Machine learning algorithms for efficient process optimisation of variable geometries at the example of fabric forming

Für einen optimalen Betrieb erfordern moderne Produktionssysteme eine sorgfältige Einstellung der eingesetzten Fertigungsprozesse. Physikbasierte Simulationen können die Prozessoptimierung wirksam unterstützen, jedoch sind deren Rechenzeiten oft eine erhebliche Hürde. Eine Möglichkeit, Rechenzeit einzusparen sind surrogate-gestützte Optimierungsverfahren (SBO1). Surrogates sind recheneffiziente, datengetriebene Ersatzmodelle, die den Optimierer im Suchraum leiten. Sie verbessern in der Regel die Konvergenz, erweisen sich aber bei veränderlichen Optimierungsaufgaben, etwa häufigen Bauteilanpassungen nach Kundenwunsch, als unhandlich. Um auch solche variablen Optimierungsaufgaben effizient zu lösen, untersucht die vorliegende Arbeit, wie jüngste Fortschritte im Maschinenlernen (ML) – im Speziellen bei neuronalen Netzen – bestehende SBO-Techniken ergänzen können. Dabei werden drei Hauptaspekte betrachtet: erstens, ihr Potential als klassisches Surrogate für SBO, zweitens, ihre Eignung zur effiziente Bewertung der Herstellbarkeit neuer Bauteilentwürfe und drittens, ihre Möglichkeiten zur effizienten Prozessoptimierung für variable Bauteilgeometrien. Diese Fragestellungen sind grundsätzlich technologieübergreifend anwendbar und werden in dieser Arbeit am Beispiel der Textilumformung untersucht. Der erste Teil dieser Arbeit (Kapitel 3) diskutiert die Eignung tiefer neuronaler Netze als Surrogates für SBO. Hierzu werden verschiedene Netzarchitekturen untersucht und mehrere Möglichkeiten verglichen, sie in ein SBO-Framework einzubinden. Die Ergebnisse weisen ihre Eignung für SBO nach: Für eine feste Beispielgeometrie minimieren alle Varianten erfolgreich und schneller als ein Referenzalgorithmus (genetischer Algorithmus) die Zielfunktion. Um die Herstellbarkeit variabler Bauteilgeometrien zu bewerten, untersucht Kapitel 4 anschließend, wie Geometrieinformationen in ein Prozess-Surrogate eingebracht werden können. Hierzu werden zwei ML-Ansätze verglichen, ein merkmals- und ein rasterbasierter Ansatz. Der merkmalsbasierte Ansatz scannt ein Bauteil nach einzelnen, prozessrelevanten Geometriemerkmalen, der rasterbasierte Ansatz hingegen interpretiert die Geometrie als Ganzes. Beide Ansätze können das Prozessverhalten grundsätzlich erlernen, allerdings erweist sich der rasterbasierte Ansatz als einfacher übertragbar auf neue Geometrievarianten. Die Ergebnisse zeigen zudem, dass hauptsächlich die Vielfalt und weniger die Menge der Trainingsdaten diese Übertragbarkeit bestimmt. Abschließend verbindet Kapitel 5 die Surrogate-Techniken für flexible Geometrien mit variablen Prozessparametern, um eine effiziente Prozessoptimierung für variable Bauteile zu erreichen. Hierzu interagiert ein ML-Algorithmus in einer Simulationsumgebung mit generischen Geometriebeispielen und lernt, welche Geometrie, welche Umformparameter erfordert. Nach dem Training ist der Algorithmus in der Lage, auch für nicht-generische Bauteilgeometrien brauchbare Empfehlungen auszugeben. Weiter zeigt sich, dass die Empfehlungen mit ähnlicher Geschwindigkeit wie die klassische SBO zum tatsächlichen Prozessoptimum konvergieren, jedoch kein bauteilspezifisches A-priori-Sampling nötig ist. Einmal trainiert, ist der entwickelte Ansatz damit effizienter. Insgesamt zeigt diese Arbeit, wie ML-Techniken gegenwärtige SBOMethoden erweitern und so die Prozess- und Produktoptimierung zu frühen Entwicklungszeitpunkten effizient unterstützen können. Die Ergebnisse der Untersuchungen münden in Folgefragen zur Weiterentwicklung der Methoden, etwa die Integration physikalischer Bilanzgleichungen, um die Modellprognosen physikalisch konsistenter zu machen

