An Efficient Quality-Related Fault Diagnosis Method for Real-Time Multimode Industrial Process

Focusing on quality-related complex industrial process performance monitoring, a novel multimode process monitoring method is proposed in this paper. Firstly, principal component space clustering is implemented under the guidance of quality variables. Through extraction of model tags, clustering information of original training data can be acquired. Secondly, according to multimode characteristics of process data, the monitoring model integrated Gaussian mixture model with total projection to latent structures is effective after building the covariance description form. The multimode total projection to latent structures (MTPLS) model is the foundation of problem solving about quality-related monitoring for multimode processes. Then, a comprehensive statistics index is defined which is based on the posterior probability of the monitored samples belonging to each Gaussian component in the Bayesian theory. After that, a combined index is constructed for process monitoring. Finally, motivated by the application of traditional contribution plot in fault diagnosis, a gradient contribution rate is applied for analyzing the variation of variable contribution rate along samples. Our method can ensure the implementation of online fault monitoring and diagnosis for multimode processes. Performances of the whole proposed scheme are verified in a real industrial, hot strip mill process (HSMP) compared with some existing methods

Advanced predictive quality control strategy involving different facilities

There are many industries that use highly technological solutions to improve quality in all of their products. The steel industry is one example. Several automatic surface-inspection systems are used in the steel industry to identify various types of defects and to help operators decide whether to accept, reroute, or downgrade the material, subject to the assessment process. This paper focuses on promoting a strategy that considers all defects in an integrated fashion. It does this by managing the uncertainty about the exact position of a defect due to different process conditions by means of Gaussian additive influence functions. The relevance of the approach is in making possible consistency and reliability between surface inspection systems. The results obtained are an increase in confidence in the automatic inspection system and an ability to introduce improved prediction and advanced routing models. The prediction is provided to technical operators to help them in their decision-making process. It shows the increase in improvement gained by reducing the 40 % of coils that are downgraded at the hot strip mill because of specific defects. In addition, this technology facilitates an increase of 50 % in the accuracy of the estimate of defect survival after the cleaning facility in comparison to the former approach. The proposed technology is implemented by means of software-based, multi-agent solutions. It makes possible the independent treatment of information, presentation, quality analysis, and other relevant functions

Visual Analysis of a Cold Rolling Process Using Data-Based Modeling

International Conference on Engineering Applications of Neural Networks (13th. 2012. Coventry Univ, Otaniemi, Finland

A Multi-Step Anomaly Detection Strategy Based on Robust Distances for the Steel Industry

Steel making industries exhibit extreme working conditions characterized by high temperature, pressure, and production speed as well as intense throughput. Due to high economic and energy investments of the overall production process, an intense and expensive preventive maintenance program is adopted to avoid breakdowns. Steel making process would greatly benefit from a predictive maintenance module able to detect incoming faults from data process analysis. However, due to intense preventive maintenance, available data recording process operations enclose only a few samples of fault events, avoiding the efficient application of classical data driven anomaly detection models. In an attempt to overcome the above mentioned limits, we report the outcome of an industrial research project on data-driven anomaly detection in a steel making production process. The study assesses a fault detection strategy for rotating machines in the hot rolling mill line: we developed an automatic two-step strategy, which combines two statistical methods over the available data set: more precisely, the combination of Re-weighted Minimum Covariance Determinant estimator and Hidden Markov Models helped identify working conditions in a drive reducer of a hot steel rolling mill line and automatically isolate signs of decreasing performance or upcoming failures. The proposed strategy has been validated on real data collected in a steel making plant placed in the South of Italy

Approach for Improved Signal-Based Fault Diagnosis of Hot Rolling Mills

Der hier vorgestellte Ansatz ist in der Lage, zwei spezifische schwere Fehler zu erkennen, sie zu identifizieren, zwischen vier verschiedenen Systemzuständen zu unterscheiden und eine Prognose bezüglich des Systemverhaltens zu geben. Die vorliegende Arbeit untersucht die Zustandsüberwachung des komplexen Herstellungsprozesses eines Warmbandwalzwerks. Eine signalbasierte Fehlerdiagnose und ein Fehlerprognoseansatz für den Bandlauf werden entwickelt. Eine Literaturübersicht gibt einen Überblick über die bisherige Forschung zu verwandten Themen. Es wird gezeigt, dass die große Anzahl vorheriger Arbeiten diese Thematik nicht gelöst hat und dass weitere Untersuchungen erforderlich sind, um eine zufriedenstellende Lösung der behandelten Probleme zu erhalten. Die Entwicklung einer neuen Signalverarbeitungskette und die Signalverarbeitungsschritte sind detailliert dargestellt. Die Klassifikationsaufgabe wird in Fehlerdiagnose, Fehleridentifikation und Fehlerprognose differenziert. Der vorgeschlagene Ansatz kombiniert fünf verschiedene Methoden zur Merkmalsextraktion, nämlich Short-Time Fourier Transformation, kontinuierliche Wavelet Transformation, diskrete Wavelet Transformation, Wigner-Ville Distribution und Empirical Mode Decomposition, mit zwei verschiedenen Klassifikationsalgorithmen, nämlich Support-Vektor Maschine und eine Variation der Kreuzkorrelation, wobei letztere in dieser Arbeit entwickelt wurde. Kombinationen dieser Merkmalsextraktion und Klassifikationsverfahren werden an Walzkraft-Daten aus einer Warmbreitbandstraße angewendet.The approach introduced here is able to detect two specific severe faults, to identify them, to distinguish between four different system states, and to give a prognosis on the system behavior. The presented work investigates the condition monitoring of the complex production process of a hot strip rolling mill. A signal-based fault diagnosis and fault prognosis approach for strip travel is developed. A literature review gives an overview about previous research on related topics. It is shown that the great amount of previous work does not cope with the problems treated in this work and that further investigation is necessary to provide a satisfactory solution. The design of a new signal processing chain is presented and the signal processing steps are detailed. The classification task is differentiated into fault detection, fault identification and fault prognosis. The proposed approach combines five different methods for feature extraction, namely short time Fourier transform, continuous wavelet transform, discrete wavelet transform, Wigner-Ville distribution, and empirical mode decomposition, with two different classification algorithms, namely support vector machine and a variation of cross-correlation, the latter developed in this work. Combinations of these feature extraction and classification methods are applied to rolling force data originating from a hot strip mill

