基于四阶累积分析的工业大肠杆菌制备过程故障诊断

工业大肠杆菌制备过程具有非线性和非高斯性共存的特征,导致难以对故障源进行有效定位,针对这个问题,提出一种基于多向核熵独立元分析(MKEICA)的过程监测方法;同时针对传统低阶监控统计量(T2, I2和SPE)无法得到非高斯信息的不足提出了四阶累积监控统计量的方法;其次通过对四阶累积监控量进行推导,得到故障产生的原因.最后将其应用在实际的工业过程并与多向核独立元分析(MKICA)监测模型进行对比验证该方法的可行性及有效性.     

基于自适应模糊聚类多模型过程监控及应用

对乙烯裂解炉建立实时监控模型具有重要的现实意义,而传统的多元统计过程监控方法都是假设过程处于单一工况下,而随着过程参数(进料负荷、产品组分等)的改变,工况也随之改变,传统方法便不再适用.本文针对工业过程中的多工况问题,提出了一种基于自适应模糊聚类的多模型过程监控方法,该方法可以减少监控方法对过程知识的依赖性,并且能够适应实际工业过程的非高斯性和非线性特征.首先对影响工况的过程变量利用自适应模糊聚类进行工况划分,然后对每种工况的建模数据分别利用最大方差展开(MVU)提取低维信息,再用支持向量数据描述(SVDD)建立多模型过程监控模型,最后再利用相应的统计指标进行过程监控.将上述方法应用在乙烯裂解炉上,并与基于高斯混合模型的多PCA方法(GMM-MPCA)进行了比较.仿真实验中,监控对裂解炉运行影响最大的33个变量,根据聚类有效性指标,将数据划分为5类时可以得到最佳的聚类效果.通过实验,将33维建模数据降到20维时误报率最小.仿真结果表明该方法在对非线性和非高斯性过程的监控上,能达到很好的效果,误报率和检测率均优于GMM-MPCA方法.     

基于改进核主元和支持向量数据描述故障检测

提出基于改进核主元和支持向量数据描述(SVDD)故障检测方法,适合于复杂工业过程具有非线性和非高斯性的情况.首先,通过对核主元(KPCA)特征空间样本进行重构误差,在样本集上自动识别异常值,减少对KPCA算法的影响并增强非线性核映射.然后,利用支持向量数据描述算法处理数据非高斯信号,据此构建统计量对工业过程进行检测.最后,将所提出的改进核主元和支持向量数据描述方法应用于田纳西-伊斯曼(TE,Tennessee Eastman)过程的仿真实验,结果说明提出方法的有效性.     

KICA模式匹配的动态过程监控与故障诊断方法

针对复杂化工过程具有的非线性、非高斯性和动态特征,提出了基于核独立成分分析(KICA)的模式匹配方法,用于动态过程监控和诊断。首先,利用滑动窗建立基准集与测试集的KICA模型,提取各自的核独立元:其次,融合余弦函数绝对值度量和距离度量,提出新的不相似度监控指标,识别训练与测试操作期间的相似模式,进行故障检测:最后,基于两类数据的核子空间之间的差异子空间,获得每个过程变量方向与该差异子空间之间的互信息,并定义新的非线性非高斯贡献度指标,进行故障诊断。基于污水处理过程的仿真结果表明,与主成分分析不相似度因子的方法、标准的独立成分分析(ICA)统计指标方法及标准的ICA T~2/SPE指标融合的贡献度方法相比,本文提出的方法具有更好的检测能力与故障诊断效果。     

基于ALSICA算法的多工况非高斯过程故障检测方法

针对工业过程数据的多模态、非高斯分布等问题,提出了一种基于自适应邻域参数的局部标准化独立元分析(adaptive local standardized independent componentanalysis,ALSICA)算法,并将该算法应用于过程故障检测中。针对传统的ICA算法未能考虑过程数据的多模态分布问题,引入局部标准化方法建立了局部标准化独立元分析(LSICA)算法。进一步,考虑到局部标准化方法的邻域参数K值选取的问题,提出了一种新的ALSICA算法,该方法基于密度最优的概念选取邻域参数K值,并且K随着数据点变化做出自适应改变。然后建立独立元监控统计变量,进行在线监控。连续搅拌反应釜(continuous stirring tank reactor,CSTR)系统仿真结果验证了ALSICA方法较传统的ICA方法效果更优。     

