Autoencoder-Ensemble-Based Unsupervised Selection of Production-Relevant Variables for Context-Aware Fault Diagnosis

Abstract

Smart factories are complex; with the increased complexity of employed cyber-physical systems, the complexity evolves further. Cyber-physical systems produce high amounts of data that are hard to capture and challenging to analyze. Real-time recording of all data is not possible due to limited network capabilities. Limited network capabilities are the reason for a chain of faults introduced via active surveillance during fault diagnosis. These introduced faults may slow down production or lead to an outage of the production line. Here, we present a novel approach to automatically select production-relevant shop floor parameters to decrease the number of surveyed variables and, at the same time, maintain quality in fault diagnosis without overloading the network. We were able to achieve higher throughput, mitigate communication losses and prevent the disruption of factory instructions. Our approach uses an autoencoder ensemble via minority voting to differentiate between normal—always on—variables and production variables that may yield a higher entropy. Our approach has been tested in a production-equal smart factory and was cross-validated by a domain expert.

Keywords

• context-aware diagnosis
• outlier detection
• cyber-physical systems
• pre-training variable selection
• autoencoder ensemble
• production-relevant variables