Five-Axis Machine Tool Condition Monitoring Using dSPACE Real-Time System

This paper presents the design, development and SIMULINK implementation of the lumped parameter model of C-axis drive from GEISS five-axis CNC machine tool. The simulated results compare well with the experimental data measured from the actual machine. Also the paper describes the steps for data acquisition using ControlDesk and hardware-in-the-loop implementation of the drive models in dSPACE real-time system. The main components of the HIL system are: the drive model simulation and input – output (I/O) modules for receiving the real controller outputs. The paper explains how the experimental data obtained from the data acquisition process using dSPACE real-time system can be used for the development of machine tool diagnosis and prognosis systems that facilitate the improvement of maintenance activities

Multi-set canonical correlation analysis for 3D abnormal gait behaviour recognition based on virtual sample generation

Small sample dataset and two-dimensional (2D) approach are challenges to vision-based abnormal gait behaviour recognition (AGBR). The lack of three-dimensional (3D) structure of the human body causes 2D based methods to be limited in abnormal gait virtual sample generation (VSG). In this paper, 3D AGBR based on VSG and multi-set canonical correlation analysis (3D-AGRBMCCA) is proposed. First, the unstructured point cloud data of gait are obtained by using a structured light sensor. A 3D parametric body model is then deformed to fit the point cloud data, both in shape and posture. The features of point cloud data are then converted to a high-level structured representation of the body. The parametric body model is used for VSG based on the estimated body pose and shape data. Symmetry virtual samples, pose-perturbation virtual samples and various body-shape virtual samples with multi-views are generated to extend the training samples. The spatial-temporal features of the abnormal gait behaviour from different views, body pose and shape parameters are then extracted by convolutional neural network based Long Short-Term Memory model network. These are projected onto a uniform pattern space using deep learning based multi-set canonical correlation analysis. Experiments on four publicly available datasets show the proposed system performs well under various conditions

DATA DRIVEN INTELLIGENT AGENT NETWORKS FOR ADAPTIVE MONITORING AND CONTROL

To analyze the characteristics and predict the dynamic behaviors of complex systems over time, comprehensive research to enable the development of systems that can intelligently adapt to the evolving conditions and infer new knowledge with algorithms that are not predesigned is crucially needed. This dissertation research studies the integration of the techniques and methodologies resulted from the fields of pattern recognition, intelligent agents, artificial immune systems, and distributed computing platforms, to create technologies that can more accurately describe and control the dynamics of real-world complex systems. The need for such technologies is emerging in manufacturing, transportation, hazard mitigation, weather and climate prediction, homeland security, and emergency response. Motivated by the ability of mobile agents to dynamically incorporate additional computational and control algorithms into executing applications, mobile agent technology is employed in this research for the adaptive sensing and monitoring in a wireless sensor network. Mobile agents are software components that can travel from one computing platform to another in a network and carry programs and data states that are needed for performing the assigned tasks. To support the generation, migration, communication, and management of mobile monitoring agents, an embeddable mobile agent system (Mobile-C) is integrated with sensor nodes. Mobile monitoring agents visit distributed sensor nodes, read real-time sensor data, and perform anomaly detection using the equipped pattern recognition algorithms. The optimal control of agents is achieved by mimicking the adaptive immune response and the application of multi-objective optimization algorithms. The mobile agent approach provides potential to reduce the communication load and energy consumption in monitoring networks. The major research work of this dissertation project includes: (1) studying effective feature extraction methods for time series measurement data; (2) investigating the impact of the feature extraction methods and dissimilarity measures on the performance of pattern recognition; (3) researching the effects of environmental factors on the performance of pattern recognition; (4) integrating an embeddable mobile agent system with wireless sensor nodes; (5) optimizing agent generation and distribution using artificial immune system concept and multi-objective algorithms; (6) applying mobile agent technology and pattern recognition algorithms for adaptive structural health monitoring and driving cycle pattern recognition; (7) developing a web-based monitoring network to enable the visualization and analysis of real-time sensor data remotely. Techniques and algorithms developed in this dissertation project will contribute to research advances in networked distributed systems operating under changing environments

