Data-driven process monitoring is an effective approach to assure safe operation of modern manufacturing and energy systems,such as thermal power plants being studied in this work.Industrial processes are inherently d...Data-driven process monitoring is an effective approach to assure safe operation of modern manufacturing and energy systems,such as thermal power plants being studied in this work.Industrial processes are inherently dynamic and need to be monitored using dynamic algorithms.Mainstream dynamic algorithms rely on concatenating current measurement with past data.This work proposes a new,alternative dynamic process monitoring algorithm,using dot product feature analysis(DPFA).DPFA computes the dot product of consecutive samples,thus naturally capturing the process dynamics through temporal correlation.At the same time,DPFA's online computational complexity is lower than not just existing dynamic algorithms,but also classical static algorithms(e.g.,principal component analysis and slow feature analysis).The detectability of the new algorithm is analyzed for three types of faults typically seen in process systems:sensor bias,process fault and gain change fault.Through experiments with a numerical example and real data from a thermal power plant,the DPFA algorithm is shown to be superior to the state-of-the-art methods,in terms of better monitoring performance(fault detection rate and false alarm rate)and lower computational complexity.展开更多
The increasing demand for unconventional oil and gas resources,especially oil shale,has highlighted the urgent need to develop rapid and accurate strata characterization methods.This paper is the first case and examin...The increasing demand for unconventional oil and gas resources,especially oil shale,has highlighted the urgent need to develop rapid and accurate strata characterization methods.This paper is the first case and examines the drilling process monitoring(DPM)method as a digital,accurate,cost-effective method to characterize oil shale reservoirs in the Ordos Basin,China.The digital DPM method provides real-time in situ testing of the relative variation in rock mechanical strength along the drill bit depth.Furthermore,it can give a refined rock quality designation based on the DPM zoning result(RQD(V_(DPM)))and a strength-grade characterization at the site.Oil shale has high heterogeneity and low strata strength.The digital results are further compared and verified with manual logging,cored samples,and digital panoramic borehole cameras.The findings highlight the innovative potential of the DPM method in identifying the zones of oil shale reservoir along the drill bit depth.The digital results provide a better understanding of the oil shale in Tongchuan and the potential for future oil shale exploration in other regions.展开更多
The evaluation of rock mass quality and its mechanical properties is crucial for tunnel construction.The basic quality(BQ)method is the national standard for rock mass classification in China,with the BQ value determi...The evaluation of rock mass quality and its mechanical properties is crucial for tunnel construction.The basic quality(BQ)method is the national standard for rock mass classification in China,with the BQ value determined by the uniaxial compressive strength(UCS)and the integrity index(Kv).However,traditional rock mechanics testing methods have inherent limitations,which complicate the rapid evaluation of rock mass quality at tunnel sites.Digital drilling process monitoring(DPM)offers a novel approach for evaluating rock mass quality and its mechanical properties.A hydraulic rotary drilling rig,equipped with the DPM system,was used to conduct digital drilling tests at the tunnel face.The DPM data for the net drilling process and each sub-process were then analyzed.The correlations between DPM parameter indices and rock mechanical parameters were investigated.Finally,the rock mass quality and its mechanical properties along three boreholes were evaluated.The results indicate that drilling speed in the linear zone(V_(DPM))is quantitatively correlated with rock UCS.Higher UCS values of the drilled rocks correspond to lower V_(DPM) values of the drilling rig.The variability in specific energy is associated with structural disturbances within the rock mass.There is an approximately linear relationship between the standard deviation of normalized specific energy and rock mass K_(v) across the three boreholes.The rock mass quality along drilling depth generally ranges from good(Ⅰ-Ⅱ)to poor(Ⅲ-Ⅴ).This digitalization method provides more detailed information for tunnel stability analysis and design optimization than geological survey data.展开更多
This study aims to enhance the digital drilling process monitoring(DPM)or monitoring while drilling(MWD)technique,which is a widely recognized method in geological exploration for evaluating rock mass quality.First,ro...This study aims to enhance the digital drilling process monitoring(DPM)or monitoring while drilling(MWD)technique,which is a widely recognized method in geological exploration for evaluating rock mass quality.First,robust displacement and torque measurement facilities for rotary-core drilling are discussed.The conventional cable encoder for displacement measurement is replaced with a magnetostrictive displacement sensor,which is more reliable in harsh field drilling environments.This enables the measurement of the bit position with an accuracy of<1 mm.Most importantly,this new instrument is proven to be successful in improving the detection of structural discontinuities with thicknesses>1 mm.In addition,by measuring the electric current of the driving motor,the torque applied to the bit is conveniently and accurately converted.These innovations ensure high-quality data collection for DPM practices.Second,two indices derived from DPM are proposed to quantitatively describe rock mass quality.The specific energy index(SEI)and specific penetration index(SPI)are based on the principles of energy conservation and Mohr-Coulomb failure criterion,respectively.Extensive field tests conducted in a dam grouting area confirm a linear relationship between the thrust force and penetration per rotation,and between the torque and penetration per rotation.The correlation ratios of the related regressions are typically>0.9.These two indices allow for the quantitative interpretation of DPM data into rock mechanics characteristics,such as uniaxial compressive strength,rock quality designation(RQD),and rock mass permeability,eliminating the need for subjective judgment normally involved in the currently used rock mass quality rating approaches.展开更多
