基于分布式ICA-PCA模型的工业过程故障监测

提出基于分布式ICA-PCA( independent component analysis-principal component analysis)模型的工业过程故障监测方法,适合于复杂工业过程难以自动划分子块及过程数据存在非高斯信息的情况。首先,对过程数据进行PCA分解,并在PCA主成分不同的方向上构建不同的子块,把原始特征空间自动划分为不同子空间。然后,对各个子块采用ICA-PCA两步信息提取的策略,提取出高斯信息和非高斯信息,并构建新的统计量和统计限。最后,通过Tennessee Eastman(TE)过程的仿真实验,验证所提出故障监测模型的有效性和可行性。     

特征空间递归更新的ICA算法及发酵过程监测应用

及时更新监测模型以适应过程的时变特性,对准确检测出化工过程异常和设备故障具有重要意义。针对普通独立元分析（ICA）算法在更新计算监测模型时计算复杂度高、效率低的缺点,提出了一种基于特征空间递归更新的在线独立元分析（RUFS-ICA）算法。将算法应用于青霉素发酵过程的在线建模与监测中,与普通ICA方法相比,仿真统计结果表明,平均误警率降低至1.67%,基本克服了漏报现象;与其他在线更新算法相比,复杂度明显降低,计算时间减少54.1%,节省了存储量。     

基于分步时空JITL-MKPLS的间歇过程故障监测

针对多阶段时变的间歇过程难以用全局模型准确描述生产过程的动态变化及传统局部建模每个工作点都需要重新筛选样本建模导致计算量较大的问题,提出一种分步时空即时学习的局部建模策略。采用仿射传播(AP)聚类的方式对历史数据样本集中的数据进行初步分类,在当前输入样本数据到达后,确定当前样本数据所属的类别,在此类别所限定的子数据样本集中使用时间和空间相结合的即时学习策略确定出局部相似样本,建立多向核偏最小二乘监测模型。将该算法在青霉素发酵仿真数据和大肠杆菌发酵过程生产数据上进行验证,结果表明,所提方法不仅减少了不必要的计算量,还能够更加精准即时地进行故障监测。     

基于ICA混合模型的多工况过程故障诊断方法

针对工业过程数据的多模态和非高斯特性,提出一种基于独立元混合模型(independent component analysis mixture model,ICAMM)的多工况过程故障诊断方法。该方法将独立元分析与贝叶斯估计结合,同时完成各个工况的数据聚类和模型参数求取,并建立基于贝叶斯框架下的集成监控统计量实时监控过程变化。在检测到故障后,针对传统的变量贡献图方法无法表征变量之间信息传递关系的缺点,提出基于信息传递贡献图的故障识别方法。该方法首先计算各变量对独立元混合模型统计量的贡献度,进一步通过最近邻传递熵描述故障变量之间的传递性,挖掘故障变量之间的因果关系,从而确定故障源变量和故障传播过程。最后对一个数值系统和连续搅拌反应釜(CSTR)过程进行仿真研究,结果验证了本文所提出方法的有效性。     

基于ICA-SVM的复杂化工过程集成故障诊断方法

针对由于复杂操作或多回路控制等因素造成复杂化工过程故障诊断难度加剧问题,提出了一种基于独立成分分析（ICA）和支持向量机（SVM）的集成故障诊断方法。该方法利用快速ICA算法建立正常工况ICA模型,通过监控统计量I²、I_e²、SPE是否超过用核密度估计方法确定相应的置信限检测故障。如检测到故障发生,即用梯度算法计算每一个监控变量对统计量I²、I_e²、SPE的贡献度,根据观察贡献度变化情况初步诊断出可能的故障源,并利用支持向量机多分类算法诊断出初始故障源。利用丁二烯精馏装置的实际工业故障数据验证提出的ICA-SVM集成故障诊断方法的有效性。     

基于非负矩阵分解的多模态过程故障监测方法

针对传统的多元统计故障监测方法往往需要假设测量数据服从单一高斯分布的不足,提出了一种基于非负矩阵分解(NMF)的多模态故障监测方法。首先使用标准的NMF算法对训练集数据进行聚类,将多模态数据划分到各个模态中;然后使用稀疏性正交非负矩阵分解(SONMF)算法对各模态分别建模,同时构造监控统计量进行故障监测。将提出的基于非负矩阵分解的多模态故障监测方法应用于数值例子和TE过程的仿真结果表明,该方法能够及时有效地检测出多模态过程中的故障。     

