A portion of the disclosure of this patent document contains material which is subject to copyright protection. The copyright owner has no objection to the facsimile reproduction by anyone of the patent disclosure, as it appears in the Patent and Trademark Office patent files or records, but otherwise reserves all copyright rights whatsoever. The following notice shall apply to this document, the data and contents as described below, and the drawings hereto: Copyright© 2019-2023, https://www.kaggle.com/c/severstal-steel-defect-detection.
The disclosure relates to a method and an apparatus for equipment anomaly detection.
At present, artificial intelligence (AI) technology has been introduced into equipment and mechanical systems to greatly reduce the adverse effects, such as product yield decline and operation losses, caused by down time in the production line. Training an AI model generally requires collecting a large amount of normal and anomaly data. However, the aging and anomaly data of electrical or mechanical equipment are usually extremely difficult to obtain, and due to the wide variety of anomalies, it is difficult to collect sufficient data for each individual anomaly. As a result, the training data is unbalanced and the prediction performance of the AI model for detecting equipment anomalies decreases. Moreover, due to the lack of training data for detecting anomalies of electrical or mechanical equipment, it is difficult to train the machine learning model to determine whether there is an anomaly in the electrical or mechanical equipment.
An embodiment of the disclosure provides an apparatus for equipment anomaly detection, which includes a data acquisition device, a storage device, and a processor. The data acquisition device is used to acquire signals of an equipment during operation. The storage device is used to store machine learning models. The processor is connected to the data acquisition device and the storage device, and is configured to acquire multiple signals of the equipment during normal operation by using the data acquisition device to train the machine learning model; acquire a real-time signal of the equipment during a current operation by using the data acquisition device; and input the acquired real-time signal to the trained machine learning model to output a detection result indicating a current operation state of the equipment.
An embodiment of the disclosure provides a method for equipment anomaly detection, which is applicable to an electronic device including a data acquisition device, a storage device, and a processor. The method includes the following steps. Multiple signals of an equipment during normal operation are acquired in advance by using the data acquisition device to train a machine learning model stored in the storage device. A real-time signal of the equipment during a current operation is acquired by using the data acquisition device. The acquired real-time signal is input to the trained machine learning model to output a detection result indicating a current operation state of the equipment.
An embodiment of the disclosure provides an apparatus for equipment anomaly detection, which includes a data acquisition device, a storage device, and a processor. The data acquisition device is used to acquire an appearance image of an equipment. The storage device is used to store a machine learning model. The processor is connected to the data acquisition device and the storage device, and is configured to acquire multiple appearance images when an equipment appearance is not damaged in advance by using the data acquisition device to be used to train the machine learning model, acquire a current image of the equipment appearance by using the data acquisition device, and input the acquired current image into the trained machine learning model to output a detection result indicating a current state of the equipment appearance.
An embodiment of the disclosure provides a method for equipment anomaly detection, which is applicable to an electronic device including a data acquisition device, a storage device, and a processor. The method includes the following steps. Multiple appearance images when an equipment appearance is not damaged are acquired in advance by using the data acquisition device to be used to train a machine learning model stored in the storage device. A current image of the equipment appearance is acquired by using the data acquisition device, and the acquired current image is input into the trained machine learning model to output a detection result indicating a current state of the equipment appearance.
In order for the features and advantages of the disclosure to be more comprehensible, the following specific embodiments are described in detail in conjunction with the drawings.
An embodiment of the disclosure provides a machine learning model that does not need to collect anomaly data of an electrical or mechanical equipment and can distinguish an equipment anomaly by sensing and collecting a large number of data of the equipment during normal operation for model training, so as to achieve the objective of intelligent pre-diagnosis. The model may combine time-domain and frequency-domain features of signals or combine image and image frequency-domain features for comprehensive prediction to obtain better accuracy, and prediction of signal data may be performed through connecting an external artificial intelligence (AI) edge computing module to the electrical or mechanical equipment.
The disclosure provides a method and an apparatus for equipment anomaly detection, which can complete the training of a machine learning model and distinguish an equipment anomaly under the condition of collecting normal data.
