Industrial processes generate complex data that challenge fault detection systems, often yielding opaque or underwhelming results despite advanced machine learning techniques. This study tackles such difficulties using the Tennessee Eastman Process, a well-established benchmark known for its intricate dynamics, to develop an innovative fault detection framework. Initial attempts with standard models revealed limitations in both performance and interpretability, prompting a shift toward a more tractable approach. By employing SHAP (SHapley Additive exPlanations), we transform the problem into a more manageable and transparent form, pinpointing the most critical process features driving fault predictions. This reduction in complexity unlocks the ability to apply causal analysis through Directed Acyclic Graphs, generated by multiple algorithms, to uncover the underlying mechanisms of fault propagation. The resulting causal structures align strikingly with SHAP findings, consistently highlighting key process elements-like cooling and separation systems-as pivotal to fault development. Together, these methods not only enhance detection accuracy but also provide operators with clear, actionable insights into fault origins, a synergy that, to our knowledge, has not been previously explored in this context. This dual approach bridges predictive power with causal understanding, offering a robust tool for monitoring complex manufacturing environments and paving the way for smarter, more interpretable fault detection in industrial systems.

Soft sensing of hard-to-measure variables is often crucial in industrial processes. Current practices rely heavily on conventional modeling techniques that show success in improving accuracy. However, they overlook the non-linear nature, dynamics characteristics, and non-Euclidean dependencies between complex process variables. To tackle these challenges, we present a framework known as a Knowledge discovery graph Attention Network for effective Soft sensing (KANS). Unlike the existing deep learning soft sensor models, KANS can discover the intrinsic correlations and irregular relationships between the multivariate industrial processes without a predefined topology. First, an unsupervised graph structure learning method is introduced, incorporating the cosine similarity between different sensor embedding to capture the correlations between sensors. Next, we present a graph attention-based representation learning that can compute the multivariate data parallelly to enhance the model in learning complex sensor nodes and edges. To fully explore KANS, knowledge discovery analysis has also been conducted to demonstrate the interpretability of the model. Experimental results demonstrate that KANS significantly outperforms all the baselines and state-of-the-art methods in soft sensing performance. Furthermore, the analysis shows that KANS can find sensors closely related to different process variables without domain knowledge, significantly improving soft sensing accuracy.

In this work, we introduce MOLA: a Multi-block Orthogonal Long short-term memory Autoencoder paradigm, to conduct accurate, reliable fault detection of industrial processes. To achieve this, MOLA effectively extracts dynamic orthogonal features by introducing an orthogonality-based loss function to constrain the latent space output. This helps eliminate the redundancy in the features identified, thereby improving the overall monitoring performance. On top of this, a multi-block monitoring structure is proposed, which categorizes the process variables into multiple blocks by leveraging expert process knowledge about their associations with the overall process. Each block is associated with its specific Orthogonal Long short-term memory Autoencoder model, whose extracted dynamic orthogonal features are monitored by distance-based Hotelling's $T^2$ statistics and quantile-based cumulative sum (CUSUM) designed for multivariate data streams that are nonparametric, heterogeneous in nature. Compared to having a single model accounting for all process variables, such a multi-block structure improves the overall process monitoring performance significantly, especially for large-scale industrial processes. Finally, we propose an adaptive weight-based Bayesian fusion (W-BF) framework to aggregate all block-wise monitoring statistics into a global statistic that we monitor for faults, with the goal of improving fault detection speed by assigning weights to blocks based on the sequential order where alarms are raised. We demonstrate the efficiency and effectiveness of our MOLA framework by applying it to the Tennessee Eastman Process and comparing the performance with various benchmark methods.

False and nuisance alarms in industrial fault detection systems are often triggered by uncertainty, causing normal process variable fluctuations to be erroneously identified as faults. This paper introduces a novel encoder-based residual design that effectively decouples the stochastic and deterministic components of process variables without imposing detection delay. The proposed model employs two distinct encoders to factorize the latent space into two orthogonal spaces: one for the deterministic part and the other for the stochastic part. To ensure the identifiability of the desired spaces, constraints are applied during training. The deterministic space is constrained to be smooth to guarantee determinism, while the stochastic space is required to resemble standard Gaussian noise. Additionally, a decorrelation term enforces the independence of the learned representations. The efficacy of this approach is demonstrated through numerical examples and its application to the Tennessee Eastman process, highlighting its potential for robust fault detection. By focusing decision logic solely on deterministic factors, the proposed model significantly enhances prediction quality while achieving nearly zero false alarms and missed detections, paving the way for improved operational safety and integrity in industrial environments.

Advanced Manufacturing (AM) has gained significant interest in the nuclear community for its potential application on nuclear materials. One challenge is to obtain desired material properties via controlling the manufacturing process during runtime. Intelligent AM based on deep reinforcement learning (DRL) relies on an automated process-level control mechanism to generate optimal design variables and adaptive system settings for improved end-product properties. A high-fidelity thermo-mechanical model for direct energy deposition has recently been developed within the MOOSE framework at the Idaho National Laboratory (INL). The goal of this work is to develop an accurate and fast-running reduced order model (ROM) for this MOOSE-based AM model that can be used in a DRL-based process control and optimization method. Operator learning (OL)-based methods will be employed due to their capability to learn a family of differential equations, in this work, produced by changing process variables in the Gaussian point heat source for the laser. We will develop OL-based ROM using Fourier neural operator, and perform a benchmark comparison of its performance with a conventional deep neural network-based ROM.

