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

Model based fault diagnosis and prognosis of nonlinear systems

Rapid technological advances have led to more and more complex industrial systems with significantly higher risk of failures. Therefore, in this dissertation, a model-based fault diagnosis and prognosis framework has been developed for fast and reliable detection of faults and prediction of failures in nonlinear systems. In the first paper, a unified model-based fault diagnosis scheme capable of detecting both additive system faults and multiplicative actuator faults, as well as approximating the fault dynamics, performing fault type determination and time-to-failure determination, is designed. Stability of the observer and online approximator is guaranteed via an adaptive update law. Since outliers can degrade the performance of fault diagnostics, the second paper introduces an online neural network (NN) based outlier identification and removal scheme which is then combined with a fault detection scheme to enhance its performance. Outliers are detected based on the estimation error and a novel tuning law prevents the NN weights from being affected by outliers. In the third paper, in contrast to papers I and II, fault diagnosis of large-scale interconnected systems is investigated. A decentralized fault prognosis scheme is developed for such systems by using a network of local fault detectors (LFD) where each LFD only requires the local measurements. The online approximators in each LFD learn the unknown interconnection functions and the fault dynamics. Derivation of robust detection thresholds and detectability conditions are also included. The fourth paper extends the decentralized fault detection from paper III and develops an accommodation scheme for nonlinear continuous-time systems. By using both detection and accommodation online approximators, the control inputs are adjusted in order to minimize the fault effects. Finally in the fifth paper, the model-based fault diagnosis of distributed parameter systems (DPS) with parabolic PDE representation in continuous-time is discussed where a PDE-based observer is designed to perform fault detection as well as estimating the unavailable system states. An adaptive online approximator is incorporated in the observer to identify unknown fault parameters. Adaptive update law guarantees the convergence of estimations and allows determination of remaining useful life --Abstract, page iv

Cooperative Virtual Sensor for Fault Detection and Identification in Multi-UAV Applications

This paper considers the problem of fault detection and identification (FDI) in applications carried out by a group of unmanned aerial vehicles (UAVs) with visual cameras. In many cases, the UAVs have cameras mounted onboard for other applications, and these cameras can be used as bearing-only sensors to estimate the relative orientation of another UAV. The idea is to exploit the redundant information provided by these sensors onboard each of the UAVs to increase safety and reliability, detecting faults on UAV internal sensors that cannot be detected by the UAVs themselves. Fault detection is based on the generation of residuals which compare the expected position of a UAV, considered as target, with the measurements taken by one or more UAVs acting as observers that are tracking the target UAV with their cameras. Depending on the available number of observers and the way they are used, a set of strategies and policies for fault detection are defined. When the target UAV is being visually tracked by two or more observers, it is possible to obtain an estimation of its 3D position that could replace damaged sensors. Accuracy and reliability of this vision-based cooperative virtual sensor (CVS) have been evaluated experimentally in a multivehicle indoor testbed with quadrotors, injecting faults on data to validate the proposed fault detection methods.Comisión Europea H2020 644271Comisión Europea FP7 288082Ministerio de Economia, Industria y Competitividad DPI2015-71524-RMinisterio de Economia, Industria y Competitividad DPI2014-5983-C2-1-RMinisterio de Educación, Cultura y Deporte FP

Composite Disturbance Filtering: A Novel State Estimation Scheme for Systems With Multi-Source, Heterogeneous, and Isomeric Disturbances

State estimation has long been a fundamental problem in signal processing and control areas. The main challenge is to design filters with ability to reject or attenuate various disturbances. With the arrival of big data era, the disturbances of complicated systems are physically multi-source, mathematically heterogenous, affecting the system dynamics via isomeric (additive, multiplicative and recessive) channels, and deeply coupled with each other. In traditional filtering schemes, the multi-source heterogenous disturbances are usually simplified as a lumped one so that the "single" disturbance can be either rejected or attenuated. Since the pioneering work in 2012, a novel state estimation methodology called {\it composite disturbance filtering} (CDF) has been proposed, which deals with the multi-source, heterogenous, and isomeric disturbances based on their specific characteristics. With the CDF, enhanced anti-disturbance capability can be achieved via refined quantification, effective separation, and simultaneous rejection and attenuation of the disturbances. In this paper, an overview of the CDF scheme is provided, which includes the basic principle, general design procedure, application scenarios (e.g. alignment, localization and navigation), and future research directions. In summary, it is expected that the CDF offers an effective tool for state estimation, especially in the presence of multi-source heterogeneous disturbances

AI-based Diagnostics for Fault Detection and Isolation in Process Equipment Service

Recent industry requires efficient fault discovering and isolation solutions in process equipment service. This problem is a real-world problem of typically ill-defined systems, hard to model, with large-scale solution spaces. Design of precise models is impractical, too expensive, or often non-existent. Support service of equipment requires generating models that can analyze the equipment data, interpreting the past behavior and predicting the future one. These problems pose a challenge to traditional modeling techniques and represent a great opportunity for the application of AI-based methodologies, which enable us to deal with imprecise, uncertain data and incomplete domain knowledge typically encountered in real-world applications. In this paper the state of the art, theoretical background of conventional and AI-based techniques in support of service tasks and illustration of some applications to process equipment service on bio-ethanol production process are shortly described

