Predictions-on-chip: model-based training and automated deployment of machine learning models at runtime

The design of gas turbines is a challenging area of cyber-physical systems where complex model-based simulations across multiple disciplines (e.g., performance, aerothermal) drive the design process. As a result, a continuously increasing amount of data is derived during system design. Finding new insights in such data by exploiting various machine learning (ML) techniques is a promising industrial trend since better predictions based on real data result in substantial product quality improvements and cost reduction. This paper presents a method that generates data from multi-paradigm simulation tools, develops and trains ML models for prediction, and deploys such prediction models into an active control system operating at runtime with limited computational power. We explore the replacement of existing traditional prediction modules with ML counterparts with different architectures. We validate the effectiveness of various ML models in the context of three (real) gas turbine bearings using over 150,000 data points for training, validation, and testing. We introduce code generation techniques for automated deployment of neural network models to industrial off-the-shelf programmable logic controllers.