TOWARD INTELLIGENT WELDING BY BUILDING ITS DIGITAL TWIN

To meet the increasing requirements for production on individualization, efficiency and quality, traditional manufacturing processes are evolving to smart manufacturing with the support from the information technology advancements including cyber-physical systems (CPS), Internet of Things (IoT), big industrial data, and artificial intelligence (AI). The pre-requirement for integrating with these advanced information technologies is to digitalize manufacturing processes such that they can be analyzed, controlled, and interacted with other digitalized components. Digital twin is developed as a general framework to do that by building the digital replicas for the physical entities. This work takes welding manufacturing as the case study to accelerate its transition to intelligent welding by building its digital twin and contributes to digital twin in the following two aspects (1) increasing the information analysis and reasoning ability by integrating deep learning; (2) enhancing the human user operative ability to physical welding manufacturing via digital twins by integrating human-robot interaction (HRI). Firstly, a digital twin of pulsed gas tungsten arc welding (GTAW-P) is developed by integrating deep learning to offer the strong feature extraction and analysis ability. In such a system, the direct information including weld pool images, arc images, welding current and arc voltage is collected by cameras and arc sensors. The undirect information determining the welding quality, i.e., weld joint top-side bead width (TSBW) and back-side bead width (BSBW), is computed by a traditional image processing method and a deep convolutional neural network (CNN) respectively. Based on that, the weld joint geometrical size is controlled to meet the quality requirement in various welding conditions. In the meantime, this developed digital twin is visualized to offer a graphical user interface (GUI) to human users for their effective and intuitive perception to physical welding processes. Secondly, in order to enhance the human operative ability to the physical welding processes via digital twins, HRI is integrated taking virtual reality (VR) as the interface which could transmit the information bidirectionally i.e., transmitting the human commends to welding robots and visualizing the digital twin to human users. Six welders, skilled and unskilled, tested this system by completing the same welding job but demonstrate different patterns and resulted welding qualities. To differentiate their skill levels (skilled or unskilled) from their demonstrated operations, a data-driven approach, FFT-PCA-SVM as a combination of fast Fourier transform (FFT), principal component analysis (PCA), and support vector machine (SVM) is developed and demonstrates the 94.44% classification accuracy. The robots can also work as an assistant to help the human welders to complete the welding tasks by recognizing and executing the intended welding operations. This is done by a developed human intention recognition algorithm based on hidden Markov model (HMM) and the welding experiments show that developed robot-assisted welding can help to improve welding quality. To further take the advantages of the robots i.e., movement accuracy and stability, the role of the robot upgrades to be a collaborator from an assistant to complete a subtask independently i.e., torch weaving and automatic seam tracking in weaving GTAW. The other subtask i.e., welding torch moving along the weld seam is completed by the human users who can adjust the travel speed to control the heat input and ensure the good welding quality. By doing that, the advantages of humans (intelligence) and robots (accuracy and stability) are combined together under this human-robot collaboration framework. The developed digital twin for welding manufacturing helps to promote the next-generation intelligent welding and can be applied in other similar manufacturing processes easily after small modifications including painting, spraying and additive manufacturing

