A Decision-Making Tool Based on Exploratory Visualization for the Automotive Industry

In recent years, the digital transformation has been advancing in industrial companies, supported by the Key Enabling Technologies (Big Data, IoT, etc.) of Industry 4.0. As a consequence, companies have large volumes of data and information that must be analyzed to give them competitive advantages. This is of the utmost importance in fields such as Failure Detection (FD) and Predictive Maintenance (PdM). Finding patterns in such data is not easy, but cutting-edge technologies, such as Machine Learning (ML), can make great contributions. As a solution, this study extends Hybrid Unsupervised Exploratory Plots (HUEPs), as a visualization technique that combines Exploratory Projection Pursuit (EPP) and Clustering methods. An extended formulation of HUEPs is proposed, adding for the first time the following EPP methods: Classical Multidimensional Scaling, Sammon Mapping and Factor Analysis. Extended HUEPs are validated in a case study associated with a multinational company in the automotive industry sector. Two real-life datasets containing data gathered from a Waterjet Cutting tool are visualized in an intuitive and informative way. The obtained results show that HUEPs is a technique that supports the continuous monitoring of machines in order to anticipate failures. This contribution to visual data analytics can help companies in decision-making, regarding FD and PdM projects.The authors would like to thank the vehicle interiors manufacturer, Grupo Antolin, for its collaboration in this research

Efficient Data Reduction at the Edge of Industrial Internet of Things for PMSM Bearing Fault Diagnosis

An efficient data reduction algorithm is designed and implemented on an industrial Internet of Things (IIoT) node for permanent magnet synchronous motor (PMSM) bearing fault diagnosis in variable speed conditions. Leakage flux and vibration signals are respectively acquired by a magnetic sensor and an accelerometer on the IIoT node in a non-invasive manner. These two signals are processed and mixed on the IIoT and transmitted to a server. The received signal is separated, the cumulative rotation angle is calculated, and the vibration signal is resampled for bearing fault identification. The proposed method can reduce about 95% of the transmission data while maintaining sufficient precision in bearing fault diagnosis in comparison with a traditional method. The proposed method based on edge computing reduces the power consumption, and hence it is suitable to use on a battery-supplied IIoT node for remote PMSM condition monitoring and fault diagnosis

Fault Diagnosis and Fault Tolerant Control of Wind Turbines: An Overview

Wind turbines are playing an increasingly important role in renewable power generation. Their complex and large-scale structure, however, and operation in remote locations with harsh environmental conditions and highly variable stochastic loads make fault occurrence inevitable. Early detection and location of faults are vital for maintaining a high degree of availability and reducing maintenance costs. Hence, the deployment of algorithms capable of continuously monitoring and diagnosing potential faults and mitigating their effects before they evolve into failures is crucial. Fault diagnosis and fault tolerant control designs have been the subject of intensive research in the past decades. Significant progress has been made and several methods and control algorithms have been proposed in the literature. This paper provides an overview of the most recent fault diagnosis and fault tolerant control techniques for wind turbines. Following a brief discussion of the typical faults, the most commonly used model-based, data-driven and signal-based approaches are discussed. Passive and active fault tolerant control approaches are also highlighted and relevant publications are discussed. Future development tendencies in fault diagnosis and fault tolerant control of wind turbines are also briefly stated. The paper is written in a tutorial manner to provide a comprehensive overview of this research topic

Underground distribution cable incipient fault diagnosis system

This dissertation presents a methodology for an efficient, non-destructive, and online incipient fault diagnosis system (IFDS) to detect underground cable incipient faults before they become catastrophic. The system provides vital information to help the operator with the decision-making process regarding the condition assessment of the underground cable. It incorporates advanced digital signal processing and pattern recognition methods to classify recorded data into designated classes. Additionally, the IFDS utilizes novel detection methodologies to detect when the cable is near failure. The classification functionality is achieved through employing an ensemble of rule-based and supervised classifiers. The Support Vector Machines, designed and used as a supervised classifier, was found to perform superior. In addition to the normalized energy features computed from wavelet packet analysis, two new features, namely Horizontal Severity Index, and Vertical Severity Index are defined and used in the classification problem. The detection functionality of the IFDS is achieved through incorporating a temporal severity measure and a detection method. The novel severity measure is based on the temporal analysis of arrival times of incipient abnormalities, which gives rise to a numeric index called the Global Severity Index (GSI). This index portrays the progressive degradation path of underground cable as catastrophic failure time approaches. The detection approach utilizes the numerical modeling capabilities of SOM as well as statistical change detection techniques. The natural logarithm of the chronologically ordered minimum modeling errors, computed from exposing feature vectors to a trained SOM, is used as the detection index. Three modified change detection algorithms, namely Cumulative Sum, Exponentially Weighted Moving Averages, and Generalized Likelihood Ratio, are introduced and applied to this application. These algorithms determine the change point or near failure time of cable from the instantaneous values of the detection index. Performance studies using field recorded data were conducted at three warning levels to assess the capability of the IFDS in predicting the faults that actually occurred in the monitored underground cable. The IFDS presents a high classification rate and satisfactory detection capability at each warning level. Specifically, it demonstrates that at least one detection technique successfully provides an early warning that a fault is imminent

