Arab J Sci Eng
DOI 10.1007/s13369-017-2915-2
RESEARCH ARTICLE - MECHANICAL ENGINEERING
Application of Parallel Multi-model Simulation Method
for Condition Monitoring of a Power Hydraulic System
Santosh Kr. Mishra1 · Jay Prakash Tripathi2 · J. Das1 · Sanjoy K. Ghoshal2
Received: 28 November 2016 / Accepted: 24 October 2017
© King Fahd University of Petroleum & Minerals 2017
Abstract In hydraulic system, the occurrence of fault is a
common phenomenon which mainly results due to abnormal
behavior of its decisive components leading to sudden alarm-
ing rise in some of its critical parameters, and hence, the need
for condition monitoring techniques arises. Residuals which
happen to be an indicator of faulty signal are equivalent to
the number of sensors set up in the plant. Hence, the need
is to place in considerable number of sensors throughout the
plant to create residuals, a prime requisite required for isolat-
ing fault. But it appears a tedious task and seems technically
improbable to isolate all potential faults with the instruments
at our disposal, and it can turn out to be an expensive affair
to put inexact number of sensors in order to evaluate indi-
vidually every physical state. To tackle with such problem,
an already-developed methodology has been implemented on
the test setup, i.e., a closed-loop hydrostatic transmission sys-
tem consisting of a variable-displacement pump and a fixed
displacement motor. In this way, an experimental exposure
is added to the revisited methodology which was lacking.
Moreover, the parameter estimation technique in the revis-
B Santosh Kr. Mishra
apsantoshmishra@gmail.com
Jay Prakash Tripathi
jay@mece.ism.ac.in
J. Das
jayanta_mech_engg@yahoo.co.in
Sanjoy K. Ghoshal
sanjoy.ghoshal@gmail.com
1 Department of Mining Machinery Engineering, Indian
Institute of Technology (ISM), Dhanbad 826004, India
2 Department of Mechanical Engineering, Indian Institute of
Technology (ISM), Dhanbad 826004, India
ited methodology is modified to tackle with the situations
where the generation of symbolic expression for estimating
the suspected parameters is not trivial due to nonlinearity
in equation. Therefore, the estimation problem is resolved
numerically in Simulink. Due to same reason of the absence
of symbolic expression, the observer-based residual is gen-
erated instead of ARR-based residual.
Keywords Hydrostatic transmission system · Parameter
estimation · Condition monitoring · Residual · Fault
signature matrix
1 Introduction
The use of hydraulic system in heavy earth moving machiner-
ies (HEMM) can be felt widespread in automotive, agricul-
tural as well as mining sectors. The type of transmission
system employed in such HEMM is continuous transmission
system. Hydrostatic transmission system (HST) is one among
these transmissions which has found tremendous application
because of its special features. These include high power-
to-weight ratio, continuously varying output speed, ease of
operation and remarkable control. It is quite evident that these
HEMM are supposed to be operating for considerable hours
per day and that too in difficult terrains consisting of low-
lying areas. Under these circumstances, there is high risk of
breaking down of the HEMM due to faulty behavior of some
of its key or critical parameters affecting major or minor
components.
Literatures pertaining where critical parameters severely
affect the performance of the HST systems are discussed sub-
sequently. Dasgupta [1] analyzed the effect of some critical
parameters on the functioning of a HST. The HST under study
or investigation focused on steady-state response which con-
123

Fig. 1 Experimental test setup (overall circuit)
tained an orbital rotor (low-speed high-torque hydrostatic
motor) and pressure-compensated swash plate-controlled
variable-displacement pump. He also examined the effect on
the swash plate angle caused by the variation in the torque of
the output shaft and ultimately identified the leakage of the
system. Fisher [2] studied the flow characteristics, restoring
moment and load capacity related to the swash plate consid-
ering the parallel and tilted positions of the slipper. Bergada
et al. [3] proposed that the swash plate angle happens to be
the main contributing factor in the variation of cylinder pres-
sure ripple which means that by the reduction of the swash
plate angle, pressure ripple would be reduced. They devised
that the output pressure was mainly responsible for the pres-
sure ripple which in turn results due to variation of turning
speed and swash plate angle. Hence, it is apparent from the
above discussion that critical parameters greatly influence
the operation of HST and any fault or deviation in it can lead
to adverse issues. In order to mitigate these kinds of situa-
tions, the prime need is to put in place desirable measures
through online monitoring ideologies such as fault detection
and isolation (FDI) and fault tolerant control (FTC) which
can provide a viable solution to deal with these kind of issues
and to guarantee an effective, secure and smooth working of
the overall system [4,5].
123
Arab J Sci Eng
FDI techniques basically consist of two phases: raising
of alarm or sensing fault and isolating the defective part.
The behavior of the system is examined constantly to check
whether fault has occurred or not during the alarm phase.
Immediately after the declaration of fault, the purpose of the
isolation stage is to find out the faulty part or component of
the system. The defective part is being isolated on the basis
of the structural characteristics corresponding to the residual
(errors between sensor and observer outputs). The residuals
are tracked in real time in order to detect the fault expe-
rienced by the overall system. They assume approximately
close to zero value during regular working conditions; other-
wise, under defective conditions, they have nonzero values.
The residuals may be generated either through observers or
through parity relations [6]. Once fault is indicated by resid-
ual, a binary fault signature matrix (FSM) is employed to
localize the fault between different components of the system
[4,7–9]. FSM is basically a table composed of residuals in
the column side and vulnerable parameters in the row side. It
comprises values which are of Boolean nature, e.g., a value of
1 in the row representing parameters sensitivity corresponds
to the residual’s sensitiveness whereas a value of 0 represents
its insensitiveness.
Arab J Sci Eng

