Review of Health Prognostics and Condition Monitoring of Electronic Components

To meet the specifications of low cost, highly reliable electronic devices, fault diagnosis techniques play an essential role. It is vital to find flaws at an early stage in design, components, material, or manufacturing during the initial phase. This review paper attempts to summarize past development and recent advances in the areas about green manufacturing, maintenance, remaining useful life (RUL) prediction, and like. The current state of the art in reliability research for electronic components, mainly includes failure mechanisms, condition monitoring, and residual lifetime evaluation is explored. A critical analysis of reliability studies to identify their relative merits and usefulness of the outcome of these studies' vis-a-vis green manufacturing is presented. The wide array of statistical, empirical, and intelligent tools and techniques used in the literature are then identified and mapped. Finally, the findings are summarized, and the central research gap is highlighted

Analysis of uncertainty and variability in finite element computational models for biomedical engineering: characterization and propagation

Computational modeling has become a powerful tool in biomedical engineering thanks to its potential to simulate coupled systems. However, real parameters are usually not accurately known, and variability is inherent in living organisms. To cope with this, probabilistic tools, statistical analysis and stochastic approaches have been used. This article aims to review the analysis of uncertainty and variability in the context of finite element modeling in biomedical engineering. Characterization techniques and propagation methods are presented, as well as examples of their applications in biomedical finite element simulations. Uncertainty propagation methods, both non-intrusive and intrusive, are described. Finally, pros and cons of the different approaches and their use in the scientific community are presented. This leads us to identify future directions for research and methodological development of uncertainty modeling in biomedical engineering

Analysis and Optimization of Process Parameters in Wire Electrical Discharge Machining Based on RSM: A Case Study

In this book chapter a review and critical analysis on current research trends in wire electrical discharge machining (WEDM) and relation between different process parameters including pulse on time, pulse off time, servo voltage, peak current, dielectric flow rate, wire speed, wire tension on different process responses include material removal rate (MRR), surface roughness (Ra), sparking gap, wire lag and wire wear ration (WWR) and surface integrity factors was investigated. On the basis of critical evaluation of the available literature following conclusions are summarized. In addition, different modeling and optimization methods used in WEDM were discussed and a case study based on response surface method (RSM) including design of experiment (DoE) carried out to find optimal process parameters effect on surface roughness was conducted. In the final part of the present study was presented some recommendations about the trends for future WEDM researches

A technical perspective on integrating artificial intelligence to solid-state welding

The implementation of artificial intelligence (AI) techniques in industrial applications, especially solid-state welding (SSW), has transformed modeling, optimization, forecasting, and controlling sophisticated systems. SSW is a better method for joining due to the least melting of material thus maintaining Nugget region integrity. This study investigates thoroughly how AI-based predictions have impacted SSW by looking at methods like Artificial Neural Networks (ANN), Fuzzy Logic (FL), Machine Learning (ML), Meta-Heuristic Algorithms, and Hybrid Methods (HM) as applied to Friction Stir Welding (FSW), Ultrasonic Welding (UW), and Diffusion Bonding (DB). Studies on Diffusion Bonding reveal that ANN and Generic Algorithms can predict outcomes with an accuracy range of 85 – 99%, while Response Surface Methodology such as Optimization Strategy can achieve up to 95 percent confidence levels in improving bonding strength and optimizing process parameters. Using ANNs for FSW gives an average percentage error of about 95%, but using metaheuristics refined it at an incrementally improved accuracy rate of about 2%. In UW, ANN, Hybrid ANN, and ML models predict output parameters with accuracy levels ranging from 85 to 96%. Integrating AI techniques with optimization algorithms, for instance, GA and Particle Swarm Optimization (PSO) significantly improves accuracy, enhancing parameter prediction and optimizing UW processes. ANN’s high accuracy of nearly 95% compared to other techniques like FL and ML in predicting welding parameters. HM exhibits superior precision, showcasing their potential to enhance weld quality, minimize trial welds, and reduce costs and time. Various emerging hybrid methods offer better prediction accuracy

