With the scale expansion
of industrial processes, the relationship between process variables
has become complex and highly nonlinear. As a result, the requirements
for fault diagnosis and safety monitoring has become demanding. To
address this problem, a novel and effective pattern-matching method
using kernel canonical variate analysis (KCVA) integrated with an
adaptive rank-order morphological filter (ARMF) is proposed for fault
diagnosis. In the proposed method, KCVA is first used to extract the
nonlinear correlation information with dynamic characteristics from
the original process data and achieve feature dimension reduction;
the features extracted by KCVA are then subjected to ARMF transformation
for output trend features and pattern matching. To accurately evaluate
the morphological similarity between the test trends and template
trends of ARMF, the dynamic time warping distance is adopted for pattern
classification. Finally, the proposed KCVA–ARMF pattern-matching
method is developed as an effective fault diagnosis model for complex
industrial processes. To validate the performance of the proposed
method, case studies using the Tennessee Eastman process are performed.
Compared with some other multivariate statistical process monitoring
methods, the simulation results indicate that the proposed KCVA–ARMF
method can obtain higher accuracy in fault diagnosis, especially for
difficult-to-diagnose faults.