Managing computational complexity through using partitioning, approximation and coordination

Problem: Complex systems are composed of many interdependent subsystems with a level of complexity that exceeds the ability of a single designer. One way to address this problem is to partition the complex design problem into smaller, more manageable design tasks that can be handled by multiple design teams. Partitioning-based design methods are decision support tools that provide mathematical foundations, and computational methods to create such design processes. Managing the interdependency among these subsystems is crucial and a successful design process should meet the requirements of the whole system which needs coordinating the solutions for all the partitions after all. Approach: Partitioning and coordination should be performed to break down the system into subproblems, solve them and put these solutions together to come up with the ultimate system design. These two tasks of partitioning-coordinating are computationally demanding. Most of the proposed approaches are either computationally very expensive or applicable to only a narrow class of problems. These approaches also use exact methods and eliminate the uncertainty. To manage the computational complexity and uncertainty, we approximate each subproblem after partitioning the whole system. In engineering design, one way to approximate the reality is using surrogate models (SM) to replace the functions which are computationally expensive to solve. This task also is added to the proposed computational framework. Also, to automate the whole process, creating a knowledge-based reusable template for each of these three steps is required. Therefore, in this dissertation, we first partition/decompose the complex system, then, we approximate the subproblem of each partition. Afterwards, we apply coordination methods to guide the solutions of the partitions toward the ultimate integrated system design. Validation: The partitioning-approximation-coordination design approach is validated using the validation square approach that consists of theoretical and empirical validation. Empirical validation of the design architecture is carried out using two industry-driven problems namely the a hot rod rolling problem’, ‘a dam network design problem’, ‘a crime prediction problem’ and ‘a green supply chain design problem’. Specific sub-problems are formulated within these problem domains to address various research questions identified in this dissertation. Contributions: The contributions from the dissertation are categorized into new knowledge in five research domains: • Creating an approach to building an ensemble of surrogate models when the data is limited – when the data is limited, replacing computationally expensive simulations with accurate, low-dimensional, and rapid surrogates is very important but non-trivial. Therefore, a cross-validation-based ensemble modeling approach is proposed. • Using temporal and spatial analysis to manage the uncertainties - when the data is time-based (for example, in meteorological data analysis) and when we are dealing with geographical data (for example, in geographical information systems data analysis), instead of feature-based data analysis time series analysis and spatial statistics are required, respectively. Therefore, when the simulations are for time and space-based data, surrogate models need to be time and space-based. In surrogate modeling, there is a gap in time and space-based models which we address in this dissertation. We created, applied and evaluated the effectiveness of these models for a dam network planning and a crime prediction problem. • Removing assumptions regarding the demand distributions in green supply chain networks – in the existent literature for supply chain network design, there are always assumptions about the distribution of the demand. We remove this assumption in the partition-approximate-compose of the green supply chain design problem. • Creating new knowledge by proposing a coordination approach for a partitioned and approximated network design. A green supply chain under online (pull economy) and in-person (push economy) shopping channels is designed to demonstrate the utility of the proposed approach

The Integrated Realization of Materials, Products and Associated Manufacturing Processes

