the dynamic, data-driven part of this system. This is followed by translating those graphs into model-based rules in the form of if-else statements, SQL queries or semantic queries such as SPARQL, in order to feed the dynamic rules into a structured model essential for further diagnosis. The RF hyperparameters are consistently updated online using the newly generated sensor data to maintain the dynamicity and accuracy of the generated graphs and rules thereafter. The architecture of the proposed method is demonstrated in a comprehensive manner, and the dynamic rules extraction phase is applied using a case study on condition monitoring of a hydraulic test rig using time-series multivariate sensor readings.

Feature selection is a crucial step to overcome the curse of dimensionality problem in data mining. This work proposes Recursive k-means Silhouette Elimination (RkSE) as a new unsupervised feature selection algorithm to reduce dimensionality in univariate and multivariate time-series datasets. Where k-means clustering is applied recursively to select the cluster representative features, following a unique application of silhouette measure for each cluster and a user-defined threshold as the feature selection or elimination criteria. The proposed method is evaluated on a hydraulic test rig, multi sensor readings in two different fashions: (1) Reduce the dimensionality in a multivariate classification problem using various classifiers of different functionalities. (2) Classification of univariate data in a sliding window scenario, where RkSE is used as a window compression method, to reduce the window dimensionality by selecting the best time points in a sliding window. Moreover, the results are validated using 10-fold cross validation technique. As well as, compared to the results when the classification is pulled directly with no feature selection applied. Additionally, a new taxonomy for k-means based feature selection methods is proposed. The experimental results and observations in the two comprehensive experiments demonstrated in this work reveal the capabilities and accuracy of the proposed method.

In this work, A hybrid component Fault Detection and Diagnosis (FDD) approach for industrial sensor systems is established and analyzed, to provide a hybrid schema that combines the advantages and eliminates the drawbacks of both model-based and data-driven methods of diagnosis. Moreover, spotting the light on a new utilization of Random Forest (RF) together with model-based diagnosis, beyond its ordinary data-driven application. RF is trained and hyperparameter tuned using 3-fold cross-validation over a random grid of parameters using random search, to finally generate diagnostic graphs as the dynamic, data-driven part of this system. Followed by translating those graphs into model-based rules in the form of if-else statements, SQL queries or semantic queries such as SPARQL, in order to feed the dynamic rules into a structured model essential for further diagnosis. The RF hyperparameters are consistently updated online using the newly generated sensor data, in order to maintain the dynamicity and accuracy of the generated graphs and rules thereafter. The architecture of the proposed method is demonstrated in a comprehensive manner, as well as the dynamic rules extraction phase is applied using a case study on condition monitoring of a hydraulic test rig using time series multivariate sensor readings.