Pattern Recognition

Pattern recognition is a very wide research field. It involves factors as diverse as sensors, feature extraction, pattern classification, decision fusion, applications and others. The signals processed are commonly one, two or three dimensional, the processing is done in real- time or takes hours and days, some systems look for one narrow object class, others search huge databases for entries with at least a small amount of similarity. No single person can claim expertise across the whole field, which develops rapidly, updates its paradigms and comprehends several philosophical approaches. This book reflects this diversity by presenting a selection of recent developments within the area of pattern recognition and related fields. It covers theoretical advances in classification and feature extraction as well as application-oriented works. Authors of these 25 works present and advocate recent achievements of their research related to the field of pattern recognition

Hybridization of machine learning for advanced manufacturing

Tesis por compendio de publicacioines[ES] En el contexto de la industria, hoy por hoy, los términos “Fabricación Avanzada”, “Industria 4.0” y “Fábrica Inteligente” están convirtiéndose en una realidad. Las empresas industriales buscan ser más competitivas, ya sea en costes, tiempo, consumo de materias primas, energía, etc. Se busca ser eficiente en todos los ámbitos y además ser sostenible. El futuro de muchas compañías depende de su grado de adaptación a los cambios y su capacidad de innovación. Los consumidores son cada vez más exigentes, buscando productos personalizados y específicos con alta calidad, a un bajo coste y no contaminantes. Por todo ello, las empresas industriales implantan innovaciones tecnológicas para conseguirlo. Entre estas innovaciones tecnológicas están la ya mencionada Fabricación Avanzada (Advanced Manufacturing) y el Machine Learning (ML). En estos campos se enmarca el presente trabajo de investigación, en el que se han concebido y aplicado soluciones inteligentes híbridas que combinan diversas técnicas de ML para resolver problemas en el campo de la industria manufacturera. Se han aplicado técnicas inteligentes tales como Redes Neuronales Artificiales (RNA), algoritmos genéticos multiobjetivo, métodos proyeccionistas para la reducción de la dimensionalidad, técnicas de agrupamiento o clustering, etc. También se han utilizado técnicas de Identificación de Sistemas con el propósito de obtener el modelo matemático que representa mejor el sistema real bajo estudio. Se han hibridado diversas técnicas con el propósito de construir soluciones más robustas y fiables. Combinando técnicas de ML específicas se crean sistemas más complejos y con una mayor capacidad de representación/solución. Estos sistemas utilizan datos y el conocimiento sobre estos para resolver problemas. Las soluciones propuestas buscan solucionar problemas complejos del mundo real y de un amplio espectro, manejando aspectos como la incertidumbre, la falta de precisión, la alta dimensionalidad, etc. La presente tesis cubre varios casos de estudio reales, en los que se han aplicado diversas técnicas de ML a distintas problemáticas del campo de la industria manufacturera. Los casos de estudio reales de la industria en los que se ha trabajado, con cuatro conjuntos de datos diferentes, se corresponden con: • Proceso de fresado dental de alta precisión, de la empresa Estudio Previo SL. • Análisis de datos para el mantenimiento predictivo de una empresa del sector de la automoción, como es la multinacional Grupo Antolin. Adicionalmente se ha colaborado con el grupo de investigación GICAP de la Universidad de Burgos y con el centro tecnológico ITCL en los casos de estudio que forman parte de esta tesis y otros relacionados. Las diferentes hibridaciones de técnicas de ML desarrolladas han sido aplicadas y validadas con conjuntos de datos reales y originales, en colaboración con empresas industriales o centros de fresado, permitiendo resolver problemas actuales y complejos. De esta manera, el trabajo realizado no ha tenido sólo un enfoque teórico, sino que se ha aplicado de modo práctico permitiendo que las empresas industriales puedan mejorar sus procesos, ahorrar en costes y tiempo, contaminar menos, etc. Los satisfactorios resultados obtenidos apuntan hacia la utilidad y aportación que las técnicas de ML pueden realizar en el campo de la Fabricación Avanzada

Vibration Monitoring: Gearbox identification and faults detection

L'abstract è presente nell'allegato / the abstract is in the attachmen