Modeling Condition And Performance

Of Mining Equipment
Tad S. Golosinski and Hui Hu

Mining Engineering
University of
Missouri-Rolla

1
 Condition and Performance Monitoring
Systems

Machine health monitoring

Allows for quick diagnostics of problems
Payload and productivity
Provides management with machine and fleet
performance data
Warning system
Alerts operator of problems, reducing the risk
of catastrophic failure
2
CATs VIMS
(Vital Information Management System)

Collects / processes Installed on

information on major
machine components
Engine control
Transmission/chassis
control
Braking control
Payload measurement
system
Off-highway trucks
785, 789, 793, 797
Hydraulic shovels
5130, 5230
Wheel loaders
994, 992G (optional)

3
Other, Similar Systems
Cummins
CENSE (Engine Module)
Euclid-Hitachi
Contronics & Haultronics
Komatsu
VHMS (Vehicle Health Monitoring System)
LeTourneau
LINCS (LeTourneau Integrated Network Control System)

4
Round Mountain Gold Mine

Truck Fleet
17 CAT 785 (150t)
11 CAT 789B
(190t)
PSA
(Product Support
Agreement) CAT
dealer guarantees
88% availability

5
 VIMS in RMG Mine
Average availability is 93%
over 70,000 operating hours
VIMS used to help with
preventive maintenance
Diagnostics after engine failure
Haul road condition assessment
Other

Holmes Safety Association Bulletin 1998 6

CAT MineStar
CAT MineStar - Integrates
Machine Tracking System
(GPS)
Computer Aided Earthmoving System
(CAES)
Fleet scheduling System
(FleetCommander)
VIMS

7
Cummins Mining Gateway

Modem

MiningGateway.co Database CENSE

m

Base
Cummins
Engine Station

RF Modem
Receiver
8
VIMS Data & Information Flow
VIMS
Mine Legacy
Site 1 Databas
e

Mine Data Extract VIMS Data

Site Data Cleanup Warehouse
2 Data Load

Mine
Site
3 Informatio
n
Extraction

Information
Data Mining
Apply
Tools
9
Earlier Research:
Data Mining of VIMS

Kaan Ataman tried modeling using:

Major Factor Analysis
Linear Regression Analysis
All this on datalogger data
Edwin Madiba tried modeling using:
Data formatting and transferring
VIMS events association
All this on datalogger and event data

10
Research Objectives
Build the VIMS data warehouse to
facilitate the data mining
Develop the data mining application for
knowledge discovery
Build the predictive models for prediction
of equipment condition and performance

11
Interactions

Data Data
Acquisition Preparation

Result
Interpretation Data Mining

12
VIMS Features
Operator

Download

Sensors & Controls

Monitor & Store Maintenance
Event list
Event recorder
Data logger
Trends Wireless Link
Cumulative data
Histograms
Payloads Management
VIMS wireless

13
Data Source

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VIMS Statistical Data Warehouse
1-3 minute interval statistical data
Minimum Regression Intercept
Maximum Regression Slope
Average
Data Range Regression SYY
Variance Standard Deviation

15
VIMS Data Description
Six CAT 789B trucks
300 MB of VIMS data
79 High Engine Speed events

One-minute data
statistics

16
SPRINT -A Decision Tree Algorithm
IBM Almaden Research Center

GINI index for the split point

gini ( s ) 1 p 2
j

n1 n2
ginisplit ( s ) gini ( s1 ) gini ( s2 )
n n
Strictly binary tree
Built-in v-fold cross validation

17
18
 VIMS EVENT PREDICTION

High Engine
Normal Engine Normal Engine
Speed
Speed Speed
Snapshot
VIMS
0 0 0 0 0 0 1 2 3 4 5 6 0 0 0 0 0
Data
High Eng

Event_ID 767_1 767_2

Predicte Other Other Eng_1 Eng_2 Other Other

d Label

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One-Minute
decision tree 20
 Decision Tree: Training on One-Minute Data
Total Errors = 120 (6.734%)

Predicted Class --> | Other | Eng1 | Eng3 | Eng2 | Eng4 | Eng6 | Eng5 |
----------------------------------------------------------------------------------------------------------------
Other | 1331 | 18 | 9| 5| 16 | 6| 1|
total = 1386
Eng1 | 0| 62 | 1| 3| 0| 0| 0|
total = 66
Eng3 | 0| 11 | 51 | 2| 2| 1| 0|
total = 67
Eng2 | 0| 12 | 8| 38 | 7| 0| 0|
total = 65
Eng4 | 0| 3| 7| 2| 55 | 0| 1|
total = 68
Eng6 | 0| 0| 0| 1| 0| 61 | 4|
total = 66
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Eng5 | 0| 0| 0| 0| 0| 0| 64 |
 Decision Tree: Test#1 on One-Minute Data
Total Errors = 24 (24%)

Predicted Class --> | Other | Eng1 | Eng3 | Eng2 | Eng4 | Eng6 | Eng5 |

-----------------------------------------------------------------------------------------------------------
Other | 59 | 3| 0| 2| 3| 0| 1|
total = 68
Eng1 | 4| 1| 0| 1| 0| 0| 0|
total = 6
Eng3 | 0| 3| 1| 0| 1| 0| 0|
total = 5
Eng2 | 1| 1| 1| 1| 0| 0| 0 |
total = 4
Eng4 | 1| 1| 0| 1| 1| 0| 0|
total = 4
Eng6 | 0| 0| 0| 0| 0| 7| 0|
total = 7
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Eng5 | 0| 0| 0| 0| 0| 0| 6|
 Decision Tree: Test#2 on One-Minute Data
Total Errors = 35 (17.86%)

