基于小波变换核主元分析和多支持向量机的过程监控

针对过程工业数据中所含的噪声和干扰信号、过程工业的非线性及基于主元分析(Principal Component Analysis,PCA)的统计性能监控法由于不用过程机理模型的信息从而对故障诊断问题难以在理论上作系统分析的缺陷,提出基于小波变换核主元分析和多支持向量机的过程监控方法,该方法首先采用基于小波变换的收缩阈值去噪法对建模数据进行预处理,以有效抑制过程数据中所含的噪声和干扰信号,然后利用核主元分析来进行故障特征的提取,从而提高非线性统计过程监控的准确性;最后提出多支持向量机用来对故障的来源进行分类,以避免求解核主元空间到原始空间的逆映射.将该方法应用到对TE(Tennessee Eastman,TE)过程的监控,表明了所提出方法的有效性,为过程的监控和故障诊断提供了一个新的方法.     

基于分段主元分析的变负荷过程监控方法

针对变负荷的多工况过程,提出了一种基于分段主元分析的监控方法。对于稳态工况,直接利用历史数据建立不同负荷下的主元监控模型。对于工况之间的过渡过程,根据先验知识可将其划分为跟踪时段和调节时段。在两大时段内分别将训练数据细分为多个子时段,进而在每一子时段内设定参考轨迹,利用训练数据与参考轨迹的残差建立主元监控模型,并采用改进的层次聚类算法合并特性相近的时段。在线监控时,根据负荷设定信息判断过程所处的工况,再选择相应的主元模型进行监控。在Alstom气化炉中的应用结果表明,该算法不仅能够避免传统多模型监控方法在工况过渡时出现的大量误警,也能在过渡过程中实现准确的故障检测。     

基于混合PCA模型的多工况过程监控方法

传统的多变量统计过程监控方法一般都假设过程只运行在一个稳定工况下,但很多实际工业过程往往具有多工况特征.针对这一问题,提出一种基于混合PCA模型的多工况过程监控方法.将混合高斯模型和PCA相结合,用改进的EM算法估计模型的工况数以及各工况的分布参数和主元数,并构建归一化的统计量实现对多工况过程的监控.TE过程的仿真研究表明,所提出的方法相对传统PCA方法能更精确地估计各工况的统计特性,从而更准确及时地检测出多工况过程的各种故障.     

基于稀疏主元分析的过程监控研究

主元分析（principal component analysis）是一种多元统计技术,在过程监控和故障诊断中具有广泛的应用。针对过程监控中数据量大的特点,提出一种稀疏主元分析（sparse principal component analysis）方法,通过引入lasso约束函数,构建稀疏主元分析的框架,将PCA降维问题转化为回归最优化问题,从而求解得到稀疏化的主元,并提高了主元模型的抗干扰能力。由于稀疏后主元相关的数据量减少,利用数据建立过程监控模型,减少了计算量,并缩短了计算时间,进而提高了监控的实时性。利用田纳西伊斯特曼过程（TE processes）进行实验仿真,并与传统的主元分析方法进行对比研究。结果表明,新提出的稀疏主元分析方法在计算效率和监控实时性上均优于传统的主元分析方法。     

改进PCA 在发酵过程监测与故障诊断中的应用

提出一种改进的主元分析(PCA)法．利用主元相关变量残差统计量代替平方预测误差Q统计量，并采用累积方差贡献率及复相关系数确定PCA模型的主元数．将改进的主元分析法应用于粘菌素发酵过程监测和故障诊断中，仿真结果表明改进的PCA方法避免了Q统计量的保守性，并保证了主元子空间中的信忠存量．与一种基于特征子空间的系统性能监控方法相比较，改进的PCA方法具有更强的有效性．     

CDC/MVT离群点去除的KPCA-MSVMs过程监控

基于主元分析(Principal Component Analysis,PCA)的统计监控模型易受建模数据中离群点的影响;大多工业过程表现出强非线性;且基于PCA的统计性能监控法由于不用过程机理模型的信息从而对故障诊断问题难以在理论上作系统分析,提出基于中心最短距离法CDC (Closest Distance to Center,CDC)/椭球多变量整理法MVT(ellipsoidal Multivariate Trimming,MVT)离群点去除的核主元分析KPCA (Kernel PCA,KPCA)-多支撑向量机MSVMs(Multiple Support Vector Machines,MSVMs)的过程监控方法.该方法首先提出改进尺度的CDC/MVT离群点去除算法以获取正常建模数据;然后利用KPCA来进行故障特征的提取,从而提高非线性统计过程监控的准确性;最后提出MSVMs用来对故障的来源进行分类,以避免求解核主元空间到原始空间的逆映射.将该方法应用到对TE(Tennessee Eastman,TE)过程的监控,表明了所提出方法的有效性,为过程的监控和故障诊断提供了一个新的方法.     

