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Mechanical vibration & acoustic signals with characteristics of multiple components, nonstationarity and nonlinearity are always used to construct the data-driven soft sensor model of industrial processes. It is one of the main approaches to measure the difficulty-to-measure process parameters inside those high energy consumption mechanical devices. Duo to the complexity of the production mechanism of these mechanical signals, most of these soft sensor models are difficult to be explained. Moreover, the characteristics of the industrial process' continuous running and the mechanical equipment' operation modes lead to the difficulty of high economic cost and long period waiting to obtain sufficient training samples. To solve these problems, a new multi-component mechanical signal modeling method based on virtual sample generation (VSG) technology is proposed. Firstly, the mechanical signals are processed into a set of sub-signals with different time scales by using adaptive multi-component signal decomposition technique; then these sub-signals are transferred to high dimensional multi-scale spectral data. Secondly, an improved selective ensemble kernel partial least squares (SENKPLS) algorithm that suits to model small sample high dimensional data is used to construct a feasibility-based programming (FBP) model with the true training samples; then prior knowledge, FBP models and information entropy are integrated to produce virtual training samples. Thirdly, mutual information (MI) method is used to select the spectral features of the new mixing training samples based on the true and virtual ones. Finally, a soft sensor model is built by using these reduced mixing spectral data. Near-infra spectra data and mechanical vibration and acoustic singals of a laboratory-scale ball mill in grinding process validate the reasonability and effectiveness of the proposed VSG techniques and multi-component mechanical signals-based modeling approach. Copyright © 2018 Acta Automatica Sinica. All rights reserved.
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