一种基于DIOCVA的过程监控方法

传统基于典型变量分析的过程监控方法无法判断故障是否影响产 品质量.为此,本文提出一种基于动态输入输出典型变量分析(Dynamic input-output canonical variate analysis, DIOCVA)的过程监控方法.该方法利用典型变量分析提取数据之间的相关性,并进一步考虑方差信息和时序相关性, 将过程数据和质量数据映射到5个子空间:输入输出相关子空间,不相关输入主元子空间, 不相关输入残差子空间,不相关输出主元子空间和不相关输出残差 子空间.所提方法能够精细区分影响质量的过程故障和不影响质量的过程故障.以Tennessee Eastman过程为例对所提方法的有效性进行了验证.     

Fault detection of process correlation structure using canonical variate analysis-based correlation features

This paper proposes a canonical variate analysis (CVA) approach based on feature representation of canonical correlation for the monitoring of faults associated with changes in process correlations, which involves two new metrics, R_s and R_r, corresponding to the state and residual spaces. The utilization of the canonical correlation feature can improve the monitoring proficiency by providing more application-dependent representations compared with the original data, as well as a decreased degree of redundancy in the feature space. A physical interpretation is provided for the canonical correlation-based method. The effectiveness of the proposed approach for the monitoring of process correlation changes is demonstrated for both abrupt (step change) and incipient (slow drift) types of faults in simulation studies of a network system. In the simulation results, the canonical correlation-based method has superior performance over both the causal dependency-based method and the traditional variable-based method.     

Information concentrated variational auto-encoder for quality-related nonlinear process monitoring

As the deep learning technology develops, many process monitoring methods based on auto-encoder (AE) are designed for the nonlinear industrial processes. However, these methods mainly focus on process variables and ignore the quality indicator which is crucial for the final production. To extract the latent variables which represent both process information and quality information, this paper proposes a novel algorithm named information concentrated variational auto-encoder (IFCVAE). To concentrate the quality-related information, a loading matrix regularization based on mutual information is designed, so that the strongly quality-related variables tend to have larger weights in the loading matrix. In addition, to monitor processes from the quality-related and unrelated aspects, IFCVAE decomposes the original space into two subspaces that are mutually orthogonal based on variational auto-encoder (VAE). With the help of an additional regression network, the two subspaces can correspond to the quality-related and unrelated spaces. For process monitoring, two statistics are designed for the subspaces according to Kullback–Leibler divergence. Finally, the effectiveness of IFCVAE is demonstrated by a numerical case and an industrial case.     

基于公共特有子空间提取的工业设备多模式运行过程故障检测方法

工业设备运行状态直接影响到最终产品质量,有必要对设备运行过程开展监控,因此着重对工业设备运行数据中存在的不同阶次信息以及多模式等复杂数据特性展开讨论.针对过程中存在的不同阶次信息问题,首先通过引入最大交互熵展开与偏最小二乘方法,将原始空间信息分解为高阶和低阶信息,并构建相应隐空间模型来提取高阶与低阶质量相关关系;其次,...     

回转窑烧成系统故障诊断方法研究

针对水泥烧成系统过程变量繁多、变量间静态关系耦合强等特点,采用因子分析方法建立静态过程监控模型。针对系统时序相关问题,结合经典动态主元分析DPCA方法和典型变量分析CVA方法,提出典型变量动态主元分析CVDPCA过程监控方法,有效解决了DPCA方法扩展后的数据矩阵维度大等不足之处。将算法用于水泥烧成系统故障检测,结果表明该算法能准确识别故障和更早检测到微小渐变故障。将CVA和DPCA算法相结合,可以同时监控动态过程和静态关系,且不需要大量的故障数据建立故障模型池,具有一定研究价值。     

Auto-regressive modeling with dynamic weighted canonical correlation analysis

Multivariate statistical analytical methods, such as principal component analysis (PCA) and canonical correlation analysis (CCA), are widely used to extract useful information from data collected in modern industrial processes. Their dynamic extensions are also designed intensively in the literature to exploit dynamic variations in the processes. However, none of these algorithms consider the inevitably strong dependence in adjacent samples caused by high sampling frequencies or relatively slow continuous process changes, and the dependence may lead to unnecessarily large time lags and sub-optimal prediction performance. In this paper, a dynamic weighted CCA (DWCCA) algorithm is proposed to address this issue with the aid of basis functions. DWCCA constructs its latent space by maximizing the correlation between current data and a weighted representation of past data. To remove the negative effect caused by strongly collinear successive samples, it is assumed that the weights of past data rely only on a limited number of basis functions, and in this work, polynomial basis, Fourier basis, and Gaussian basis functions are considered and compared. Comprehensive modeling scheme is also designed for DWCCA with subsequent PCA decomposition to exploit static and dynamic variations concurrently. Case studies on the Tennessee Eastman process and the boiler process are presented to illustrate the effectiveness of the proposed dynamic models over other existing dynamic methods.     