Spatially resolved texture analysis of Napoleonic War era copper bolts

The spatial resolution achievable by a time-of-flight neutron strain scanner has been harnessed using a new data analysis methodology (NyRTex) to determine, nondestructively, the spatial variation of crystallographic texture in objects of cultural heritage. Previous studies on the crystallographic texture at the centre of three Napoleonic War era copper bolts, which demonstrated the value of this technique in differentiating between the different production processes of the different types of bolts, were extended to four copper bolts from the wrecks of HMS Impregnable (completed 1786), HMS Amethyst (1799), HMS Pomone (1805) and HMS Maeander (1840) along with a cylindrical `segment' of a further incomplete bolt from HMS Pomone. These included bolts with works stamps, allowing comparison with documentary accounts of the manufacturing processes used, and the results demonstrated unequivocally that bolts with a `Westwood and Collins' patent stamp were made using the Collins rather than the Westwood process. In some bolts there was a pronounced variation in texture across the cross section. In some cases this is consistent with what is known of the types of hot and cold working used, but the results from the latest study might also suggest that, even in the mature phase of this technology, some hand finishing was sometimes necessary. This examination of bolts from a wider range of dates is an important step in increasing our understanding of the introduction and evolution of copper fastenings in Royal Navy warships

On-line learning and anomaly detection methods : applications to fault assessment