Low carbon manufacturing: Fundamentals, methodology and application case studies

This thesis was submitted for the degree of Doctor of Philosophy and awarded by Brunel University.The requirement and awareness of the carbon emissions reduction in several scales and application of sustainable manufacturing have been now critically reviewed as important manufacturing trends in the 21st century. The key requirements for carbon emissions reduction in this context are energy efficiency, resource utilization, waste minimization and even the reduction of total carbon footprint. The recent approaches tend to only analyse and evaluate carbon emission contents of interested engineering systems. However, a systematic approach based on strategic decision making has not been officially defined with no standards or guidelines further formulated yet. The above requirements demand a fundamentally new approach to future applications of sustainable low carbon manufacturing. Energy and resource efficiencies and effectiveness based low carbon manufacturing (EREEbased LCM) is thus proposed in this research. The proposed EREE-based LCM is able to provide the systematic approach for integrating three key elements (energy efficiency, resource utilization and waste minimization) and taking account of them comprehensively in a scientific manner. The proposed approach demonstrates the solution for reducing carbon emissions in manufacturing systems at both the machine and shop floor levels. An integrated framework has been developed to demonstrate the feasible approach to achieve effective EREE-based LCM at different manufacturing levels including machine, shop floor, enterprise and supply chains. The framework is established in the matrix form with appropriate tools and methodologies related to the three keys elements at each manufacturing level. The theoretical model for EREE-based LCM is also presented, which consists of three essential elements including carbon dioxide emissions evaluation, an optimization method and waste reduction methodology. The preliminary experiment and simulations are carried out to evaluate the proposed concept. The modelling of EREE-based LCM has been developed for both the machine and shop floor levels. At the machine level, the modelling consists of the simulation of energy consumption due to the effect of machining set-up, the optimization model and waste minimization related to the optimized machining set-up. The simulation is established using sugeno type fuzzy logic. The learning method uses on experimental data (cutting trials) while the optimization model is created using mamdani type fuzzy logic with grey relational grade technique. At the shop floor level, the modelling is designed dependent on the cooperation with machine level modelling. The determination of the work assignment including machining set-up depends on fuzzy integer linear programming for several objectives with the evaluation of energy consumption data from machine level modelling. The simulation method is applied as the part of shop floor level modelling in order to maximize resource utilization and minimize undesired waste. The output from the shop floor level modelling is machine production a planning with preventive plan that can minimize the total carbon footprint. The axiomatic design theory has been applied to generate the comprehensive conceptual model E-R-W-C (energy, resource, waste and carbon footprint) of EREE-based LCM as a generic perspective of the systematic modelling. The implementation of EREE-based LCM on both the machine and shop floor levels are demonstrated using MATLAB toolbox and ProModel based simulation. The proposed concept, framework and modelling have been further evaluated and validated through case studies and experimental results.This work is financially supported by The Royal Thai Government

An intelligent manufacturing system for heat treatment scheduling

This thesis was submitted for the degree of Doctor of Philosophy and awarded by Brunel University.This research is focused on the integration problem of process planning and scheduling in steel heat treatment operations environment using artificial intelligent techniques that are capable of dealing with such problems. This work addresses the issues involved in developing a suitable methodology for scheduling heat treatment operations of steel. Several intelligent algorithms have been developed for these propose namely, Genetic Algorithm (GA), Sexual Genetic Algorithm (SGA), Genetic Algorithm with Chromosome differentiation (GACD), Age Genetic Algorithm (AGA), and Mimetic Genetic Algorithm (MGA). These algorithms have been employed to develop an efficient intelligent algorithm using Algorithm Portfolio methodology. After that all the algorithms have been tested on two types of scheduling benchmarks. To apply these algorithms on heat treatment scheduling, a furnace model is developed for optimisation proposes. Furthermore, a system that is capable of selecting the optimal heat treatment regime is developed so the required metal properties can be achieved with the least energy consumption and the shortest time using Neuro-Fuzzy (NF) and Particle Swarm Optimisation (PSO) methodologies. Based on this system, PSO is used to optimise the heat treatment process by selecting different heat treatment conditions. The selected conditions are evaluated so the best selection can be identified. This work addresses the issues involved in developing a suitable methodology for developing an NF system and PSO for mechanical properties of the steel. Using the optimisers, furnace model and heat treatment system model, the intelligent system model is developed and implemented successfully. The results of this system were exciting and the optimisers were working correctly

Seepage criteria based optimal design of water retaining structures with reliability quantification utilizing surrogate model linked simulation-optimization approach