The method and the apparatus for equipment anomaly detection of the disclosure can distinguish the equipment anomaly through sensing and collecting a large amount of data of the equipment during normal operation to train the machine learning model. Through combining a time-domain signal and a frequency-domain signal to train the machine learning model, better accuracy can be obtained. The trained machine learning model may be stored in an external device, thereby implementing edge computing and intelligent pre-diagnosis.
The data acquisition device 12 is, for example, a wired connection device such as a universal serial bus (USB), RS232, a universal asynchronous receiver/transmitter (UART), an internal integrated circuit (I2C), a serial peripheral interface (SPI), a display port, a thunderbolt, or a local area network (LAN) interface, or a wireless connection device supporting communication protocol such as wireless fidelity (Wi-Fi), RFID, Bluetooth, infrared, near-field communication (NFC), or device-to-device (D2D), which is not limited thereto. The data acquisition device 12 may be connected to a local or remote equipment 20 or a sensor disposed on the equipment 20 and is used to acquire a signal, such as a voltage signal, a current signal, a sound signal, or a vibration signal, of the equipment 20 during operation, which is not limited thereto.
The storage device 14 is, for example, any type of fixed or removable random-access memory (RAM), read-only memory (ROM), flash memory, hard disk drive, other similar devices, or a combination of the devices to store a program executable by the processor 16. In some embodiments, the storage device 14 may store a machine learning model established by using equipment operation information. The machine learning model is, for example, a convolutional neural network (CNN), a recurrent neural network (RNN), or a long short-term memory (LSTM) recurrent neural network, which is not limited by the disclosure.
The processor 16 is, for example, coupled to the data acquisition device 12 and the storage device 14 through a bus bar 18 to control the operation of the apparatus for equipment anomaly detection 10. In some embodiments, the processor 16 is, for example, a central processing unit (CPU), other programmable general-purpose or specific-purpose microprocessors, digital signal processors (DSPs), programmable controllers, application specific integrated circuits (ASICs), field programmable gate arrays (FPGAs), programmable logic controllers (PLCs), other similar devices, or a combination of the devices to load and execute the program stored in the storage device 14, so as to execute the method for equipment anomaly detection of the embodiment of the disclosure.
In Step S202, the processor 16 of the apparatus for equipment anomaly detection 10 acquires multiple signals of the equipment 20 during normal operation in advance by using the data acquisition device 12 to train a machine learning model. Taking a motor of a robotic arm as an example, the processor 16 may acquire voltage signals and current signals of the motor of the robotic arm during normal operation, but not limited thereto. In other embodiments, the processor 16 may also acquire a sound signal, a vibration signal, or other signals of the motor of the robotic arm during normal operation, which is not limited thereto.
In Step S204, the processor 16 acquires a real-time signal of the equipment 20 during a current operation by using the data acquisition device 12. The equipment 20 is, for example, a source equipment of the signal acquired during the previous training of the machine learning model or an equipment of the same type as the source equipment, which is not limited thereto. In other words, the trained machine learning model may be used to detect an operation state of the equipment of the same type.
In Step S206, the processor 16 inputs the acquired real-time signal to the machine learning model to output a detection result indicating a current operation state of the equipment 20. In the embodiment, a large number of signals of the equipment 20 during normal operation are collected to train the machine learning model, so even in the absence of a signal of an anomaly of the equipment 20, the machine learning model can distinguish the anomaly of the equipment 20, so as to achieve the effect of intelligent pre-diagnosis.
In some embodiments, the machine learning model is formed by connecting an encoder composed of an neural network to an outlier detection model (ODM). The outlier detection model is, for example, a one-class support vector machine (OCSVM), an isolation forest, a local outlier factor (LOF), etc., but not limited thereto.
The processor 16, for example, inputs the real-time signal of the equipment 20 during the current operation acquired by the data acquisition device 12 to a trained encoder, and the encoder performs feature extraction and dimension reduction on the input signal to output compressed representation data of the signal. Then, the processor 16 inputs the compressed representation data to the trained outlier detection model to distinguish the current operation state of the equipment 20 and output the detection result.
For example,
The encoder 32 and the outlier detection model are both pre-trained. For example, the encoder is trained first, and the outlier detection model is then trained.