基于非负矩阵分解的多模态过程故障监测方法

针对传统的多元统计故障监测方法往往需要假设测量数据服从单一高斯分布的不足,提出了一种基于非负矩阵分解(NMF)的多模态故障监测方法。首先使用标准的NMF算法对训练集数据进行聚类,将多模态数据划分到各个模态中;然后使用稀疏性正交非负矩阵分解(SONMF)算法对各模态分别建模,同时构造监控统计量进行故障监测。将提出的基于非负矩阵分解的多模态故障监测方法应用于数值例子和TE过程的仿真结果表明,该方法能够及时有效地检测出多模态过程中的故障。     

基于故障判别增强KECA算法的故障检测

基于核熵主成分分析方法的统计模型仅利用正常工况下数据进行建模，而忽略了监控系统数据库中一些已知类别的先前故障数据。为了利用先前故障数据中包含的故障信息来增强故障检测性能，提出了一种故障判别增强KECA（fault discriminant enhanced kernel entropy component analysis, FDKECA）算法。该法通过采用无监督学习和监督学习方法建立模型，同时监测非线性核熵主成分（kernel entropy component, KEC）和故障判别成分（fault discriminant component, FDC）两类数据特征。此外，利用贝叶斯推理将相应的监视统计信息转换为故障概率，并通过加权两个子模型的结果来构建基于总体概率的监视统计量。通过数值仿真和田纳西伊斯曼（Tennessee Eastman, TE）过程仿真实验，证明和传统KECA相比，FDKECA算法能够有效利用故障数据提高故障检测率。     

基于IJB-PCA-ICA算法的故障检测

针对现代工业过程数据的高维性和分布复杂性等问题,提出了一种基于IJB-PCA-ICA(improved Jarque-Beraprincipal component analysis-independent component analysis)的故障检测方法。首先采用改进的Jarque-Bera检测方法(J-B test)对原始数据划分高斯与非高斯核心部分,并对其中的高斯性与非高斯性均不明显的变量划分半高斯部分。将半高斯部分通过高斯分布置信概率加权与高斯核心部分和非高斯核心部分分别建立高斯子空间和分高斯子空间,然后对高斯子空间进行相关性划分后采用PCA方法得到高斯子空间的统计量;对非高斯子空间进行主元投影划分后采用ICA方法得到非高斯子空间的统计量,接着通过贝叶斯推断得到的联合统计量进行故障检测。最后通过Tenessee Eastman(TE)仿真实验,有效验证了所提出方法的有效性。     

Quality‐relevant and process‐relevant fault monitoring with concurrent projection to latent structures

This paper proposes a new concurrent projection to latent structures is proposed in this paper for the monitoring of output‐relevant faults that affect the quality and input‐relevant process faults. The input and output data spaces are concurrently projected to five subspaces, a joint input‐output subspace that captures covariations between input and output, an output‐principal subspace, an output‐residual subspace, an input‐principal subspace, and an input‐residual subspace. Fault detection indices are developed based on these subspaces for various fault detection alarms. The proposed monitoring method offers complete monitoring of faults that happen in the predictable output subspace and the unpredictable output residual subspace, as well as faults that affect the input spaces only. Numerical simulation examples and the Tennessee Eastman challenge problem are used to illustrate the effectiveness of the proposed method. © 2012 American Institute of Chemical Engineers AIChE J, 59: 496–504, 2013     

A non-Gaussian pattern matching based dynamic process monitoring approach and its application to cryogenic air separation process

Principal component analysis (PCA) based pattern matching methods have been applied to process monitoring and fault detection. However, the conventional pattern matching approaches do not specifically take into account the non-Gaussian dynamic features in chemical processes. Furthermore, those techniques are more focused on fault detection instead of fault diagnosis. In this study, a non-Gaussian pattern matching based fault detection and diagnosis method is developed and applied to monitor cryogenic air separation process. First, independent component analysis (ICA) models are built on the normal benchmark and monitored data sets along sliding windows. The IC subspaces from the benchmark and monitored data are then extracted to evaluate the non-Gaussian patterns and detect process faults through a mutual information based dissimilarity index. Further, a difference subspace between the two IC subspaces is computed to characterize the divergence of the dynamic and non-Gaussian patterns between the benchmark and monitored data. Subsequently, the mutual information between the IC difference subspace and each process variable direction is defined as a new non-Gaussian contribution index for fault identification and diagnosis. The presented approach is applied to a simulated cryogenic air separation plant and the monitoring results are compared against those of PCA based pattern matching techniques and ICA based monitoring method. The application study demonstrates that the developed non-Gaussian pattern matching approach can effectively monitor the complex air separation process with superior fault detection and diagnosis capability.     

