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.     

Dynamic process fault monitoring based on neural network and PCA

A newly developed method, NNPCA, integrates two data driven techniques, neural network (NN) and principal component analysis (PCA), for process monitoring. NN is used to summarize the operating process information into a nonlinear dynamic mathematical model. Chemical dynamic processes are so complex that they are presently ahead of theoretical methods from a fundamental physical standpoint. NN functions as the nonlinear dynamic operator to remove processes' nonlinear and dynamic characteristics. PCA is employed to generate simple monitoring charts based on the multivariable residuals derived from the difference between the process measurements and the neural network prediction. It can evaluate the current performance of the process. Examples from the recent monitoring practice in the industry and the large-scale system in the Tennessee Eastman process problem are presented to help the reader delve into the matter.     

基于分层分块DLPPCA-SVM的复杂工业过程监测与故障诊断方法

针对工业过程动态性及非线性强等特点,提出一种基于动态局部保持主成分分析法的过程监测方法.该方法通过构造扩展矩阵来解决动态过程中各采样点间相关性强的问题,并将局部保持投影(LPP)与主成分分析法(PCA)相结合从而实现提取流形结构的最大方差信息.在此基础上,针对复杂工业过程变量复杂多变、呈不同特性的特点,提出基于分层分块DLPPCA-SVM(dynamic locality preserving principal component analysis-support vector machine, DLPPCA-SVM)的过程监测及故障诊断方法,该方法针对不同特性的子块分别采用DLPPCA和PCA进行建模,并利用支持向量机进行故障诊断.将该方法用于田纳西-伊斯曼(TE)化工过程和发电机组的在线监测和故障诊断,仿真结果验证了所提出方法的有效性.     

Predictive monitoring for abnormal situation management

A novel process monitoring method is proposed that uses predictions from a dynamic model to predict whether process variables will violate an emergency limit in the future. The predictions are based on a Kalman filter and disturbance estimation. A critical feature of the proposed method is the evaluation of a T² statistic as a “reality check” for deciding if the future predictions are reliable and thus can be used for making control decisions. Several simulation examples demonstrate the effectiveness of the proposed technique for both linear and nonlinear processes, and for a variety of disturbances.     

Local and global principal component analysis for process monitoring

In this paper, a novel data projection method, local and global principal component analysis (LGPCA) is proposed for process monitoring. LGPCA is a linear dimensionality reduction technique through preserving both of local and global information in the observation data. Beside preservation of the global variance information of Euclidean space that principal component analysis (PCA) does, LGPCA is characterized by capturing a good linear embedding that preserves local structure to find meaningful low-dimensional information hidden in the high-dimensional process data. LGPCA-based T² (D) and squared prediction error (Q) statistic control charts are developed for on-line process monitoring. The validity and effectiveness of LGPCA-based monitoring method are illustrated through simulation processes and Tennessee Eastman process (TEP). The experimental results demonstrate that the proposed method effectively captures meaningful information hidden in the observations and shows superior process monitoring performance compared to those regular monitoring methods.     

基于多尺度核主元分析的非线性过程监控方法研究

针对化工过程数据的多尺度性和非线性特性,提出了一种多尺度核主元分析方法(MSKPCA)监控过程的运行状态。使用小波变换在不同尺度下分解测量信号．然后借助于核函数对分解后的数据进行非线性变换,在变换后的线性空间中用主元分析(PCA)提取过程数据的主要特征,构造监控统计量T2和Q来检测故障。在此基础上,提出了一种贡献图方法．计算过程变量对故障的贡献量,用于故障变量的分离。在TE过程上的监控结果表明,MSKPCA可以比PCA和动态PCA更迅速地检测到过程故障,贡献图方法能够正确地分离故障变量。     

A multi-scale orthogonal nonlinear strategy for multi-variate statistical process monitoring

In this paper a multi-scale nonlinear PCA strategy for process monitoring is proposed. The strategy utilizes the optimal wavelet decomposition in such a way that only the approximation and the highest detail functions are used, thus simplifying the overall structure and making the interpretation at each scale more meaningful. An orthogonal nonlinear PCA procedure is incorporated to capture the nonlinear characteristics with a minimum number of principal components. The proposed nonlinear strategy also eliminates the requirement of nonlinear functions relating the nonlinear principal scores to process measurements for Q-statistics as in other nonlinear PCA process monitoring approaches. In addition, the strategy is considerably robust to the presence of typical outliers.     

Process monitoring through manifold regularization-based GMM with global/local information

The nonlinear and multimodal characteristics in many manufacturing processes have posed some difficulties to regular multivariate statistical process control (MSPC) (e.g., principal component analysis (PCA)-based monitoring method) because a fundamental assumption is that the process data follow unimodal and Gaussian distribution. To explicitly address these important data distribution characteristics in some complicated processes, a novel manifold learning algorithm, joint local intrinsic and global/local variance preserving projection (JLGLPP) is proposed for information extraction from process data. Based on the features extracted by JLGLPP, local/nonlocal manifold regularization-based Gaussian mixture model (LNGMM) is proposed to estimate process data distributions with nonlinear and multimodal characteristics. A probabilistic indicator for quantifying process states is further developed, which effectively combines local and global information extracted from a baseline GMM. Thus, the JLGLPP and LNGMM-based monitoring model can be used effectively for online process monitoring under complicated working conditions. The experimental results illustrate that the proposed method effectively captures meaningful information hidden in the process signals and shows superior process monitoring performance compared to regular monitoring methods.     

