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This paper describes an expert system which is designed to perform automatic data analysis, identify anomalous events and determine the characteristic features of these events. We have employed both artificial intelligence and neural net approaches in the design of this expert system.

Neural networks have been employed for learning fault behavior from rocket engine simulator parameters and for diagnosing faults on the basis of the learned behavior. Two problems in applying neural networks to learning and diagnosing faults are (1) the complexity of the sensor data to fault mapping to be modeled by the neural network, which implies difficult and lengthy training procedures; and (2) the lack of sufficient training data to adequately represent the very large number of different types of faults which might occur. Methods are derived and tested in an architecture which addresses these two problems. First, the sensor data to fault mapping is decomposed into three simpler mappings which perform sensor data compression, hypothesis generation, and sensor fusion. Efficient training is performed for each mapping separately. Secondly, the neural network which performs sensor fusion is structured to detect new unknown faults for which training examples were not presented during training. These methods were tested on a task of fault diagnosis by employing rocket engine simulator data. Results indicate that the decomposed neural network architecture can be trained efficiently, can identify faults for which it has been trained, and can detect the occurrence of faults for which it has not been trained.

Transformation of data into knowledge through conceptual induction has been the focus of our research described in this paper. We have developed a Machine Learning System (MLS) to analyze the rocket engine simulation data. MLS can provide to its users fault analysis, characteristics, and conceptual descriptions of faults, and the relationships of attributes and sensors. All the results are critically important in identifying faults.

The goal of the ongoing research described in this paper is to analyze real-time ground test data in order to identify patterns associated with the anomalous engine behavior, and on the basis of this analysis to develop an expert system which detects anomalous engine behavior in the early stages of fault development. A prototype of the expert system has been developed and tested on the high frequency data of two SSME tests, namely Test #901-0516 and Test #904-044. The comparison of our results with the post-test analyses indicates that the expert system detected the presence of the anomalies in a significantly early stage of fault development.

An architecture for a flight expert system (FLES) to assist pilots in monitoring, diagnosing, and recovering from inflight faults is described. A prototype was implemented and an attempt was made to automate the knowledge acquisition process by employing a learning by being told methodology. The scope of acquired knowledge ranges from domain knowledge, including the information about objects and their relationships, to the procedural knowledge associated with the functionality of the mechanisms. AKAS (automatic knowledge acquisition system) is the constructed prototype for demonstration proof of concept, in which the expert directly interfaces with the knowledge acquisition system to ultimately construct the knowledge base for the particular application. The expert talks directly to the system using a natural language restricted only by the extent of the definitions in an analyzer dictionary, i.e., the interface understands a subset of concepts related to a given domain. In this case, the domain is the electrical system of the Boeing 737. Efforts were made to define and employ heuristics as well as algorithmic rules to conceptualize data produced by normal and faulty jet engine behavior examples. These rules were employed in developing the machine learning system (MLS). The input to MLS is examples which contain data of normal and faulty engine behavior and which are obtained from an engine simulation program. MLS first transforms the data into discrete selectors. Partial descriptions formed by those selectors are then generalized or specialized to generate concept descriptions about faults. The concepts are represented in the form of characteristic and discriminant descriptions, which are stored in the knowledge base and are employed to diagnose faults. MLS was successfully tested on jet engine examples.

An expert system is being developed which can detect anomalies in Space Shuttle Main Engine (SSME) sensor data significantly earlier than the redline algorithm currently in use. The training of such an expert system focuses on two approaches which are based on low frequency and high frequency analyses of sensor data. Both approaches are being tested on data from SSME tests and their results compared with the findings of NASA and Rocketdyne experts. Prototype implementations have detected the presence of anomalies earlier than the redline algorithms that are in use currently. It therefore appears that these approaches have the potential of detecting anomalies early eneough to shut down the engine or take other corrective action before severe damage to the engine occurs.

The detection and diagnosis of SSME faults in an early stage is important in order to allow enough time for fault preventive or corrective measurements. Since most of the faults in a complex system like SSME develop rapidly, early detection and diagnosis of faults is critical for the survival of space vehicles. An expert system has been designed for automatic learning, detection, identification, verification, and correction of anomalous propulsion system operations. This paper describes an innovative machine learning approach which is employed for the automatic training of this expert system.