Table 1 List of components used in test setup fault [8–10]. Another method of fault localization among the
S/n Item description parameters sensitive to unstructured residuals without opti-
mization is presented in [11]. But, it is only valid with the
1 Electric motor assumption that only one component of the system can be
2 Variable-displacement pump faulty at a time (single fault hypothesis). In this method, non-
3 Charge pump isolable fault candidates (parameters) belonging to a specific
4 Pressure transducer (system) fault subspace are estimated from analytical redundancy rela-
5 LSHT motor tions (ARR) involving the corresponding parameters, and
6 Gear box (1:20) then, they are used in specifically designated fault models in
7 Loading pump which nominal parameter values are used for all other com-
8 Pressure relief valve ponents. Then separate models incorporating these estimated
9 Flow transducer (inlet) values are simulated parallely with the plant once the fault in
10 Flow transducer (outlet) the system is detected. Thereafter, the contrast linked with the
11 Pressure transducer (outlet) model behaviors guides to ascertain the faulty parameters.
12 Speed indicator (electric motor The motivation for carrying out this work is drawn from
13 Torque indicator (electric motor) the application of the HEMM in mining as well as in low-
14 Flow indicator (motor return) lying areas, where due to malfunctioning of some critical
15 Pressure indicator (system)
components, process failures are faced. Hence, there arises
the need of the utilization of FDI and FTC techniques which
16 Flow indicator (motor inlet)
can help in the detection and isolation of the defective com-
17 Speed indicator (motor)
ponents such that the normal working of the machinery is
18 Torque indicator (motor)
restored. The defective part is being localized on the basis
19 Computer with cRIO
of the structural characteristics corresponding to the resid-
20 Swash plate command signal
ual (errors between sensor and observer outputs) with the
21 Pressure relief valve command
help of FSM. The work of fault localization via multi-model
simulation as reported in this article is motivated by the fact
that it appears a tedious task and seems technically improb-
In order to have clear demarcation regarding the localiza- able to isolate all potential faults with the instruments at our
tion of fault, it is of prime importance to generate structured disposal or it can turn out to be an expensive affair to put
residuals (individual residual are considered to be sensitive in exact number of sensors in order to evaluate individually
to a single parameter) which can be accomplished only by every state.
installing many sensors in the whole plant/system. Else all The major contributions of this work are that it provides
the parameters which are sensitive to unstructured residuals the experimental validation of the methodology applied by
are expected to be evaluated through optimization and com- Samantaray and Ghosal [11] which was missing. Addition-
pared to their respective nominal values for localization of ally, the modification in the parameter estimation technique

