System and method for signal prediction
First Claim
1. A system for identifying trends of fault occurrences in a manufacturing process, the system including computer-readable medium tangibly embodying computer-executable instructions for:
- receiving a plurality of data series and input parameters, the input parameters comprising a time step parameter, said data series including discrete data elements that identify the fault occurrences in the manufacturing process;
preprocessing the plurality of data series according to the input parameters, to form binned and classified data series, where the discrete data elements in each of the data series are classified into a particular bin depending on when they occurred per the time parameter, wherein preprocessing the plurality of data series includes clustering the classified data series to iteratively arrange the data elements into clusters to provide a predetermined criteria, and wherein preprocessing the plurality of data series includes classifying the data elements that identify the fault occurrences according to frequency of occurrence, mean time to repair and/or duration of downtime and selecting the most frequently occurring fault occurrences and/or the fault occurrences resulting in the longest downtime duration;
processing the binned and classified data series, the processing comprising;
initializing a model for trend prediction including determining the number of known states in the model based on the data series and associating a state of the model for each class of data determined by the binned and classified data series;
training the model for trend prediction of the binned and classified data series to form a trained model, said model being trained to predict trends of the data series by determining the probability of states of the data as classified and binned and the probability of transition of the data from state to state where the state probabilities are calculated for the data series by evaluating a probability in a training window, wherein training the model includes training the model to predict the frequency of occurrence, the mean time to repair and/or the downtime duration of the fault occurrences, using the model to predict frequency and/or duration of the fault occurrences during a testing period that immediately succeeds a training period of the model to identify trend predictions of the fault occurrences, and evaluating the accuracy of the trend predictions by comparing the trend predictions during the testing period with actual data obtained during the testing period; and
deploying the trained model for trend prediction in the manufacturing process, the deploying comprising;
outputting trend predictions that identify predictions of fault occurrences that may occur during the manufacturing process; and
updating training of the model when new data is obtained during the manufacturing process.
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Abstract
Disclosed herein are a system and method for trend prediction of signals in a time series using a Markov model. The method includes receiving a plurality of data series and input parameters, where the input parameters include a time step parameter, preprocessing the plurality of data series according to the input parameters, to form binned and classified data series, and processing the binned and classified data series. The processing includes initializing a Markov model for trend prediction, and training the Markov model for trend prediction of the binned and classified data series to form a trained Markov model. The method further includes deploying the trained Markov model for trend prediction, including outputting trend predictions. The method develops an architecture for the Markov model from the data series and the input parameters, and disposes the Markov model, having the architecture, for trend prediction.
26 Citations
20 Claims
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1. A system for identifying trends of fault occurrences in a manufacturing process, the system including computer-readable medium tangibly embodying computer-executable instructions for:
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receiving a plurality of data series and input parameters, the input parameters comprising a time step parameter, said data series including discrete data elements that identify the fault occurrences in the manufacturing process; preprocessing the plurality of data series according to the input parameters, to form binned and classified data series, where the discrete data elements in each of the data series are classified into a particular bin depending on when they occurred per the time parameter, wherein preprocessing the plurality of data series includes clustering the classified data series to iteratively arrange the data elements into clusters to provide a predetermined criteria, and wherein preprocessing the plurality of data series includes classifying the data elements that identify the fault occurrences according to frequency of occurrence, mean time to repair and/or duration of downtime and selecting the most frequently occurring fault occurrences and/or the fault occurrences resulting in the longest downtime duration; processing the binned and classified data series, the processing comprising; initializing a model for trend prediction including determining the number of known states in the model based on the data series and associating a state of the model for each class of data determined by the binned and classified data series; training the model for trend prediction of the binned and classified data series to form a trained model, said model being trained to predict trends of the data series by determining the probability of states of the data as classified and binned and the probability of transition of the data from state to state where the state probabilities are calculated for the data series by evaluating a probability in a training window, wherein training the model includes training the model to predict the frequency of occurrence, the mean time to repair and/or the downtime duration of the fault occurrences, using the model to predict frequency and/or duration of the fault occurrences during a testing period that immediately succeeds a training period of the model to identify trend predictions of the fault occurrences, and evaluating the accuracy of the trend predictions by comparing the trend predictions during the testing period with actual data obtained during the testing period; and deploying the trained model for trend prediction in the manufacturing process, the deploying comprising; outputting trend predictions that identify predictions of fault occurrences that may occur during the manufacturing process; and updating training of the model when new data is obtained during the manufacturing process. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8)