For example,
Please refer to
Through the above method, in the embodiment of the disclosure, the easily collected time-domain signal of the equipment in the normal operation state is used to train the machine learning model, and there is no need to collect or use equipment anomaly data. Therefore, the issue of poor prediction performance caused by unbalanced data categories can be solved.
In the embodiment, the time-domain signal is used to train the machine learning model which is used to distinguish the current operation state of the equipment. In other embodiments, the disclosure may also use frequency-domain signals to train the machine learning model or simultaneously use the time-domain and frequency-domain signals to train the machine learning model and to distinguish the current operation state of the equipment, which can also achieve the intelligent pre-diagnosis.
For example,
The apparatus for equipment anomaly detection inputs the currently acquired frequency-domain signal 51 to a trained frequency-domain encoder 52, and the frequency-domain encoder 52 performs feature extraction and dimension reduction on the frequency-domain signal 51 to output compressed representation data 53 of the signal 51. Then, the apparatus for equipment anomaly detection inputs the compressed representation data 53 to a trained outlier detection model 54 to distinguish a current operation state of the equipment and to output a detection result 55. For example, when the current operation state of the equipment is distinguished to be normal, the detection result 55 of logic 0 is output, and when the current operation state of the equipment is distinguished to be abnormal, the detection result 55 of logic 1 is output.
Similar to the embodiment in
For example,
Please refer to
Through the above method, in the embodiment of the disclosure, the easily collected frequency-domain signal of the equipment in the normal operation state is used to train the machine learning model, and there is no need to collect or use equipment anomaly data. Therefore, the issue of poor machine learning effect caused by data imbalance can be solved.
On the other hand,
The apparatus for equipment anomaly detection inputs the currently acquired time-domain signal 71a to a trained time-domain encoder 72a, and the time-domain encoder 72a performs feature extraction and dimension reduction on the time-domain signal 71a to output compressed representation data 73a of the time-domain signal 71a. In addition, the apparatus for equipment anomaly detection also inputs the currently acquired frequency-domain signal 71b to a trained frequency-domain encoder 72b, and the frequency-domain encoder 72b performs feature extraction and dimension reduction on the frequency-domain signal 71b to output compressed representation data 73b of the frequency-domain signal 71b. Then, the apparatus for equipment anomaly detection concatenates the compressed representation data 73a of the time-domain signal 71a and the compressed representation data 73b of the frequency-domain signal 71b into compressed representation data 73, and inputs the compressed representation data 73 to a trained outlier detection model 74 to distinguish a current operation state of the equipment and output a detection result 75. For example, when the current operation state of the equipment is distinguished to be normal, the detection result 75 of logic 0 is output, and when the current operation state of the equipment is distinguished to be abnormal, the detection result 75 of logic 1 is output.
Similar to the embodiments in
Different from the foregoing embodiments, in the apparatus for equipment anomaly detection of the embodiment, weights in the trained time-domain encoder and the frequency-domain encoder are fixed and connected the outlier detection model to train the outlier detection model.
Through the above method, in the embodiment of the disclosure, the easily collected time-domain signal and frequency-domain signal of the equipment in the normal operation state are used to train the machine learning model, and there is no need to collect or use equipment anomaly data. Therefore, the issue of low performance of machine learning caused by imbalanced data can be solved.
Table 1 below shows an accuracy comparison table of a machine learning model trained by adopting time-domain signals (hereinafter referred to as a time-domain model), a machine learning model trained by adopting frequency-domain signals (hereinafter referred to as a frequency-domain model), and a machine learning model trained by simultaneously adopting time-domain signals and frequency-domain signals (hereinafter referred to as a hybrid model). In the embodiment, the outlier detection model is one-class support vector machine (OCSVM), but is not limited thereto. It can be seen from Table 1 that for prediction through the time-domain model of the embodiment of the disclosure, the inference accuracy of normal signals is 99.87% and the inference accuracy of abnormal signals is 91.68%; for prediction through the frequency-domain model of the embodiment of the disclosure, the inference accuracy of normal signals is 93.98% and the inference accuracy of abnormal signals is 100.0%; however, for prediction through the hybrid model of the embodiment of the disclosure, the inference accuracy of normal signals is 99.04% and the inference accuracy of abnormal signals is 100.0%. In other words, for prediction through the hybrid model trained by simultaneously adopting the time-domain signals and the frequency-domain signals, the normal and abnormal signals can both be predicted with better accuracy.
