A key enabler of intelligent maintenance systems is the ability to predict the remaining useful lifetime (RUL) of its components, i.e., prognostics. The development of data-driven prognostics models requires datasets with run-to-failure trajectories. However, large representative run-to-failure datasets are often unavailable in real applications because failures are rare in many safety-critical systems. To foster the development of prognostics methods, we develop a new realistic dataset of run-to-failure trajectories for a fleet of aircraft engines under real flight conditions. The dataset was generated with the Commercial Modular Aero-Propulsion System Simulation (CMAPSS) model developed at NASA. The damage propagation modelling used in this dataset builds on the modelling strategy from previous work and incorporates two new levels of fidelity. First, it considers real flight conditions as recorded on board of a commercial jet. Second, it extends the degradation modelling by relating the degradation process to its operation history. This dataset also provides the health, respectively, fault class. Therefore, besides its applicability to prognostics problems, the dataset can be used for fault diagnostics.

Model-based prognostics approaches rely on physics-based models that describe the behavior of systems and their components. These models must account for the several different damage processes occurring simultaneously within a component. Each of these damage and wear processes contributes to the overall component degradation. We develop a model-based prognostics methodology that consists of a joint state-parameter estimation problem, in which the state of a system along with parameters describing the damage progression are estimated, followed by a prediction problem, in which the joint state-parameter estimate is propagated forward in time to predict end of life and remaining useful life. The state-parameter estimate is computed using a particle filter and is represented as a probability distribution, allowing the prediction of end of life and remaining useful life within a probabilistic framework that supports uncertainty management. We also develop a novel variance control algorithm that maintains an uncertainty bound around the unknown parameters to limit the amount of estimation uncertainty and, consequently, reduce prediction uncertainty. We construct a detailed physics-based model of a centrifugal pump that includes damage progression models, to which we apply our model-based prognostics algorithm. We illustrate the operation of the prognostic solution with a number of simulation-based experiments and demonstrate the performance of the approach when multiple damage mechanisms are active.

In this paper, we investigate the use of first-order reliability methods to quantify the uncertainty in the remaining useful life (RUL) estimate of components used in engineering applications. The prediction of RUL is affected by several sources of uncertainty, and it is important to systematically quantify their combined effect on the RUL prediction in order to aid risk assessment, risk mitigation, and decision-making. While sampling-based algorithms have been conventionally used for quantifying the uncertainty in RUL, analytical approaches are computationally cheaper, and sometimes they are better suited for online decision-making. Exact analytical algorithms may not be available for practical engineering applications, but effective approximations can be made using first-order reliability methods. This paper describes three first-order reliability-based methods for RUL uncertainty quantification: first-order second moment method (FOSM), the first-order reliability method (FORM), and the inverse first-order reliability method (inverse-FORM). The inverse-FORM methodology is particularly useful in the context of online health monitoring, and this method is illustrated using the power system of an unmanned aerial vehicle, where the goal is to predict the end of discharge of a lithium-ion battery.