Enhanced Industrial Machinery Condition Monitoring Methodology based on Novelty Detection and Multi-Modal Analysis

This paper presents a condition-based monitoring methodology based on novelty detection applied to industrial machinery. The proposed approach includes both, the classical classification of multiple a priori known scenarios, and the innovative detection capability of new operating modes not previously available. The development of condition-based monitoring methodologies considering the isolation capabilities of unexpected scenarios represents, nowadays, a trending topic able to answer the demanding requirements of the future industrial processes monitoring systems. First, the method is based on the temporal segmentation of the available physical magnitudes, and the estimation of a set of time-based statistical features. Then, a double feature reduction stage based on Principal Component Analysis and Linear Discriminant Analysis is applied in order to optimize the classification and novelty detection performances. The posterior combination of a Feed-forward Neural Network and One-Class Support Vector Machine allows the proper interpretation of known and unknown operating conditions. The effectiveness of this novel condition monitoring scheme has been verified by experimental results obtained from an automotive industry machine.Postprint (published version

Statistical process monitoring of a multiphase flow facility

Industrial needs are evolving fast towards more flexible manufacture schemes. As a consequence, it is often required to adapt the plant production to the demand, which can be volatile depending on the application. This is why it is important to develop tools that can monitor the condition of the process working under varying operational conditions. Canonical Variate Analysis (CVA) is a multivariate data driven methodology which has been demonstrated to be superior to other methods, particularly under dynamically changing operational conditions. These comparative studies normally use computer simulated data in benchmark case studies such as the Tennessee Eastman Process Plant (Ricker, N.L. Tennessee Eastman Challenge Archive, Available at 〈http://depts.washington.edu/control/LARRY/TE/download.html〉 Accessed 21.03.2014). The aim of this work is to provide a benchmark case to demonstrate the ability of different monitoring techniques to detect and diagnose artificially seeded faults in an industrial scale multiphase flow experimental rig. The changing operational conditions, the size and complexity of the test rig make this case study an ideal candidate for a benchmark case that provides a test bed for the evaluation of novel multivariate process monitoring techniques performance using real experimental data. In this paper, the capabilities of CVA to detect and diagnose faults in a real system working under changing operating conditions are assessed and compared with other methodologies. The results obtained demonstrate that CVA can be effectively applied for the detection and diagnosis of faults in real complex systems, and reinforce the idea that the performance of CVA is superior to other algorithms

Vibration-based adaptive novelty detection method for monitoring faults in a kinematic chain

Postprint (published version

On-line anomaly detection with advanced independent component analysis of multi-variate residual signals from causal relation networks.

Anomaly detection in todays industrial environments is an ambitious challenge to detect possible faults/problems which may turn into severe waste during production, defects, or systems components damage, at an early stage. Data-driven anomaly detection in multi-sensor networks rely on models which are extracted from multi-sensor measurements and which characterize the anomaly-free reference situation. Therefore, significant deviations to these models indicate potential anomalies. In this paper, we propose a new approach which is based on causal relation networks (CRNs) that represent the inner causes and effects between sensor channels (or sensor nodes) in form of partial sub-relations, and evaluate its functionality and performance on two distinct production phases within a micro-fluidic chip manufacturing scenario. The partial relations are modeled by non-linear (fuzzy) regression models for characterizing the (local) degree of influences of the single causes on the effects. An advanced analysis of the multi-variate residual signals, obtained from the partial relations in the CRNs, is conducted. It employs independent component analysis (ICA) to characterize hidden structures in the fused residuals through independent components (latent variables) as obtained through the demixing matrix. A significant change in the energy content of latent variables, detected through automated control limits, indicates an anomaly. Suppression of possible noise content in residuals—to decrease the likelihood of false alarms—is achieved by performing the residual analysis solely on the dominant parts of the demixing matrix. Our approach could detect anomalies in the process which caused bad quality chips (with the occurrence of malfunctions) with negligible delay based on the process data recorded by multiple sensors in two production phases: injection molding and bonding, which are independently carried out with completely different process parameter settings and on different machines (hence, can be seen as two distinct use cases). Our approach furthermore i.) produced lower false alarm rates than several related and well-known state-of-the-art methods for (unsupervised) anomaly detection, and ii.) also caused much lower parametrization efforts (in fact, none at all). Both aspects are essential for the useability of an anomaly detection approach