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9. A system for identifying trends of fault occurrences in a manufacturing process with a Markov model, the system comprising:
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a plurality of modules wherein each module includes non-transitory computer-readable medium with an executable program stored thereon, the plurality of modules including; an input module configured to receive a plurality of data series and input parameters; a sort module configured to sort the plurality of data series to form a sorted plurality of data series, said data series including discrete data elements that identify the fault occurrences in the manufacturing process; a selection module configured to select data series from the sorted plurality of data series to form selected data series; a class development module configured to develop a plurality of classes from the selected data series and input parameters; and a binning and classification module configured to bin and classify the selected data series according to an input parameter and the plurality of classes, where the discrete data elements in each of the data series are classified into a particular bin depending on when they occurred, wherein the binning and classification module clusters the classified data series to iteratively arrange the data elements into clusters to meet a predetermined criteria, and wherein classifying the selected data series includes identifying the fault occurrences according to frequency of occurrence, mean time to repair and/or duration of downtime and selecting the most frequently occurring fault occurrences and/or the fault occurrences resulting in the longest downtime duration; a Markov model initialization module configured to initialize the Markov model for trend prediction including determining the number of known states in the Markov model based on the data series and associating a state of the Markov model for each class of data determined by the binned and classified data series; a Markov model training module configured to train the Markov model for trend prediction of the binned and classified data series to form a trained Markov model, said Markov model being trained to predict trends of the data series by determining the probability of states of the data as classified and binned and the probability of the transition of data from state to state where the state probabilities are calculated for the data series by evaluating a probability in a training window, wherein training the Markov model includes training the model to predict the frequency of occurrence, the mean time to repair and/or the downtime duration of the fault occurrences, using the model to predict frequency and/or duration of the fault occurrences during a testing period immediately succeeding a training period of the model, and evaluating the accuracy of the trend predictions by comparing the trend predictions during the testing period with actual data obtained during the testing period; an output module configured to output trend predictions upon deployment of the trained Markov model that identify predictions of fault occurrences that may occur during the manufacturing process; and updating the training of the model when new data is obtained during the manufacturing process. - View Dependent Claims (10, 11, 12, 13)
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14. A system for identifying trends of fault occurrences in a manufacturing process, the system including computer-readable medium tangibly embodying computer-executable instructions for:
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receiving a data series and input parameters, said data series including discrete data elements that identify the fault occurrences in the manufacturing process; classifying the discrete data elements in each of the data series into a predetermined bin depending on when they occurred, wherein classifying the discrete data elements of data series includes clustering the classified data series to iteratively arrange the data elements into clusters to meet a predetermined criteria, and wherein classifying the discrete data elements includes classifying the fault occurrences according to frequency of occurrence, mean time to repair and/or duration of downtime and selecting the most frequently occurring fault occurrences and/or the fault occurrences resulting in the longest downtime duration; developing an architecture for a Markov model from the data series and the input parameters including determining the number of known states in the Markov model based on the data series and associating a state of the Markov model for each class of data determined by the binned and classified data series, wherein developing an architecture for a Markov model includes training the model to predict the frequency of occurrence, the mean time to repair and/or the downtime duration of the fault occurrences, using the model to predict frequency and/or duration of the fault occurrences during a testing period immediately succeeding a training period of the model, and evaluating the accuracy of the trend predictions by comparing the trend predictions during the testing period with actual data obtained during the testing period; disposing a Markov model having the architecture for trend prediction, said Markov model being trained to predict trends of the data series by determining the probability of states of the data as classified and binned and the probability of the transition of data from state to state where the state probabilities are calculated for the data series by evaluating a probability in a training window that identify predictions of fault occurrences that may occur during the manufacturing process; and updating the training of the model when new data is obtained during the manufacturing process. - View Dependent Claims (15, 16, 17, 18, 19, 20)
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Specification