Slow feature analysis for monitoring and diagnosis of control performance

Recently, slow feature analysis (SFA), a novel dimensionality reduction technique, has been adopted for integrated monitoring of operating condition and process dynamics. By isolating temporal behaviors from steady-state information, the SFA-based monitoring scheme enables improved discrimination of nominal operating point changes from real faults. In this study, we demonstrate that the temporal dynamics is an additional indicator of control performance changes, and further exploit its unique efficacy in control performance monitoring. Because of its data-driven nature and ease from first-principle knowledge, the SFA-based monitoring scheme allows an overall assessment of the plant-wide control performance and is compatible with different control strategies. An attractive feature of the SFA-based approach compared to existing ones is that generic process monitoring indices are used, which renders contribution plots naturally applicable to real-time diagnosis of control performance. As a result, potential fault variables as root causes of control performance changes can be identified, including not only controlled variables (CV) but also manipulated variables (MV) and disturbance variables (DV). Simulated and experimental studies demonstrate the effectiveness of the proposed method.     

一种基于可变多簇结构的动态概率粒子群优化算法

针对传统粒子群优化算法中全连接型拓扑和环形拓扑的特点,引入了一种粒子群信息共享方式——多簇结构,进而基于多簇结构提出了动态可变拓扑策略以协调动态概率粒子群优化算法的勘探和开采能力,并从理论上分析了最优信息在各种拓扑中的传播,同时从图论角度分析了几种经典拓扑以及动态可变多簇结构的统计特性.通过典型的Benchmark函数优化问题测试并比较了几种经典拓扑以及可变拓扑在高斯动态粒子群优化算法中的性能.实验结果表明,基于多簇结构的可变拓扑策略在求解复杂优化问题时优势明显,可以有效地避免算法陷入局部最优,在保证收敛速度的同时增强了算法的全局搜索能力.     

Parallel quality-related dynamic principal component regression method for chemical process monitoring

Traditional quality-related process monitoring mainly focuses on the magnitude change of the quality variables caused by additive faults. However, the abnormal fluctuations in the quality variables caused by multiplicative faults are often overlooked. In this paper, a novel parallel dynamic principal component regression (P-DPCR) algorithm is proposed to monitor the changes in the magnitude and fluctuation of the quality variables simultaneously. Firstly, in order to eliminate the interference of quality-unrelated variables, the quality-related process variables are selected on the basis of correlation analysis. Secondly, the dynamic extension and moving window are carried out for process variables and quality variables, in which the dynamic variables space (called X-space/Y-space) and the variance space (called VX-space/VY-space) are constructed. Afterwards, double quality-related statistics based on the regression model of these four spaces are given, and the comprehensive monitoring decision can be obtained. Finally, two numerical cases and the Tennessee Eastman process are used to show the effectiveness of the proposed method.     

Quality-relevant fault detection based on adversarial learning and distinguished contribution of latent variables to quality

Quality-relevant fault detection is a primary task to reveal the changes of quality variables in process monitoring. Current works mainly focus on learning quality-relevant features, however, how to distinguish quality-relevant and irrelevant information is responsible for the excellent monitoring performance. In this study, a novel quality-relevant fault detection method is proposed on the basis of adversarial learning and distinguished contribution of latent features to quality is originally introduced. First of all, we map the input variables into a gaussian manifold in adversarial and unsupervised manner. Then a fully connected neural network is trained to learn the relationship between latent and quality variables. To distinguish necessary information in such manifold, the Jacobi operator at the corresponding point is calculated to project the latent variables into quality-relevant and quality-irrelevant subspaces. Third, fault detection is implemented in these dynamic subspaces using the probabilities of latent variables. Finally, the proposed method is evaluated by numerical example, the Tennessee-Eastman process and wind turbine blade icing process.     

Sensitivity enhancing transformations for monitoring the process correlation structure

In this article we address the general problem of monitoring the process cross- and auto-correlation structure through the incorporation of information about its internal structure in a pre-processing stage, where sensitivity enhancing transformations are applied to collected data. We have found out that the sensitivity of the monitoring statistics based on partial or marginal correlations in detecting structural changes is directly related to the nominal levels of the correlation coefficients during normal operation conditions (NOC). The highest sensitivities are obtained when the process variables involved are uncorrelated, a situation that is hardly met in practice. However, not all transformations perform equally well in producing uncorrelated transformed variables with enhanced detection sensitivities. The most successful ones are based on the incorporation of the natural relationships connecting the process variables. In this context, a set of sensitivity enhancing transformations are proposed, which are based on a network reconstruction algorithm. These new transformations make use of fine structural information of the variables connectivity and therefore are able to improve the detection capability to local changes in correlation, leading to better performances when compared to current marginal-based methods, namely those based on latent variables models, such as PCA or PLS. Moreover, a novel monitoring statistic for the transformed variables variance proved to be very useful in the detection of structural changes resulting from model mismatch. This statistic allows for the detection of multiple structural changes within the same monitoring scheme and with higher detection performances when compared to the current methods.     