Fig. 2 Experimental test setup

123

Fig. 3 Electric motor
Fig. 4 Variable-displacement pump
is done to handle the situations in case the generation of sym-
bolic expression of ARR is not trivial due to nonlinearity in
equation. Hence, the estimation problem is resolved numeri-
cally in Simulink and residuals are generated from observer.
2 System Description
The physical system under consideration consists of a
variable-displacement swash plate axial piston pump and
a low-speed high-torque (LSHT) fixed displacement motor.
The flow is catered toward motor via cross line relief block
by means of a swash plate-controlled variable-displacement
pump which is shown in Fig. 1. There is a provision for the
connection of the pump with the motor via return line. In
123
Arab J Sci Eng
order to compensate for the leakage of the system, a small
refilling charge pump is provided which is integral of the
system. The capacity of the charge or feed pump both in
terms of pressure and flow is very small. In order to permit
make-up fluid to reach the main pump via return line, the
cross line relief valve is provided in the circuit which also
keeps the high-pressure side isolated. The make-up circuit
relief valve is designed at the maximum system pressure of
the circuit and has to act according to the necessities of the
main pump. Plenum is considered as the amount of volume
of fluid in-between the outlet of source pump and the inlet of
directional control valve. It is assumed that for the smooth
free working of the motor, surging effect is provided by the
plenum in association with the flexible conduit. The inertial
and viscous loads are driven by the motor.
In the circuit, the nonlinear resistive element comprises the
inlet and outlet ports of distributor valve. Correspondingly,
various elements including leakage paths of motor and pump
which are considered resistive elements whose features are
governed by the supply flow rate and differential pressure
across them. The load used here is an artificial load which is
applied through the relief valve. The load is varied by chang-
ing the cracking pressure of the proportional pressure relief
valve. The designed or maximum pressure of the relief valve
is being set at 110 Bar. The hydraulic fluid after being driven
by means of pump arrive at the hydraulic motor inlet via
high-pressure line and finally gets re-circulated back to the
pump after being returned by the hydraulic motor through
the low-pressure line. The swash plate location influences
the flow reaching the motor by changing the pistons stroke
of the hydraulic pump. Under the conditions of full stroke, the
pistons cover the maximum stroke length possible eventually
leading to the pumping of maximum quantity of fluid. The
response from all the sensors installed in the system is being
Arab J Sci Eng

Fig. 5 Loading arrangement

fed to the input module of the controller (cRIO) which is basi-

cally the data acquisition unit (DAQ) in the setup performing
the dual role of data acquisition as well as controlling the
proportional PRV by varying its resistance. The output sig-
nals or responses that are obtained via the output module of
cRIO comprise command signals to operate swash plate and
pressure relief valve as shown in Fig. 8. The software execu-
tion of the system necessitates configuration of the hardware,
the development of a program relating the I/O device con-
nectivity (namely, sensor input and the proportional valve)
and implantation of it in the panel of field programmable
gate array (FPGA) is basically a device consisting a matrix
of reconfigurable gate array logical circuits and formulating
Fig. 6 Solenoid operated DCV and pressure reducing valve
a frontend graphical user interface (GUI) establishing the
connectivity with respect to closed-loop controller and asso-
ciating it with the access program corresponding to the FPGA variation of command voltage and is shown in Figs. 9, 10 and
I/O. It is feasible to modify the gain values of the controller 11, respectively.
within the block, and the results can be obtained which can The experiment was performed in a closed-loop hydro-
be stored in appropriate data files in the host computer. static transmission basically consisting of a variable-
Figures 2, 3, 4, 5, 6, 7 and 8 show the photographic view displacement swash plate axial piston pump and a low-speed
of the complete hydraulic setup. The test setup has been high-torque motor under LabVIEW environment through
designed quite sturdy to cater the issues relating to various controller (cRIO). NI CompactRIO-based system having
loading problems. 16-bit analog input receives input from the sensors of the
experimental setup and an analog voltage output module in
performs the task to control the REXROTH proportional PRV
and swash plate of variable-displacement pump which is not
3 Experiment Description varied here. The front end GUI along with the embedded con-
troller is being developed in LabVIEW 13.1 which is utilized
The calibration of the components of the experimental setup by the system and implanted in the CompactRIO’s FPGA
was done before performing experiment. The command volt- panel, and by employing the NI LabView FPGA, program is
age was supplied through the cRIO, and the response of the run in real-time environment. The 0–10-V input modules of
measurable properties like system pressure, motor pressure, a cRIO data acquisition system of NI systems are linked with
flow rate, motor rpm, etc., was obtained with respect to the the sensors employed in the setup. The input and output slots

123
 Arab J Sci Eng

Fig. 7 Amplifier card

Fig. 8 Data acquisition system

Fig. 9 Variation of system pressure with command voltage Fig. 10 Variation of flow rate with command voltage

of cRIO are used for configuring the analog input and output analog input blog by the analog input module, and the exe-
operations. The LabVIEW back panel program is shown in cuting signal is sent to the output module via output blog.
Fig. 12. Analog input and analog output block are the basic A ‘while loop’ shown in gray color line in Fig. 12 having a
constituents of the FPGA program. The signal is fed to the ‘stop’ button for stopping the loop confines the program. The

