Methods and apparatus for the creation and use of reusable fault model components in fault modeling and complex system prognostics

A method for using reusable sub-assemblies in a fault model associated with a system, the method comprising:

• associating one or more algorithms to a reusable sub-assembly comprising a reusable fault model component, the one or more algorithms describing behavior of the reusable fault model component, wherein the one or more algorithms comprises at least one of a transfer function, a signal-to-noise ratio, estimated non-linearities, and an error counter;
• incorporating the reusable sub-assembly into the fault model, the reusable sub-assembly representing a component of the system;
• and
• during runtime of the fault model,
• recognizing a current regime associated with the reusable fault model component, wherein the current regime provides a context for operation of the reusable fault model component, and wherein the current regime comprises an indication of equipment mode and state affecting a rate at which equipment usage is accumulated, at which fault indications are viewed as legitimate, at which condition indicators are reliable, and at which data needs to be collected;
• collecting the data associated with the reusable fault model component, based on the context provided by the current regime;
• tuning the reusable fault model component, using available data associated with the fault model;
• and
• predicting potential faults of the system using the reusable sub-assembly, based on the collected data and the tuning, wherein the potential faults indicate degradation of the system.

A non-transitory, computer-readable medium containing instructions thereon, which, when executed by a processor, perform a method comprising:

• adjusting parameters associated with a reusable fault model component of a fault model for a system, using real-time data produced by execution of the fault model, by:
• associating one or more algorithms to the reusable fault model component, the one or more algorithms describing behavior of the reusable fault model component, wherein the one or more algorithms comprises at least one of a transfer function, a signal-to-noise ratio, estimated non-linearities, and an error counter;
• and
• incorporating the reusable fault model component and the one or more algorithms into the fault model;
• executing the fault model using the adjusted parameters, to produce adjusted output;
• and
• during runtime of the fault model,
• recognizing a current regime associated with the reusable fault model component, wherein the current regime provides a context for operation of the reusable fault model component, and wherein the current regime comprises an indication of equipment mode and state affecting a rate at which equipment usage is accumulated, at which fault indications are viewed as legitimate, at which condition indicators are reliable, and at which data needs to be collected;
• collecting the data associated with the reusable fault model component, based on the context provided by the current regime;
• tuning the reusable fault model component, using available data associated with the fault model;
• and
• predicting remaining life of the system, based on the collected data and the tuning.