Design Method of Fault Detector for Injection Unit

An injection unit is considered as a speed control system utilizing a reaction-force sensor. Our purpose is to design a fault detector that detects and isolates actuator and sensor faults given that the system is disturbed by a reaction force. First described is the fault detector’s general structure. In this system, a disturbance observer that estimates the reaction force is designed for the speed control system in order to obtain the residual signals, and then post-filters that separate the specific frequency elements from the residual signals are applied in order to generate the decision signals. Next, we describe a fault detector designed specifically for a model of the injection unit. It is shown that the disturbance imposed on the decision variables can be made significantly small by appropriate adjustments to the observer bandwidth, and that most of the sensor faults and actuator faults can be detected and some of them can be isolated in the frequency domain by setting the frequency characteristics of the post-filters appropriately. Our result is verified by experiments for an actual injection unit.