基于主元子空间故障重构技术的故障诊断研究

针对基于主元分析(PCA)的统计性能监控法,由于不用过程机理模型的信息,因此,对故障诊断问题有难以在理论上作系统分析的缺陷,于是提出了一种基于主元子空间故障重构技术的故障诊断方法。利用故障子空间的概念,在故障重构技术的基础上,研究基于T~2统计量的故障诊断问题,提出故障识别指标和诊断算法。通过对双效蒸发过程的仿真监测,验证该诊断方法的有效性。     

基于改进混合概率主元分析模型的过程监控

基于混合概率主元分析（MPPCA）的监控方法，存在要求各子模型中主元个数相同、监控指标不一致、监控表格过多等缺陷．为此对MPPCA算法进行改进，分两步建立模型：首先求出混合高斯模型（GMM），然后利用概率主元分析（PPCA）建立每个子模型的主元模型．改进方法中各子模型主元的选取兼顾了主元的解释宰及其变化趋势，并引进基于PPCA的监控方法，保证了监控指标的一致性，减少了过程监控图．     

铸铝电解槽电压过程控制仿真研究北大核心CSCD

在电解铝的实际生产过程中,由于不能实时监控槽电压的变化情况,容易发生电压摆动的问题。为了实时监控槽电压的变化以及预防电解槽的电压摆,提出了基于主成分分析(PCA)的极限学习机(ELM)多神经网络结构模型,用于铝电解生产过程槽电压预测。一方面,将极限学习机方法同主成分分析方法相结合,将高维输入变量压缩处理为低维主元变量,简化极限学习机模型,提高主成分分析极限学习机(PCA-ELM)算法的泛化性能。另一方面,将多个PCA-ELM子神经网络按照连接权值综合起来,建立铝电解生产过程槽电压的预测模型,进一步提高多神经网络模型的预测能力和预测精度。通过实际数据仿真结果表明,多神经网络预测模型能够准确的实时监控槽电压以及预防电压摆。     

基于GMM的多工况过程监测方法

传统基于主元分析的故障检测方法大多假设工业过程只运行在1个稳定工况,数据服从单一的高斯分布。若这些方法直接用于多工况过程则将会产生大量的误检。为此,本文提出了1种基于高斯混合模型的多工况过程监测方法。首先利用PCA变换对过程数据集进行降维,在主元空间建立高斯混合模型对过程数据进行聚类,自动获取工况数和相关分布特性。然后对每个工况建立主元分析(principal component analysis,PCA)模型来描述整个运行过程数据分布的统计特性。最后在过程监测中,根据监测样本属于各个工况的概率构造综合统计量,实现对多工况过程的故障检测。TE过程的仿真结果表明,本文提出的方法与传统的PCA方法相比,能自动获取工况和精确估计各个工况的统计特性,从而能更准确及时地检测出多工况过程的各种故障。     

Performance monitoring of processes with multiple operating modes through multiple PLS models

Many industrial processes possess multiple operating modes in virtue of different manufacturing strategies or varying feedstock. Direct application of many of the current multivariate statistical process monitoring (MSPM) techniques such as PCA (principal component analysis) and PLS (projection to latent structures) to such a process tends to produce inferior performance. This can most be attributed to the adopted assumption by most MSPM methodologies of only one nominal operating region for the underlying process. It is therefore reasonable to develop separate models for different operating modes. In this paper, based on metrics in the form of principal angles to measure the similarities of any two models, a multiple PLS model based process monitoring scheme is proposed. Popular multivariate statistics such as SPE (squared prediction error) and T² can be incorporated in this framework straightforwardly. The proposed technique is assessed through application to the monitoring of an industrial pyrolysis furnace.     

Reconstruction-based multivariate contribution analysis for fault isolation: A branch and bound approach

Identification of faulty variables is an important component of multivariate statistical process monitoring (MSPM); it provides crucial information for further analysis of the root cause of the detected fault. The main challenge is the large number of combinations of process variables under consideration, usually resulting in a combinatorial optimization problem. This paper develops a generic reconstruction based multivariate contribution analysis (RBMCA) framework to identify the variables that are the most responsible for the fault. A branch and bound (BAB) algorithm is proposed to efficiently solve the combinatorial optimization problem. The formulation of the RBMCA does not depend on a specific model, which allows it to be applicable to any MSPM model. We demonstrate the application of the RBMCA to a specific model: the mixture of probabilistic principal component analysis (PPCA mixture) model. Finally, we illustrate the effectiveness and computational efficiency of the proposed methodology through a numerical example and the benchmark simulation of the Tennessee Eastman process.     

