Enhanced Temperature Control Method Using ANFIS with FPGA

Temperature control in etching process is important for semiconductor manufacturing technology. However, pressure variations in vacuum chamber results in a change in temperature, worsening the accuracy of the temperature of the wafer and the speed and quality of the etching process. This work develops an adaptive network-based fuzzy inference system (ANFIS) using a field-programmable gate array (FPGA) to improve the effectiveness. The proposed method adjusts every membership function to keep the temperature in the chamber stable. The improvement of the proposed algorithm is confirmed using a medium vacuum (MV) inductively-coupled plasma- (ICP-) type etcher

Horno cementero rotatorio: una revisión al control mediante sistemas expertos

This article presents a review of research carried out using different control strategies applied in rotary cement kilns, a system where clinker is manufactured, an essential material for cement production. This exploration mentions studies that have been developed from the eighties to the present, highlighting in each one the control methodology used, the benefits obtained in the process and its future applications, in order to provide the reader with a global vision of the use of control techniques for rotary cement kilns and how scientific advances, over the years, have contributed to this industry in the efficiency and improvement of its production processes; therefore, contributions and control methods such as expert systems (ES), model predictive control (MPC), artificial neural networks and fuzzy logic are mentioned. At the end of the aforementioned review, it is inferred that artificial intelligence and industry 4.0 technologies that are currently available such as cloud computing, the processing of large volumes of data, the use of digital twins, the execution of machine learning algorithms and it’s prediction tools, together with the application of ES and other control techniques mentioned, would allow advanced control, which can respond satisfactorily to current production needs and offer multiple benefits such as response time control, stability, and improvements in production and material quality in a rotary kiln.Este artículo presenta una revisión de investigaciones realizadas mediante diferentes estrategias de control aplicadas en hornos cementeros rotatorios, sistema donde se da la fabricación de clínker, material indispensable para la elaboración del cemento. Esta exploración menciona estudios que se han desarrollado desde los años ochenta hasta el presente, destacando en cada una la metodología de control utilizada, los beneficios obtenidos en el proceso y sus futuras aplicaciones, esto con el fin de brindar al lector una visión global del uso de técnicas de control para hornos cementeros rotatorios y de cómo los avances científicos, con el paso de los años, han contribuido a esta industria en la eficiencia y mejora de sus procesos productivos; por tanto, se mencionan aportes y métodos de control como sistemas expertos (SE), control predictivo basado en modelo (MPC), redes neuronales artificiales y lógica difusa. Al finalizar la mencionada revisión se infiere que tecnologías de inteligencia artificial y de la industria 4.0 que se tienen actualmente como la computación en la nube, el procesamiento de grandes volúmenes de datos, el uso de los gemelos digitales, la ejecución de algoritmos de aprendizaje automático (machine learning) y sus herramientas de predicción, junto con la aplicación de SE y demás técnicas de control mencionadas, permitirían realizar un control avanzado, que pueda responder de forma satisfactoria a las necesidades de producción actuales y ofrecer múltiples beneficios como el tiempo de respuesta del control, la estabilidad, y mejoras en producción y calidad del material en un horno rotatorio

Intelligent identification of vehicle’s dynamics based on local model network

This paper proposes an intelligent approach for dynamic identification of the vehicles. The proposed approach is based on the data-driven identification and uses a high-performance local model network (LMN) for estimation of the vehicle’s longitudinal velocity, lateral acceleration and yaw rate. The proposed LMN requires no pre-defined standard vehicle model and uses measurement data to identify vehicle’s dynamics. The LMN is trained by hierarchical binary tree (HBT) learning algorithm, which results in a network with maximum generalizability and best linear or nonlinear structure. The proposed approach is applied to a measurement dataset, obtained from a Volvo V70 vehicle to estimate its longitudinal velocity, lateral acceleration and yaw rate. The results of identification revealed that the LMN can identify accurately the vehicle’s dynamics. Furthermore, comparison of LMN results and a multi-layer perceptron (MLP) neural network demonstrated the far-better performance of the proposed approach

Process fault prediction and prognosis based on a hybrid technique

The present study introduces a novel hybrid methodology for fault detection and diagnosis (FDD) and fault prediction and prognosis (FPP). The hybrid methodology combines both data-driven and process knowledge driven techniques. The Hidden Markov Model (HMM) and the auxiliary codes detect and predict the abnormalities based on process history while the Bayesian Network (BN) diagnoses the root cause of the fault based on process knowledge. In the first step, the system performance is evaluated for fault detection and diagnosis and in the second step, prediction and prognosis are evaluated. In both cases, an HMM trained with Normal Operating Condition data is used to determine the log-likelihoods (LL) of each process history data string. It is then used to develop the Conditional Probability Tables of BN while the structure of BN is developed based on process knowledge. Abnormal behaviour of the system is identified through HMM. The time of detection of an abnormality, respective LL value, and the probabilities of being in the process condition at the time of detection are used to generate the likelihood evidence to BN. The updated BN is then used to diagnose the root cause by considering the respective changes of the probabilities. Performance of the new technique is validated with published data of Tennessee Eastman Process. Eight of the ten selected faults were successfully detected and diagnosed. The same set of faults were predicted and prognosed accurately at different levels of maximum added noise

