CN111783856A - A manufacturing-oriented equipment fault auxiliary diagnosis method and system - Google Patents
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Abstract
本发明公开了一种面向制造业的设备故障辅助诊断方法及系统,该方法包括但不限于如下的过程:生成待诊断设备运转状态的预测值;实时监控待诊断设备运转状态的真实值;基于预测值与真实值的差值判断待诊断设备是否故障。该系统包括但不限于状态预测模块、状态监控模块以及故障判断模块;状态预测模块用于生成待诊断设备运转状态的预测值,状态监控模块用于实时监控待诊断设备运转状态的真实值,故障判断模块用于基于预测值与真实值的差值判断待诊断设备是否故障。本发明能够有效辅助维修人员判断被监控的设备是否发生故障,具有故障诊断时间短、人力成本低、对人员经验和技术水平依赖小等优点,进而能够提高制造业的设备运维效率和生产效益。
The invention discloses a manufacturing-oriented equipment fault auxiliary diagnosis method and system. The method includes but is not limited to the following processes: generating a predicted value of the operation state of the equipment to be diagnosed; monitoring the real value of the operation state of the equipment to be diagnosed in real time; The difference between the predicted value and the actual value determines whether the equipment to be diagnosed is faulty. The system includes, but is not limited to, a state prediction module, a state monitoring module, and a fault judgment module; the state prediction module is used to generate a predicted value of the operating state of the equipment to be diagnosed, and the state monitoring module is used to monitor the real value of the operating state of the equipment to be diagnosed in real time. The judgment module is used for judging whether the equipment to be diagnosed is faulty based on the difference between the predicted value and the actual value. The invention can effectively assist maintenance personnel to judge whether the monitored equipment is faulty, and has the advantages of short fault diagnosis time, low labor cost, little dependence on personnel experience and technical level, etc., thereby improving the equipment operation and maintenance efficiency and production efficiency of the manufacturing industry. .
Description
技术领域technical field
本发明涉及机器学习技术领域,更为具体来说,本发明涉及一种面向制造业的设备故障辅助诊断方法及系统。The present invention relates to the technical field of machine learning, and more particularly, the present invention relates to a manufacturing-oriented equipment fault auxiliary diagnosis method and system.
背景技术Background technique
目前,越来越多的制造业企业已开始推行数字化、自动化和智能化的改造,从而提升制造效率和制造质量、降低运营成本和人力成本。可见高稳定性和高可靠性的制造系统将会是企业提升生产效率的重要保障。At present, more and more manufacturing enterprises have begun to implement digital, automated and intelligent transformation, thereby improving manufacturing efficiency and quality, and reducing operating costs and labor costs. It can be seen that a high-stability and high-reliability manufacturing system will be an important guarantee for enterprises to improve production efficiency.
制造业企业的设备故障诊断往往依靠人工巡检维护,巡检人员需每天定时巡视机器,发现故障再上报给维修人员,维修人员根据故障大小采取不同的措施,进而反馈给车间主任,再汇报给工厂厂长等。显而易见地,人工巡检方式整个流程耗费了大量人力资源、人力成本较高,而且对巡检人员的经验和技术水平有较高的要求且存在依赖性,设备诊断的时间长、检修周期短、维护效率低,无法实时跟踪设备运转状况,所以现有的人工巡检维护方案无法保证制造系统的稳定性和可靠性,无法实现制造业企业数字化、自动化和智能化的改造。The equipment fault diagnosis of manufacturing enterprises often relies on manual inspection and maintenance. The inspection personnel need to inspect the machine regularly every day, and report the fault to the maintenance personnel. The maintenance personnel take different measures according to the size of the fault, and then feedback to the workshop director, and then report to Factory manager, etc. Obviously, the whole process of manual inspection method consumes a lot of human resources, and the labor cost is high, and it has high requirements and dependence on the experience and technical level of the inspectors, and the equipment diagnosis time is long, the maintenance cycle is short, The maintenance efficiency is low, and the operation status of the equipment cannot be tracked in real time. Therefore, the existing manual inspection and maintenance scheme cannot guarantee the stability and reliability of the manufacturing system, and cannot realize the digitalization, automation and intelligent transformation of manufacturing enterprises.
虽然有人提出了设备故障的智能化诊断方案,但由于其技术上存在的局限,仍存在人力成本较高、对人员的经验和技术水平依赖较大以及设备故障诊断时间较长等问题。Although some people have proposed an intelligent diagnosis scheme for equipment faults, due to its technical limitations, there are still problems such as high labor costs, greater dependence on personnel experience and technical level, and long equipment fault diagnosis time.
发明内容SUMMARY OF THE INVENTION
为了解决制造业设备的现有故障诊断方案存在的人力成本较高、故障诊断时间较长、对人员依赖过大等问题,本发明创新提供了一种面向制造业的设备故障辅助诊断方法及系统。In order to solve the problems of high labor cost, long fault diagnosis time, and excessive dependence on personnel in the existing fault diagnosis scheme of manufacturing equipment, the present invention innovatively provides a manufacturing equipment fault auxiliary diagnosis method and system. .
