This paper focuses on the development of a physics-based diagnostic tool for alternating current (AC) solenoid valves which are categorized as critical components of many machines used in the process industry. Signal processing and machine learning based approaches have been proposed in the literature to diagnose the health state of solenoid valves. However, the approaches do not give a physical explanation of the failure modes. In this work, being capable of diagnosing failure modes while using a physically interpretable model is proposed. Feature attribution methods are applied to CNN on a large data set of the current signals acquired from accelerated life tests of several AC solenoid valves. The results reveal important regions of interest on current signals that guide the modeling of the main missing component of an existing physical model. Two model parameters, which are the shading ring and kinetic coulomb forces, are then identified using current measurements along the lifetime of valves. Consistent trends are found for both parameters allowing to diagnose the failure modes of the solenoid valves. Future work will consist of not only diagnosing the failure modes, but also of predicting the remaining useful life.

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There is an emerging industrial demand for predictive maintenance algorithms that exhibit high levels of predictive accuracy. Such condition monitoring tools must estimate dynamic quantities, such as Remaining Useful Lifetime (RUL) and the State of Health (SOH), based on a, typically, restricted set of measurements that can be obtained in an operational setting. These quantities exhibit inherent stochasticity and can only be approximately determined a posteriori to system failure. This paper proposes a generic prognostic tool for probabilistic condition monitoring of mechatronic systems, with the aim to improve the probabilistic prediction of condition metrics, specifically RUL and SOH. Therefore we propose to identify a Hidden Markov Model (HMM) from a fully instrumented measurement set, that is only available for a restricted set of run-to-failure experiments, typically gathered in an R&D setting. Although being artificial and retrospectively constructed metrics, we interpret RUL and SOH as physical measurements with the purpose to identify accurate degradation dynamics. Once the degradation model is identified, we practice the mathematical flexibility of the HMM framework to estimate several of the no longer available dynamic quantities of interest in real-time, from the limited set of measurements that are available in an operational setting. This modelling paradigm is known as virtual sensing. Predictive performance and computational efficiency are further improved by domain knowledge based pre-processing of the measurements. We apply our methodology to solenoid valves (SV), a widely used and often critical component in many industrial systems, which display a large variation in useful lifetime. Benchmark results show that the predictive capabilities of the presented methodology compares with prognostic techniques that are more computationally and memory demanding.