Multimode system condition monitoring using sparsity reconstruction for quality control

In this paper, we introduce an improved multivariate statistical monitoring method based on the stacked sparse autoencoder (SSAE). Our contribution focuses on the choice of the SSAE model based on neural networks to solve diagnostic problems of complex systems. In order to monitor the process performance, the squared prediction error (SPE) chart is linked with nonparametric adaptive confidence bounds which arise from the kernel density estimation to minimize erroneous alerts. Then, faults are localized using two methods: contribution plots and sensor validity index (SVI). The results are obtained from experiments and real data from a drinkable water processing plant, demonstrating how the applied technique is performed. The simulation results of the SSAE model show a better ability to detect and identify sensor failures

Targeted collapse regularized autoencoder for anomaly detection: black hole at the center

Autoencoders have been extensively used in the development of recent anomaly detection techniques. The premise of their application is based on the notion that after training the autoencoder on normal training data, anomalous inputs will exhibit a significant reconstruction error. Consequently, this enables a clear differentiation between normal and anomalous samples. In practice, however, it is observed that autoencoders can generalize beyond the normal class and achieve a small reconstruction error on some of the anomalous samples. To improve the performance, various techniques propose additional components and more sophisticated training procedures. In this work, we propose a remarkably straightforward alternative: instead of adding neural network components, involved computations, and cumbersome training, we complement the reconstruction loss with a computationally light term that regulates the norm of representations in the latent space. The simplicity of our approach minimizes the requirement for hyperparameter tuning and customization for new applications which, paired with its permissive data modality constraint, enhances the potential for successful adoption across a broad range of applications. We test the method on various visual and tabular benchmarks and demonstrate that the technique matches and frequently outperforms alternatives. We also provide a theoretical analysis and numerical simulations that help demonstrate the underlying process that unfolds during training and how it can help with anomaly detection. This mitigates the black-box nature of autoencoder-based anomaly detection algorithms and offers an avenue for further investigation of advantages, fail cases, and potential new directions.Comment: 16 pages, 4 figures, 4 table

Moving Target Detection Based on an Adaptive Low-Rank Sparse Decomposition

For the exact detection of moving targets in video processing, an adaptive low-rank sparse decomposition algorithm is proposed in this paper. In the paper's algorithm, the background model and the solved frame vector are first used to construct an augmented matrix, then robust principal component analysis (RPCA) is used to perform a low-rank sparse decomposition on the enhanced augmented matrix. The separated low-rank part and sparse noise correspond to the background and motion foreground of the video frame, respectively, the incremental singular value decomposition method and the current background vector are used to update the background model. The experimental results show that the algorithm can deal with complex scenes such as light changes and background motion better, and the algorithm's delay and memory consumption can be reduced effectively

A review on deep learning applications in prognostics and health management

Deep learning has attracted intense interest in Prognostics and Health Management (PHM), because of its enormous representing power, automated feature learning capability and best-in-class performance in solving complex problems. This paper surveys recent advancements in PHM methodologies using deep learning with the aim of identifying research gaps and suggesting further improvements. After a brief introduction to several deep learning models, we review and analyze applications of fault detection, diagnosis and prognosis using deep learning. The survey validates the universal applicability of deep learning to various types of input in PHM, including vibration, imagery, time-series and structured data. It also reveals that deep learning provides a one-fits-all framework for the primary PHM subfields: fault detection uses either reconstruction error or stacks a binary classifier on top of the network to detect anomalies; fault diagnosis typically adds a soft-max layer to perform multi-class classification; prognosis adds a continuous regression layer to predict remaining useful life. The general framework suggests the possibility of transfer learning across PHM applications. The survey reveals some common properties and identifies the research gaps in each PHM subfield. It concludes by summarizing some major challenges and potential opportunities in the domain

Novel deep cross-domain framework for fault diagnosis or rotary machinery in prognostics and health management