基于核T-PLS的化工过程故障检测算法

针对全潜结构投影法（T-PLS）在检测非线性过程故障时误报率和漏报率较高的缺点,提出了基于核函数的全潜结构投影法（KT-PLS）。该算法通过核函数将过程数据从低维输入空间非线性地映射到高维特征空间,实现非线性问题的线性化;然后在质量变量的引导下将特征空间分为与质量直接相关、与质量正交、与质量无关和残差四个子空间;最后分别构建D和Q统计量进行故障检测。将该算法应用到Tennessee Eastman process（TEP）,多种故障模式下的仿真结果表明,KT-PLS比T-PLS更适合监控具有强非线性的生产过程。     

Quality-relevant and process-relevant fault monitoring based on GNPER and the fault quantification index for industrial processes

Traditional quality-relevant fault monitoring methods focus on extracting the relationship between the global structural features of the process and quality variables but ignore the local features. At the same time, they lack the quantification of quality-relevant faults. To solve these problems, a quality-relevant and process-relevant fault monitoring method and its fault quantification index based on global neighbourhood preserving embedding regression (GNPER) are proposed. First, by seeking the direction of maximum global variance, the global objective function is applied to neighbourhood preserving embedding algorithm, and the global neighbourhood preserving embedding (GNPE) model is established to fully extract the global and local information of process data. Second, on the basis of GNPE, through the idea of projection regression, the GNPER model is established to obtain mapping relationships among process variables and quality variables, and quality-relevant subspace and process-relevant subspace are extracted, the corresponding subspace statistics are established for fault monitoring. Finally, the fault quantification index is established for the faults in the two subspaces, which can provide more meaningful fault monitoring results. A numerical example, the hot rolling mill and the Tennessee Eastman (TE) process, verify the superiority and accuracy of the proposed method.     

Modeling and monitoring of multimode process based on subspace separation

In the paper, a new process monitoring approach is proposed for handling the multimode monitoring problem in the industrial batch processes. Compared to conventional method, the contributions are as follows: a new method of extracting the common subspace of different modes is proposed based on the subspace separation; after that the two different subspaces are separated, the kernel principal component models is built for the common and specific subspace respectively and the monitoring is carried out in subspace. The monitoring is carried out in the subspaces. The corresponding confidence regions are constructed according to their models respectively.     

基于统计量模式分析的T-KPLS间歇过程故障监控

核函数的全影结构投影(total kernel projection to latent structures,T-KPLS)最近在故障监控领域取得了广泛应用, 其实质是对数据矩阵的协方差矩阵进行分解, 没有利用数据的高阶统计量等有用信息, 在进行特征提取时会造成数据有用信息的丢失, 导致故障识别效果差。为了解决此问题, 提出了统计量模式分析(statistics pattern analysis, SPA)与核函数的全影结构投影法(total kernel projection to latent structures, T-KPLS)相结合的多向统计量模式分析的核函数的全影结构投影法(multi-way statistics pattern analysis total kernel projection to latent structures, MSPAT-KPLS)。该方法首先构造样本的不同阶次统计量, 将数据从原始的数据空间映射到统计量样本空间, 然后利用核函数将统计量样本空间映射到高维核空间并在质量变量的引导下将特征空间分为过程变量与质量变量相关、过程变量与质量变量无关、过程变量与质量变量正交和残差4个子空间;最后针对与质量变量相关和残差空间建立联合监控模型, 当监控到有故障发生时进行故障变量追溯。最后将该方法应用到微生物发酵过程中, 并与传统方法进行比较, 发现该方法具有更好的监控性能。     

基于全变量信息的子空间监控方法

实际化工过程采集得到的数据往往维度较高,直接建模比较复杂。主元分析(principal component analysis,PCA)方法可以提取原始数据主要特征,得到低维数据,但传统的PCA过程监控方法仅保留了方差较大的主元,会造成信息缺失,这将大大影响过程监控性能。针对这一问题,提出了一种新的基于全变量信息(full variable information,FVI)的子空间监控方法。首先,依据每个变量与主元空间(principal component subspace,PCS)和残差空间(residual subspace,RS)相似性的高低,将原始数据空间划分为3个维度较低的子空间,3个子空间保存了全部过程变量,可以更充分地利用过程信息。其次,在每个子空间中,分别建立监控模型,并利用贝叶斯推断整合子空间的监控结果。最后,通过数值仿真及Tennessee Eastman(TE)过程仿真研究验证FVI方法的有效性。     