A multiscale strategy for fouling prediction and mitigation in gas turbines

Gas turbines are one of the primary sources of power for both aerospace and land-based applications. Precisely for this reason, they are often forced to operate in harsh environmental conditions, which involve the occurrence of particle ingestion by the engine. The main implications of this problem are often underestimated. The particulate in the airflow ingested by the machine can deposit or erode its internal surfaces, and lead to the variation of their aerodynamic geometry, entailing performance degradation and, possibly, a reduction in engine life. This issue affects the compressor and the turbine section and can occur for either land-based or aeronautical turbines. For the former, the problem can be mitigated (but not eliminated) by installing filtration systems. For what concern the aerospace field, filtration systems cannot be used. Volcanic eruptions and sand dust storms can send particulate to aircraft cruising altitudes. Also, aircraft operating in remote locations or low altitudes can be subjected to particle ingestion, especially in desert environments. The aim of this work is to propose different methodologies capable to mitigate the effects of fouling or predicting the performance degradation that it generates. For this purpose, both hot and cold engine sections are considered. Concerning the turbine section, new design guidelines are presented. This is because, for this specific component, the time scales of failure events due to hot deposition can be of the order of minutes, which makes any predictive model inapplicable. In this respect, design optimization techniques were applied to find the best HPT vane geometry that is less sensitive to the fouling phenomena. After that, machine learning methods were adopted to obtain a design map that can be useful in the first steps of the design phase. Moreover, after a numerical uncertainty quantification analysis, it was demonstrated that a deterministic optimization is not sufficient to face highly aleatory phenomena such as fouling. This suggests the use of robust or aggressive design techniques to front this issue. On the other hand, with respect to the compressor section, the research was mainly focused on the building of a predictive maintenance tool. This is because the time scales of failure events due to cold deposition are longer than the ones for the hot section, hence the main challenge for this component is the optimization of the washing schedule. As reported in the previous sections, there are several studies in the literature focused on this issue, but almost all of them are data-based instead of physics-based. The innovative strategy proposed here is a mixture between physics-based and data-based methodologies. In particular, a reduced-order model has been developed to predict the behaviour of the whole engine as the degradation proceeds. For this purpose, a gas path code that uses the components’ characteristic maps has been created to simulate the gas turbine. A map variation technique has been used to take into account the fouling effects on each engine component. Particularly, fouling coefficients as a function of the engine architecture, its operating conditions, and the contaminant characteristics have been created. For this purpose, both experimental and computational results have been used. Specifically for the latter, efforts have been done to develop a new numerical deposition/detachment model.Le turbine a gas sono una delle pricipali fonti di energia, sia per applicazioni aeronautiche che terrestri. Proprio per questa ragione, esse sono spesso costrette ad operare in ambienti non propriamente puliti, il che comporta l’ingestione di contaminanti solidi da parte del motore. Le principali implicazioni di questo problema sono spesso sottovalutate. Le particelle solide presenti nel flusso d’aria che il motore ingerisce durante il suo funzionamento possono depositarsi o erodere le superfici interne della macchina, e portare a variazioni alla sua aerodinamica, quindi a degrado di performance e, molto probabilmente, alla diminuzione della sua vita utile. Questo problema aflligge sia la parte del compressore che la parte della turbina, e si manifesta sia in applicazioni terrestri che aeronautiche. Per quanto riguarda la prima, la questione può essere mitigata (ma non eliminata) dall’installazione di sistemi di filtraggio all’ingresso della macchina. Per le applicazioni aeronautiche invece, i sistemi di filtraggio non possono essere utilizzati. Questo implica che il particolato presente ad alte quote, magari grazie ad eventi catastrofici quali eruzioni vulcaniche, o a basse quote, quindi ambienti deseritic, entra liberamente nella turbina a gas. Lo scopo principale di questo lavoro di tesi, è quello di proporre differenti metodologieallo scopo di mitigare gli effetti dello sporcamento o predirre il degrado che esso comporta nelle turbine a gas. Per questo scopo, sia la parte del compressore che quella della turbina sono state prese in considerazione. Per quanto riguarda la parte turbina, saranno presentate nuove guide progettuali volte al trovare la geometria che sia meno sensibile possibile al problema dello sporcamento. Dopo di ciò, i risultati ottenuti verranno trattati tramite tecniche di machine learning, ottenendo una mappa di progetto che potrà essere utile nelle prime fasi della progettazione di questi componenti. Inoltre, essendo l’analisi fin qui condotta di tipo deterministico, un’analisi delle principali fonti di incertezza verrà eseguita con l’utilizzo di tecniche derivanti dall’uncertainty quantification. Questo dimostrerà che l’analisi deterministica è troppo semplificativa, e che sarebbe opportuno spingersi verso una progettazione robusta per affrontare questa tipologia di problemi. D’altro canto, per quanto concerne la parte compressore, la ricerca è stata incentrata principalmente sulla costruzione di uno strumento predittivo, questo perchè la scala temporale del degrado dovuto alla deposizione a "freddo" è molto più dilatata rispetto a quella della sezione "calda". La trategia proposta in questo lavoro di tesi è un’insieme di modelli fisici e data-driven. In particolare, si è sviluppato un modello ad ordine ridotto per la previsione del comportamento del motore soggetto a degrado dovuto all’ingestione di particolato, durante un’intera missione aerea. Per farlo, si è generato un codice cosiddetto gas-path, che modella i singoli componenti della macchina attraverso le loro mappe caratteristiche. Quest’ultime vengono modificate, a seguito della deposizione, attraverso opportuni coefficienti di degrado. Tali coefficienti devono essere adeguatamente stimati per avere una corretta previsione degli eventi, e per fare ciò verrà proposta una strategia che comporta l’utilizzo sia di metodi sperimentali che computazionali, per la generazione di un algoritmo che avrà lo scopo di fornire come output questi coefficienti

A Kernel Based Approach to Determine Atypicality

This dissertation outlines the development and use for a new probabilistic measure for categorization, referred to as atypicality. Given a set of known source objects, we can create a corresponding set of similarity scores between them. Assuming the set of scores has a normal distribution, we can estimate its parameters. Then, we can introduce new trace objects to the problem, and compute similarity scores for them. The main goal of the atypicality score is to determine if the new trace objects are similar to the source objects. To do this, we bootstrap many new scores using the estimated parameters (from the source scores), and compare the likelihood of these new scores to the scores belonging to the trace objects. We then make note of how often the trace objects have a higher likelihood value. The bootstrap result will be a number between zero and one, with smaller values indicating that the trace objects are not similar to the source objects. This is the atypicality value. We can use this as a p-value in a hypothesis test where the null hypothesis states that the trace objects are similar to the source objects. This can be used in a variety of applications, especially where we have multiple trace objects in multi-dimensional space. This dissertation will outline the development and use of the atypicality measure, show the results when the objects and scores are not normal, discuss the power of atypicality, and provide a comparison to support vector machines

Using the modified k-mean algorithm with an improved teaching-learning-based optimization algorithm for feedforward neural network training

In this paper we proposed a novel procedure for training a feedforward neural network. The accuracy of artificial neural network outputs after determining the proper structure for each problem depends on choosing the appropriate method for determining the best weights, which is the appropriate training algorithm. If the training algorithm starts from a good starting point, it is several steps closer to achieving global optimization. In this paper, we present an optimization strategy for selecting the initial population and determining the optimal weights with the aim of minimizing neural network error. Teaching-learning-based optimization (TLBO) is a less parametric algorithm rather than other evolutionary algorithms, so it is easier to implement. We have improved this algorithm to increase efficiency and balance between global and local search. The improved teaching-learning-based optimization (ITLBO) algorithm has added the concept of neighborhood to the basic algorithm, which improves the ability of global search. Using an initial population that includes the best cluster centers after clustering with the modified k-mean algorithm also helps the algorithm to achieve global optimum. The results are promising, close to optimal, and better than other approach which we compared our proposed algorithm with them