Improving the reliability of engineered systems is a crucial problem in many applications in various engineering fields, such as aerospace, nuclear energy, and water declination industries. This requires efficient and effective system health monitoring methods, including processing and analyzing massive machinery data to detect anomalies and performing diagnosis and prognosis. In recent years, deep learning has been a fast-growing field and has shown promising results for Prognostics and Health Management (PHM) in interpreting condition monitoring signals such as vibration, acoustic emission, and pressure due to its capacity to mine complex representations from raw data. This doctoral research provides a systematic review of state-of-the-art deep learning-based PHM frameworks, an empirical analysis on bearing fault diagnosis benchmarks, and a novel multi-source domain adaptation framework. It emphasizes the most recent trends within the field and presents the benefits and potentials of state-of-the-art deep neural networks for system health management. Besides, the limitations and challenges of the existing technologies are discussed, which leads to opportunities for future research. The empirical study of the benchmarks highlights the evaluation results of the existing models on bearing fault diagnosis benchmark datasets in terms of various performance metrics such as accuracy and training time. The result of the study is very important for comparing or testing new models. A novel multi-source domain adaptation framework for fault diagnosis of rotary machinery is also proposed, which aligns the domains in both feature-level and task-level. The proposed framework transfers the knowledge from multiple labeled source domains into a single unlabeled target domain by reducing the feature distribution discrepancy between the target domain and each source domain. Besides, the model can be easily reduced to a single-source domain adaptation problem. Also, the model can be readily updated to unsupervised domain adaptation problems in other fields such as image classification and image segmentation. Further, the proposed model is modified with a novel conditional weighting mechanism that aligns the class-conditional probability of the domains and reduces the effect of irrelevant source domain which is a critical issue in multi-source domain adaptation algorithms. The experimental verification results show the superiority of the proposed framework over state-of-the-art multi-source domain-adaptation models

Unknown Health States Recognition With Collective Decision Based Deep Learning Networks In Predictive Maintenance Applications

At present, decision making solutions developed based on deep learning (DL) models have received extensive attention in predictive maintenance (PM) applications along with the rapid improvement of computing power. Relying on the superior properties of shared weights and spatial pooling, Convolutional Neural Network (CNN) can learn effective representations of health states from industrial data. Many developed CNN-based schemes, such as advanced CNNs that introduce residual learning and multi-scale learning, have shown good performance in health state recognition tasks under the assumption that all the classes are known. However, these schemes have no ability to deal with new abnormal samples that belong to state classes not part of the training set. In this paper, a collective decision framework for different CNNs is proposed. It is based on a One-vs-Rest network (OVRN) to simultaneously achieve classification of known and unknown health states. OVRN learn state-specific discriminative features and enhance the ability to reject new abnormal samples incorporated to different CNNs. According to the validation results on the public dataset of Tennessee Eastman Process (TEP), the proposed CNN-based decision schemes incorporating OVRN have outstanding recognition ability for samples of unknown heath states, while maintaining satisfactory accuracy on known states. The results show that the new DL framework outperforms conventional CNNs, and the one based on residual and multi-scale learning has the best overall performance

VIDEO FOREGROUND LOCALIZATION FROM TRADITIONAL METHODS TO DEEP LEARNING

These days, detection of Visual Attention Regions (VAR), such as moving objects has become an integral part of many Computer Vision applications, viz. pattern recognition, object detection and classification, video surveillance, autonomous driving, human-machine interaction (HMI), and so forth. The moving object identification using bounding boxes has matured to the level of localizing the objects along their rigid borders and the process is called foreground localization (FGL). Over the decades, many image segmentation methodologies have been well studied, devised, and extended to suit the video FGL. Despite that, still, the problem of video foreground (FG) segmentation remains an intriguing task yet appealing due to its ill-posed nature and myriad of applications. Maintaining spatial and temporal coherence, particularly at object boundaries, persists challenging, and computationally burdensome. It even gets harder when the background possesses dynamic nature, like swaying tree branches or shimmering water body, and illumination variations, shadows cast by the moving objects, or when the video sequences have jittery frames caused by vibrating or unstable camera mounts on a surveillance post or moving robot. At the same time, in the analysis of traffic flow or human activity, the performance of an intelligent system substantially depends on its robustness of localizing the VAR, i.e., the FG. To this end, the natural question arises as what is the best way to deal with these challenges? Thus, the goal of this thesis is to investigate plausible real-time performant implementations from traditional approaches to modern-day deep learning (DL) models for FGL that can be applicable to many video content-aware applications (VCAA). It focuses mainly on improving existing methodologies through harnessing multimodal spatial and temporal cues for a delineated FGL. The first part of the dissertation is dedicated for enhancing conventional sample-based and Gaussian mixture model (GMM)-based video FGL using probability mass function (PMF), temporal median filtering, and fusing CIEDE2000 color similarity, color distortion, and illumination measures, and picking an appropriate adaptive threshold to extract the FG pixels. The subjective and objective evaluations are done to show the improvements over a number of similar conventional methods. The second part of the thesis focuses on exploiting and improving deep convolutional neural networks (DCNN) for the problem as mentioned earlier. Consequently, three models akin to encoder-decoder (EnDec) network are implemented with various innovative strategies to improve the quality of the FG segmentation. The strategies are not limited to double encoding - slow decoding feature learning, multi-view receptive field feature fusion, and incorporating spatiotemporal cues through long-shortterm memory (LSTM) units both in the subsampling and upsampling subnetworks. Experimental studies are carried out thoroughly on all conditions from baselines to challenging video sequences to prove the effectiveness of the proposed DCNNs. The analysis demonstrates that the architectural efficiency over other methods while quantitative and qualitative experiments show the competitive performance of the proposed models compared to the state-of-the-art

