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==A deep learning-based Prognostic Framework for Aeroengine Exhaust Gas Temperature Margin==
'''Weigang Fu<sup>1,*</sup>, Xiang Tan <sup>2</sup>, Liangzhong Ao<sup>1</sup>, Yaoming Fu<sup>1</sup> and Peng Guo<sup>2,*</sup>'''
<sup>1</sup> Aviation Engineering Institute, Civil Aviation Flight University of China, Guanghan, 618307, China
<sup>2</sup> School of Mechanical Engineering, Southwest Jiaotong University, Chengdu, 610031, China
'''*''' Correspondence: Weigang Fu ([mailto:jiaodafwg@126.com jiaodafwg@126.com] (W. F); Peng Guo([mailto:pengguo318@swjtu.edu.cn pengguo318@swjtu.edu.cn])
-->
==Abstract==
The value of the gas-path parameter, exhaust gas temperature margin (EGTM), is the critical index for predicting aeroengine performance degradation. Accurate predictions help to improve engine maintenance, replacement schedules, and flight safety. The outside air temperature (OAT), altitude of the airport, the number of flight cycles, and water washing information were chosen as the sample input variables for the data-driven prognostic model for predicting the take-off EGTM of the on-wing engine. An attention-based deep learning framework was proposed for the aeroengine performance prediction model. Specifically, the multiscale convolutional neural network (CNN) structure is designed to initially learn sequential features from raw input data. Subsequently, the long short-term memory (LSTM) structure is employed to further extract the features processed by the multiscale CNN structure. Furthermore, the proposed attention mechanism is adopted to learn the influence of features and time steps, assigning different weights according to their importance. The actual operation data of the aeroengine are used to conduct experiments, where the experimental results verify the effectiveness of our proposed method in EGTM prediction.
'''Keywords''': Convolution neural network, long short-term memory, attention mechanism, aeroengine gas-path performance, exhaust gas temperature margin
==1. Introduction==
The aeroengine operates at the highest temperature, pressure, speed, and frequency of transitional working states during the take-off phase when compared to the other flight phases like cruise and landing [1,2]. The slow decline of engine performance is inevitable during the active process. Prediction and evaluation of the decline degree of engine performance are necessary for performing preventive maintenance on the aeroengine. Most engine failures are caused by the gas-path system fault, and accurate gas-path performance prediction provides the possibility for aeroengine performance evaluation and maintenance plan optimization. This is significant for ensuring the flight safety of aircraft.
The gas path parameters include exhaust gas temperature (EGT), rotor speed, and fuel flow. The EGT margin (EGTM) is usually adopted to perform gas path analysis and monitor the engine performance degradation, which can show whether the aeroengines are in the normal state or not [3]. During actual monitoring and maintenance, the take-off EGTM [4] is usually chosen as the critical gas-path parameter to evaluate the performance state of the aeroengine. A deteriorated engine will consume more fuel, thus increasing the EGT and decreasing the EGTM [5]. The net thrust, fuel flow, low rotor speed, core rotor speed, pressure ratio, air temperature at engine fan inlet, take-off EGTM, and specific fuel consumption are regarded as input parameters for estimating the EGT [6]. These input parameters were collected by the sensors during the flight [7], and they are unknown for the prognostic analysis. In that work, the relationship between EGT decline rate and the flight cycles was established to predict the remaining life of a PW4000-94 engine. The EGTM was influenced by the unknown real-time data, obtained by sensor data during the flight, as well as the known data obtained before the flight. This work aims to utilize the above-known data as the input parameters to predict the EGTM prior to flight.
Take-off EGTM, as shown in [[#img-1|Figure 1]], reflects the state of engine performance. When the take-off EGTM equals 0 °C, the EGT has reached the red line value. The EGTM in the take-off phase directly relates to the airport outside air temperature (OAT) and altitude. However, empirical data do not exist to allow a correlation between EGTM deterioration and the OAT or altitude of the airport.
<div id='img-1'></div>
{| class="wikitable" style="margin: 1em auto 0.1em auto;border-collapse: collapse;width:auto;"
|-style="background:white;"
|style="text-align: center;padding:10px;"| [[Image:Review_393375948024-image1.png|306px]]
|-
| style="background:#efefef;text-align:left;padding:10px;font-size: 85%;"| '''Figure 1'''. Effect of OAT in the airport on EGTM deterioration
|}
The value of EGTM significantly affects engine life. Reducing EGTM will extend engine life on the wing, thereby reducing operating costs. If the engine is arranged to take off at the airport at a lower OAT and altitude, EGT will likely not cross the red line. With regard to meeting the aircraft performance requirements, the engine is designed to provide a given thrust level at a temperature below the corner point OAT. As the OAT in the airport increases, more fuel is required, EGT increases, and EGTM decreases. However, at a temperature above the corner point OAT, the EGTM is less than zero, and the thrust output must be reduced. If it does not reduce, the engine will be damaged [8]. Similarly, as the altitude of the airport increases, more fuel will be required to provide a given thrust output, so the EGT will increase, resulting in a decrease in the EGTM [9].
