Data-driven Soft Sensors in the Process Industry

In the last two decades Soft Sensors established themselves as a valuable alternative to the traditional means for the acquisition of critical process variables, process monitoring and other tasks which are related to process control. This paper discusses characteristics of the process industry data which are critical for the development of data-driven Soft Sensors. These characteristics are common to a large number of process industry fields, like the chemical industry, bioprocess industry, steel industry, etc. The focus of this work is put on the data-driven Soft Sensors because of their growing popularity, already demonstrated usefulness and huge, though yet not completely realised, potential. A comprehensive selection of case studies covering the three most important Soft Sensor application fields, a general introduction to the most popular Soft Sensor modelling techniques as well as a discussion of some open issues in the Soft Sensor development and maintenance and their possible solutions are the main contributions of this work

Self-Adapting Soft Sensor for On-Line Prediction

When it comes to application of computational learning techniques in practical scenarios, like for example adaptive inferential control, it is often difficult to apply the state-of-the-art techniques in a straight forward manner and usually some effort has to be dedicated to tuning either the data, in a form of data pre-processing, or the modelling techniques, in form of optimal parameter search or modification of the training algorithm. In this work we present a robust approach to on-line predictive modelling which is focusing on dealing with challenges like noisy data, data outliers and in particular drifting data which are often present in industrial data sets. The approach is based on the local learning approach, where models of limited complexity focus on partitions of the input space and on an ensemble building technique which combines the predictions of the particular local models into the final predicted value. Furthermore, the technique provides the means for on-line adaptation and can thus be deployed in a dynamic environment which is demonstrated in this work in terms of an application of the presented approach to a raw industrial data set exhibiting drifting data, outliers, missing values and measurement noise

Neuro-Fuzzy Based Intelligent Approaches to Nonlinear System Identification and Forecasting

Nearly three decades back nonlinear system identification consisted of several ad-hoc approaches, which were restricted to a very limited class of systems. However, with the advent of the various soft computing methodologies like neural networks and the fuzzy logic combined with optimization techniques, a wider class of systems can be handled at present. Complex systems may be of diverse characteristics and nature. These systems may be linear or nonlinear, continuous or discrete, time varying or time invariant, static or dynamic, short term or long term, central or distributed, predictable or unpredictable, ill or well defined. Neurofuzzy hybrid modelling approaches have been developed as an ideal technique for utilising linguistic values and numerical data. This Thesis is focused on the development of advanced neurofuzzy modelling architectures and their application to real case studies. Three potential requirements have been identified as desirable characteristics for such design: A model needs to have minimum number of rules; a model needs to be generic acting either as Multi-Input-Single-Output (MISO) or Multi-Input-Multi-Output (MIMO) identification model; a model needs to have a versatile nonlinear membership function. Initially, a MIMO Adaptive Fuzzy Logic System (AFLS) model which incorporates a prototype defuzzification scheme, while utilising an efficient, compared to the Takagi–Sugeno–Kang (TSK) based systems, fuzzification layer has been developed for the detection of meat spoilage using Fourier transform infrared (FTIR) spectroscopy. The identification strategy involved not only the classification of beef fillet samples in their respective quality class (i.e. fresh, semi-fresh and spoiled), but also the simultaneous prediction of their associated microbiological population directly from FTIR spectra. In the case of AFLS, the number of memberships for each input variable was directly associated to the number of rules, hence, the “curse of dimensionality” problem was significantly reduced. Results confirmed the advantage of the proposed scheme against Adaptive Neurofuzzy Inference System (ANFIS), Multilayer Perceptron (MLP) and Partial Least Squares (PLS) techniques used in the same case study. In the case of MISO systems, the TSK based structure, has been utilized in many neurofuzzy systems, like ANFIS. At the next stage of research, an Adaptive Fuzzy Inference Neural Network (AFINN) has been developed for the monitoring the spoilage of minced beef utilising multispectral imaging information. This model, which follows the TSK structure, incorporates a clustering pre-processing stage for the definition of fuzzy rules, while its final fuzzy rule base is determined by competitive learning. In this specific case study, AFINN model was also able to predict for the first time in the literature, the beef’s temperature directly from imaging information. Results again proved the superiority of the adopted model. By extending the line of research and adopting specific design concepts from the previous case studies, the Asymmetric Gaussian Fuzzy Inference Neural Network (AGFINN) architecture has been developed. This architecture has been designed based on the above design principles. A clustering preprocessing scheme has been applied to minimise the number of fuzzy rules. AGFINN incorporates features from the AFLS concept, by having the same number of rules as well as fuzzy memberships. In spite of the extensive use of the standard symmetric Gaussian membership functions, AGFINN utilizes an asymmetric function acting as input linguistic node. Since the asymmetric Gaussian membership function’s variability and flexibility are higher than the traditional one, it can partition the input space more effectively. AGFINN can be built either as an MISO or as an MIMO system. In the MISO case, a TSK defuzzification scheme has been implemented, while two different learning algorithms have been implemented. AGFINN has been tested on real datasets related to electricity price forecasting for the ISO New England Power Distribution System. Its performance was compared against a number of alternative models, including ANFIS, AFLS, MLP and Wavelet Neural Network (WNN), and proved to be superior. The concept of asymmetric functions proved to be a valid hypothesis and certainly it can find application to other architectures, such as in Fuzzy Wavelet Neural Network models, by designing a suitable flexible wavelet membership function. AGFINN’s MIMO characteristics also make the proposed architecture suitable for a larger range of applications/problems

