Tensor-Based State Scoring for Abnormal Process Detection
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Solution Overview
Problem
Existing systems for determining abnormal states in processes require training data that distinguishes between normal and abnormal states, which is challenging to obtain, especially for equipment that operates normally initially and may only experience errors due to aging.
Innovation Solution
A tensor-based state score derivation system that uses only normal-state data to generate a 2D normal-state matrix and a 2D checking target matrix, calculating a state score by analyzing the differences between these matrices, even without abnormal state-related training data.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If training data with distinguished normal and abnormal states is used for AI model training, then the accuracy of abnormal state detection is improved, but the difficulty of securing abnormal state data increases
Solution Approach 1:
Instead of training the model to directly detect abnormal states using abnormal data, the patent inverts the approach by training the model to recognize normal states using only normal data. The abnormal state detection is then achieved by identifying deviations from the learned normal state patterns, effectively detecting anomalies through the absence of normal characteristics rather than presence of abnormal characteristics.
Solution Approach 2:
The patent extracts and focuses solely on the normal state data characteristics, separating them from abnormal state data. By extracting only the normal state patterns and building the model around these extracted features, the system eliminates the need to collect and process difficult-to-obtain abnormal state data while maintaining detection capability through deviation analysis.
2Ease of manufacture
If only normal state data is used for training, then the ease of data collection is improved, but the ability to detect abnormal states deteriorates
Solution Approach 1:
The patent implements a feedback mechanism where the trained model continuously compares incoming data patterns against the learned normal state representations. When deviations are detected, the system can flag potential abnormal states, and this feedback loop allows the system to maintain high reliability by constantly measuring against the established normal baseline rather than requiring direct examples of abnormal states.
Solution Approach 2:
The patent performs preliminary action by thoroughly training the model on normal state data before deployment, establishing a robust baseline of normal behavior patterns. This preliminary training with abundant normal data prepares the system in advance to reliably detect abnormal states through deviation analysis, compensating for the lack of abnormal training data through advance preparation of the normal state reference.
3Measurement precision
If normal state data is divided into multiple sections with weighted cells, then the state calculation accuracy is improved, but the computational complexity increases
Solution Approach 1:
The patent segments the normal state data into multiple distinct sections or categories, allowing the model to learn different patterns and characteristics within the normal state. By dividing the data into sections and applying weighted cells to represent different normal state patterns, the system achieves higher calculation accuracy for detecting deviations, with the segmentation enabling more nuanced comparison against multiple normal references rather than a single aggregate normal state.
Data Source
AI summary
A state score derivation system includes a normal-state matrix generation unit configured to receive process data in a normal state for a plurality of points in time and generate a two-dimensional (2D) normal-state matrix representative of the relationship between the data values of a current point in time and a previous point in time for each point in time; a process data reception unit configured to receive process data; a checking target matrix generation unit configured to periodically check the received process data and generate a 2D checking target matrix representative of the relationship between the data values of a current point in time and a previous point in time for each period; and a state score derivation unit configured to derive a state score.