A neural network was trained to distinguish anomalies in Space Shuttle Main Engine sensor data from noisy normal steady-state sensor data. Power spectra of successive windows of individual sensor data were presented to a neural network using Kohonen's topological feature map training algorithm. The trained network for each sensor was then tested to determine if it would detect anomalies in the sensor data, and if so, the time at which the anomaly would be detected. Power spectra from a few hundred seconds of actual test data from NASA tests 901-364 and 904-044 were used to test the network. In both cases, the neural network detected the onset of anomalous engine behavior at approximately the same time within each test as the onset times reported by NASA and Rocketdyne experts in their post-test analyses.

Two problems in applying neural networks to fault detection and identification are (1) the complexity of the sensor data to fault mapping and (2) the lack of sufficient training data. Here, methods are derived and tested in an architecture which addresses these two problems. First, the sensor data to fault mapping is decomposed into three simpler mappings which perform sensor data compression, hypothesis generation, and sensor fusion. Efficient training is performed for each mapping separately. Second, the neural network which performs sensor fusion is structured to detect new unknown faults for which training examples were not presented. These methods were tested on a task of fault detection and identification in the Space Shuttle Main Engine (SSME). Results indicate that the decomposed neural network architecture can be trained efficiently, can identify faults for which it has been trained, and can detect the occurrence of faults for which it has not been trained.

An expert system, called LEADER, has been designed and implemented for automatic learning, detection, identification, verification, and correction of anomalous propulsion system operations in real time. LEADER employs a set of sensors to monitor engine component performance and to detect, identify, and validate abnormalities with respect to varying engine dynamics and behavior. Two diagnostic approaches are adopted in the architecture of LEADER. In the first approach fault diagnosis is performed through learning and identifying engine behavior patterns. LEADER, utilizing this approach, generates few hypotheses about the possible abnormalities. These hypotheses are then validated based on the SSME design and functional knowledge. The second approach directs the processing of engine sensory data and performs reasoning based on the SSME design, functional knowledge, and the deep-level knowledge, i.e., the first principles (physics and mechanics) of SSME subsystems and components. This paper describes LEADER's architecture which integrates a design based reasoning approach with neural network-based fault pattern matching techniques. The fault diagnosis results obtained through the analyses of SSME ground test data are presented and discussed.

This paper describes an expert system which is designed to perform automatic data analysis, identify anomalous events, and determine the characteristic features of these events. We have employed both artificial intelligence and neural net approaches in the design of this expert system. The artificial intelligence approach is useful because it provides (1) the use of human experts' knowledge of sensor behavior and faulty engine conditions in interpreting data; (2) the use of engine design knowledge and physical sensor locations in establishing relationships among the events of multiple sensors; (3) the use of stored analysis of past data of faulty engine conditions; and (4) the use of knowledge-based reasoning in distinguishing sensor failure from actual faults. The neural network approach appears promising because neural nets (1) can be trained on extremely noisy data and produce classifications which are more robust under noisy conditions than other classification techniques; (2) avoid the necessity of noise removal by digital filtering and therefore avoid the need to make assumptions about frequency bands or other signal characteristics of anomalous behavior; (3) can, in effect, generate their own feature detectors based on the characteristics of the sensor data used in training; and (4) are inherently parallel and therefore are potentially implementable in special-purpose parallel hardware.

This paper focuses on the application of expert systems technology to the automatic detection, verification and correction of anomalous rocket engine operations through interfacing with an intelligent adaptive control system. The design of a reliable and intelligent propulsion control and monitoring system is outlined which includes the architecture of an Integrated Expert System (IES) serving as the core component. The IES functions include automatic knowledge acquisition, integrated knowledge base, and fault diagnosis and prediction methodology. The results of fault analysis and diagnostic techniques are presented for an example fault in the SSME main combustion chamber injectors.

The increasing complexity of modern aircraft creates a need for a larger number of caution and warning devices. But more alerts require more memorization and higher workloads for the pilot and tend to induce a higher probability of errors. Therefore, an architecture for a flight expert system (FLES) is developed to assist pilots in monitoring, diagnosing and recovering from in-flight faults. A prototype of FLES has been implemented. A sensor simulation model was developed and employed to provide FLES with airplane status information during the diagnostic process. The simulator is based on the Lockheed Advanced Concept System (ACS), a future generation airplane, and on the Boeing 737. A distinction between two types of faults, maladjustments and malfunctions, has led to two approaches to fault diagnosis. These approaches are evident in two FLES subsystems: the flight phase monitor and the sensor interrupt handler. The specific problem addressed in these subsystems has been that of integrating information received from multiple sensors with domain knowledge in order to access abnormal situations during airplane flight. Malfunctions and maladjustments are handled separately, diagnosed using domain knowledge.