Modern industrial processes are typically characterized by large-scale and intricate internal relationships.Therefore,the distributed modeling process monitoring method is effective.A novel distributed monitoring sche...Modern industrial processes are typically characterized by large-scale and intricate internal relationships.Therefore,the distributed modeling process monitoring method is effective.A novel distributed monitoring scheme utilizing the Kantorovich distance-multiblock variational autoencoder(KD-MBVAE)is introduced.Firstly,given the high consistency of relevant variables within each sub-block during the change process,the variables exhibiting analogous statistical features are grouped into identical segments according to the optimal quality transfer theory.Subsequently,the variational autoencoder(VAE)model was separately established,and corresponding T^(2)statistics were calculated.To improve fault sensitivity further,a novel statistic,derived from Kantorovich distance,is introduced by analyzing model residuals from the perspective of probability distribution.The thresholds of both statistics were determined by kernel density estimation.Finally,monitoring results for both types of statistics within all blocks are amalgamated using Bayesian inference.Additionally,a novel approach for fault diagnosis is introduced.The feasibility and efficiency of the introduced scheme are verified through two cases.展开更多
As a dynamic projection to latent structures(PLS)method with a good output prediction ability,dynamic inner PLS(DiPLS)is widely used in the prediction of key performance indi-cators.However,due to the oblique decompos...As a dynamic projection to latent structures(PLS)method with a good output prediction ability,dynamic inner PLS(DiPLS)is widely used in the prediction of key performance indi-cators.However,due to the oblique decomposition of the input space by DiPLS,there are false alarms in the actual industrial process during fault detection.To address the above problems,a dynamic modeling method based on autoregressive-dynamic inner total PLS(AR-DiTPLS)is proposed.The method first uses the regression relation matrix to decompose the input space orthogonally,which reduces useless information for the predic-tion output in the quality-related dynamic subspace.Then,a vector autoregressive model(VAR)is constructed for the predic-tion score to separate dynamic information and static informa-tion.Based on the VAR model,appropriate statistical indicators are further constructed for online monitoring,which reduces the occurrence of false alarms.The effectiveness of the method is verified by a Tennessee-Eastman industrial simulation process and a three-phase flow system.展开更多
A novel online process monitoring and fault diagnosis method of condenser based on kernel principle component analysis （KPCA） and Fisher discriminant analysis （FDA） is presented. The basic idea of this method is：...A novel online process monitoring and fault diagnosis method of condenser based on kernel principle component analysis （KPCA） and Fisher discriminant analysis （FDA） is presented. The basic idea of this method is： First map data from the original space into high-dimensional feature space via nonlinear kernel function and then extract optimal feature vector and discriminant vector in feature space and calculate the Euclidean distance between feature vectors to perform process monitoring. Similar degree between the present discriminant vector and optimal discriminant vector of fault in historical dataset is used for diagnosis. The proposed method can effectively capture the nonlinear relationship among process variables. Simulating results of the turbo generator＇s fault data set prove that the proposed method is effective.展开更多
Multivariate statistical process monitoring and control (MSPM&C) methods for chemical process monitoring with statistical projection techniques such as principal component analysis (PCA) and partial least squares ...Multivariate statistical process monitoring and control (MSPM&C) methods for chemical process monitoring with statistical projection techniques such as principal component analysis (PCA) and partial least squares (PLS) are surveyed in this paper. The four-step procedure of performing MSPM&C for chemical process, modeling of processes, detecting abnormal events or faults, identifying the variable(s) responsible for the faults and diagnosing the source cause for the abnormal behavior, is analyzed. Several main research directions of MSPM&C reported in the literature are discussed, such as multi-way principal component analysis (MPCA) for batch process, statistical monitoring and control for nonlinear process, dynamic PCA and dynamic PLS, and on-line quality control by inferential models. Industrial applications of MSPM&C to several typical chemical processes, such as chemical reactor, distillation column, polymerization process, petroleum refinery units, are summarized. Finally, some concluding remarks and future considerations are made.展开更多
Abstract Data-driven tools, such as principal component analysis （PCA） and independent component analysis （ICA） have been applied to different benchmarks as process monitoring methods. The difference between the t...Abstract Data-driven tools, such as principal component analysis （PCA） and independent component analysis （ICA） have been applied to different benchmarks as process monitoring methods. The difference between the two methods is that the components of PCA are still dependent while ICA has no orthogonality constraint and its latentvariables are independent. Process monitoring with PCA often supposes that process data or principal components is Gaussian distribution. However, this kind of constraint cannot be satisfied by several practical processes. To ex-tend the use of PCA, a nonparametric method is added to PCA to overcome the difficulty, and kernel density estimation （KDE） is rather a good choice. Though ICA is based on non-Gaussian distribution intormation, .KDE can help in the close monitoring of the data. Methods, such as PCA, ICA, PCA.with .KDE（KPCA）, and ICA with KDE,（KICA）, are demonstrated and. compared by applying them to a practical industnal Spheripol craft polypropylene catalyzer reactor instead of a laboratory emulator.展开更多
In the past decades, on-line monitoring of batch processes using multi-way independent component analysis （MICA） has received considerable attention in both academia and industry. This paper focuses on two troubleso...In the past decades, on-line monitoring of batch processes using multi-way independent component analysis （MICA） has received considerable attention in both academia and industry. This paper focuses on two troublesome issues concerning selecting dominant independent components without a standard criterion and deter- mining the control limits of monitoring statistics in the presence of non-Gaussian distribution. To optimize the number of key independent components~ we introctuce-anoveiconcept of-system-cleviation, which is ab^e＇io＇evalu[ ate the reconstructed observations with different independent components. The monitored statistics arc transformed to Gaussian distribution data by means of Box-Cox transformation, which helps readily determine the control limits. The proposed method is applied to on-line monitoring of a fed-hatch penicillin fermentation simulator, and the ex- _perimental results indicate the advantages of the improved MICA monitoring compared to the conventional methods.展开更多
