Data-driven Soft Sensors in the Process Industry

In the last two decades Soft Sensors established themselves as a valuable alternative to the traditional means for the acquisition of critical process variables, process monitoring and other tasks which are related to process control. This paper discusses characteristics of the process industry data which are critical for the development of data-driven Soft Sensors. These characteristics are common to a large number of process industry fields, like the chemical industry, bioprocess industry, steel industry, etc. The focus of this work is put on the data-driven Soft Sensors because of their growing popularity, already demonstrated usefulness and huge, though yet not completely realised, potential. A comprehensive selection of case studies covering the three most important Soft Sensor application fields, a general introduction to the most popular Soft Sensor modelling techniques as well as a discussion of some open issues in the Soft Sensor development and maintenance and their possible solutions are the main contributions of this work

Intelligent flight control systems

The capabilities of flight control systems can be enhanced by designing them to emulate functions of natural intelligence. Intelligent control functions fall in three categories. Declarative actions involve decision-making, providing models for system monitoring, goal planning, and system/scenario identification. Procedural actions concern skilled behavior and have parallels in guidance, navigation, and adaptation. Reflexive actions are spontaneous, inner-loop responses for control and estimation. Intelligent flight control systems learn knowledge of the aircraft and its mission and adapt to changes in the flight environment. Cognitive models form an efficient basis for integrating 'outer-loop/inner-loop' control functions and for developing robust parallel-processing algorithms

Using an extended Kalman filter learning algorithm for feed-forward neural networks to describe tracer correlations

International audienceIn this study a new extended Kalman filter (EKF) learning algorithm for feed-forward neural networks (FFN) is used. With the EKF approach, the training of the FFN can be seen as state estimation for a non-linear stationary process. The EKF method gives excellent convergence performances provided that there is enough computer core memory and that the machine precision is high. Neural networks are ideally suited to describe the spatial and temporal dependence of tracer-tracer correlations. The neural network performs well even in regions where the correlations are less compact and normally a family of correlation curves would be required. For example, the CH4-N2O correlation can be well described using a neural network trained with the latitude, pressure, time of year, and CH4 volume mixing ratio (v.m.r.). The neural network was able to reproduce the CH4-N2O correlation with a correlation coefficient between simulated and training values of 0.9997. The neural network Fortran code used is available for download

Model migration neural network for predicting battery aging trajectories

Accurate prediction of batteries’ future degradation is a key solution to relief users’ anxiety on battery lifespan and electric vehicle’s driving range. Technical challenges arise from the highly nonlinear dynamics of battery aging. In this paper, a feed-forward migration neural network is proposed to predict the batteries’ aging trajectories. Specifically, a base model that describes the capacity decay over time is first established from the existed battery aging dataset. This base model is then transformed by an input-output slope-and-bias-correction (SBC) method structure to capture the degradation of target cell. To enhance the model’s nonlinear transfer capability, the SBC-model is further integrated into a four-layer neural network, and easily trained via the gradient correlation algorithm. The proposed migration neural network is experimentally verified with four different commercial batteries. The predicted RMSEs are all lower than 2.5% when using only the first 30% of aging trajectories for neural network training. In addition, illustrative results demonstrate that a small size feed-forward neural network (down to 1-5-5-1) is sufficient for battery aging trajectory prediction

Review on Battery State Estimation and Management Solutions for Next-Generation Connected Vehicles

The transport sector is tackling the challenge of reducing vehicle pollutant emissions and carbon footprints by means of a shift to electrified powertrains, i.e., battery electric vehicles (BEVs) and plug-in hybrid electric vehicles (PHEVs). However, electrified vehicles pose new issues associated with the design and energy management for the efficient use of onboard energy storage systems (ESSs). Thus, strong attention should be devoted to ensuring the safety and efficient operation of the ESSs. In this framework, a dedicated battery management system (BMS) is required to contemporaneously optimize the battery’s state of charge (SoC) and to increase the battery’s lifespan through tight control of its state of health (SoH). Despite the advancements in the modern onboard BMS, more detailed data-driven algorithms for SoC, SoH, and fault diagnosis cannot be implemented due to limited computing capabilities. To overcome such limitations, the conceptualization and/or implementation of BMS in-cloud applications are under investigation. The present study hence aims to produce a new and comprehensive review of the advancements in battery management solutions in terms of functionality, usability, and drawbacks, with specific attention to cloud-based BMS solutions as well as SoC and SoH prediction and estimation. Current gaps and challenges are addressed considering V2X connectivity to fully exploit the latest cloud-based solutions

A review on analysis and synthesis of nonlinear stochastic systems with randomly occurring incomplete information

