The goal of the paper is the design of soft sensors for single input single output (SISO) nonlinear processes. This goal is of essential importance for process monitoring, fault detection and fault isolation. The observer-based technique, being a fruitful direction in soft sensor design, is followed to develop soft sensors for nonlinear processes with known dynamics and unknown physical parameters. A new and general approach, based on the identified I/O linear approximant system descriptions, around prespecified operating points, and a bank of switching linear observers, will be developed. The system property of the I/O reconstructability of the state space linear approximant of a nonlinear model is presented. The design of each observer is based on the I/O measurements and structural characteristics of the nonlinear process. Observer-oriented target areas are introduced, and the respective dense web principle is formulated. The design is completed by the design of a data-driven rule-based system, providing stepwise switching among the observers of the bank. The number of observers of the bank is equal to the number of the linear approximants of the nonlinear process model and is equal to the number of the respective target operating areas. The target operating areas are required to satisfy the dense web principle. The information provided by the soft sensor is the estimation of the non-measured variables of the process. The information used by the soft sensor is the identified I/O approximants of the process as well as the real time values of the measurement variables. The efficiency of the design scheme is illustrated through symbolic and numerical simulation results for a chemostat. The nonlinear model of the chemostat is initially approximated by a set of ten linear approximants. After, the I/O approximants are identified, the respective observers are designed and the target operating areas are determined, where several cases of the satisfaction of the dense web principle are investigated. The soft sensor is composed in terms of the designed observers. Simulation results illustrate the satisfactory performance of the designed soft sensor.
Keywords: data-driven observer design; data-driven soft sensor design; nonlinear processes; switching observers.