Process monitoring techniques are of paramount importance in the chemical industry to improve both the product quality and plant safety.Small or incipient irregularities may lead to severe degradation in complex chemi...Process monitoring techniques are of paramount importance in the chemical industry to improve both the product quality and plant safety.Small or incipient irregularities may lead to severe degradation in complex chemical processes,and the conventional process monitoring techniques cannot detect these irregularities.In this study to improve the performance of monitoring,an online multiscale fault detection approach is proposed by integrating multiscale principal component analysis(MSPCA) with cumulative sum(CUSUM) and exponentially weighted moving average(EWMA) control charts.The new Hotelling's T~2 and square prediction error(SPE) based fault detection indices are proposed to detect the incipient irregularities in the process data.The performance of the proposed fault detection methods was tested for simulated data obtained from the CSTR system and compared to that of conventional PCA and MSPCA based methods.The results demonstrate that the proposed EWMA based MSPCA fault detection method was successful in detecting the faults.Moreover,a comparative study shows that the SPEEWMA monitoring index exhibits a better performance with lower values of missed detections ranging from 0% to 0.80% and false alarms ranging from 0% to 21.20%.展开更多
For complex industrial processes with multiple operational conditions, it is important to develop effective monitoring algorithms to ensure the safety of production processes. This paper proposes a novel monitoring st...For complex industrial processes with multiple operational conditions, it is important to develop effective monitoring algorithms to ensure the safety of production processes. This paper proposes a novel monitoring strategy based on fuzzy C-means. The high dimensional historical data are transferred to a low dimensional subspace spanned by locality preserving projection. Then the scores in the novel subspace are classified into several overlapped clusters, each representing an operational mode. The distance statistics of each cluster are integrated though the membership values into a novel BID (Bayesian inference distance) monitoring index. The efficiency and effectiveness of the proposed method are validated though the Tennessee Eastman benchmark process.展开更多
For the complex batch process with characteristics of unequal batch data length,a novel data-driven batch process monitoring method is proposed based on mixed data features analysis and multi-way kernel entropy compon...For the complex batch process with characteristics of unequal batch data length,a novel data-driven batch process monitoring method is proposed based on mixed data features analysis and multi-way kernel entropy component analysis(MDFA-MKECA)in this paper.Combining the mechanistic knowledge,different mixed data features of each batch including statistical and thermodynamics entropy features,are extracted to finish data pre-processing.After that,MKECA is applied to reduce data dimensionality and finally establish a monitoring model.The proposed method is applied to a reheating furnace industry process,and the experimental results demonstrate that the MDFA-MKECA method can reduce the calculated amount and effectively provide on-line monitoring of the batch process.展开更多
For plant-wide processes with multiple operating conditions,the multimode feature imposes some challenges to conventional monitoring techniques.Hence,to solve this problem,this paper provides a novel local component b...For plant-wide processes with multiple operating conditions,the multimode feature imposes some challenges to conventional monitoring techniques.Hence,to solve this problem,this paper provides a novel local component based principal component analysis(LCPCA)approach for monitoring the status of a multimode process.In LCPCA,the process prior knowledge of mode division is not required and it purely based on the process data.Firstly,LCPCA divides the processes data into multiple local components using finite Gaussian mixture model mixture(FGMM).Then,calculating the posterior probability is applied to determine each sample belonging to which local component.After that,the local component information(such as mean and standard deviation)is used to standardize each sample of local component.Finally,the standardized samples of each local component are combined to train PCA monitoring model.Based on the PCA monitoring model,two monitoring statistics T^(2) and SPE are used for monitoring multimode processes.Through a numerical example and the Tennessee Eastman(TE)process,the monitoring result demonstrates that LCPCA outperformed conventional PCA and LNS-PCA in the fault detection rate.展开更多
Reliable process monitoring is important for ensuring process safety and product quality.A production process is generally characterized bymultiple operation modes,and monitoring thesemultimodal processes is challengi...Reliable process monitoring is important for ensuring process safety and product quality.A production process is generally characterized bymultiple operation modes,and monitoring thesemultimodal processes is challenging.Most multimodal monitoring methods rely on the assumption that the modes are independent of each other,which may not be appropriate for practical application.This study proposes a transition-constrained Gaussian mixture model method for efficient multimodal process monitoring.This technique can reduce falsely and frequently occurring mode transitions by considering the time series information in the mode identification of historical and online data.This process enables the identified modes to reflect the stability of actual working conditions,improve mode identification accuracy,and enhance monitoring reliability in cases of mode overlap.Case studies on a numerical simulation example and simulation of the penicillin fermentation process are provided to verify the effectiveness of the proposed approach inmultimodal process monitoring with mode overlap.展开更多
In order to reduce the variations of the product quality in batch processes, multivariate statistical process control methods according to multi-way principal component analysis (MPCA) or multi-way projection to laten...In order to reduce the variations of the product quality in batch processes, multivariate statistical process control methods according to multi-way principal component analysis (MPCA) or multi-way projection to latent structure (MPLS) were proposed for on-line batch process monitoring. However, they are based on the decomposition of relative covariance matrix and strongly affected by outlying observations. In this paper, in view of an efficient projection pursuit algorithm, a robust statistical batch process monitoring (RSBPM) framework,which is resistant to outliers, is proposed to reduce the high demand for modeling data. The construction of robust normal operating condition model and robust control limits are discussed in detail. It is evaluated on monitoring an industrial streptomycin fermentation process and compared with the conventional MPCA. The results show that the RSBPM framework is resistant to possible outliers and the robustness is confirmed.展开更多
