Search

Fault detection and classification is a crucial issue in modern industrial processes for ensuring steady operation and high product quality. The process data collected and stored fully reflect the equipment running state and the production process. Moreover, the extracted nonlinear features can directly affect the effectiveness of the data‐driven fault classification model. In this paper, a novel fault classification method based on nonlinear feature extraction using reconstructed distance‐based discriminant locality preserving projection (RD‐DLPP) is proposed. First, a hypersphere model for each class of data is developed according to the spatial structures and classes information in high‐dimensional space. The hyperspheres are used as indicators to evaluate the discriminatory difficulty of samples. Second, the constraints of the correlations between the k‐nearest neighbour points of the sample and the hypersphere are introduced, which can efficiently reconstruct new measure metrics between the sample and its k‐nearest neighbour points. Finally, an improved fault classification model based on RD‐DLPP is established for the construction of the highly discriminant subspace. The Bayesian decision is then used to classify the samples. The feasibility and efficiency of the proposed method are verified by the Tennessee Eastman process as a case study. [ABSTRACT FROM AUTHOR]

Since industrial process data often presents strong correlations, high complexity, and nonlinear patterns, a proficient deep learning model is required for the fault classification task. Recent researches have shown that deep learning models like stacked autoencoder (SAE) are able to learn deep abstract features from complex process data. Nevertheless, a traditional SAE cannot extract the informative fault-relevant features and data distribution features from industrial process data, which are necessary for effective fault classification in industrial processes. Thus, this study proposes a semi-supervised Inter-Relational Mahalanobis SAE (IRM-SAE) model to learn inter-relational distribution and fault-relevant dynamic features of process data for fault classification. First, the Inter-Relational Mahalanobis loss is introduced into the original objective function of SAE to learn meaningful inter-relational distribution features within the data. Then, an active time frame technique is developed to preprocess the input data to capture the dynamic features of the data. Furthermore, to fully utilize both labeled and unlabeled data in industrial processes, the semi-supervised strategy is introduced to learn fault-related features for better fault classification. To validate the performance of the proposed model, it is applied on the Tennessee–Eastman process and a real-world industrial hydrocracking process. The experimental results show that the proposed model has higher fault classification performance compared to other deep learning models. • A novel semi-supervised Inter-Relational Mahalanobis SAE (IRM-SAE) model is proposed to learn inter-relational distribution and fault-relevant dynamic features of process data. • An active time frame technique is developed to preprocess the process data to capture the dynamic features of the data. • To fully utilize both labeled and unlabeled data in industrial processes, the semi-supervised strategy is introduced to learn fault-related features for better fault classification. • The experimental results on two industrial processes show that the proposed model has higher fault classification performance compared to other deep learning models. [ABSTRACT FROM AUTHOR]