Predictive Maintenance on the Machining Process and Machine Tool

This paper presents the process required to implement a data driven Predictive Maintenance (PdM) not only in the machine decision making, but also in data acquisition and processing. A short review of the different approaches and techniques in maintenance is given. The main contribution of this paper is a solution for the predictive maintenance problem in a real machining process. Several steps are needed to reach the solution, which are carefully explained. The obtained results show that the Preventive Maintenance (PM), which was carried out in a real machining process, could be changed into a PdM approach. A decision making application was developed to provide a visual analysis of the Remaining Useful Life (RUL) of the machining tool. This work is a proof of concept of the methodology presented in one process, but replicable for most of the process for serial productions of pieces

Machine learning and its applications in reliability analysis systems

In this thesis, we are interested in exploring some aspects of Machine Learning (ML) and its application in the Reliability Analysis systems (RAs). We begin by investigating some ML paradigms and their- techniques, go on to discuss the possible applications of ML in improving RAs performance, and lastly give guidelines of the architecture of learning RAs. Our survey of ML covers both levels of Neural Network learning and Symbolic learning. In symbolic process learning, five types of learning and their applications are discussed: rote learning, learning from instruction, learning from analogy, learning from examples, and learning from observation and discovery. The Reliability Analysis systems (RAs) presented in this thesis are mainly designed for maintaining plant safety supported by two functions: risk analysis function, i.e., failure mode effect analysis (FMEA) ; and diagnosis function, i.e., real-time fault location (RTFL). Three approaches have been discussed in creating the RAs. According to the result of our survey, we suggest currently the best design of RAs is to embed model-based RAs, i.e., MORA (as software) in a neural network based computer system (as hardware). However, there are still some improvement which can be made through the applications of Machine Learning. By implanting the 'learning element', the MORA will become learning MORA (La MORA) system, a learning Reliability Analysis system with the power of automatic knowledge acquisition and inconsistency checking, and more. To conclude our thesis, we propose an architecture of La MORA

Reinforcement learning for efficient network penetration testing

Penetration testing (also known as pentesting or PT) is a common practice for actively assessing the defenses of a computer network by planning and executing all possible attacks to discover and exploit existing vulnerabilities. Current penetration testing methods are increasingly becoming non-standard, composite and resource-consuming despite the use of evolving tools. In this paper, we propose and evaluate an AI-based pentesting system which makes use of machine learning techniques, namely reinforcement learning (RL) to learn and reproduce average and complex pentesting activities. The proposed system is named Intelligent Automated Penetration Testing System (IAPTS) consisting of a module that integrates with industrial PT frameworks to enable them to capture information, learn from experience, and reproduce tests in future similar testing cases. IAPTS aims to save human resources while producing much-enhanced results in terms of time consumption, reliability and frequency of testing. IAPTS takes the approach of modeling PT environments and tasks as a partially observed Markov decision process (POMDP) problem which is solved by POMDP-solver. Although the scope of this paper is limited to network infrastructures PT planning and not the entire practice, the obtained results support the hypothesis that RL can enhance PT beyond the capabilities of any human PT expert in terms of time consumed, covered attacking vectors, accuracy and reliability of the outputs. In addition, this work tackles the complex problem of expertise capturing and re-use by allowing the IAPTS learning module to store and re-use PT policies in the same way that a human PT expert would learn but in a more efficient way

A comparative study of image processing thresholding algorithms on residual oxide scale detection in stainless steel production lines

The present work is intended for residual oxide scale detection and classification through the application of image processing techniques. This is a defect that can remain in the surface of stainless steel coils after an incomplete pickling process in a production line. From a previous detailed study over reflectance of residual oxide defect, we present a comparative study of algorithms for image segmentation based on thresholding methods. In particular, two computational models based on multi-linear regression and neural networks will be proposed. A system based on conventional area camera with a special lighting was installed and fully integrated in an annealing and pickling line for model testing purposes. Finally, model approaches will be compared and evaluated their performance..Universidad de Málaga. Campus de Excelencia Internacional Andalucía Tech

Machine prognostics based on health state estimation using SVM

The ability to accurately predict the remaining useful life of machine components is critical for continuous operations in machines which can also improve productivity and enhance system safety. In condition-based maintenance (CBM), effective diagnostics and prognostics are important aspects of CBM which provide sufficient time for maintenance engineers to schedule a repair and acquire replacement components before the components finally fail. All machine components have certain characteristics of failure patterns and are subjected to degradation processes in real environments. This paper describes a technique for accurate assessment of the remnant life of machines based on prior expert knowledge embedded in closed loop prognostics systems. The technique uses Support Vector Machines (SVM) for classification of faults and evaluation of health for six stages of bearing degradation. To validate the feasibility of the proposed model, several fault historical data from High Pressure Liquefied Natural Gas (LNG) pumps were analysed to obtain their failure patterns. The results obtained were very encouraging and the prediction closely matched the real life particularly at the end of term of the bearings

Learning models for semantic classification of insufficient plantar pressure images

Establishing a reliable and stable model to predict a target by using insufficient labeled samples is feasible and effective, particularly, for a sensor-generated data-set. This paper has been inspired with insufficient data-set learning algorithms, such as metric-based, prototype networks and meta-learning, and therefore we propose an insufficient data-set transfer model learning method. Firstly, two basic models for transfer learning are introduced. A classification system and calculation criteria are then subsequently introduced. Secondly, a dataset of plantar pressure for comfort shoe design is acquired and preprocessed through foot scan system; and by using a pre-trained convolution neural network employing AlexNet and convolution neural network (CNN)- based transfer modeling, the classification accuracy of the plantar pressure images is over 93.5%. Finally, the proposed method has been compared to the current classifiers VGG, ResNet, AlexNet and pre-trained CNN. Also, our work is compared with known-scaling and shifting (SS) and unknown-plain slot (PS) partition methods on the public test databases: SUN, CUB, AWA1, AWA2, and aPY with indices of precision (tr, ts, H) and time (training and evaluation). The proposed method for the plantar pressure classification task shows high performance in most indices when comparing with other methods. The transfer learning-based method can be applied to other insufficient data-sets of sensor imaging fields

Evaluation of Cognitive Architectures for Cyber-Physical Production Systems

Cyber-physical production systems (CPPS) integrate physical and computational resources due to increasingly available sensors and processing power. This enables the usage of data, to create additional benefit, such as condition monitoring or optimization. These capabilities can lead to cognition, such that the system is able to adapt independently to changing circumstances by learning from additional sensors information. Developing a reference architecture for the design of CPPS and standardization of machines and software interfaces is crucial to enable compatibility of data usage between different machine models and vendors. This paper analysis existing reference architecture regarding their cognitive abilities, based on requirements that are derived from three different use cases. The results from the evaluation of the reference architectures, which include two instances that stem from the field of cognitive science, reveal a gap in the applicability of the architectures regarding the generalizability and the level of abstraction. While reference architectures from the field of automation are suitable to address use case specific requirements, and do not address the general requirements, especially w.r.t. adaptability, the examples from the field of cognitive science are well usable to reach a high level of adaption and cognition. It is desirable to merge advantages of both classes of architectures to address challenges in the field of CPPS in Industrie 4.0

Vibration-based adaptive novelty detection method for monitoring faults in a kinematic chain

Postprint (published version