In this paper, we describe a new batch process monitoring method based on multilevel independent component analysis and principal component analysis (MLICA-PCA). Unlike the conventional multi-way principal component a...In this paper, we describe a new batch process monitoring method based on multilevel independent component analysis and principal component analysis (MLICA-PCA). Unlike the conventional multi-way principal component analysis (MPCA) method, MLICA-PCA provides a separated interpretation for multilevel batch process data. Batch process data are partitioned into two levels: the within-batch level and the between-batch level. In each level, the Gaussian and non-Gaussian components of process information can be separately extracted. I2, T2 and SPE statistics are individually built and monitored. The new method facilitates fault diagnosis. Since the two variation levels are decomposed, the variables responsible for faults in each level can be identified and interpreted more easily. A case study of the Dupont benchmark process showed that the proposed method was more efficient and interpretable in fault detection and diagnosis, compared to the alternative batch process monitoring method.展开更多
Conventional process monitoring method based on fast independent component analysis(Fast ICA) cannot take the ubiquitous measurement noises into account and may exhibit degraded monitoring performance under the advers...Conventional process monitoring method based on fast independent component analysis(Fast ICA) cannot take the ubiquitous measurement noises into account and may exhibit degraded monitoring performance under the adverse effects of the measurement noises. In this paper, a new process monitoring approach based on noisy time structure ICA(Noisy TSICA) is proposed to solve such problem. A Noisy TSICA algorithm which can consider the measurement noises explicitly is firstly developed to estimate the mixing matrix and extract the independent components(ICs). Subsequently, a monitoring statistic is built to detect process faults on the basis of the recursive kurtosis estimations of the dominant ICs. Lastly, a contribution plot for the monitoring statistic is constructed to identify the fault variables based on the sensitivity analysis. Simulation studies on the continuous stirred tank reactor system demonstrate that the proposed Noisy TSICA-based monitoring method outperforms the conventional Fast ICA-based monitoring method.展开更多
Recently, with the rapid growth of information technology, many studies have been performed to implement Web-based manufacturing system. Such technologies are expected to meet the need of many manufacturing industries...Recently, with the rapid growth of information technology, many studies have been performed to implement Web-based manufacturing system. Such technologies are expected to meet the need of many manufacturing industries who want to adopt E-manufacturing system for the construction of globalization, agility, and digitalization to cope with the rapid changing market requirements. In this research, a real-time Web-based machine tool and machining process monitoring system is developed as the first step for implementing E-manufacturing system. In this system, the current variations of the main spindle and feeding motors are measured using hall sensors. And the relationship between the cutting force and the spindle motor RMS (Root Mean Square) current at various spindle rotational speeds is obtained. Thermocouples are used to measure temperature variations of important heat sources of a machine tool. Also, a rule-based expert system is applied in order to decide the machining process and machine tool are in normal conditions. Finally, the effectiveness of the developed system is verified through a series of experiments.展开更多
An approach for batch processes monitoring and fault detection based on multiway kernel partial least squares(MKPLS) was presented.It is known that conventional batch process monitoring methods,such as multiway partia...An approach for batch processes monitoring and fault detection based on multiway kernel partial least squares(MKPLS) was presented.It is known that conventional batch process monitoring methods,such as multiway partial least squares(MPLS),are not suitable due to their intrinsic linearity when the variations are nonlinear.To address this issue,kernel partial least squares(KPLS) was used to capture the nonlinear relationship between the latent structures and predictive variables.In addition,KPLS requires only linear algebra and does not involve any nonlinear optimization.In this paper,the application of KPLS was extended to on-line monitoring of batch processes.The proposed batch monitoring method was applied to a simulation benchmark of fed-batch penicillin fermentation process.And the results demonstrate the superior monitoring performance of MKPLS in comparison to MPLS monitoring.展开更多
基金supported in part by the National Science Fund for Distinguished Young Scholars of China(62225303)the National Natural Science Fundation of China(62303039,62433004)+2 种基金the China Postdoctoral Science Foundation(BX20230034,2023M730190)the Fundamental Research Funds for the Central Universities(buctrc202201,QNTD2023-01)the High Performance Computing Platform,College of Information Science and Technology,Beijing University of Chemical Technology
文摘Data-driven process monitoring is an effective approach to assure safe operation of modern manufacturing and energy systems,such as thermal power plants being studied in this work.Industrial processes are inherently dynamic and need to be monitored using dynamic algorithms.Mainstream dynamic algorithms rely on concatenating current measurement with past data.This work proposes a new,alternative dynamic process monitoring algorithm,using dot product feature analysis(DPFA).DPFA computes the dot product of consecutive samples,thus naturally capturing the process dynamics through temporal correlation.At the same time,DPFA's online computational complexity is lower than not just existing dynamic algorithms,but also classical static algorithms(e.g.,principal component analysis and slow feature analysis).The detectability of the new algorithm is analyzed for three types of faults typically seen in process systems:sensor bias,process fault and gain change fault.Through experiments with a numerical example and real data from a thermal power plant,the DPFA algorithm is shown to be superior to the state-of-the-art methods,in terms of better monitoring performance(fault detection rate and false alarm rate)and lower computational complexity.