Multi-Level Data-Driven Battery Management: From Internal Sensing to Big Data Utilization

Battery management system (BMS) is essential for the safety and longevity of lithium-ion battery (LIB) utilization. With the rapid development of new sensing techniques, artificial intelligence and the availability of huge amounts of battery operational data, data-driven battery management has attracted ever-widening attention as a promising solution. This review article overviews the recent progress and future trend of data-driven battery management from a multi-level perspective. The widely-explored data-driven methods relying on routine measurements of current, voltage, and surface temperature are reviewed first. Within a deeper understanding and at the microscopic level, emerging management strategies with multi-dimensional battery data assisted by new sensing techniques have been reviewed. Enabled by the fast growth of big data technologies and platforms, the efficient use of battery big data for enhanced battery management is further overviewed. This belongs to the upper and the macroscopic level of the data-driven BMS framework. With this endeavor, we aim to motivate new insights into the future development of next-generation data-driven battery management

Real-Time Monitoring and Fault Diagnostics in Roll-To-Roll Manufacturing Systems

A roll-to-roll (R2R) process is a manufacturing technique involving continuous processing of a flexible substrate as it is transferred between rotating rolls. It integrates many additive and subtractive processing techniques to produce rolls of product in an efficient and cost-effective way due to its high production rate and mass quantity. Therefore, the R2R processes have been increasingly implemented in a wide range of manufacturing industries, including traditional paper/fabric production, plastic and metal foil manufacturing, flexible electronics, thin film batteries, photovoltaics, graphene films production, etc. However, the increasing complexity of R2R processes and high demands on product quality have heightened the needs for effective real-time process monitoring and fault diagnosis in R2R manufacturing systems. This dissertation aims at developing tools to increase system visibility without additional sensors, in order to enhance real-time monitoring, and fault diagnosis capability in R2R manufacturing systems. First, a multistage modeling method is proposed for process monitoring and quality estimation in R2R processes. Product-centric and process-centric variation propagation are introduced to characterize variation propagation throughout the system. The multistage model mainly focuses on the formulation of process-centric variation propagation, which uniquely exists in R2R processes, and the corresponding product quality measurements with both physical knowledge and sensor data analysis. Second, a nonlinear analytical redundancy method is proposed for sensor validation to ensure the accuracy of sensor measurements for process and quality control. Parity relations based on nonlinear observation matrix are formulated to characterize system dynamics and sensor measurements. Robust optimization is designed to identify the coefficient of parity relations that can tolerate a certain level of measurement noise and system disturbances. The effect of the change of operating conditions on the value of the optimal objective function – parity residuals and the optimal design variables – parity coefficients are evaluated with sensitivity analysis. Finally, a multiple model approach for anomaly detection and fault diagnosis is introduced to improve the diagnosability under different operating regimes. The growing structure multiple model system (GSMMS) is employed, which utilizes Voronoi sets to automatically partition the entire operating space into smaller operating regimes. The local model identification problem is revised by formulating it into an optimization problem based on the loss minimization framework and solving with the mini-batch stochastic gradient descent method instead of least squares algorithms. This revision to the GSMMS method expands its capability to handle the local model identification problems that cannot be solved with a closed-form solution. The effectiveness of the models and methods are determined with testbed data from an R2R process. The results show that those proposed models and methods are effective tools to understand variation propagation in R2R processes and improve estimation accuracy of product quality by 70%, identify the health status of sensors promptly to guarantee data accuracy for modeling and decision making, and reduce false alarm rate and increase detection power under different operating conditions. Eventually, those tools developed in this thesis contribute to increase the visibility of R2R manufacturing systems, improve productivity and reduce product rejection rate.PHDMechanical EngineeringUniversity of Michigan, Horace H. Rackham School of Graduate Studieshttps://deepblue.lib.umich.edu/bitstream/2027.42/146114/1/huanyis_1.pd