为实现上述技术目的,本发明具体公开了一种面向制造业的设备故障辅助诊断方法,该方法包括但不限于如下过程:生成待诊断设备运转状态的预测值;实时监控所述待诊断设备运转状态的真实值;基于所述预测值与所述真实值的差值判断所述待诊断设备是否故障。In order to achieve the above technical purpose, the present invention specifically discloses a manufacturing-oriented equipment fault auxiliary diagnosis method, which includes but is not limited to the following processes: generating a predicted value of the operation state of the equipment to be diagnosed; monitoring the operation of the equipment to be diagnosed in real time The actual value of the state; based on the difference between the predicted value and the actual value, determine whether the device to be diagnosed is faulty.
进一步地,所述生成待诊断设备运转状态的预测值的过程包括但不限于如下过程:以设定频率采集待诊断设备的历史实时运转数据;统计在第一预设时长内历史实时运转数据的分布特征,并生成在第二预设时长内历史实时运转数据的时序特征;利用所述分布特征训练特征分类器,以通过所述特征分类器预测未来运转情况的第一特征值;利用所述时序特征训练特征回归器,以通过所述特征回归器预测未来运转情况的第二特征值;将所述第一特征值和所述第二特征值进行特征融合,以生成所述预测值。Further, the process of generating the predicted value of the operating state of the equipment to be diagnosed includes but is not limited to the following processes: collecting historical real-time operating data of the equipment to be diagnosed at a set frequency; distribution features, and generate time series features of historical real-time operation data within a second preset time period; use the distribution features to train a feature classifier, so as to predict the first feature value of future operating conditions through the feature classifier; use the The time series feature trains a feature regressor to predict a second feature value of future operating conditions through the feature regressor; the first feature value and the second feature value are feature-fused to generate the predicted value.
进一步地,判断所述待诊断设备是否故障的过程包括但不限于如下过程:将所述预测值与所述真实值的差值作为逻辑回归分类器的输入,依据逻辑回归分类器的输出判断所述待诊断设备是否故障;逻辑回归分类器的训练集包括带标注样本的训练数据。Further, the process of judging whether the device to be diagnosed is faulty includes but is not limited to the following process: taking the difference between the predicted value and the actual value as the input of the logistic regression classifier, and judging the fault based on the output of the logistic regression classifier. Describe whether the equipment to be diagnosed is faulty; the training set of the logistic regression classifier includes training data with labeled samples.
进一步地,该方法还包括:在判断出所述待诊断设备故障时,计算当前故障对应的各真实值特征权重,然后根据所述特征权重和所述各真实值为用户提供可视化排查参考数据。Further, the method further includes: when judging the fault of the equipment to be diagnosed, calculating the feature weights of each real value corresponding to the current fault, and then providing the user with visual inspection reference data according to the feature weight and each real value.
进一步地,采用时间序列滑动窗口方式生成所述时序特征,且滑动窗口的时长小于或等于所述第二预设时长。Further, the time series feature is generated in a time series sliding window manner, and the duration of the sliding window is less than or equal to the second preset duration.
进一步地,所述分布特征为低频特征,所述时序特征为高频特征;且所述第一预设时长大于所述第二预设时长。Further, the distribution feature is a low frequency feature, and the time sequence feature is a high frequency feature; and the first preset duration is greater than the second preset duration.
进一步地,通过如下方式训练所述逻辑回归分类器:Further, the logistic regression classifier is trained as follows:
S1,使用逻辑回归分类器对当前主动学习样本集的样本进行分类,以得到每个主动学习样本集里的样本的分类结果;S1, use the logistic regression classifier to classify the samples of the current active learning sample set, so as to obtain the classification results of the samples in each active learning sample set;
S2,对分类结果概率在预设区间的样本进行人工标注,并将标注好的样本加入到训练集里;S2, manually label the samples whose classification result probability is in the preset interval, and add the labeled samples to the training set;
S3,使用当前所有标注的训练样本对当前逻辑回归分类器进行参数调整,以更新当前逻辑回归分类器;S3, use all the currently labeled training samples to adjust the parameters of the current logistic regression classifier to update the current logistic regression classifier;
S4,验证当前逻辑回归分类器的分类准确度是否达到设定值或者主动学习样本集里没有无标注的样本,则结束迭代,否则循环执行步骤S1~S4。S4 , verify whether the classification accuracy of the current logistic regression classifier reaches the set value or there are no unlabeled samples in the active learning sample set, then the iteration is ended, otherwise steps S1 to S4 are executed in a loop.
为实现上述的技术目的,本发明还公开了一种面向制造业的设备故障辅助诊断系统,该系统包括但不限于状态预测模块、状态监控模块及故障判断模块。状态预测模块,用于生成待诊断设备运转状态的预测值;状态监控模块,用于实时监控所述待诊断设备运转状态的真实值;故障判断模块,用于基于所述预测值与所述真实值的差值判断所述待诊断设备是否故障。In order to achieve the above technical purpose, the present invention also discloses a manufacturing-oriented equipment fault auxiliary diagnosis system, which includes but is not limited to a state prediction module, a state monitoring module and a fault judgment module. The state prediction module is used to generate the predicted value of the operation state of the equipment to be diagnosed; the state monitoring module is used to monitor the real value of the operation state of the equipment to be diagnosed in real time; the fault judgment module is used to based on the predicted value and the real value The difference of the values determines whether the device to be diagnosed is faulty.
