Remaining useful life prediction based on noisy condition monitoring signals using constrained Kalman filter

In this paper, a statistical prognostic method to predict the remaining useful life (RUL) of individual units based on noisy condition monitoring signals is proposed. The prediction accuracy of existing data-driven prognostic methods depends on the capability of accurately modeling the evolution of condition monitoring (CM) signals. Therefore, it is inevitable that the RUL prediction accuracy depends on the amount of random noise in CM signals. When signals are contaminated by a large amount of random noise, RUL prediction even becomes infeasible in some cases. To mitigate this issue, a robust RUL prediction method based on constrained Kalman filter is proposed. The proposed method models the CM signals subject to a set of inequality constraints so that satisfactory prediction accuracy can be achieved regardless of the noise level of signal evolution. The advantageous features of the proposed RUL prediction method is demonstrated by both numerical study and case study with real world data from automotive lead-acid batteries. •A computationally efficient constrained Kalman filter is proposed.•Proposed filter is integrated into an online failure prognosis framework.•A set of proper constraints significantly improves the failure prediction accuracy.•Promising results are reported in the application of battery failure prognosis.