Subspace decomposition approach of fault deviations and its application to fault reconstruction

In the present work, a new subspace decomposition approach of fault deviations is developed in the context of principal component analysis (PCA) based monitoring system for fault diagnosis via reconstruction. The fault effects are decomposed in different monitoring subspaces, principal subspace (PCS) and residual subspace (RS), and the significant fault deviations that are responsible for the concerned alarming monitoring statistic are calculated. This is achieved by designing a two-step feature decomposition procedure in each monitoring subspace. In the first step, the relative fault deviations are sorted by comparing the fault variations with the normal variations. All possible fault deviations that may contribute to the out-of-control monitoring statistics are collected. In the second step, PCA is performed on the chosen fault information where the largest fault deviation directions are decomposed in order. By the two-step decomposition, in each monitoring subspace, two different parts are separated for the purpose of fault reconstruction. One is composed of the concerned fault deviations that contribute to alarming monitoring statistics which are thus significant to remove the out-of-control signals. The other is composed of general variations that are deemed to follow normal rules and thus insignificant to remove alarming monitoring statistics. Theoretical support is framed and the related statistical characteristics are analyzed. Its feasibility and performance are illustrated with data from the three-tank system and the Tennessee Eastman (TE) benchmark process.     

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\begin{document}$ \pmb k $\end{document}近邻主元得分差分的故障检测策略

针对具有非线性和多模态特征过程的故障检测问题, 本文提出一种基于k近邻主元得分差分的故障检测策略.首先, 通过主元分析(Principal component analysis, PCA)方法计算样本的真实得分.然后, 应用样本的k近邻均值计算样本估计得分.接下来, 通过上述两种得分计算样本的得分差分矩阵和残差矩阵, 其中残差矩阵由样本的估计得分计算得到,这区别于传统方法.最后, 在差分子空间和残差子空间中分别建立新的统计指标进行故障检测.值得注意的是本文的得分差分方法能够消除数据结构对过程故障检测的影响, 同时, 新的统计量能够提高过程的故障检测率.将本文方法在两个模拟例子和Tennessee Eastman (TE)过程中进行测试, 并与传统方法如PCA、KPCA、DPCA和~FD-kNN等进行对比分析, 测试结果证明了本文方法的有效性.     

基于广义主成分分析的重构故障子空间建模方法

在线故障诊断是工业过程中十分重要的问题.相比传统贡献图而言,基于重构的故障诊断受到特别关注.传统的主元分析方法没有考虑故障数据中同时包含正常工况信息和故障信息,因而提取出故障子空间对故障的描述准确性不足.为提高故障子空间的准确性,提出一种基于广义主成分分析的重构故障子空间建模方法.首先,同时考虑正常工况数据和故障数据,分析数据关联,提取出两个数据的广义主成分,利用投影关系建立故障子空间模型;然后,构建主成分分析故障监测模型,通过监测重构数据筛选广义主成分和故障方向数量,得到正常运行和故障子空间最优组合.该方法充分利用正常工况和故障工况的数据,所提取的故障子空间能够更加充分地反映故障信息,对后续提高故障诊断的准确性具有重要的作用.最后,通过Matlab数值仿真和TE工业过程验证所提出方法的有效性.     

CSMWPCA方法及其在批过程故障诊断中的应用

鉴于传统的多向主元分析（MPCA）难以保证在线状态监测和故障诊断的实时性,提出了一种基于特征子空间的滑动窗主元分析（CSMWPCA）故障监测与诊断方法。在实时故障监测与诊断时,该方法采用适当大小的滑动窗逐步更新当前子数据空间,对当前子数据空间故障的识别通过依次计算其与基底库中各故障的匹配度来进行,克服了传统的MPCA不能处理非线性过程和实时性问题。与一种新的移动窗多向主元分析（MWMPCA）方法相比,CSMWPCA方法能更有效地识别故障发生的原因。     

Improved fault diagnosis in multivariate systems using regression-based reconstruction

Subspace monitoring has recently been proposed as a condition monitoring tool that requires considerably fewer variables to be analysed compared to dynamic principal component analysis (PCA). This paper analyses subspace monitoring in identifying and isolating fault conditions, which reveals that existing work suffers from inherent limitations if complex fault scenarios arise. Based on the assumption that the fault signature is deterministic while the monitored variables are stochastic, the paper introduces a regression-based reconstruction technique to overcome these limitations. The utility of the proposed fault identification and isolation method is shown using a simulation example and the analysis of experimental data from an industrial reactive distillation unit.     