基于T-PLS贡献图方法的故障诊断技术

多变量统计过程监控对于复杂工业过程是一种有效的故障检测和诊断技术. 最小二乘(或称潜空间投影)模型是多变量统计过程监控中常用的一种投影模型, 能够同时对过程数据和质量数据进行建模. 讨论了一种新的基于全潜空间投影模型的故障诊断技术. 全潜空间投影模型中有4个检测统计量. 提出了一种新的T2贡献图计算方法, 对于所有检测统计量, 得到了相应的贡献图算法. 为了确定一个变量是否发生了故障, 计算所有变量贡献图的控制限. 该技术可以将辨识到的故障变量分为与Y有关和与Y无关的两类. 基于Tennessee Eastman过程的案例研究表明了该技术的有效性.     

质量相关的带钢热连轧过程监控

带钢热连轧过程控制是钢铁制造过程极其复杂的过程,近年来随着市场对带钢产品质量要求的日益提高,提高热连轧带钢质量具有广泛的经济和社会效益。为了确保热连轧过程安全运行,同时提高产品质量,有必要对热连轧过程的异常状况或故障进行检测、诊断和消除。以多元统计过程监控技术(MSPM)为理论指导,以主元分析(PCA)和偏最小二乘方法(PLS)为依托,研究和分析了PCA和PLS以及二者与核函数结合构成的核主元分析方法(KP-CA)和核偏最小二乘方法(KPLS)在热连轧机质量相关的故障分析与检测,通过现场数据及实验验证,在厚度质量相关的故障检测与诊断中取得较好的效果。     

Incipient fault detection with smoothing techniques in statistical process monitoring

In modern industry, detecting incipient faults timely is of vital importance to prevent serious system performance deterioration and ensure optimal process operation. Recently, multivariate statistical process monitoring (MSPM) techniques have been extensively studied and widely applied to modern industrial systems. However, conventional fault detection indices utilized in statistical process monitoring are not sensitive to incipient faults with small magnitude. In this paper, by introducing two representative smoothing techniques, novel incipient fault detection strategies based on a generic fault detection index in MSPM are proposed. Fault detectability for each proposed strategy is analyzed. In addition, the effects of the smoothing parameters on fault detection, including advantages and disadvantages, are also investigated. Finally, case studies on a numerical example and two practical industrial processes are carried out to demonstrate the effectiveness of the proposed incipient fault detection strategies.     

Intelligent process monitoring by interfacing knowledge-based systems and multivariate statistical monitoring

An intelligent process monitoring and fault diagnosis environment has been developed by interfacing multivariate statistical process monitoring (MSPM) techniques and knowledge-based systems (KBS) for monitoring multivariable process operation. The real-time KBS developed in G2 is used with multivariate SPM methods based on canonical variate state space (CVSS) process models. Fault detection is based on T ² charts of state variables. Contribution plots in G2 are used for determining the process variables that have contributed to the out-of-control signal indicated by large T ² values, and G2 Diagnostic Assistant (GDA) is used to diagnose the source causes of abnormal process behavior. The MSPM modules developed in Matlab are linked with G2. This intelligent monitoring and diagnosis system can be used to monitor multivariable processes with autocorrelated, crosscorrelated, and collinear data. The structure of the integrated system is described and its performance is illustrated by simulation studies.     

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.     

Recursive PCA for adaptive process monitoring

While principal component analysis (PCA) has found wide application in process monitoring, slow and normal process changes often occur in real processes, which lead to false alarms for a fixed-model monitoring approach. In this paper, we propose two recursive PCA algorithms for adaptive process monitoring. The paper starts with an efficient approach to updating the correlation matrix recursively. The algorithms, using rank-one modification and Lanczos tridiagonalization, are then proposed and their computational complexity is compared. The number of principal components and the confidence limits for process monitoring are also determined recursively. A complete adaptive monitoring algorithm that addresses the issues of missing values and outlines is presented. Finally, the proposed algorithms are applied to a rapid thermal annealing process in semiconductor processing for adaptive monitoring.     

A novel process monitoring and fault detection approach based on statistics locality preserving projections

Data-driven fault detection technique has exhibited its wide applications in industrial process monitoring. However, how to extract the local and non-Gaussian features effectively is still an open problem. In this paper, statistics locality preserving projections (SLPP) is proposed to extract the local and non-Gaussian features. Firstly, statistics pattern analysis (SPA) is applied to construct process statistics and grasp the non-Gaussian statistical property using high order statistics. Then, locality preserving projections (LPP) method is used to discover local manifold structure of the statistics. In essence, LPP tries to map the close points in the original space to close in the low-dimensional space. Lastly, T² and squared prediction error (SPE) charts of SLPP model are used to detect process faults. One simple simulated system and the Tennessee Eastman process show that the proposed SLPP method is more effective than principal component analysis, LPP and statistics principal component analysis in fault detection performance.