Novel chemometric proposals for advanced multivariate data analysis, processing and interpretation

The present Ph.D. thesis, primarily conceived to support and reinforce the relation between academic and industrial worlds, was developed in collaboration with Shell Global Solutions (Amsterdam, The Netherlands) in the endeavour of applying and possibly extending well-established latent variable-based approaches (i.e. Principal Component Analysis - PCA - Partial Least Squares regression - PLS - or Partial Least Squares Discriminant Analysis - PLSDA) for complex problem solving not only in the fields of manufacturing troubleshooting and optimisation, but also in the wider environment of multivariate data analysis. To this end, novel efficient algorithmic solutions are proposed throughout all chapters to address very disparate tasks, from calibration transfer in spectroscopy to real-time modelling of streaming flows of data. The manuscript is divided into the following six parts, focused on various topics of interest: Part I - Preface, where an overview of this research work, its main aims and justification is given together with a brief introduction on PCA, PLS and PLSDA; Part II - On kernel-based extensions of PCA, PLS and PLSDA, where the potential of kernel techniques, possibly coupled to specific variants of the recently rediscovered pseudo-sample projection, formulated by the English statistician John C. Gower, is explored and their performance compared to that of more classical methodologies in four different applications scenarios: segmentation of Red-Green-Blue (RGB) images, discrimination of on-/off-specification batch runs, monitoring of batch processes and analysis of mixture designs of experiments; Part III - On the selection of the number of factors in PCA by permutation testing, where an extensive guideline on how to accomplish the selection of PCA components by permutation testing is provided through the comprehensive illustration of an original algorithmic procedure implemented for such a purpose; Part IV - On modelling common and distinctive sources of variability in multi-set data analysis, where several practical aspects of two-block common and distinctive component analysis (carried out by methods like Simultaneous Component Analysis - SCA - DIStinctive and COmmon Simultaneous Component Analysis - DISCO-SCA - Adapted Generalised Singular Value Decomposition - Adapted GSVD - ECO-POWER, Canonical Correlation Analysis - CCA - and 2-block Orthogonal Projections to Latent Structures - O2PLS) are discussed, a new computational strategy for determining the number of common factors underlying two data matrices sharing the same row- or column-dimension is described, and two innovative approaches for calibration transfer between near-infrared spectrometers are presented; Part V - On the on-the-fly processing and modelling of continuous high-dimensional data streams, where a novel software system for rational handling of multi-channel measurements recorded in real time, the On-The-Fly Processing (OTFP) tool, is designed; Part VI - Epilogue, where final conclusions are drawn, future perspectives are delineated, and annexes are included.La presente tesis doctoral, concebida principalmente para apoyar y reforzar la relación entre la academia y la industria, se desarrolló en colaboración con Shell Global Solutions (Amsterdam, Países Bajos) en el esfuerzo de aplicar y posiblemente extender los enfoques ya consolidados basados en variables latentes (es decir, Análisis de Componentes Principales - PCA - Regresión en Mínimos Cuadrados Parciales - PLS - o PLS discriminante - PLSDA) para la resolución de problemas complejos no sólo en los campos de mejora y optimización de procesos, sino también en el entorno más amplio del análisis de datos multivariados. Con este fin, en todos los capítulos proponemos nuevas soluciones algorítmicas eficientes para abordar tareas dispares, desde la transferencia de calibración en espectroscopia hasta el modelado en tiempo real de flujos de datos. El manuscrito se divide en las seis partes siguientes, centradas en diversos temas de interés: Parte I - Prefacio, donde presentamos un resumen de este trabajo de investigación, damos sus principales objetivos y justificaciones junto con una breve introducción sobre PCA, PLS y PLSDA; Parte II - Sobre las extensiones basadas en kernels de PCA, PLS y PLSDA, donde presentamos el potencial de las técnicas de kernel, eventualmente acopladas a variantes específicas de la recién redescubierta proyección de pseudo-muestras, formulada por el estadista inglés John C. Gower, y comparamos su rendimiento respecto a metodologías más clásicas en cuatro aplicaciones a escenarios diferentes: segmentación de imágenes Rojo-Verde-Azul (RGB), discriminación y monitorización de procesos por lotes y análisis de diseños de experimentos de mezclas; Parte III - Sobre la selección del número de factores