Prognostic Model Development with Missing Labels - A Condition-Based Maintenance Approach Using Machine Learning

Condition-based maintenance (CBM) has emerged as a proactive strategy for determining the best time for maintenance activities. In this paper, a case of a milling process with imperfect maintenance at a German automotive manufacturer is considered. Its major challenge is that only data with missing labels are available, which does not provide a sufficient basis for classical prognostic maintenance models. To overcome this shortcoming, a data science study is carried out that combines several analytical methods, especially from the field of machine learning (ML). These include time-domain and time–frequency domain techniques for feature extraction, agglomerative hierarchical clustering and time series clustering for unsupervised pattern detection, as well as a recurrent neural network for prognostic model training. With the approach developed, it is possible to replace decisions that were made based on subjective criteria with data-driven decisions to increase the tool life of the milling machines. The solution can be employed beyond the presented case to similar maintenance scenarios as the basis for decision support and prognostic model development. Moreover, it helps to further close the gap between ML research and the practical implementation of CBM

Sensors Fault Diagnosis Trends and Applications

Fault diagnosis has always been a concern for industry. In general, diagnosis in complex systems requires the acquisition of information from sensors and the processing and extracting of required features for the classification or identification of faults. Therefore, fault diagnosis of sensors is clearly important as faulty information from a sensor may lead to misleading conclusions about the whole system. As engineering systems grow in size and complexity, it becomes more and more important to diagnose faulty behavior before it can lead to total failure. In the light of above issues, this book is dedicated to trends and applications in modern-sensor fault diagnosis

Proceedings of the 2nd Conference on Production Systems and Logistics (CPSL 2021)

Proceedings of the CPSL 202

Applications

Volume 3 describes how resource-aware machine learning methods and techniques are used to successfully solve real-world problems. The book provides numerous specific application examples: in health and medicine for risk modelling, diagnosis, and treatment selection for diseases in electronics, steel production and milling for quality control during manufacturing processes in traffic, logistics for smart cities and for mobile communications

Evolving Clustering Algorithms And Their Application For Condition Monitoring, Diagnostics, & Prognostics

Applications of Condition-Based Maintenance (CBM) technology requires effective yet generic data driven methods capable of carrying out diagnostics and prognostics tasks without detailed domain knowledge and human intervention. Improved system availability, operational safety, and enhanced logistics and supply chain performance could be achieved, with the widespread deployment of CBM, at a lower cost level. This dissertation focuses on the development of a Mutual Information based Recursive Gustafson-Kessel-Like (MIRGKL) clustering algorithm which operates recursively to identify underlying model structure and parameters from stream type data. Inspired by the Evolving Gustafson-Kessel-like Clustering (eGKL) algorithm, we applied the notion of mutual information to the well-known Mahalanobis distance as the governing similarity measure throughout. This is also a special case of the Kullback-Leibler (KL) Divergence where between-cluster shape information (governed by the determinant and trace of the covariance matrix) is omitted and is only applicable in the case of normally distributed data. In the cluster assignment and consolidation process, we proposed the use of the Chi-square statistic with the provision of having different probability thresholds. Due to the symmetry and boundedness property brought in by the mutual information formulation, we have shown with real-world data that the algorithm’s performance becomes less sensitive to the same range of probability thresholds which makes system tuning a simpler task in practice. As a result, improvement demonstrated by the proposed algorithm has implications in improving generic data driven methods for diagnostics, prognostics, generic function approximations and knowledge extractions for stream type of data. The work in this dissertation demonstrates MIRGKL’s effectiveness in clustering and knowledge representation and shows promising results in diagnostics and prognostics applications

Sensor data-based decision making

Increasing globalization and growing industrial system complexity has amplified the interest in the use of information provided by sensors as a means of improving overall manufacturing system performance and maintainability. However, utilization of sensors can only be effective if the real-time data can be integrated into the necessary business processes, such as production planning, scheduling and execution systems. This integration requires the development of intelligent decision making models that can effectively process the sensor data into information and suggest appropriate actions. To be able to improve the performance of a system, the health of the system also needs to be maintained. In many cases a single sensor type cannot provide sufficient information for complex decision making including diagnostics and prognostics of a system. Therefore, a combination of sensors should be used in an integrated manner in order to achieve desired performance levels. Sensor generated data need to be processed into information through the use of appropriate decision making models in order to improve overall performance. In this dissertation, which is presented as a collection of five journal papers, several reactive and proactive decision making models that utilize data from single and multi-sensor environments are developed. The first paper presents a testbed architecture for Auto-ID systems. An adaptive inventory management model which utilizes real-time RFID data is developed in the second paper. In the third paper, a complete hardware and inventory management solution, which involves the integration of RFID sensors into an extremely low temperature industrial freezer, is presented. The last two papers in the dissertation deal with diagnostic and prognostic decision making models in order to assure the healthy operation of a manufacturing system and its components. In the fourth paper a Mahalanobis-Taguchi System (MTS) based prognostics tool is developed and it is used to estimate the remaining useful life of rolling element bearings using data acquired from vibration sensors. In the final paper, an MTS based prognostics tool is developed for a centrifugal water pump, which fuses information from multiple types of sensors in order to take diagnostic and prognostics decisions for the pump and its components --Abstract, page iv

Volume 3 – Conference

We are pleased to present the conference proceedings for the 12th edition of the International Fluid Power Conference (IFK). The IFK is one of the world’s most significant scientific conferences on fluid power control technology and systems. It offers a common platform for the presentation and discussion of trends and innovations to manufacturers, users and scientists. The Chair of Fluid-Mechatronic Systems at the TU Dresden is organizing and hosting the IFK for the sixth time. Supporting hosts are the Fluid Power Association of the German Engineering Federation (VDMA), Dresdner Verein zur Förderung der Fluidtechnik e. V. (DVF) and GWT-TUD GmbH. The organization and the conference location alternates every two years between the Chair of Fluid-Mechatronic Systems in Dresden and the Institute for Fluid Power Drives and Systems in Aachen. The symposium on the first day is dedicated to presentations focused on methodology and fundamental research. The two following conference days offer a wide variety of application and technology orientated papers about the latest state of the art in fluid power. It is this combination that makes the IFK a unique and excellent forum for the exchange of academic research and industrial application experience. A simultaneously ongoing exhibition offers the possibility to get product information and to have individual talks with manufacturers. The theme of the 12th IFK is “Fluid Power – Future Technology”, covering topics that enable the development of 5G-ready, cost-efficient and demand-driven structures, as well as individual decentralized drives. Another topic is the real-time data exchange that allows the application of numerous predictive maintenance strategies, which will significantly increase the availability of fluid power systems and their elements and ensure their improved lifetime performance. We create an atmosphere for casual exchange by offering a vast frame and cultural program. This includes a get-together, a conference banquet, laboratory festivities and some physical activities such as jogging in Dresden’s old town.:Group 8: Pneumatics Group 9 | 11: Mobile applications Group 10: Special domains Group 12: Novel system architectures Group 13 | 15: Actuators & sensors Group 14: Safety & reliabilit