CN112925202B - Fermentation process stage division method based on dynamic feature extraction - Google Patents
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Abstract
The invention discloses a stage division method based on dynamic feature extraction, which is used for solving the problem that the dynamic feature change in the capturing process of the existing method is not sensitive enough. Firstly, expanding original data along batches, performing partial least square analysis on each time slice matrix to obtain a score matrix of a process variable and a quality variable, and clustering a combined score matrix by adopting an AP algorithm to realize the 1 st division; and then, extracting dynamic characteristics representing the dynamic property of the process by adopting an encoder-decoder model, carrying out 2 nd-step division on the dynamic characteristics by adopting an AP algorithm, and finally dividing the production process into different stable stages and transition stages by comprehensively analyzing two-step division results. After the stage division is completed, an attention LSTM quality prediction model can be further established for each divided stage respectively for expanding application.
Description
Technical Field
The invention relates to the technical field of process monitoring based on data driving, in particular to a fermentation process stage division method based on dynamic feature extraction, which is provided aiming at the multi-stage characteristics of the fermentation process. The invention uses the joint scoring matrix to realize the 1 st division; and then, extracting dynamic characteristics representing the process dynamics by adopting an encoder-decoder model to realize the 2 nd step division, comprehensively analyzing the two-step division results, and finally dividing the production process into different stable stages and transition stages.
Background
The intermittent process is an extremely important production mode in the modern industrial process, and is widely applied to the production of various high-value-added products such as medicines, foods, biochemical engineering, semiconductors and the like. However, in certain production processes, such as fermentation processes, the quality variables are difficult to measure online. The manual off-line measurement is complex and time-consuming in operation, extra workload is brought to people, and in case of careless operation in the sampling process, the whole fermentation tank is possibly infected with mixed bacteria, so that great waste is brought to production. Therefore, the importance of online quality prediction is increasingly highlighted to improve product quality and process efficiency.
The multi-stage characteristic is a typical characteristic in the fermentation process, and obviously, the establishment of a single model for the whole production process is incomplete, so that a great deal of research on staging is carried out by many experts at home and abroad. Yu et al propose a stage division method based on Gaussian Mixture Model (GMM), camacho et al propose a linear local model approximation method to achieve the purpose of stage division, lu et al propose an intermittent process sub-period division method based on K-means, but these methods belong to hard classification methods and ignore transition information between two stages. Compared with the operating state of each stable stage, the transition between the stages does not represent the main process operation mechanism, but is a general phenomenon and important process behavior, and shows a dynamic gradual change trend. On the basis, ZHao et al introduces fuzzy membership as a weight coefficient of two adjacent stable stages, then uses K-means to perform stage division, and Qi et al uses fuzzy C-means clustering (FCM) to perform stage division on time slices. However, the method does not consider the influence of the quality variable on the stage division, and each sampling moment is independently regarded as a unit for analysis, so that the relation between the front and the back of different moments is ignored, and the method is not sensitive to capturing the dynamic characteristic change of the process. The multi-stage characteristics of the fermentation process are reflected by the dynamic property of the change of the characterization process to a great extent, and the fermentation process has different dynamic characteristics in different stages.
Disclosure of Invention
The multi-stage characteristics of the fermentation process are reflected by the dynamics of the representation process change to a great extent, and if the process dynamic characteristic change is ignored, the whole production process cannot be accurately divided into a plurality of sub-stages, so the method is designed by adopting a design idea based on dynamic characteristic extraction, and the problem that the division of the fermentation process stages in the prior art is inaccurate is solved. The invention mainly has the following innovation points: 1) Because the relation before and after the time slice is neglected in time slice PLS modeling, and the traditional PLS method belongs to a static method, the method provided by the invention takes the static characteristics and the dynamic characteristics of the original data into consideration, and the dynamic characteristics extracted by an encoder-decoder model are adopted to carry out 2-time division to make up for the deficiency of 1-time division. 2) In most cases, it is difficult to know the exact number of stages for a complex, strange industrial process. The stage division method designed by the invention does not need to specify the exact number of stages and meets the requirement of practical application. 3) The whole operation stage can be divided into a stable stage and a transition stage by comprehensively analyzing the division results of the two steps, so that the division results conform to the actual production process.
