Multi-model adaptive soft sensor modeling method using local learning and online support vector regression for nonlinear time-variant batch processes

Batch processes are often characterized by inherent nonlinearity, multiplicity of operating phases, and batch-to-batch variations, which poses great challenges for accurate and reliable online prediction of soft sensor. Especially, the soft sensor built with old data may encounter performance deterioration due to a failure of capturing the time-variant behaviors of batch processes, thus adaptive strategies are necessary. Unfortunately, conventional adaptive soft sensors cannot efficiently account for the within-batch as well as between-batch time-variant changes in batch process characteristics, which results in poor prediction accuracy. Therefore, a novel multi-model adaptive soft sensor modeling method is proposed based on the local learning framework and online support vector regression (OSVR) for nonlinear time-variant batch processes. First, a batch process is identified with a set of local domains and then the localized OSVR models are built for all isolated domains. Further, the estimation for a query data is obtained by adaptively combining multiple local models that perform best on the similar samples to the query point. The proposed multi-model OSVR (MOSVR) method provides four types of adaptation strategies: (i) adaptive combination based on Bayesian ensemble learning; (ii) online offset compensation; (iii) incremental updating of local models; and (iv) database updating. The effectiveness of the MOSVR approach and its superiority over traditional adaptive soft sensors in dealing with the within-batch and between-batch shifting dynamics is demonstrated through a simulated fed-batch penicillin fermentation process as well as an industrial fed-batch chlortetracycline fermentation process.