The number of flight cycles significantly affects the take-off EGTM of aeroengines. For an available gas turbine engine, the levels of degradation drop by increasing the flight cycles, and all engine health parameters deviate slowly from their nominal values [10]. The degradation data of the booster were used to illustrate the clean compressor map and degraded compressor maps at 3000 and 6000 flight cycles for the JT9D turbofan engine [11]. The degraded maps were utilized to predict the overall degradation effects on the engine performance. In the take-off phase, the engine accelerates from idle to maximum power resulting in maximum rotor speed and EGT, which causes the turbine blade to elongate and creep [12]. In addition, abrasion between the elongated turbine blade and the stationary parts occurs. The turbine clearance increases during the thermal cycles, such as the start and stop cycles, namely flight cycles. The engine wear and higher clearance lead to a deterioration of the engine efficiency, which decreases the turbine efficiency [13]. In this case, more fuel is consumed to maintain a given thrust level, so the EGTM will decrease, and the engine performance will degrade.
Meanwhile, low cycle fatigue (LCF) [14] is associated with engines that have been in service for long periods. LCF occurs due to machine cyclic loading, like start/stop cycles, which is closely related to the flight cycles. The LCF life of a component is determined by the number and the intensity of cycles the component material must endure [15]. In contrast, the creep life of a component depends on the time it spends operating within the material's creep temperature range. The number of flight cycles can influence the communicative time effect on the wear, creep, and fatigue life of hot section components.
Periodical on-wing water washing is an efficient and economical method to improve engine performance and restore the take-off EGTM [16]. Engines in the take-off phase and the approaching landing phase of each flight cycle are more affected by the airborne pollutant due to the lower altitude they operate, making them more susceptible to compressor fouling degradation. The changing value of the mass flow rate and the compressor's efficiency due to compressor fouling can be expressed as a linear relationship concerning the flight cycle [17]. Besides the effect of online washing with different water-to-air ratios and engine loads on performance recovery [18], the effect of inlet pressure and droplet diameter of washing liquid on compressor fouling removal [19], and the recovery efficiency of power loss with washing [20] have been studied.
To predict the take-off EGTM of the on-wing engine in advance, we choose the OAT and altitude of the airport, the number of flight cycles, and water washing information as the sample input variables for a prediction algorithm. All these parameters can be obtained before the flight, making the prognostic of the engine's performance degradation known in advance. The aeroengine performance degradation prediction is a time series forecasting task. Deep architectures such as convolutional neural networks (CNN) and long short-term memory (LSTM) can extract and effectively capture the feature information of raw input data. However, the ability of normal CNN is affected by the size of convolution kernels, which should be accurately determined. Another key issue is that once the sequence is too long, the traditional LSTM cannot effectively use the location information of time series data and capture the long-term interdependence. As such, an attention mechanism was added for assigning different weights to features of different importance.
The main contributions of this paper are summarized as follows:
:1) A multiscale CNN-LSTM structure is developed to handle raw aeroengine data to learn temporal sequence features and extract useful degradation information.
:2) We propose a deep learning framework based on an attention mechanism. The attention mechanism can learn the importance of sequential features and time steps, assigning different weights according to their preference.
:3) We conduct experiments on real datasets to evaluate the effectiveness of our proposed method. The experimental results show that the proposed method shows a considerable improvement in aeroengine performance estimation.
The rest of this paper is organized as follows. Section 2 reviews the related works. Section 3 describes the suggested method based on deep learning, and section 4 includes the computational experiments and an analysis of the results. Finally, section 5 concludes this work and gives future studies.
==2. Related works==
Multiple methods are utilized in engineering applications to analyze the gas-path system for aeroengine performance prediction. In general, these prediction methods can be divided into two categories: model-based methods [21]–[23] and data-driven methods [24]. The nonlinear simulation model of a twin-spool turbofan engine was constructed as a component level model by Adibhatla et al. [21]. A bank of parallel Kalman filters and a hierarchical structure were used for the multiple model adaptive estimation methods of in-flight failures test by Maybeck [22]. The nonlinear dynamics of the jet engine are linearized and a set of linear models corresponding to various operating modes of the engine at each operating point is obtained by Lu et al [23]. However, the component structures and accessory systems of aeroengines are becoming increasingly complex and integrated. Accurate modeling remains difficult with model-based methods due to the challenge of mastering various nonlinear mathematical relationships between components and systems [25].