The fermentation process stage division method based on dynamic feature extraction is characterized by comprising the following steps of:
i, carrying out data preprocessing;
the data includes historical process data and historical quality variable data, wherein the quality variable refers to product concentration, and the historical process data is J of a fermentation process for producing a certain product x Three-dimensional matrix X (I × J) composed of variables, I batches, and K sampling instants for each batch x XK). Preprocessing the three-dimensional data, specifically: three-dimensional process data X (I × J) x xK) is expanded along the batch direction to obtain K time slice data submatrices X k (I×J x ) Wherein X is k A time slice data matrix representing the kth time instant, K =1,2, \8230;, K; after spreading along the batch, each time slice matrix is normalized as follows:
wherein J represents a process variable, J =1,2, \8230j; k represents the sampling time, K =1,2, \8230k;
x k,j ，
and S kj Are all in the form of I x 1 dimensional data.
Represents the normalized k-th time slice matrix; x is the number of k,j The time slice matrix is a kth time slice matrix and consists of sampling values of the jth process variable at the kth sampling moment in all I batches;
the average value matrix of the kth time slice matrix is composed of the average sampling value of the jth process variable at the kth sampling moment in all I batches; s k,j Criterion for the kth time slice matrixThe difference matrix consists of the standard deviation of sampling values of the jth process variable at the kth sampling moment in all the I batches; the same process is performed on the historical quality variable data Y (I × Jy × K), where Jy represents the quality variable number.
II, dividing in a first step;
1) After standardization, performing PLS regression analysis on each time slice data matrix to obtain a score vector T of a corresponding process variable data set X and a score vector U of a corresponding quality variable data set Y; and (4) arranging the two scoring matrixes into a matrix from left to right to obtain a combined scoring matrix of each time slice data matrix.
2) And calculating a similarity matrix S of the samples, and inputting the similarity matrix into an AP clustering algorithm for clustering. Considering that the 1 st partition is based on the static characteristics of data, and therefore there may be more jump points, for this reason, when a time constraint is added in calculating the similarity of the sample matrix at two time instants, the calculation formula is as follows:
S(i,k)＝-||(T,U) i -(T,U) k ||*A-|k-j|*B
the A and B are determined by a cross-validation method, the values of the A and B are required to ensure that samples in the same stage are compact, samples in different stages are discrete, and the fluctuation phenomenon of the conversion part of two adjacent stages is allowed.
3) If the conversion part between two adjacent stages has no fluctuation, calculating a Silhouette value corresponding to each sampling moment, taking the average value of the Silhouette criterion of the sampling points as a judgment threshold value through multiple experiments in order to reasonably judge whether the clustering effect is good or not, and judging that the Silhouette value is good when the Silhouette value is greater than a set threshold value; otherwise it is inferior.
III, dividing;
1) And further processing the two-dimensional data obtained after the batch expansion according to a variable expansion mode, and then continuously sampling each batch of data by using a sliding window with the window width of d to obtain an input sequence required by an encoder-decoder model. And extracting dynamic characteristics by adopting a trained encoder-decoder model. And combining the dynamic characteristics of different batches at each moment into a dynamic characteristic time slice C.
2) And calculating a similarity matrix S among the dynamic characteristic time slice data matrixes, and inputting the similarity matrix into an AP clustering algorithm for clustering. Because the extracted dynamic characteristics have stronger correlation with time, the similarity between the samples is defined as follows:
wherein the content of the first and second substances,
represents k 1 The dynamic feature matrix of the time of day,
represents k 2 A dynamic feature matrix of time instants.
3) Measuring the 'good and bad' degree of the current sample point divided to the corresponding stage by adopting a Silhouette criterion, taking the average value of the Silhouette criterion of the sampling points as a judgment threshold value through multiple experiments in order to reasonably judge whether the clustering effect is good or bad, and judging that the sample point is good when the Silhouette value is greater than a set threshold value; otherwise it is inferior.
