Deep Learning of Complex Batch Process Data and Its Application on Quality Prediction

Abstract

Batch process quality prediction is an important application in manufacturing and chemical industries. The complexity of batch processes is characterized by multiphase, nonlinearity, dynamics, and uneven durations so that modeling of these batch processes is rather difficult. Moreover, there are other challenges in the face of quality prediction. Specifically, the process trajectories over the whole running duration potentially make specific contributions to the final targets so that the prediction issue embraces tremendously high-dimensional inputs but very low-dimensional outputs. This means that the prediction suffers from a severe dimensional imbalance between inputs and outputs. Motivated by these difficulties, this paper proposes a new deep learning-based framework for complex feature representative and quality prediction. Long short-term memory (LSTM) is used to extract comprehensive quality-relevant hidden features from a long-time sequence in each phase, significantly reducing the predictor dimensions. And these features from different phases are further integrated and compressed by a stacked auto-encoder (SAE). A practical industrial example testifies to the efficacy of the proposed framework.