A hierarchical Mamdani-type fuzzy modelling approach with new training data selection and multi-objective optimisation mechanisms: A special application for the prediction of mechanical properties of alloy steels

In this paper, a systematic data-driven fuzzy modelling methodology is proposed, which allows to construct Mamdani fuzzy models considering both accuracy (precision) and transparency (interpretability) of fuzzy systems. The new methodology employs a fast hierarchical clustering algorithm to generate an initial fuzzy model efficiently; a training data selection mechanism is developed to identify appropriate and efficient data as learning samples; a high-performance Particle Swarm Optimisation (PSO) based multi-objective optimisation mechanism is developed to further improve the fuzzy model in terms of both the structure and the parameters; and a new tolerance analysis method is proposed to derive the confidence bands relating to the final elicited models. This proposed modelling approach is evaluated using two benchmark problems and is shown to outperform other modelling approaches. Furthermore, the proposed approach is successfully applied to complex high-dimensional modelling problems for manufacturing of alloy steels, using ‘real’ industrial data. These problems concern the prediction of the mechanical properties of alloy steels by correlating them with the heat treatment process conditions as well as the weight percentages of the chemical compositions

Adaptive inferential sensors based on evolving fuzzy models

A new technique to the design and use of inferential sensors in the process industry is proposed in this paper, which is based on the recently introduced concept of evolving fuzzy models (EFMs). They address the challenge that the modern process industry faces today, namely, to develop such adaptive and self-calibrating online inferential sensors that reduce the maintenance costs while keeping the high precision and interpretability/transparency. The proposed new methodology makes possible inferential sensors to recalibrate automatically, which reduces significantly the life-cycle efforts for their maintenance. This is achieved by the adaptive and flexible open-structure EFM used. The novelty of this paper lies in the following: (1) the overall concept of inferential sensors with evolving and self-developing structure from the data streams; (2) the new methodology for online automatic selection of input variables that are most relevant for the prediction; (3) the technique to detect automatically a shift in the data pattern using the age of the clusters (and fuzzy rules); (4) the online standardization technique used by the learning procedure of the evolving model; and (5) the application of this innovative approach to several real-life industrial processes from the chemical industry (evolving inferential sensors, namely, eSensors, were used for predicting the chemical properties of different products in The Dow Chemical Company, Freeport, TX). It should be noted, however, that the methodology and conclusions of this paper are valid for the broader area of chemical and process industries in general. The results demonstrate that well-interpretable and with-simple-structure inferential sensors can automatically be designed from the data stream in real time, which predict various process variables of interest. The proposed approach can be used as a basis for the development of a new generation of adaptive and evolving inferential sensors that can a- ddress the challenges of the modern advanced process industry

An artificial immune systems based predictive modelling approach for the multi-objective elicitation of Mamdani fuzzy rules: a special application to modelling alloys

In this paper, a systematic multi-objective Mamdani fuzzy modeling approach is proposed, which can be viewed as an extended version of the previously proposed Singleton fuzzy modeling paradigm. A set of new back-error propagation (BEP) updating formulas are derived so that they can replace the old set developed in the singleton version. With the substitution, the extension to the multi-objective Mamdani Fuzzy Rule-Based Systems (FRBS) is almost endemic. Due to the carefully chosen output membership functions, the inference and the defuzzification methods, a closed form integral can be deducted for the defuzzification method, which ensures the efficiency of the developed Mamdani FRBS. Some important factors, such as the variable length coding scheme and the rule alignment, are also discussed. Experimental results for a real data set from the steel industry suggest that the proposed approach is capable of eliciting not only accurate but also transparent FRBS with good generalization ability

An immune algorithm based fuzzy predictive modeling mechanism using variable length coding and multi-objective optimization allied to engineering materials processing