基金supported by grants from the Research Grant Council of the Hong Kong Special Administrative Region,China(Grant No.HKU 7137/03E)the National Natural Science Foundation of China(Grant No.41977248)the Strategic Priority Research Program of the Chinese Academy of Sciences(Grant No.XDB10030100).
文摘The increasing demand for unconventional oil and gas resources,especially oil shale,has highlighted the urgent need to develop rapid and accurate strata characterization methods.This paper is the first case and examines the drilling process monitoring(DPM)method as a digital,accurate,cost-effective method to characterize oil shale reservoirs in the Ordos Basin,China.The digital DPM method provides real-time in situ testing of the relative variation in rock mechanical strength along the drill bit depth.Furthermore,it can give a refined rock quality designation based on the DPM zoning result(RQD(V_(DPM)))and a strength-grade characterization at the site.Oil shale has high heterogeneity and low strata strength.The digital results are further compared and verified with manual logging,cored samples,and digital panoramic borehole cameras.The findings highlight the innovative potential of the DPM method in identifying the zones of oil shale reservoir along the drill bit depth.The digital results provide a better understanding of the oil shale in Tongchuan and the potential for future oil shale exploration in other regions.
基金The support provided by the National Natural Science Foundation of China(Grant No.42277160)the Natural Science Foundation of Hubei Province(Grant No.2021CFA081)the Fundamental Research Funds for the Central Universities(Grant No.2042023kf0210)is gratefully acknowledged.
文摘The evaluation of rock mass quality and its mechanical properties is crucial for tunnel construction.The basic quality(BQ)method is the national standard for rock mass classification in China,with the BQ value determined by the uniaxial compressive strength(UCS)and the integrity index(Kv).However,traditional rock mechanics testing methods have inherent limitations,which complicate the rapid evaluation of rock mass quality at tunnel sites.Digital drilling process monitoring(DPM)offers a novel approach for evaluating rock mass quality and its mechanical properties.A hydraulic rotary drilling rig,equipped with the DPM system,was used to conduct digital drilling tests at the tunnel face.The DPM data for the net drilling process and each sub-process were then analyzed.The correlations between DPM parameter indices and rock mechanical parameters were investigated.Finally,the rock mass quality and its mechanical properties along three boreholes were evaluated.The results indicate that drilling speed in the linear zone(V_(DPM))is quantitatively correlated with rock UCS.Higher UCS values of the drilled rocks correspond to lower V_(DPM) values of the drilling rig.The variability in specific energy is associated with structural disturbances within the rock mass.There is an approximately linear relationship between the standard deviation of normalized specific energy and rock mass K_(v) across the three boreholes.The rock mass quality along drilling depth generally ranges from good(Ⅰ-Ⅱ)to poor(Ⅲ-Ⅴ).This digitalization method provides more detailed information for tunnel stability analysis and design optimization than geological survey data.
基金financially supported by the National Natural Science Foundation of China(Grant No.52079150)Science and Technology Major Project of the Xizang Autonomous Region of China(XZ202201ZD0003G)Water Conservancy Technology Demonstration Project(SF-202404).
