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A System-Level Approach for Enablement of Prognostics and Health Management - Utilizing Industrial AI
Luleå University of Technology, Department of Civil, Environmental and Natural Resources Engineering, Operation, Maintenance and Acoustics.
2026 (English)Licentiate thesis, comprehensive summary (Other academic)
Abstract [en]

Industrial production systems depend on key assets to maintain process continuity and support essential operational tasks. To meet these requirements, assets must consistently deliver their intended functions. Failures can reduce system performance and result in downtime, production loss, and increased maintenance costs. Furthermore, severe failures may compromise asset integrity and introduce safety risks. These potential consequences highlight the importance of systematic health management to promote reliable and safe operation throughout the asset’s life cycle.

Maintenance plays a vital role in ensuring asset functionality. However, relying solely on corrective or schedule-based maintenance approaches often proves insufficient. When maintenance occurs too late, early signs of degradation may remain undetected and progress into more severe failures. In contrast, performing maintenance too early leads to unnecessary work and higher costs. Prognostics and Health Management (PHM), which encompasses state detection, diagnostics, and prognostics, and maintenance decision support, enhances the ability to understand the asset condition and intervene proactively.

The work described in this thesis aims at enabling PHM by establishing essential steps: system-level description of the asset and its functions, failure analysis, and detecting deviations in critical components. Assets are decomposed into subsystems and components to clarify their roles and interactions. Further, the thesis examines how asset functions can be impaired and identifies the components whose degradation is most critical to functional performance. These insights guide the selection of components that require condition monitoring. Methods are then developed for deviation detection from expected performance, forming the basis for state detection within a PHM framework. Additionally, a review of data-driven PHM approaches for mining processing machines highlights gaps in system-level health management and the use of different data modalities, further motivating the structured methods developed in this thesis.

The contributions are demonstrated through two case studies in construction and mining, respectively. In the construction case study, 3D point-cloud data are used to identify missing or deviated scaffolding elements that compromise structural stability. In mining, image-based analysis is applied to a Rotary Vacuum Drum Filter (RVDF) to detect wire failures that can damage the filter cloth and reduce asset availability. Early fault detection supports structural integrity, reduces downtime and lowers maintenance costs. By combining asset structure analysis, failure analysis to identify critical components, and methods for deviation detection, this work delivers essential building blocks for the enablement of PHM. Future work will explore the development of diagnostics, prognostics models and multimodal data integration to further support maintenance decision-making and to strengthen health management capabilities.

Place, publisher, year, edition, pages
Luleå University of Technology, 2026.
Series
Licentiate thesis / Luleå University of Technology, ISSN 1402-1757
Keywords [en]
Prognostics and Health Management, Maintenance, Mining, Construction, Scaffolding, Rotary Vacuum Drum Filter, Point cloud, Image processing, Deep learning
National Category
Other Civil Engineering
Research subject
Operation and Maintenance Engineering
Identifiers
URN: urn:nbn:se:ltu:diva-115921ISBN: 978-91-8048-975-1 (print)ISBN: 978-91-8048-976-8 (electronic)OAI: oai:DiVA.org:ltu-115921DiVA, id: diva2:2026999
Presentation
2026-03-09, E632, Luleå University of Technology, Luleå, 09:30 (English)
Opponent
Supervisors
Available from: 2026-01-12 Created: 2026-01-12 Last updated: 2026-03-03Bibliographically approved
List of papers
1. Artificial intelligence-driven safety assessment of scaffolding using LiDAR sensing
Open this publication in new window or tab >>Artificial intelligence-driven safety assessment of scaffolding using LiDAR sensing
2026 (English)In: Frontiers in Built Environment, E-ISSN 2297-3362, Vol. 12, article id 1723491Article in journal (Refereed) Published
Abstract [en]

The construction industry is embracing transformation through the integration of digitization, artificial intelligence (AI), and immersive technologies. On a construction site, continuous assessment is vital for ensuring both the reliability of assets and safety of workers. Scaffolding is a key structural support asset that requires regular inspections for detection and identification of alterations from the design rules that could compromise integrity and stability. At present, such inspections to identify deviations are primarily visual and conducted by the site managers or accredited personnel. However, visual inspection is time-intensive and susceptible to human errors, which can lead to unsafe conditions. This study explores the use of AI and digital technologies to automate and enhance scaffolding inspections process to contribute toward safety improvement. A cloud-based AI platform is developed to process and analyze 3D point-cloud data of scaffolding structures to detect modifications through comparisons as well as evaluate the certified reference scan with a recent scan. The proposed workflow incorporates prognostics and health management concepts with continuous monitoring to identify structural modifications and further assist with decision-making. The results indicate that the proposed approach can limit reliance on manual visual inspections. By enabling automated monitoring of scaffolding, the proposed approach reduces the time and effort required for inspection process, while enhancing the safety on a construction site.

