Electrical contacts provide a well-proven solution to switching various loads in a wide variety of applications, such as power distribution, control applications, automotive and telecommunications. However, electrical contacts are known for limited reliability due to degradation effects upon the switching contacts due to arcing and fretting. Essentially, the life of the device may be determined by the limited life of the contacts. Failure to trip, spurious tripping and contact welding can, in critical applications such as control systems for avionics and nuclear power application, cause significant costs due to downtime, as well as safety implications. Prognostics provides a way to assess the remaining useful life (RUL) of a component based on its current state of health and its anticipated future usage and operating conditions. In this thesis, the effects of contact wear on a set of electromagnetic relays used in an avionic power controller is examined, and how contact resistance combined with a prognostic approach, can be used to ascertain the RUL of the device. Two methodologies are presented, firstly a Physics based Model (PbM) of the degradation using the predicted material loss due to arc damage. Secondly a computationally efficient technique using posterior degradation data to form a state space model in real time via a Sliding Window Recursive Least Squares (SWRLS) algorithm. Health monitoring using the presented techniques can provide knowledge of impending failure in high reliability applications where the risks associated with loss-of-functionality are too high to endure. The future states of the systems has been estimated based on a Particle and Kalman-filter projection of the models via a Bayesian framework. Performance of the prognostication health management algorithm during the contacts life has been quantified using performance evaluation metrics. Model predictions have been correlated with experimental data. Prognostic metrics including Prognostic Horizon (PH), alpha-Lamda (α-λ), and Relative Accuracy have been used to assess the performance of the damage proxies and a comparison of the two models made.

This thesis presents a novel hybrid prognostic methodology, integrating physics-based and data-driven prognostic models, to enhance the prognostic accuracy, robustness, and applicability. The presented prognostic methodology integrates the short-term predictions of a physics-based model with the longer term projection of a similarity-based data-driven model, to obtain remaining useful life estimations. The hybrid prognostic methodology has been applied on specific components of two different engineering systems, one which represents accelerated, and the other a nominal degradation process. Clogged filter and fatigue crack propagation failure cases are selected as case studies. An experimental rig has been developed to investigate the accelerated clogging phenomena whereas the publicly available Virkler fatigue crack propagation dataset is chosen after an extensive literature search and dataset analysis. The filter clogging experimental rig is designed to obtain reproducible filter clogging data under different operational profiles. This data is thought to be a good benchmark dataset for prognostic models. The performance of the presented methodology has been evaluated by comparing remaining useful life estimations obtained from both hybrid and individual prognostic models. This comparison has been based on the most recent prognostic evaluation metrics. The results show that the presented methodology improves accuracy, robustness and applicability. The work contained herein is therefore expected to contribute to scientific knowledge as well as industrial technology development.

La construction de modèles de pronostic nécessite la compréhension du processus de dégradation des composants critiques surveillés afin d’estimer correctement leurs durées de fonctionnement avant défaillance. Un processus de d´dégradation peut être modélisé en utilisant des modèles de Connaissance issus des lois de la physique. Cependant, cette approche n´nécessite des compétences Pluridisciplinaires et des moyens expérimentaux importants pour la validation des modèles générés, ce qui n’est pas toujours facile à mettre en place en pratique. Une des alternatives consiste à apprendre le modèle de dégradation à partir de données issues de capteurs installés sur le système. On parle alors d’approche guidée par des données. Dans cette thèse, nous proposons une approche de pronostic guidée par des données. Elle vise à estimer à tout instant l’état de santé du composant physique et prédire sa durée de fonctionnement avant défaillance. Cette approche repose sur deux phases, une phase hors ligne et une phase en ligne. Dans la phase hors ligne, on cherche à sélectionner, parmi l’ensemble des signaux fournis par les capteurs, ceux qui contiennent le plus d’information sur la dégradation. Cela est réalisé en utilisant un algorithme de sélection non supervisé développé dans la thèse. Ensuite, les signaux sélectionnés sont utilisés pour construire différents indicateurs de santé représentant les différents historiques de données (un historique par composant). Dans la phase en ligne, l’approche développée permet d’estimer l’état de santé du composant test en faisant appel au filtre Bayésien discret. Elle permet également de calculer la durée de fonctionnement avant défaillance du composant en utilisant le classifieur k-plus proches voisins (k-NN) et le processus de Gauss pour la régression. La durée de fonctionnement avant défaillance est alors obtenue en comparant l’indicateur de santé courant aux indicateurs de santé appris hors ligne. L’approche développée à été vérifiée sur des données expérimentales issues de la plateforme PRO-NOSTIA sur les roulements ainsi que sur des données fournies par le Prognostic Center of Excellence de la NASA sur les batteries et les turboréacteurs. / Constructing prognostics models rely upon understanding the degradation process of the monitoredcritical components to correctly estimate the remaining useful life (RUL). Traditionally, a degradationprocess is represented in the form of physical or experts models. Such models require extensiveexperimentation and verification that are not always feasible in practice. Another approach that buildsup knowledge about the system degradation over time from component sensor data is known as datadriven. Data driven models require that sufficient historical data have been collected.In this work, a two phases data driven method for RUL prediction is presented. In the offline phase, theproposed method builds on finding variables that contain information about the degradation behaviorusing unsupervised variable selection method. Different health indicators (HI) are constructed fromthe selected variables, which represent the degradation as a function of time, and saved in the offlinedatabase as reference models. In the online phase, the method estimates the degradation state usingdiscrete Bayesian filter. The method finally finds the most similar offline health indicator, to the onlineone, using k-nearest neighbors (k-NN) classifier and Gaussian process regression (GPR) to use it asa RUL estimator. The method is verified using PRONOSTIA bearing as well as battery and turbofanengine degradation data acquired from NASA data repository. The results show the effectiveness ofthe method in predicting the RUL.