Feedback and time are essential for the optimal control of computing systems

The performance, reliability, cost, size and energy usage of computing systems can be improved by one or more orders of magnitude by the systematic use of modern control and optimization methods. Computing systems rely on the use of feedback algorithms to schedule tasks, data and resources, but the models that are used to design these algorithms are validated using open-loop metrics. By using closed-loop metrics instead, such as the gap metric developed in the control community, it should be possible to develop improved scheduling algorithms and computing systems that have not been over-engineered. Furthermore, scheduling problems are most naturally formulated as constraint satisfaction or mathematical optimization problems, but these are seldom implemented using state of the art numerical methods, nor do they explicitly take into account the fact that the scheduling problem itself takes time to solve. This paper makes the case that recent results in real-time model predictive control, where optimization problems are solved in order to control a process that evolves in time, are likely to form the basis of scheduling algorithms of the future. We therefore outline some of the research problems and opportunities that could arise by explicitly considering feedback and time when designing optimal scheduling algorithms for computing systems

Inspection by exception: a new machine learning-based approach for multistage manufacturing

Manufacturing processes usually consist of multiple different stages, each of which is influenced by a multitude of factors. Therefore, variations in product quality at a certain stage are contributed to by the errors generated at the current, as well as preceding, stages. The high cost of each production stage in the manufacture of high-quality products has stimulated a drive towards decreasing the volume of non-added value processes such as inspection. This paper presents a new method for what the authors have referred to as ‘inspection by exception’ – the principle of actively detecting and then inspecting only the parts that cannot be categorized as healthy or unhealthy with a high degree of certainty. The key idea is that by inspecting only those parts that are in the corridor of uncertainty, the volume of inspections are considerably reduced. This possibility is explored using multistage manufacturing data and both unsupervised and supervised learning algorithms. A case study is presented whereby material conditions and time domain features for force, vibration and tempering temperature are used as input data. Fuzzy C-Means (FCM) clustering is implemented to achieve inspection by exception in an unsupervised manner based on the normalized Euclidean distances between the principal components and cluster centres. Also, deviation vectors for product health are obtained using a comparator system to train neural networks for supervised learning-based inspection by exception. It is shown that the volume of inspections can be reduced by as much as 82% and 93% using the unsupervised and supervised learning approaches, respectively

Global supply chains of high value low volume products

Imperial Users onl

A novel haptic model and environment for maxillofacial surgical operation planning and manipulation

This paper presents a practical method and a new haptic model to support manipulations of bones and their segments during the planning of a surgical operation in a virtual environment using a haptic interface. To perform an effective dental surgery it is important to have all the operation related information of the patient available beforehand in order to plan the operation and avoid any complications. A haptic interface with a virtual and accurate patient model to support the planning of bone cuts is therefore critical, useful and necessary for the surgeons. The system proposed uses DICOM images taken from a digital tomography scanner and creates a mesh model of the filtered skull, from which the jaw bone can be isolated for further use. A novel solution for cutting the bones has been developed and it uses the haptic tool to determine and define the bone-cutting plane in the bone, and this new approach creates three new meshes of the original model. Using this approach the computational power is optimized and a real time feedback can be achieved during all bone manipulations. During the movement of the mesh cutting, a novel friction profile is predefined in the haptical system to simulate the force feedback feel of different densities in the bone

Optimal parameter selection for nonlinear multistage systems with time-delays

In this paper, we consider a novel dynamic optimization problem for nonlinear multistage systems with time-delays. Such systems evolve over multiple stages, with the dynamics in each stage depending on both the current state of the system and the state at delayed times. The optimization problem involves choosing the values of the time-delays, as well as the values of additional parameters that influence the system dynamics, to minimize a given cost functional. We first show that the partial derivatives of the system state with respect to the time-delays and system parameters can be computed by solving a set of auxiliary dynamic systems in conjunction with the governing multistage system. On this basis, a gradient-based optimization algorithm is proposed to determine the optimal values of the delays and system parameters. Finally, two example problems, one of which involves parameter identification for a realistic fed-batch fermentation process, are solved to demonstrate the algorithm’s effectiveness