Problem: A materials design revolution is underway in the recent past where the focus is to design (not select) the material microstructure and processing paths to achieve multiple property or performance requirements that are often in conflict. The advancements in computer simulations have resulted in the speeding up of the process of discovering new materials and has paved way for rapid assessment of process-structure-property-performance relationships of materials, products, and processes. This has led to the simulation-based design of material microstructure (microstructure-mediated design) to satisfy multiple property or performance goals of the product/process/system thereby replacing the classical material design and selection approaches. The foundational premise for this dissertation is that systems-based materials design techniques offer the potential for tailoring materials, their processing paths and the end products that employ these materials in an integrated fashion for challenging applications to satisfy conflicting product and process level property and performance requirements. The primary goal in this dissertation is to establish some of the scientific foundations and tools that are needed for the integrated realization of materials, products and manufacturing processes using simulation models that are typically incomplete, inaccurate and not of equal fidelity by managing the uncertainty associated. Accordingly, the interest in this dissertation lies in establishing a systems-based design architecture that includes system-level synthesis methods and tools that are required for the integrated design of complex materials, products and associated manufacturing processes starting from the end requirements. Hence the primary research question: What are the theoretical, mathematical and computational foundations needed for establishing a comprehensive systems-based design architecture to realize the integrated design of the product, its environment, manufacturing processes and material as a system? Major challenges to be addressed here are: a) integration of models (material, process and product) to establish processing-structure-property-performance relationships, b) goal-oriented inverse design of material microstructures and processing paths to meet multiple conflicting performance/property requirements, c) robust concept exploration by managing uncertainty across process chains and d) systematic, domain-independent, modular, reconfigurable, reusable, computer interpretable, archivable, and multi-objective decision support in the early stages of design to different users. Approach: In order to address these challenges, the primary hypothesis in this dissertation is to establish the theoretical, mathematical and computational foundations for: 1) forward material, product and process workflows through systematic identification and integration of models to define the processing-structure-property-performance relationships; 2) a concept exploration framework supporting systematic formulation of design problems facilitating robust design exploration by bringing together robust design principles and multi-objective decision making protocols; 3) a generic, goal-oriented, inverse decision-based design method that uses 1) and 2) to facilitate the systems-based inverse design of material microstructures and processing paths to meet multiple product level performance/property requirements, thereby generating the problem-specific inverse decision workflow; and 4) integrating the workflows with a knowledge-based platform anchored in modeling decision-related knowledge facilitating capture, execution and reuse of the knowledge associated with 1), 2) and 3). This establishes a comprehensive systems-based design architecture to realize the integrated design of the product, its environment, manufacturing processes and material as a system. Validation: The systems-based design architecture for the integrated realization of materials, products and associated manufacturing processes is validated using the validation-square approach that consists of theoretical and empirical validation. Empirical validation of the design architecture is carried out using an industry driven problem namely the ‘Integrated Design of Steel (Material), Manufacturing Processes (Rolling and Cooling) and Hot Rolled Rods (Product) for Automotive Gears’. Specific sub-problems are formulated within this problem domain to address various research questions identified in this dissertation. Contributions: The contributions from the dissertation are categorized into new knowledge in four research domains: a) systematic model integration (vertical and horizontal) for integrated material and product workflows, b) goal-oriented, inverse decision support, c) robust concept exploration of process chains with multiple conflicting goals and d) knowledge-based decision support for rapid and robust design exploration in simulation-based integrated material, product and process design. The creation of new knowledge in this dissertation is associated with the development of a systems-based design architecture involving systematic function-based approach of formulating forward material workflows, a concept exploration framework for systematic design exploration, an inverse decision-based design method, and robust design metrics, all integrated with a knowledge-based platform for decision support. The theoretical, mathematical and computational foundations for the design architecture are proposed in this dissertation to facilitate rapid and robust exploration of the design and solution spaces to identify material microstructures and processing paths that satisfy conflicting property and performance for complex materials, products and processes by managing uncertainty

30th International Conference on Condition Monitoring and Diagnostic Engineering Management (COMADEM 2017)

Proceedings of COMADEM 201

Research of the acoustic phenomenon produced by isolated scatterers and its applicability as a noise reducing device in transport infrastructures. Search for an optimised and sustainable design.