When compared with these model-based methods, data-driven methods do not require an understanding of the complex operation mechanisms of the mechanical system. Therefore, data-driven methods have been widely used in aeroengine performance prediction. The previously collected data of gas path systems were time-series data of multiple state parameters. A CNN is designed to extract the features from this input data. The CNN prediction technology was combined with a delta fuel flow degradation baseline to estimate the performance recovery by the water washing [26]. A CNN-based multitask learning framework was proposed to accurately estimate the remaining useful life (RUL) by simultaneous learning. The estimations occurred during a health state identification, where inter-dependencies of both tasks were considered using general features extracted from the shared network [27]. A CNN and extreme gradient boosting (CNN-XGB) were combined through model averaging. A CNN-XGB with an extended time window was utilized for a RUL estimation [28].
A hybrid method of convolutional and recurrent neural network (CNN-RNN) was proposed for the RUL estimation, where it can extract the local features and capture the degradation process [29]. A RNN has the advantage of a data-driven model with short time dependencies. Nevertheless, a RNN has poor performance in dealing with long-time dependencies data. LSTM neural networks have been proposed to address these dependencies for predicting the RUL of any system. The LSTM model has the advantage of retaining time domain information for a long duration of time. The accuracy of an online LSTM method was improved by comparing it to the proposed methods in Kakati et al. [30] for RUL estimation of a turbofan engine. The LSTM, as well as the statistical process analysis, were performed to predict the fault of aeroengine components with multi-stage performance degradation [31]. The linear regression model and LSTM were utilized to construct the data-driven model of degradation trend prediction and RUL estimation [32]. RUL estimation for predictive maintenance was achieved by using the support vector regression (SVR) model and an LSTM network [33].
A novel performance degradation prediction method based on the attention model and SVR is proposed for RUL prediction. The attention mechanism can focus on the important features in the time-sequential data, while the SVR model identifies the mapping relationship between multiple state parameters and performance degradation [34]. Many hidden layers were constructed for the machine learning model and a large number of training data to learn more useful features and improve the accuracy of classification and prediction. The designed system [35] is based on reinforcement learning and a deep learning framework, which consists of an input, modeling, and a decision layer. Li et al. [36] proposed a new data-driven approach for prognostics by using deep CNN. In that work, a time window approach employed for sample preparation achieves better feature extraction by deep CNN leading to high prognostic accuracy with regards to the RUL estimation.
An intelligent deep learning method was proposed for forecasting the health evolution trend of aeroengine by Jiang et al. [37]. This method systematically blends the dispersion entropy-based multi-scale series aggregation scheme with a long LSTM neural network. Remadna et al. [38] introduced a new hybrid RUL prediction approach by combining two deep learning methods sequentially. The hybrid model uses a CNN with bidirectional LSTM networks where the CNN extracts spatial features while bidirectional LSTM extracts temporal features. Chu et al. [39] proposed an integrated deep learning approach with CNN and LSTM networks to learn the latent features and estimate RUL value with a deep survival model based on the discrete Weibull distribution. In their work, the turbofan engine degradation simulation datasets provided by NASA were utilized to validate the proposed approach.
==3. Methodology==
This section describes the aeroengine EGTM prediction problem. Next, the proposed attention-based multiscale CNN-LSTM method is introduced in detail. This includes the theoretical background of the components and the method’s overall framework.
===3.1 Problem description===
From the perspective of health management, aeroengine EGTM prediction can be regarded as a time series problem. The EGTM prediction problem can be defined as follows. The input is <math display="inline">{X}_{t}^{k}</math>, where <math display="inline">k\in R^n</math>, <math display="inline">t = (1,2, \ldots ,T)</math>. In addition, <math display="inline">{X}_{t}^{k}</math>represents the collected input data during aeroengine operation, <math>n</math> represents the number of features, and <math>T</math> represents the length of the time step. The corresponding output is the EGTM prediction result <math display="inline">{Y}_{t}</math> for each time step. EGTM is predicted in real-time by establishing the mapping relationship between the output and input data. The mapping relationship is expressed as follows:
{| class="formulaSCP" style="width: 100%; text-align: center;"
|-
|
{| style="text-align: center; margin:auto;"
|-
| <math>{Y}_{t}=f({X}_{t}^{k})</math>
|}
| style="width: 5px;text-align: right;white-space: nowrap;" | (1)
|}
When building the performance prediction model, the above input data are directly imported from the raw data file to predict EGTM. As such, a large amount of mixed noise exists in the data. To fully extract the time-series features of the data, we design a multiscale CNN-LSTM deep learning framework based on an attention mechanism to construct mapping relationships, as introduced in detail in the following subsections.
