Online Tool Condition Monitoring Based on Parsimonious Ensemble+

Accurate diagnosis of tool wear in metal turning process remains an open challenge for both scientists and industrial practitioners because of inhomogeneities in workpiece material, nonstationary machining settings to suit production requirements, and nonlinear relations between measured variables and tool wear. Common methodologies for tool condition monitoring still rely on batch approaches which cannot cope with a fast sampling rate of metal cutting process. Furthermore they require a retraining process to be completed from scratch when dealing with a new set of machining parameters. This paper presents an online tool condition monitoring approach based on Parsimonious Ensemble+, pENsemble+. The unique feature of pENsemble+ lies in its highly flexible principle where both ensemble structure and base-classifier structure can automatically grow and shrink on the fly based on the characteristics of data streams. Moreover, the online feature selection scenario is integrated to actively sample relevant input attributes. The paper presents advancement of a newly developed ensemble learning algorithm, pENsemble+, where online active learning scenario is incorporated to reduce operator labelling effort. The ensemble merging scenario is proposed which allows reduction of ensemble complexity while retaining its diversity. Experimental studies utilising real-world manufacturing data streams and comparisons with well known algorithms were carried out. Furthermore, the efficacy of pENsemble was examined using benchmark concept drift data streams. It has been found that pENsemble+ incurs low structural complexity and results in a significant reduction of operator labelling effort.Comment: this paper has been published by IEEE Transactions on Cybernetic

Evolving Ensemble Fuzzy Classifier

The concept of ensemble learning offers a promising avenue in learning from data streams under complex environments because it addresses the bias and variance dilemma better than its single model counterpart and features a reconfigurable structure, which is well suited to the given context. While various extensions of ensemble learning for mining non-stationary data streams can be found in the literature, most of them are crafted under a static base classifier and revisits preceding samples in the sliding window for a retraining step. This feature causes computationally prohibitive complexity and is not flexible enough to cope with rapidly changing environments. Their complexities are often demanding because it involves a large collection of offline classifiers due to the absence of structural complexities reduction mechanisms and lack of an online feature selection mechanism. A novel evolving ensemble classifier, namely Parsimonious Ensemble pENsemble, is proposed in this paper. pENsemble differs from existing architectures in the fact that it is built upon an evolving classifier from data streams, termed Parsimonious Classifier pClass. pENsemble is equipped by an ensemble pruning mechanism, which estimates a localized generalization error of a base classifier. A dynamic online feature selection scenario is integrated into the pENsemble. This method allows for dynamic selection and deselection of input features on the fly. pENsemble adopts a dynamic ensemble structure to output a final classification decision where it features a novel drift detection scenario to grow the ensemble structure. The efficacy of the pENsemble has been numerically demonstrated through rigorous numerical studies with dynamic and evolving data streams where it delivers the most encouraging performance in attaining a tradeoff between accuracy and complexity.Comment: this paper has been published by IEEE Transactions on Fuzzy System

Using ensembles for accurate modelling of manufacturing processes in an IoT data-acquisition solution

The development of complex real-time platforms for the Internet of Things (IoT) opens up a promising future for the diagnosis and the optimization of machining processes. Many issues have still to be solved before IoT platforms can be profitable for small workshops with very flexible workloads and workflows. The main obstacles refer to sensor implementation, IoT architecture, and data processing, and analysis. In this research, the use of different machine-learning techniques is proposed, for the extraction of different information from an IoT platform connected to a machining center, working under real industrial conditions in a workshop. The aim is to evaluate which algorithmic technique might be the best to build accurate prediction models for one of the main demands of workshops: the optimization of machining processes. This evaluation, completed under real industrial conditions, includes very limited information on the machining workload of the machining center and unbalanced datasets. The strategy is validated for the classification of the state of a machining center, its working mode, and the prediction of the thermal evolution of the main machine-tool motors: the axis motors and the milling head motor. The results show the superiority of the ensembles for both classification problems under analysis and all four regression problems. In particular, Rotation Forest-based ensembles turned out to have the best performance in the experiments for all the metrics under study. The models are accurate enough to provide useful conclusions applicable to current industrial practice, such as improvements in machine programming to avoid cutting conditions that might greatly reduce tool lifetime and damage machine components.Projects TIN2015-67534-P (MINECO/FEDER, UE) of the Ministerio de Economía Competitividad of the Spanish Government and projects CCTT1/17/BU/0003 and BU085P17 (JCyL/FEDER, UE) of the Junta de Castilla y León, all of them co-financed through European-Union FEDER funds

