Driver Attention in Automatic Transmission Cars
ORIGINAL ARTICLE
Data-driven system health monitoring technique using autoencoder for the safety management of commercial aircraft
Hyunseong Lee1 • Hyung Jin Lim1 • Aditi Chattopadhyay2
Received: 15 April 2020 / Accepted: 11 July 2020 / Published online: 23 July 2020 � Springer-Verlag London Ltd., part of Springer Nature 2020
Abstract This paper presents the development of a real-time and data-driven aircraft health monitoring technique to monitor in-flight
operations by detecting off-nominal flight operation such as aircraft upset, which is strongly related to aviation safety and is
a primary contributor to fatal accidents worldwide. A deep autoencoder is adopted to effectively estimate the complex
flight responses from historical flight datasets and capture potential upset precursors. Key sensing variables highly relevant
to upset primary factors are selected based on aircraft accident reports. The variables are then preprocessed using deci-
mation and Savitzky–Golay filter for sampling frequency synchronization and denoising. Statistical detection baselines are
employed to extract statistically unusual operation patterns that highly correlate with upset precursors. The performance of
the developed methodology is evaluated by demonstrating real-time detection of upset precursors in flight datasets. An
actual accident scenario is introduced to validate detection robustness. The results show that the proposed aircraft upset
detector technique can enhance pilots’ situational awareness by providing early safety alert for more effective flight safety
management.
Keywords Aircraft health monitoring � Aircraft upset detection � Autoencoder � Aviation safety
1 Introduction
Despite the significant advances in commercial aircraft
guidance and control technologies in recent years, the risk
of encountering aircraft upset conditions remains a critical
safety issue [1]. Aircraft upset conditions can be defined as
‘‘any uncommanded or inadvertent event with an anoma-
lous aircraft attitude, attitude rate, acceleration, airspeed, or
trajectory,’’ all of which can lead to aircraft accidents [2].
One of the most important causes of aircraft accidents is
loss of control in-flight (LOC-I), a main contributor to fatal
aviation accidents worldwide, with the highest number of
fatalities [3]. An LOC-I event is highly complex event and
is often caused by aircraft upset conditions with an
individual or multiple causal factors. A statistical analysis
of commercial aircrafts conducted by the Boeing Company
showed a total of 51 fatal accidents occurring between
2008 and 2019, out of which a total of 1183 fatalities
(46.7% of total fatalities) resulted from 13 LOC-I accidents
(25.5% of fatal accidents) [4]. A comprehensive study by
the National Aeronautics and Space Administration
(NASA) Langley Research Center of 126 LOC-I accidents
(Part 121) occurring between 1979 and 2009 showed sev-
eral contributing factors and the worst scenarios created by
the combination of these factors [3, 5]. Three primary
factors were identified: (1) system faults and errors (69
frequencies (33.3% of total factors)) with 1544 fatalities
(29% of total fatalities)), (2) icing (27 frequencies (21.4%
of total factors)) with 590 fatalities (9.7% of total fatali-
ties)), and (3) inappropriate crew response (18 frequencies
(14.3% of total factors)) with 1095 fatalities (14.3% of total
fatalities)). Specifically, system faults and errors events
were associated with autopilot, engine, and control surface
malfunctions or faults; icing events were related to the
airfoil contamination that led to severe stall condition; and
inappropriate crew response events were associated with
& Hyung Jin Lim [email protected]
1 School for Engineering of Matter, Transport, and Energy,
Arizona State University, Tempe, AZ 85287, USA
2 Mechanical and Aerospace Engineering, School for
Engineering of Matter, Transport, and Energy, Arizona State
University, Tempe, AZ 85287, USA
123
Neural Computing and Applications (2021) 33:3235–3250 https://doi.org/10.1007/s00521-020-05186-x(0123456789().,-volV)(0123456789().,-volV)
the lack of pilots’ situational awareness, which caused
failure to recover upset conditions.
In recent studies, a report by the International Air
Transport Association (IATA) has shown that the number
of worldwide flight passengers and air traffic is expected to
double by 2035 [6]. This study shows that an increase in
safety-related issues may not be able to be completely
managed by current aviation safety infrastructures, partic-
ularly since the current aviation system relies heavily on
manual operations, inspections, and communications
between pilots and air traffic controllers (ATCs). Thus,
there is an increased need for automated and proactive
safety management techniques for aviation safety. Tech-
niques that monitor aircraft system to accurately diagnose
upset conditions at initial stage and to prevent further
development of catastrophic accidents with potential
domino effects on the air traffic system are an emerging
need. As an example, the Federal Aviation Administration
(FAA) is currently developing the Next Generation Air
Transportation System (NextGen) to efficiently manage
aircraft and air traffic safety through an interconnected
information process between aircraft and ATCs [7]. As
such, there is a need for a reliable and automated in-flight
aircraft system health monitoring (SHM) technique to
prevent aircraft accidents and enhance overall aviation
safety. Furthermore, such monitoring techniques are also
expected to enhance the pilots’ situational awareness to
mitigate aircraft upsets at early stage.
Many techniques have been proposed to monitor aircraft
system and detect upset conditions, and generally they fall
into two broad categories: (1) model-based and (2) data-
driven. Most model-based techniques adopt a physics-
based numerical model to identify upset events [8–15].
These techniques use aircraft flight dynamics models to
estimate safe operating envelopes and to capture upset
events when the aircraft operates near the edge or out of the
envelopes. In addition, such techniques adaptively estimate
the envelopes to provide safety margins under varying
flight conditions. For instance, an adaptive and predictive
control algorithm was developed to predict the safety
margins in real time as the aircraft operation approaches
the edge of the safe operating envelopes [9]. An adaptive
estimation technique using differential vortex lattice algo-
rithm in conjunction with extended Kalman filter was
proposed to estimate impaired aircraft performance
envelopes [13]. However, the main limitations of these
model-based approaches are (1) the high cost of modeling a
complete aircraft, (2) a lack of generalization (strictly
system dependent), and (3) limited ability to quantify
uncertainties in realistic flight operations [16].