123
Arab J Sci Eng
Fig. 11 Variation of motor speed with command voltage
host program is linked with the FPGA program through ‘visa
resource’ blog. The ‘waveform chart’ is employed to plot the
input and output signals with respect to the elapsed time.
The objective of the experiment was to study the effect in
the speed (rpm) of the LSHT motor shaft due to the enforce-
ment of fault in the pump loading. It was provided by varying
the cracking pressure of the proportional pressure relief valve
through the controller and that happens to the way of impos-
ing fault in the system. The step load was supplied by means
of controller to the solenoid of the proportional PRV, and
correspondingly the shift or variation in speed of the motor
was examined. The sensor responses obtained by varying the
resistances of the load (variation of load is done by propor-
tional PRV as depicted in the loading circuit in Fig. 1) on
Fig. 12 LabView back panel program for data acquisition and PRV control
the system pressure and speed of motor is shown in Figs. 13
and 14, respectively. The front panel utilized for data acqui-
sition work has been provided in Fig. 15. These responses
are being plotted at dissimilar command (being supplied to
the PRV) that monitors the flow and pressure behavior of
the valve and indirectly the viscous friction coefficient Rv as
discussed earlier. As the command voltage gets incremented,
there is increase in resistances also.
3.1 The Hydraulic System Modeling and Experimental
Validation
The paper encompasses developing model of the hydraulic
system in MATLAB–Simulink and validating the model with
the real-time data obtained from the system. The model-
ing of the hydraulic system performed in this investigation
corresponds to the nomenclature along with the parameter
values given in Tables 2 and 3, respectively. The mathemati-
cal model that is finally formulated by the established inputs
provided by the numerical simulation of the dynamic system
provides an insight of the nature of the respective system. The
following assumptions were considered for the formulation
of the dynamic model associated with the system:
• The inertia of the hydraulic fluid has been ignored.
• The nature of the fluid used for the experiment has New-
tonian characteristics.
• Vapor pressure and density of the fluid is not considered
for the analysis of the model
• The outlet pressure is taken as zero.
123

Fig. 13 Variation of experimental plenum pressure with time
Fig. 14 Variation of experimental motor speed with time
• There is prompt response of the unloading relief valve
and the check valves.
• The discharge of fluid from the pump is steady; hence,
for simplicity, the consequence of the flow ripples on the
dynamics of the system is neglected.
• Although the hydraulic system under study is a closed-
loop system, it is simplified into open-loop system for
modeling.
The modeling of hydraulic components has been done
with the help of constraint analytical relations. In this respect,
the variation in the control volume of fluid with respect to
time at pump plenum is given by:
 Ps 1 d Ps
Dp ωp − Cd Ao (Ps − Pm ) − = (1)
Rlkgp pblkstf dt
The external leakage flow of the pump is RPlkgp
s
, where Rlkgp
is the leakage resistance associated with the pump and pblkstf
represents the bulk stiffness of the fluid at pump plenum.
123
Arab J Sci Eng
The volume change rate of fluid at motor plenum is given as:
 Pm 1 d Pm
−Dm ωm + Cd Ao (Ps − Pm ) − = (2)
Rlkgm m blkstf dt
The external leakage flow of the motor is RPlkgm m
, where
Rlkgm is the leakage resistance associated with the hydraulic
motor and m blkstf represents the bulk stiffness of the fluid at
motor plenum.
The net torque experienced:
Dm Pm − Rv ωm − Tld = Jl α (3)
where the first term represents the theoretical torque of the
hydromotor, the second term is the torque loss due to vis-
cous friction coefficient Rv , the third term is the constant
torque loss due to coulomb friction and stiction that is mainly
predominant in case of low speed range of the motor. The
phenomenon of pump loading is equivalently modeled by
the viscous friction resistance (Rv ). The term Jl represents
the inertia load.
The speed of the motor is given by:
Tld
ωm = (4)
Jl
The outlet flow of the loading pump is restricted by varying
the port opening area of the proportional PRV by changing its
cracking pressure. As a result, the full pump flow will not be
able to rotate fully due to the resistance being developed by
the partial closure of flow path by the PRV. This will result in
development of back pressure which is being applied by the
pump on motor which is mainly due to the viscous frictional
coefficient Rv as the fluid in the loading pump is viscous
fluid. Finally, with the variation of load in PRV, the viscous
friction coefficient also varies.
The plant model is allocated zero initial conditions, and
then, only simulation is performed. It should be noted that
the record of number of samples is being maintained from
the point when the initial conditions corresponding to the
observer are found and which is further employed to derive
the history of the process for comparing with the models
which are faulty. Figures 16 and 17 depict the response
obtained from the sensors established in the plant along with
those obtained from simulation. The detailed descriptions
regarding the specifications of the sensors have been pro-
vided in Table 4. The variations in response obtained from
the estimated model and the one obtained experimentally
from plant approximately match with each other. Now, this
validated model can be used for further fault isolation anal-
ysis.
Arab J Sci Eng

