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A 3-layered nonlinear process monitoring strategy with a novel fault diagnosis approach

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Abstract

The article proposes the development of a layered process monitoring strategy based on multi-block kernel principal component analysis (MBKPCA). MBKPCA aids in the development of a distributed process monitoring strategy by taking into account the nonlinear relationships existing amongst the measured characteristics. A distributed process monitoring strategy stratifies the proposed process into a multi-layered structure comprising of blocks, sub-blocks etc. In this article, an MBKPCA-based monitoring strategy was devised for a wire rod manufacturing facility (WRMF) of an integrated steel plant (ISP). The proposed monitoring strategy stratified the entire process into 3 layers, with the first layer comprising the manufacturing stages, the next layer comprising the sub-stages and the third layer comprising the characteristics to be monitored within the respective sub-stages. The detection of the fault was carried out with the aid of kernel principal component analysis (KPCA) score–based Hotelling T2 chart. Fault detection was followed by fault diagnosis, for which new fault diagnostic statistics were proposed which took into account the contribution of the main and the auxiliary characteristics. The study also proposed the concept of cumulative percent contribution ratio (CPCR) to limit the number of parameters (stages/sub-stages/characteristics) that needs to be retained in fault diagnosis.

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The authors declare that no funds, grants or other support were received during the preparation of this manuscript.

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Authors and Affiliations

  1. Department of Mechanical Engineering, National Institute of Technology Patna, Patna, Bihar, India

    Bhagwan Kumar Mishra & Anupam Das

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  1. Bhagwan Kumar Mishra
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  2. Anupam Das
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BKM was responsible for collection of relevant data and its subsequent analysis. AD was involved in the conceptualization of the overall idea and in the preparation of the article.

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Correspondence to Anupam Das.

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Mishra, B.K., Das, A. A 3-layered nonlinear process monitoring strategy with a novel fault diagnosis approach. Int J Adv Manuf Technol 130, 163–176 (2024). https://doi.org/10.1007/s00170-023-12678-2

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