INDUSTRIAL ASSET TEMPORAL ANOMALY DETECTION WITH FAULT VARIABLE RANKING

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First Claim
1. A method of temporal anomaly detection, the method comprising:
 accessing sensor data readings obtained at a monitored industrial asset;
performing a data cleanup operation on at least a portion of the accessed sensor data readings;
transforming at least the cleanedup portion of the accessed sensor data readings to time series feature space sensor data;
applying a multikernelbased projection algorithm to the time series feature space sensor data;
computing a respective anomaly score and a respective ranking for one or more variables of the sensor data readings; and
providing at least the computed respective anomaly score or the respective ranking for at least one of the one or more variables to a user.
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Abstract
A method of temporal anomaly detection includes accessing sensor data readings obtained at a monitored industrial asset, performing a data cleanup operation on at least a portion of the accessed sensor data readings, transforming at least the cleanedup portion of the accessed sensor data readings to time series feature space sensor data, applying a multikernelbased projection algorithm to the time series feature space sensor data, computing a respective anomaly score and a respective ranking for one or more variables of the sensor data readings, and providing at least the computed respective anomaly score or the respective ranking for at least one of the one or more variables to a user. Ranking the anomaly score includes comparing each anomaly score to a threshold and then assigning a ranking to scores with a magnitude greater than the threshold based on its magnitude. A system and a nontransitory computerreadable medium are also disclosed.
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15 Claims
 1. A method of temporal anomaly detection, the method comprising:
accessing sensor data readings obtained at a monitored industrial asset; performing a data cleanup operation on at least a portion of the accessed sensor data readings; transforming at least the cleanedup portion of the accessed sensor data readings to time series feature space sensor data; applying a multikernelbased projection algorithm to the time series feature space sensor data; computing a respective anomaly score and a respective ranking for one or more variables of the sensor data readings; and providing at least the computed respective anomaly score or the respective ranking for at least one of the one or more variables to a user.  View Dependent Claims (2, 3, 4, 5)
 6. A nontransitory computerreadable medium having stored thereon instructions which when executed by a control processor cause the control processor to perform a method of temporal anomaly detection, the method comprising:
accessing sensor data readings obtained at a monitored industrial asset; performing a data cleanup operation on at least a portion of the accessed sensor data readings; transforming at least the cleanedup portion of the accessed sensor data readings to time series feature space sensor data; applying a multikernelbased projection algorithm to the time series feature space sensor data; computing a respective anomaly score and a respective ranking for one or more variables of the sensor data readings; and providing at least the computed respective anomaly score or the respective ranking for at least one of the one or more variables to a user.  View Dependent Claims (7, 8, 9, 10)
 11. A system for temporal anomaly detection, the system comprising:
a control processor in communication with a data store across an electronic communication network, the control processor including a processor unit; the data store including executable instructions and sensor data records representing monitored conditions of one or more components of an industrial asset; the executable instructions when executed by the processor unit cause the processor unit to perform a method, the method comprising; accessing sensor data readings obtained at a monitored industrial asset; performing a data cleanup operation on at least a portion of the accessed sensor data readings; transforming at least the cleanedup portion of the accessed sensor data readings to time series feature space sensor data; applying a multikernelbased projection algorithm to the time series feature space sensor data; computing a respective anomaly score and a respective ranking for one or more variables of the sensor data readings; and providing at least the computed respective anomaly score or the respective ranking for at least one of the one or more variables to a user.  View Dependent Claims (12, 13, 14, 15)
1 Specification
Effective datadriven analytics is possible using advancements in sensor technologies and networked industrial machinery design. Industrial assets often have multiple sensors monitoring operation. With connection to the Internet of Things (IoT), access to the sensor data can be obtained in data streams at almost real time. This increasing availability of streaming time series data can have a practical purpose in detecting anomalies in the operation of the industrial asset.
An industrial asset can be, among other things and without limitation, a generator, gas turbine, power plant, manufacturing equipment on a production line, aircraft engine, wind turbine generator, locomotive, imaging device (e.g., Xray, MRI, CT, PET, SPECT systems), or mining operation drilling equipment. Each instance of a time series data set is recorded at a certain timestamp of an asset. An event is a failure case that happens at a certain timestamp within the time series data.