基于高阶累计统计量的微生物发酵过程监测

传统多向核独立成分分析(MKICA)方法的实质是把基于独立成分分析(ICA)中的白化处理主元分析(PCA)替换为核主元分析(KPCA)后利用二阶统计量进行过程监控,并未利用过程数据的阶段特性和高阶累积量信息,为了解决此问题,提出高阶累积量分析(HCA)与多向核熵独立成份分析(MKECA)相结合的多向高阶累计量的核熵独立成分分析方法(HCA-MKEICA).首先,采用核熵独立成份分析(KECA)对原始数据进行数据转换,解决数据的非线性;然后,在高维核熵空间利用HCA技术构建新的统计量用于过程监控;最后,将该方法应用于青霉素仿真平台和实际的工业过程并与MKICA方法进行对比,以验证所提出方法的有效性.     

独立成分相关分析的自适应故障监测方法

工业过程数据具有动态、非高斯等特性.独立成分分析(independent component analysis, ICA)既可以分析数据的非高斯形式,又可以极大地去除多变量间的耦合且满足独立性要求.本文引入粒子群算法优化ICA模型参数,自适应地确定独立成分个数.同时,提出一种基于隐马尔科夫链模型(hidden Markov model, HMM)的自适应检测限设计方法,将时间相关数据块的特征信息变化作为过程故障的检测依据.首先利用由时间窗方法确定的独立成分组成监测矩阵来训练HMM模型,旨在提高独立成分间相关性水平的表示能力;然后将得到的HMM模型对监测矩阵进行相关性评估,并在一定容许裕度的基础上设计评估值的自适应因子及检测限,并据此监测特征信息变化,动态地进行在线故障检测.最后, Tennessee Eastman (TE)仿真平台的实验结果表明了所提方法的有效性.     

基于鲁棒ICA-PCA的TE故障诊断*

针对复杂工业过程混合分布的问题,提出了鲁棒ICA-PCA(Independent Component Analysis-Principal Component Analysis, ICA-PCA)的故障诊断的新方法。由于实际工业过程数据不可避免的带有大量干扰,为降低数据粗差的影响,首先采用小波去噪算法提高建模数据质量,然后利用鲁棒ICA-PCA算法提取过程的非高斯和高斯信息,并构建了三个统计量进行故障的监控。最后把上述方法应用到田纳西-伊斯曼(Tennessee Eastman,TE)化工过程。仿真结果表明,相比于传统PCA算法、ICA-PCA等算法,鲁棒ICA-PCA方法能够有效的检测故障的发生,该方法具有较好的鲁棒性和灵敏性。     

Modified non-Gaussian multivariate statistical process monitoring based on the Gaussian distribution transformation

Independent component analysis (ICA) has been applied for non-Gaussian multivariate statistical process monitoring (MSPM) for several years. As the independent components do not satisfy the multivariate Gaussian distribution, a missed alarm occurs when monitoring with traditional statistics. In this paper, we propose a Gaussian distribution transformation (GDT)-based monitoring method. Independent components are first transformed into approximate Gaussian distributions through the proposed nonlinear mapping. Then, we propose new statistics and their control limits to reduce missed alarms. The proposed method is particularly suitable for slight magnitude fault and early-stage fault detection. The ratio part of the area above the curve (RPAAC) is developed to evaluate the performance in fault detection. The experimental results from a synthetic example show the effectiveness of our proposed method. We also apply our method to monitor an electrical fused magnesia furnace (EFMF), and eruption and furnace wall melt faults can be detected in time.     

Statistical process monitoring with independent component analysis

In this paper we propose a new statistical method for process monitoring that uses independent component analysis (ICA). ICA is a recently developed method in which the goal is to decompose observed data into linear combinations of statistically independent components [1 and 2]. Such a representation has been shown to capture the essential structure of the data in many applications, including signal separation and feature extraction. The basic idea of our approach is to use ICA to extract the essential independent components that drive a process and to combine them with process monitoring techniques. I², I_e² and SPE charts are proposed as on-line monitoring charts and contribution plots of these statistical quantities are also considered for fault identification. The proposed monitoring method was applied to fault detection and identification in both a simple multivariate process and the simulation benchmark of the biological wastewater treatment process, which is characterized by a variety of fault sources with non-Gaussian characteristics. The simulation results clearly show the power and advantages of ICA monitoring in comparison to PCA monitoring.     