And IV, comprehensively analyzing the two-step division results, judging which stage each sampling moment belongs to, and finishing the final stage division, wherein the steps are as follows:
for the sampling moment k, when the dynamic feature clustering effect is excellent, but the static feature clustering effect is inferior, the moment is in a reasonable stable stage, namely the moment is in the same stage as the last sampling moment;
for the sampling moment k, when the static characteristic clustering effect is excellent, but the dynamic characteristic clustering effect is poor, the moment has a transition trend, and the moment is still assigned to be a reasonable stable stage, namely the moment is in the same stage as the last sampling moment;
for the sampling moment k, when the dynamic feature clustering effect is poor and the static feature clustering effect is poor, the moment is in a transition stage, that is, the moment is in a different stage from the last sampling moment.
Advantageous effects
The method realizes the multi-stage division of the intermittent process, combines the score matrix U of the quality variable and the score matrix T of the process variable to obtain a joint score matrix in order to simultaneously consider the influence of the process variable and the quality variable on the production process stage division during the stage division, and uses an AP clustering algorithm to divide the joint score matrix of each time slice in the step 1; and then, extracting dynamic characteristics by adopting a trained encoder-decoder model, wherein the input degree of each moment can obtain the dynamic characteristics of the corresponding moment. And then combining the dynamic features obtained from all batches to obtain dynamic feature time slices, performing 2 nd-step division on all time slices by using an AP clustering algorithm, and finally comprehensively analyzing the two-step division results, so that the accuracy of stage division can be effectively improved, the accuracy of online quality prediction is improved, and the method has great significance for the quality prediction of the industrial process.
Drawings
FIG. 1 is a view developed along the batch direction;
FIG. 2 is a diagram showing an encoder-decoder model structure;
FIG. 3 is a diagram illustrating a data processing process;
FIG. 4 is a graphical representation of the staging results;
FIG. 5 is a graphical representation of the results of an attention-based LSTM prediction;
FIG. 6 is a graphical representation of the prediction results based on attention LSTM after one-step partitioning;
FIG. 7 is a graphical representation of the results of attention-based LSTM prediction after a two-step partition;
FIG. 8 is a flow chart illustrating the present invention and its expanded applications.
Detailed Description
The Pensim simulation platform is a penicillin simulation platform with relatively great influence on the world, and related researches show that the Pensim simulation platform is practical and effective. The experimental simulation is carried out on the penicillin fermentation process based on the platform, the fermentation time of each batch is set to be 400h, the sampling time interval is 1h, 11 process variables (including ventilation rate, stirring power, substrate feeding rate, substrate temperature, dissolved oxygen concentration, exhaust carbon dioxide concentration, pH value, temperature, reaction heat, cold water flow acceleration rate and substrate concentration) and 1 quality variable (product concentration) are selected for monitoring, 40 batches of penicillin fermentation processes are selected for training and modeling, and 20 batches of penicillin fermentation processes are predicted.
TABLE 1 penicillin fermentation Process variables
Table 1 Process variables of Penicillin fermentation
Based on the above description, according to the invention, the specific process is implemented as follows:
and I, carrying out data preprocessing. The process data for 40 batches selected herein is denoted X 400×40×11 Spreading the time slice data in the batch direction to obtain 400 time slice data submatrices X as shown in FIG. 1 k (40×11)。
II, carrying out first-step division. 1) For time slice X k (40X 11) is normalized and then subjected to PLS regression analysis for each time slice data pair to yield corresponding score vectors T for X and U for Y, which are good characterizations of data X and Y.
2) And after the data are processed, clustering the obtained joint score matrix by adopting an AP algorithm. And comprehensively considering the similarity and time constraint between the matrixes, determining that the value of the parameter A is 2 and the value of the parameter B is 1 by adopting a cross-validation method, and defining the similarity of the AP clustering algorithm as follows:
the results of the division are shown in FIG. 4, and it is evident from the results of the division that there is no fluctuation at times 1 to 43, 68 to 142, 197 to 266, and 301 to 400, but the fluctuation is very strong at times 44 to 67, 143 to 196, and 267 to 300.
III, carrying out second-step division.