In some embodiments, the data acquisition device 12 in the apparatus for equipment anomaly detection 10 includes, for example, a charge coupled device (CCD), a complementary metal-oxide semiconductor (CMOS) element or cameras of other types of photosensitive elements for acquiring an appearance image of an equipment to be detected. In other embodiments, the data acquisition device 12 is, for example, an interface such as a universal serial bus (USB), RS232, Bluetooth (BT), wireless fidelity (Wi-Fi), and other wired or wireless transmission interfaces for connecting to a camera to receive the appearance image of the equipment acquired by the camera. The embodiment of the disclosure does not limit the type and the function of the data acquisition device 12.
The processor 16 of the apparatus for equipment anomaly detection 10, for example, inputs a current image of the equipment acquired by the data acquisition device 12 into a trained encoder, and the encoder performs feature extraction and dimension reduction on the current image, so as to output a compressed representation data of the image. Then, the processor 16 inputs the compressed representation data into a trained outlier detection model to distinguish a current state of the appearance of the equipment 20 and output a detection result.
For example,
The encoder and the outlier detection model are both pre-trained. For example, the encoder is trained first, and the outlier detection model is then trained.
For example,
Please refer to
Through the above method, in the embodiment of the disclosure, the machine learning model is trained by using the easily collected appearance images when the equipment appearance is normal without the need to collect or use data of abnormal equipment appearance. Therefore, the issue of the low accuracy of the machine learning model caused by unbalanced data categories can be solved.
In the embodiment, the image is used to train the machine learning model and is used to distinguish the current appearance state of the equipment. In other embodiments, the disclosure may also use the image frequency-domain signal to train the machine learning model or simultaneously use the image and the image frequency-domain signal to train the machine learning model and to distinguish the current appearance state of the equipment, which can also achieve the intelligent pre-diagnosis.
For example,
The apparatus for equipment anomaly detection inputs the transformed two-dimensional image frequency-domain signal 111a into a trained image frequency-domain encoder 112. The image frequency-domain encoder 112 performs feature extraction and dimension reduction on the two-dimensional image frequency-domain signal 111a to output compressed representation data 113 of the signal. Then, the apparatus for equipment anomaly detection inputs the compressed representation data 113 into a trained outlier detection model 114 to distinguish a current appearance state of the equipment and output a detection result 115. For example, when the current state of the equipment appearance is distinguished to be normal, the detection result 115 of logic 0 is output, and when the current state of the equipment appearance is distinguished to be abnormal, the detection result 115 of logic 1 is output.
The same as the embodiment of
For example,
Please refer to
Through the above method, in the embodiment of the disclosure, the machine learning model is trained by using the easily collected appearance images (transformed into the two-dimensional image frequency-domain signals) when the appearance state is normal without the need to collect or use data of abnormal equipment appearance. Therefore, the issue of the low accuracy of the machine learning model caused by unbalanced data categories can be solved.
On the other hand,
The apparatus for equipment anomaly detection inputs the current appearance image 131a of the equipment into a trained image encoder 132a, and the image encoder 132a performs feature extraction and dimension reduction on the appearance image 131a to output compressed representation data 133a of the appearance image 131a. In addition, the apparatus for equipment anomaly detection also inputs the two-dimensional image frequency-domain signal 131b into a trained image frequency-domain encoder 132b, and the image frequency-domain encoder 132b performs feature extraction and dimension reduction on the two-dimensional image frequency-domain signal 131b to output compressed representation data 133b of the two-dimensional image frequency-domain signal 131b. Then, the apparatus for equipment anomaly detection splices the compressed representation data 133a of the appearance image 131a and the compressed representation data 133b of the two-dimensional image frequency-domain signal 131b into compressed representation data 133, and inputs the compressed representation data 133 into a trained outlier detection model 134 to distinguish a current appearance state of the equipment and output a detection result 135. For example, when the current state of the equipment appearance is distinguished to be normal, the detection result 135 of logic 0 is output, and when the current state of the equipment appearance is distinguished to be abnormal, the detection result 135 of logic 1 is output.