进一步地,所述状态预测模块包括但不限于数据采集单元、特征提取单元、初步预测单元及特征融合单元。数据采集单元,用于以设定频率采集待诊断设备的历史实时运转数据;特征提取单元,用于统计在第一预设时长内历史实时运转数据的分布特征,并用于生成在第二预设时长内历史实时运转数据的时序特征;初步预测单元,用于利用所述分布特征训练特征分类器,以通过所述特征分类器预测未来运转情况的第一特征值;以及用于利用所述时序特征训练特征回归器,以通过所述特征回归器预测未来运转情况的第二特征值;特征融合单元,用于将所述第一特征值和所述第二特征值进行特征融合,以生成所述预测值。Further, the state prediction module includes but is not limited to a data acquisition unit, a feature extraction unit, a preliminary prediction unit and a feature fusion unit. The data collection unit is used to collect historical real-time operation data of the equipment to be diagnosed at a set frequency; the feature extraction unit is used to count the distribution characteristics of the historical real-time operation data within the first preset time period, and is used to generate the second preset time period. time series features of historical real-time operation data within a time period; a preliminary prediction unit for training a feature classifier by using the distribution features, so as to predict the first feature value of future operating conditions through the feature classifier; and for using the time series The feature trains a feature regressor to predict the second feature value of the future operation through the feature regressor; a feature fusion unit is configured to perform feature fusion on the first feature value and the second feature value to generate the the predicted value.
进一步地,所述故障判断模块,用于将所述预测值与所述真实值的差值作为逻辑回归分类器的输入,依据逻辑回归分类器的输出判断所述待诊断设备是否故障;逻辑回归分类器的训练集包括带标注样本的训练数据。Further, the fault judging module is used to use the difference between the predicted value and the actual value as the input of the logistic regression classifier, and judge whether the equipment to be diagnosed is faulty according to the output of the logistic regression classifier; logistic regression The training set of the classifier consists of training data with labeled samples.
进一步地,该系统还包括排查参考模块。排查参考模块用于在所述待诊断设备故障时计算当前故障对应的各真实值特征权重,以及用于根据所述特征权重和所述各真实值为用户提供可视化排查参考数据。Further, the system also includes a checking reference module. The troubleshooting reference module is configured to calculate the feature weights of each real value corresponding to the current fault when the equipment to be diagnosed is faulty, and to provide a user with visual troubleshooting reference data according to the feature weights and the respective real values.
本发明的有益效果为:本发明能够有效地辅助维修人员判断被监控的设备是否发生故障,具有故障诊断时间短、人力成本低以及对人员经验和技术水平依赖小等优点,进而能够提高制造业的设备运维效率和生产效益。The beneficial effects of the present invention are as follows: the present invention can effectively assist maintenance personnel to judge whether the monitored equipment is faulty, and has the advantages of short fault diagnosis time, low labor cost, and little dependence on personnel experience and technical level, and thus can improve the manufacturing industry. equipment operation and maintenance efficiency and production efficiency.
针对制造业相关设备监控,本发明能够实时监控设备运转状况和高效诊断设备故障原因,实时呈现设备运行偏差,以保证制造系统的正常运转。而且本发明采集的设备状态信息具有连续性,具有较高的数据挖掘价值。Aiming at the monitoring of manufacturing related equipment, the present invention can monitor the running status of the equipment in real time, diagnose the cause of equipment failure efficiently, and present the running deviation of the equipment in real time, so as to ensure the normal operation of the manufacturing system. Moreover, the equipment state information collected by the present invention has continuity and has high data mining value.
另外,针对制造业企业难以通过获取大量真实存在的异常数据而手工整理和标注设备异常数据的问题,本发明提出了基于主动学习的异常检测方案,显著降低了传统的人工打标签的人力成本。In addition, in view of the problem that it is difficult for manufacturing enterprises to manually organize and label equipment abnormal data by acquiring a large amount of real abnormal data, the present invention proposes an abnormal detection scheme based on active learning, which significantly reduces the labor cost of traditional manual labeling.
附图说明Description of drawings
图1示出了面向制造业的设备故障辅助诊断方法的流程示意图。FIG. 1 shows a schematic flowchart of a manufacturing-oriented equipment fault assistant diagnosis method.
图2示出了本发明一些实施例面向制造业的设备故障辅助诊断系统工作原理示意图。FIG. 2 shows a schematic diagram of the working principle of a manufacturing-oriented equipment fault auxiliary diagnosis system according to some embodiments of the present invention.
具体实施方式Detailed ways
下面结合说明书附图对本发明所提供的一种面向制造业的设备故障辅助诊断方法及系统进行详细的解释和说明。A manufacturing-oriented equipment fault auxiliary diagnosis method and system provided by the present invention will be explained and described in detail below with reference to the accompanying drawings.
实施例一:Example 1:
如图1、2所示,为解决现有技术存在的至少一个问题,本实施例可提供一种面向制造业的设备故障辅助诊断方法,能够实现设备运转状况的实时监控和设备故障的高效辅助诊断。该方法包括但不限于如下的过程。As shown in FIGS. 1 and 2 , in order to solve at least one problem existing in the prior art, the present embodiment can provide a manufacturing-oriented equipment fault auxiliary diagnosis method, which can realize real-time monitoring of equipment operating conditions and efficient assistance of equipment faults. diagnosis. The method includes, but is not limited to, the following processes.