Copyright q 2012 Hongli Dong et al. This is an open access article distributed under the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.In the context of systems and control, incomplete information refers to a dynamical system in which knowledge about the system states is limited due to the difficulties in modeling complexity in a quantitative way. The well-known types of incomplete information include parameter uncertainties and norm-bounded nonlinearities. Recently, in response to the development of network technologies, the phenomenon of randomly occurring incomplete information has become more and more prevalent. Such a phenomenon typically appears in a networked environment. Examples include, but are not limited to, randomly occurring uncertainties, randomly occurring nonlinearities, randomly occurring saturation, randomly missing measurements and randomly occurring quantization. Randomly occurring incomplete information, if not properly handled, would seriously deteriorate the performance of a control system. In this paper, we aim to survey some recent advances on the analysis and synthesis problems for nonlinear stochastic systems with randomly occurring incomplete information. The developments of the filtering, control and fault detection problems are systematically reviewed. Latest results on analysis and synthesis of nonlinear stochastic systems are discussed in great detail. In addition, various distributed filtering technologies over sensor networks are highlighted. Finally, some concluding remarks are given and some possible future research directions are pointed out. © 2012 Hongli Dong et al.This work was supported in part by the National Natural Science Foundation of China under Grants 61273156, 61134009, 61273201, 61021002, and 61004067, the Engineering and Physical Sciences Research Council (EPSRC) of the UK under Grant GR/S27658/01, the Royal Society of the UK, the National Science Foundation of the USA under Grant No. HRD-1137732, and the Alexander von Humboldt Foundation of German

Development of software sensors for on-line monitoring of bakers yeast fermentation process

