<p>In high-temperature manufacturing, operators must reach a target state <InlineEquation ID="IEq1"> <EquationSource Format="TEX">\((T^*,P^*)\)</EquationSource> </InlineEquation> under safety, defect-risk, and energy constraints, while accounting for the fact that once active pressurization stops, continued heating induces thermal expansion that <i>passively</i> raises pressure. Thus, the most critical and low-cost decision is <i>when to stop pressurization</i>: ideally, <InlineEquation ID="IEq2"> <EquationSource Format="TEX">\((T^*,P^*)\)</EquationSource> </InlineEquation> is achieved by heating alone without over- or under-pressurization; however, rule-of-thumb decisions are difficult to audit and often unstable. We propose an <i>interpretable deep learning</i> approach that reduces reliance on operator experience. Using a small, physics-aligned feature set—current temperature/pressure, recent temperature slope <InlineEquation ID="IEq3"> <EquationSource Format="TEX">\(k_T=\textrm{d}T/\textrm{d}t\)</EquationSource> </InlineEquation> [<InlineEquation ID="IEq4"> <EquationSource Format="TEX">\(^{\circ}\text {Cs}^{-1}\)</EquationSource> </InlineEquation>], and gaps to <InlineEquation ID="IEq5"> <EquationSource Format="TEX">\((T^*,P^*)\)</EquationSource> </InlineEquation>—we train a lightweight soft sensor to predict the expansion-phase pressure-rise slope <InlineEquation ID="IEq6"> <EquationSource Format="TEX">\(\hat{k}_P\)</EquationSource> </InlineEquation> [<InlineEquation ID="IEq7"> <EquationSource Format="TEX">\(\hbox {kPa}\,\hbox {s}^{-1}\)</EquationSource> </InlineEquation>] after stopping. Coupled with a three-phase efficiency model (slower just after stopping, faster in the mid phase, slower near the target), we compute an effective time <InlineEquation ID="IEq8"> <EquationSource Format="TEX">\(\Delta t_{\textrm{eff}}\)</EquationSource> </InlineEquation> to extrapolate pressure at <InlineEquation ID="IEq9"> <EquationSource Format="TEX">\(T^*\)</EquationSource> </InlineEquation> and trigger stopping via a transparent “tolerance + <i>M</i>-consecutive-frames” rule. We evaluate on industrial data with train/validation/test splits by run ID. In replay analyses, the same-actual-stop evaluation achieves 93.75% coverage (15/16 runs) under a 5% relative tolerance, with a mean absolute pressure error of <InlineEquation ID="IEq10"> <EquationSource Format="TEX">\(2.44\pm 2.09\)</EquationSource> </InlineEquation>&#xa0;kPa and a mean absolute percentage error of <InlineEquation ID="IEq11"> <EquationSource Format="TEX">\(2.03\pm 1.49\%\)</EquationSource> </InlineEquation>. At the earliest stable stop, the method achieves a 100% hit rate over 11 eligible runs, with <InlineEquation ID="IEq12"> <EquationSource Format="TEX">\(|P(T^*)-P^*|=1.08\pm 0.65\)</EquationSource> </InlineEquation>&#xa0;kPa and a median cycle-time gain of 120&#xa0;s. The framework is lightweight and auditable, supports de-experientialized stop timing, quantifies cycle-time benefits, and provides uncertainty-aware guidance for tolerance setting.</p>

错误:搜索内容不能为空,请输入英文关键词
错误:关键词超出字数限制,请精简
高级检索

Interpretable deep learning for online press-stop decision: soft sensor and three-phase extrapolation

  • Yibo Yan,
  • Heng Zhao,
  • Beichen Zhu,
  • Chen Wan,
  • Zhoujin Lv,
  • Qiupeng Zhang

摘要

In high-temperature manufacturing, operators must reach a target state \((T^*,P^*)\) under safety, defect-risk, and energy constraints, while accounting for the fact that once active pressurization stops, continued heating induces thermal expansion that passively raises pressure. Thus, the most critical and low-cost decision is when to stop pressurization: ideally, \((T^*,P^*)\) is achieved by heating alone without over- or under-pressurization; however, rule-of-thumb decisions are difficult to audit and often unstable. We propose an interpretable deep learning approach that reduces reliance on operator experience. Using a small, physics-aligned feature set—current temperature/pressure, recent temperature slope \(k_T=\textrm{d}T/\textrm{d}t\) [ \(^{\circ}\text {Cs}^{-1}\) ], and gaps to \((T^*,P^*)\) —we train a lightweight soft sensor to predict the expansion-phase pressure-rise slope \(\hat{k}_P\) [ \(\hbox {kPa}\,\hbox {s}^{-1}\) ] after stopping. Coupled with a three-phase efficiency model (slower just after stopping, faster in the mid phase, slower near the target), we compute an effective time \(\Delta t_{\textrm{eff}}\) to extrapolate pressure at \(T^*\) and trigger stopping via a transparent “tolerance + M-consecutive-frames” rule. We evaluate on industrial data with train/validation/test splits by run ID. In replay analyses, the same-actual-stop evaluation achieves 93.75% coverage (15/16 runs) under a 5% relative tolerance, with a mean absolute pressure error of \(2.44\pm 2.09\)  kPa and a mean absolute percentage error of \(2.03\pm 1.49\%\) . At the earliest stable stop, the method achieves a 100% hit rate over 11 eligible runs, with \(|P(T^*)-P^*|=1.08\pm 0.65\)  kPa and a median cycle-time gain of 120 s. The framework is lightweight and auditable, supports de-experientialized stop timing, quantifies cycle-time benefits, and provides uncertainty-aware guidance for tolerance setting.