文摘This study aims to enhance the digital drilling process monitoring(DPM)or monitoring while drilling(MWD)technique,which is a widely recognized method in geological exploration for evaluating rock mass quality.First,robust displacement and torque measurement facilities for rotary-core drilling are discussed.The conventional cable encoder for displacement measurement is replaced with a magnetostrictive displacement sensor,which is more reliable in harsh field drilling environments.This enables the measurement of the bit position with an accuracy of<1 mm.Most importantly,this new instrument is proven to be successful in improving the detection of structural discontinuities with thicknesses>1 mm.In addition,by measuring the electric current of the driving motor,the torque applied to the bit is conveniently and accurately converted.These innovations ensure high-quality data collection for DPM practices.Second,two indices derived from DPM are proposed to quantitatively describe rock mass quality.The specific energy index(SEI)and specific penetration index(SPI)are based on the principles of energy conservation and Mohr-Coulomb failure criterion,respectively.Extensive field tests conducted in a dam grouting area confirm a linear relationship between the thrust force and penetration per rotation,and between the torque and penetration per rotation.The correlation ratios of the related regressions are typically>0.9.These two indices allow for the quantitative interpretation of DPM data into rock mechanics characteristics,such as uniaxial compressive strength,rock quality designation(RQD),and rock mass permeability,eliminating the need for subjective judgment normally involved in the currently used rock mass quality rating approaches.
基金support from the National Key Research&Development Program of China(2021YFC2101100)the National Natural Science Foundation of China(62322309,61973119).
文摘Modern industrial processes are typically characterized by large-scale and intricate internal relationships.Therefore,the distributed modeling process monitoring method is effective.A novel distributed monitoring scheme utilizing the Kantorovich distance-multiblock variational autoencoder(KD-MBVAE)is introduced.Firstly,given the high consistency of relevant variables within each sub-block during the change process,the variables exhibiting analogous statistical features are grouped into identical segments according to the optimal quality transfer theory.Subsequently,the variational autoencoder(VAE)model was separately established,and corresponding T^(2)statistics were calculated.To improve fault sensitivity further,a novel statistic,derived from Kantorovich distance,is introduced by analyzing model residuals from the perspective of probability distribution.The thresholds of both statistics were determined by kernel density estimation.Finally,monitoring results for both types of statistics within all blocks are amalgamated using Bayesian inference.Additionally,a novel approach for fault diagnosis is introduced.The feasibility and efficiency of the introduced scheme are verified through two cases.
基金supported by the National Natural Science Foundation of China(62273354,61673387,61833016).
文摘As a dynamic projection to latent structures(PLS)method with a good output prediction ability,dynamic inner PLS(DiPLS)is widely used in the prediction of key performance indi-cators.However,due to the oblique decomposition of the input space by DiPLS,there are false alarms in the actual industrial process during fault detection.To address the above problems,a dynamic modeling method based on autoregressive-dynamic inner total PLS(AR-DiTPLS)is proposed.The method first uses the regression relation matrix to decompose the input space orthogonally,which reduces useless information for the predic-tion output in the quality-related dynamic subspace.Then,a vector autoregressive model(VAR)is constructed for the predic-tion score to separate dynamic information and static informa-tion.Based on the VAR model,appropriate statistical indicators are further constructed for online monitoring,which reduces the occurrence of false alarms.The effectiveness of the method is verified by a Tennessee-Eastman industrial simulation process and a three-phase flow system.
基金The National Natural Science Foundation of China(No60504033)
文摘A novel online process monitoring and fault diagnosis method of condenser based on kernel principle component analysis （KPCA） and Fisher discriminant analysis （FDA） is presented. The basic idea of this method is： First map data from the original space into high-dimensional feature space via nonlinear kernel function and then extract optimal feature vector and discriminant vector in feature space and calculate the Euclidean distance between feature vectors to perform process monitoring. Similar degree between the present discriminant vector and optimal discriminant vector of fault in historical dataset is used for diagnosis. The proposed method can effectively capture the nonlinear relationship among process variables. Simulating results of the turbo generator＇s fault data set prove that the proposed method is effective.
基金Supported by the National High-Tech Development Program of China(No.863-511-920-011,2001AA411230).
文摘Multivariate statistical process monitoring and control (MSPM&C) methods for chemical process monitoring with statistical projection techniques such as principal component analysis (PCA) and partial least squares (PLS) are surveyed in this paper. The four-step procedure of performing MSPM&C for chemical process, modeling of processes, detecting abnormal events or faults, identifying the variable(s) responsible for the faults and diagnosing the source cause for the abnormal behavior, is analyzed. Several main research directions of MSPM&C reported in the literature are discussed, such as multi-way principal component analysis (MPCA) for batch process, statistical monitoring and control for nonlinear process, dynamic PCA and dynamic PLS, and on-line quality control by inferential models. Industrial applications of MSPM&C to several typical chemical processes, such as chemical reactor, distillation column, polymerization process, petroleum refinery units, are summarized. Finally, some concluding remarks and future considerations are made.
基金Supported by the National Natural Science Foundation of China （No.60574047） and the Doctorate Foundation of the State Education Ministry of China （No.20050335018）.
文摘Abstract Data-driven tools, such as principal component analysis （PCA） and independent component analysis （ICA） have been applied to different benchmarks as process monitoring methods. The difference between the two methods is that the components of PCA are still dependent while ICA has no orthogonality constraint and its latentvariables are independent. Process monitoring with PCA often supposes that process data or principal components is Gaussian distribution. However, this kind of constraint cannot be satisfied by several practical processes. To ex-tend the use of PCA, a nonparametric method is added to PCA to overcome the difficulty, and kernel density estimation （KDE） is rather a good choice. Though ICA is based on non-Gaussian distribution intormation, .KDE can help in the close monitoring of the data. Methods, such as PCA, ICA, PCA.with .KDE（KPCA）, and ICA with KDE,（KICA）, are demonstrated and. compared by applying them to a practical industnal Spheripol craft polypropylene catalyzer reactor instead of a laboratory emulator.
