Anomaly detection in time series has attracted much attention recently and is quite a challenging task. In this paper, a novel deep-learning approach (AL-CNN) that classifies the time series as normal or abnormal with less domain knowledge is proposed. The proposed algorithm combines Convolutional Neural Networks (CNNs) and Long Short-Term Memory (LSTM) to effectively model the spatial and temporal information contained in time-series data, the techniques of Squeeze-and-Excitation are applied to implement the feature recalibration. However, the difficulty of selecting multiple parameters and the long training time of a single model make AL-CNN less effective. To alleviate these challenges, a hybrid dynamic membrane system (HM-AL-CNN) is designed which is a new distributed and parallel computing model. We have performed a detailed evaluation of this proposed approach on three well-known benchmarks including the Yahoo S5 datasets. Experiments show that the proposed method possessed a rob... [more]

Liquid−solid circulating fluidised beds (CFB) possess many qualities which makes them useful for industrial operations where particle−liquid contact is vital, e.g., improved heat transfer performance, and consequent uniform temperature, limited back mixing, exceptional solid−liquid contact. Despite this, circulating fluidised beds have seen no application in the micro-technology context. Liquid−solid micro circulating fluidised bed (µCFBs), which basically involves micro-particles fluidisation in fluidised beds within the bed of cross-section or inner diameter at the millimetre scale, could find potential applications in the area of micro-process and microfluidics technology. From an engineering standpoint, it is vital to know the solid circulating velocity, since that dictates the bed capability and operability as processing equipment. Albeit there are several studies on solid circulating velocity measurement in CFBs, this article is introducing the first experimental study on solid c... [more]

As various activities related to entertainment, business, shopping, and conventions are done increasingly indoors, the demand for indoor spatial information and indoor environmental data is growing. Unlike the case of outdoor environments, obtaining spatial information in indoor environments is difficult. Given the absence of GNSS (Global Navigation Satellite System) signals, various technologies for indoor positioning, mapping and modeling have been proposed. Related business models for indoor space services, safety, convenience, facility management, and disaster response, moreover, have been suggested. An autonomous scanning system for collection of indoor spatial and environmental data is proposed in this paper. The proposed system can be utilized to collect spatial dimensions suitable for extraction of a two-dimensional indoor drawing and obtainment of spatial imaging as well as indoor environmental data on temperature, humidity and particulate matter. For these operations, the sys... [more]

The main roles of fault detection and diagnosis (FDD) for industrial processes are to make an effective indicator which can identify faulty status of a process and then to take a proper action against a future failure or unfavorable accidents. In order to enhance many process performances (e.g., quality and throughput), FDD has attracted great attention from various industrial sectors. Many traditional FDD techniques have been developed for checking the existence of a trend or pattern in the process or whether a certain process variable behaves normally or not. However, they might fail to produce several hidden characteristics of the process or fail to discover the faults in processes due to underlying process dynamics. In this paper, we present current research and developments of FDD approaches for process monitoring as well as a broad literature review of many useful FDD approaches.

The complex data characteristics collected in Industry 4.0 cannot be efficiently handled by classical Six Sigma statistical toolkit based mainly in least squares techniques. This may refrain people from using Six Sigma in these contexts. The incorporation of latent variables-based multivariate statistical techniques such as principal component analysis and partial least squares into the Six Sigma statistical toolkit can help to overcome this problem yielding the Multivariate Six Sigma: a powerful process improvement methodology for Industry 4.0. A multivariate Six Sigma case study based on the batch production of one of the star products at a chemical plant is presented.

The development of fuel cell electric vehicles in recent years has led to increased interest in the use of fuel cells as sources of renewable energy. To achieve successful commercialization of fuel cell vehicles, it will be necessary to guarantee the safety, reliability, and lifetime of fuel cell systems by predictive fault detection and isolation (FDI). In this study, the parity equation, an observer, and a Kalman filter are employed together to compare the characteristics of FDI, focusing on the sensors of the thermal management system. Residuals corresponding to the difference between temperature outputs of linear models under driving cycles and nonlinear temperature outputs are used to isolate faults. Then, assessment of three model-based sensor FDI schemes is used to isolate sensor faults using the Cumulative Sum Control Chart (CUSUM) method. Generated residuals are evaluated by CUSUM to detect the presence of a sensor fault. As a result, isolated sensor faults are assessed.