基于故障重构的故障识别

针对基于主元分析(Principal Component Analysis,PCA)的统计过程性能监测法,尽管不依赖于精确的数学模型,然而却限制了其在故障诊断方面的能力问题,在故障重构技术的基础上,研究了基于统计量的故障诊断问题,获得了主元子空间中故障可重构性的理论条件,提出了故障识别指标和诊断算法.通过对双效蒸发过程...     

Variable reconstruction and sensor fault identification using canonical variate analysis

The detection and identification of faults in dynamic continuous processes has received considerable recent attention from researchers in academia and industry. In this paper, a canonical variate analysis (CVA)-based sensor fault detection and identification method via variable reconstruction is described. Several previous studies have shown that CVA-based monitoring techniques can effectively detect faults in dynamic processes. Here we define two monitoring indices in the state and noise spaces for fault detection and, for sensor fault identification, we propose three variable reconstruction algorithms based on the proposed monitoring indices. The variable reconstruction algorithms are based on the concepts of conditional mean replacement and object function minimization. The proposed approach is applied to a simulated continuous stirred tank reactor and the results are compared to those obtained using the traditional dynamic monitoring technique, dynamic principal component analysis (PCA). The results indicate that the proposed methodology is quite effective for monitoring dynamic processes in terms of sensor fault detection and identification.     

Comprehensive subspace decomposition and isolation of principal reconstruction directions for online fault diagnosis

Reconstruction based fault diagnosis isolates the fault cause by finding fault subspace to bring the faulty data back to normal. However, the conventional reconstruction model was often defined using principal component analysis (PCA) to extract the general distribution information of fault data and may not well discriminate fault from normal status. It thus may fail to recover the fault-free data efficiently. To overcome the above problem, a relative principal component of fault reconstruction (RPCFR) modeling algorithm is proposed in the present work for fault subspace extraction and online fault diagnosis. Instead of directly modeling fault data to extract the reconstruction directions, the algorithm gives the original fault space a comprehensive decomposition according to its relationship with the normal process information. Those fault directions that can more efficiently characterize the effects of fault deviations relative to normal data are separated from the others and used for fault reconstruction. Its performance on online fault diagnosis is illustrated by the data from the Tennessee Eastman process.     

A new subspace identification approach based on principal component analysis

Principal component analysis (PCA) has been widely used for monitoring complex industrial processes with multiple variables and diagnosing process and sensor faults. The objective of this paper is to develop a new subspace identification algorithm that gives consistent model estimates under the errors-in-variables (EIV) situation. In this paper, we propose a new subspace identification approach using principal component analysis. PCA naturally falls into the category of EIV formulation, which resembles total least squares and allows for errors in both process input and output. We propose to use PCA to determine the system observability subspace, the A, B, C, and D matrices and the system order for an EIV formulation. Standard PCA is modified with instrumental variables in order to achieve consistent estimates of the system matrices. The proposed subspace identification method is demonstrated using a simulated process and a real industrial process for model identification and order determination. For comparison the MOESP algorithm and N4SID algorithm are used as benchmarks to demonstrate the advantages of the proposed PCA based subspace model identification (SMI) algorithm.     

基于数据变化率和重构贡献图的微小故障诊断方法

针对复杂工业过程的微小故障诊断问题,提出一种数据预处理与重构贡献图相结合的故障诊断方法;为了克服非高斯分布数据对故障检测准确性的影响,通过基于数据变化率的方法对样本原始数据进行预处理后,可以有效地检测过程变量的微小故障,以此建立故障诊断主元分析模型;检测出系统故障后,为了提高故障辨识准确度,采用一种平均残差差值重构贡献图的方法对故障进行辨识;通过正常样本数据和故障数据在残差子空间中的投影,获取两个数值的残差差值向量,计算重构贡献值来确定故障变量;以田纳西-伊斯曼(TE)过程为对象进行了故障诊断仿真实验,并与传统贡献图和重构贡献图方法的辨识准确率相比较,结果表明所提方法具有良好的故障诊断性能。     

基于特征子空间的滑动窗PCA在批过程故障诊断中的应用

基于传统的多向主元分析MPCA(multiway principal component analysis)常会导致误诊断,且对批过程难以保证在线状态监测和故障诊断的实时性,提出了一种基于特征子空间的滑动窗主元分析方法。在实时故障监测与诊断时,该方法采用适当大小的滑动窗逐步更新当前子数据空间,对当前子数据空间故障的识别通过依次计算其与基底库中各故障的匹配度来进行。这种方法克服了传统的MPCA不能处理非线性过程和实时性问题,并避免了MPCA在线应用时预报未来测量值带来的误差, 提高了批过程性能监测和故障诊断的准确性。     