1) And further processing the two-dimensional data obtained after the batch expansion according to a variable expansion mode, and then continuously sampling the data of each batch by using a sliding window with the window width of d to obtain an input sequence required by an encoder-decoder model, wherein the data expansion sampling process is shown in fig. 3. An encoder-decoder model is adopted to extract dynamic characteristics, the structure of the encoder-decoder model is shown in figure 2, LSTM is adopted as a basic unit in the model, the main parameters to be set comprise the number of nodes of an implicit layer and the size of a sampling time window, and a grid search method is adopted to alternately optimize and determine the two parameters. The number of hidden layer nodes is finally selected to be 24 and the sampling window width is 10.
2) And calculating a similarity matrix S' among the dynamic characteristic time slice data matrixes, and inputting the similarity matrix into an AP clustering algorithm for clustering. The similarity is defined here as:
the observation result shows that different from the similarity function of the static characteristic, the time constraint is not considered at the moment, the dynamic characteristic time slice can be ideally divided, and the strong fluctuation state when two adjacent stages are converted does not exist. Therefore, a Silhouette criterion is introduced to evaluate the clustering effect. Through several experiments, it was considered reasonable to set the cut-off value to 0.7. A Silhouette value lower than 0.7 is considered to be poor in clustering effect. Since the sampling width is 10, the dynamic features at the first 9 moments cannot be extracted, and the 1 st sub-stage moment is far greater than 9 by observing the static feature division result, so that the division result at the first 9 moments and the 10 th sub-stage are not divided into the same stage. According to the Silhouette values, the clustering effect is poor at the time points of 41-54, 77-175 and 238-275, and the clustering effect is good at other time points.
IV, finally, comprehensively analyzing and dividing the moments 1-43, 55-142, 176-266, 276-400 into a stable stage, and dividing the moments 44-54, 143-175, 267-275 into a transition stage.
According to the division results, an attention LSTM soft measurement model is established for each stage respectively for quality prediction experiment verification. And for the process variable acquired on line, judging which stage the moment belongs to according to the time point, and predicting the quality by using the model of the stage. In order to show the specific embodiment of the present invention more clearly and intuitively, the simulation result of the present invention will be presented below. The penicillin fermentation process has a batch duration of 400h and a sampling interval of 1h. The selection of 11 major process variables is shown in table 1, one mass variable (product concentration) is selected. 40 batches of penicillin fermentation processes were selected for training modeling and 20 batches for prediction. In order to ensure the consistency of the simulation environment and the actual production field environment, certain white noise interference is added to the training sample set.
TABLE 2 prediction accuracy index of penicillin concentration
Table 2 Prediction accuracy index of penicillin concentration
In order to verify the effectiveness of the method provided by the invention, experiments compare the method with an attention LSTM integrated prediction model which is not classified in stages and a method for directly establishing the attention LSTM integrated prediction model for the first-step classification result. Using the predicted Root Mean Square Error (RMSE) and R 2 Evaluation indexes as a model:
as can be seen from fig. 5 to 7, in comparison with the method of excluding the segmentation and only considering the one-step segmentation, the segmentation method based on the dynamic feature extraction is improved in the accuracy of the quality prediction.
