Time-slice dynamic prediction and multiway serial PCA for batch industrial process monitoring

Abstract

This paper introduces an innovative method for batch industrial process monitoring and fault detection. By combining time-slice dynamic prediction with an enhanced adaptive multiway principal component analysis (PCA) technique, it aims to balance the trade-off between high fault detection rates and low false alarm rates in monitoring batch industrial data. The method extracts dynamic features from 3D batch data time slices and utilizes a serial PCA framework with variable control limits for real-time monitoring. Comparative evaluations against traditional adaptive multiway PCA and dynamic time-slice canonical correlation analysis approaches demonstrate its superior performance. A case study using a novel cold rolling mill simulation model underscores its effectiveness for batch industrial process monitoring and fault detection.