Model-based fault monitoring of a plastic film extrusion process

S.-H Hur, R. Katebi, A. Taylor

Research output: Contribution to journalArticlepeer-review

3 Citations (Scopus)


This study reports the modelling of a plastic film extrusion process and the development and implementation of a model-based fault monitoring system. The model is mainly derived from the first-principles of chemical and mechanical engineering in addition to empirical knowledge related to the behaviour of polymer and designed to provide a safe offline platform for developing monitoring and control systems. The fault monitoring system constructs a residual via parity relations, and a multi-objective optimisation problem must therefore be solved in order that the residual can be sensitive to faults but insensitive to disturbances and modelling errors. In this paper, a genetic algorithm is exploited for solving this multi-objective optimisation problem, and the resulting fault monitoring system is applied to the model. Simulation results demonstrate that various types of faults can be detected and
diagnosed successfully.
Original languageEnglish
Pages (from-to)2075-2088
Number of pages14
JournalIET Control Theory and Applications
Issue number18
Publication statusPublished - 8 Dec 2011


  • plastic film extrusion
  • web process
  • first principles modelling
  • fault detection
  • fault diagnosis
  • parity relations
  • genetic algorithm


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