Tesis por compendio[ES] El control de ruido ambiental es una preocupación de primera magnitud para las sociedades avanzadas, debido a los problemas derivados que ocasionan en la salud de los ciudadanos. Una de las soluciones más extendidas para el control del ruido en su fase de transmisión en la utilización de pantallas acústicas. La aparición de nuevos materiales formados por redes de dispersores acústicos aislados, denominados cristales de sonido, está revolucionando el campo del apantallamiento acústico, posibilitando el avance tecnológico de esta área. Así, en los últimos años, las pantallas acústicas basadas en cristales de sonido se han posicionado como una alternativa viable a las pantallas acústicas tradicionales, puesto que ofrecen múltiples ventajas frente a las soluciones actuales. En el presente trabajo se muestra primeramente una recopilación de los avances realizados en el campo del apantallamiento acústico mediante esta tipología de pantallas. No obstante, aún existen líneas de investigación abiertas en esta área, que es necesario abordar para conseguir el objetivo de aplicar esta tecnología como atenuadores de sonido en las infraestructuras de transporte. Durante el periodo de formación de la doctoranda, se ha trabajado en algunas de las líneas de investigación activas en este campo del apantallamiento acústico. Una de estas investigaciones condujo al descubrimiento de interferencias entre los efectos de la resonancia y la dispersión múltiple de los cristales de sonido cuando estos efectos se producen en rangos de frecuencia cercanos. También hemos diseñado un nuevo dispositivo de reducción de ruido basado en cristales de sonido, utilizando herramientas de optimización multiobjetivo, que permitan apantallar y reflejar de forma difusa el ruido. El empleo de esta nueva herramienta de diseño identificó la necesidad de realizar un estudio comparativo de los métodos de simulación más utilizados para estimar el rendimiento de los dispositivos basados en cristales de sonido. Por último, hemos realizado un estudio psicoacústico para determinar la percepción de la reducción de molestia que proporcionan las pantallas acústicas basadas en cristales sonido y las barreras tradicionales, determinando si los parámetros objetivos que evalúan su rendimiento coinciden con la respuesta subjetiva de los usuarios.[CA] El control de soroll ambiental és una preocupació de primera magnitud per a les societats avançades, a causa dels problemes derivats que ocasionen en la salut dels ciutadans. Una de les solucions més esteses per al control del soroll en la seua fase de transmissió en la utilització de pantalles acústiques. L'aparició de nous materials formats per xarxes de dispersors acústics aïllats, denominats cristals de so, està revolucionant el camp de l'apantallament acústic, possibilitant l'avanç tecnològic d'esta àrea. Així, en els últims anys, les pantalles acústiques basades en cristals de so s'han posicionat com una alternativa viable a les pantalles acústiques tradicionals, ja que oferixen múltiples avantatges enfront de les solucions actuals. En el present treball es mostra primerament una recopilació dels avanços realitzats en el camp de l'apantallament acústic per mitjà d'esta tipologia de pantalles. No obstant això, encara hi ha línies d'investigació obertes en esta àrea, que és necessari abordar per a aconseguir l'objectiu d'aplicar esta tecnologia com a atenuadors de so en les infraestructures de transport. Durant el període de formació de la doctoranda, s'ha treballat en algunes de les línies d'investigació actives en este camp de l'apantallament acústic. Una d'estes investigacions va conduir al descobriment d'interferències entre els efectes de la ressonància i la dispersió múltiple dels cristals de so quan estos efectes es produïxen en rangs de freqüència pròxims. També hem dissenyat un nou dispositiu de reducció de soroll basat en cristals de so, utilitzant ferramentes d'optimització multiobjectiu, que permeten apantallar i reflectir de forma difusa el soroll. L'ús d'esta nova ferramenta de disseny va identificar la necessitat de realitzar un estudi comparatiu dels mètodes de simulació més utilitzats per a estimar el rendiment dels dispositius basats en cristals de so. Finalment, hem realitzat un estudi psicoacústic per a determinar la percepció de la reducció de molèstia que proporcionen les pantalles acústiques basades en cristals so i les barreres tradicionals, determinant si els paràmetres objectius que avaluen el seu rendiment coincidixen amb la resposta subjectiva dels usuaris.[EN] Control of environmental noise is a major concern for advanced societies because of the resulting problems for citizens' health. One of the most widespread solutions for controlling noise in its transmission phase is the use of acoustic screens. The emergence of new materials made up of arrays of isolated acoustic scatterers, called sonic crystals, is revolutionizing the field of acoustic screening. In recent years, acoustic screens based on sonic crystals have positioned themselves as a viable alternative to traditional acoustic screens, as they offer multiple advantages over current traditional solutions. This Doctoral dissertation compiles the advances in the field of acoustic screening using this type of sonic crystals. However, there is still active research in this area which needs to be addressed and studied in order to apply this technology as noise reduction devices in transport infrastructures. Therefore, during the PhD student's training period, we have researched the acoustic phenomena produced by isolated scatterers in order to better understand the physical phenomena behind the lasts designs of this type of screen. One of these researches led to the discovery of interferences between the effects of resonance and multiple scattering of sonic crystals when occurring in nearby frequency ranges. Also we have designed a new noise reduction device based on sonic crystals, using multi-objective optimization tools, which would block and diffuse the noise. This new designing tool identified the need for a comparative study of the most commonly used simulation methods to estimate the performance of devices based on sonic crystals. Finally, we have carried out a psychoacoustic study that determined the perception of the annoyance reduction provided by acoustic screens based on sonic crystals and traditional barriers, determining whether the objective parameters that evaluate their performance match to the subjective response of the users.Agradezco al Ministerio de Ciencia e Innovación por la ayuda concedida dentro del programa Doctores Industriales. Asimismo, a mi tutor en empresa Dr. Juan José Martín Pino, por posibilitar la realización de esta investigación dentro de la empresa BECSA. Al Departamento de Física Aplicada de la Universitat Politècnica de València, a la Comisión Académica del Programa de Doctorado de Matemáticas y al Centro de Tecnologías Físicas: Acústica, Materiales y Astrofísica.Peiró Torres, MDP. (2021). Research of the acoustic phenomenon produced by isolated scatterers and its applicability as a noise reducing device in transport infrastructures. Search for an optimised and sustainable design [Tesis doctoral]. Universitat Politècnica de València. https://doi.org/10.4995/Thesis/10251/164903TESISCompendi