The safety of hydraulic water retaining structures (HWRS) is an important issue as many instances of HWRS failure have been reported. Failure of HWRS may lead to catastrophic events, especially those associated with seepage failures. Therefore, seepage safety factors recommended for HWRS design are generally very conservative. These safety factors have been developed based on approximation calculations, unreliable assumptions, and ideal experimental conditions, which are rarely replicated in real field situations. However, with the development of the numerical methods, and high speed processors, more accurate seepage analysis has become possible, even for complex flow domains, different scenarios of boundary conditions, and varied hydraulic conductivity. On the other hand, because construction of HWRS requires a significant amount of construction material and engineering effort, the construction cost efficiency of HWRS is an issue that must be considered in design of HWRS. This study aims to determine the minimum cost design of HWRS constructed on permeable soils, incorporating numerical solutions of a seepage system related to HWRS, utilizing linked a simulation–optimization (S-O) model. Due to the complexity and inefficacy of directly linking a simulation model to the optimization model, the numerical simulation model was replaced by trained surrogate models. These surrogate models can be trained based on numerically simulated data sets. Therefore, trained surrogate models expeditiously and accurately provide predicted responses relating to seepage characteristics pertaining to HWRS. The optimization model based on the linked S-O technique incorporated different safety factors and hydraulic structure design requirements as constraints. The majority of these constraints and objective function(s) were affected by the responses of predicted seepage characteristics based on the developed surrogate models. To improve the safety of HWRS design, the effect of non-homogenous and anisotropic hydraulic conductivity were incorporated in the S-O model. Obtained solution results demonstrated that considering stratification of the flow domain due to different hydraulic conductivity values or anisotropic ratios can significantly change the optimum design of HWRS. Low hydraulic conductivity and anisotropic ratios resulted in more critical seepage characteristics. Consequently, the minimum construction cost increased due to an increase of dimensions of involved seepage protection design variables. Furthermore, uncertainty in estimating hydraulic conductivity is incorporated in the S-O model. The reliability based optimal design (RBOD) framework based on the multi-realization optimization technique was implemented using the S-O model. The uncertainty in seepage quantities due to uncertainty of hydraulic conductivity was represented using many stochastic ensemble surrogate models. Each ensemble model included many surrogate models trained in utilizing input– output data sets simulated with different scenarios of hydraulic conductivity drawn from diverse random fields based on different log-normal distributions. Obtained results of this approach demonstrated substantial consequences of considering uncertainty in hydraulic conductivity. Also, the deterministic safety factors, especially for those pertaining to the exit gradient, were insufficient to provide prescribed safety in the long term. Although surrogate models are utilized in S-O approaches, each run of the S-O model takes a long time as developed S-O models are applied to complex and large scale problems. Hence, efficiency of the S-O model was a key factor to successfully implement the methodology. Three main techniques were utilized to increase the efficiency of the S-O technique: using parallel computing, utilizing nested function technique, and using a vectorised formulation system. These strategies substantially boosted efficiency of implementing the S-O model. The S-O models were implemented for many hypothetical scenarios for different purposes. In general, results demonstrated that optimum design of the seepage protection system relating to HWRS design must include two end cut-offs with an apron between them. The dimensions of these components were augmented with an increase of upstream water head, and reduction of anisotropic ratios or hydraulic conductivity value. The main role of the downstream cut-off was to decrease the actual exit gradient value. This impact is more pronounced if the inclination angle of the cut-off is toward the downstream side (>90 degrees). The role of the upstream cut-off was to decrease uplift pressure values on the HWRS base. Consequently, this partially contributed to decreasing the exit gradient value. The effect of the upstream cut-off in reducing the uplift pressure was more when the inclination angle was toward the upstream side (<90 degrees). Moreover, the apron (floor) width helped to increase the stability of HWRS. This variable provided the required weight to improve HWRS resistance to external hydraulic forces and to uplift pressure. Incorporating the weight of water (hydrostatic pressure) at the upstream side in counterbalancing momentum and hydraulic forces showed improvement in the safety of the HWRS. Also, all conditions and safety factors pertaining to HWRS design were satisfied. The exit gradient safety factor was the most important critical factor affecting optimum design as obtained optimum solutions satisfied the minimum permissible values of the exit gradient safety factor, i.e., at the minimum permissible value. Also, the eccentric load condition played a crucial role in resulting optimum solutions. Finally, applying the S-O model to obtain reliable and safe design of HWRS at minimum cost was successfully implemented for performance evaluation purposes. This technique may be extended to incorporate more complex scenarios in HWRS design where the impact of dynamic and seismic load could be incorporated. The effect of unsteady state seepage system could be another interesting direction for future studies. Further, incorporating more sources of the uncertainty associated with design parameters could achieve a more accurate estimation of actual safety for the HWRS design

Improving the cost model development process using fuzzy logic

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