Recently, data-driven approaches have been extensively
used to perform aircraft SHM because of their efficient
information fusion of multivariate time series data and
robust diagnostic capabilities [17–31]. In general, flight
data recorder (FDR) datasets obtained from aircraft
onboard sensors or simulated flight data can be used to
train machine learning (ML) algorithms to model aircraft
system [21]. Based on these trained ML models, the current
status of the aircraft system is assessed, and future flight
performances are predicted. For instance, a predictive
monitoring technique that used a neural network (NN) and
Markov chain (MC) to predict landing state such as vertical
speed, acceleration, and distance was proposed to mitigate
landing safety issue, which can efficiently prevent further
potential domino effects near airport [22]. Similarly, an
aviation safety monitoring technique using a Gaussian
mixture model was proposed to detect abnormal flight
operations during takeoff and approach flight phases in the
FDR datasets. The detected anomalies were validated by
aviation experts, and the detection capability was examined
by comparing the detection results with conventional
exceedance detection (industry standard), multiple kernel
anomaly detection, and cluster-based anomaly detection
methods [23]. Additionally, a detection technique using
logarithmic multivariate Gaussian (LMG) model was
developed to capture the operational anomalies in the FDR
datasets. Specifically, multiple LMG models were sepa-
rately trained for each flight phase to eliminate the effect of
correlation changes in the sensing variables at different
flight phases, and the anomaly detection was performed for
each flight phase [24]. While many data-driven approaches
to perform aircraft SHM are available, the diagnostic
capabilities of current approaches are limited since they do
not address the following issues: (1) real-time monitoring
of entire in-flight operation to detect abnormal flight con-
ditions prior to actual upsets; (2) system health assessment
by monitoring key sensing variables that are directly rela-
ted to upset events; and (3) performance evaluation under
actual upset scenario.
Motivated by these challenges, a real-time and data-
driven SHM technique that uses a deep autoencoder (DAE)
to detect potential upset precursors of commercial aircraft
is presented in this paper. This SHM technique tackles the
limitation of previous data-driven approaches, as men-
tioned earlier, and is expected to improve the situational
awareness of pilots while providing a sufficient margin of
time for pilots to prevent hazardous situations. The FDR
datasets recorded from commercial aircraft are utilized to
develop the proposed technique and to capture possible
upset precursors in the datasets. Based on the investigation
of aircraft accident reports, key sensing variables that
highly correlate with upset contributing factors are selected
from the FDR datasets. Decimation and Savitzky–Golay
(SG) filtering are utilized to preprocess the sensing vari-
ables to implement sampling rate synchronization and
denoising. Subsequently, a DAE model is constructed and
3236 Neural Computing and Applications (2021) 33:3235–3250
123
trained using the preprocessed variables to model the
complex relationships and statistical patterns among the
key sensing variables. The architecture and hyperparame-
ters of the DAE are optimized based on the trained model
performances. The potential upset precursors are detected
and localized using the detection baselines derived from
the reconstruction error distributions. The proposed tech-
nique is then validated through a demonstrative real-time
precursor detection in the FDR datasets. The associated
possible upset initiation and coupled response are analyzed.
Finally, a FDR dataset obtained from an actual accident
report is used in order to further demonstrate the diagnostic
robustness of the proposed approach. The developed air-
craft SHM technique can serve as a part of an integrated
aviation health management system (e.g., the NextGen
system) that automatically interconnects information
between aircraft and air traffic controllers (ATCs) for
efficient and proactive health assessment.
The remaining part of the paper is organized as follows.
The research background for the DAE model and the FDR
datasets used in this study are described in Sect. 2. In
Sect. 3, the aircraft SHM technique using the DAE model
and detection baseline is detailed. The performance of the
developed technique is evaluated in Sect. 4. Finally, in
Sect. 5, the concluding remarks are presented.
2 Research background
2.1 Deep autoencoder (DAE)
Autoencoder (AE) is an unsupervised artificial neural net-
work model and is used to estimate reconstructed input
variables (outputs) that are close to their original inputs by
accounting for the complex relationships and statistical
patterns in multivariate variables [32, 33]. As shown in
Fig. 1, the AE model mainly consists of three types of
layers: (1) input (Layer 1), (2) bottleneck hidden (Layer 2),
and (3) output (Layer 3). In particular, the AE model with a
single hidden layer includes a process of encoding (Layer 1
to 2) and decoding (Layer 2 to 3); the equation of the
encoding and decoding can be formulated as Eq. 1 and
Eq. 2, respectively [34]:
z ¼ a Wxzx þ bxzð Þ ð1Þ x̂ ¼ a Wzxz þ bzxð Þ: ð2Þ
The encoding process in Eq. 1 maps the input variables
x in Layer 1 to a hidden representation z in Layer 2 through
an affine transformation (weight W and bias b) with a
nonlinear transformation (activation) function a. The original inputs are reconstructed (x̂) by mapping the hidden
representation in Layer 2 back to its original input space
(Layer 3) in the decoding process (Eq. 2). Subsequently,
the reconstruction errors � between the original and
reconstructed inputs are estimated as
� ¼ x � x̂k k; ð3Þ
where �k k is often set to be ‘2-norm. In the training process, the AE model is optimized by minimizing the reconstruc-
tion error. In general, the AE model with more than one
hidden layer is called DAE, and the additional encoding
and decoding processes are implemented in each added
hidden layer. By adding multiple hidden layers, DAE can
effectively represent the complex patterns and nonlinear
relations over input variables [35].