An anomaly in the time series data can indicate a change in the industrial asset'"'"'s status (e.g., a change in turbine rotation). Identification of the anomaly can be beneficial in predicting faults and/or updating maintenance schedules.
Embodying systems and methods provide detection of temporal anomaly(ies) in multivariate time series data. An embodying temporal anomaly detection (TAD) algorithm can be an unsupervised, highdimensional detector that incorporates manifold learning and provides kernel construction options. An embodying TAD algorithm can provide an anomaly score for each input sample, and also a corresponding feature/variable ranking.
A temporal anomaly can be difficult to detect, but the temporal anomaly can serve as an early warning that there could be an underlying problem with the industrial asset. An embodying TAD algorithm can provide an anomaly score for each input sample (stream of sensor data). The anomaly score is indicative of the likelihood of the corresponding sample being the anomaly—for example, a higher anomaly score makes it more likely of a sample being the anomaly source. It should be readily understood that the invention is not so limited, and that other scales can be applied to the anomaly score.
In accordance with embodiments, along with an anomaly score, an embodying TAD algorithm can support further decisionmaking by performing root cause analysis. Also, the TAD algorithm can provide a corresponding feature/variable ranking, which can rank the most contributing feature(s) to the detected anomaly(ies).
An embodying TAD algorithm can have one or more of the following characteristics:
(1) Unsupervised: Anomaly detection can be unsupervised (i.e., no anomaly label is required). In this implementation, the algorithm can detect those anomalies that are not wellunderstood or quantified. The algorithm'"'"'s training set is assumed to be normal. The training set need not be purely normal, as long as the abnormality in the training data represents a small portion. Any samples with strongly deviated pattern in a testing set would be assigned a high anomaly score.
(2) Highdimensional: In this implementation there is an assumption that on the occurrence of an anomaly (e.g., component failure), an anomalous pattern appears in the time series data for multiple variables simultaneously. This approach can be effective when there are a lot of possiblyrelated variables to the anomalies. The algorithm can effectively detect anomalous patterns from a large number of input tags (raw variables or derived variables), where input data dimensions can be voluminous (e.g., hundreds or perhaps thousands).
(3) Multikernels: The algorithm can operate with the selection of differing options of kernel construction. The algorithm can include more than one kernel to measure the degree of anomaly, which can not only built upon Euclidean space (e.g. Gaussian kernel), but also other linear and nonlinear kernel space.
Options of kernel construction can include, but are not limited to, “braycurtis”, “Canberra”, “Chebyshev”, “cityblock”, “correlation”, “cosine”, “dice”, “euclidean”, “hamming”, “jaccard”, “kulsinski”, “mahalanobis”, “matching”, “minkowski”, “rogerstanimoto”, “russellrao”, “euclidean”, “sokalmichener”, “sokalsneath”, “sqeuclidean”, “yule”. The kernel selection can depend on differentiability of the data in that kernel space. The distribution of training dataset (which can be normal or near normal) should be differentiable in the selected kernel space.
The raw sensor reading data variables can be transformed, step 115, to time series features (transformed variables) using temporal feature engineering techniques. In some implementations, feature transformation is calculated with a slidingwindow with a certain length l. Although not limiting, two types of feature transformations can be: univariate and pairwise. The input is vector b related to one/two raw features, with length(b)=l. The output is one scalar which describes the statistics of b in a certain way.
Given a timeseries vector b ∈ R^{l×1}, the following univariate feature transformation options can include: Movingaverage: mean(b); Standard deviation: std(b); Levelshift: lsf(b)=max(b)−min(b); Autocorrelation: autocorr(b); Standard deviation of delta: sdn(b)=std(diff(b)); Vibration degree: vbr(b)=std(b)×sdn(b); and Spike:
For the a two dimensional timeseries vector b ∈R^{l×2}, the following pairwise feature transformation options can include: Covariance: cov(b)=covariance (b_{:,1}, b_{:,2}); and Correlation: crl(b)=correlation(k_{:,1}, b_{:,2}). The transformed data set can be projected, step 120, onto a low embedding space using multikernelbased projection method(s).
The training data set can be expresses as X_{trn }∈ R^{n1×m }and the testing data set as X_{tst }∈ R^{n2×m}, where n1 (n2) is the number of training (or testing) samples, and m is the number of transformed features. The number of low embedding kernels is represented by k. MKP algorithm 200 can provide an anomaly score output s ∈ R^{n2×1 }for the testing data set.