首先,以设定频率采集待诊断设备的历史实时运转数据。设定频率可根据实际需要设定,比如0.1Hz等,本实施例可以根据设备的差异每10s获取一次设备不同传感器的实时数据。例如可以通过各种传感器采集机器相应的实时运转数据,该实时运转数据包括但不限于压力、温度、转速等,实施时可通过压力传感器采集压力数据、通过温度传感器采集温度等等。First, the historical real-time operation data of the equipment to be diagnosed is collected at a set frequency. The set frequency can be set according to actual needs, such as 0.1 Hz, etc. In this embodiment, real-time data of different sensors of the device can be acquired every 10s according to the difference of the device. For example, the corresponding real-time operation data of the machine can be collected through various sensors. The real-time operation data includes but not limited to pressure, temperature, rotational speed, etc. During implementation, pressure data can be collected through a pressure sensor, and temperature can be collected through a temperature sensor.
其次,本发明根据采集的设备实时运转数据得到相应时序特征和分布特征,以对设备运转数据分频率分析处理。多频时序特征处理过程可同步进行,具体说明如下。Secondly, the present invention obtains corresponding time sequence characteristics and distribution characteristics according to the collected real-time operation data of the equipment, so as to analyze and process the equipment operation data by frequency division. The multi-frequency time series feature processing process can be performed synchronously, and the specific description is as follows.
统计在第一预设时长内历史实时运转数据的分布特征,例如按照日频统计分析不同设备不同传感器数据值的分布范围,然后再将设备值按范围分布到不同的特征桶中,为低频特征预测做数据准备。即本实施例的分布特征为低频特征,第一预设时长例如可以是一天。举例说明如下:对于某小型零件生产线上的设备,其转速为零件生产个数除以生产时间,其转速取值区间大致在[0个/分钟,60个/分钟],本实施例可以将其分为三个特征桶:小于10个/分钟,10个/分钟至30个/分钟之间,30个/分钟以上。Count the distribution characteristics of historical real-time operation data within the first preset time period, for example, analyze the distribution range of different sensor data values of different devices according to daily frequency statistics, and then distribute the device values into different feature buckets according to the range, which is a low-frequency feature. Predictions do data preparation. That is, the distribution feature in this embodiment is a low-frequency feature, and the first preset duration may be, for example, one day. An example is as follows: For a device on a small part production line, its rotational speed is the number of parts produced divided by the production time, and its rotational speed range is roughly [0 pieces/minute, 60 pieces/minute]. Divided into three characteristic buckets: less than 10/min, between 10/min and 30/min, and more than 30/min.
生成在第二预设时长内历史实时运转数据的时序特征,第一预设时长往往大于第二预设时长。采用时间序列滑动窗口方式生成时序特征,滑动窗口的时长可小于或等于第二预设时长。本实施例用滑动窗口以10分钟为滑动窗口的时长,以将数据切成一个个时间窗口的序列,优选取每分钟特征均值作为该分钟的特征值,最后获得10分钟内10个序列的特征值[w1,w2,…,w10],为高频特征预测做数据准备;即本实施例的时序特征可为高频特征,第二预设时长例如可以是10分钟。A time series feature of historical real-time operation data within a second preset time period is generated, and the first preset time period is often greater than the second preset time period. The time series feature is generated in a time series sliding window manner, and the duration of the sliding window may be less than or equal to the second preset duration. In this example, a sliding window is used to take 10 minutes as the duration of the sliding window to cut the data into a sequence of time windows. It is preferable to take the average feature value of each minute as the feature value of the minute, and finally obtain the features of 10 sequences within 10 minutes. The value [w 1 , w 2 , .
再次,通过训练机器学习模型来预测设备实时运转数据,同时实时地监控设备运转情况。预测设备运转数据过程可包括基学习器学习阶段和元学习器学习阶段,通过基学习器学习得到第一特征值和第二特征值 Third, by training the machine learning model to predict the real-time operation data of the equipment, and at the same time monitor the operation of the equipment in real time. The process of predicting equipment operation data may include a basic learner learning stage and a meta-learner learning stage, and the first feature value is obtained through the basic learner learning and the second eigenvalue
基学习器学习阶段:利用分布特征训练特征分类器,以通过特征分类器预测未来运转情况的第一特征值本实施例的特征分类器优选为低频的贝叶斯特征分类器。贝叶斯特征分类器是从日频统计设备在一天的不同小时的设备最可能的特征值,比如转速值。模型输入为小时值,比如上午10点,输入值即为10,最后通过分类器可预测出10点该设备的最可能的特征值:Basic learner learning stage: use the distribution features to train the feature classifier to predict the first feature value of the future operation through the feature classifier The feature classifier in this embodiment is preferably a low-frequency Bayesian feature classifier. The Bayesian feature classifier is derived from the daily frequency statistics of the most likely feature values of the device at different hours of the day, such as rotational speed values. The model input is the hour value, such as 10 am, the input value is 10, and finally the classifier can predict the most likely feature value of the device at 10 o'clock:
其中,用于表示预测的特征结果;xi表示与预测特征相关的特征(即所有除当前特征的以外的其他特征);n表示其他特征数量;P(y)表示事件y发生的概率,P(xi|y)表示事件y发生条件下xi的概率。in, Used to represent the predicted feature results; xi represents the features related to the predicted feature (that is, all other features except the current feature); n represents the number of other features; P(y) represents the probability of event y, P(x i |y) represents the probability of x i under the condition that event y occurs.
