Systems and methods for identifying machine anomaly root cause based on a selected reduced order model and a selected fault model

A system for identifying a cause of a machine operating anomaly, comprising:

• one or more processors;
• and
• one or more memory devices having stored thereon instructions that when executed by the one or more processors cause the one or more processors to;
• create a reduced order model (ROMs) for a digital twin model of a selected machine type, including:
• creating a plurality of reduced order models (ROMs) for the digital twin model for the selected machine type;
• feeding historical data from a plurality of machines of the selected machine type into the plurality of reduced order models (ROMs) for the digital twin model and the digital twin model;
• comparing an output from the digital twin model with an output from each of the plurality of reduced order models (ROMs) for the digital twin model;
• and
• selecting, from the plurality of ROMs, a ROM with an output most closely matching the output of the digital twin model;
• receive current data from a plurality of sensors on a deployed machine;
• feed the current data into the ROM;
• compare a current output from the ROM with a measured output from the current data;
• determine that an operating anomaly exists when a difference between the current output and the measured output exceeds a selected anomaly threshold;
• and
• identify the cause of the operating anomaly, including:
• feeding the current data into a plurality of fault models, wherein each fault model includes a particular component failure;
• comparing a fault model output from each of the plurality of fault models with the measured output from the current data;
• selecting a fault model with the fault model output most closely matching the measured output;
• and
• identifying a component failure associated with the selected fault model as the cause of the operating anomaly.

One or more non-transitory computer-readable media storing computer-executable instructions that, when executed by one or more processors, cause the one or more processors to perform operations comprising:

• creating a reduced order model (ROMs) for a digital twin model of a selected machine type, including:
• creating a plurality of reduced order models (ROMs) for the digital twin model for the selected machine type;
• feeding historical data from a plurality of machines of the selected machine type into the plurality of reduced order models (ROMs) for the digital twin model and the digital twin model;
• comparing an output from the digital twin model with an output from each of the plurality of reduced order models (ROMs) for the digital twin model;
• and
• selecting, from the plurality of ROMs, a ROM with an output most closely matching the output of the digital twin model;
• feeding current data from a deployed machine into the ROM;
• comparing a current output from the ROM with a measured output from the current data;
• determining that an operating anomaly exists when a difference between the current output and the measured output exceeds a selected anomaly threshold;
• and
• identifying the cause of the operating anomaly, including:
• feeding the current data into a plurality of fault models, wherein each fault model includes a particular component failure;
• comparing a fault model output from each of the plurality of fault models with the measured output from the current data;
• selecting a fault model with the fault model output most closely matching the measured output;
• and
• identifying a component failure associated with the selected fault model as the cause of the operating anomaly.