In addition, DAE model can be utilized for deviation-
based anomaly detection where anomalous instances are
scored by reconstruction errors. For instance, in a semi-
supervised manner, normal instances (assumed majority of
the datasets) can be used to train the DAE model so that the
trained model provides an accurate estimation with small
reconstruction errors when the inputs are normal events. In
contrast, large reconstruction errors are observed when
inputs are anomalous events (minority of the datasets)
[36, 37]. This concept can be extended to aircraft upset
detection scenarios where the instances of normal events
are abundant, while upset events are rare. Hence, in this
study, the DAE model is adopted to model standard flight
operations; abnormal operations or potential upsets are
detected using the reconstruction error and the statistical
detection baselines. The detailed description of the DAE
model construction and detection baselines for the upset
precursor detection is addressed in Sect. 3.4.
Fig. 1 Schematic of general autoencoder (AE) model
Neural Computing and Applications (2021) 33:3235–3250 3237
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2.2 Dataset construction and assumptions
In general, FDR datasets (also called the ‘‘black-box’’
datasets) are recorded from onboard sensors in commercial
aircraft during flight operations and used for flight analytics
and forensics after aircraft incidents or accidents. In this
study, large FDR datasets of commercial aircraft, which
have been sanitized and obtained from NASA’s Discovery
in Aeronautics Systems Health (DASH) link network [38],
are utilized (referred to as DASHlink datasets in this work).
The DASHlink datasets involve the recorded sensing
variables in time series from 186 onboard sensors as dis-
crete or continuous forms. For instance, the discrete vari-
ables are generally integers that indicate a particular flight
state or mode, such as flight phase and landing gear posi-
tion. The continuous variables display the current aircraft
performances and operations, such as aircraft position,
velocity, and engine operation-related variables. The flight
phases in the datasets are categorized into seven groups: (1)
parking, (2) taxi, (3) takeoff, (4) ascent, (5) cruise, (6)
descent, and (7) landing. Each digit represents the current
flight phase of the aircraft. The sampling rate of the
recorded variables varies between 0.25 and 16 Hz, and the
flight duration range is from 56 min to 3 h and 22 min,
which hinders the direct usage of the datasets for aircraft
monitoring [21]. Furthermore, the DASHlink datasets are
unlabeled, so any explicit information about aircraft type,
system health metrics, and flight plan (departure, way-
points, and arrival) is not provided.
The aforementioned problems prevent direct compar-
ison with reported flight incidents or accidents in public
records and limit the performance of data-driven, in-flight
monitoring techniques since flight performances are highly
dependent on flight plans. Therefore, a decision boundary
was assumed that flight operations under potential upset
events will exhibit statistically significant off-nominal
tendencies with the abnormal flight dynamics. In addition,
the DASHlink datasets were categorized by the flight plans,
and the potential aircraft type was identified to mitigate
these issues. A total of 92,329 flights were investigated; the
recorded latitude (LATP) and longitude (LONP) at the
beginning and end of in-flight (weight on wheels switch
off) were used to identify the departure and arrival airports,
respectively. In particular, the locations of the airports were
pinpointed by searching the closest airports from the
recorded LATP and LONP within 0.005 decimal degrees.
With this process, the DASHlink datasets were categorized
by the flight plans. Among them, 1179 flights categorized
by three flight plans, where the largest number of flight
events is available among the datasets, were investigated.
Table 1 details the investigated DASHlink datasets
including the airports and number of flight events.
Subsequently, the identification of the potential aircraft
type was conducted by matching flight history record with
two additional databases: (1) Bureau of Transportation
Statistics [39] and (2) NASA Sherlock [40]; these data-
bases include the past flight schedules with the aircraft
types and airport information. For instance, the departure
and arrival time at a certain airport in the DASHlink
datasets were matched with the recorded flight schedules in
these databases. The potential aircraft type was presumed
as a small-sized and single-aisle aircraft such as Bom-
bardier CRJ700, De Havilland Canada Dash 8 (DHC-8)
Q400, and Embraer E170 series aircrafts. Based on the
presumed aircraft type, accidents from Part 121 occurred
between 2000 and 2019 (20 years) were investigated from
the National Transportation Safety Board (NTSB) database
[41]. Among the reported accidents, a scenario of the
severe aerodynamic stall was found and investigated [42].
Hence, two FDR datasets were used in this study: The
DASHlink datasets were utilized to develop the proposed
aircraft SHM technique and demonstrate its detection
capabilities, and the accident dataset obtained from the
National Transportation Safety Board (NTSB) database
(referred to as NTSB dataset in this work) was used to
further validate the diagnostic capabilities of the proposed
SHM method under actual upset scenario. In-flight opera-
tions, including takeoff, ascent, cruise, and descent flight
phases, were considered in this work to examine the
robustness of the developed technique under flight phase
variations.
3 Aircraft system health monitoring using deep autoencoder
3.1 Overview
The proposed detection approach is mainly divided into a
training (off-line) phase and a monitoring (online) phase, as
shown in Fig. 2. In the training phase, the data prepro-
cessing and DAE model training are implemented. Key
sensing variables that are directly related to primary air-
craft upset contributing factors are selected from the orig-
inal DASHlink datasets for accurate and efficient aircraft
SHM, as detailed in Sect. 3.2. The selected key variables
are preprocessed using the decimation in conjunction with
the SG filter to synchronize sampling rates and reduce
inherent noise in the sensing variables, as described in
Sect. 3.3. Subsequently, the preprocessed variables are
utilized to train the DAE model to estimate the standard
flight performances during in-flight operations. The statis-
tical detection baselines derived from the reconstruction
errors are modeled to detect abnormal flight operations that
are related to upset precursors; this is further expanded
3238 Neural Computing and Applications (2021) 33:3235–3250
123
upon in Sect. 3.4. In the monitoring phase, the FDR data-
sets are introduced into the trained DAE model with the
detection baselines to capture upset precursors. In partic-
ular, the precursors are initially detected by the global
baselines and then localized by the local baselines,
respectively. The training process of the DAE model and
the detection results are presented in Sect. 4.