Predicted Class --> | Other | Eng1 | Eng3 | Eng2 | Eng4 | Eng6 | Eng5 |
--------------------------------------------------------------------------------------------------------
Other | 141 | 9| 2| 4| 4| 0| 0 | total
= 160
Eng1 | 2| 2| 1| 1| 0| 0| 0| total
=6
Eng3 | 2| 1| 2| 0| 1| 0| 0| total
=6
Eng2 | 2| 1| 2| 1| 0| 0| 0|
total = 6
Eng4 | 1| 0| 1| 1| 3| 0| 0|
total = 6
Eng6 | 0| 0| 0| 0| 0| 6| 0|
total = 6
Eng5 | 0| 0| 0| 0| 0| 0 | 23 6 |
total = 6
Two-Minute
decision tree
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 Decision Tree
Training on Two-Minute Data Sets

Total Errors = 51 (5.743%)

Predicted Class --> | OTHER | ENG1 | ENG2 | ENG3 |

---------------------------------------------------------------------
OTHER | 657 | 6| 19 | 3| total =
685
ENG1 | 0| 62 | 10 | 0| total =
72
ENG2 | 0| 13 | 54 | 0| total =
67
ENG3 | 0| 0| 0| 64 | total =
64
--------------------------------------------------------------------- 25
 Decision Tree
Test #1 on Two-Minute Data

Total Errors = 14 (29.79%)

Predicted Class --> | OTHER | ENG1 | ENG2 | ENG3 |

---------------------------------------------------------------------
OTHER | 28 | 5| 4| 1|
total = 38
ENG1 | 1| 0| 0| 0|
total = 1
ENG2 | 2| 1| 1| 0|
total = 4
ENG3 | 0| 0| 0| 4|
total = 4
---------------------------------------------------------------------
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 Decision Tree
Test #2 on Two-Minute Data

Total Errors = 15 (15.31%)

Predicted Class --> | OTHER | ENG1 | ENG2 | ENG3 |

---------------------------------------------------------------------
OTHER | 71 | 8| 1| 0| total
= 80
ENG1 | 3| 3| 0| 0|
total = 6
ENG2 | 0| 3| 3| 0|
total = 6
ENG3 | 0| 0| 0| 6|
total = 6
---------------------------------------------------------------------
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Three-Minute
decision tree
28
Decision Tree
Training on Three-Minute Data

Total Errors = 28 (4.878%)

Predicted Class --> | OTHER | ENG1 | ENG2 |

----------------------------------------------------
OTHER | 411 | 23 | 4|
total = 438
ENG1 | 1| 65 | 0|
total = 66
ENG2 | 0| 0| 70 |
total = 70
----------------------------------------------------
412 | 88 | 74 |
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total = 574
Decision Tree
Test #1 on Three-Minute Data

Total Errors = 12 (19.05%)

Predicted Class --> | OTHER | ENG1 | ENG2 |

----------------------------------------------------
OTHER | 42 | 9| 0| total
= 51
ENG1 | 3| 5| 0| total
=8
ENG2 | 0| 0| 4| total
=4
----------------------------------------------------
45 | 14 | 4
30|
Decision Tree
Test #2 on Three-Minute Data

Total Errors = 9 (14.06%)

Predicted Class --> | OTHER | ENG1 | ENG2 |

----------------------------------------------------
OTHER | 47 | 5| 0| total
= 52
ENG1 | 4| 2| 0|
total = 6
ENG2 | 0| 0| 6|
total = 6
----------------------------------------------------
51 | 7| 316 |
total = 64
Decision Tree Summary
One-Minute model needs more complex tree
structure
One-Minute model gives low accuracy of
predictions
Three-Minute decision tree model gives
reasonable accuracy of predictions
Based on test #1 &#2
Other - 13% error rate
Eng1 - 50% error rate
Eng2 0 error rate
Other approach?

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 Backpropagation
A Neural Network Classification Algorithm

Node
Node Detail

x1
w1
w2
x2 f(z)
w3
x3
z = iwixi
Input Hidden Out
Layer
Some choices for F(z):
Characteristic: Each output f(z) = 1 / [1+e-z] (sigmoid)
corresponds to a possible classification. f(z) = (1-e-2z) / (1+e-2z) (tanh)

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 Minimize the Sum of Squares
SSQ Error Function

1 m
E ( t k yk )2
2 k 1
1 m
min E ( t k yk ) 2
2 k 1

yk (output) is a function of
the weights wj,k. Freeman & Skapura, Neural Networks,
Addison Wesley, 1992
tk is the true value. In the graph:

Ep is the sum of
E squares error
EW j ,k and solve EW j ,k 0 for Wj,k
W j ,k Ep is the gradient,
(direction of maximum
function increase)

34
More
Neural Network Modeling Results
Three-Minute training set

35
Neural Network Modeling Result
Three-Minute set: test #1 and #2
Test #1

Test #2

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NN Summary
Insufficient
data for one-minute and two-
minute prediction models
Three-minute network shows better
performance than the decision tree
model:
Other - 17% error rate
Eng1 - 28% error rate
Eng2 - 20% error rate

37
Conclusions
Predictivemodel can be built
Neural Network model is more accurate
than the Decision Tree one
Based on all data
Overall accuracy is not sufficient for
practical applications
More data is needed to train and test the
models

38
References
Failure Pattern Recognition of a Mining
Truck with a Decision Tree Algorithm
Tad Golosinski & Hui Hu, Mineral Resources
Engineering, 2002 (?)

Intelligent Miner-Data Mining Application for

Modeling VIMS Condition Monitoring Data
Tad Golosinski and Hui Hu, ANNIE, 2001, St. Louis

Data Mining VIMS Data for Information on

Truck Condition
Tad Golosinski and Hui Hu, APCOM 2001, Beijing, P.R.
China

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