The doctoral research abstracts. Vol:7 2015 / Institute of Graduate Studies, UiTM

Foreword: The Seventh Issue of The Doctoral Research Abstracts captures the novelty of 65 doctorates receiving their scrolls in UiTM’s 82nd Convocation in the field of Science and Technology, Business and Administration, and Social Science and Humanities. To the recipients I would like to say that you have most certainly done UiTM proud by journeying through the scholastic path with its endless challenges and impediments, and persevering right till the very end. This convocation should not be regarded as the end of your highest scholarly achievement and contribution to the body of knowledge but rather as the beginning of embarking into high impact innovative research for the community and country from knowledge gained during this academic journey. As alumni of UiTM, we will always hold you dear to our hearts. A new ‘handshake’ is about to take place between you and UiTM as joint collaborators in future research undertakings. I envisioned a strong research pact between you as our alumni and UiTM in breaking the frontier of knowledge through research. I wish you all the best in your endeavour and may I offer my congratulations to all the graduands. ‘UiTM sentiasa dihati ku’ / Tan Sri Dato’ Sri Prof Ir Dr Sahol Hamid Abu Bakar , FASc, PEng Vice Chancellor Universiti Teknologi MAR

Failure Prognosis of Wind Turbine Components

Wind energy is playing an increasingly significant role in the World\u27s energy supply mix. In North America, many utility-scale wind turbines are approaching, or are beyond the half-way point of their originally anticipated lifespan. Accurate estimation of the times to failure of major turbine components can provide wind farm owners insight into how to optimize the life and value of their farm assets. This dissertation deals with fault detection and failure prognosis of critical wind turbine sub-assemblies, including generators, blades, and bearings based on data-driven approaches. The main aim of the data-driven methods is to utilize measurement data from the system and forecast the Remaining Useful Life (RUL) of faulty components accurately and efficiently. The main contributions of this dissertation are in the application of ALTA lifetime analysis to help illustrate a possible relationship between varying loads and generators reliability, a wavelet-based Probability Density Function (PDF) to effectively detecting incipient wind turbine blade failure, an adaptive Bayesian algorithm for modeling the uncertainty inherent in the bearings RUL prediction horizon, and a Hidden Markov Model (HMM) for characterizing the bearing damage progression based on varying operating states to mimic a real condition in which wind turbines operate and to recognize that the damage progression is a function of the stress applied to each component using data from historical failures across three different Canadian wind farms