文摘In the past decades, on-line monitoring of batch processes using multi-way independent component analysis （MICA） has received considerable attention in both academia and industry. This paper focuses on two troublesome issues concerning selecting dominant independent components without a standard criterion and deter- mining the control limits of monitoring statistics in the presence of non-Gaussian distribution. To optimize the number of key independent components~ we introctuce-anoveiconcept of-system-cleviation, which is ab^e＇io＇evalu[ ate the reconstructed observations with different independent components. The monitored statistics arc transformed to Gaussian distribution data by means of Box-Cox transformation, which helps readily determine the control limits. The proposed method is applied to on-line monitoring of a fed-hatch penicillin fermentation simulator, and the ex- _perimental results indicate the advantages of the improved MICA monitoring compared to the conventional methods.
基金Department for the technical and administrative support and the financial support from the Yayasan UTP grant(Cost centre:015LC0-132).
文摘Process monitoring techniques are of paramount importance in the chemical industry to improve both the product quality and plant safety.Small or incipient irregularities may lead to severe degradation in complex chemical processes,and the conventional process monitoring techniques cannot detect these irregularities.In this study to improve the performance of monitoring,an online multiscale fault detection approach is proposed by integrating multiscale principal component analysis(MSPCA) with cumulative sum(CUSUM) and exponentially weighted moving average(EWMA) control charts.The new Hotelling's T~2 and square prediction error(SPE) based fault detection indices are proposed to detect the incipient irregularities in the process data.The performance of the proposed fault detection methods was tested for simulated data obtained from the CSTR system and compared to that of conventional PCA and MSPCA based methods.The results demonstrate that the proposed EWMA based MSPCA fault detection method was successful in detecting the faults.Moreover,a comparative study shows that the SPEEWMA monitoring index exhibits a better performance with lower values of missed detections ranging from 0% to 0.80% and false alarms ranging from 0% to 21.20%.
基金Supported by the National Natural Science Foundation of China (61074079)Shanghai Leading Academic Discipline Project (B054)
文摘For complex industrial processes with multiple operational conditions, it is important to develop effective monitoring algorithms to ensure the safety of production processes. This paper proposes a novel monitoring strategy based on fuzzy C-means. The high dimensional historical data are transferred to a low dimensional subspace spanned by locality preserving projection. Then the scores in the novel subspace are classified into several overlapped clusters, each representing an operational mode. The distance statistics of each cluster are integrated though the membership values into a novel BID (Bayesian inference distance) monitoring index. The efficiency and effectiveness of the proposed method are validated though the Tennessee Eastman benchmark process.
基金supported by National Key R&D Program of China(Smart process control technology for aluminum&copper strip based on industrial big data)(2017YFB0306405)。
文摘For the complex batch process with characteristics of unequal batch data length,a novel data-driven batch process monitoring method is proposed based on mixed data features analysis and multi-way kernel entropy component analysis(MDFA-MKECA)in this paper.Combining the mechanistic knowledge,different mixed data features of each batch including statistical and thermodynamics entropy features,are extracted to finish data pre-processing.After that,MKECA is applied to reduce data dimensionality and finally establish a monitoring model.The proposed method is applied to a reheating furnace industry process,and the experimental results demonstrate that the MDFA-MKECA method can reduce the calculated amount and effectively provide on-line monitoring of the batch process.
基金National Natural Science Foundation of China(61673279)。
文摘For plant-wide processes with multiple operating conditions,the multimode feature imposes some challenges to conventional monitoring techniques.Hence,to solve this problem,this paper provides a novel local component based principal component analysis(LCPCA)approach for monitoring the status of a multimode process.In LCPCA,the process prior knowledge of mode division is not required and it purely based on the process data.Firstly,LCPCA divides the processes data into multiple local components using finite Gaussian mixture model mixture(FGMM).Then,calculating the posterior probability is applied to determine each sample belonging to which local component.After that,the local component information(such as mean and standard deviation)is used to standardize each sample of local component.Finally,the standardized samples of each local component are combined to train PCA monitoring model.Based on the PCA monitoring model,two monitoring statistics T^(2) and SPE are used for monitoring multimode processes.Through a numerical example and the Tennessee Eastman(TE)process,the monitoring result demonstrates that LCPCA outperformed conventional PCA and LNS-PCA in the fault detection rate.
基金supported in part by National Natural Science Foundation of China under Grants 61973119 and 61603138in part by Shanghai Rising-Star Program under Grant 20QA1402600+1 种基金in part by the Open Funding from Shandong Key Laboratory of Big-data Driven Safety Control Technology for Complex Systems under Grant SKDN202001in part by the Programme of Introducing Talents of Discipline to Universities(the 111 Project)under Grant B17017.
