Anomaly detection using large-scale multimode industrial data: An integration method of nonstationary kernel and autoencoder

Kernel methods and neural networks (NNs) are two mainstream nonlinear data modeling methods and have been widely applied to industrial process monitoring. However, they both present imperfect properties, so the relevant applications are limited. On the one hand, kernels are not so reconstructable, scalable, and robust to hyperparameters that they suffer performance degradation for large-scale data modeling and monitoring. On the other hand, the high-dimensional parameter space of NNs that is sorted to parameter initialization presents severe anomaly detection performance inconsistency, which makes the industry cautious about using NNs. Motivated by these facts, we propose to integrate kernels and NNs, forming a new model structure that is scalable, reconstructable, and performance-consistent. Specifically, a novel autoencoder-based nonstationary pattern selection kernel (AE-NPSK) is proposed by (1) selecting from the training set the critical edges and interior data as the centers of the radial basis functions in the hidden layers and (2) adaptively adjusting the kernel width in the training procedure. Also, the new NN has strong performance consistency, which facilitates the search for optimal parameters. Finally, we test the performance of the proposed method on the challenging multimode processes. The results validate the efficacy of the proposed method. © 2024 Elsevier Ltd