Multimode process monitoring based on robust dictionary learning with application to aluminium electrolysis process

• Main Authors: Yang, Chunhua, Zhou, Longfei, Huang, Keke, Ji, Hongquan, Long, Cheng, Chen, Xiaofang, Xie, Yongfang
• Other Authors: School of Computer Science and Engineering
• Format: Article
• Language: English
• Published: 2020
• Subjects: Engineering::Computer science and engineering; Multimode Process Monitoring; Outliers
• Online Access: https://hdl.handle.net/10356/142996
• Institution: Nanyang Technological University

In modern process industries, many parameters or states can be acquired with sensors, and these parameters or states often have a close relationship with operation conditions. Unfortunately, the process often operates under different modes, and labels thereof are often unknown. In practice, labeling for sampled data is expensive and time-consuming, so identifying the operation conditions of the industrial process is difficult. In addition, sampled data from the industrial system are always contaminated by outliers or noise. Therefore, a robust process monitoring method for the multimode process is particularly important and challenging. In this paper, a robust dictionary learning method is proposed for processes with multiple unknown modes. Firstly, by taking the sparsity of outliers into account, a robust dictionary learning method is proposed to identify and remove the outliers and noise in the sampled training data. Secondly, an iterative minimization algorithm is designed for solving the dictionary learning optimization program. Thirdly, based on the sparsity of the sparse code, we partition the sparse code into different clusters via spectral clustering method, and then the dictionary is divided into some sub-dictionaries according to the cluster results of sparse code. Lastly, when a new sample is generated, we reconstruct it under different sub-dictionaries, and the smallest dictionary reconstruction error is calculated as a classifier for process monitoring and fault detection. To evaluate the validity and effectiveness of the proposed monitoring approach, we conduct extensive experiments on a numerical simulation, the continuous stirred tank heater (CSTH) process, and an industrial aluminum electrolysis process, in comparison with several state-of-the-art methods. The experimental results demonstrate that the proposed method is able to provide satisfying monitoring results, and it is also robust to outliers in the sampled training data. It is worth mentioning that the proposed method is an unsupervised learning method, therefore, it is more suitable for the process monitoring of real industrial systems.