Currently, the use of industrial seawater reverse osmosis desalination (ISROD) plants has increased in popularity in light of the growing global demand for freshwater. In ISROD plants, any fault in the components of their control systems can lead to a plant malfunction, and this condition can originate safety risks, energy waste, as well as affect the quality of freshwater. This paper addresses the design of a fault detection and isolation (FDI) system based on a structural analysis approach for an ISROD plant located in Lima (Peru). Structural analysis allows obtaining a plant model, which is useful to generate diagnostic tests. Here, diagnostic tests via fault-driven minimal structurally overdetermined (FMSO) sets are computed, and then, binary integer linear programming (BILP) is used to select the FMSO sets that guarantee isolation. Simulations shows that all the faults of interest (sensors and actuators faults) are detected and isolated according to the proposed design.

The fault detection method has been used usually to give a diagnosis of the performance and efficiency in the proton exchange membrane fuel cell (PEMFC) systems. To be able to use this method a lot of sensors are implemented in the PEMFC to measure different parameters like pressure, temperature, voltage, and electrical current. However, despite the high reliability of the sensors, they can fail or give erroneous measurements. To address this problem, an efficient solution to replace the sensors must be found. For this reason, in this work, the immersion and invariance method is proposed to develop an oxygen pressure estimator based on the voltage, electrical current density, and temperature measurements. The estimator stability region is calculated by applying Lyapunov’s Theorem and constraints to achieve stability are established for the oxygen pressure, electrical current density, and temperature. Under these estimator requirements, oxygen pressure measurements of high reliability a... [more]

Data-based process monitoring methods have received tremendous attention in recent years, and modern industrial process data often exhibit dynamic and nonlinear characteristics. Traditional autoencoders, such as stacked denoising autoencoders (SDAEs), have excellent nonlinear feature extraction capabilities, but they ignore the dynamic correlation between sample data. Feature extraction based on manifold learning using spatial or temporal neighbors has been widely used in dynamic process monitoring in recent years, but most of them use linear features and do not take into account the complex nonlinearities of industrial processes. Therefore, a fault detection scheme based on temporal-spatial neighborhood enhanced sparse autoencoder is proposed in this paper. Firstly, it selects the temporal neighborhood and spatial neighborhood of the sample at the current time within the time window with a certain length, the spatial similarity and time serial correlation are used for weighted reconst... [more]

In response to the high demand of the operation reliability and predictive maintenance, health monitoring and fault diagnosis and classification have been paramount for complex industrial systems (e.g., wind turbine energy systems). In this study, data-driven fault diagnosis and fault classification strategies are addressed for wind turbine energy systems under various faulty scenarios. A novel algorithm is addressed by integrating fast Fourier transform and uncorrelated multi-linear principal component analysis techniques in order to achieve effective three-dimensional space visualization for fault diagnosis and classification under a variety of actuator and sensor faulty scenarios in 4.8 MW wind turbine benchmark systems. Moreover, comparison studies are implemented by using multi-linear principal component analysis with and without fast Fourier transform, and uncorrelated multi-linear principal component analysis with and without fast Fourier transformation data pre-processing, resp... [more]

Demodulation plays an important role in fault feature extraction for rotating machinery. The fast kurtogram method was proved to be effective for rotating machinery demodulation. However, the demodulation effectiveness of fast kurtogram was poor for multiple fault features extraction under low signal-to-noise ratio. In this paper, an improved method of fast kurtogram, called P-kurtogram, is presented. The proposed method extracted the multiple weak fault features from multiple envelope signals-based principal component analysis. Compared with extracting features from one envelope signal of fast kurtogram, P-kurtogram showed a better demodulation performance for multiple faults. Combined with principal component analysis method, the proposed method also showed a good performance under low signal-to-noise ratio(SNR). By simulation analysis, the P-kurtogram method showed good performance for multiple modulation features extraction and robust performance in demodulation under low SNR. Then... [more]

In order to explore the dynamic characteristics of the mechanical seal under different fault degrees, this paper selected the upstream pumping mechanical seal as the object of study. The research established the rotating ring-fluid film-stationary ring 3D model, which was built to analyze the fault mechanism. To study extrusion fault mechanism and characteristics, different dynamic parameters were used in the analysis process. Theoretical analysis, numerical simulation, and comparison were conducted to study the relationship between the fault degree and dynamic characteristics. It is the first time to research the dynamic characteristics of mechanical seals in the specific extrusion fault. This paper proved feasibility and effectiveness of the new analysis method. The fluid film thickness and dynamic characteristics could reflect the degree of the extrusion fault. Results show that the fluid film pressure fluctuation tends to be more intensive under the serious extrusion fault conditio... [more]

This paper proposes a feature selection (FS) approach, namely, correlation and fitness value-based feature selection (CFFS). CFFS is an improvement feature selection approach of correlation-based feature selection (CFS) for the common failure cases of the induction motor. CFFS establishes the induction motor fault detection (FD) system with artificial neural network (ANN). This study analyzes the current signal of the induction motor with multiresolution analysis (MRA), extracts the features, and uses feature selection approaches (ReliefF, CFS, and CFFS) to reduce the number of features and maintain the accuracy of the induction motor fault detection system. Finally, the induction motor fault detection system is trained by the feature selection approaches selected features. The best induction motor fault detection system will be established through the comparison of the efficiency of these FS approaches.