en el PCA por pruebas de permutación, donde aportamos una guía extensa sobre cómo conseguir la selección de componentes de PCA mediante pruebas de permutación y una ilustración completa de un procedimiento algorítmico original implementado para tal fin; Parte IV - Sobre la modelización de fuentes de variabilidad común y distintiva en el análisis de datos multi-conjunto, donde discutimos varios aspectos prácticos del análisis de componentes comunes y distintivos de dos bloques de datos (realizado por métodos como el Análisis Simultáneo de Componentes - SCA - Análisis Simultáneo de Componentes Distintivos y Comunes - DISCO-SCA - Descomposición Adaptada Generalizada de Valores Singulares - Adapted GSVD - ECO-POWER, Análisis de Correlaciones Canónicas - CCA - y Proyecciones Ortogonales de 2 conjuntos a Estructuras Latentes - O2PLS). Presentamos a su vez una nueva estrategia computacional para determinar el número de factores comunes subyacentes a dos matrices de datos que comparten la misma dimensión de fila o columna y dos planteamientos novedosos para la transferencia de calibración entre espectrómetros de infrarrojo cercano; Parte V - Sobre el procesamiento y la modelización en tiempo real de flujos de datos de alta dimensión, donde diseñamos la herramienta de Procesamiento en Tiempo Real (OTFP), un nuevo sistema de manejo racional de mediciones multi-canal registradas en tiempo real; Parte VI - Epílogo, donde presentamos las conclusiones finales, delimitamos las perspectivas futuras, e incluimos los anexos.La present tesi doctoral, concebuda principalment per a recolzar i reforçar la relació entre l'acadèmia i la indústria, es va desenvolupar en col·laboració amb Shell Global Solutions (Amsterdam, Països Baixos) amb l'esforç d'aplicar i possiblement estendre els enfocaments ja consolidats basats en variables latents (és a dir, Anàlisi de Components Principals - PCA - Regressió en Mínims Quadrats Parcials - PLS - o PLS discriminant - PLSDA) per a la resolució de problemes complexos no solament en els camps de la millora i optimització de processos, sinó també en l'entorn més ampli de l'anàlisi de dades multivariades. A aquest efecte, en tots els capítols proposem noves solucions algorítmiques eficients per a abordar tasques dispars, des de la transferència de calibratge en espectroscopia fins al modelatge en temps real de fluxos de dades. El manuscrit es divideix en les sis parts següents, centrades en diversos temes d'interès: Part I - Prefaci, on presentem un resum d'aquest treball de recerca, es donen els seus principals objectius i justificacions juntament amb una breu introducció sobre PCA, PLS i PLSDA; Part II - Sobre les extensions basades en kernels de PCA, PLS i PLSDA, on presentem el potencial de les tècniques de kernel, eventualment acoblades a variants específiques de la recentment redescoberta projecció de pseudo-mostres, formulada per l'estadista anglés John C. Gower, i comparem el seu rendiment respecte a metodologies més clàssiques en quatre aplicacions a escenaris diferents: segmentació d'imatges Roig-Verd-Blau (RGB), discriminació i monitorització de processos per lots i anàlisi de dissenys d'experiments de mescles; Part III - Sobre la selecció del nombre de factors en el PCA per proves de permutació, on aportem una guia extensa sobre com aconseguir la selecció de components de PCA a través de proves de permutació i una il·lustració completa d'un procediment algorítmic original implementat per a la finalitat esmentada; Part IV - Sobre la modelització de fonts de variabilitat comuna i distintiva en l'anàlisi de dades multi-conjunt, on discutim diversos aspectes pràctics de l'anàlisis de components comuns i distintius de dos blocs de dades (realitzat per mètodes com l'Anàlisi Simultània de Components - SCA - Anàlisi Simultània de Components Distintius i Comuns - DISCO-SCA - Descomposició Adaptada Generalitzada en Valors Singulars - Adapted GSVD - ECO-POWER, Anàlisi de Correlacions Canòniques - CCA - i Projeccions Ortogonals de 2 blocs a Estructures Latents - O2PLS). Presentem al mateix temps una nova estratègia computacional per a determinar el nombre de factors comuns subjacents a dues matrius de dades que comparteixen la mateixa dimensió de fila o columna, i dos plantejaments nous per a la transferència de calibratge entre espectròmetres d'infraroig proper; Part V - Sobre el processament i la modelització en temps real de fluxos de dades d'alta dimensió, on dissenyem l'eina de Processament en Temps Real (OTFP), un nou sistema de tractament racional de mesures multi-canal registrades en temps real; Part VI - Epíleg, on presentem les conclusions finals, delimitem les perspectives futures, i incloem annexos.Vitale, R. (2017). Novel chemometric proposals for advanced multivariate data analysis, processing and interpretation [Tesis doctoral no publicada]. Universitat Politècnica de València. https://doi.org/10.4995/Thesis/10251/90442TESI

