MATLAB , Step by step

1) Understanding Workflows for Algorithm Development

The following illustration shows a workflow for developing a predictive maintenance algorithm.

Beginning with data that describes your system in a range of healthy and faulty conditions, you develop a
detection model (for condition monitoring) or a prediction model (for prognostics). Developing such a model
requires identifying appropriate condition indicators and training a model to interpret them. That process is
very likely to be iterative, as you try different condition indicators and different models until you find the
best model for your application. Finally, you deploy the algorithm and integrate it into your systems for
machine monitoring and maintenance.
a) Acquire Data
Designing predictive maintenance algorithms begins with a body of data. Often you must manage and
process large sets of data, including data from multiple sensors and multiple machines running at different
times and under different operating conditions. You might have access to one or more of the following
types of data:
 Real data from normal system operation
 Real data from system operating in a faulty condition
 Real data from system failures (run-to-failure data)
For instance, you might have sensor data from system operation such as temperature, pressure, and
vibration. Such data is typically stored as signal or time series data. You might also have text data, such as
data from maintenance records, or data in other forms. This data is stored in files, databases, or
distributed file systems such as Hadoop®.
In many cases, failure data from machines is not available, or only a limited number of failure datasets
exist because of regular maintenance being performed and the relative rarity of such incidents. In this
case, failure data can be generated from a Simulink ® model representing the system operation under
different fault conditions.
Predictive Maintenance Toolbox provides functionality for organizing, labeling, and accessing such data
stored on disk. It also provides tools to facilitate the generation of data from Simulink models for predictive
maintenance algorithm development. For more information, see Data Ensembles for Condition Monitoring
and Predictive Maintenance.
b) Preprocess Data
Data preprocessing is often necessary to convert the data into a form from which condition indicators are
easily extracted. Data preprocessing includes simple techniques such as outlier and missing value
removal, and advanced signal processing techniques such as short-time Fourier transforms and
transformations to the order domain.
Understanding your machine and the kind of data you have can help determine what preprocessing
methods to use. For example, if you are filtering noisy vibration data, knowing what frequency range is
 most likely to display useful features can help you choose preprocessing techniques. Similarly, it might be
useful to transform gearbox vibration data to the order domain, which is used for rotating machines when
the rotational speed changes over time. However, that same preprocessing would not be useful for
vibration data from a car chassis, which is a rigid body.
For more information on preprocessing data for predictive maintenance algorithms, see Data
Preprocessing for Condition Monitoring and Predictive Maintenance.
c) Identify Condition Indicators
A key step in predictive maintenance algorithm development is identifying condition indicators, features
in your system data whose behavior changes in a predictable way as the system degrades. A condition
indicator can be any feature that is useful for distinguishing normal from faulty operation or for predicting
remaining useful life. A useful condition indicator clusters similar system status together, and sets
different status apart. Examples of condition indicators include quantities derived from:
 Simple analysis, such as the mean value of the data over time
 More complex signal analysis, such as the frequency of the peak magnitude in a signal spectrum,
or a statistical moment describing changes in the spectrum over time
 Model-based analysis of the data, such as the maximum eigenvalue of a state space model which
has been estimated using the data
 Combination of multiple features into a single effective condition indicator (fusion)
For example, you can monitor the condition of a gearbox using vibration data. Damage to the gearbox
results in changes to the frequency and magnitude of the vibrations. The peak frequency and peak
magnitude are thus useful condition indicators, providing information about the kind of vibrations
present in the gearbox. To monitor the health of the gearbox, you can continuously analyze the vibration
data in the frequency domain to extract these condition indicators.
Even when you have real or simulated data representing a range of fault conditions, you might not know
how to analyze that data to identify useful condition indicators. The right condition indicators for your
application depend on what type of system, system data, and system knowledge you have. Therefore,
identifying condition indicators can require some trial and error, and is often iterative with the training
step of the algorithm development workflow. Among the techniques commonly used for extracting
condition indicators are:
 Order analysis
 Modal analysis
 Spectrum analysis
 Envelope spectrum
 Fatigue analysis
 Nonlinear time-series analysis
 Model-based analysis such as residual computation, state estimation, and parameter estimation
Predictive Maintenance Toolbox supplements functionality in other toolboxes such as Signal Processing
Toolbox™ with functions for extracting signal-based or model-based condition indicators from measured
or generated data. For more information, see Identify Condition Indicators.
d) Train Detection or Prediction Model
At the heart of the predictive maintenance algorithm is the detection or prediction model. This model
analyzes extracted condition indicators to determine the current condition of the system (fault detection
and diagnosis) or predict its future condition (remaining useful life prediction).
Fault Detection and Diagnosis
Fault detection and diagnosis relies on using one or more condition indicator values to distinguish
between healthy and faulty operation, and between different types of faults. A simple fault-detection
model is a threshold value for the condition indicator that is indicative of a fault condition when
exceeded. Another model might compare the condition indicator to a statistical distribution of indicator
values to determine the likelihood of a particular fault state. A more complex fault-diagnosis approach is
to train a classifier that compares the current value of one or more condition indicators to values
associated with fault states, and returns the likelihood that one or another fault state is present.
 When designing your predictive maintenance algorithm, you might test different fault detection and
diagnosis models using different condition indicators. Thus, this step in the design process is likely
iterative with the step of extraction condition indicators, as you try different indicators, different
combinations of indicators, and different decision models. Statistics and Machine Learning Toolbox™ and
other toolboxes include functionality that you can use to train decision models such as classifiers and
regression models. For more information, see Decision Models for Fault Detection and Diagnosis.
Remaining Useful Life Prediction
Examples of prediction models include:
 A model that fits the time evolution of a condition indicator and predicts how long it will be
before the condition indicator crosses some threshold value indicative of a fault condition.
 A model that compares the time evolution of a condition indicator to measured or simulated time
series from systems that ran to failure. Such a model can compute the most likely time-to-failure
of the current system.
You can predict remaining useful life by forecasting with dynamic system models or state estimators.
Additionally, Predictive Maintenance Toolbox includes specialized functionality for RUL prediction based
on such techniques as similarity, threshold, and survival analysis. For more information, see Models for
Predicting Remaining Useful Life.
e) Deploy and Integrate
When you have identified a working algorithm for handling your new system data, processing it
appropriately, and generating a prediction, deploy the algorithm and integrate it into your system. Based
the specifics of your system, you can deploy your algorithm on the cloud or on embedded devices.
A cloud implementation can be useful when you are gathering and storing large amounts of data on the
cloud. Removing the need to transfer data between the cloud and local machines that are running the
prognostics and health monitoring algorithm makes the maintenance process more effective. Results
calculated on the cloud can be made available through tweets, email notifications, web apps, and
dashboards.
Alternatively, the algorithm can run on embedded devices that are closer to the actual equipment. The
main benefits of doing this are that the amount of information sent is reduced as data is transmitted only
when needed, and updates and notifications about equipment health are immediately available without
any delay. .
A third option is to use a combination of the two. The pre processing and feature extraction parts of the
algorithm can be run on embedded devices, while the predictive model can run on the cloud and
generate notifications as needed. In systems such as oil drills and aircraft engines that are run
continuously and generate huge amounts of data, storing all the data on board or transmitting it is not
always viable because of cellular bandwidth and cost limitations. Using an algorithm that operates on
streaming data or on batches of data lets you store and send data only when needed.
2) Step by step activities