Fig. 15 Front panel picture used for data acquisition

Table 2 Nomenclature Table 3 Parameter values used in simulation

Symbol Description Description Values Unit

Alv Port opening area of the proportional PRV Electric motor speed 152 rad/s
Ao Throttle port opening area of check valve Variable-displacement bidirectional pump
Cd Coefficient of discharge Maximum displacement 4.45 × 10−6 m3 /rad
Dp Maximum pump displacement rate used Rotational speed 152 rad/s
in the closed circuit Leakage resistance of pump 1013 Ns/m5
Dm Volume displacement rate of the motor
Bulk stiffness of the pump 5 × 1010 N/m5
Gr Gear ratio
Hydraulic motor
J Generalized inertia of the driving shaft
Maximum displacement 4.45 × 10−5 m3 /rad
and the connected load
Leakage resistance of motor 1011 Ns/m5
Mblkstf Bulk stiffness of the hydraulic motor
Mtrlkg Leakage resistance of the hydraulic motor Bulk stiffness of the motor 5 × 1010 N/m5

MoIGr Total equivalent M.I. of the rotating parts Charge pump

referred to the hydraulic motor axis Maximum displacement 5 × 10−7 m3 /rad
Patm Atmospheric pressure Rotational speed 152 rad/s
Pmpspd Speed of the variable displacement pump Coefficient of discharge 1 –
Pblkstf Bulk stiffness of the driving pump Gear ratio 0.5 (1:20) –
Pmplkg Leakage resistance of the driving pump Nominal fluid density 900 kg/m3
Pm Pressure of the hydromotor Area opening of proportional pressure 8 × 10−10 m2
Ps Recorded system pressure relief valve
Pp Pump plenum pressure Atmospheric pressure 1 × 105 Pa
Plp Loading pump pressure Total equivalent M.I. of the rotating 6.18 Kg m2
parts referred to the hydraulic motor axis
Rv Viscous friction coefficient
Viscous friction coefficient 11.271 Nms/rad
Rl Viscous friction load connected with the
motor end
θ Angle of rotation of the motor shaft
ωem Speed of the electric motor 4 Method for Isolating Fault
Tld Constant loading torque
FSM Fault signature matrix The methodology reported in Samantaray and Ghoshal [11]
HEMM Heavy earth moving machineries has been used for condition monitoring of the HST system
under consideration along with resolving of a new problem

123
 Arab J Sci Eng

Table 4 Specification of the sensors

Components Specifications

Speed sensor
Model S T-60
RPM range 0–500
Accuracy Within 0.1% FSR ± 1 count
Flow sensor
Model TFM-1015
Flow range 2–50 lpm
Accuracy ± 0.5% over 10–100% flow range
Pressure sensor
Model S-10
Pressure range 0–100 Bar
Fig. 16 Comparison between predicted and the experimental pump Accuracy ≤ 0.25%
plenum pressure

Table 5 A depiction showing example of FSM

r1 r2 r3
Mb Ib

ϕ1 1 0 0 1 1

ϕ2 0 1 0 1 1
ϕ3 U 0 0 1 1 0
Up1
ϕ4 0 0 1 1 0
ϕ5 Up
0 1 1 1 0
Up2
ϕ6 0 1 1 1 0
Fig. 17 Comparison between predicted and the experimental motor
speed

where algebraic expressions for generation of residual and
parameter estimation are not available. In order to present a
clear picture of the methodology, it is being again discussed
here.
Suppose the number of sensors corresponds to n and
apparently residuals will also be n in number. The residual
set has been represented by rn . Let U = (ϕ1 , ϕ2 , . . . , ϕm )
denotes the set of parameters and Ud stands for assigned X
dependent parameters. So, the set or space containing inde-
pendent parameters is equal to; Ui = U − Ud . By taking the
help of instruments at our disposal, l (l ≤ m − X ) parame-
ters can be isolated from fault in FSM. Now, the parameters
which cannot be isolated can be put in a subset or subspace
U p (dimension m–X –p) which  happens to be non-empty.
Moreover, suppose n  n  ≤ n residuals, rn  (rn  ⊂ rn ), that
are suspected to be not behaving normally, as per decision
process, are likely to be having multiple similarity in the
FSM. So, U p ⊂ U p comprises the set (if m  refers to their
number) of suspect parameters that are included in every
residual elements of rn  .
Every single parameter φi ∈ U p (i = 1, . . . , m  ) is being
estimated with the idea that the remaining parameters ( j =
1, . . . , m  and i = j) are considered to be nominal. This
ultimately heads to models m  in number that needs to be
solved at the same time.
A FSM shown in Table 5 further explains the definitions
discussed above, where ϕi = 1, . . . , 6 are independently
behaving parameters and r j , j = 1, . . . , 3 represent the
three considered residuals. A variable is monitored (Mb = 1)
when it is present at nothing less than one residual. The
defective parts or components are isolated utilizing FSM
that accounts for the involvement of several constituents in
every residual. The defect in any parameter associated with
the component is isolable (Ib = 1) under the condition that
firstly it should be monitored and its signature as seen in resid-
uals is dissimilar with respect to the remaining variables and
parts/components.
The coherence vector C = [1 0 0] can be assigned these
values in case residual 1 is faulty if at all it has a distinct
signature in the FSM and finally the element representing

