Data-Driven Joint Fault Diagnosis Based on RMK-ASSA and DBSKNet for Blast Furnace Iron-Making Process

Abstract

Blast furnace iron-making process (BFIP) is one of the most critical procedures in the iron and steel industry where timely detection and accurate classification of faults have always been of core focus. However, the coupling effects of system’s nonlinear and nonstationary characteristics often cause process consistent underlying information to be buried, allowing accurate extraction to be a significant challenge. This also complicates the development of BFIP fault diagnosis model. Therefore, we propose a novel data-driven joint fault diagnosis strategy that employs regularized mutual kernel analytic stationary subspace analysis (RMK-ASSA) and deep broad stationary kernel network (DBSKNet) to eliminate this interference. To develop this method, we first construct an RMK-ASSA approach to address the poor modeling accuracy caused by standard analytic stationary subspace analysis (ASSA)’s inability to handle complex process nonlinearity. Global and local kernels are utilized to account for multiple nonlinearities in BFIP data. The weight of different nonlinear data is calculated by regularized principal component analysis, and the main information is imported into ASSA to obtain more robust and accurate modeling results by eliminating the interference of redundant noise. Subsequently, we design a DBSKNet-based classifier to implement the fault diagnosis task. This network further considers the nonlinearity by boosting kernel structure in depth and width while distinguishing the respective contributions of different kernels to fault diagnosis results. Finally, a double-layer loop parameter optimization algorithm is used for optimizing. Simulated cases and practical BFIP tests validate that RMK-ASSA eliminates the negative impact caused by nonstationary data and that the proposed joint fault diagnosis strategy outperforms other methods. <italic xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink">Note to Practitioners</i> —BFIP’s nonlinear and nonstationary coupling properties pose unique challenges in eliminating distractions, constructing fault classifiers and accurately detecting process anomalies. To tackle these challenges, this paper proposes a joint fault diagnosis strategy based on RMK-ASSA and DBSKNet. RMK-ASSA effectively estimates nonlinear consistent features, while DBSKNet mines rich deep nonlinear information, accurately distinguishing variations in BFIP data under different working conditions. Experimental results demonstrate that this data-driven strategy can perform high-quality fault diagnosis, enabling field engineers to execute operations efficiently.