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

Risk-Averse Model Predictive Operation Control of Islanded Microgrids

In this paper we present a risk-averse model predictive control (MPC) scheme for the operation of islanded microgrids with very high share of renewable energy sources. The proposed scheme mitigates the effect of errors in the determination of the probability distribution of renewable infeed and load. This allows to use less complex and less accurate forecasting methods and to formulate low-dimensional scenario-based optimisation problems which are suitable for control applications. Additionally, the designer may trade performance for safety by interpolating between the conventional stochastic and worst-case MPC formulations. The presented risk-averse MPC problem is formulated as a mixed-integer quadratically-constrained quadratic problem and its favourable characteristics are demonstrated in a case study. This includes a sensitivity analysis that illustrates the robustness to load and renewable power prediction errors

Optimum Allocation of Inspection Stations in Multistage Manufacturing Processes by Using Max-Min Ant System

In multistage manufacturing processes it is common to locate inspection stations after some or all of the processing workstations. The purpose of the inspection is to reduce the total manufacturing cost, resulted from unidentified defective items being processed unnecessarily through subsequent manufacturing operations. This total cost is the sum of the costs of production, inspection and failures (during production and after shipment). Introducing inspection stations into a serial multistage manufacturing process, although constituting an additional cost, is expected to be a profitable course of action. Specifically, at some positions the associated inspection costs will be recovered from the benefits realised through the detection of defective items, before wasting additional cost by continuing to process them. In this research, a novel general cost modelling for allocating a limited number of inspection stations in serial multistage manufacturing processes is formulated. In allocation of inspection station (AOIS) problem, as the number of workstations increases, the number of inspection station allocation possibilities increases exponentially. To identify the appropriate approach for the AOIS problem, different optimisation methods are investigated. The MAX-MIN Ant System (MMAS) algorithm is proposed as a novel approach to explore AOIS in serial multistage manufacturing processes. MMAS is an ant colony optimisation algorithm that was designed originally to begin an explorative search phase and, subsequently, to make a slow transition to the intensive exploitation of the best solutions found during the search, by allowing only one ant to update the pheromone trails. Two novel heuristics information for the MMAS algorithm are created. The heuristic information for the MMAS algorithm is exploited as a novel means to guide ants to build reasonably good solutions from the very beginning of the search. To improve the performance of the MMAS algorithm, six local search methods which are well-known and suitable for the AOIS problem are used. Selecting relevant parameter values for the MMAS algorithm can have a great impact on the algorithm’s performance. As a result, a method for tuning the most influential parameter values for the MMAS algorithm is developed. The contribution of this research is, for the first time, a methodology using MMAS to solve the AOIS problem in serial multistage manufacturing processes has been developed. The methodology takes into account the constraints on inspection resources, in terms of a limited number of inspection stations. As a result, the total manufacturing cost of a product can be reduced, while maintaining the quality of the product. Four numerical experiments are conducted to assess the MMAS algorithm for the AOIS problem. The performance of the MMAS algorithm is compared with a number of other methods this includes the complete enumeration method (CEM), rule of thumb, a pure random search algorithm, particle swarm optimisation, simulated annealing and genetic algorithm. The experimental results show that the effectiveness of the MMAS algorithm lies in its considerably shorter execution time and robustness. Further, in certain conditions results obtained by the MMAS algorithm are identical to the CEM. In addition, the results show that applying local search to the MMAS algorithm has significantly improved the performance of the algorithm. Also the results demonstrate that it is essential to use heuristic information with the MMAS algorithm for the AOIS problem, in order to obtain a high quality solution. It was found that the main parameters of MMAS include the pheromone trail intensity, heuristic information and evaporation of pheromone are less sensitive within the specified range as the number of workstations is significantly increased

Air recovery assessment on high-pressure pneumatic systems

A computational simulation and experimental work of the fluid flow through the pneumatic circuit used in a stretch blow moulding machine is presented in this paper. The computer code is built around a zero-dimensional thermodynamic model for the air blowing and recycling containers together with a non-linear time-variant deterministic model for the pneumatic three stations single acting valve manifold, which, in turn, is linked to a quasi-one-dimensional unsteady flow model for the interconnecting pipes. The flow through the pipes accounts for viscous friction, heat transfer, cross-sectional area variation, and entropy variation. Two different solving methods are applied: the method of characteristics and the Harten-Lax-Van Leer (HLL) Riemann first-order scheme. The numerical model allows prediction of the air blowing process and, more significantly, permits determination of the recycling rate at each operating cycle. A simplified experimental set-up of the industrial process was designed, and the pressure and temperature were adequately monitored. Predictions of the blowing process for various configurations proved to be in good agreement with the measured results. In addition, a novel design of a valve manifold intended for the polyethylene terephthalate (PET) plastic bottle manufacturing industry is also presented.Peer ReviewedPostprint (author's final draft