Digital twin for civil engineering systems: an exploratory review for distributed sensing updating

We live in an environment of ever-growing demand for transport networks, which also have ageing infrastructure. However, it is not feasible to replace all the infrastructural assets that have surpassed their service lives. The commonly established alternative is increasing their durability by means of Structural Health Monitoring (SHM)-based maintenance and serviceability. Amongst the multitude of approaches to SHM, the Digital Twin model is gaining increasing attention. This model is a digital reconstruction (the Digital Twin) of a real-life asset (the Physical Twin) that, in contrast to other digital models, is frequently and automatically updated using data sampled by a sensor network deployed on the latter. This tool can provide infrastructure managers with functionalities to monitor and optimize their asset stock and to make informed and data-based decisions, in the context of day-to-day operative conditions and after extreme events. These data not only include sensor data, but also include regularly revalidated structural reliability indices formulated on the grounds of the frequently updated Digital Twin model. The technology can be even pushed as far as performing structural behavioral predictions and automatically compensating for them. The present exploratory review covers the key Digital Twin aspects—its usefulness, modus operandi, application, etc.—and proves the suitability of Distributed Sensing as its network sensor component.This research was funded by Fondazione CARITRO Cassa di Risparmio di Trento e Rovereto, grant number 2021.0224.Peer ReviewedPostprint (published version

Integrated performance prediction and quality control in manufacturing systems

textPredicting the condition of a degrading dynamic system is critical for implementing successful control and designing the optimal operation and maintenance strategies throughout the lifetime of the system. In many situations, especially in manufacturing, systems experience multiple degradation cycles, failures, and maintenance events throughout their lifetimes. In such cases, historical records of sensor readings observed during the lifecycle of a machine can yield vital information about degradation patterns of the monitored machine, which can be used to formulate dynamic models for predicting its future performance. Besides the ability to predict equipment failures, another major component of cost effective and high-throughput manufacturing is tight control of product quality. Quality control is assured by taking periodic measurements of the products at various stages of production. Nevertheless, quality measurements of the product require time and are often executed on costly measurement equipment, which increases the cost of manufacturing and slows down production. One possible way to remedy this situation is to utilize the inherent link between the manufacturing equipment condition, mirrored in the readings of sensors mounted on that machine, and the quality of products coming out of it. The concept of Virtual Metrology (VM) addresses the quality control problem by using data-driven models that relate the product quality to the equipment sensors, enabling continuous estimation of the quality characteristics of the product, even when physical measurements of product quality are not available. VM can thus bring significant production benefits, including improved process control, reduced quality losses and higher productivity. In this dissertation, new methods are formulated that will combine long-term performance prediction of sensory signatures from a degrading manufacturing machine with VM quality estimation, which enables integration of predictive condition monitoring (prediction of sensory signatures) with predictive manufacturing process control (predictive VM model). The recently developed algorithm for prediction of sensory signatures is capable of predicting the system condition by comparing the similarity of the most recent performance signatures with the known degradation patterns available in the historical records. The method accomplishes the prediction of non-Gaussian and non-stationary time-series of relevant performance signatures with analytical tractability, which enables calculations of predicted signature distributions with significantly greater speeds than what can be found in literature. VM quality estimation is implemented using the recently introduced growing structure multiple model system paradigm (GSMMS), based on the use of local linear dynamic models. The concept of local models enables representation of complex, non-linear dependencies with non-Gaussian and non-stationary noise characteristics, using a locally tractable model representation. Localized modeling enables a VM that can detect situations when the VM model is not adequate and needs to be improved, which is one of the main challenges in VM. Finally, uncertainty propagation with Monte Carlo simulation is pursued in order to propagate the predicted distributions of equipment signatures through the VM model to enable prediction of distributions of the quality variables using the readily available sensor readings streaming from the monitored manufacturing machine. The newly developed methods are applied to long-term production data coming from an industrial plasma-enhanced chemical vapor deposition (PECVD) tool operating in a major semiconductor manufacturing fab.Mechanical Engineerin