3.2 Key sensing variable selection
In general, data-driven SHM techniques, especially per-
formed on large datasets associated with irrelevant vari-
ables, suffer from expensive computational cost and
overfitting problems. These issues can adversely affect the
real-time diagnostic abilities of the monitoring technique.
Therefore, a relevant variable selection is vital to improve
the detection accuracy with computational efficiency for
real-time monitoring. Furthermore, the relevant sensing
variable selection based on an understanding of the actual
upset scenarios and its main contributing factors (primary
causes of aircraft upsets) is necessary to enhance the
detection accuracy while minimizing false alarm rates by
incorporating a priori physics-based knowledge into the
data-driven SHM technique. For instance, Turkish Airlines
Flight 1951 was stalled during the approach phase and
crashed at a runway in Amsterdam Schiphol Airport,
Table 1 Investigated DASHlink datasets categorized by flight plans
Flight
plan
Departure airport Arrival airport Number of
flights
1 Minneapolis–Saint Paul International Airport
(KMSP)
Cleveland Hopkins International Airport (KCLE) 424
2 KMSP Cincinnati/Northern Kentucky International Airport
(KCVG)
387
3 Hartsfield–Jackson Atlanta International Airport
(KATL)
Memphis International Airport (KMEM) 368
Fig. 2 Schematic of the proposed real-time aircraft health monitoring method
Neural Computing and Applications (2021) 33:3235–3250 3239
123
Netherlands, led to 9 fatalities; this event was caused by a
radio altimeter fault, which changed the auto-throttle con-
figuration to decrease engine thrust level to idle [43]. In
this case, monitoring changes in the altitude and engine
operations is key to capturing the upset initiations, as a
means to prevent the severe upset event. Based on the
investigations of upset accidents with corresponding con-
tributing factors [3, 5], 41 key sensing variables that are
directly related to the primary factors were selected from
the DASHlink datasets (the number of original sensing
variables n = 186) to train the DAE model and to capture
potential upset precursors in the datasets. The selected key
sensing variables include flight dynamics and engine
operation-related variables, as summarized in Table 2.
3.3 Data preprocessing
The main issues in the DASHlink datasets are the different
sampling rates of each sensing variable and random noises,
which cannot be directly employed for the proposed tech-
nique. Therefore, the decimation and SG filter were
adopted to conduct the sampling rate synchronization and
for denoising the selected key sensing variables. The dec-
imation technique is a down-sampling technique with two
steps: (1) eliminating high-frequency components with a
digital low-pass filter for anti-aliasing and (2) down-sam-
pling with an integer factor [44]. In each flight event p
(p ¼ 1; 2; . . .; q; q is the number of flights), the selected
key sensing variable can be described as x j i , where i is a
sensing variable index (i ¼ 1; 2; . . .; m; m is the number of selected variables) and j is a time step ðj ¼ 1; 2; . . .; liÞ. li is the number of the time steps for the ith sensing variable and
varies due to the different sampling rates in each variable.
The resampled ith sensing variable with the synchronized
time step k (k ¼ 1; 2; . . .; L; L is the number of synchro- nized time steps) using the decimation method can be
described as
~xki ¼ XW�1
w¼0 x jD�v½ � i � h w½ �; ð4Þ
where ~xki , D, h, and W denote the resampled variable,
integer factor, impulse response, and its length, respec-
tively. In this study, a finite impulse response (FIR) filter
was used to prevent aliasing with computational efficiency
because of no iterations in the filtering process. The order
of the FIR filter was set as 30 to perform the filtering
process on various sampling rates of the sensing variables.
With this approach, the sampling rates of the selected
variables were synchronized to 1 Hz; the different data
lengths of the variables li were synchronized to the length
L. For instance, the sampling rate of the engine fan speed 1
(FS 1) is synchronized from 4 to 1 Hz, as shown in Fig. 3.
Furthermore, the SG filtering was performed to denoise the
sensing variables originally recorded under 1 Hz. The
performance of this filter has shown promising denoising
capabilities with a decreased signal distortion compared to
Table 2 List of selected key sensing variables from
DASHlink datasets
Variable name Description Unit Category
ALT Altitude Ft Flight dynamics
LATP Latitude Deg Flight dynamics
LONP Longitude Deg Flight dynamics
PTCH Pitch angle Deg Flight dynamics
ROLL Roll angle Deg Flight dynamics
MH Magnetic heading Deg Flight dynamics
DA Drift angle Deg Flight dynamics
VS Vertical speed ft/s Flight dynamics
GS Ground speed Knots Flight dynamics
IAS Indicated airspeed Knots Flight dynamics
LONG Longitudinal acceleration G Flight dynamics
VRTG Vertical acceleration G Flight dynamics
LATG Lateral acceleration G Flight dynamics
PLA 1-4 Engine power lever angle input 1-4 Deg Engine operation
FS 1-4 Engine fan speed 1-4 %rpm Engine operation
CS 1-4 Engine core speed 1-4 %rpm Engine operation
FF 1-4 Fuel flow rate 1-4 lbs/h Engine operation
EGT 1-4 Engine exhaust gas temperature 1-4 Deg Engine operation
OIT 1-4 Oil temperature 1-4 Deg Engine operation
OIP 1-4 Oil pressure 1-4 Psi Engine operation
3240 Neural Computing and Applications (2021) 33:3235–3250
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the moving average filters in the literature [45]. Therefore,
the filtered ith sensing variable for the time step k using the
SG filter can be represented as follows:
~xk�i ¼ PM
j¼�M cjx jþk½ � i
N ; ð5Þ
where ~xk�i , cj, N, and M are the filtered sensing variable, coefficient for jth filtering, number of datapoints, and half-
width of the smoothing window, respectively. The window
size is defined as 2M þ 1.