A similarity matrix (A_{1:t}=[A_{1}, A_{2}, . . . , A_{t}] for X_{trn}) is constructed, step 210; where t is the number of the chosen kernel options and A_{i }∈ R^{n1×n1 }is the similarity matrix based on each kernel (1≤i≤t). For each element of the similarity matrix (A_{i }in A_{1:t}), a projection matrix is calculated, step 215.
Calculation of the projection matrix includes first, calculating
L_{i}=D_{i}−A_{i } (EQ. 1)
where D_{i }is the degree matrix of A_{i}; then, calculating top k eigenvectors Ψ_{i }∈ R^{n1×k }with the smallest eigenvalues
λ_{i }∈ R^{1×k }of L_{i } (EQ. 2)
The projection matrix can then be calculated as
P_{i }∈ R^{m×k } (EQ. 3)
from L_{i }to ψ_{i }using elastic net regression.
After a projection matrix is calculated for each element of the similarity matrix, step 220, the MKP algorithm proceeds. The MKP algorithm follows steps 225235 to calculate projected embeddings and an anomaly score matrix.
At step 225, for each element in the projection matrix (P_{i}), projected embeddings are calculated by applying each P_{i }to X_{tst }to get the projected embeddings
ϕ_{i }∈ R^{n2×k } (EQ. 4)
Corresponding elements of an anomaly score matrix are calculated, step 230, and can be expressed as
S_{i,j}=Σ_{p}e^{−λ}^{i,p}ϕ_{i }(j,p) (EQ. 5)
where j is the index of testing sample, p is the index of eigenvector/eigenvalue.
The projected embeddings and corresponding anomaly score matrix elements are calculated for all elements of the projection matrix, step 235. Once all elements are calculated, a final anomaly score vector (s by s_{j}=Σ_{i }S_{i,j}; where j is the index of each testing sample) is computed, step 240. The anomaly score is calculated by measuring the neighborhood density of each sample in the low embedding space. The results of MKP algorithm 200 are returned to TAD algorithm 100.
With reference again to
The data store can include sensor data records 326 that contain operational data monitored by sensor suite 355 in industrial asset 350. Only one industrial asset is depicted, however, there can be multiple industrial assets each including sensor suites that provide monitored data across electronic communication network 340 to data store 320. The data store can also include TAD algorithm 324, MKP algorithm 330, training data set 330, and testing data set 332.
In some embodiments, the anomaly score and variable ranking outputs of TAD algorithm 100 (step 125) can be presented graphically.
TAD output curve 410 represents monitored sensor data over a time period from a single sensor. This output curve depicts the data in time series feature space after processing by TAD algorithm 100. Failure spike 440 represents a failure in an industrial asset (e.g., a lean blowout (LBO) in a turbine generator). Operator effect spike 450 indicates failure propagation.
Alert spike 430, 432 each represent a failure event in the industrial asset. These spikes occur at different times, and each exceeds user predefined threshold 420. Analysis of TAD output curve 420 shows that before the LBO occurrence, the TAD algorithm successfully detected a problem(s) prior to the occurrence of the failure event. This early detection can provide a possibility for any early response to prevent failure events and their subsequent failure propagation.
In accordance with some embodiments, a computer program application stored in nonvolatile memory or computerreadable medium (e.g., register memory, processor cache, RAM, ROM, hard drive, flash memory, CD ROM, magnetic media, etc.) may include code or executable program instructions that when executed may instruct and/or cause a controller or processor to perform methods discussed herein such as a method of temporal anomaly detection and fault analysis, as disclosed above.
The computerreadable medium may be a nontransitory computerreadable media including all forms and types of memory and all computerreadable media except for a transitory, propagating signal. In one implementation, the nonvolatile memory or computerreadable medium may be external memory.
Although specific hardware and methods have been described herein, note that any number of other configurations may be provided in accordance with embodiments of the invention. Thus, while there have been shown, described, and pointed out fundamental novel features of the invention, it will be understood that various omissions, substitutions, and changes in the form and details of the illustrated embodiments, and in their operation, may be made by those skilled in the art without departing from the spirit and scope of the invention. Substitutions of elements from one embodiment to another are also fully intended and contemplated. The invention is defined solely with regard to the claims appended hereto, and equivalents of the recitations therein.