Adaptive probability scheme for behaviour monitoring of the elderly using a specialised ambient device

A Hidden Markov Model (HMM) modified to work in combination with a Fuzzy System is utilised to determine the current behavioural state of the user from information obtained with specialised hardware. Due to the high dimensionality and not-linearly-separable nature of the Fuzzy System and the sensor data obtained with the hardware which informs the state decision, a new method is devised to update the HMM and replace the initial Fuzzy System such that subsequent state decisions are based on the most recent information. The resultant system first reduces the dimensionality of the original information by using a manifold representation in the high dimension which is unfolded in the lower dimension. The data is then linearly separable in the lower dimension where a simple linear classifier, such as the perceptron used here, is applied to determine the probability of the observations belonging to a state. Experiments using the new system verify its applicability in a real scenario

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

Application of Audible Signals in Tool Condition Monitoring using Machine Learning Techniques

Machining is always accompanied by many difficulties like tool wear, tool breakage, improper machining conditions, non-uniform workpiece properties and some other irregularities, which are some of major barriers to highly-automated operations. Effective tool condition monitoring (TCM) system provides a best solution to monitor those irregular machining processes and suggest operators to take appropriate actions. Even though a wide variety of monitoring techniques have been developed for the online detection of tool condition, it remains an unsolved problem to look for a reliable, simple and cheap solution. This research work mainly focuses on developing a real-time tool condition monitoring model to detect the tool condition, part quality in machining process by using machine learning techniques through sound monitoring. The present study shows the development of a process model capable of on-line process monitoring utilizing machine learning techniques to analyze the sound signals collected during machining and train the proposed system to predict the cutting phenomenon during machining. A decision-making system based on the machine learning technique involving Support Vector Machine approach is developed. The developed system is trained with pre-processed data and tested, and the system showed a significant prediction accuracy in different applications which proves to be an effective model in applying to machining process as an on-line process monitoring system. In addition, this system also proves to be effective, cheap, compact and sensory position invariant. The successful development of the proposed TCM system can provide a practical tool to reduce downtime for tool changes and minimize the amount of scrap in metal cutting industry

Prognostics and health management for maintenance practitioners - Review, implementation and tools evaluation.

In literature, prognostics and health management (PHM) systems have been studied by many researchers from many different engineering fields to increase system reliability, availability, safety and to reduce the maintenance cost of engineering assets. Many works conducted in PHM research concentrate on designing robust and accurate models to assess the health state of components for particular applications to support decision making. Models which involve mathematical interpretations, assumptions and approximations make PHM hard to understand and implement in real world applications, especially by maintenance practitioners in industry. Prior knowledge to implement PHM in complex systems is crucial to building highly reliable systems. To fill this gap and motivate industry practitioners, this paper attempts to provide a comprehensive review on PHM domain and discusses important issues on uncertainty quantification, implementation aspects next to prognostics feature and tool evaluation. In this paper, PHM implementation steps consists of; (1) critical component analysis, (2) appropriate sensor selection for condition monitoring (CM), (3) prognostics feature evaluation under data analysis and (4) prognostics methodology and tool evaluation matrices derived from PHM literature. Besides PHM implementation aspects, this paper also reviews previous and on-going research in high-speed train bogies to highlight problems faced in train industry and emphasize the significance of PHM for further investigations

Investigation into the effect of fixturing systems on the design of condition monitoring for machining operations

The global market competition has drawn the manufacturer’s attention on automated manufacturing processes using condition monitoring systems. These systems have been used for improving product quality, eliminating inspection, and enhancing manufacturing productivity. Fixtures are essential devices in machining processes to hold the tool or workpiece, hence they are influenced directly by the stability of the cutting tool. Therefore, tool and fixturing faults play an important part in the inaccuracy of the machining processes causing deterioration of surface roughness. For the above mentioned reasons, and the limited work in this domain, this thesis develops an experimental investigation to evaluate the effect of fixturing quality on the design of condition monitoring systems. The proposed monitoring system implements multisensors and signal processing methods able to analyse the sensory information and make an appropriate decision. Therefore, several sensors namely force, vibration, acoustic emission, eddy current, power, strain and sound, are combined with a newly suggested approach, named Taylor’s Equation Induced Pattern (TIP), and neural networks to detect tool wear and tool breakage. It also evaluates the monitoring system to provide valuable data to show the effect of fixturing quality. Surface roughness of the workpiece has been measured and compared with the sensitivity of the monitoring system, which reflects the state of tool and fixturing conditions

Monitoring of hybrid manufacturing using acoustic emission sensor

The approach of hybrid manufacturing addressed in this research uses two manufacturing processes, one process builds a metal part using laser metal deposition, and the other process finishes the part using a milling machining. The ability to produce complete functioning parts in a short time with minimal cost and energy consumption has made hybrid manufacturing popular in many industries for parts repair and rapid prototyping. Monitoring of hybrid manufacturing processes has become popular because it increases the quality and accuracy of the parts produced and reduces both costs and production time. The goal of this work is to monitor the entire hybrid manufacturing process. During the laser metal deposition, the acoustic emission sensor will monitor the defect formation. The acoustic emission sensor will monitor the depth of cut during milling machining. There are three tasks in this study. The first task addresses depth-of-cut detection and tool-workpiece engagement using an acoustic emission monitoring system during milling machining for a deposited material. The second task, defects monitoring system was proposed to detect and classify defects in real time using an acoustic emission (AE) sensor and an unsupervised pattern recognition analysis (K-means clustering) in conjunction with a principal component analysis (PCA). In the third task, a study was conducted to investigate the ability of AE to detect and identify defects during laser metal deposition using a Logistic Regression Model (LR) and an Artificial Neural Network (ANN) --Abstract, page iv