Abstract
Applications of fault detection techniques in industrial environments are increasing in order to improve the operational safety, as well as to reduce the costs related to unscheduled stoppages. Although there are numerous proposals in the literature about fault detection techniques, most of the approaches demand extensive computational effort or even require too many thresholds or problem-specific parameters to be predefined in advance, impairing their use in real-time applications. Aiming to overcome these problems, we propose in this paper an approach for real-time fault detection of industrial plants based on the analysis of the control and error signals, using recursive density estimation. Our proposed approach is based on the concept of the density in the data space, which is not the same as probability density function, but is a very useful measure for abnormality/outliers detection. The density can be calculated recursively, which makes it suitable for real-time environments. We define a criterion for density drop integral/sum, which is used as a problem- and user-insensitive (automatic) threshold to identify the faults/anomalies. In order to validate our proposal, we present experimental results from a level control laboratory process, where control and error signals are used as features for the fault detection, but the approach is generic and the number of features can be significant due to the computationally lean methodology, since covariance or more complex calculations are not required. The obtained results are encouraging when compared with the traditional statistical approach.
Similar content being viewed by others
References
Angelov, P. (2012a). Anomalous system state identification, patent GB1208542.9, priority date: 15 May 2012.
Angelov, P. (2012b). Autonomous learning systems: from data to knowledge in real time. New York: Willey.
Angelov, P., & Buswell, R. (2001). Evolving rule-based models: A tool for intelligent adaptation. In IFSA world congress and 20th NAFIPS international conference, 2001. Joint 9th (vol. 2, pp. 1062–1067).
Angelov, P., & Zhou, X. (2008). Evolving fuzzy-rule-based classifiers from data streams. IEEE Transactions on Fuzzy Systems, 16(6), 1462–1475.
Angelov, P., Ramezani, R., & Zhou, X. (2008). Autonomous novelty detection and object tracking in video streams using evolving clustering and takagi-sugeno type neuro-fuzzy system. In IEEE international joint conference on neural networks, 2008. IJCNN 2008. (IEEE world congress on computational intelligence) (pp. 1456–1463).
Anwar, S., & Chen, L. (2007). An analytical redundancy-based fault detection and isolation algorithm for a road-wheel control subsystem in a steer-by-wire system. IEEE Transactions on Vehicular Technology, 56(5), 2859–2869.
Anzanello, M. J. (2010). Feature extraction and feature selection: A survey of methods in industrial applications. Hoboken: Wiley.
Bernieri, A., Betta, G., & Liguori, C. (1996). On-line fault detection and diagnosis obtained by implementing neural algorithms on a digital signal processor. IEEE Transactions on Instrumentation and Measurement, 45(5), 894–899.
Breunig, M., Kriegel, H. P., Ng, R. T., & Sander, J. (2000). LOF: Identifying density-based local outliers. In Proceedings of the 2000 ACM SIGMOD international conference on management of data (pp. 93–104). ACM.
Chen, W., & Saif, M. (2007). Observer-based strategies for actuator fault detection, isolation and estimation for certain class of uncertain nonlinear systems. IET Control Theory Applications, 1(6), 1672–1680.
Cook, G., Maxwell, J., Barnett, R., & Strauss, A. (1997). Statistical process control application to weld process. IEEE Transactions on Industry Applications, 33(2), 454–463.
Costa, B., Bezerra, C. G., & Guedes, L. A. (2010). Java fuzzy logic tool-box for industrial process control. In Proceedings of the 2010 Brazilian conference on automatics (CBA), Brazilian Society for Automatics (SBA), Bonito-MS, Brazil.
Costa, B., Bezerra, C., & Guedes, L. (2012). A multistage fuzzy controller: Toolbox for industrial applications. In IEEE international conference on industrial technology (ICIT) (pp. 1142–1147).
Costa, B., Skrjanc, I., Blazic, S., & Angelov, P. (2013). A practical implementation of self-evolving cloud-based control of a pilot plant. In 2013 IEEE international conference on cybernetics, Lausanne, Switzerland.
Dash, S., Rengaswamy, R., & Venkatasubramanian, V. (2003). Fuzzy-logic based trend classification for fault diagnosis of chemical processes. Computers & Chemical Engineering, 27(3), 347–362.
DeLorenzo, (2009). DL2314br—Didactic process control pilot plant. DeLorenzo Italy: Catalog.
