Intelligent approach for the industrialization of deep learning solutions applied to fault detection

Abstract

Early fault detection, both in equipment and the products in process, is of paramount importance in industrial processes to ensure the quality of the final product, avoid abnormal operating conditions, expensive repairs, and even production process shutdown. The growing complexity of industrial systems and the increase in the amount of available data have encouraged the development of intelligent systems for automatic fault prediction/detection, mainly based on Industry 4.0 technologies and, particularly, those based on deep learning methodologies. However, the vast majority of proposals and research carried out to date define specific solutions for specific cases, which still requires a high level of expert knowledge for scaling the solutions to industrial environments. Actually, one of the major issues towards the industrialization of deep learning solutions is the determination of the optimal, or near-optimal, hyper-parameters. In this paper, we propose a low-level set-up effort intelligent failure detection system that integrates deep neural networks with a Bayesian Optimization algorithm for self-tuning of the system hyper-parameters. In addition, to facilitate the industrialization of the proposal and its incorporation into current industrial systems, we embedded the proposal in our previously formulated and tested Simulai architecture which allows for containing and interaction with multiple and heterogeneous technological components of manufacturing processes. Finally, our proposal is tested in two real cases of a different nature. The obtained results show a successful performance and demonstrate the easy online integration and interaction in a real production system.