Aluminium Process Fault Detection and Diagnosis

Abstract

The challenges in developing a fault detection and diagnosis system for industrial applications are not inconsiderable, particularly complex materials processing operations such as aluminium smelting. However, the organizing into groups of the various fault detection and diagnostic systems of the aluminium smelting process can assist in the identification of the key elements of an effective monitoring system. This paper reviews aluminium process fault detection and diagnosis systems and proposes a taxonomy that includes four key elements: knowledge, techniques, usage frequency, and results presentation. Each element is explained together with examples of existing systems. A fault detection and diagnosis system developed based on the proposed taxonomy is demonstrated using aluminium smelting data. A potential new strategy for improving fault diagnosis is discussed based on the ability of the new technology, augmented reality, to augment operators’ view of an industrial plant, so that it permits a situation-oriented action in real working environments.