a. Step 1:
Download Free MATLAB trial @ Trials - MATLAB & Simulink (mathworks.com)
You will get access to Simulink , Predictive maintenance toolbox

b. Step 2:
Acquire Vibration data from different sources:
 Actual vibration acceleration data (time domain) from vSens IoT sensors.
 Vibration data from repositories in public domain.

o UC Irvine ML Repository

o Google Datasets

o GitHub

o kaggle Predictive Maintenance

o kaggle Bosch Production Line Performance

o Prognostics Data Repository

 If the above data does not have fault conditions then the same can be generated using the
Simulink tool.

c. Step 3:
Preprocess data by Cleaning & Labelling .
Data cleaning is the process of modifying data to remove or correct information in preparation for
analysis. A common belief among practitioners is that 80% of analysis time is spent on this data
cleaning phase. But why?

When data is collected, there are often various challenges to address. Data sets may contain missing
points or outliers, or need to be merged with other data sets. Engineering and scientific data often
has specific requirements, such as managing high-frequency timestamps, signal processing, and data
labeling. You need to make decisions on how to deal with these data cleaning tasks.
 This might sound painful, but it doesn’t have to be. MATLAB® provides many apps and functions for
data cleaning tasks to make this phase faster and more informative so you can focus on your analysis
and problem solving. For example, use MATLAB to:

 Explore, discover, and clean problems with time-series data with the Data Cleaner app.
 Synchronize, smooth, remove, or fill missing data and outliers with Live Editor tasks to
experiment with individual data cleaning methods
 Call functions such as smoothdata and fillmissing, with many options for managing the data
and convenient function hints.
 Quickly perform domain-specific data cleaning with the Signal Analyzer, Signal Labeler,
and Image Labeler apps.
All of the apps and Live Editor tasks automatically generate MATLAB code to document and
automate your interactive work.

Using the Data Cleaner app in MATLAB to explore and clean time-series data.

d. Step 4:
Identify Condition /Features indicators using the Diagnostic feature designer App.
Feature Extraction Using Diagnostic Feature Designer App Video - MATLAB (mathworks.com)

e. Step 5:
Now the Model has to be selected based on the type of vibration data which is available.
Predictive Maintenance Toolbox includes specialized functionality for RUL prediction based on such
techniques as Similarity, Degradation & Survival models.

After the selection of Model , the Model has to be trained with the available data. The data has to be
split into 2 halves with the 1st half forming the Teaching data & the 2 nd half forming the Testing data.
f. Step 6:
Now the Model is ready for the Deployment & Integration with the real time data. This Model will
deliver results which will become more accurate with the passage of time.