接着,利用时序特征训练特征回归器,通过特征回归器预测未来运转情况的第二特征值本实施例的特征回归器优选为高频的LightGBM(Light Gradient BoostingMachine,基于决策树算法的分布式梯度提升框架)特征回归器。本实施例的LightGBM特征回归器可从过去10分钟的特征值预测设备未来10s的特征值,比如转速值。模型输入为过去十分钟里每分钟的特征均值[w1,w2,…,w10],预测未来10s的特征值。LightGBM是微软2017开发的一个开源机器学习项目,高效地实现了梯度提升决策树(GBDT,GradientBoostingDecisionTree)算法,对传统的GBDT和Xgboost(eXtreme GradientBoosting,极端梯度提升)做了工程上的优化,可在不损失精度的情况下提升算法运算速度,比如采用下述的方式进行运算。Next, use the time series feature to train the feature regressor, and predict the second feature value of the future operation through the feature regressor The feature regressor in this embodiment is preferably a high-frequency LightGBM (Light Gradient Boosting Machine, a distributed gradient boosting framework based on a decision tree algorithm) feature regressor. The LightGBM feature regressor in this embodiment can predict the feature value of the device in the next 10s, such as the rotational speed value, from the feature value of the past 10 minutes. The model input is the feature mean value [w 1 ,w 2 ,...,w 10 ] every minute in the past ten minutes, and predicts the feature value for the next 10s. LightGBM is an open source machine learning project developed by Microsoft in 2017. It efficiently implements the gradient boosting decision tree (GBDT, GradientBoostingDecisionTree) algorithm, and has made engineering optimizations for traditional GBDT and Xgboost (eXtreme GradientBoosting, extreme gradient boosting), which can be found in To improve the operation speed of the algorithm without losing precision, for example, use the following method to perform the operation.
其中,用于表示特征预测结果,Fi(xj)表示第i颗决策树的预测结果,Li表示第i颗决策树基于第i-1颗决策树训练目标。in, It is used to represent the feature prediction result, F i (x j ) represents the prediction result of the ith decision tree, and Li represents the training target of the ith decision tree based on the i-1th decision tree.
然后,进行元学习器学习阶段:即融合基学习器的预测结果,例如可包括但不限于预测10s后的特征值。将第一特征值和第二特征值进行特征融合,进而生成预测值。Then, the meta-learner learning stage is performed: that is, the prediction result of the fusion base learner, for example, may include but not limited to the feature value after 10s of prediction. The first eigenvalue and the second eigenvalue are feature-fused to generate a predicted value.
元学习器的输入为基学习器的预测结果预测结果为10s后设备的特征值,本实施例采用ElasticNet(弹性网络)回归算法,能够将L1正则项和L2正则项完美结合在一起,抑制模型过拟合,提高模型泛化能力:The input of the meta-learner is the prediction result of the base learner The prediction result is the eigenvalue of the device after 10s. The ElasticNet (elastic network) regression algorithm is used in this embodiment, which can perfectly combine the L 1 regular term and the L 2 regular term, suppressing the overfitting of the model and improving the generalization ability of the model:
其中L为回归算法的损失函数,W为回归方程系数,是L1正则项系数平衡L1和L2正则项,α是正则项整体的系数。where L is the loss function of the regression algorithm, W is the coefficient of the regression equation, is the L 1 canonical term coefficient to balance the L 1 and L 2 canonical terms, and α is the coefficient of the entire canonical term.
所以本发明能通过基学习器学习阶段和元学习器学习阶段生成待诊断设备运转状态的预测值,而且本发明可实时监控待诊断设备运转状态的真实值。Therefore, the present invention can generate the predicted value of the operating state of the equipment to be diagnosed through the learning stage of the basic learner and the learning stage of the meta-learner, and the present invention can monitor the real value of the operating state of the equipment to be diagnosed in real time.
最后,基于得到的预测值与真实值的差值判断待诊断设备是否故障。本实施例涉及的的预测值和真实值均可为相应参数的特征值。可利用分类算法分析设备是否出现异常,并可提供辅助诊断的异常原因。更为具体地,判断待诊断设备是否故障的过程包括:将预测值与真实值的差值作为逻辑回归分类器(设备异常分类器)的输入,依据逻辑回归分类器的输出判断待诊断设备是否故障。如图2所示,本实施例可提供基于主动学习的异常检测,包括主动学习部分和辅助诊断部分。Finally, it is judged whether the equipment to be diagnosed is faulty based on the difference between the obtained predicted value and the actual value. Both the predicted value and the actual value involved in this embodiment can be the characteristic value of the corresponding parameter. The classification algorithm can be used to analyze whether there is an abnormality in the equipment, and the abnormal cause of the auxiliary diagnosis can be provided. More specifically, the process of judging whether the equipment to be diagnosed is faulty includes: taking the difference between the predicted value and the actual value as the input of the logistic regression classifier (equipment anomaly classifier), and judging whether the equipment to be diagnosed is not based on the output of the logistic regression classifier. Fault. As shown in FIG. 2 , this embodiment can provide anomaly detection based on active learning, including an active learning part and an auxiliary diagnosis part.
