Distributed process monitoring framework based on decomposed modified partial least squares

Abstract

With the growing complexity of industrial processes, the scale of production processes tends to be large. The significant amount of measurement data in large‐scale processes poses challenges in data collection, management, and storage. In order to perform effective process monitoring in large‐scale processes, the distributed process monitoring strategy is widely applied. Meanwhile, product quality is an important indicator for industrial production. Therefore, a novel quality‐based distributed process monitoring scheme is proposed. Firstly, the Girvan‐Newman (GN) algorithm in complex network divides process variables into multiple sub‐blocks. Secondly, greedy algorithm‐based high‐dimensional mutual information (HDMI) is used to extract quality‐related variables in each sub‐block, through which the irrelevant and redundant variables are eliminated. Thirdly, the decomposed modified partial least squares (DMPLS) approach is used to detect whether a fault is quality‐related or not in each sub‐block. Finally, the Bayesian inference strategy is adopted to combine the detection results of all sub‐blocks. The effectiveness of the distributed DMPLS approach is illustrated through a numerical simulation and the Tennessee Eastman (TE) process. The results show the superiority of our proposed monitoring scheme.