Ensemble modified independent component analysis for enhanced non-Gaussian process monitoring

As a multivariate statistical tool, the modified independent component analysis (MICA) has drawn considerable attention within the non-Gaussian process monitoring circle since it can solve two main problems in the original ICA method. Despite the diversity in applications, the determination logic for non-quadratic functions involved in the iterative procedures of MICA algorithm has always been empirical. Given that the MICA is an unsupervised modeling method, a direct rational study that can conclusively demonstrate which non-quadratic function is optimal for the general purpose of fault detection is inaccessible. The selection of non-quadratic functions is still a challenge that has rarely been attempted. Recognition of this issue and motivated by the superiority of ensemble learning strategy, a novel ensemble MICA (EMICA) modeling approach is presented for enhancing non-Gaussian process monitoring performance. Instead of focusing on a single non-quadratic function, the proposed method combines multiple base MICA models derived from different non-quadratic functions into an ensemble one, and the Bayesian inference is employed as a decision fusion method to form a unique monitoring index for fault detection. The enhanced fault detectability of the EMICA method is also illustrated on two industrial processes.     

Quality relevant nonlinear batch process performance monitoring using a kernel based multiway non-Gaussian latent subspace projection approach

Multiway kernel partial least squares method (MKPLS) has recently been developed for monitoring the operational performance of nonlinear batch or semi-batch processes. It has strong capability to handle batch trajectories and nonlinear process dynamics, which cannot be effectively dealt with by traditional multiway partial least squares (MPLS) technique. However, MKPLS method may not be effective in capturing significant non-Gaussian features of batch processes because only the second-order statistics instead of higher-order statistics are taken into account in the underlying model. On the other hand, multiway kernel independent component analysis (MKICA) has been proposed for nonlinear batch process monitoring and fault detection. Different from MKPLS, MKICA can extract not only nonlinear but also non-Gaussian features through maximizing the higher-order statistic of negentropy instead of second-order statistic of covariance within the high-dimensional kernel space. Nevertheless, MKICA based process monitoring approaches may not be well suited in many batch processes because only process measurement variables are utilized while quality variables are not considered in the multivariate models. In this paper, a novel multiway kernel based quality relevant non-Gaussian latent subspace projection (MKQNGLSP) approach is proposed in order to monitor the operational performance of batch processes with nonlinear and non-Gaussian dynamics by combining measurement and quality variables. First, both process measurement and quality variables are projected onto high-dimensional nonlinear kernel feature spaces, respectively. Then, the multidimensional latent directions within kernel feature subspaces corresponding to measurement and quality variables are concurrently searched for so that the maximized mutual information between the measurement and quality spaces is obtained. The I² and SPE monitoring indices within the extracted latent subspaces are further defined to capture batch process faults resulting in abnormal product quality. The proposed MKQNGLSP method is applied to a fed-batch penicillin fermentation process and the operational performance monitoring results demonstrate the superiority of the developed method as apposed to the MKPLS based process monitoring approach.     

基于独立成分分析及其扩展模型的工业过程监测方法综述

独立成分分析(independent component analysis, ICA)是一种多变量统计分析方法,常用于非高斯过程监测,它能够有效利用信号的高阶统计信息(三阶以上)提取相互独立的独立成分,在工业过程监测中得到了广泛的应用,是当前国际过程监测领域的研究热点.鉴于此,介绍经典ICA模型、改进ICA模型及其在工业过程的过程监测技术.首先,对经典ICA模型进行介绍,在此基础上对经典ICA模型进行分类并指出其优缺点;其次,针对经典ICA模型存在的缺陷,从ICA自身存在的问题、噪声和离群值3方面梳理改进ICA模型的发展;然后,以工业过程为主要应用背景,介绍ICA的过程监测技术如何从简单工业过程衍变至复杂工业过程,以及面向工业过程运行数据的单一特性和混合特性,综述ICA及其扩展模型在工业过程监测中的研究现状;最后,探讨该研究领域亟需解决的问题和未来的发展方向.     

