arXiv:2607.22486cs.CV2026-07

用最优传输图像+深度协方差对齐,提升工业阀门卡滞检测的泛化能力

Optimal Transport Image Representation and Deep Covariance Alignment (CORAL) for Control Valve Stiction Detection

  • 将控制信号转为最优传输图像,用CNN学习跨域不变特征
  • 在20个真实工况测试中诊断18个,13种卡滞案例召回率100%
  • 适合工业界部署,显著降低模拟到实际数据的性能下降

阀门卡滞是工业过程控制回路中导致振荡和性能下降的常见问题。基于数据的方法可自动检测卡滞,但仅在仿真数据上训练的模型常因领域偏移难以泛化到真实工业场景。本文提出一种新方法,结合最优传输(OT)成像技术与深度相关性对齐(Deep CORAL)算法。将控制器输出与过程变量等闭环信号转化为二维OT图像,以捕捉控制回路动态特性。所提方法采用卷积神经网络编码器,通过联合优化交叉熵损失(在标注仿真数据上)与Deep CORAL损失(对齐仿真数据与无标签目标域工业数据的协方差),学习域不变特征。在独立测试集上评估20个工业卡滞基准回路,成功诊断18个,所有13个卡滞案例实现100%召回率,准确率达90.00%,F1分数为92.86%。相比传统手工特征方法,该方法显著缓解了领域偏移,为真实工业控制回路提供鲁棒可靠的卡滞检测。

原文摘要 · Abstract (English)

Control valve stiction is a common cause of unwanted oscillations and poor control-loop performance in industrial processes. Data-driven methods can automatically detect stiction, but models trained purely on simulated data often struggle to generalize to real industrial control loops due to domain shift. To bridge this gap, this work propose a novel stiction detection methodology that combines optimal transport (OT) imaging technique with deep correlation alignment (Deep CORAL) algorithm. Closed loop signals: controller output and process variable are converted into two-dimensional OT images. These images capture the dynamic behaviour of control loops. The proposed methodology includes a convolutional neural network (CNN) encoder (or feature extractor) trained to learn domain-invariant representations by optimizing a combined objective: a cross-entropy loss on labeled simulation data and a Deep CORAL (covariance-alignment) loss between simulation data and unlabeled target-domain industrial data. Downstream classifiers trained on the domain-invariant target features were evaluated on an independent test set of 20 benchmark loops from industrial stiction data benchmark. The proposed methodology successfully diagnosed 18 out of the 20 loops and achieved100% recall across all 13 stiction cases, an accuracy of 90.00% and an F1-score of 92.86%. Compared to standard baseline approach (hand-crafted features-based method), the proposed methodology significantly mitigates domain shift, providing robust, highly reliable stiction detection for real-world industrial control loops.

工业检测最优传输域适应阀门故障

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