Fuelling the zero-emissions road freight of the future: routing of mobile fuellers

The future of zero-emissions road freight is closely tied to the sufficient availability of new and clean fuel options such as electricity and Hydrogen. In goods distribution using Electric Commercial Vehicles (ECVs) and Hydrogen Fuel Cell Vehicles (HFCVs) a major challenge in the transition period would pertain to their limited autonomy and scarce and unevenly distributed refuelling stations. One viable solution to facilitate and speed up the adoption of ECVs/HFCVs by logistics, however, is to get the fuel to the point where it is needed (instead of diverting the route of delivery vehicles to refuelling stations) using "Mobile Fuellers (MFs)". These are mobile battery swapping/recharging vans or mobile Hydrogen fuellers that can travel to a running ECV/HFCV to provide the fuel they require to complete their delivery routes at a rendezvous time and space. In this presentation, new vehicle routing models will be presented for a third party company that provides MF services. In the proposed problem variant, the MF provider company receives routing plans of multiple customer companies and has to design routes for a fleet of capacitated MFs that have to synchronise their routes with the running vehicles to deliver the required amount of fuel on-the-fly. This presentation will discuss and compare several mathematical models based on different business models and collaborative logistics scenarios

Dynamical systems : mathematical and numerical approaches

Proceedings of the 13th Conference „Dynamical Systems - Theory and Applications" summarize 164 and the Springer Proceedings summarize 60 best papers of university teachers and students, researchers and engineers from whole the world. The papers were chosen by the International Scientific Committee from 315 papers submitted to the conference. The reader thus obtains an overview of the recent developments of dynamical systems and can study the most progressive tendencies in this field of science