Fault detection and identification methodology under an incremental learning framework applied to industrial machinery

An industrial machinery condition monitoring methodology based on ensemble novelty detection and evolving classification is proposed in this study. The methodology contributes to solve current challenges dealing with classical electromechanical system monitoring approaches applied in industrial frameworks, that is, the presence of unknown events, the limitation to the nominal healthy condition as starting knowledge, and the incorporation of new patterns to the available knowledge. The proposed methodology is divided into four main stages: 1) a dedicated feature calculation and reduction over available physical magnitudes to increase novelty detection and fault classification capabilities; 2) a novelty detection based on the ensemble of one-class support vector machines to identify not previously considered events; 3) a diagnosis by means of eClass evolving classifiers for patterns recognition; and 4) re-training to include new patterns to the novelty detection and fault identification models. The effectiveness of the proposed fault detection and identification methodology has been compared with classical approaches, and verified by experimental results obtained from an automotive end-of-line test machine.This work was supported in part by the Generalitat de Catalunya (GRC MCIA) under Grant n◦ SGR 2014-101, in part by the Spanish Ministry of Economy and Competitiveness under Project TRA2016-80472-R Research, and in part by the CONACyT Scholarship under Grant 313604

Application of the Wigner-Ville distribution for the detection of rotor asymmetries and eccentricity through high-order harmonics

The diagnosis of induction machines through the use of methods based on the study of the startup current has become an issue of special interest. These techniques may provide, in certain situations (unbalanced supply voltages, load torque oscillations, variable load, etc.) and for certain faults (broken bars, eccentricity, stator short circuit, etc.) substantial advantages in comparison with the classical method, based on the Fourier spectrum of the steady-state current. Nevertheless, in the case of rotor asymmetries, these transient-based techniques have been mainly focused on the tracing of the lower sideband harmonic (LSH). In this paper, a wideband diagnosis method is proposed, in which the Wigner-Ville distribution is applied to the detection of eccentricity and other high-order components also introduced by the rotor asymmetry. It is shown that the proposed wide band analysis might help to reach a more reliable diagnosis conclusion in cases in which the tracing of commonly used harmonics may be difficult (inter-bar currents, load torque oscillations, non stationary regimes, etc.). An evaluation of the method is carried out through simulations and laboratory tests. The results show the potential of the tool for the detection and quantification of these components as a basis to diagnose such faults. © 2012 Elsevier B.V