Software sensors and bioprocess are well-established research areas which have much to offer each other. Under the perspective of the software sensors area, bioprocess can be considered as a broad application area with a growing number of complex and challenging tasks to be dealt with, whose solutions can contribute to achieving high productivity and high-quality products. Although throughout the past years in the field of software sensors and bioprocess, progress has been quick and with a high degree of success, there is still a lack of inexpensive and reliable sensors for on-line state and parameter estimation. Therefore, the primary objective of this research was to design an inexpensive measurement system for on-line monitoring of ethanol production during the backers yeast cultivation process. The measurement system is based on commercially available metal oxide semiconductor gas sensors. From the bioreactor headspace, samples are pumped past the gas sensors array for 10 s every five minutes and the voltage changes of the sensors are measured. The signals from the gas sensor array showed a high correlation with ethanol concentration during cultivation process. In order to predict ethanol concentrations from the data of the gas sensor array, a principal component regression (PCR) model was developed. For the calibration procedure no off-line sampling was used. Instead, a theoretical model of the process is applied to simulate the ethanol production at any given time. The simulated ethanol concentrations were used as reference data for calibrating the response of the gas sensor array. The obtained results indicate that the model-based calibrated gas sensor array is able to predict ethanol concentrations during the cultivation process with a high accuracy (root mean square error of calibration as well as the percentage error for the validation sets were below 0.2 gL-1 and 7 %, respectively). However the predicted values are only available every five minutes. Therefore, the following plan of the research goal was to implement an estimation method for continues prediction of ethanol as well as glucose, biomass and the growth rates. For this reason, two nonlinear extensions of the Kalman filter namely the extended Kalman filter (EKF) and the unscented Kalman filter (UKF) were implemented separately for state and parameter estimation. Both prediction methods were validated on three different cultivation with variability of the substrate concentrations. The obtained results showed that both estimation algorithms show satisfactory results with respect to estimation of concentrations of substrates 6 and biomass as well as the growth rate parameters during the cultivation. However, despite the easier implementation producer of the UKF, this method shows more accurate prediction results compared to the EKF prediction method. Another focus of this study was to design and implement an on-line monitoring and control system for the volume evaluation of dough pieces during the proofing process of bread making. For this reason, a software sensor based on image processing was designed and implemented for measuring the dough volume. The control system consists of a fuzzy logic controller which takes into account the estimated volume. The controller is designed to maintain the volume of the dough pieces similar to the volume expansion of a dough piece in standard conditions during the proofing process by manipulating the temperature of the proofing chamber. Dough pieces with different amounts of backers yeast added in the ingredients and in different temperature starting states were prepared and proofed with the supervision of the software sensor and the fuzzy controller. The controller was evaluated by means of performance criteria and the final volume of the dough samples. The obtained results indicate that the performance of the system is very satisfactory with respect to volume control and set point deviation of the dough pieces.Softwaresensoren und Bioprozese sind gut etablierte Forschungsgebiete, die sich gegenseitig viel befruchten können. Unter dem Blickwinkel der Softwaresensorik kann der Bioprozess als ein breites Anwendungsgebiet mit einer wachsenden Zahl komplexer und anspruchsvoller Aufgabenstellungen betrachtet werden, deren Lösung zur Erzielung hoher Produktivität und qualitativ hochwertiger Produkte beitragen kann. Obwohl in den letzten Jahren auf dem Gebiet der Softwaresensoren und des Bioprozesses rasch und mit großem Erfolg Untersuchung erzielt wurden, fehlt es immer noch an kostengünstigen und zuverlässigen Sensoren für die Online-Zustands- und Parameterschätzung. Daher war das primäre Ziel dieser Forschung die Entwicklung eines kostengünstigen Messsystems für die Online-Überwachung der Ethanolproduktion während des Kultivierungsprozesses von Backhefe. Das Messsystem basiert auf kommerziell erhältlichen Metalloxid-Halbleiter-Gassensoren. Die Headspace-Proben des Bioreaktors werden alle fünf Minuten für 10 s an der Gassensor-Anordnung vorbeigepumpt und die Spannungsänderungen der Sensoren werden gemessen. Die Signale des Gassensorarrays zeigten eine hohe Korrelation mit der Ethanolkonzentration während des Kultivierungsprozesses. Um die Ethanolkonzentrationen aus den Daten des Gassensorarrays vorherzusagen, wurde ein Hauptkomponenten-Regressionsmodell (PCR) verwendet. Für das Kalibrierungsverfahren ist keine Offline-Probenahme notwendig. Stattdessen wird ein theoretisches Modell des Prozesses genutzt, um die Ethanolproduktion zu jedem beliebigen Zeitpunkt zu simulieren. Die kinetischen Parameter des Modells werden im Rahmen der Kalibration bestimmt. Die simulierten Ethanolkonzentrationen wurden als Referenzdaten für die Kalibrierung des Ansprechverhaltens des Gassensorarrays verwendet. Die erhaltenen Ergebnisse zeigen, dass das modellbasierte kalibrierte Gassensorarray in der Lage ist, die Ethanolkonzentrationen während des Kultivierungsprozesses mit hoher Genauigkeit vorherzusagen (der mittlere quadratische Fehler der Kalibrierung sowie der prozentuale Fehler für die Validierungssätze lagen unter 0,2 gL-1 bzw. 7 %). Die vorhergesagten Werte sind jedoch nur alle fünf Minuten verfügbar. Daher war der folgende Plan der Untersuchung die Implementierung einer Schätzmethode zur kontinuierlichen Vorhersage von Ethanol sowie von Glukose, Biomasse und der Wachstumsrate. Aus diesem Grund wurden zwei nichtlineare Erweiterungen des Kalman Filters, nämlich der erweiterte Kalman Filter (EKF) und der unscented Kalman Filter (UKF), getrennt für die Zustands und Parameterschätzung implementiert. Beide 8 Vorhersagemethoden wurden an drei verschiedenen Kultivierungen mit Variabilität der Start substratkonzentrationen validiert. Die erhaltenen Ergebnisse zeigen, dass beide Schätzungsalgorithmen zufriedenstellende Ergebnisse hinsichtlich der Schätzung der Konzentrationen von Substraten und Biomasse sowie der Parameter der Wachstumsrate während der Kultivierung ermitteln. Trotz der einfacheren Implementierung des UKF zeigt diese Methode jedoch genauere Vorhersageergebnisse im Vergleich zur EKF-Vorhersagemethode. Ein weiterer Schwerpunkt dieser Untersuchung war der Entwurf und die Implementierung eines Online-Überwachungs- und Regelungssystems für die Volumenauswertung von Teigstücken während des Gärprozesses bei der Brotherstellung. Aus diesem Grund wurde ein auf Bildverarbeitung basierendes Überwachungssystem zur Messung der Teigvolumenauswertung entworfen und implementiert. Das Regelsystem besteht aus einem Fuzzy-Logic-Controller, der das gemessene Volumen für die Regelung nutzt. Die Regelung ist so ausgelegt, dass das Volumen der Teiglinge mit Werten des Volumens eines Teiglings unter Standardbedingungen während des Gärprozesses vergleicht und die Temperatur der Gärkammer entsprechend anpasst. Teiglinge mit unterschiedlichen Hefemengen in den Zutaten und verschiedenen Temperaturstartwerten wurden vorbereitet und unter Anwendung des Fuzzy-Reglers gegärt. Der Regler wurde anhand von Leistungskriterien und dem Endvolumen der Teigproben bewertet. Die erhaltenen Ergebnisse zeigen, dass die Leistung des Systems in Bezug auf die Volumenregelung und die Sollwertabweichung der Teigstücke sehr zufriedenstellend ist