3.4 Aircraft upset precursor detection using deep autoencoder
This section discusses the proposed detection technique
using the DAE model with the detection baselines for the
upset precursor detection and localization. First, the pre-
processed 41 key sensing variables were scaled between 0
and 1 to avoid the optimization issue during the training
process. Subsequently, the scaled variables were intro-
duced into the input layer to train the DAE model. The
number of 41 neurons was defined in the input and output
layers. The reconstructed variables (output) were then
scaled back to their original scales in the monitoring phase.
Therefore, each reconstructed variable is estimated as a
function of all input variables as follows:
x̂i ¼ f x1; x2; . . .xnð Þ: ð6Þ
This process allows the estimation of the flight perfor-
mance by modeling the complex relationships and inter-
actions between the variables. For the activation function, a
rectified linear unit (ReLU) was used to avoid gradient
vanishing problem and fulfill computational efficiency
[46]. Mean square error (MSE) was selected as a loss
function to train the DAE model. In addition, batch nor-
malization was implemented for the efficient training
process and enhanced model generalization by reducing the
internal covariate shift phenomenon [47]. In this case, the
off-nominal flight operations in the DASHlink datasets are
assumed to be an overfitting contributor since these
behaviors are statistically a minor portion of the datasets
and may significantly deviate from a major portion (nom-
inal flights). Therefore, the off-nominal trends are most
likely ignored during the training process with the batch
normalization, and the DAE model parameters are mainly
trained by the majority of the datasets (nominal flights).
With this assumption, the abnormal operations potentially
related to upset conditions are expected to be detected by
large reconstruction errors. The reconstruction error from
the trained DAE model was used to define the statistical
detection baselines. The reconstruction error of the ith key
sensing variable is standardized as
��i ¼ ��i � li ri
; ð7Þ
where � and �� indicate the ‘2-norm reconstruction error and
standardized reconstruction error, and l and r are the mean and standard deviation of the reconstruction error, respec-
tively. The standardized errors were used to define the
detection baselines based on assumption that each error is
normally distributed. In particular, the global detection
baseline estimated by the multivariate Gaussian (MG)
distribution was used to detect the upset precursors based
on global estimation. After the detection, the sources of the
upset precursors were localized by testing each variable
using the local detection baselines estimated by the uni-
variate Gaussian (UG) distributions. With the number of 41
reconstruction errors, the global probability density func-
tion p ��; l; Rð Þ of the MG distribution [48] can be defined as follows:
p ��; l; Rð Þ ¼ 1 ffiffiffiffiffiffiffiffiffiffiffi 2p Rj j
p exp � 1
2 �� � lð ÞTRT �� � lð Þ
� � ; ð8Þ
where R is the covariance matrix. In this study, the detection baselines were defined with 0.1% of off-nominal
ratio. Therefore, the statistically off-nominal responses are
captured when the standardized reconstruction errors vio-
late the defined global baseline. The global off-nominal
Fig. 3 Comparison between the original and preprocessed FS 1
during a entire flight phases and b descent and approaching flight phases (close look of a)
Neural Computing and Applications (2021) 33:3235–3250 3241
123
metric H at jth time step can be defined by binary variables as
H j ¼ 1; if p �� j; l; Rð Þ\w
0; otherwise
� ; ð9Þ
where 1 and 0 represent the global off-nominal and nom-
inal indicators, respectively, and w is a threshold value defined by the off-nominal ratio. The local off-nominal
metrics h for the ith sensing variable at jth time step is defined by
h ji ¼ 1; if ��
j i
�� �� [ / 0; otherwise
� ð10Þ
where 1 and 0 denote the local off-nominal and nominal
indicators, respectively, and / is a threshold value. In this study, / ¼ 6r was used to only identify significant off- nominal trends induced by the dramatic changes in flight
dynamics, while minimizing the unnecessary alarms that
can cause the pilot fatigue [49, 50]. The upset precursors
are detected when the standardized reconstruction errors
violate at both global and local baselines for at least 5 s to
ignore sensor and data acquisition errors that are not
indicative of any upset behaviors. The optimization process
of the DAE model architecture (i.e., the number of hidden
layers and neurons), the training process, and the demon-
stration of the assumption for the detection baselines will
be discussed in Sect. 4.1.
4 Results and discussion
4.1 Model training process and evaluation
This section presents the training process and the evalua-
tion of the trained DAE model. A total of 1179 flights
categorized by flight plans in Table 1 were divided into
two segments to train and validate the model: (1) training
set (70% of total flights) and (2) validation set (30% of total
flights). For instance, the datasets of the flight plan 1 (424
flights) were split into 297 flights and 127 flights for
training and validating the DAE model, respectively. The
validation process was mainly performed to prevent over-
fitting issues that decrease the estimation accuracy [51].