Context-based identification of energy consumption in industrial plants

Nowadays, reducing energy consumption is one of the highest priorities and biggest challenges faced worldwide and in particular in the industrial sector. Given the increasing trend of consumption and the current economical crisis, identifying cost reductions on the most energy-intensive sectors has become one of the main concerns among companies and researchers. Particularly in industrial environments, energy consumption is affected by several factors, namely production factors(e.g. equipments), human (e.g. operators experience), environmental (e.g. temperature), among others, which influence the way of how energy is used across the plant. Therefore, several approaches for identifying consumption causes have been suggested and discussed. However, the existing methods only provide guidelines for energy consumption and have shown difficulties in explaining certain energy consumption patterns due to the lack of structure to incorporate context influence, hence are not able to track down the causes of consumption to a process level, where optimization measures can actually take place. This dissertation proposes a new approach to tackle this issue, by on-line estimation of context-based energy consumption models, which are able to map operating context to consumption patterns. Context identification is performed by regression tree algorithms. Energy consumption estimation is achieved by means of a multi-model architecture using multiple RLS algorithms, locally estimated for each operating context. Lastly, the proposed approach is applied to a real cement plant grinding circuit. Experimental results prove the viability of the overall system, regarding both automatic context identification and energy consumption estimation.project LifeSaver - Context sensitive monitoring of energy consumption to support energy savings and emissions trading in industry (G.A. FP7-ICT-287652

The role of artificial intelligence-driven soft sensors in advanced sustainable process industries: a critical review

With the predicted depletion of natural resources and alarming environmental issues, sustainable development has become a popular as well as a much-needed concept in modern process industries. Hence, manufacturers are quite keen on adopting novel process monitoring techniques to enhance product quality and process efficiency while minimizing possible adverse environmental impacts. Hardware sensors are employed in process industries to aid process monitoring and control, but they are associated with many limitations such as disturbances to the process flow, measurement delays, frequent need for maintenance, and high capital costs. As a result, soft sensors have become an attractive alternative for predicting quality-related parameters that are ‘hard-to-measure’ using hardware sensors. Due to their promising features over hardware counterparts, they have been employed across different process industries. This article attempts to explore the state-of-the-art artificial intelligence (Al)-driven soft sensors designed for process industries and their role in achieving the goal of sustainable development. First, a general introduction is given to soft sensors, their applications in different process industries, and their significance in achieving sustainable development goals. AI-based soft sensing algorithms are then introduced. Next, a discussion on how AI-driven soft sensors contribute toward different sustainable manufacturing strategies of process industries is provided. This is followed by a critical review of the most recent state-of-the-art AI-based soft sensors reported in the literature. Here, the use of powerful AI-based algorithms for addressing the limitations of traditional algorithms, that restrict the soft sensor performance is discussed. Finally, the challenges and limitations associated with the current soft sensor design, application, and maintenance aspects are discussed with possible future directions for designing more intelligent and smart soft sensing technologies to cater the future industrial needs

Dynamic Analysis of Cracked Rotor in Viscous Medium and its Crack Diagnosis Using Intelligent Techniques

Fatigue cracks have high potential to cause catastrophic failures in the rotor which can lead to catastrophic failure if undetected properly and in time. This fault may interrupt smooth, effective and efficient operation and performance of the machines. Thereby the importance of identification of crack in the rotor is not only for leading safe operation but also to prevent the loss of economy and lives.The condition monitoring of the engineering systems is attracted by the researchers and scientists very much to invent the automated fault diagnosis mechanism using the change in dynamic response before and after damage. When the rotor with transverse crack immersed in the viscous fluid, analysis of cracked rotor is difficult and complex. The analysis of cracked rotor partially submerged in the viscous fluid is widely used in various engineering systems such as long spinning shaft used drilling the seabed for the extracting the oil, high-speed turbine rotors, and analysis of centrifuges in a fluid medium. Therefore, dynamic analysis of cracked rotor partially submerged in the viscous medium have been presented in the current study. The theoretical analysis has been performed to measure the vibration signatures (Natural Frequencies and Amplitude) of multiple cracked mild steel rotor partially submerged in the viscous medium. The presence of the crack in rotor generates an additional flexibility. That is evaluated by strain energy release rate given by linear fracture mechanics. The additional flexibility alters the dynamic characteristics of cracked rotor in a viscous fluid. The local stiffness matrix has been calculated by the inverse of local dimensionless compliance matrix. The finite element analysis has been carried out to measure the vibration characteristics of cracked rotor partially submerged in the viscous medium using commercially available finite element software package ANSYS. It is observed from the current analysis, the various factors such as the viscosity of fluid, depth and position of the cracks affect the performance of the rotor and effectiveness of crack detection techniques. Various Artificial Intelligent (AI) techniques such as fuzzy logic, hybrid BPNN-RBFNN neural network, MANFIS and hybrid fuzzy-rule base controller based multiple faults diagnosis systems are developed using the dynamic response of rotating cracked rotor in a viscous medium to monitor the presence of crack. Experiments have been conducted to authenticate the performance and accuracy of proposed methods. Good agreement is observed between the results