主动学习部分:目标时在尽可能少的标注样本情况下学习一个足够好的分类模块。设备异常分类器的输入为多级特征预测模块的特征预测值和真实特征值的差值,输出为分类结果,表示当前机器是否是异常状况。Active learning part: The goal is to learn a good enough classification module with as few labeled samples as possible. The input of the equipment abnormality classifier is the difference between the feature prediction value of the multi-level feature prediction module and the real feature value, and the output is the classification result, indicating whether the current machine is abnormal.
设备异常分类器的算法流程如下:(1)选择逻辑回归分类器和相应的训练集(初始为零)、验证集(带标注样本),主动学习样本集(未标注样本);(2)初始化逻辑回归分类器(图2中的设备异常分类器)参数;(3)使用逻辑回归分类器对当前主动学习样本集的样本进行逐一分类,以得到每个主动学习样本集里的样本的分类结果,选择分类结果概率在预设区间的样本,本实施例中的预设区间为[0.4,0.6];分类结果越接近0.5,表示当前模型对于该样本具有较高的不确定性,可进行相应的人工标注;(4)维修人员对选择出的在预设区间的样本可进行人工标注,然后将标注好的样本加入到训练集里,则逻辑回归分类器的训练集包括带标注样本的训练数据;本实施例要比单纯通过标注样本判断故障减少很多人工标注工作量,所以本发明能够有效减少制造业企业标记异常设备数据成本;(5)使用当前所有标注的训练样本对当前逻辑回归分类器进行参数调整(fine-tuning),以更新当前逻辑回归分类器;(6)验证当前逻辑回归分类器的分类准确度是否达到设定值,例如使用当前逻辑回归分类器对验证集进行镜像验证,如果当前逻辑回归分类器的性能达到分类准确度80%或者主动学习样本集里没有无标注的样本,则结束迭代,否则循环执行(3)-(6)。上述的主动学习过程的目的是尽可能在少量标注样本前提下在逻辑回归分类器上学习一个分类模块,以降低人工打标(标记异常设备数据)的人力成本。The algorithm flow of the equipment anomaly classifier is as follows: (1) Select the logistic regression classifier and the corresponding training set (initially zero), validation set (with labeled samples), and active learning sample set (unlabeled samples); (2) Initialization Logistic regression classifier (device anomaly classifier in Figure 2) parameters; (3) Use the logistic regression classifier to classify the samples of the current active learning sample set one by one to obtain the classification results of the samples in each active learning sample set , select a sample whose classification result probability is in the preset interval, the preset interval in this embodiment is [0.4, 0.6]; the closer the classification result is to 0.5, the higher the uncertainty of the current model for the sample, and the corresponding (4) The maintenance personnel can manually label the selected samples in the preset interval, and then add the labeled samples to the training set, then the training set of the logistic regression classifier includes the training of the labeled samples. This embodiment reduces a lot of manual labeling workload than simply judging faults by labeling samples, so the present invention can effectively reduce the cost of labeling abnormal equipment data for manufacturing enterprises; (5) Use all currently labeled training samples to classify the current logistic regression (6) Verify whether the classification accuracy of the current logistic regression classifier reaches the set value, for example, use the current logistic regression classifier to perform mirror verification on the validation set , if the performance of the current logistic regression classifier reaches the classification accuracy of 80% or there are no unlabeled samples in the active learning sample set, the iteration ends, otherwise (3)-(6) are executed in a loop. The purpose of the above-mentioned active learning process is to learn a classification module on the logistic regression classifier under the premise of a small number of labeled samples as much as possible, so as to reduce the labor cost of manual labeling (labeling abnormal device data).
辅助诊断部分:目标在于监测设备运转状况和对出现异常状况的设备提供设备异常信息。对于设备实时状态数据,本实施例利用多级特征预测模型得到预测值和当前实时数据的偏差,可视化出每个特征偏差值提供给维修人员监控设备运转情况;然后可利用主动学习模块当前次迭代学习的模型分析当前设备是否出现故障,若出现故障,将不同特征的偏差提供给维修人员帮助诊断是设备哪些特征出了问题,然后提供逻辑回归模型不同特征的系数,进而帮助维修人员诊断是哪些特征对此次故障最相关及辅助维修人员排查原因。在本发明一些实施方案中,在判断出待诊断设备故障时,计算当前故障对应的各真实值特征权重,然后可根据特征权重和各真实值为用户提供可视化排查参考数据。Auxiliary diagnosis part: The goal is to monitor the operation status of the equipment and provide equipment abnormal information to the equipment with abnormal conditions. For the real-time status data of the equipment, this embodiment uses the multi-level feature prediction model to obtain the deviation between the predicted value and the current real-time data, and visualizes each feature deviation value and provides it to the maintenance personnel to monitor the operation of the equipment; then the current iteration of the active learning module can be used. The learned model analyzes whether the current equipment is faulty. If there is a fault, the deviation of different characteristics is provided to the maintenance personnel to help diagnose which characteristics of the equipment are faulty, and then the coefficients of different characteristics of the logistic regression model are provided to help the maintenance personnel diagnose which ones are The characteristics are the most relevant to the fault and the auxiliary maintenance personnel investigate the cause. In some embodiments of the present invention, when judging the fault of the equipment to be diagnosed, the feature weight of each real value corresponding to the current fault is calculated, and then visual inspection reference data can be provided to the user according to the feature weight and each real value.
