Transfer learning for process monitoring using reflection-mode ultrasonic sensing

The fourth industrial revolution is set to integrate entire manufacturing processes using industrial digital technologies such as the Internet of Things, Cloud Computing, and machine learning to improve process productivity, efficiency, and sustainability. Sensors collect the real-time data required to optimise manufacturing processes and are therefore a key technology in this transformation. Ultrasonic sensors have benefits of being low-cost, in-line, non-invasive, and able to operate in opaque systems. Supervised machine learning models can correlate ultrasonic sensor data to useful information about the manufacturing materials and processes. However, this requires a reference measurement of the process material to label each data point for model training. Labelled data is often difficult to obtain in factory environments, and so a method of training models without this is desirable. This work compares two domain adaptation methods to transfer models across processes, so that no labelled data is required to accurately monitor a target process. The two method compared are a Single Feature transfer learning approach and Transfer Component Analysis using three features. Ultrasonic waveforms are unique to the sensor used, attachment procedure, and contact pressure. Therefore, only a small number of transferable features are investigated. Two industrially relevant processes were used as case studies: mixing and cleaning of fouling in pipes. A reflection-mode ultrasonic sensing technique was used, which monitors the sound wave reflected from the interface between the vessel wall and process material. Overall, the Single Feature method produced the highest prediction accuracies: up to 96.0% and 98.4% to classify the completion of mixing and cleaning, respectively; and R² values of up to 0.947 and 0.999 to predict the time remaining until completion. These results highlight the potential of combining ultrasonic measurements with transfer learning techniques to monitor industrial processes. Although, further work is required to study various effects such as changing sensor location between source and target domains.