El-Shal, S., & Morris, A. (2000). A fuzzy expert system for fault detection in statistical process control of industrial processes. Systems, Man, and Cybernetics C, 30(2), 281–289.
Hautamaki, V., Karkkainen, I., & Franti, P. (2004). Outlier detection using k-nearest neighbour graph. In Proceedings of the 17th international conference on pattern recog-nition, 2004, ICPR 2004 (vol. 3, pp. 430–433).
Hossain, A., Choudhury, Z., & Suyut, S. (1996). Statistical process control of an industrial process in real time. IEEE Transactions on Industry Applications, 32(2), 243–249.
Hwang, I., Kim, S., Kim, Y., & Seah, C. (2010). A survey of fault detection, isolation, and reconfiguration methods. IEEE Transactions on Control Systems Technology, 18(3), 636–653.
Kano, M., Sakata, T., & Hasebe, S. (2010). Just-in-time statistical process control for exible fault management. In Proceedings of SICE annual conference 2010 (pp. 1482–1485).
Kembhavi, A., Harwood, D., & Davis, L. (2011). Vehicle detection using partial least squares. IEEE Transactions on Pattern Analysis and Machine Intelligence, 33(6), 1250–1265.
Kolev, D., Angelov, P., Markarian, G., Suvorov, M., & Lysanov, S. (2013). ARFA: Automated real time flight data analysis using evolving clustering, classifiers and recursive density estimation. In Proceedings of the IEEE symposium series on computational intelligence SSCI-2013, Singapore (pp. 91–97).
Laukonen, E., Passino, K., Krishnaswami, V., Luh, G. C., & Rizzoni, G. (1995). Fault detection and isolation for an experimental internal combustion engine via fuzzy identification. IEEE Transactions on Control Systems Technology, 3(3), 347–355.
Laurentys, C., Palhares, R., & Caminhas, W. (2010a). Design of an artificial immune system based on danger model for fault detection. Expert Systems with Applications, 37(7), 5145–5152.
Laurentys, C., Ronacher, G., Palhares, R., & Caminhas, W. (2010b). Design of an artificial immune system for fault detection: A negative selection approach. Expert Systems with Applications, 37(7), 5507–5513.
Leite, D. F., Hell, M. B., Jr, P. C., & Gomide, F. (2009). Real-time fault diagnosis of nonlinear systems. Nonlinear Analysis: Theory, Methods and Applications, 71(12), e2665–e2673.
Levine, M. (1969). Feature extraction: A survey. Proceedings of the IEEE, 57(8), 1391–1407.
Li, X. J., & Yang, G. H. (2012). Dynamic observer-based robust control and fault detection for linear systems. IET Control Theory Applications, 6(17), 2657–2666.
Liu, H., Chen, G., Jiang, S., & Song, G. (2008). A survey of feature extraction approaches in analog circuit fault diagnosis. In Pacific-Asia workshop on computational intelligence and industrial application, 2008. PACIIA ’08 (vol. 2, pp. 676–680).
Liu, J., Lim, K. W., Ho, W. K., Tan, K. C., Tay, A., & Srinivasan, R. (2005). Using the opc standard for real-time process monitoring and control. IEEE Software, 22(6), 54–59.
Liukkonen, T., & Tuominen, A. (2004). A case study of spc in circuit board assembly: Statistical mounting process control. In 24th international conference on microelectronics, 2004 (vol. 2, pp 445–448).
Maiying, Z., Chenghui, Z., Steven, D., & James, L. (2004). Observer-based fault detection scheme for a class of discrete time-delay systems. Journal of Systems Engineering and Electronics, 15(3), 288–294.
Malhi, A., & Gao, R. (2004). PCA-based feature selection scheme for machine defect classification. IEEE Transactions on Instrumentation and Measurement, 53(6), 1517–1525.
Marins, A. (2009). Continuous process workbench. DeLorenzo Brazil: Technical manual.
Martin, E., Morris, A. J., & Zhang, J. (1996). Process performance monitoring using multivariate statistical process control. IEE Proceedings Control Theory and Applications, 143(2), 132–144.
Miljkovic, D. (2011). Fault detection methods: A literature survey. In MIPRO, 2011 proceedings of the 34th international convention (pp. 750–755).