基于局部保持投影–加权k近邻规则的 多模态间歇过程故障检测策略

针对多模态间歇过程故障检测问题,本文提出一种基于局部保持投影–加权k近邻规则(LPP--Wk NN)的故障检测策略.首先,应用局部保持投影(LPP)方法将原始数据投影到低维主元子空间;接下来,在主元子空间中,应用样本第k近邻的局部近邻集确定每个样本的权重并计算权重统计量Dw;最后,应用核密度估计方法确定Dw控制限并进行故障检测.本文方法应用LPP对过程数据进行维数约减,既能够降低训练过程中离群点对模型的影响,又能够降低在线故障检测的计算复杂度.同时,加权k近邻规则(Wk NN)方法通过引入权重规则能够使得过程故障检测统计量分布具有单模态结构.相比传统的k NN统计量,本文引入的权重统计量具有更高的故障检测性能.通过数值例子和半导体蚀刻过程的仿真实验,并与主元分析(PCA), k NN, Wk NN, LPP--k NN等方法进行比较,实验结果验证了本文方法的有效性.     

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.     

Fault detection using robust multivariate control chart

We introduce a new multivariate statistical process control chart for fault detection using robust statistics and principal component analysis. The proposed approach consists of two main steps. In the first step, a robust covariance matrix is determined using the minimum covariance determinant algorithm. In the second step, an eigen-analysis of the robust correlation matrix is performed to derive the robust control limits of the proposed multivariate chart. Our experimental results illustrate the much better fault detection performance of the proposed method in comparison with existing statistical monitoring and process controlling charts.     

Closed-loop subspace identification using the parity space

It is known that many subspace algorithms give biased estimates for closed-loop data due to the existence of feedback. In this paper we present a new subspace identification method using the parity space employed in fault detection in the past. The basic algorithm, known as subspace identification method via principal component analysis (SIMPCA), gives consistent estimation of the deterministic part and stochastic part of the system under closed loop. Column weighting for SIMPCA is introduced which shows improved efficiency/accuracy. A simulation example is given to illustrate the performance of the proposed algorithm in closed-loop identification and the effect of column weighting.     

基于非线性故障重构的旋转机械故障预测方法

对旋转机械的状态进行在线监测和故障预测是一个具有重要应用价值的工程问题. 采用基于核主元分析的非线性故障重构技术研究了多变量相关条件下旋转机械的故障估计及预测问题. 首先利用核主元分析对旋转机械系统进行离线非线性建模,并进行异常检测. 通过对故障程度进行定量描述,用最优化方法求解故障重构意义下的故障估计;然后 用多层递阶的方法对估计出的故障幅值的发展趋势进行预测. 最后,以中国石化北京燕山分公司的烟气轮机作为实际应用对象,验证了该方法的有效性.     

基于递归稀疏主成分分析的工业过程在线故障监测和诊断

提出一种基于递归稀疏主成分分析(recursive sparse principal component analysis,RSPCA)的工业过程故障监测与诊断方法,可用于时变工业过程的自适应故障监测与诊断.通过引入弹性回归网,将主成分问题转化为Lasso与Ridge结合的凸优化问题,采用秩-1矩阵修正对协方差矩阵进行递归分解,递归更新稀疏载荷矩阵和监测统计量的过程控制限,以实现连续工业过程长时间自适应故障监测,对检测出来的故障通过贡献图法实现对故障的诊断.在田纳西-伊斯曼(TE)过程进行实验验证,结果表明,与传统的故障监测方法相比,所提出的方法有效降低了故障漏检率和误报率,且时间复杂度低,确保了故障监测的灵敏度和实时性.     

重构与趋势分析相结合的工业过程异常原因诊断

针对传统重构方法难以分离方向相似的产品质量或运行状态相关的故障或异常,提出了一种重构与定性趋势分析相结合的异常原因诊断方法.首先,采用主元分析算法进行建模和监控,并利用重构方法提取故障方向和估计故障幅值;接下来,分别利用角度相似度和定性趋势分析定义故障方向和故障幅值序列的相似度;然后,根据故障方向和故障幅值变化趋势的相...     

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.