Due to the complex structure and wide excitation of the range extender, the misalignment and stator short-circuit coupling fault can easily occur. Therefore, it is necessary to study the coupling fault mechanism of the range extender, analyze the cause of the fault and the fault evolution law, and research the coupling fault characteristics. To reveal the mechanism of misalignment and stator-short-circuit coupling fault, the misalignment mechanism was analyzed and the bending and torsion electromagnetic stiffness of the generator in the stator short-circuit fault was derived. Then the dynamic model of bending and torsion coupling for the generator was established. Furthermore, we used the Runge-Kutta method to study the vibration response characteristics of generator rotor under coupling fault. Then through finite element analysis, the feasibility of coupled fault diagnosis was verified. The results show that the response of the generator rotor not only has the frequency component of s... [more]

The present work presents a methodology based on data reconciliation to monitor membrane separation processes reliably, online and in real time for the first time. The proposed methodology was implemented in accordance with the following steps: data acquisition; data pre-treatment; data characterization; data reconciliation; gross error detection; and critical evaluation of measured data with a soft sensor. The acquisition of data constituted the slowest stage of the monitoring process, as expected in real-time applications. The pre-treatment stage was fundamental to assure the robustness of the code and the initial characterization of collected data was carried out offline. The characterization of the data showed that steady-state modeling of the process would be appropriate, also allowing the implementation of faster numerical procedures for the data reconciliation step. The data reconciliation step performed well, quickly and consistently. Thus, data reconciliation allowed the estim... [more]

Ibuprofen is one of the best-known nonsteroidal anti-inflammatory and analgesic drugs. Following the previous work, the current study is focused on estimating the effect of different chromatographic conditions on the sensitivity of thin-layer chromatography in combination with UV densitometry, i.e., the detection and quantification of ibuprofen in a wide range of its concentrations including the lowest limits of detection (LOD) and quantification (LOQ). For this purpose, a reliable and easy-to-use calculation procedure for LOD and LOQ determination is presented in this work. In addition, the impact of type plates and mobile phase composition on the LOD and LOQ, respectively, of this active substance is accurately described. The results of detection and the quantification level of ibuprofen obtained under applied chromatographic conditions confirmed the utility of silica gel plates as well as silica gel bonded phases (i.e., reversed-phase (RP) plates) in the thin-layer chromatography (T... [more]

Diagnosis of bearing faults is crucial in various industries. Time series classification (TSC) assigns each time series to one of a set of pre-defined classes, such as normal and fault, and has been regarded as an appropriate approach for bearing fault diagnosis. Considering late and inaccurate fault diagnosis may have a significant impact on maintenance costs, it is important to classify bearing signals as early and accurately as possible. TSC, however, has a major limitation, which is that a time series cannot be classified until the entire series is collected, implying that a fault cannot be diagnosed using TSC in advance. Therefore, it is important to classify a partially collected time series for early time series classification (ESTC), which is a TSC that considers both accuracy and earliness. Feature-based TSCs can handle this, but the problem is to determine whether a partially collected time series is enough for a decision that is still unsolved. Motivated by this, we propose... [more]

A convolutional neural network (CNN) has been used to successfully realize end-to-end bearing fault diagnosis due to its powerful feature extraction ability. However, the CNN is prone to focus on local information, ignoring the relationship between the whole and the part of the signal due to its unique structure. In addition, it extracts some fault features with poor robustness under noisy environment. A novel diagnosis model based on feature fusion and feature selection, GL-mRMR-SVM, is proposed to address this problem in this paper. First, the model combines the global features in the time-domain and frequency-domain of the raw data with the local features extracted by CNN to make full use of the signal information and overcome the weakness of traditional CNNs neglecting the overall signal. Then, the max-relevance min-redundancy (mRMR) algorithm is used to automatically extract the discriminative features from the fused features without any prior knowledge. Finally, the extracted dis... [more]

This paper presents a monitoring framework to detect drifts and faults in the behavior of the central processing unit (CPU)-graphics processing unit (GPU) chips powering them. To construct the framework, an incremental model and a fault detection and isolation (FDI) algorithm are hereby proposed. The reference model is composed of a set of interconnected exchangeable subsystems that allows it to be adapted to changes in the structure of the system or operating modes, by replacing or extending its components. It estimates a set of variables characterizing the operating state of the chip from only two global inputs. Then, through analytical redundancy, the estimated variables are compared to the output of the system in the FDI module, which generates alarms in the presence of faults or drifts in the system. Furthermore, the interconnected nature of the model allows for the direct localization and isolation of any detected abnormalities. The implementation of the proposed framework requir... [more]