Mini-batch stochastic optimization using an adaptive
moment estimation (Adam) optimizer [52] was performed
with the 2048 batch size and learning rate of 1e-8 to
minimize the MSE between the inputs (ground truth) and
reconstructed inputs. In addition, parametric studies were
performed to obtain the optimized DAE model with dif-
fering three parameters: the numbers of (1) neurons, (2)
hidden layers, and (3) epochs (iterations). The reconstruc-
tion errors for each case of the trained DAE model were
quantitatively measured by root-mean-square error
(RMSE) to evaluate their respective performances. The
DAE model training, validation, and testing were con-
ducted on a TensorFlow 2.0.0 with Python 3.7.4 environ-
ment and desktop with an AMD Ryzen 7 3700X (eight
cores with a 3.6 GHz core clock), NVIDIA GeForce GTX
1050 graphics processing unit (GPU) (640 CUDA cores
with a 1.3 GHz core clock), and 32 GB DDR4 memory
running on a Windows 10 (64-bit) operating system.
Initially, five cases of the DAE model training were
performed by varying the number of neurons in hidden
layers, as described in Table 3. For a consistent evaluation,
the number of neurons was decreased or increased linearly
over hidden layers for all cases. Case 2 showed the best
performance (7.22e-5 RMSE in training and 2.83e-4
RMSE in validation) compared to the other cases, as shown
in Fig. 4a. With the optimized number of neurons, the DAE
models were trained by differing the number of hidden
layers. Figure 4b compares the RMSE values for each case;
the DAE with five hidden layers presented the best per-
formance (6.05e-5 RMSE in training and 2.04e-4 RMSE
in validation). Subsequently, the number of epochs was
optimized to obtain reconstruction accuracy, while mini-
mizing the overfitting issue. In particular, the DAE models
were separately trained using three different flight plans
with the optimized model architecture (i.e., optimized
number of neurons and hidden layers). The optimized
epochs were determined by capturing the point of inflection
in the validation RMSE. Figure 4c illustrates a comparison
of the RMSE between training and validation in the case of
flight plan 1. The training RMSE showed a monotonic
decrease over epochs, while the validation RMSE slightly
increased after 2602 epochs (1.67e-4 RMSE) due to the
possible initiation of the overfitting. In the same way, the
optimized epochs for flight plans 2 and 3 were determined
as 2432 and 2118 epochs, respectively. Therefore, the
optimized DAE architecture and number of epochs were
used to monitor aircraft system health. As an example,
Fig. 4d shows a comparison between the original and
reconstructed longitudinal acceleration (LONG) during the
entire in-flight operation, showing good correlation.
In addition, the reconstruction errors were analyzed to
demonstrate the assumption that the evaluated errors from
the optimized DAE model follow Gaussian distribution.
Therefore, the standardized reconstruction errors of 41 key
sensing variables were examined using the datasets of the
flight plan 1 (424 flights). Furthermore, chi-square tests
were implemented to quantitatively measure the degree of
normality [53]. For instance, the error distributions of the
pitch angle (PTCH) and indicated airspeed (IAS) show
close similarities with UG distribution, as presented in
Fig. 5a and b, respectively. The chi-square tests with a 5%
significance level were performed on the standardized
3242 Neural Computing and Applications (2021) 33:3235–3250
123
errors from the 41 key sensing variables and verified that
all error distributions follow UG distributions within the
significance level. These results demonstrated the
feasibility of using MG and UG distributions for the upset
precursor detection and localization, respectively. In
addition, the processing time of the proposed detection
Fig. 4 Optimization process and model evaluation of the
DAE model: a number of neurons, b number of hidden layers, c number of epochs, and d comparison between the original and reconstructed
LONG
Fig. 5 Standardized reconstruction error histograms:
a PTCH and b IAS
Table 3 Cases of number of neurons in hidden layers
Case 1st encoder 2nd encoder Bottleneck 1st decoder 2nd encoder
1 37 34 31 34 37
2 35 30 25 30 35
3 33 26 19 26 33
4 31 22 13 22 31
5 29 18 7 18 29
Neural Computing and Applications (2021) 33:3235–3250 3243
123
technique was measured to examine the computational
efficiency for real-time monitoring. The 41 key sensing
variables with a time step of 50 s were preprocessed and
introduced into the trained DAE model. Ten measurements
were performed on the same computational environment,
and the average processing time was measured as 0.766 s;
the processing time will be less for a single time step input
(1 s). Thus, the computational efficiency of the proposed
technique for real-time monitoring was demonstrated. It is
noted that the proposed technique is possibly applicable to
aviation health management systems, such as NextGen,
where the aircraft and air traffic monitoring are imple-
mented on a distributed, but interconnected computational
environment between the aircraft, the air traffic controller,
and dedicated processing nodes.
4.2 Real-time aircraft upset precursor detection
In this section, the proposed monitoring technique was
validated through the demonstrations of real-time upset
precursor detection. Furthermore, the detected precursors
associated with the coupled responses were analyzed. In
order to detect and analyze the upset precursors in the
DASHlink datasets, the preprocessed 41 input key sensing
variables from 1179 flight cases (Table 1) were separately
introduced into each case of the trained DAE model in real
time. The precursors were captured when the standardized
reconstruction errors violate the global and local detection
baselines for at least 5 s. In addition, a case of aircraft
accident dataset (NTSB dataset) was utilized to further
demonstrate the detection capability of the proposed
method under the actual upset scenario. The cases of
analyzed flights are detailed in Table 4.
4.2.1 Spiral descent
In case 1, the spiral descent trajectories with the associated
responses were detected during the descent flight phase.