实施例二:Embodiment 2:
如图2所示,与实施例一基于相同的发明构思,本实施例提供了一种面向制造业的设备故障辅助诊断系统。整个设备故障辅助诊断系统框架可包括三个部分:数据采集部分、多级特征预测模型部分及基于主动学习的异常检测部分,多级特征预测模型部分可包括两级预测,思想来源于集成学习stacking(堆叠)框架,分为基学习部分和元学习部分。具体地,该故障辅助诊断系统可以包括但不限于状态预测模块、状态监控模块、故障判断模块及排查参考模块。As shown in FIG. 2 , based on the same inventive concept as the first embodiment, the present embodiment provides an auxiliary diagnosis system for equipment faults oriented to the manufacturing industry. The entire equipment fault auxiliary diagnosis system framework can include three parts: data acquisition part, multi-level feature prediction model part and anomaly detection part based on active learning, multi-level feature prediction model part can include two-level prediction, the idea comes from integrated learning stacking (Stacked) framework, divided into a base learning part and a meta learning part. Specifically, the auxiliary fault diagnosis system may include, but is not limited to, a state prediction module, a state monitoring module, a fault judgment module, and a troubleshooting reference module.
状态预测模块,用于生成待诊断设备运转状态的预测值。状态预测模块包括但不限于数据采集单元、特征提取单元、初步预测单元及特征融合单元。The state prediction module is used to generate the predicted value of the operating state of the equipment to be diagnosed. The state prediction module includes but is not limited to a data acquisition unit, a feature extraction unit, a preliminary prediction unit and a feature fusion unit.
数据采集单元,用于以设定频率采集待诊断设备的历史实时运转数据。The data collection unit is used to collect historical real-time operation data of the equipment to be diagnosed at a set frequency.
特征提取单元,用于统计在第一预设时长内历史实时运转数据的分布特征,并用于生成在第二预设时长内历史实时运转数据的时序特征;本实施例可采用时间序列滑动窗口方式生成时序特征,且滑动窗口的时长小于或等于第二预设时长。其中,分布特征为低频特征,时序特征为高频特征,第一预设时长大于第二预设时长。The feature extraction unit is used to count the distribution characteristics of the historical real-time operation data within the first preset time period, and is used to generate the time series characteristics of the historical real-time operation data within the second preset period of time; in this embodiment, a time-series sliding window method can be used A time series feature is generated, and the duration of the sliding window is less than or equal to the second preset duration. The distribution feature is a low frequency feature, the time sequence feature is a high frequency feature, and the first preset duration is greater than the second preset duration.
初步预测单元,用于利用分布特征训练特征分类器,以通过特征分类器预测未来运转情况的第一特征值;以及用于利用时序特征训练特征回归器,以通过特征回归器预测未来运转情况的第二特征值。The preliminary prediction unit is used for training the feature classifier by using the distribution feature, so as to predict the first feature value of the future operation condition by the feature classifier; second eigenvalue.
特征融合单元,用于将第一特征值和第二特征值进行特征融合,以生成预测值。The feature fusion unit is used for feature fusion of the first feature value and the second feature value to generate a predicted value.
状态监控模块,用于实时监控待诊断设备运转状态的真实值。The status monitoring module is used to monitor the real value of the running status of the equipment to be diagnosed in real time.
故障判断模块,用于基于预测值与真实值的差值判断待诊断设备是否故障。故障判断模块还用于将预测值与真实值的差值作为逻辑回归分类器的输入,依据逻辑回归分类器的输出判断待诊断设备是否故障;逻辑回归分类器的训练集包括带标注样本的训练数据。The fault judgment module is used for judging whether the equipment to be diagnosed is faulty based on the difference between the predicted value and the actual value. The fault judgment module is also used to use the difference between the predicted value and the actual value as the input of the logistic regression classifier, and judge whether the equipment to be diagnosed is faulty according to the output of the logistic regression classifier; the training set of the logistic regression classifier includes the training with labeled samples. data.
排查参考模块,用于在待诊断设备故障时计算当前故障对应的各真实值特征权重,以及用于根据特征权重和各真实值为用户提供可视化排查参考数据。The troubleshooting reference module is used to calculate the feature weight of each real value corresponding to the current fault when the equipment to be diagnosed is faulty, and to provide the user with visual troubleshooting reference data according to the feature weight and each real value.