Application of Deep Learning in Chemical Processes: Explainability, Monitoring and Observability

The last decade has seen remarkable advances in speech, image, and language recognition tools that have been made available to the public through computer and mobile devices’ applications. Most of these significant improvements were achieved by Artificial Intelligence (AI)/ deep learning (DL) algorithms (Hinton et al., 2006) that generally refers to a set of novel neural network architectures and algorithms such as long-short term memory (LSTM) units, convolutional networks (CNN), autoencoders (AE), t-distributed stochastic embedding (TSNE), etc. Although neural networks are not new, due to a combination of relatively novel improvements in methods for training the networks and the availability of increasingly powerful computers, one can now model much more complex nonlinear dynamic behaviour by using complex structures of neurons, i.e. more layers of neurons, than ever before (Goodfellow et al., 2016). However, it is recognized that the training of neural nets of such complex structures requires a vast amount of data. In this sense manufacturing processes are good candidates for deep learning applications since they utilize computers and information systems for monitoring and control thus generating a massive amount of data. This is especially true in pharmaceutical companies such as Sanofi Pasteur, the industrial collaborator for the current study, where large data sets are routinely stored for monitoring and regulatory purposes. Although novel DL algorithms have been applied with great success in image analysis, speech recognition, and language translation, their applications to chemical processes and pharmaceutical processes, in particular, are scarce. The current work deals with the investigation of deep learning in process systems engineering for three main areas of application: (i) Developing a deep learning classification model for profit-based operating regions. (ii) Developing both supervised and unsupervised process monitoring algorithms. (iii) Observability Analysis It is recognized that most empirical or black-box models, including DL models, have good generalization capabilities but are difficult to interpret. For example, using these methods it is difficult to understand how a particular decision is made, which input variable/feature is greatly influencing the decision made by the DL models etc. This understanding is expected to shed light on why biased results can be obtained or why a wrong class is predicted with a higher probability in classification problems. Hence, a key goal of the current work is on deriving process insights from DL models. To this end, the work proposes both supervised and unsupervised learning approaches to identify regions of process inputs that result in corresponding regions, i.e. ranges of values, of process profit. Furthermore, it will be shown that the ability to better interpret the model by identifying inputs that are most informative can be used to reduce over-fitting. To this end, a neural network (NN) pruning algorithm is developed that provides important physical insights on the system regarding the inputs that have positive and negative effect on profit function and to detect significant changes in process phenomenon. It is shown that pruning of input variables significantly reduces the number of parameters to be estimated and improves the classification test accuracy for both case studies: the Tennessee Eastman Process (TEP) and an industrial vaccine manufacturing process. The ability to store a large amount of data has permitted the use of deep learning (DL) and optimization algorithms for the process industries. In order to meet high levels of product quality, efficiency, and reliability, a process monitoring system is needed. The two aspects of Statistical Process Control (SPC) are fault detection and diagnosis (FDD). Many multivariate statistical methods like PCA and PLS and their dynamic variants have been extensively used for FD. However, the inherent non-linearities in the process pose challenges while using these linear models. Numerous deep learning FDD approaches have also been developed in the literature. However, the contribution plots for identifying the root cause of the fault have not been derived from Deep Neural Networks (DNNs). To this end, the supervised fault detection problem in the current work is formulated as a binary classification problem while the supervised fault diagnosis problem is formulated as a multi-class classification problem to identify the type of fault. Then, the application of the concept of explainability of DNNs is explored with its particular application in FDD problem. The developed methodology is demonstrated on TEP with non-incipient faults. Incipient faults are faulty conditions where signal to noise ratio is small and have not been widely studied in the literature. To address the same, a hierarchical dynamic deep learning algorithm is developed specifically to address the issue of fault detection and diagnosis of incipient faults. One of the major drawbacks of both the methods described above is the availability of labeled data i.e. normal operation and faulty operation data. From an industrial point of view, most data in an industrial setting, especially for biochemical processes, is obtained during normal operation and faulty data may not be available or may be insufficient. Hence, we also develop an unsupervised DL approach for process monitoring. It involves a novel objective function and a NN architecture that is tailored to detect the faults effectively. The idea is to learn the distribution of normal operation data to differentiate among the fault conditions. In order to demonstrate the advantages of the proposed methodology for fault detection, systematic comparisons are conducted with Multiway Principal Component Analysis (MPCA) and Multiway Partial Least Squares (MPLS) on an industrial scale Penicillin Simulator. Past investigations reported that the variability in productivity in the Sanofi's Pertussis Vaccine Manufacturing process may be highly correlated to biological phenomena, i.e. oxidative stresses, that are not routinely monitored by the company. While the company monitors and stores a large amount of fermentation data it may not be sufficiently informative about the underlying phenomena affecting the level of productivity. Furthermore, since the addition of new sensors in pharmaceutical processes requires extensive and expensive validation and certification procedures, it is very important to assess the potential ability of a sensor to observe relevant phenomena before its actual adoption in the manufacturing environment. This motivates the study of the observability of the phenomena from available data. An algorithm is proposed to check the observability for the classification task from the observed data (measurements). The proposed methodology makes use of a Supervised AE to reduce the dimensionality of the inputs. Thereafter, a criterion on the distance between the samples is used to calculate the percentage of overlap between the defined classes. The proposed algorithm is tested on the benchmark Tennessee Eastman process and then applied to the industrial vaccine manufacturing process

