Fault detection and diagnosis for the engine electrical system of a space launcher based on a temporal convolutional autoencoder and calibrated classifiers

In the context of the health monitoring for the next generation of reusable space launchers, we outline a first step toward developing an onboard fault detection and diagnostic capability for the electrical system that controls the engine valves. Unlike existing approaches in the literature, our solution is designed to meet a broader range of key requirements. This includes estimating confidence levels for predictions, detecting out-of-distribution (OOD) cases, and controlling false alarms. The proposed solution is based on a temporal convolutional autoencoder to automatically extract low-dimensional features from raw sensor data. Fault detection and diagnosis are respectively carried out using a binary and a multiclass classifier trained on the autoencoder latent and residual spaces. The classifiers are histogram-based gradient boosting models calibrated to output probabilities that can be interpreted as confidence levels. A relatively simple technique, based on inductive conformal anomaly detection, is used to identify OOD data. We leverage other simple yet effective techniques, such as cumulative sum control chart (CUSUM) to limit the false alarms, and threshold moving to address class imbalance in fault detection. The proposed framework is highly configurable and has been evaluated on simulated data, covering both nominal and anomalous operational scenarios. The results indicate that our solution is a promising first step, though testing with real data will be necessary to ensure that it achieves the required maturity level for operational use.