[Abstract] This work lays at the intersection of two disciplines, Machine Learning (ML) research and predictive maintenance of machinery. On the one hand, Machine Learning aims at detecting patterns in data gathered from phenomena which can be very different in nature. On the other hand, predictive maintenance of industrial machinery is the discipline which, based on the measurement of physical conditions of its internal components, assesses its present and near future condition in order to prevent fatal failures. In this work it is highlighted that these two disciplines can benefit from their synergy. Predictive maintenance is a challenge for Machine Learning algorithms due to the nature of data generated by rotating machinery: (a) each machine constitutes an new individual case so fault data is not available for model construction and (b) working conditions of the machine are changeable in many situations and affects captured data. Machine Learning can help predictive maintenance to: (a) cut plant costs though the automation of tedious periodic tasks which are carried out by experts and (b) reduce the probability of fatal damages in machinery due to the possibility of monitoring it more frequently at a modest cost increase. General purpose ML techniques able to deal with the aforementioned conditions are proposed. Also, its application to the specific field of predictive maintenance of rotating machinery based on vibration signature analysis is thoroughly treated. Since only normal state data is available to model the vibration captures of a machine, we are restricted to the use of anomaly detection algorithms, which will be one of the main blocks of this work. In addition, predictive maintenance also aims at assessing its state in the near future. The second main block of this work, on-line learning algorithms, will help us in this task. A novel on-line learning algorithm for a single layer neural network with a non-linear output function is proposed. In addition to the application to predictive maintenance, the proposed algorithm is able to continuously train a network in a one pattern at a time manner. If some conditions are hold, it analytically ensures to reach a global optimal model. As well as predictive maintenance, the proposed on-line learning algorithm can be applied to scenarios of stream data learning such as big data sets, changing contexts and distributed data. Some of the principles described in this work were introduced in a commercial software prototype, GIDASR ? . This software was developed and installed in real plants as part of the work of this thesis. The experiences in applying ML to fault detection with this software are also described and prove that the proposed methodology can be very effective. Fault detection experiments with simulated and real vibration data are also carried out and demonstrate the performance of the proposed techniques when applied to the problem of predictive maintenance of rotating machinery.[Resumen] La presente tesis doctoral se sitúa en el ámbito de dos disciplinas, la investigación en Aprendizaje Computacional (AC) y el Mantenimiento Predictivo (MP) de maquinaria rotativa. Por una parte, el AC estudia la problemática de detectar y clasificar patrones en conjuntos de datos extraídos de fenómenos de interés de la más variada naturaleza. Por su parte, el MP es la disciplina que, basándose en la monitorización de variables físicas de los componentes internos de maquinaria industrial, se encarga de valorar las condiciones de éstos tanto en el momento presente como en un futuro próximo con el fin último de prevenir roturas que pueden resultar de fatales consecuencias. En este trabajo se pone de relevancia que ambas disciplinas pueden beneficiarse de su sinergia. El MP supone un reto para el AC debido a la naturaleza de los datos generados por la maquinaria: (a) las propiedades de las medidas físicas recogidas varían para cada máquina y, debido a que la monitorización debe comenzar en condiciones correctas, no contamos con datos de fallos para construir un modelo de comportamiento y (b) las condiciones de funcionamiento de las máquinas pueden ser variables y afectar a los datos generados por éstas. El AC puede ayudar al MP a: (a) reducir costes a través de la automatización de tareas periódicas tediosas que tienen que ser realizadas por expertos en el área y (b) reducir la probabilidad de grandes da˜nos a la maquinaria gracias a la posibilidad de monitorizarla con una mayor frecuencia sin elevar los costes sustancialmente. En este trabajo, se proponen algoritmos de AC de propósito general capaces de trabajar en las condiciones anteriores. Además, su aplicación específica al campo del mantenimiento predictivo de maquinaria rotativa basada en el análisis de vibraciones se estudia en detalle, aportando resultados para casos reales. El hecho de disponer sólamente de datos en condiciones de normalidad de la maquinaria nos restringe al uso de técnicas de detección de anomalías. éste será uno de los bloques principales del presente trabajo. Por otra parte, el MP también intenta valorar si la maquinaria se encontrará en un estado inaceptable en un futuro próximo. En el segundo bloque se presenta un nuevo algoritmo de aprendizaje en tiempo real (on-line) que será de gran ayuda en esta tarea. Se propone un nuevo algoritmo de aprendizaje on-line para una red neuronas monocapa con función de transferencia no lineal. Además de su aplicación al mantenimiento predictivo, el algoritmo propuesto puede ser empleado en otros escenarios de aprendizaje on-line como grandes conjuntos de datos, cambios de contexto o datos distribuidos. Algunas de las ideas descritas en este trabajo fueron implantadas en un prototipo de software comercial, GIDASR ? . Este software fue desarrollado e implantado en plantas reales por el autor de este trabajo y las experiencias extraídas de su aplicación también se describen en el presente volumen[Resumo] O presente traballo sitúase no ámbito de dúas disciplinas, a investigación en Aprendizaxe Computacional (AC) e o Mantemento Predictivo (MP) de maquinaria rotativa. Por unha banda, o AC estuda a problemática de detectar e clasificar patróns en conxuntos de datos extraídos de fenómenos de interese da máis variada natureza. Pola súa banda, o MP é a disciplina que, baseándose na monitorización de variables físicas dos seus compo˜nentes internos, encárgase de valorar as condicións destes tanto no momento presente como nun futuro próximo co fin último de previr roturas que poden resultar de fatais consecuencias. Neste traballo ponse de relevancia que ambas disciplinas poden beneficiarse da súa sinergia. O MP supón un reto para o AC debido á natureza dos datos xerados pola maquinaria: (a) as propiedades das medidas físicas recolleitas varían para cada máquina e, debido a que a monitorización debe comezar en condicións correctas, non contamos con datos de fallos para construír un modelo de comportamento e (b) as condicións de funcionamento das máquinas poden ser variables e afectar aos datos xerados por estas. O AC pode axudar ao MP a: (a) reducir custos a través da automatización de tarefas periódicas tediosas que te˜nen que ser realizadas por expertos no área e (b) reducir a probabilidade de grandes danos na maquinaria grazas á posibilidade de monitorizala cunha maior frecuencia sen elevar os custos sustancialmente. Neste traballo, propó˜nense algoritmos de AC de propósito xeral capaces de traballar nas condicións anteriores. Ademais, a súa aplicación específica ao campo do mantemento predictivo de maquinaria rotativa baseada na análise de vibracións estúdase en detalle aportando resultados para casos reais. Debido a contar só con datos en condicións de normalidade da maquinaria, estamos restrinxidos ao uso de técnicas de detección de anomalías. éste será un dos bloques principais do presente traballo. Por outra banda, o MP tamén intenta valorar si a maquinaria atoparase nun estado inaceptable nun futuro próximo. No segundo bloque do presente traballo preséntase un novo algoritmo de aprendizaxe en tempo real (on-line) que será de gran axuda nesta tarefa. Proponse un novo algoritmo de aprendizaxe on-line para unha rede neuronas monocapa con función de transferencia non lineal. Ademais da súa aplicación ao mantemento predictivo, o algoritmo proposto pode ser empregado en escenarios de aprendizaxe on-line como grandes conxuntos de datos, cambios de contexto ou datos distribuídos. Algunhas das ideas descritas neste traballo foron implantadas nun prototipo de software comercial, GIDASR ? . Este software foi desenvolvido e implantado en plantas reais polo autor deste traballo e as experiencias extraídas da súa aplicación tamén se describen no presente volume