The proliferation of automated data collection schemes and the advances in sensorics are increasing the amount of data we are able to monitor in real-time. However, given the high annotation costs and the time required by quality inspections, data is often available in an unlabeled form. This is fostering the use of active learning for the development of soft sensors and predictive models. In production, instead of performing random inspections to obtain product information, labels are collected by evaluating the information content of the unlabeled data. Several query strategy frameworks for regression have been proposed in the literature but most of the focus has been dedicated to the static pool-based scenario. In this work, we propose a new strategy for the stream-based scenario, where instances are sequentially offered to the learner, which must instantaneously decide whether to perform the quality check to obtain the label or discard the instance. The approach is inspired by the optimal experimental design theory and the iterative aspect of the decision-making process is tackled by setting a threshold on the informativeness of the unlabeled data points. The proposed approach is evaluated using numerical simulations and the Tennessee Eastman Process simulator. The results confirm that selecting the examples suggested by the proposed algorithm allows for a faster reduction in the prediction error.

Data-driven soft sensors are extensively used in industrial and chemical processes to predict hard-to-measure process variables whose real value is difficult to track during routine operations. The regression models used by these sensors often require a large number of labeled examples, yet obtaining the label information can be very expensive given the high time and cost required by quality inspections. In this context, active learning methods can be highly beneficial as they can suggest the most informative labels to query. However, most of the active learning strategies proposed for regression focus on the offline setting. In this work, we adapt some of these approaches to the stream-based scenario and show how they can be used to select the most informative data points. We also demonstrate how to use a semi-supervised architecture based on orthogonal autoencoders to learn salient features in a lower dimensional space. The Tennessee Eastman Process is used to compare the predictive performance of the proposed approaches.

Multi-variate soft sensor seeks accurate estimation of multiple quality variables using measurable process variables, which have emerged as a key factor in improving the quality of industrial manufacturing. The current progress stays in some direct applications of multitask network architectures; however, there are two fundamental issues remain yet to be investigated with these approaches: (1) negative transfer, where sharing representations despite the difference of discriminate representations for different objectives degrades performance; (2) seesaw phenomenon, where the optimizer focuses on one dominant yet simple objective at the expense of others. In this study, we reformulate the multi-variate soft sensor to a multi-objective problem, to address both issues and advance state-of-the-art performance. To handle the negative transfer issue, we first propose an Objective-aware Mixture-of-Experts (OMoE) module, utilizing objective-specific and objective-shared experts for parameter sharing while maintaining the distinction between objectives. To address the seesaw phenomenon, we then propose a Pareto Objective Routing (POR) module, adjusting the weights of learning objectives dynamically to achieve the Pareto optimum, with solid theoretical supports. We further present a Task-aware Mixture-of-Experts framework for achieving the Pareto optimum (TMoE-P) in multi-variate soft sensor, which consists of a stacked OMoE module and a POR module. We illustrate the efficacy of TMoE-P with an open soft sensor benchmark, where TMoE-P effectively alleviates the negative transfer and seesaw issues and outperforms the baseline models.

Do you prefer positive reinforcement or negative reinforcement? In the behavioral sciences, this refers to the reward system and associative learning process, when a person or animal or plant or machine learn an association between two stimuli or events or actions or information. A reinforcement (by reward) or a punishment is given after a given behavior, changing the frequency and/or form of that behavior. Positive reinforcement refers to the addition of a pleasant factor, reinforcer. Negative reinforcement refers to the removal or withholding of an unpleasant factor.

Advanced reactors to be deployed in the coming decades will face deregulated energy markets, and may adopt flexible operation to boost profitability. To aid in the transition from baseload to flexible operation paradigm, autonomous operation is sought. This work focuses on the control aspect of autonomous operation. Specifically, a hierarchical control system is designed to support constraint enforcement during routine operational transients. Within the system, data-driven modeling, physics-based state observation, and classical control algorithms are integrated to provide an adaptable and robust solution. A 320 MW Fluoride-cooled High-temperature Pebble-bed Reactor is the design basis for demonstrating the control system. The hierarchical control system consists of a supervisory layer and low-level layer. The supervisory layer receives requests to change the system's operating conditions, and accepts or rejects them based on constraints that have been assigned. Constraints are issued to keep the plant within an optimal operating region. The low-level layer interfaces with the actuators of the system to fulfill requested changes, while maintaining tracking and regulation duties. To accept requests at the supervisory layer, the Reference Governor algorithm was adopted. To model the dynamics of the reactor, a system identification algorithm, Dynamic Mode Decomposition, was utilized. To estimate the evolution of process variables that cannot be directly measured, the Unscented Kalman Filter, incorporating a nonlinear model of nuclear dynamics, was adopted. The composition of these algorithms led to a numerical demonstration of constraint enforcement during a 40 % power drop transient. Adaptability was demonstrated by modifying the constraint values, and enforcing them during the transient. Robustness was demonstrated by enforcing constraints under noisy environments.