===3.2 Multiscale CNN===
A traditional CNN can directly process the input raw data and extract the hidden features. However, the amount of raw data is relatively large. Thus, using a single convolution kernel may cause the model to omit locally important features in the process of adaptively extracting features. By adjusting the scale of the convolution kernel and using several different convolution kernels, designing a network capable of extracting the raw data features may be possible. This results in the performance of the model prediction improving.
This work proposes an improved CNN with a multiscale convolution operation to compensate for the limitation of a traditional CNN. Specifically, each convolution layer consists of 64 convolution kernels, and we set the convolution kernel size to 1, 3, and 5. The multiscale convolution operation is embodied as a structure to extract the hidden features by performing a multiscale convolution operation on the raw data. Initially, this establishes a shallow mapping relationship between the raw data and EGTM. The specific network structure is shown in [[#img-2|Figure 2]].
<div id='img-2'></div>
{| class="wikitable" style="margin: 1em auto 0.1em auto;border-collapse: collapse;width:auto;"
|-style="background:white;"
|style="text-align: center;padding:10px;"| [[Image:Review_393375948024-image2-c.png|420px]]
|-
| style="background:#efefef;text-align:left;padding:10px;font-size: 85%;"| '''Figure 2'''. Structure of multiscale CNN
|}
===3.3 Long short-term memory network===
The data in the proposed prediction model, discussed previously, are time series, the nodes of the RNN are connected along the sequence, and the RNN is designed to learn the correlation of the time series. However, the standard RNN often encounters the problem of gradient disappearance and gradient explosion during the training process. As a result, both the model’s ability to capture the previous information and its performance in modeling long-term dependencies decreases.
To solve this problem, Hochreiter proposed a new architecture named long and short-term memory network (LSTM) [42]. LSTM is a special RNN, which has been widely used in various time sequence modeling tasks such as stock market price prediction and energy consumption prediction. The advantage of LSTM involves its ability to overcome shortcomings of traditional RNN, such as the influence of gradient disappearance and gradient explosion. The basic architecture of a typical LSTM is shown in [[#img-3|Figure 3]].
<div id='img-1'></div>
{| class="wikitable" style="margin: 1em auto 0.1em auto;border-collapse: collapse;width:auto;"
|-style="background:white;"
|style="text-align: center;padding:10px;"| [[Image:Review_393375948024-image3.png|336px]]
|-
| style="background:#efefef;text-align:left;padding:10px;font-size: 85%;"| '''Figure 3'''. Structure of LSTM
|}
One notable feature includes how it delicately designs the structure of the recurrent unit. The sigmoid activation function, tanh activation function, and element-wise product work together to form three gate structures: forget gate, input gate, and output gate. Two gates are used to control the state of the memory cell <math display="inline"> c</math>. The first gate is the forget gate, while the other is the input gate. When the forget gate is turned on, some information from the previous memory cell state <math display="inline"> c_{t-1}</math> could be ignored, and others will be kept. When the input gate is activating, the information from the current input <math display="inline">x_t</math> can be added to the memory cell <math display="inline">c</math>. LSTM uses the output gate to control how much information of the memory cell state <math display="inline">c_t</math> will be added to the current output <math display="inline">h_t</math>. For the given inputs <math display="inline">x_t</math>, <math display="inline">h_{t-1}</math>, and <math display="inline"> c_{t-1}</math>, the update process of LSTM for time step <math display="inline">t</math> is shown as Eq.(2)
{| class="formulaSCP" style="width: 100%; text-align: center;"
|-
|
{| style="text-align: center; margin:auto;"
|-
| <math>\left\{ \begin{matrix}\&{i}_{t}=\sigma ({W}_{i}[{h}_{t-1},{x}_{t}]+{b}_{i})\\\&{f}_{t}=\sigma ({W}_{f}[{h}_{t-1},{x}_{t}]+{b}_{f})\\\&{o}_{t}=\sigma ({W}_{o}[{h}_{t-1},{x}_{t}]+{b}_{o})\\\&{\tilde{c}}_{t}=\tanh({W}_{c}[{h}_{t-1},{x}_{t}]+{b}_{c})\\\&{c}_{t}={f}_{t}\odot {c}_{t-1}+{i}_{t}\odot {\tilde{c}}_{t}\\\&{h}_{t}={o}_{t}\odot \tanh({c}_{t})\end{matrix}\right.</math>
|}
| style="width: 5px;text-align: right;white-space: nowrap;" | (2)
|}
Return to Fu et al 2022a.
Published on 16/05/23
Accepted on 08/05/23
Submitted on 08/05/22
Volume 39, Issue 2, 2023
DOI: 10.23967/j.rimni.2023.05.002
Licence: CC BY-NC-SA license
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