123
Arab J Sci Eng
Fig. 18 Block diagram of
condition monitoring process
parameter ϕ1 is considered as isolable and is regarded as a
faulty prospect. In the same way, ϕ2 can be localized under
the condition that residual r2 is behaving abnormally. The
faults associated with remaining parts cannot be isolated, and
hence, a set is constructed as U p = U p1 ∪ U p2 . In the case
of abnormality of residual r3 U p = U p1 , and under the con-
dition if residuals r2 and r3 both are showing abnormality,
U p = U p2 . Based on the concept of single fault hypoth-
esis which is being implemented in the FSM, the starting
step involved in isolating fault furnishes a list of suspected
prospects or candidates  F ∈ [ϕ1 ϕ2 (ϕ3 , ϕ4 ) (ϕ5 , ϕ6 )], in
which further refining is necessary for end two elements via
parameter evaluation. FSM alone is not capable to localize all
the defective elements. The refining process is called second-
level isolation technique. When required instruments are not
available in the system, then only the need arises for higher-
level isolating techniques.
Eventually, in the second-level isolation, the fault isolation
methodology is linked with estimation of process parameters
which are suspected. The recursive parameter estimation is
done in MATLAB–Simulink 2015 framework. These esti-
mated parameters are incorporated in m  parallel Simulink
models and run parallely and the obtained responses are com-
pared with that of the plant. The magnitude of the error among
‘m’ models helps in identifying the faulty parameters. The
minimum error corresponding to a model implies that the sus-
pected parameter which was incorporated after estimation is
only having actual fault. The block diagram of the general
condition monitoring methodology followed has shown in
Fig. 18.
The methodology proposed above is now being imple-
mented in the hydraulic system under consideration to
examine its effectiveness in condition monitoring in a real-
istic situation.
123
 Arab J Sci Eng

5 Implementation in the Hydraulic System

The real plant or test bed is considered and alongside

with it a prototype model of its being developed. A set of
measurements (ωm , Ps ) are obtained from plant and the cor-
responding outputs (ωm , Ps ) are also found out from the
model. Now, the outputs from both plant and simulation
model are compared online, the obtained residual should be
having nominal value. Hence, it is assumed that in this con-
dition, all the components of the plant are in normal working
condition and there is no need to perform the task of fault
isolation as there is no defect. But in certain possible situ-
ations, this may not be the case and there is quite likely of
Fig. 19 Variation of residual response with time corresponding to
variation or deviation of the parameters and they can cross pump plenum pressure
the predefined boundary of threshold values. This implies
that some of the parameters are faulty and isolation process
needs to be implemented. Hence, the necessity is to identify
the suspected variables along with the residuals related with
the system and the construction of FSM with the help of those
residuals to detect fault.

5.1 Generation of Numerical Residual and Construction

of FSM

It is quite clear from Fig. 1 that two sensors are present in the
test setup. Consequently, it is possible to get two residuals.
The residuals deduced from the model are given as below:
Fig. 20 Variation of residual response with time corresponding to
r1 = Ps − Ps (5) motor speed
r2 = ωm − ωm (6)
Table 6 Fault signature matrix Residuals Mb Ib
The normalization of residuals r1 and r2 is done consid- (FSM)
ering the uncertainties linked with the process and is given r1 r2
below:
Parameters
ri |t = tk − i (tk )ηi (u k ) Dp 1 1 1 0
ri |t = tk = (7)
zΦi (u k )σi (u k ) Rlkgp 1 1 1 0
Dm 1 1 1 0
where ri represents the ith residual of kth sample, (tk ) and Rlkgm 1 1 1 0
φ(tk ) represents the time varying coefficients by changing Rv 1 1 1 0
the mean and the variance respectively, u k corresponds to Tld 1 1 1 0
the input, tk represents the time, ηi stands for residual mean
and z is a coefficient associated with the confidence level
[12].
The normalized residual curves corresponding to mea- From FSM, it can be deduced that the parameter subspace
surements shown in Figs. 13 and 14 have been shown in sensitive to residuals r1 and r2 are {Dp , Rlkgp , Dm , Rlkgm ,
Figs. 19 and 20, respectively. In healthy condition, the max- Rv , Tld }. Apparently, only a single parameter of this sub-
imum deviation in normalized residuals lies within ± 1. space can be faulty under single fault hypothesis. However,
Hence, ± 1 is considered as fixed threshold and shown by it is not possible to isolate them with the FSM only (first-
dash line. level isolation as shown in Fig. 18). Hence, the second-level
For isolation of faulty components, the FSM is constructed isolation process is being employed by incorporating the esti-
and is shown in Table 6. Model Builder software [13] can also mated value of the suspected parameters (Dm , Rv ) via two
be employed to build this. parallel operating multi-block Simulink models.

