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面向大規模工業生產過程的數據驅動故障診斷方法綜述

A survey of data-driven fault-diagnosis methods for large-scale industrial production processes

  • 摘要: 聚焦于大規模工業生產過程智能化、精準化和多源化的需求,故障診斷對保障工業生產過程的安全可靠運行與實時有效維護具有重要意義. 數據驅動方法作為一種創新范式,通過融合歷史數據、實時數據以及多源信息,避免了對精確模型的依賴,能夠有效提升故障檢測與識別的準確率和效率. 首先,本文梳理了數據驅動框架下的故障診斷方法,著重探討了信號處理、統計模式識別、多元統計等系統穩態特性分析方法,并針對系統的動態、非線性和非高斯分布等復雜特性,進一步綜述了動態多元統計、子空間辨識、深度學習和核空間投影等故障診斷方法. 其次,介紹了大規模工業生產過程的分布式故障診斷方法. 從系統的分布式結構和分布式傳感器網絡出發,分別闡述了該方法在系統分解和數據融合、相關性分析以及一致性方法等三個方面的最新進展. 分布式故障診斷方法將監測職能分散到各子單元,使各子單元可根據自身及相鄰子單元的運行狀態自行做出安全性能判斷,在大規模工業生產過程的監測和故障診斷中具有優勢. 最后,總結了數據驅動的分布式故障診斷方法的實際應用,并指出其在定性定量混合分析、魯棒性診斷和數據安全等方面的發展趨勢.

     

    Abstract: Fault diagnosis for large-scale industrial production systems has attracted considerable research interest in response to the complex, multisource, and precision requirements of these processes. Fault diagnosis is crucial for the safe, reliable, and real-time maintenance of industrial production processes. This work presents a comprehensive survey of fault-diagnosis methods and emphasizes two cornerstone strategies: data-driven paradigms and distributed methods. Traditional fault-diagnosis methods based on mechanism have limited applications because precise modeling of the systems considered is required. Data-driven approaches avoid the dependence on precise modeling; thus, the research focus on fault diagnosis for industrial production processes has gradually shifted from mechanism-based to data-driven methods that integrate historical data, real-time data, and multisource information to enhance the accuracy and efficiency of the fault detection and identification approaches. A comprehensive overview of data-driven fault-diagnosis methods is given in the first part of this work. Specifically, smooth data from industrial processes is collected and used for fault diagnosis. The internal state variables may continuously change, and accompanied with time correlation among the process measurements. Integrating data-driven and dynamic analyses, necessitated by the dynamic nature of the process variables, offers a more accurate representation of system behavior. This can be achieved through the introduction of time-series modeling in basic multivariate statistics and the capture of dynamic properties by subspace identification. Furthermore, deep learning and kernel methods address nonlinearity, and non-Gaussian traits are tackled by independent component analysis (ICA) and other methods. Second, distributed fault-diagnosis methods for large-scale industrial production processes are reviewed. The usual fault-diagnosis methods for large-scale systems rely on centralized sensor network monitoring. Centralization necessitates consolidated data processing, which can create immense computational stress. Applying distributed fault-diagnosis methods spreads the monitoring capacities among all the subsystems, enabling each subsystem to independently assess its safety and performance based on its own data and interactions with neighboring subsystems. The latest advances in system decomposition and data fusion, correlation analysis, and consensus mechanisms are elaborated on subsystems based on the distributed structure and sensor networks in large-scale systems. System decomposition focuses on the local features of each subsystem although adopting a purely subsystem-centric approach to data processing often leans toward decentralization, in contrast to the essence of distribution. Thus, the effective integration of data is critical for achieving comprehensive information about large-scale systems. Correlation analysis examines the intricate relationships among subsystems or nodes. It elucidates mutual interactions and uncovers dependencies and influences. Meanwhile, consensus analysis focuses on the communication topology of the nodes, ensuring that all nodes converge to a unified data state at any instant. Finally, the practical applications for evaluating the performance of distributed data-driven fault-diagnosis methods are summarized. The potential trends are also highlighted, including qualitative and quantitative methods integration, improved diagnosis robustness, and data security assurance.

     

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