文摘Reliable process monitoring is important for ensuring process safety and product quality.A production process is generally characterized bymultiple operation modes,and monitoring thesemultimodal processes is challenging.Most multimodal monitoring methods rely on the assumption that the modes are independent of each other,which may not be appropriate for practical application.This study proposes a transition-constrained Gaussian mixture model method for efficient multimodal process monitoring.This technique can reduce falsely and frequently occurring mode transitions by considering the time series information in the mode identification of historical and online data.This process enables the identified modes to reflect the stability of actual working conditions,improve mode identification accuracy,and enhance monitoring reliability in cases of mode overlap.Case studies on a numerical simulation example and simulation of the penicillin fermentation process are provided to verify the effectiveness of the proposed approach inmultimodal process monitoring with mode overlap.
文摘In order to reduce the variations of the product quality in batch processes, multivariate statistical process control methods according to multi-way principal component analysis (MPCA) or multi-way projection to latent structure (MPLS) were proposed for on-line batch process monitoring. However, they are based on the decomposition of relative covariance matrix and strongly affected by outlying observations. In this paper, in view of an efficient projection pursuit algorithm, a robust statistical batch process monitoring (RSBPM) framework,which is resistant to outliers, is proposed to reduce the high demand for modeling data. The construction of robust normal operating condition model and robust control limits are discussed in detail. It is evaluated on monitoring an industrial streptomycin fermentation process and compared with the conventional MPCA. The results show that the RSBPM framework is resistant to possible outliers and the robustness is confirmed.
基金Project (No. 60774067) supported by the National Natural ScienceFoundation of China
文摘In this paper, we describe a new batch process monitoring method based on multilevel independent component analysis and principal component analysis (MLICA-PCA). Unlike the conventional multi-way principal component analysis (MPCA) method, MLICA-PCA provides a separated interpretation for multilevel batch process data. Batch process data are partitioned into two levels: the within-batch level and the between-batch level. In each level, the Gaussian and non-Gaussian components of process information can be separately extracted. I2, T2 and SPE statistics are individually built and monitored. The new method facilitates fault diagnosis. Since the two variation levels are decomposed, the variables responsible for faults in each level can be identified and interpreted more easily. A case study of the Dupont benchmark process showed that the proposed method was more efficient and interpretable in fault detection and diagnosis, compared to the alternative batch process monitoring method.
基金Supported by the National Natural Science Foundation of China(61273160)the Natural Science Foundation of Shandong Province(ZR2011FM014)+1 种基金the Fundamental Research Funds for the Central Universities(12CX06071A)the Postgraduate Innovation Funds of China University of Petroleum(CX2013060)
文摘Conventional process monitoring method based on fast independent component analysis(Fast ICA) cannot take the ubiquitous measurement noises into account and may exhibit degraded monitoring performance under the adverse effects of the measurement noises. In this paper, a new process monitoring approach based on noisy time structure ICA(Noisy TSICA) is proposed to solve such problem. A Noisy TSICA algorithm which can consider the measurement noises explicitly is firstly developed to estimate the mixing matrix and extract the independent components(ICs). Subsequently, a monitoring statistic is built to detect process faults on the basis of the recursive kurtosis estimations of the dominant ICs. Lastly, a contribution plot for the monitoring statistic is constructed to identify the fault variables based on the sensitivity analysis. Simulation studies on the continuous stirred tank reactor system demonstrate that the proposed Noisy TSICA-based monitoring method outperforms the conventional Fast ICA-based monitoring method.
基金Project (No. KRF-2005-202-D00046) supported by the Korea Re-search Foundation
文摘Recently, with the rapid growth of information technology, many studies have been performed to implement Web-based manufacturing system. Such technologies are expected to meet the need of many manufacturing industries who want to adopt E-manufacturing system for the construction of globalization, agility, and digitalization to cope with the rapid changing market requirements. In this research, a real-time Web-based machine tool and machining process monitoring system is developed as the first step for implementing E-manufacturing system. In this system, the current variations of the main spindle and feeding motors are measured using hall sensors. And the relationship between the cutting force and the spindle motor RMS (Root Mean Square) current at various spindle rotational speeds is obtained. Thermocouples are used to measure temperature variations of important heat sources of a machine tool. Also, a rule-based expert system is applied in order to decide the machining process and machine tool are in normal conditions. Finally, the effectiveness of the developed system is verified through a series of experiments.
基金National Natural Science Foundation of China (No. 61074079)Shanghai Leading Academic Discipline Project,China (No.B504)
文摘An approach for batch processes monitoring and fault detection based on multiway kernel partial least squares(MKPLS) was presented.It is known that conventional batch process monitoring methods,such as multiway partial least squares(MPLS),are not suitable due to their intrinsic linearity when the variations are nonlinear.To address this issue,kernel partial least squares(KPLS) was used to capture the nonlinear relationship between the latent structures and predictive variables.In addition,KPLS requires only linear algebra and does not involve any nonlinear optimization.In this paper,the application of KPLS was extended to on-line monitoring of batch processes.The proposed batch monitoring method was applied to a simulation benchmark of fed-batch penicillin fermentation process.And the results demonstrate the superior monitoring performance of MKPLS in comparison to MPLS monitoring.