基于独立分量分析的过程监控方法研究

为了解决多变量系统的各个变量之间往往相互影响,且一般不能严格服从高斯分布的问题,采用ICA方法时正常状态下观测的数据进行分析处理,从中提取出统计独立的独立分量,为简化后续分析,对得到的独立分量进行筛选、划分,并分别计算两类统计量:I2统计量和SPE统计量,确定其控制限,与在线数据进行对比,用于监控系统运行.通过一多变量过程仿真实例,证明了这种方法的可靠性,这为ICA应用于监控多变量系统的运行、检测故障的发生提供了有益的思路.     

Integrating independent component analysis and support vector machine for multivariate process monitoring

This study aims to develop an intelligent algorithm by integrating the independent component analysis (ICA) and support vector machine (SVM) for monitoring multivariate processes. For developing a successful SVM-based fault detector, the first step is feature extraction. In real industrial processes, process variables are rarely Gaussian distributed. Thus, this study proposes the application of ICA to extract the hidden information of a non-Gaussian process before conducting SVM. The proposed fault detector will be implemented via two simulated processes and a case study of the Tennessee Eastman process. Results demonstrate that the proposed method possesses superior fault detection when compared to conventional monitoring methods, including PCA, ICA, modified ICA, ICA–PCA and PCA–SVM.     

Online monitoring of nonlinear multivariate industrial processes using filtering KICA–PCA

In this paper, a novel approach for processes monitoring, termed as filtering kernel independent component analysis–principal component analysis (FKICA–PCA), is developed. In FKICA–PCA, first, a method to calculate the variance of independent component is proposed, which is significant to make Gaussian features and non-Gaussian features comparable and to select dominant components legitimately; second, Genetic Algorithm is used to determine the kernel parameter through minimizing false alarm rate and maximizing detection rate; furthermore, exponentially weighted moving average (EWMA) scheme is used to filter the monitoring indices of KICA–PCA to improve monitoring performance. In addition, a novel contribution analysis scheme is developed for FKICA–PCA to diagnosis faults. The feasibility and effectiveness of the proposed method are validated on the Tennessee Eastman (TE) process.     

Weighted preliminary-summation-based principal component analysis for non-Gaussian processes

For industrial chemical process, preliminary-summation-based principal component analysis (PS-PCA), an amended PCA method was recently provided for coping with both Gaussian and non-Gaussian characteristics. By summing the training and monitoring data respectively, PS-PCA is capable of resolving the issue of non-Gaussian processes and achieves higher fault detection rate than the traditional PCA. However, in the PS-PCA summation operation, all data samples are regarded as the same weight, which results in the fault information of newly-samples may be diluted, leading to significant detection delays. To address this challenge, in this paper, we propose a novel weighted PS-PCA (WPS-PCA) method that employs an exponential weighting scheme to put more emphasis on recent information. Subsequently, a mathematical argument demonstrates that when the number of variables is enough plentiful, the obtained summation combined with the generalized central limit theorem conforms to approximately a Gaussian distribution. The kurtosis relationships indicate this conversion will bring out well-pleasing feasibility for conventional PCA. Ultimately, the proposed technique verifies detection performance using the Tennessee Eastman process, which is compared with the existing PCA and PS-PCA schemes, in terms of the fault detection time and fault detection rate. The simulation studies reveal that the proposed method is efficient and superior.     

Integrating independent component analysis and local outlier factor for plant-wide process monitoring

We propose a novel process monitoring method integrating independent component analysis (ICA) and local outlier factor (LOF). LOF is a recently developed outlier detection technique which is a density-based outlierness calculation method. In the proposed monitoring scheme, ICA transformation is performed and the control limit of LOF value is obtained based on the normal operating condition (NOC) dataset. Then, at the monitoring phase, the LOF value of current observation is computed at each monitoring time, which determines whether the current process is a fault or not. The comparison experiments are conducted with existing ICA-based monitoring schemes on widely used benchmark processes, a simple multivariate process and the Tennessee Eastman process. The proposed scheme shows the improved accuracy over existing schemes. By adopting LOF, the monitoring statistic is computed regardless of data distribution. Therefore, the proposed scheme integrating ICA and LOF is more suitable for real industry where the monitoring variables are the mixture of Gaussian and non-Gaussian variables, whereas existing ICA-based schemes assume only non-Gaussian distribution.