The same as the embodiments of
Different from the foregoing embodiments, in the apparatus for equipment anomaly detection of the embodiment, weights in the trained image encoder and the image frequency-domain encoder are fixed and the outlier detection model is connected to train the outlier detection model.
Through the above method, in the embodiment of the disclosure, the machine learning model is trained by using the appearance images when the equipment appearance is not damaged and the transformed two-dimensional image frequency-domain signal without the need to collect or use data when the equipment appearance is damaged. Therefore, the issue of the low accuracy of the machine learning model caused by unbalanced data categories can be solved.
Table 2 below is an accuracy comparison table of a machine learning model adopting image training (hereinafter referred to as an image model), a machine learning model adopting two-dimensional image frequency-domain signal training (hereinafter referred to as an image frequency-domain model), and a machine learning model simultaneously adopting image signal and two-dimensional image frequency-domain signal training (hereinafter referred to as a hybrid model) according to an embodiment of the disclosure. In the embodiment, the outlier detection model is a one-class support vector machine (OCSVM) model, but not limited thereto. It can be seen from Table 2 that for prediction through the image model of the embodiment of the disclosure, the inference accuracy of normal images is 94.00% and the inference accuracy of abnormal images is 80.00%; for prediction through the two-dimensional image frequency-domain model of the embodiment of the disclosure, the inference accuracy of normal images is 89.50% and the inference accuracy of abnormal images is 100.0%; however, for prediction through the hybrid model of the embodiment of the disclosure, the inference accuracy of normal images is 95.75% and the inference accuracy of abnormal images is 100.00%. In other words, for prediction by the hybrid model simultaneously adopting image and two-dimensional image frequency-domain signal training, better accuracy can be obtained in the prediction of both normal and abnormal signals.
In Step S1502, the processor 16 of the apparatus for equipment anomaly detection 10 acquires multiple appearance images of the equipment 20 when the appearance is not damaged by using the data acquisition device 12 to be used to train a machine learning model stored in the storage device 14. In some embodiments, the machine learning model is formed by connecting an encoder composed of a neural network to an outlier detection model. The outlier detection model is, for example, a one-class support vector machine, an isolation forest, a local outlier factor, etc., but not limited thereto.
In Step S1504, the processor 16 acquires a current image of the appearance of the equipment 20 by using the data acquisition device 12.
In Step S1506, the processor 16 inputs the acquired current image into the machine learning model to output a detection result indicating a current state of the appearance of the equipment 20. In the embodiment, a large number of images of the equipment 20 when the appearance is not damaged is collected and used to train the machine learning model, so that even in the absence of images of the equipment 20 when the appearance is damaged, the machine learning model can still distinguish the abnormal state of the appearance of the equipment 20 by itself, thereby achieving the objective of intelligent pre-diagnosis.
In summary, the method and the apparatus for equipment anomaly detection according to the embodiments of the disclosure can distinguish the anomaly in function or equipment appearance through sensing and collecting a large amount of data of the equipment during normal operation or images when the appearance is not damaged to train the machine learning model, so as to achieve the goal of intelligent pre-diagnosis for equipment. The machine learning model of the embodiments of the disclosure can perform comprehensive prediction in conjunction with the image and image frequency-domain features of the signals to obtain better accuracy. Through storing the trained machine learning model in the apparatus for equipment anomaly detection and acquiring the current appearance image of the equipment, anomaly detection can be performed, thereby implementing edge computing and intelligent pre-diagnosis.
Although the disclosure has been disclosed in the above embodiments, the embodiments are not intended to limit the disclosure. Persons skilled in the art may make some changes and modifications without departing from the spirit and scope of the disclosure. Therefore, the protection scope of the disclosure shall be defined by the appended claims.
Number | Date | Country | Kind |
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111122909 | Jun 2022 | TW | national |
111148853 | Dec 2022 | TW | national |
This application claims the priority benefit of U.S. provisional application Ser. No. 63/341,426, filed on May 13, 2022, Taiwan application serial no. 111122909, filed on Jun. 20, 2022, and Taiwan application serial no. 111148853, filed on Dec. 20, 2022. The entirety of each of the above-mentioned patent applications is hereby incorporated by reference herein and made a part of this specification.
Number | Date | Country | |
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63341426 | May 2022 | US |