In this paper, a systematic multi-objective fuzzy modeling approach is proposed, which can be regarded as a three-stage modeling procedure. In the first stage, an evolutionary based clustering algorithm is developed to extract an initial fuzzy rule base from the data. Based on this model, a back-propagation algorithm with momentum terms is used to refine the initial fuzzy model. The refined model is then used to seed the initial population of an immune inspired multi-objective optimization algorithm in the third stage to obtain a set of fuzzy models with improved transparency. To tackle the problem of simultaneously optimizing the structure and parameters, a variable length coding scheme is adopted to improve the efficiency of the search. The proposed modeling approach is applied to a real data set from the steel industry. Results show that the proposed approach is capable of eliciting not only accurate but also transparent fuzzy models

The application of ANFIS prediction models for thermal error compensation on CNC machine tools

Thermal errors can have significant effects on CNC machine tool accuracy. The errors come from thermal deformations of the machine elements caused by heat sources within the machine structure or from ambient temperature change. The effect of temperature can be reduced by error avoidance or numerical compensation. The performance of a thermal error compensation system essentially depends upon the accuracy and robustness of the thermal error model and its input measurements. This paper first reviews different methods of designing thermal error models, before concentrating on employing an adaptive neuro fuzzy inference system (ANFIS) to design two thermal prediction models: ANFIS by dividing the data space into rectangular sub-spaces (ANFIS-Grid model) and ANFIS by using the fuzzy c-means clustering method (ANFIS-FCM model). Grey system theory is used to obtain the influence ranking of all possible temperature sensors on the thermal response of the machine structure. All the influence weightings of the thermal sensors are clustered into groups using the fuzzy c-means (FCM) clustering method, the groups then being further reduced by correlation analysis. A study of a small CNC milling machine is used to provide training data for the proposed models and then to provide independent testing data sets. The results of the study show that the ANFIS-FCM model is superior in terms of the accuracy of its predictive ability with the benefit of fewer rules. The residual value of the proposed model is smaller than ±4 μm. This combined methodology can provide improved accuracy and robustness of a thermal error compensation system

Thermal error modelling of machine tools based on ANFIS with fuzzy c-means clustering using a thermal imaging camera

Thermal errors are often quoted as being the largest contributor to CNC machine tool errors, but they can be effectively reduced using error compensation. The performance of a thermal error compensation system depends on the accuracy and robustness of the thermal error model and the quality of the inputs to the model. The location of temperature measurement must provide a representative measurement of the change in temperature that will affect the machine structure. The number of sensors and their locations are not always intuitive and the time required to identify the optimal locations is often prohibitive, resulting in compromise and poor results. In this paper, a new intelligent compensation system for reducing thermal errors of machine tools using data obtained from a thermal imaging camera is introduced. Different groups of key temperature points were identified from thermal images using a novel schema based on a Grey model GM (0, N) and Fuzzy c-means (FCM) clustering method. An Adaptive Neuro-Fuzzy Inference System with Fuzzy c-means clustering (FCM-ANFIS) was employed to design the thermal prediction model. In order to optimise the approach, a parametric study was carried out by changing the number of inputs and number of membership functions to the FCM-ANFIS model, and comparing the relative robustness of the designs. According to the results, the FCM-ANFIS model with four inputs and six membership functions achieves the best performance in terms of the accuracy of its predictive ability. The residual value of the model is smaller than ± 2 μm, which represents a 95% reduction in the thermally-induced error on the machine. Finally, the proposed method is shown to compare favourably against an Artificial Neural Network (ANN) model

Model fusion using fuzzy aggregation: Special applications to metal properties

To improve the modelling performance, one should either propose a new modelling methodology or make the best of existing models. In this paper, the study is concentrated on the latter solution, where a structure-free modelling paradigm is proposed. It does not rely on a fixed structure and can combine various modelling techniques in ‘symbiosis’ using a ‘master fuzzy system’. This approach is shown to be able to include the advantages of different modelling techniques altogether by requiring less training and by minimising the efforts relating optimisation of the final structure. The proposed approach is then successfully applied to the industrial problems of predicting machining induced residual stresses for aerospace alloy components as well as modelling the mechanical properties of heat-treated alloy steels, both representing complex, non-linear and multi-dimensional environments