自动编码器与典型相关分析方法联合驱动的工业过程质量监测

本文将自动编码器(AE)特征提取方法和典型相关分析方法(CCA)有机结合,提出了一种联合驱动的质量监测模型及其质量相关的故障检测方法.首先,利用AE算法对输入样本进行无监督自动学习和重构,实现数据的特征提取和降维;其次,利用CCA算法实现特征与质量变量关联最大化,建立质量变量与特征变量的关系模型;根据监测模型的潜结构投影,构建T2统计量和SPE统计量及其相应控制限.将提出的方法用于分析带钢热连轧过程现场实际数据,结果表明,基于自动编码器-典型相关分析方法(AE-CCA)的质量监测方法能够准确的检测出故障,并且检测效果优于传统的核典型相关分析(KCCA)算法.     

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...     

基于混合变分自编码器回归模型的软测量建模方法EI北大核心CSCD

近年来,变分自编码器(Variational auto-encoder,VAE)模型由于在概率数据描述和特征提取能力等方面的优越性,受到了学术界和工业界的广泛关注,并被引入到工业过程监测、诊断和软测量建模等应用中.然而,传统基于VAE的软测量方法使用高斯分布作为潜在变量的分布,限制了其对复杂工业过程数据,尤其是多模态数据的建模能力.为了解决这一问题,本论文提出了一种混合变分自编码器回归模型(Mixture variational autoencoder regression,MVAER),并将其应用于复杂多模态工业过程的软测量建模.具体来说,该方法采用高斯混合模型来描述VAE的潜在变量分布,通过非线性映射将复杂多模态数据映射到潜在空间,学习各模态下的潜在变量,获取原始数据的有效特征表示.同时,建立潜在特征表示与关键质量变量之间的回归模型,实现软测量应用.通过一个数值例子和一个实际工业案例,对所提模型的性能进行了评估,验证了该模型的有效性和优越性.     

间歇过程动态潜结构阶段划分与在线监控

阶段划分是间歇过程准确建模和有效监控的前提.针对传统阶段划分方法未考虑间歇过程的动态性造成阶段划分不准确、影响监控精度,且具有参数选择难、鲁棒性差的局限,提出一种基于动态潜结构的动态间歇过程阶段划分与在线监控方法.首先,对间歇过程三维张量数据沿变量方向展开,并增加时滞变量构建增广矩阵来提取过程动态关系;然后,以增广矩阵...     

Recursive cointegration analytics for adaptive monitoring of nonstationary industrial processes with both static and dynamic variations

Conventional adaptive monitoring strategies detect anomalies in time-varying process by frequently updating models, which requires high computation complexity and may falsely include abnormal samples. Cointegration analysis (CA) based monitoring strategies can be implemented with less model updating since they are developed based on the extracted long-term equilibrium relationship. However, once the cointegration relationship changes, the previous CA model cannot accurately reflect the operation status of future nonstationary process. In this study, an adaptive monitoring scheme based on recursive CA is proposed to address the aforementioned issues for nonstationary processes. First, a recursive strategy is developed for CA to effectively update the monitoring model. After that, three monitoring statistics are developed to reflect the operation status of the industrial process with representation of both static deviation and dynamic fluctuation. Finally, an adaptive monitoring strategy is constructed based on the proposed recursive CA using the aforementioned monitoring statistics. Experimental results of two real industrial processes show that the adaptive monitoring strategy based on recursive CA can effectively adapt to normal process changes without frequent model updating.     

Multivariate statistical process control of an industrial fluidised-bed reactor

Multivariate statistical process control (MSPC) is a tool for the comprehensive monitoring of the performance of a manufacturing process. There is now a real need to demonstrate the applicability of MSPC to complex manufacturing processes and highlight the benefits that can be derived from its implementation. Alongside this, is the increasing interest in predicting quality or important chemical quality variables associated with product yield and production. This paper demonstrates the performance monitoring potential of MSPC and the predictive capability of canonical variates analysis and projection to latent structures by application to an industrial fluidised-bed reactor.     

A probabilistic principal component analysis-based approach in process monitoring and fault diagnosis with application in wastewater treatment plant

Probabilistic principal component analysis (PPCA) based approaches have been widely used in the field of process monitoring. However, the traditional PPCA approach is still limited to linear dimensionality reduction. Although the nonlinear projection model of PPCA can be obtained by Gaussian process mapping, the model still lacks robustness and is susceptible to process noise. Therefore, this paper proposes a new nonlinear process monitoring and fault diagnosis approach based on the Bayesian Gaussian latent variable model (Bay-GPLVM). Bay-GPLVM can obtain the posterior distribution rather than point estimation for latent variables, so the model is more robust. Two monitoring statistics corresponding to latent space and residual space are constructed for PM-FD purpose. Further, the cause of fault is analyzed by calculating the gradient value of the variable at the fault point. Compared with several PPCA-based monitoring approaches in theory and practical application, the Bay-GPLVM-based process monitoring approach can better deal with nonlinear processes and show high efficiency in process monitoring.     

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.