Physically Consistent Soft-Sensor Development Using Sequence-to-Sequence Neural Networks

Abstract

Soft sensors attempt to predict the key quality variables that are infrequently available using the sensor and manipulated variables that are readily available. Since only limited amount of labeled data are available, there is always the concern whether the underlying physics were captured so that the model can be reasonably extrapolated. A sequence-to-sequence model in the form of a nonlinear state-observer/encoder and predictor/decoder was proposed. The observer can be trained using a large amount of unlabeled data, but in a supervised manner in which the process dynamics is tracked. The encoder output and manipulated variables are used to train the quality predictor. The model is applied to the product impurity predictions of an industrial column. Results show that good predictions and excellent consistency in the sign of estimated gains can be achieved even with limited amount of data. These findings indicated that the proposed sequence-to-sequence data-driven approach is able to capture the underlying physics of the process.