A quality relevant non‐Gaussian latent subspace projection method for chemical process monitoring and fault detection

Partial least‐squares (PLS) method has been widely used in multivariate statistical process monitoring field. The goal of traditional PLS is to find the multidimensional directions in the measurement‐variable and quality‐variable spaces that have the maximum covariances. Therefore, PLS method relies on the second‐order statistics of covariance only but does not takes into account the higher‐order statistics that may involve certain key features of non‐Gaussian processes. Moreover, the derivations of control limits for T² and squared prediction error (SPE) indices in PLS‐based monitoring method are based on the assumption that the process data follow a multivariate Gaussian distribution approximately. Meanwhile, independent component analysis (ICA) approach has recently been developed for process monitoring, where the goal is to find the independent components (ICs) that are assumed to be non‐Gaussian and mutually independent by means of maximizing the high‐order statistics such as negentropy instead of the second‐order statistics including variance and covariance. Nevertheless, the IC directions do not take into account the contributions from quality variables and, thus, ICA may not work well for process monitoring in the situations when the quality variables have strong influence on process operations. To capture the non‐Gaussian relationships between process measurement and quality variables, a novel projection‐based monitoring method termed as quality relevant non‐Gaussian latent subspace projection (QNGLSP) approach is proposed in this article. This new technique searches for the feature directions within the measurement‐variable and quality‐variable spaces concurrently so that the two sets of feature directions or subspaces have the maximized multidimensional mutual information. Further, the new monitoring indices including I² and SPE statistics are developed for quality relevant fault detection of non‐Gaussian processes. The proposed QNGLSP approach is applied to the Tennessee Eastman Chemical process and the process monitoring results of the present method are demonstrated to be superior to those of the PLS‐based monitoring method. © 2013 American Institute of Chemical Engineers AIChE J 60: 485–499, 2014     

变量加权型主元分析算法及其在故障检测中的应用

传统主成分分析（PCA）算法旨在挖掘训练数据各变量间的相关性特征,已在数据驱动的故障检测领域得到了广泛的研究与应用。然而,传统PCA方法在建模过程中通常认为各个测量变量的重要性是一致的,因此不能有效而全面地描述出变量间相关性的差异。为此,提出一种变量加权型PCA（VWPCA）算法并将之应用于故障检测。首先,通过对训练数据进行加权处理,使处理后的数据能够充分体现出变量间相关性的差异。然后,在此基础上建立分布式的PCA故障检测模型。在线实施故障检测时,则通过贝叶斯准则将多组监测结果融合为一组概率指标。VWPCA方法通过相关性大小为各变量赋予不同的权值,从而将相关性差异考虑进了PCA的建模过程中,相应模型对训练数据特征的描述也就更全面。最后,通过在TE过程上的测试验证VWPCA方法用于故障检测的优越性。     

Quality‐relevant fault diagnosis with concurrent phase partition and analysis of relative changes for multiphase batch processes

Multiplicity of phases as indicated by changes of process characteristics is an inherent nature of many batch processes for both normal and fault cases. To more efficiently perform online fault diagnosis via reconstruction for multiphase batch processes, the phase nature and the relationship between normal and fault cases within each phase should be deeply addressed. This article proposes a quality‐relevant fault diagnosis strategy with concurrent phase partition and analysis of relative changes for multiphase batch processes. First, a concurrent phase partition algorithm is developed. The basic idea is to track the changes of process characteristics at normal and fault statuses jointly so that multiple sequential modeling phases are identified simultaneously for both normal and fault cases. Then, the relative changes from the normal status to each fault case are analyzed in each phase to reveal the specific fault effects more efficiently. The fault effects are decomposed in two different monitoring subspaces, principal subspace, and residual subspace, by capturing their different roles in removing out‐of‐control signals. The significant increases relative to the normal case are judged to be responsible for the concerned alarm monitoring statistics in each phase. The others are composed of general variations that are deemed to still follow normal rules and thus insignificant to remove alarm monitoring statistics. Those alarm‐responsible fault deviations are then used to develop reconstruction models which can more efficiently recover the fault‐free part for online fault diagnosis. The proposed algorithm is illustrated with a typical multiphase batch process with one normal case and three fault cases. © 2014 American Institute of Chemical Engineers AIChE J, 60: 2048–2062, 2014