Spiral mode is an unstable flight condition and often ini-
tiated by a disturbance in the sideslip angle, which typi-
cally follows a disturbance in the roll angle and leads to a
wing to drop. Once the spiral mode is excited, the aircraft
maneuvers in a slow diverging path in both the roll and
yaw angles. The aircraft loses its altitude since the vertical
forces are no longer in equilibrium. Hence, the associated
flight path is most likely a spiral descent. It is noted that
most spiral descents can be recognized and addressed by
pilots within a sufficient margin of time since the rate at
which the mode diverges is very slow [54]. However, the
pilots’ ability to recognize spiral descent can be signifi-
cantly reduced under poor weather conditions, which may
be further developed and lead to severe aircraft upsets. This
abnormal behavior was observed in the DASHlink datasets
as shown in Fig. 6. In particular, the initiation of the spiral
descent was detected at 4835 s when the reconstruction
errors violated the defined global detection baseline as
shown in Fig. 6a. Subsequently, the precursors in each
variable were captured and localized by the local detection
baselines. Figure 6b–e shows the comparisons between the
original and the reconstructed variables with the error plots
showing the detected precursors. In particular, the initiation
and continuation of disturbances (precursors) in roll angle
(ROLL) and magnetic heading (MH) were observed as
shown in Fig. 6b and c. The abrupt changes in ROLL were
initially detected at 4919 s, and the two additional abrupt
changes were captured at 5202 s and 5440 s, respectively,
as the spiral descent continued. Similarly, the instantaneous
changes in MH were observed at 5835 s and 6687 s,
respectively. These rapid changes were also observed in
PTCH and captured at 5607 s, 6253 s, and 6952 s,
respectively as shown in Fig. 6d. In addition, the distur-
bances in IAS were captured at 6886 s and 6975 s,
respectively, while there was no detection occurring in
vertical speed (VS), as shown in Fig. 6e and f. It is
hypothesized that the potential upset behavior was initiated
in ROLL, and the coupled effects were caused due to the
propagation of the potential upsets in ROLL; these pre-
cursors were accurately captured by the proposed tech-
nique. The obtained results demonstrated the ability of the
proposed method to detect and localize the upset
precursors.
4.2.2 Normal flight operation
In case 2, nominal flight operation was investigated to
demonstrate the reliability of the precursor detection. In
particular, the normal operation, where the reconstruction
errors did not violate any detection baselines, was selected
from the datasets in flight plan 2 (Table 1). Figure 7a
illustrates the flight trajectories during the entire in-flight
operation; any sudden changes or off-nominal responses
were not observed. In addition, the key sensing variables
Table 4 Cases of analyzed flights
Case Scenario Flight phase Data source
1 Spiral descent Descent DASHlink
2 Normal flight operation All DASHlink
3 Severe aerodynamic stall Approach NTSB accident report
3244 Neural Computing and Applications (2021) 33:3235–3250
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between the original and the reconstruction during the in-
flight operation are compared in Fig. 7b–f. In general, the
variables showed stable responses during the cruise flight
phase, while dynamic and nonlinear behaviors were
observed in the other flight phases. The trained DAE model
accurately estimated the flight operation in both stable and
dynamic states, showing smaller reconstruction errors
compared to case 1. It can be seen that the patterns of
normal operation (case 2) were recognized as the common
patterns in the trained DAE model.
4.2.3 Severe aerodynamic stall due to icing
A case of a reported upset accident primarily caused by a
severe aerodynamic stall (NTSB accident ID:
DCA09MA027) [42] was selected from the NTSB database
and utilized to further validate the proposed technique. The
accident aircraft was a Bombardier DHC-8 Q400 operated
by Colgan Air, Inc., and it crashed into a residence near
Buffalo-Niagara International Airport, Buffalo, NY, during
the approach flight phase, which led to 50 fatalities. One of
the main contributing factors identified by the NTSB
investigation team was the flight crew’s inappropriate
response to the activation of the stick shaker that resulted in
an irrecoverable aerodynamic stall. Another main con-
tributing factor to the accident was the flight crew’s failure
to monitor airspeed under icing conditions, indicative of
the importance of situation awareness in such a hazardous
situation. In this study, 18 key sensing variables were
selected from the NTSB dataset, also available in
Fig. 6 Detected upset precursors in case 1 (spiral
descent in DASHlink datasets):
a flight trajectories, b ROLL, c MH, d PTCH, e IAS, and f VS
Neural Computing and Applications (2021) 33:3235–3250 3245
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DASHlink datasets, including flight dynamics and engine
operation variables, as detailed in Table 5. As the same
flight plan of the accident data was not available in the
DASHlink datasets, the flight plan 3 dataset in Table 1 was
selected because it headed in a similar direction as the
accident data. With this approach, 18 variables within flight
plan 3 were extracted from the DASHlink datasets and
these variables were used to train the DAE model. It is
noted that the longitude (LONP) and latitude (LATP)
variables were excluded in the training datasets since the
same flight plan was not available, and the duration of the
scenario was too short to consider the flight plan-dependent
aircraft performances. Furthermore, the DAE model
architecture was modified as the number of input sensing
variables was changed. The optimization process of the
DAE model was implemented with varying the numbers of
(1) neurons, (2) hidden layers, and (3) epochs. Conse-
quently, five hidden layers were determined, and the
number of neurons was optimized as 15, 12, 9, 12, and 15
neurons for 1st, 2nd, 3rd, 4th, and 5th layer, respectively.
The optimal number of epochs was determined as 1448
epochs. Subsequently, the preprocessed 18 sensing vari-
ables from the NTSB dataset were injected into the trained
DAE model, and the upset precursors and actual upsets
were marked when the reconstruction error violated the
detection baselines for at least 5 s.