123
Arab J Sci Eng

Fig. 22 Estimation of suspected parameter D̂m

Fig. 21 Simulink model used for estimating Pm from Eq. 9

5.2 Estimation of the Suspected Parameters

The values of the suspected parameters (Dm , Rv ) have been

estimated at steady state to omit the derivative of measured
variables. The steady-state system equation obtained from
Eqs. 1–3 is written in Eqs. 8–10, respectively.

 Ps
Dp ωp − Cd Ao (Ps − Pm ) − =0 (8)
Rlkgp
 Pm
−Dm ωm + Cd Ao (Ps − Pm ) − =0 (9)
Rlkgm
Dm Pm − Rv ωm − Tld = 0 (10)
To solve Dm or Rv from Eq. (10), Pm need to be numeri-
cally evaluated either from Eq. 8 or Eq. 9 and then substituted
in Eq. 10. The algebraic expression of Pm is comparatively
complex if obtained from Eq. 9 rather than Eq. 8. To avoid this
complexity, Pm is obtained numerically in Simulink which is
done quite simply even with Eq. 9 as shown in Fig. 21. It can
be seen that the Simulink model is containing an algebraic
loop. To solve this loop, a loop solving routine is being called
by Simulink software during every time step. The solution
pertaining to the problem is ascertained with the loop solver
by performing iterations.
Based on the estimation, the corresponding values of D̂m
and R̂v corresponding to the model as obtained are given in
Figs. 22 and 23, respectively. From residual plots, the time
Fig. 23 Estimation of suspected parameter R̂v
of occurrence of fault has already been detected. From that
time, a time lag of 2 s is introduced before estimation of the
parameters. This is done in order to obtain the measurement
at steady state. The estimation done under steady-state con-
ditions are shown in Figs. 22 and 23, respectively.
5.3 Fault Isolation Using Multi-Block Parallel
Simulation Method
Until this juncture, the scenario is such that it is possible to
estimate the defective parameters on the basis of the response
got from the residual, but it is not feasible to clearly justify the
right estimation or simply it can be concluded the localization
of fault is not possible. The solution of the problem is pro-
vided by parallel simulation technique [14] which has been
applied here for isolating the fault. The isolation of faults is
possible only by utilizing two models because of the exis-

123

Fig. 24 Estimated error corresponding to D̂m
Fig. 25 Estimated error corresponding to R̂v
tence of two parameters (Rv , Dm ) which are non-isolable.
The estimated values of displacement (Dm ) of hydromotor
have been utilized for isolating the fault in first model with
the consideration that rest of the parameters involved in the
model are having nominal values. The estimated value of
viscous friction coefficient (Rv ) is employed for localizing
second model with the consideration that rest of the parame-
ters involved in the model are having nominal values. If any
fault is detected in the model corresponding to the displace-
ment Dm of hydromotor, the defective nature of the plant
is shown by only the first model, and it is possible to get
zero output error if the comparison is done between eval-
uated outcomes obtained via plant with estimated outcome
obtained from the first model. Applying the same idea to the
second model, i.e., if the defect is in the model linked with
the viscous friction coefficient (Rv ), the defective nature of
the plant is shown by the second model only.
The strategy for executing the formulated architecture
is depicted in Fig. 18 by utilizing two parallel operating
switched Simulink models. These newly observer output val-
ues related to each parameter obtained through multi-block
simulation are compared with the output of the sensors values
established in plant and the variation or deviation between
these obtained values is reported as error. The parameter
corresponding to which minimum error is reported is then
123
Arab J Sci Eng
considered faulty and is finally isolated. The error corre-
sponding to Rv and Dm has been shown in Figs. 24 and
25 respectively.
The estimation of error was carried out at steady state;
therefore, another consecutive time lag of 2 s is introduced.
Hence, the error till 11 s is made forcibly zero so that the tran-
sient state does not come in to the picture. The error plots are
shown in Figs. 24 and 25, respectively. In this case, Rv hap-
pens to be the parameter corresponding to which minimum
error is obtained and consequently it is being isolated.
6 Conclusions
A condition monitoring technique has been put forward
which is based on the concept of parameter evaluation
obtained from residual assuming single fault hypothesis .The
detailed modeling of the entire system has been carried out
in MATLAB–Simulink framework, and regarding experi-
mental validation, LabVIEW has been thoroughly employed
for controlling the proportional PRV by changing its crack-
ing pressure for the imposition of fault and data acquisition
through the available sensors established in the system. The
perspective adopted here follows the strategy that in case
the specified threshold is being crossed by the normalized
residuals, a set containing suspected parameters are located
or spotted. The fault evaluation methodology projected here
adopts a perspective which is based on simple relation rather
than employing algebraic equations, and moreover, the real
fault or defect is not evaluated through a single step. A
second-level isolation process utilizes the plots obtained from
the plant and the ones obtained from the parallel Simulink
models. Besides, due to the use of lesser number of sensors
and nonlinear equation, it was not trivial to have algebraic
equations to generate ARR or to estimate parameters. This
task is achieved numerically for simplicity. Based on results
obtained through simulation which also takes into account
the uncertainty associated with the parameters along with the
noises related to sensors, it has been found that estimation of
the parameters matches with its real value subsequently the
imposition of fault. Distinct models are put to use containing
the values of estimated parameters having zero initial condi-
tions, and then, finally simulation is being done. The isolation
of fault is done only after the attainment of the steady-
state condition, and then, the contrast between the responses
obtained from the plant and simulated model is obtained. The
methodology is quite handy in improving the potential to iso-
late faults in FDI systems in situations if existent instruments
are not adequate enough to localize those faults or defects.
Although the detection of fault takes place instantly, the pro-
cess of isolating the fault is delayed. The methodology has
been implemented in a closed-loop hydrostatic transmission
test setup consisting of a variable-displacement pump and
Arab J Sci Eng