Oblak, S., Skrjanc, I., & Blazic, S. (2007). Fault detection for non-linear systems with uncertain parameters based on the interval fuzzy model. Engineering Applications of Artificial Intelligence, 20(4), 503–510.
Pande, S. S., & Prabhu, B. S. (1990). An expert system for automatic extraction of machining features and tooling selection for automats. Computer-Aided Engineering Journal, 7(4), 99–103.
Papadimitriou, S., Kitagawa, H., Gibbons, P., & Faloutsos, C. (2003). Loci: fast outlier detection using the local correlation integral. In Proceedings. 19th international conference on data engineering, 2003 (pp. 315–326).
Ramezani, R., Angelov, P., & Zhou, X. (2008). A fast approach to novelty detection in video streams using recursive density estimation. In Intelligent systems, 2008. IS ’08. 4th international IEEE conference (vol. 2, pp 142–147).
Samantaray, A. K., & Bouamama, B. O. (2008). Model-based process supervision: A bond graph approach (1st ed.). London: Springer.
Schwarz, M. H., & Boercsoek, J. (2007). A survey on ole for process control (OPC). Proceedings of the 7th conference on 7th WSEAS international conference on applied computer science, World Scientific and Engineering Academy and Society (WSEAS) (pp. 186–191). Wisconsin: Stevens Point.
Simani, S., & Patton, R. J. (2008). Fault diagnosis of an industrial gas turbine prototype using a system identification approach. Control Engineering Practice, 16(7), 769–786.
Sneider, H., & Frank, P. (1996). Observer-based supervision and fault detection in robots using nonlinear and fuzzy logic residual evaluation. IEEE Transactions on Control Systems Technology, 4(3), 274–282.
Song, F., Mei, D., & Li, H. (2010). Feature selection based on linear discriminant analysis. In International Conference on intelligent system design and engineering application (ISDEA), 2010 (vol. 1, pp. 746–749).
Tang, J., Chen, Z., Fu, A. W. C., & Cheung, D. W. L. (2002). Enhancing effectiveness of outlier detections for low density patterns. In Proceedings of the 6th Pacific-Asia conference on advances in knowledge discovery and data mining, PAKDD ’02 (pp. 535–548). Springer: London
Thornhill, N. F., & Horch, A. (2007). Advances and new directions in plant-wide disturbance detection and diagnosis. Control Engineering Practice, 15(10), 1196–1206.
Vemuri, A., Polycarpou, M., & Diakourtis, S. (1998). Neural network based fault detection in robotic manipulators. IEEE Transactions on Robotics and Automation, 14(2), 342–348.
Venkatasubramanian, V., Rengaswamy, R., & Kavuri, S. N. (2003a). A review of process fault detection and diagnosis: Part II: Qualitative models and search strategies. Computers & Chemical Engineering, 27(3), 313–326.
Venkatasubramanian, V., Rengaswamy, R., Kavuri, S. N., & Yin, K. (2003b). A review of process fault detection and diagno-sis: Part III: Process history based methods. Computers & Chemical Engineering, 27(3), 327–346.
Venkatasubramanian, V., Rengaswamy, R., Yin, K., & Kavuri, S. N. (2003c). A review of process fault detection and diagnosis: Part I: Quantitative model-based methods. Computers & Chemical Engineering, 27(3), 293–311.
Wang, P., & Guo, C. (2013). Based on the coal mine’s essential safety management system of safety accident cause analysis. American Journal of Environment, Energy and Power Research, 1(3), 62–68.
Xu, L., & Tseng, H. (2007). Robust model-based fault detection for a roll stability control system. IEEE Transactions on Control Systems Technology, 15(3), 519–528.
Yang, H., Xia, Y., & Liu, B. (2011). Fault detection for t-s fuzzy discrete systems in finite-frequency domain. Systems, Man, and Cybernetics B, 41(4), 911–920.
Zio, E. (2009). Reliability engineering: Old problems and new challenges. Reliability Engineering & System Safety, 94(2), 125–141.
Acknowledgments
The first author would like to acknowledge the support of CAPES Foundation, Ministry of Education of Brazil, Braslia- DF 70040-020, Brazil.
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Costa, B.S.J., Angelov, P.P. & Guedes, L.A. Real-Time Fault Detection Using Recursive Density Estimation. J Control Autom Electr Syst 25, 428–437 (2014). https://doi.org/10.1007/s40313-014-0128-4
Received:
Revised:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s40313-014-0128-4