Timely monitoring and control of critical process parameters and product attributes are still the basic tasks in bioprocess development. The current trend of automation and digitization in bioprocess technology targets an improvement of these tasks by reducing human error and increasing through-put. The gaps in such automation procedures are still the sampling procedure, sample preparation, sample transfer to analyzers, and the alignment of process and sample data. In this study, an automated sampling system and the respective data management software were evaluated for system performance; applicability with HPLC for measurement of vitamins, product and amino acids; and applicability with a biochemical analyzer. The focus was especially directed towards the adaptation and assessment of an appropriate amino acid method, as these substances are critical in cell culture processes. Application of automated sampling in a CHO fed-batch revealed its potential with regard to data evaluation. T... [more]

Industry 4.0 (I4.0) represents the Fourth Industrial Revolution in manufacturing, expressing the digital transformation of industrial companies employing emerging technologies. Factories of the future will enjoy hybrid solutions, while quality is the heart of all manufacturing systems regardless of the type of production and products. Quality 4.0 is a branch of I4.0 with the aim of boosting quality by employing smart solutions and intelligent algorithms. There are many conceptual frameworks and models, while the main challenge is to have the experience of Quality 4.0 in action at the workshop level. In this paper, a hybrid model based on a neural network (NN) and expert system (ES) is proposed for dealing with control chart patterns (CCPs). The idea is to have, instead of a passive descriptive model, a smart predictive model to recommend corrective actions. A construction plaster-producing company was used to present and evaluate the advantages of this novel approach, while the result... [more]

Various types of risks exist in a supply chain, and disruptions could lead to economic loss or even breakdown of a supply chain without an effective mitigation strategy. The ability to detect disruptions early can help improve the resilience of the supply chain. In this paper, the application of principal component analysis (PCA) and dynamic PCA (DPCA) in fault detection and diagnosis of a supply chain system is investigated. In order to monitor the supply chain, data such as inventory levels, market demands and amount of products in transit are collected. PCA and DPCA are used to model the normal operating conditions (NOC). Two monitoring statistics, the Hotelling's T-squared and the squared prediction error (SPE), are used to detect abnormal operation of the supply chain. The confidence limits of these two statistics are estimated from the training data based on the $\chi^2$- distributions. The contribution plots are used to identify the variables with abnormal behavior when at le... [more]

Graphene is a material gaining attention as a candidate for new application fields such as chemical sensing. In this review, we discuss recent advancements in the field of hydrogen gas sensors based on graphene. Accordingly, the main part of the paper focuses on hydrogen gas sensors and examines the influence of different manufacturing scenarios on the applicability of graphene and its derivatives as key components of sensing layers. An overview of pristine graphene customization methods is presented such as heteroatom doping, insertion of metal/metal oxide nanosized domains, as well as creation of graphene-polymer blends. Volumetric structuring of graphene sheets (single layered and stacked forms) is also considered as an important modifier of its effective use. Finally, a discussion of the possible advantages and weaknesses of graphene as sensing material for hydrogen detection is provided.

Degradation state recognition and failure prediction are the key steps of prognostic and health management (PHM), which directly affect the reliability of the equipment and the selection of preventive maintenance strategy. Given the problem that the distinction between feature vectors is not obvious and the accuracy of fault prediction is low, a method based on multi-class Gaussian process classification and Gaussian process regression (GPR) is studied by the vibration signal and flow signal in six degraded states of the axial piston pump. For degradation state recognition, the variational mode decomposition (VMD) was used to decompose the vibration signal, and obtaining intrinsic mode function (IMF) components with rich information. Subsequently, multi-scale permutation entropy (MPE) was employed to select feature vectors of IMF components in different states. In order to reduce feature dimensions and improve recognition performance, ReliefF was used to select feature vectors with hig... [more]

In conditional microbial screening, a limited number of candidate strains are tested at different conditions searching for the optimal operation strategy in production (e.g., temperature and pH shifts, media composition as well as feeding and induction strategies). To achieve this, cultivation volumes of >10 mL and advanced control schemes are required to allow appropriate sampling and analyses. Operations become even more complex when the analytical methods are integrated into the robot facility. Among other multivariate data analysis methods, principal component analysis (PCA) techniques have especially gained popularity in high throughput screening. However, an important issue specific to high throughput bioprocess development is the lack of so-called golden batches that could be used as a basis for multivariate analysis. In this study, we establish and present a program to monitor dynamic parallel cultivations in a high throughput facility. PCA was used for process monitoring and a... [more]