a fixed displacement motor which provides an experimental 8. Samantaray, A.K.; Bouamama, B.O.: Isolation of structurally non-
validation of the proposed technique that can be quite benefi- isolatable faults. Model Based Process Superv. Bond Gr. Approach.
1, 347–372 (2008)
cial in understanding its aspects linked with physical system. 9. Samantaray, A.K.; Ghoshal, S.K.: Sensitivity bond graph approach
to multiple fault isolation through parameter estimation. Proc. Inst.
Mech. Eng. Part I J. Syst. Control Eng. 221(4), 577–587 (2007)
References 10. Borutzky, W.: Isolation of multiple parametric faults from a hybrid
model. In: Borutzky, W (ed.) Bond Graph Model-Based Fault Diag-
nosis of Hybrid Systems, pp. 123–148. Springer, New York (2015)
1. Dasgupta, K.: Analysis of a hydrostatic transmission system using
11. Samantaray, A.K.; Ghoshal, S.K.; Chakraborty, S.; Mukherjee, A.:
low speed high torque hydrostatic motor. Mech. Mach. Theory
Improvements to single-fault isolation using estimated parameters.
359(10), 1481–1499 (2000)
Simulation 81(12), 827–845 (2005)
2. Fischer, M.J.: A Theoretical Determination of Some Characteris-
12. Samantaray, A.K.; Ghoshal, S.K.: Sensitivity bond graph approach
tics of a Tilted Hydrostatic Slipper Bearing. British Hydromechan-
to multiple fault isolation through parameter estimation. Proc. Inst.
ics Research Association, Cambridge (1962)
Mech. Eng. Part I J. Syst. Control Eng. 221(4), 577–587 (2007)
3. Bergada, J.M.; Kumar, S.; Davies, D.L.; Watton, J.: A complete
13. Bouamama, B.O.; Samantaray, A.K.; Medjaher, K.; Staroswiecki,
analysis of axial pump leakage and output flow ripples. Appl. Math.
M.; Dauphin-Tanguy, G.: Model builder using functional and bond
Model. 36(4), 1731–1751 (2012)
graph tools for FDI design. Control Eng. Pract. 13(7), 875–891
4. Wang, D.; Yu, M.; Low, C.B.; Arogeti, S.: Model-Based Health
(2005)
Monitoring of Hybrid Systems. Springer, New York (2013)
14. Ghoshal, S.K.; Samantaray, A.K.; Mukherjee, A.: Improvements to
5. Blanke, M.; Kinnaert, M.; Lunze, J.; et al.: Diagnosis and Fault-
single fault isolation using estimated parameters. In: Proceedings
Tolerant Control. Springer, New York (2010)
of ICBGM’05, pp. 301–306 (2005)
6. Venkatasubramanian, V.; Rengaswamy, R.; Yin, K.; Kavuri, S.N.:
A review of process fault detection and diagnosis. Part 1: quanti-
tative model based methods. Comput. Chem. Eng. 27(3), 293–311
(2003)
7. Bouamama, B.O.; Medjaher, K.; Bayart, M.; Samantaray, A.K.;
Conrard, B.: Fault detection and isolation of smart actuators using
bond graphs and external models. Control Eng. Pract. 13(2), 159–
175 (2005)

123