Place, publisher, year, edition, pages
Frontiers Media S.A., 2026
Keywords
3D point-cloud analysis, artificial intelligence, cloud-based monitoring platform, construction safety, prognostics and health management, scaffolding inspection
National Category
Construction Management
Research subject
Operation and Maintenance Engineering
Identifiers
urn:nbn:se:ltu:diva-115917 (URN)10.3389/fbuil.2026.1723491 (DOI)2-s2.0-105030816692 (Scopus ID)
Funder
Svenska Byggbranschens Utvecklingsfond (SBUF), 14110
Note

Full text license: CC BY;

This article has previously appeared as a manuscript in a thesis.

Available from: 2026-01-12 Created: 2026-01-12 Last updated: 2026-03-04
2. A proposed approach to implement Prognostics and Health Management of drum filters in mining production using Industrial AI
Open this publication in new window or tab >>A proposed approach to implement Prognostics and Health Management of drum filters in mining production using Industrial AI
2025 (English)Conference paper, Published paper (Refereed)
National Category
Engineering and Technology
Identifiers
urn:nbn:se:ltu:diva-115918 (URN)
Conference
International Congress and Workshop on Industrial AI and eMaintenance
Available from: 2026-01-12 Created: 2026-01-12 Last updated: 2026-01-12
3. Minimizing Unplanned Downtime in Rotary Vacuum Drum Filters for Iron Ore Mining through Image-based Analysis
Open this publication in new window or tab >>Minimizing Unplanned Downtime in Rotary Vacuum Drum Filters for Iron Ore Mining through Image-based Analysis
Show others...
2025 (English)In: Proceedings of the Annual Conference of the PHM Society 2025 / [ed] C. S. Kulkarni; M. E. Orchard, Prognostics and Health Management Society , 2025Conference paper, Published paper (Refereed)
Abstract [en]

In iron mining the processing phase broadly consists of sorting, concentrating, and pelletizing of the iron ore, this is to increase the iron content in the final product. In pelletizing, the filtering stage which controls the moisture content in the iron cake plays a crucial role. A Rotatory Vacuum Drum Filter (RVDF) is one of the mining equipment for removing excessive moisture by separating solid iron cake from slurry. A supporting wire which holds the cloth mounted on the frame of the RVDF is one of the critical components. During operation, recursive compression and stretching due to variation in pressure may lead to wire failure. This failure significantly impacts the integrity and efficiency of filter cloth that affects the filtration performance. If the wire failure is not detected promptly, it can lead to prolonged maintenance time, substantial maintenance cost and unplanned downtime, consequently affecting system availability. This work demonstrates health monitoring of filtering system in mining, designed to alert the operators about the emerging failure, to take appropriate maintenance action and minimize further damage, and unplanned downtime.

This paper introduces a computer-vision based monitoring approach that leverages image data of the drum filter during operation. The proposed approach identifies wire-induced degradation pattern on the filter cloth. Extracted video frames from the drum filter are processed to isolate the region of interest. Using Hough transform horizontal sections of the drum are detected followed by a sliding window analysis to evaluate the variations in pixel intensity. For normal surface, the average intensity variations remain low, typically ranging from 5 to 10. However, it spikes up to around 40 when irregular patterns are detected. The focus of this work is on detection and diagnostics, a transition towards prognostics is envisioned by incorporating pressure sensor data. Integrating multi-modal data may enhance the capability of predicting failure and improve the system availability.

Place, publisher, year, edition, pages
Prognostics and Health Management Society, 2025
Series
Annual Conference of the PHM Society, E-ISSN 2325-0178 ; 17:1
National Category
Other Civil Engineering
Research subject
Operation and Maintenance Engineering
Identifiers
urn:nbn:se:ltu:diva-115919 (URN)10.36001/phmconf.2025.v17i1.4362 (DOI)2-s2.0-105025349397 (Scopus ID)
Conference
17th Annual Conference of the Prognostics and Health Management (PHM) Society, Bellevue, WA, USA, October 27-30, 2025
Note

Full text license: CC BY 3.0

Available from: 2026-01-12 Created: 2026-01-12 Last updated: 2026-01-14Bibliographically approved
4. Data-driven Prognostics and Health Management for mining processing machine: A systematic review
Open this publication in new window or tab >>Data-driven Prognostics and Health Management for mining processing machine: A systematic review
(English)In: Article in journal (Refereed) Submitted
National Category
Engineering and Technology
Identifiers
urn:nbn:se:ltu:diva-115920 (URN)
Available from: 2026-01-12 Created: 2026-01-12 Last updated: 2026-01-12

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Prabhu, Sameer

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