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

Gating Artificial Neural Network Based Soft Sensor

This work proposes a novel approach to Soft Sensor modelling, where the Soft Sensor is built by a set of experts which are artificial neural networks with randomly generated topology. For each of the experts a meta neural network is trained, the gating Artificial Neural Network. The role of the gating network is to learn the performance of the experts in dependency on the input data samples. The final prediction of the Soft Sensor is a weighted sum of the individual experts predictions. The proposed meta-learning method is evaluated on two different process industry data sets

Behavioural pattern identification and prediction in intelligent environments

In this paper, the application of soft computing techniques in prediction of an occupant's behaviour in an inhabited intelligent environment is addressed. In this research, daily activities of elderly people who live in their own homes suffering from dementia are studied. Occupancy sensors are used to extract the movement patterns of the occupant. The occupancy data is then converted into temporal sequences of activities which are eventually used to predict the occupant behaviour. To build the prediction model, different dynamic recurrent neural networks are investigated. Recurrent neural networks have shown a great ability in finding the temporal relationships of input patterns. The experimental results show that non-linear autoregressive network with exogenous inputs model correctly extracts the long term prediction patterns of the occupant and outperformed the Elman network. The results presented here are validated using data generated from a simulator and real environments

Online Tool Condition Monitoring Based on Parsimonious Ensemble+

Accurate diagnosis of tool wear in metal turning process remains an open challenge for both scientists and industrial practitioners because of inhomogeneities in workpiece material, nonstationary machining settings to suit production requirements, and nonlinear relations between measured variables and tool wear. Common methodologies for tool condition monitoring still rely on batch approaches which cannot cope with a fast sampling rate of metal cutting process. Furthermore they require a retraining process to be completed from scratch when dealing with a new set of machining parameters. This paper presents an online tool condition monitoring approach based on Parsimonious Ensemble+, pENsemble+. The unique feature of pENsemble+ lies in its highly flexible principle where both ensemble structure and base-classifier structure can automatically grow and shrink on the fly based on the characteristics of data streams. Moreover, the online feature selection scenario is integrated to actively sample relevant input attributes. The paper presents advancement of a newly developed ensemble learning algorithm, pENsemble+, where online active learning scenario is incorporated to reduce operator labelling effort. The ensemble merging scenario is proposed which allows reduction of ensemble complexity while retaining its diversity. Experimental studies utilising real-world manufacturing data streams and comparisons with well known algorithms were carried out. Furthermore, the efficacy of pENsemble was examined using benchmark concept drift data streams. It has been found that pENsemble+ incurs low structural complexity and results in a significant reduction of operator labelling effort.Comment: this paper has been published by IEEE Transactions on Cybernetic

Identification of Evolving Rule-based Models.

An approach to identification of evolving fuzzy rule-based (eR) models is proposed. eR models implement a method for the noniterative update of both the rule-base structure and parameters by incremental unsupervised learning. The rule-base evolves by adding more informative rules than those that previously formed the model. In addition, existing rules can be replaced with new rules based on ranking using the informative potential of the data. In this way, the rule-base structure is inherited and updated when new informative data become available, rather than being completely retrained. The adaptive nature of these evolving rule-based models, in combination with the highly transparent and compact form of fuzzy rules, makes them a promising candidate for modeling and control of complex processes, competitive to neural networks. The approach has been tested on a benchmark problem and on an air-conditioning component modeling application using data from an installation serving a real building. The results illustrate the viability and efficiency of the approach. (c) IEEE Transactions on Fuzzy System

Adaptive inferential sensors based on evolving fuzzy models

A new technique to the design and use of inferential sensors in the process industry is proposed in this paper, which is based on the recently introduced concept of evolving fuzzy models (EFMs). They address the challenge that the modern process industry faces today, namely, to develop such adaptive and self-calibrating online inferential sensors that reduce the maintenance costs while keeping the high precision and interpretability/transparency. The proposed new methodology makes possible inferential sensors to recalibrate automatically, which reduces significantly the life-cycle efforts for their maintenance. This is achieved by the adaptive and flexible open-structure EFM used. The novelty of this paper lies in the following: (1) the overall concept of inferential sensors with evolving and self-developing structure from the data streams; (2) the new methodology for online automatic selection of input variables that are most relevant for the prediction; (3) the technique to detect automatically a shift in the data pattern using the age of the clusters (and fuzzy rules); (4) the online standardization technique used by the learning procedure of the evolving model; and (5) the application of this innovative approach to several real-life industrial processes from the chemical industry (evolving inferential sensors, namely, eSensors, were used for predicting the chemical properties of different products in The Dow Chemical Company, Freeport, TX). It should be noted, however, that the methodology and conclusions of this paper are valid for the broader area of chemical and process industries in general. The results demonstrate that well-interpretable and with-simple-structure inferential sensors can automatically be designed from the data stream in real time, which predict various process variables of interest. The proposed approach can be used as a basis for the development of a new generation of adaptive and evolving inferential sensors that can a- ddress the challenges of the modern advanced process industry

Application of Computational Intelligence Techniques to Process Industry Problems

In the last two decades there has been a large progress in the computational intelligence research field. The fruits of the effort spent on the research in the discussed field are powerful techniques for pattern recognition, data mining, data modelling, etc. These techniques achieve high performance on traditional data sets like the UCI machine learning database. Unfortunately, this kind of data sources usually represent clean data without any problems like data outliers, missing values, feature co-linearity, etc. common to real-life industrial data. The presence of faulty data samples can have very harmful effects on the models, for example if presented during the training of the models, it can either cause sub-optimal performance of the trained model or in the worst case destroy the so far learnt knowledge of the model. For these reasons the application of present modelling techniques to industrial problems has developed into a research field on its own. Based on the discussion of the properties and issues of the data and the state-of-the-art modelling techniques in the process industry, in this paper a novel unified approach to the development of predictive models in the process industry is presented

Evolving Ensemble Fuzzy Classifier

The concept of ensemble learning offers a promising avenue in learning from data streams under complex environments because it addresses the bias and variance dilemma better than its single model counterpart and features a reconfigurable structure, which is well suited to the given context. While various extensions of ensemble learning for mining non-stationary data streams can be found in the literature, most of them are crafted under a static base classifier and revisits preceding samples in the sliding window for a retraining step. This feature causes computationally prohibitive complexity and is not flexible enough to cope with rapidly changing environments. Their complexities are often demanding because it involves a large collection of offline classifiers due to the absence of structural complexities reduction mechanisms and lack of an online feature selection mechanism. A novel evolving ensemble classifier, namely Parsimonious Ensemble pENsemble, is proposed in this paper. pENsemble differs from existing architectures in the fact that it is built upon an evolving classifier from data streams, termed Parsimonious Classifier pClass. pENsemble is equipped by an ensemble pruning mechanism, which estimates a localized generalization error of a base classifier. A dynamic online feature selection scenario is integrated into the pENsemble. This method allows for dynamic selection and deselection of input features on the fly. pENsemble adopts a dynamic ensemble structure to output a final classification decision where it features a novel drift detection scenario to grow the ensemble structure. The efficacy of the pENsemble has been numerically demonstrated through rigorous numerical studies with dynamic and evolving data streams where it delivers the most encouraging performance in attaining a tradeoff between accuracy and complexity.Comment: this paper has been published by IEEE Transactions on Fuzzy System