Intelligent machining methods for Ti6Al4V: a review

Digital manufacturing is a necessity to establishing a roadmap for the future manufacturing systems projected for the fourth industrial revolution. Intelligent features such as behavior prediction, decision- making abilities, and failure detection can be integrated into machining systems with computational methods and intelligent algorithms. This review reports on techniques for Ti6Al4V machining process modeling, among them numerical modeling with finite element method (FEM) and artificial intelligence- based models using artificial neural networks (ANN) and fuzzy logic (FL). These methods are intrinsically intelligent due to their ability to predict machining response variables. In the context of this review, digital image processing (DIP) emerges as a technique to analyze and quantify the machining response (digitization) in the real machining process, often used to validate and (or) introduce data in the modeling techniques enumerated above. The widespread use of these techniques in the future will be crucial for the development of the forthcoming machining systems as they provide data about the machining process, allow its interpretation and quantification in terms of useful information for process modelling and optimization, which will create machining systems less dependent on direct human intervention.publishe

BIM-based software for construction waste analytics using artificial intelligence hybrid models

The Construction industry generates about 30% of the total waste in the UK. Current high landfill cost and severe environmental impact of waste reveals the need to reduce waste generated from construction activities. Although literature reveals that the best approach to Construction Waste (CW) management is minimization at the design stage, current tools are not robust enough to support architects and design engineers. Review of extant literature reveals that the key limitations of existing CW management tools are that they are not integrated with the design process and that they lack Building Information Modelling (BIM) compliance. This is because the tools are external to design BIM tools used by architects and design engineers. This study therefore investigates BIM-based strategies for CW management and develops Artificial Intelligent (AI) hybrid models to predict CW at the design stage. The model was then integrated into Autodesk Revit as an add-in (BIMWaste) to provide CW analytics. Based on a critical realism paradigm, the study adopts exploratory sequential mixed methods, which combines both qualitative and quantitative methods into a single study. The study starts with the review of extant literature and (FGIs) with industry practitioners. The transcripts of the FGIs were subjected to thematic analysis to identify prevalent themes from the quotations. The factors from literature review and FGIs were then combined and put together in a questionnaire survey and distributed to industry practitioners. The questionnaire responses were subjected to rigorous statistical process to identify key strategies for BIM-based approach to waste efficient design coordination. Results of factor analysis revealed five groups of BIM strategies for CW management, which are: (i)improved collaboration for waste management, (ii)waste-driven design process and solutions, (iii)lifecycle waste analytics, (iv) Innovative technologies for waste intelligence and analytics, and (v)improved documentation for waste management. The results improve the understanding of BIM functionalities and how they could improve the effectiveness of existing CW management tools. Thereafter, the key strategies were developed into a holistic BIM framework for CW management. This was done to incorporate industrial and technological requirements for BIM enabled waste management into an integrated system.The framework guided the development of AI hybrid models and BIM based tool for CW management. Adaptive Neuro-Fuzzy Inference System (ANFIS) model was developed for CW prediction and mathematical models were developed for CW minimisation. Based on historical Construction Waste Record (CWR) from 117 building projects, the model development reveals that two key predictors of CW are “GFA” and “Construction Type”. The final models were then incorporated into Autodesk Revit to enable the prediction of CW from building designs. The performance of the final tool was tested using a test plan and two test cases. The results show that the tool performs well and that it predicts CW according to waste types, element types, and building levels. The study generated several implications that would be of interest to several stakeholders in the construction industry. Particularly, the study provides a clear direction on how CW management strategies could be integrated into BIM platform to streamline the CW analytics