Study of Computational and Experimental Methodologies for Cracks Recognition of Vibrating Systems using Modal Parameters

Mostly the structural members and machine elements are subjected to progressive static and dynamic loading and that may cause initiation of defects in the form of crack. The cause of damage may be due to the normal operation, accidents or severe natural calamities such as earthquake or storm. That may lead to catastrophic failure or collapse of the structures. Thereby the importance of identification of damage in the structures is not only for leading safe operation but also to prevent the loss of economy and lives. The condition monitoring of the engineering systems is attracted by the researchers and scientists very much to invent the automated fault diagnosis mechanism using the change in vibration response before and after damage. The structural steel is widely used in various engineering systems such as bridges, railway coaches, ships, automobiles, etc. The glass fiber reinforced epoxy layered composite material has become popular for constructing the various engineering structures due to its valuable characteristics such as higher stiffness and strength to weight ratio, better damage tolerance capacity and wear resistance. Therefore, layered composite and structural steel have been taken into account in the current study. The theoretical analysis has been performed to measure the vibration signatures (Natural Frequencies and Mode Shapes) of multiple cracked composite and structural steel. The presence of the crack in structures generates an additional flexibility. That is evaluated by strain energy release rate given by linear fracture mechanics. The additional flexibility alters the dynamic signatures of cracked beam. The local stiffness matrix has been calculated by the inverse of local dimensionless compliance matrix. The finite element analysis has been carried out to measure the vibration signatures of cracked cantilever beam using commercially available finite element software package ANSYS. It is observed from the current analysis, the various factors such as the orientation of cracks, number and position of the cracks affect the performance and effectiveness of damage detection techniques. The various automated artificial intelligent (AI) techniques such as fuzzy controller, neural network and hybrid AI techniques based multiple faults diagnosis systems are developed using vibration response of cracked cantilever beams. The experiments have been conducted to verify the performance and accuracy of proposed methods. A good agreement is observed between the results

Multiple Damage Identification of Beam Structure Using Vibration Analysis and Artificial Intelligence Techniques

This thesis investigates the problem of multiple damage detection in vibrating structural members using the dynamic response of the system. Changes in the loading patterns, weakening/degeneration of structures with time and influence of environment may cause cracks in the structure, especially in engineering structures which are developed for prolonged life. Hence, early detection of presence of damage can prevent the catastrophic failure of the structures by appropriately monitoring the response of the system. In recent times, condition monitoring of structural systems have attracted scientists and researchers to develop on line damage diagnostic tool. Primarily, the structural health monitoring technique utilizes the methodology for damage assessment using the monitored vibration parameters. In the current analysis, special attention has been focused on those methods capable of detecting multiple cracks present in system by comparing the information for damaged and undamaged state of the structure. In the current research, methodologies have been developed for damage detection of a cracked cantilever beam with multiple cracks using analytical, Finite Element Analysis (FEA), fuzzy logic, neural network, fuzzy neuro, MANFIS, Genetic Algorithm and hybrid techniques such as GA-fuzzy, GA-neural, GA-neuro- fuzzy. Analytical study has been performed on the cantilever beam with multiple cracks to obtain the vibration characteristics of the beam member by using the expressions of strain energy release rate and stress intensity factor. The presence of cracks in a structural member introduces local flexibility that affects its dynamic response. The local stiffness matrices have been measured using the inverse of local dimensionless compliance matrix for finding out the deviation in the vibrating signatures of the cracked cantilever beam from that of the intact beam. Finite Element Analysis has been carried out to derive the vibration indices of the cracked structure using the overall flexibility matrix, total flexibility matrix, flexibility matrix of the intact beam. From the research done here, it is concluded that the performance of the damage assessment methods depends on several factors for example, the number of cracks, the number of sensors used for acquiring the dynamic response, location and severity of damages. Different artificial intelligent model based on fuzzy logic, neural network, genetic algorithm, MANFIS and hybrid techniques have been designed using the computed vibration signatures for multiple crack diagnosis in cantilever beam structures with higher accuracy and considerably low computational time