Claims (5)
1. The fermentation process stage division method based on dynamic feature extraction is characterized by comprising the following steps of:
i, carrying out data preprocessing;
the data includes historical process variable data indicating product concentration in the fermentation process and historical quality variable data indicating J of the fermentation process for producing a product x Three-dimensional matrix X (I × J) composed of variables, I batches, and K sampling moments of each batch x X K); preprocessing the three-dimensional data, specifically: convert three-dimensional Process data X (I × J) x xK) is expanded along the batch direction to obtain K time slice data submatrices X k (I×J x ) Wherein X is k A time slice data matrix representing the kth time instant, K =1,2, \8230;, K; after the development along the batch, each time slice matrix is normalized according to the following formula:
wherein J represents a process variable, J =1,2, \8230j; k represents the sampling time, K =1,2, \8230k;
and S k,j Are all in I × 1 dimensional data form;
representing the normalized kth time slice matrix; x is the number of k,j The time slice matrix is a kth time slice matrix and consists of sampling values of the jth process variable at the kth sampling moment in all I batches;
the average value matrix of the kth time slice matrix is composed of the average sampling value of the jth process variable at the kth sampling moment in all I batches; s k,j As a kth time slice matrixThe standard deviation matrix consists of standard deviations of sampling values of the jth process variable at the kth sampling moment in all the I batches; the historical quality variable data Y (I multiplied by Jy multiplied by K) are processed in the same way, wherein Jy represents the quantity of quality variables;
II, dividing in a first step;
1) After standardization, performing PLS regression analysis on each time slice data matrix to obtain a score vector T of corresponding historical process data X and a score vector U of corresponding historical quality variable data Y; the two scoring matrixes are arranged into a matrix from left to right, and a combined scoring matrix of each time slice data matrix is obtained;
2) Calculating a similarity matrix S among all the joint score matrixes, inputting the similarity matrix S into an AP clustering algorithm for clustering, and completing primary stage division of all sampling moments by using static characteristics;
3) If the conversion part between two adjacent stages has no fluctuation, the Silhouette criterion is adopted to measure the degree of 'good and bad' of the score to the corresponding stage during each sampling;
III, dividing;
1) Processing the two-dimensional data obtained after batch expansion further according to a variable expansion mode, and then continuously sampling each batch of data by using a sliding window with the window width of d to obtain an input sequence required by an encoder-decoder model; extracting dynamic characteristics by adopting a trained encoder-decoder model; combining the dynamic characteristics of different batches at each moment into a dynamic characteristic time slice C;
2) Calculating a similarity matrix S 'among the dynamic characteristic time slice data matrixes, inputting the similarity matrix S' into an AP clustering algorithm for clustering, and completing secondary stage division of all sampling moments by using the dynamic characteristics;
3) Measuring the 'good and bad' degree of the current sample point divided into corresponding stages by adopting a Silhouette criterion;
and IV, comprehensively analyzing the two-step division results, judging which stage each sampling moment belongs to, and finishing the final stage division, wherein the steps are as follows:
for a sampling moment k, when the dynamic feature clustering effect is good, but the static feature clustering effect is bad, the moment is in a reasonable stable stage, namely the moment is in the same stage as the last sampling moment;
for the sampling moment k, when the static characteristic clustering effect is excellent, but the dynamic characteristic clustering effect is poor, the moment has a transition trend, and the moment is still assigned to be a reasonable stable stage, namely the moment is in the same stage as the last sampling moment;
for the sampling moment k, when the dynamic feature clustering effect is poor and the static feature clustering effect is poor, the moment is in a transition stage, that is, the moment is in a different stage from the last sampling moment.
2. The fermentation process staging method based on dynamic feature extraction as claimed in claim 1, characterized in that:
in the second step of the partitioning process, a similarity calculation formula among different time slice matrixes related in the AP clustering algorithm is as follows:
wherein k is 1 、k 2 Respectively, represent a different sampling instant of time,
represents k 1 A joint scoring matrix of the time slice data matrix,
represents k 2 A joint score matrix of the time slice data matrix; a and B are determined by cross-validation.
3. The fermentation process staging method based on dynamic feature extraction as claimed in claim 2, characterized in that:
the values of A and B are to ensure the compactness among samples in the same stage, the dispersion among samples in different stages and the fluctuation of the conversion part of two adjacent stages.
4. The fermentation process staging method based on dynamic feature extraction as claimed in claim 1, characterized in that:
the clustering method in the second step of the partitioning process is an AP clustering algorithm, wherein the similarity among the samples involved in the AP clustering algorithm is as follows:
wherein the content of the first and second substances,
represents k 1 A matrix of the dynamic characteristics of the time of day,
represents k 2 A dynamic feature matrix of time instants.
5. The dynamic feature extraction-based fermentation process staging method according to claim 1, characterized in that:
the clustering effect in the first and second partitions is excellent, and the intra-class samples are compact and the samples at different stages are discrete after clustering; otherwise, the clustering effect is bad;
the specific judging method comprises the following steps: calculating a Silhouette value corresponding to each sampling moment, taking the average value of the Silhouette criterion of the sampling points as a judgment threshold value through multiple experiments in order to reasonably judge whether the clustering effect is good or not, and judging that the Silhouette value is good when the Silhouette value is larger than the set threshold value; otherwise it is inferior.
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