DEEP ADVERSARIAL APPROACHES IN RELIABILITY

Reliability engineering has long been proposed with the problem of predicting failures using all available data. As modeling techniques have become more sophisticated, so too have the data sources from which reliability engineers can draw conclusions. The Internet of Things (IoT) and cheap sensing technologies have ushered in a new expansive set of multi-dimensional big machinery data in which previous reliability engineering modeling techniques remain ill-equipped to handle. Therefore, the objective of this dissertation is to develop and advance reliability engineering research by proposing four comprehensive deep learning methodologies to handle these big machinery data sets. In this dissertation, a supervised fault diagnostic deep learning approach with applications to the rolling element bearings incorporating a deep convolutional neural network on time-frequency images was developed. A semi-supervised generative adversarial networks-based approach to fault diagnostics using the same time-frequency images was proposed. The time-frequency images were used again in the development of an unsupervised generative adversarial network-based methodology for fault diagnostics. Finally, to advance the studies of remaining useful life prediction, a mathematical formulation and subsequent methodology to combine variational autoencoders and generative adversarial networks within a state-space modeling framework to achieve both unsupervised and semi-supervised remaining useful life estimation was proposed. All four proposed contributions showed state of the art results for both fault diagnostics and remaining useful life estimation. While this research utilized publicly available rolling element bearings and turbofan engine data sets, this research is intended to be a comprehensive approach such that it can be applied to a data set of the engineer’s chosen field. This research highlights the potential for deep learning-based approaches within reliability engineering problems

NASA Tech Briefs, July 2002

Topics include: a technology focus sensors, software, electronic components and systems, materials, mechanics, machinery/automation, manufacturing, bio-medical, physical sciences, information sciences, book and reports, and a special section of Photonics Tech Briefs