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For multiphase batch process, the characteristics of process data under various batches differ. Consequently, the soft sensor model built for a particular working condition is inapplicable to other working conditions. Besides, each batch can be divided into several phases whose characteristics are probably different. To address the above problems, a soft sensor model based on phase division and transfer learning strategy is proposed. First, transfer learning strategy is adopted to construct a soft sensor model applicable to various working conditions. Specifically, geodesic flow kernel based on linear local tangent space alignment (LLTSA-GFK) algorithm is designed. By projecting process data to the common manifold subspace, the distribution difference of data between various batches is reduced and the performance of the soft sensor model is enhanced. In addition, sequence-based fuzzy clustering and just-in-time learning (JITL) are adopted to solve the multistage characteristic for batch process. The root-mean-square error (RMSE), coefficient of determination ( R 2 ) , and mean absolute error (MAE) are adopted to compare the conventional soft sensing approach (i.e., partial least-square regression based on JITL, support vector regression, and back propagation neural network) with the proposed approach. The superiority of the proposed model is verified by a fed-batch penicillin fermentation process. [ABSTRACT FROM AUTHOR]

Apart from strong nonlinearity and time-varying behaviors in industrial processes, the hidden time-delay information, which is unfortunately overlooked in most existing modeling methods, should also be taken into account in soft sensor modeling. In view of this, a novel soft sensor, referred to as local time-delay reconstruction based moving window time difference Gaussian process regression (LTR-MWTDGPR), is proposed in this paper. To deal with the time-delay, a fuzzy curve analysis based local time-delay parameter extraction procedure is performed along with a strategy of a moving window, which simultaneously captures the process time-varying feature. Then the local window training dataset and new query sample are reconstructed according to the time-delay parameter set at the next sampling instant. Afterwards, the time difference Gaussian process regression is employed to handle the drifting feature of local reconstructed dataset. The effectiveness and accuracy of the proposed LTR-MWTDGPR approach in predicting quality variables are verified through a real sulfur recovery unit and an industrial debutanizer column. [ABSTRACT FROM AUTHOR]

Accurate and real-time quality prediction to realize the optimal process control at a competitive price is an important issue in Industrial 4.0. This paper shows a successful engineering application of how smart soft sensors can be combined with machine learning technique to significantly save human resources and improve performance under complex industrial conditions. Ensemble learning based soft sensors succeed in capturing complex nonlinearities, frequent dynamic changes, as well as time-varying characteristics in industrial processes. However, local model regions under traditional ensemble modelling methods are highly dependent on labeled data samples and, hence, their prediction accuracy might get affected when labeled samples are limited. A novel active learning (AL) framework upon the ensemble Gaussian process regression (GPR) model is proposed for smart soft sensor design in order to overcome this drawback. Firstly, to iteratively select the most informative unlabeled samples for labeling with hierarchical sampling based AL strategy, to then apply Gaussian mixture model (GMM) technique to autonomously identify operation phases, to further construct local GPR models without human involvement, and finally to integrate the base predictors by applying the Bayesian fusion strategy. Comparative studies for the penicillin fermentation process demonstrate the reliability and superiority of the recommended smart soft sensing. The cost of human annotation can be dramatically reduced by at least half while the prediction performance simultaneously keeps high. [ABSTRACT FROM AUTHOR]