Fault Diagnosis and Fault Tolerant Control of Wind Turbines: An Overview

Wind turbines are playing an increasingly important role in renewable power generation. Their complex and large-scale structure, however, and operation in remote locations with harsh environmental conditions and highly variable stochastic loads make fault occurrence inevitable. Early detection and location of faults are vital for maintaining a high degree of availability and reducing maintenance costs. Hence, the deployment of algorithms capable of continuously monitoring and diagnosing potential faults and mitigating their effects before they evolve into failures is crucial. Fault diagnosis and fault tolerant control designs have been the subject of intensive research in the past decades. Significant progress has been made and several methods and control algorithms have been proposed in the literature. This paper provides an overview of the most recent fault diagnosis and fault tolerant control techniques for wind turbines. Following a brief discussion of the typical faults, the most commonly used model-based, data-driven and signal-based approaches are discussed. Passive and active fault tolerant control approaches are also highlighted and relevant publications are discussed. Future development tendencies in fault diagnosis and fault tolerant control of wind turbines are also briefly stated. The paper is written in a tutorial manner to provide a comprehensive overview of this research topic

Increasing the robustness of autonomous systems to hardware degradation using machine learning

Autonomous systems perform predetermined tasks (missions) with minimum supervision. In most applications, the state of the world changes with time. Sensors are employed to measure part or whole of the world’s state. However, sensors often fail amidst operation; feeding as such decision-making with wrong information about the world. Moreover, hardware degradation may alter dynamic behaviour, and subsequently the capabilities, of an autonomous system; rendering the original mission infeasible. This thesis applies machine learning to yield powerful and robust tools that can facilitate autonomy in modern systems. Incremental kernel regression is used for dynamic modelling. Algorithms of this sort are easy to train and are highly adaptive. Adaptivity allows for model adjustments, whenever the environment of operation changes. Bayesian reasoning provides a rigorous framework for addressing uncertainty. Moreover, using Bayesian Networks, complex inference regarding hardware degradation can be answered. Specifically, adaptive modelling is combined with Bayesian reasoning to yield recursive estimation algorithms that are robust to sensor failures. Two solutions are presented by extending existing recursive estimation algorithms from the robotics literature. The algorithms are deployed on an underwater vehicle and the performance is assessed in real-world experiments. A comparison against standard filters is also provided. Next, the previous algorithms are extended to consider sensor and actuator failures jointly. An algorithm that can detect thruster failures in an Autonomous Underwater Vehicle has been developed. Moreover, the algorithm adapts the dynamic model online to compensate for the detected fault. The performance of this algorithm was also tested in a real-world application. One step further than hardware fault detection, prognostics predict how much longer can a particular hardware component operate normally. Ubiquitous sensors in modern systems render data-driven prognostics a viable solution. However, training is based on skewed datasets; datasets where the samples from the faulty region of operation are much fewer than the ones from the healthy region of operation. This thesis presents a prognostic algorithm that tackles the problem of imbalanced (skewed) datasets

Predictive speed control of a DC universal motor applied to monitor electric vehicle batteries

This article deals with the design of a simple predictive control algorithm applied to a bidirectional DC-DC power converter for the angular speed control of a DC motor. We used the dynamics of a DC motor but mathematically reduced them to arrive at a simple model that is ideal for our purpose, not only to meet the control objective but also to generate reliable data for further analysis. This predictive control approach is based on the discrete time mathematical model of a DC motor. A huge capacitor to emulate an electric vehicle battery was then successfully connected to our experimental platform. Due to the robustness of the proposed control algorithm, the same predictive control scheme provided sufficient information to monitor the battery’s state. On this basis, and due to the system’s efficiency, it was possible to configure a fault detection scheme in our electric car battery emulator using only classical statistical tools. A PIC18F252 microcontroller was used in our experimental platform to implement our predictive control algorithm. It was then appropriately coupled to the power electronics required by the DC-DC converter to drive the DC motor. Our experimental results proved the excellent performance of the control method and also of the health monitoring system. On the other hand, the main difficulty in achieving our main goal was the realization of discrete control, which had to be as simple as possible while maintaining the control objective and while also being capable of generating reliable data for the health monitoring stage. Thus, the primary contribution of this work was the development of the predictive control of the speed of a universal motor, followed by the modification of the experimental design to simulate an electric car battery and the introduction of a novel statistical method for fault detection.Peer ReviewedPostprint (published version

Advances in Robotics, Automation and Control

The book presents an excellent overview of the recent developments in the different areas of Robotics, Automation and Control. Through its 24 chapters, this book presents topics related to control and robot design; it also introduces new mathematical tools and techniques devoted to improve the system modeling and control. An important point is the use of rational agents and heuristic techniques to cope with the computational complexity required for controlling complex systems. Through this book, we also find navigation and vision algorithms, automatic handwritten comprehension and speech recognition systems that will be included in the next generation of productive systems developed by man

Data fusion and type-2 fuzzy inference in contextual data stream monitoring

Data stream monitoring provides the basis for building intelligent context-aware applications over contextual data streams. A number of wireless sensors could be spread in a specific area and monitor contextual parameters for identifying phenomena e.g., fire or flood. A back-end system receives measurements and derives decisions for possible abnormalities related to negative effects. We propose a mechanism, which based on multivariate sensors data streams, provides real-time identification of phenomena. The proposed framework performs contextual information fusion over consensus theory for the efficient measurements aggregation while time-series prediction is adopted to result future insights on the aggregated values. The unanimous fused and predicted pieces of context are fed into a Type-2 fuzzy inference system to derive highly accurate identification of events. The Type-2 inference process offers reasoning capabilities under the uncertainty of the phenomena identification. We provide comprehensive experimental evaluation over real contextual data and report on the advantages and disadvantages of the proposed mechanism. Our mechanism is further compared with Type-1 fuzzy inference and other mechanisms to demonstrate its false alarms minimization capability