在流程图中表示或在此以其他方式描述的逻辑和/或步骤,例如,可以被认为是用于实现逻辑功能的可执行指令的定序列表,可以具体实现在任何计算机可读存储介质中,以供指令执行系统、装置或设备(如基于计算机的系统、包括处理器的系统或其他可以从指令执行系统、装置或设备取指令并执行指令的系统)使用,或结合这些指令执行系统、装置或设备而使用。就本说明书而言,"计算机可读存储介质"可以是任何可以包含、存储、通信、传播或传输程序以供指令执行系统、装置或设备或结合这些指令执行系统、装置或设备而使用的装置。计算机可读存储介质的更具体的示例(非穷尽性列表)包括以下:具有一个或多个布线的电连接部(电子装置),便携式计算机盘盒(磁装置),随机存取存储器(RAM,Random Access Memory),只读存储器(ROM,Read-Only Memory),可擦除可编辑只读存储器(EPROM,Erasable Programmable Read-Only Memory,或闪速存储器),光纤装置,以及便携式光盘只读存储器(CDROM,Compact Disc Read-Only Memory)。另外,计算机可读存储介质甚至可以是可在其上打印所述程序的纸或其他合适的介质,因为可以例如通过对纸或其他介质进行光学扫描,接着进行编辑、解译或必要时以其他合适方式进行处理来以电子方式获得所述程序,然后将其存储在计算机存储器中。Logic and/or steps represented in flowcharts or otherwise described herein, for example, may be considered an ordered listing of executable instructions for implementing the logical functions, and may be embodied in any computer-readable storage medium , for use by an instruction execution system, apparatus, or device (such as a computer-based system, a system including a processor, or other system that can fetch and execute instructions from an instruction execution system, apparatus, or device), or in conjunction with these instruction execution systems, device or equipment. For the purposes of this specification, a "computer-readable storage medium" can be any device that can contain, store, communicate, propagate, or transmit a program for use by or in conjunction with an instruction execution system, apparatus, or apparatus . More specific examples (non-exhaustive list) of computer readable storage media include the following: electrical connections with one or more wiring (electronic devices), portable computer disk cartridges (magnetic devices), random access memory (RAM, Random Access Memory), Read-Only Memory (ROM, Read-Only Memory), Erasable Programmable Read-Only Memory (EPROM, Erasable Programmable Read-Only Memory, or Flash Memory), Optical Devices, and Portable Optical Disc Read-Only Memory (CDROM, Compact Disc Read-Only Memory). In addition, the computer-readable storage medium may even be paper or other suitable medium on which the program can be printed, as the paper or other medium may be optically scanned, for example, and then edited, interpreted or, if necessary, otherwise Process in a suitable manner to obtain the program electronically and then store it in computer memory.
应当理解,本发明的各部分可以用硬件、软件、固件或它们的组合来实现。在上述实施方式中,多个步骤或方法可以用存储在存储器中且由合适的指令执行系统执行的软件或固件来实现。例如,如果用硬件来实现,和在另一实施方式中一样,可用本领域公知的下列技术中的任一项或他们的组合来实现:具有用于对数据信号实现逻辑功能的逻辑门电路的离散逻辑电路,具有合适的组合逻辑门电路的专用集成电路,可编程门阵列(PGA,Programmable Gate Array),现场可编程门阵列(FPGA,Field Programmable Gate Array)等。It should be understood that various parts of the present invention may be implemented in hardware, software, firmware or a combination thereof. In the above-described embodiments, various steps or methods may be implemented in software or firmware stored in memory and executed by a suitable instruction execution system. For example, if implemented in hardware, as in another embodiment, it can be implemented by any one or a combination of the following techniques known in the art: Discrete logic circuits, application-specific integrated circuits with suitable combinational logic gate circuits, Programmable Gate Array (PGA, Programmable Gate Array), Field Programmable Gate Array (FPGA, Field Programmable Gate Array), etc.
在本说明书的描述中,参考术语“本实施例”、“一个实施例”、“一些实施例”、“示例”、“具体示例”、或“一些示例”等的描述意指结合该实施例或示例描述的具体特征、结构、材料或者特点包含于本发明的至少一个实施例或示例中。在本说明书中,对上述术语的示意性表述不必须针对的是相同的实施例或示例。而且,描述的具体特征、结构、材料或者特点可以在任一个或多个实施例或示例中以合适的方式结合。此外,在不相互矛盾的情况下,本领域的技术人员可以将本说明书中描述的不同实施例或示例以及不同实施例或示例的特征进行结合和组合。In the description of this specification, reference to the terms "this embodiment", "one embodiment", "some embodiments", "example", "specific example", or "some examples" or the like is meant to be combined with the description of the embodiment A particular feature, structure, material or characteristic described or exemplified is included in at least one embodiment or example of the present invention. In this specification, schematic representations of the above terms are not necessarily directed to the same embodiment or example. Furthermore, the particular features, structures, materials or characteristics described may be combined in any suitable manner in any one or more embodiments or examples. Furthermore, those skilled in the art may combine and combine the different embodiments or examples described in this specification, as well as the features of the different embodiments or examples, without conflicting each other.
此外,术语“第一”、“第二”仅用于描述目的,而不能理解为指示或暗示相对重要性或者隐含指明所指示的技术特征的数量。由此,限定有“第一”、“第二”的特征可以明示或者隐含地包括至少一个该特征。在本发明的描述中,“多个”的含义是至少两个,例如两个,三个等,除非另有明确具体的限定。In addition, the terms "first" and "second" are only used for descriptive purposes, and should not be construed as indicating or implying relative importance or implying the number of indicated technical features. Thus, a feature delimited with "first", "second" may expressly or implicitly include at least one of that feature. In the description of the present invention, "plurality" means at least two, such as two, three, etc., unless otherwise expressly and specifically defined.
以上所述仅为本发明的较佳实施例而已,并不用以限制本发明,凡在本发明实质内容上所作的任何修改、等同替换和简单改进等,均应包含在本发明的保护范围之内。The above descriptions are only preferred embodiments of the present invention, and are not intended to limit the present invention. Any modifications, equivalent replacements and simple improvements made in the essence of the present invention should be included in the protection scope of the present invention. Inside.
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