A Framework for an ML-Based Predictive Turbofan Engine Health Model

A predictive health modeling framework was developed for a family of turbofan engines, focusing on early detection of performance degradation. Turbine Gas Temperature (TGT) was employed as the primary indicator of engine health within the model, due to its strong correlation with core engine performance and thermal stress. The present research uses engine health monitoring (EHM) data acquired from in-service turbofan family engines. TGT is typically measured downstream of the high-pressure turbine stage and is regarded as the key thermodynamic variable of the gas turbine cycle. Three new training approaches were proposed using data segmentation based on time between major overhauls and compared with the conventional train–test split method. Detrending was employed to effectively remove trends and seasonality, enabling the ML-based model to learn more intrinsic relationships. Large generalized models based on the entire engine family were also investigated. Prediction performance was evaluated using selected machine learning (ML) models, including both linear and nonlinear algorithms, as well as a long short-term memory (LSTM) approach. The models were compared based on accuracy and other relevant performance metrics. The prediction accuracies of ML models depend on the selection of data size and segmentation for training and testing. For individual engines, the proposed training approaches predicted TGT with the accuracy of 4 ∘C to 6 ∘C in root mean square error (RMSE) by utilizing 65% less data than the train (80%)–test (20%) split method. Utilizing the data of each family engine, the large generalized model achieved similar prediction accuracy in RMSE with a smaller interquartile range. However, the amount of data required was 45–300 times larger than the proposed approaches. The sensitivity of prediction accuracy to the size of the training dataset offers valuable insights into the framework’s applicability, even for engines with limited data availability. Uncertainty quantification showed a coverage width criterion (CWC) between 29 ∘C and 40 ∘C, varying with different family engines.