Smart Sensor Monitoring in Machining of Difficult-to-cut Materials

The research activities presented in this thesis are focused on the development of smart sensor monitoring procedures applied to diverse machining processes with particular reference to the machining of difficult-to-cut materials. This work will describe the whole smart sensor monitoring procedure starting from the configuration of the multiple sensor monitoring system for each specific application and proceeding with the methodologies for sensor signal detection and analysis aimed at the extraction of signal features to feed to intelligent decision-making systems based on artificial neural networks. The final aim is to perform tool condition monitoring in advanced machining processes in terms of tool wear diagnosis and forecast, in the perspective of zero defect manufacturing and green technologies. The work has been addressed within the framework of the national MIUR PON research project CAPRI, acronym for “Carrello per atterraggio con attuazione intelligente” (Landing Gear with Intelligent Actuation), and the research project STEP FAR, acronym for “Sviluppo di materiali e Tecnologie Ecocompatibili, di Processi di Foratura, taglio e di Assemblaggio Robotizzato” (Development of eco-compatible materials and technologies for robotised drilling and assembly processes). Both projects are sponsored by DAC, the Campania Technological Aerospace District, and involve two aerospace industries, Magnaghi Aeronautica S.p.A. and Leonardo S.p.A., respectively. Due to the industrial framework in which the projects were developed and taking advantage of the support from the industrial partners, the project activities have been carried out with the aim to contribute to the scientific research in the field of machining process monitoring as well as to promote the industrial applicability of the results. The thesis was structured in order to illustrate all the methodologies, the experimental tests and the results obtained from the research activities. It begins with an introduction to “Sensor monitoring of machining processes” (Chapter 2) with particular attention to the main sensor monitoring applications and the types of sensors which are employed in machining. The key methods for advanced sensor signal processing, including the implementation of sensor fusion technology, are discussed in details as they represent the basic input for cognitive decision-making systems construction. The chapter finally presents a brief discussion on cloud-based manufacturing which will represent one of the future developments of this research work. Chapters 3 and 4 illustrate the case studies of machining process sensor monitoring investigated in the research work. Within the CAPRI project, the feasibility of the dry turning process of Ti6Al4V alloy (Chapter 3) was studied with particular attention to the optimization of the machining parameters avoiding the use of coolant fluids. Since very rapid tool wear is experienced during dry machining of Titanium alloys, the multiple sensor monitoring system was used in order to develop a methodology based on a smart system for on line tool wear detection in terms of maximum flank wear land. Within the STEP FAR project, the drilling process of carbon fibre reinforced (CFRP) composite materials was studied using diverse experimental set-ups. Regarding the tools, three different types of drill bit were employed, including traditional as well as innovative geometry ones. Concerning the investigated materials, two different types of stack configurations were employed, namely CFRP/CFRP stacks and hybrid Al/CFRP stacks. Consequently, the machining parameters for each experimental campaign were varied, and also the methods for signal analysis were changed to verify the performance of the different methodologies. Finally, for each case different neural network configurations were investigated for cognitive-based decision making. First of all, the applicability of the system was tested in order to perform tool wear diagnosis and forecast. Then, the discussion proceeds with a further aim of the research work, which is the reduction of the number of selected sensor signal features, in order to improve the performance of the cognitive decision-making system, simplify modelling and facilitate the implementation of these methodologies in a cloud manufacturing approach to tool condition monitoring. Sensor fusion methodologies were applied to the extracted and selected sensor signal features in the perspective of feature reduction with the purpose to implement these procedures for big data analytics within the Industry 4.0 framework. In conclusion, the positive impact of the proposed tool condition monitoring methodologies based on multiple sensor signal acquisition and processing is illustrated, with particular reference to the reliable assessment of tool state in order to avoid too early or too late cutting tool substitution that negatively affect machining time and cost

Assembly Line

An assembly line is a manufacturing process in which parts are added to a product in a sequential manner using optimally planned logistics to create a finished product in the fastest possible way. It is a flow-oriented production system where the productive units performing the operations, referred to as stations, are aligned in a serial manner. The present edited book is a collection of 12 chapters written by experts and well-known professionals of the field. The volume is organized in three parts according to the last research works in assembly line subject. The first part of the book is devoted to the assembly line balancing problem. It includes chapters dealing with different problems of ALBP. In the second part of the book some optimization problems in assembly line structure are considered. In many situations there are several contradictory goals that have to be satisfied simultaneously. The third part of the book deals with testing problems in assembly line. This section gives an overview on new trends, techniques and methodologies for testing the quality of a product at the end of the assembling line