The upset precursor in the altitude (ALT) was detected
at 22:15:22 eastern standard time (EST), which was 68 s
Fig. 7 Comparisons between the original and the
reconstructed variables in case 2
(normal flight in DASHlink
datasets): a flight trajectories, b ROLL, c PTCH, d FS 2, e IAS, and f VS
3246 Neural Computing and Applications (2021) 33:3235–3250
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earlier than the activation of the stick shaker (alarm of
aerodynamic stall), and the upset was detected at 22:16:41
EST after the stall had occurred, as illustrated in Fig. 8a.
Similarly, the upset precursor in IAS was detected at
22:14:41 EST (109 s earlier detection than the stick sha-
ker), and the upset was captured at 22:16:11 EST (19 s
early detection) and continued until the time when the stick
pusher was activated as shown in Fig. 8b. In addition, the
precursors were detected in PTCH and vertical acceleration
(VRTG) (key features of aerodynamic stall). The upset
precursors in PTCH were captured at 22:16:17 EST (13 s
early detection) and continued until the end of the flight, as
shown in Fig. 8c. The precursor in VRTG was detected at
22:16:12 EST and continued until 22:16:36 EST, as pre-
sented in Fig. 8d. In addition, the precursors were detected
in ROLL (Fig. 8e) and the engine fan speed 2 (FS 2)
(Fig. 8f) at 22:15:30 EST (60 s early detection) and
22:14:28 EST (122 s early detection), respectively, and the
upsets were detected at 22:16:21 EST (9 s early detection)
and 22:16:32 EST, respectively. The results demonstrated
the capability to accurately detect the aircraft upset pre-
cursors in real time prior to actual upset event, which can
improve the pilots’ situational awareness to prevent aircraft
upsets or LOC-I in early stage.
5 Conclusion
In this study, a real-time and data-driven aircraft system
health monitoring (SHM) technique was developed to
capture potential aircraft upset precursors during in-flight
operations to improve aviation safety. Flight data recorder
(FDR) datasets recorded from onboard sensors in com-
mercial aircraft were used to develop the proposed
technique and demonstrate its diagnostic capabilities.
Reported aircraft accident scenarios with the main con-
tributing factors were investigated, and relevant key
sensing variables that were physically related to the upset
contributing factors were employed to enhance detection
accuracy with computational efficiency for real-time
detection. Data preprocessing using the decimation and
Savitzky–Golay (SG) filter was performed for the sam-
pling rate synchronization and denoising the selected
variables. The deep autoencoder (DAE) model was con-
structed and trained using the preprocessed variables to
estimate the standard flight performances and operations.
The architecture and hyperparameter of the DAE model
were optimized through parametric studies, and their
respective performances for each case were evaluated.
The processing time of the proposed technique with a
time step of 50 s was measured as 0.766 s, which
demonstrated the computational efficiency necessary for
real-time health monitoring in the integrated aviation
safety management system. With the trained DAE model
and the statistical detection baselines, a demonstrative
real-time upset precursor detection was performed in the
DASHlink FDR datasets. Initiation of a spiral descent was
detected by the disturbance in the roll angle; the associ-
ated coupled responses in other sensing variables were
also analyzed. In addition, the FDR dataset from the
actual upset accident was used for further demonstration.
The precursors indicating the initiation of upsets were
successfully captured by the proposed technique prior to
the severe upset situation. In particular, the precursors
were detected prior to the activation of the stick shaker
(maximum 122 s early). The results demonstrate the early
detection capability and detection accuracy of the devel-
oped method. By providing the precursor alerts to pilots
Table 5 List of selected sensing variables from NTSB accident
dataset used for validation of the
proposed detection technique
Variable name Description Unit Category
ALT Altitude Ft Flight dynamics
PTCH Pitch angle Deg Flight dynamics
ROLL Roll angle Deg Flight dynamics
MH Magnetic heading Deg Flight dynamics
DA Drift angle Deg Flight dynamics
GS Ground speed Knots Flight dynamics
IAS Indicated airspeed Knots Flight dynamics
LONG Longitudinal acceleration G Flight dynamics
VRTG Vertical acceleration G Flight dynamics
LATG Lateral acceleration G Flight dynamics
PLA 1-2 Engine power lever angle input 1-2 Deg Engine operation
FS 1-2 Engine fan speed 1-2 %rpm Engine operation
CS 1-2 Engine core speed 1-2 %rpm Engine operation
FF 1-2 Fuel flow rate 1-2 lbs/h Engine operation
Neural Computing and Applications (2021) 33:3235–3250 3247
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prior to upset situations, the developed framework can
improve the pilots’ situational awareness and provide a
sufficient margin of time to recover from these situations.
Future research will include extension to other flight plans
and the integration of the developed technique with flight
simulations to investigate generalized diagnostic capabil-
ities under various aircraft upset scenarios.
Acknowledgements The research reported in this paper was sup- ported by funds from NASA University Leadership Initiative program
(Contract No. NNX17AJ86A, Project Officer: Dr. Anupa Bajwa,
Project Manager: Dr. Koushik Datta). The authors would also like to
thank Dr. P. K. Menon for his domain expertise and helpful discus-
sions. All supports are gratefully acknowledged.
Compliance with ethical standards
Conflict of interest The authors declared that they have no conflicts of interest to this work.
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- Data-driven system health monitoring technique using autoencoder for the safety management of commercial aircraft
- Abstract
- Introduction
- Research background
- Deep autoencoder (DAE)
- Dataset construction and assumptions
- Aircraft system health monitoring using deep autoencoder
- Overview
- Key sensing variable selection
- Data preprocessing
- Aircraft upset precursor detection using deep autoencoder
- Results and discussion
- Model training process and evaluation
- Real-time aircraft upset precursor detection
- Spiral descent
- Normal flight operation
- Severe aerodynamic stall due to icing
- Conclusion
- Acknowledgements
- References