变工况下中药制粒产线孪生迁移建模及故障诊断研究

Twin migration modeling and fault diagnosis of traditional Chinese medicine granulation production line under variable working conditions

  • 摘要: 中药制药具有多品种、小批量、工况复杂多变的生产特点,针对特定场景建立的数字孪生模型缺乏工况变化的自适应能力,难以快速准确地识别制药设备故障问题. 本研究提出一种变工况下中药制粒产线孪生迁移建模及故障诊断研究方法. 通过分析制药导致工况发生动态变化的影响因素,搭建制药工艺孪生模型自适应迁移框架,分析判断不同品规加工设备故障状态和时变特性,引入Swin transformer(Shifted window transformer)、CNN(Convolutional neural network)与GRU(Gated recurrent units)相结合的STFusionGRU(Swin transformer–CNN–GRU)模型,融合空间与时间特征,设计包括识别、训练、更新、预测的多级自适应迁移策略,在新工况下可快速适配模型并保持高性能,解决了数据稀缺、相似故障内和相异故障间、设备异构条件下的知识迁移难题,有效提升复杂工况下设备故障的预测精度. 实验结果表明:在工艺参数波动超过大、产品批次切换等典型变工况场景下,故障预测准确率达到0.98,验证了方法的有效性与实用性. 本研究实现了多品规、变工况制药工艺孪生模型的自适应更新,迁移后模型的故障预测误差低于0.05,研发方法可应用于其他复杂工况下设备故障精准预测,为提高数字孪生模型自适应能力提供了新思路.

     

    Abstract: Traditional Chinese medicine manufacturing is characterized by diverse product varieties, small batch sizes, and complex, variable operating conditions. Digital twin models established for specific scenarios lack the adaptive capability to handle changing operating conditions, making it difficult to identify equipment failures. This study proposes a research method for twin migration modeling and fault diagnosis of traditional Chinese medicine granulation production lines under various operating conditions. We first analyze the sources and mechanisms behind dynamic condition shifts in pharmaceutical production. These include material property differences across product specifications, batch switching, environmental humidity variations, and complex equipment-process interactions. Building on this analysis, we develop an adaptive migration framework for pharmaceutical digital twins, allowing the model to evolve with changing manufacturing conditions. This framework supports the identification of time-varying process behaviors, modeling of heterogeneous equipment states, and the representation of cross-specification processing patterns. Together, these elements provide a unified path for adaptive twin updating. To overcome the limitations of current digital twin-based fault diagnosis methods, particularly in model reuse, cross-condition adaptation, and knowledge transfer, we design a multilevel adaptive migration strategy that consists of four key stages: working-condition identification, offline training, model updating, and online fault prediction. The strategy facilitates both intra-fault knowledge transfer, which occurs within similar fault types, and inter-fault knowledge transfer across different fault scenarios. It also addresses common pharmaceutical production challenges, such as equipment heterogeneity and data scarcity. At the algorithm level, we propose STFusionGRU, a hybrid spatial-temporal fusion model that combines the global spatial representation ability of the swin transformer, fine-grained local perception of convolutional neural networks (CNNs), and temporal modeling capability of gated recurrent units. This model captures multiscale spatial patterns in process parameters, extracts hierarchical temporal dependencies, and represents dynamic fault evolution pathways. By integrating global and local spatiotemporal information, STFusionGRU improves robustness under varying operating conditions and accurately characterizes subtle abnormal patterns. We evaluate the proposed method across multiple typical variable-condition scenarios in TCM granulation production. These include significant process-parameter fluctuations, frequent batch transitions, and cross-specification switching. Our approach achieved a fault prediction accuracy of 0.98, outperforming baseline models in both adaptability and stability. After migration, the digital twin model maintains a fault prediction error below 0.05. This confirms that the adaptive migration strategy effectively preserves model performance under new conditions. Our method not only alleviates issues of insufficient labeled data and inconsistent fault distributions, but also enables reliable knowledge transfer across equipment types and production scenarios. In summary, this study establishes a transferable and self-adapting digital twin framework for multi-specification, variable-condition pharmaceutical manufacturing. By integrating adaptive migration, spatiotemporal feature fusion, and digital twin-driven fault modeling, we provide a novel solution for equipment fault prediction under complex and uncertain working conditions. The methodology shows strong generalization potential and can be extended to other industrial domains that face similar challenges related to dynamic conditions and equipment heterogeneity. This study enhances the resilience and adaptability of digital twin systems, contributing new insights into intelligent manufacturing and paving the way for next-generation adaptive fault diagnosis in pharmaceutical production.

     

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