基于特征空间k最近邻的批次过程监视

针对具有非高斯、非线性及多工况特性的批次过程,提出一种基于特征量最近邻统计指标的过程监视方法. 首先,将批次过程正常工况原始数据投影到其特征空间,提取主元T和平方预测误差SPE,并进行特征量k最近邻距离平方和的求解. 然后,采用核密度估计法获得概率密度分布函数,确定统计监视控制限. 特征空间的主元T和SPE特征量能全面代表原始数据的有用信息. 采用特征量k最近邻建立监视模型将会节省存储空间,提高建模样本数量与变量之比以及检测异常工况的速度. 另外,利用局部近邻数据建模可以解决过程具有的非线性和多工况问题,而应用核密度估计法可以解决过程数据具有的非高斯分布问题. 最后,在半导体生产过程的成功应用表明了所提方法的有效性.     

Monitoring and prediction of big process data with deep latent variable models and parallel computing

Process monitoring and quality prediction are crucial for maintaining favorable operating conditions and have received considerable attention in previous decades. For majority complicated cases in chemical and biological industrial processes with particular nonlinear characteristics, traditional latent variable models, such as principal component analysis (PCA), principal component regression (PCR), partial least squares (PLS), may not work well. In this paper, various nonlinear latent variable models based on autoencoder (AE) are developed. In order to extract deeper nonlinear features from process data, the basic shallow AE models are extended to the deep latent variable models, which provides a deep generative structure for nonlinear process monitoring and quality prediction. Meanwhile, with the ever increasing scale of industrial data, the computational burden for process modeling and analytics has becoming more and more tremendous, particularly for large-scale processes. To handle the big data problem, the parallel computing strategy is further applied to the above model, which partitions the whole computational task into a few sub-tasks and assigns them to parallel computing nodes. Then the parallel models are utilized for process monitoring and quality prediction applications. The effectiveness of the developed methods are evaluated through the Tennessee Eastman (TE) benchmark process and a real-life industrial process in an ammonia synthesis plant (ASP).     

A novel process monitoring approach with dynamic independent component analysis

A novel process monitoring scheme is proposed to compensate for shortcomings in the conventional independent component analysis (ICA) based monitoring method. The primary idea is first to augment the observed data matrix in order to take the process dynamic into consideration. An outlier rejection rule is then proposed to screen out outliers, in order to better describe the majority of the data. Finally, a rectangular measure is used as a monitoring statistic. The proposed approach is investigated via three cases: a simulation example, the Tennessee Eastman process and a real industrial case. Results indicate that the proposed method is more efficient as compared to alternate methods.     

部分子块通讯的分布式PCA厂级工业过程监测方法

针对现代工业过程具有检测、控制变量多,且变量关系复杂、耦合严重等特点,厂级工业过程监测通常采用分块的方式建立模型.然而,实际过程中每个子块间存在物流、能流的交换和信息的传递,这种建模方式通常只利用子块本身的信息建立模型,恰恰忽略了子块之间内在的联系,可能导致子块监测模型一定程度上丢失其他子块所提供的过程信息.针对现有方法的局限性,提出一种部分子块通讯的分布式主元分析(PCA)过程监测方法.首先利用先验知识对厂级过程进行分块,增加用于描述子块间连接方式的拓扑矩阵;以迭代更新的思路,利用其他节点提供的压缩信息,按照拓扑矩阵不断更新系数矩阵,进而得到最终的监测模型;代入待监测数据后,综合考虑其余子块携带的异常信息得出监测结果.在tennessee eastman过程和加氢裂化过程中,将所提出的方法与传统分块PCA、全部子块交互的分布式PCA方法进行对比,所得结果表明了所提出方法的合理性和有效性.     

基于统计特征的不等长间歇过程故障诊断研究

为了提高不等长间歇过程故障诊断的性能, 同时降低算法的复杂度, 提出了一种基于统计特征的不等长间歇过程故障诊断算法。首先计算每个不等长批次的均值、方差、偏度、峭度和任意两个变量间的欧氏距离, 并将这些统计特征组合成一个等长的特征向量; 然后运用主元分析(PCA)进行过程监视。半导体工业实例的仿真结果表明, 与传统的多向主元分析(MPCA)方法相比, 基于统计特征的不等长间歇过程故障诊断算法的故障诊断率提高15%, 故障检测时间减少了0. 002 s, 因此该算法具有很好的故障诊断性能。     

Latent‐variable Nonlinear Model Predictive Control Strategy for a pH Neutralization Process

Linear model predictive control (MPC) is a widely‐used control strategy in chemical processes. Its extension to nonlinear MPC (NMPC) has drawn increasing attention since many process systems are inherently nonlinear. When implementing the NMPC based on a nonlinear predictive model, a nonlinear dynamic optimization problem must be calculated. For the sake of solving this optimization problem efficiently, a latent‐variable dynamic optimization approach is proposed. Two kinds of constraint formulations, original variable constraint and Hotelling T² statistic constraint, are also discussed. The proposed method is illustrated in a pH neutralization process. The results demonstrate that the latent‐variable dynamic optimization based the NMPC strategy is efficient and has good control performance.     