Boundary conditions for the application of machine learning based monitoring systems for supervised anomaly detection in machining

Monitoring systems may contribute increasing the availability of machine tools and detecting process deviations in time. In the past, machine learning has been used to solve a variety of monitoring problems in machining. However, boundary conditions for the assessment of the principal applicability of machine learning approaches for supervised anomaly detection in machining have not been exhaustively described in the literature. In this paper, objectives as well as deficits of literature approaches are identified and influencing factors on the monitoring quality are described. As a result, we derive boundary conditions and discuss challenges for successful implementation of machine learning based monitoring systems for supervised anomaly detection in industrial practice

Application of Audible Signals in Tool Condition Monitoring using Machine Learning Techniques

Machining is always accompanied by many difficulties like tool wear, tool breakage, improper machining conditions, non-uniform workpiece properties and some other irregularities, which are some of major barriers to highly-automated operations. Effective tool condition monitoring (TCM) system provides a best solution to monitor those irregular machining processes and suggest operators to take appropriate actions. Even though a wide variety of monitoring techniques have been developed for the online detection of tool condition, it remains an unsolved problem to look for a reliable, simple and cheap solution. This research work mainly focuses on developing a real-time tool condition monitoring model to detect the tool condition, part quality in machining process by using machine learning techniques through sound monitoring. The present study shows the development of a process model capable of on-line process monitoring utilizing machine learning techniques to analyze the sound signals collected during machining and train the proposed system to predict the cutting phenomenon during machining. A decision-making system based on the machine learning technique involving Support Vector Machine approach is developed. The developed system is trained with pre-processed data and tested, and the system showed a significant prediction accuracy in different applications which proves to be an effective model in applying to machining process as an on-line process monitoring system. In addition, this system also proves to be effective, cheap, compact and sensory position invariant. The successful development of the proposed TCM system can provide a practical tool to reduce downtime for tool changes and minimize the amount of scrap in metal cutting industry

Initial results on fault diagnosis of DSN antenna control assemblies using pattern recognition techniques

Initial results obtained from an investigation using pattern recognition techniques for identifying fault modes in the Deep Space Network (DSN) 70 m antenna control loops are described. The overall background to the problem is described, the motivation and potential benefits of this approach are outlined. In particular, an experiment is described in which fault modes were introduced into a state-space simulation of the antenna control loops. By training a multilayer feed-forward neural network on the simulated sensor output, classification rates of over 95 percent were achieved with a false alarm rate of zero on unseen tests data. It concludes that although the neural classifier has certain practical limitations at present, it also has considerable potential for problems of this nature

Towards Probabilistic and Partially-Supervised Structural Health Monitoring

One of the most significant challenges for signal processing in data-based structural health monitoring (SHM) is a lack of comprehensive data; in particular, recording labels to describe what each of the measured signals represent. For example, consider an offshore wind-turbine, monitored by an SHM strategy. It is infeasible to artificially damage such a high-value asset to collect signals that might relate to the damaged structure in situ; additionally, signals that correspond to abnormal wave-loading, or unusually low-temperatures, could take several years to be recorded. Regular inspections of the turbine in operation, to describe (and label) what measured data represent, would also prove impracticable -- conventionally, it is only possible to check various components (such as the turbine blades) following manual inspection; this involves travelling to a remote, offshore location, which is a high-cost procedure. Therefore, the collection of labelled data is generally limited by some expense incurred when investigating the signals; this might include direct costs, or loss of income due to down-time. Conventionally, incomplete label information forces a dependence on unsupervised machine learning, limiting SHM strategies to damage (i.e. novelty) detection. However, while comprehensive and fully labelled data can be rare, it is often possible to provide labels for a limited subset of data, given a label budget. In this scenario, partially-supervised machine learning should become relevant. The associated algorithms offer an alternative approach to monitor measured data, as they can utilise both labelled and unlabelled signals, within a unifying training scheme. In consequence, this work introduces (and adapts) partially-supervised algorithms for SHM; specifically, semi-supervised and active learning methods. Through applications to experimental data, semi-supervised learning is shown to utilise information in the unlabelled signals, alongside a limited set of labelled data, to further update a predictive-model. On the other hand, active learning improves the predictive performance by querying specific signals to investigate, which are assumed the most informative. Both discriminative and generative methods are investigated, leading towards a novel, probabilistic framework, to classify, investigate, and label signals for online SHM. The findings indicate that, through partially-supervised learning, the cost associated with labelling data can be managed, as the information in a selected subset of labelled signals can be combined with larger sets of unlabelled data -- increasing the potential scope and predictive performance for data-driven SHM