Nonlinear process monitoring using kernel dictionary learning with application to aluminum electrolysis process

In practice, because of complex mechanism processes, such as heating process, volume heterogeneity, and various chemical reaction characteristics, there is a nonlinear relationship among variables in industrial systems. The nonlinearity brings some difficulties to process monitoring. In order to ensure that the process monitoring system can work normally in nonlinear production processes, the nonlinear relationship between variables ought to be considered. In this work, a new fault detection and isolation method based on kernel dictionary learning is presented. In detail, the linearly inseparable data is mapped to a high-dimensional space. Then, a new nonlinear dictionary learning method based on kernel method was proposed to learn the dictionary. After obtaining the dictionary, the control limit can be calculated from the training data according to the kernel density estimation (KDE) method. When new data arrive, they can be represented by the well-learned dictionary, and the kernel reconstruction error can be used as a classifier for process monitoring. As for the fault data, the iterative reconstruction based method is proposed for fault isolation. In order to evaluate the effectiveness of the proposed process monitoring method, some extensive experiments on a numerical simulation, the continuous stirred tank heater (CSTH) process, and a real industrial aluminum electrolysis process are conducted. The proposed method is compared with several state-of-the-art process monitoring methods and the experimental results show that the proposed method can provide satisfactory monitoring results, especially for some small faults, thus it is suitable for process monitoring of nonlinear industrial processes.     

基于自适应混合核典型变量分析的工业过程质量相关故障检测

质量相关故障检测技术是保障工业过程安全顺行和质量稳定的重要手段,是当前流程工业过程控制领域的研究热点.针对工业过程的非线性与动态特性及其质量相关故障的时变特性,提出一种基于自适应混合核典型变量分析(AMKCVA)的质量相关故障检测方法.该方法通过设计合理的混合核函数和自适应监测统计量,提升了工业过程质量相关故障的检测性能.通过对典型的热轧过程现场数据进行仿真验证,并与传统方法对比分析,表明了所提算法的有效性和实用性.     

Non-Gaussian chemical process monitoring with adaptively weighted independent component analysis and its applications

Chemical process monitoring based on independent component analysis (ICA) is among the most widely used multivariate statistical process monitoring methods and has progressed very quickly in recent years. Generally, ICA methods initially employ several independent components (ICs) that are ordered according to certain criteria for process monitoring. However, fault information has no definite mapping relationship to a certain IC, and useful information might be submerged under the retained ICs. Thus, weighted independent component analysis (WICA) for fault detection and identification is proposed to process useful submerged information and reduce missed detection rates of I² statistics. The main idea of WICA is to initially build the conventional ICA model and then use the change rate of the I² statistic (RI²) to evaluate the importance of each IC. The important ICs tend to have higher RI²; thus, higher weighting values are then adaptively set for these ICs to highlight the useful fault information. Case studies on both simple simulated and Tennessee Eastman processes demonstrate the effectiveness of the WICA method. Monitoring results indicate that the performance of I² statistics improved significantly compared with principal component analysis and conventional ICA methods.     

基于主元分析得分重构差分的故障检测策略

基于主元分析(PCA)的统计过程控制方法通常假设数据的生成过程是独立同分布的.当数据存在多模态结构或过程变量非线性相关时, PCA方法的故障检测性能将受到影响.针对上述问题,本文提出一种基于PCA得分重构差分的故障检测策略.首先,应用PCA将输入空间分解为主元子空间和残差子空间;接下来,应用k近邻(k NN)规则重构当前样本得分向量并计算样本的得分重构差分向量;最后,计算得分重构差分向量的统计值并进行故障检测.本文方法不仅可以降低数据多模态和变量非线性相关等特征对过程故障检测的影响,同时可以降低统计量的自相关性、提高过程故障检测率.将本文方法在两个模拟例子和田纳西–伊斯曼(TE)过程中进行测试,并与PCA、核主元分析(KPCA)、动态主元分析(DPCA)和k最近邻故障检测(FD–k NN)方法进行对比分析,测试结果证明了本文方法的有效性.     

Wavelets and non-linear principal components analysis for process monitoring

A non-linear principal component analysis (PCA) algorithm is proposed for process performance monitoring based upon an input-training neural network. Prior to assessing the capabilities of the monitoring scheme on an industrial dryer, the data is first pre-processed to remove noise and spikes through wavelet de-noising. The wavelet coefficients obtained are used as the inputs for the non-linear PCA algorithm. Performance monitoring charts with non-parametric control limits are then applied to identify the occurrence of non-conforming operation prior to interrogating differential contribution plots to help identify the potential source of the fault. Encouraging results were achieved.