Defect and thickness inspection system for cast thin films using machine vision and full-field transmission densitometry

Quick mass production of homogeneous thin film material is required in paper, plastic, fabric, and thin film industries. Due to the high feed rates and small thicknesses, machine vision and other nondestructive evaluation techniques are used to ensure consistent, defect-free material by continuously assessing post-production quality. One of the fastest growing inspection areas is for 0.5-500 micrometer thick thin films, which are used for semiconductor wafers, amorphous photovoltaics, optical films, plastics, and organic and inorganic membranes. As a demonstration application, a prototype roll-feed imaging system has been designed to inspect high-temperature polymer electrolyte membrane (PEM), used for fuel cells, after being die cast onto a moving transparent substrate. The inspection system continuously detects thin film defects and classifies them with a neural network into categories of holes, bubbles, thinning, and gels, with a 1.2% false alarm rate, 7.1% escape rate, and classification accuracy of 96.1%. In slot die casting processes, defect types are indicative of a misbalance in the mass flow rate and web speed; so, based on the classified defects, the inspection system informs the operator of corrective adjustments to these manufacturing parameters. Thickness uniformity is also critical to membrane functionality, so a real-time, full-field transmission densitometer has been created to measure the bi-directional thickness profile of the semi-transparent PEM between 25-400 micrometers. The local thickness of the 75 mm x 100 mm imaged area is determined by converting the optical density of the sample to thickness with the Beer-Lambert law. The PEM extinction coefficient is determined to be 1.4 D/mm and the average thickness error is found to be 4.7%. Finally, the defect inspection and thickness profilometry systems are compiled into a specially-designed graphical user interface for intuitive real-time operation and visualization.M.S.Committee Chair: Tequila Harris; Committee Member: Levent Degertekin; Committee Member: Wayne Dale

Design and Application of Additive Manufacturing

Additive manufacturing (AM) is continuously improving and offering innovative alternatives to conventional manufacturing techniques. The advantages of AM (design freedom, reduction in material waste, low-cost prototyping, etc.) can be exploited in different sectors by replacing or complementing traditional manufacturing methods. For this to happen, the combination of design, materials and technology must be deeply analyzed for every specific application. Despite the continuous progress of AM, there is still a need for further investigation in terms of design and applications to boost AM's implementation in the manufacturing industry or even in other sectors where short and personalized series productions could be useful, such as the medical sector. This Special Issue gathers a variety of research articles (12 peer-reviewed papers) involving the design and application of AM, including innovative design approaches where AM is applied to improve conventional methods or currently used techniques, design and modeling methodologies for specific AM applications, design optimization and new methods for the quality control and calibration of simulation methods

Business analytics in industry 4.0: a systematic review

Recently, the term “Industry 4.0” has emerged to characterize several Information Technology and Communication (ICT) adoptions in production processes (e.g., Internet-of-Things, implementation of digital production support information technologies). Business Analytics is often used within the Industry 4.0, thus incorporating its data intelligence (e.g., statistical analysis, predictive modelling, optimization) expert system component. In this paper, we perform a Systematic Literature Review (SLR) on the usage of Business Analytics within the Industry 4.0 concept, covering a selection of 169 papers obtained from six major scientific publication sources from 2010 to March 2020. The selected papers were first classified in three major types, namely, Practical Application, Reviews and Framework Proposal. Then, we analysed with more detail the practical application studies which were further divided into three main categories of the Gartner analytical maturity model, Descriptive Analytics, Predictive Analytics and Prescriptive Analytics. In particular, we characterized the distinct analytics studies in terms of the industry application and data context used, impact (in terms of their Technology Readiness Level) and selected data modelling method. Our SLR analysis provides a mapping of how data-based Industry 4.0 expert systems are currently used, disclosing also research gaps and future research opportunities.The work of P. Cortez was supported by FCT - Fundação para a Ciência e Tecnologia within the R&D Units Project Scope: UIDB/00319/2020. We would like to thank to the three anonymous reviewers for their helpful suggestions

Technology 2001: The Second National Technology Transfer Conference and Exposition, volume 1

Papers from the technical sessions of the Technology 2001 Conference and Exposition are presented. The technical sessions featured discussions of advanced manufacturing, artificial intelligence, biotechnology, computer graphics and simulation, communications, data and information management, electronics, electro-optics, environmental technology, life sciences, materials science, medical advances, robotics, software engineering, and test and measurement

Technology 2002: the Third National Technology Transfer Conference and Exposition, Volume 1

The proceedings from the conference are presented. The topics covered include the following: computer technology, advanced manufacturing, materials science, biotechnology, and electronics

MANUFACTURE OF INDIVIDUALIZED DOSING: DEVELOPMENT AND CONTROL OF A DROPWISE ADDITIVE MANUFACTURING PROCESS FOR MELT BASED PHARMACEUTICAL PRODUCTS

The improvements in healthcare systems and the advent of precision medicine initiative have created the need to develop more innovative manufacturing methods for the delivery of individualized dosing and personalized treatments. In recent years, the US Food and Drug Administration (FDA) introduced the Quality by Design (QbD) and Process Analytical Technology (PAT) guidelines to encourage innovation and efficiency in pharmaceutical development, manufacturing and quality assurance. As a result of emerging technologies and encouragement from the regulatory authorities, the pharmaceutical industry has begun to develop more efficient production systems with more intensive use of on-line measurement and sensing, real time quality control and process control tools, which offer the potential for reduced variability, increased flexibility and efficiency, and improved product quality

Modern Machine Learning Tools for Monitoring and Control of Industrial Processes: A Survey

Over the last ten years, we have seen a significant increase in industrial data, tremendous improvement in computational power, and major theoretical advances in machine learning. This opens up an opportunity to use modern machine learning tools on large-scale nonlinear monitoring and control problems. This article provides a survey of recent results with applications in the process industry.Comment: IFAC World Congress 202

Big data analytics: Machine learning and Bayesian learning perspectives—What is done? What is not?

Big data analytics provides an interdisciplinary framework that is essential to support the current trend for solving real-world problems collaboratively. The progression of big data analytics framework must be clearly understood so that novel approaches can be developed to advance this state-of-the-art discipline. An ignorance of observing the progression of this fast-growing discipline may lead to duplications in research and waste of efforts. Its main companion field, machine learning, helps solve many big data analytics problems; therefore, it is also important to understand the progression of machine learning in the big data analytics framework. One of the current research efforts in big data analytics is the integration of deep learning and Bayesian optimization, which can help the automatic initialization and optimization of hyperparameters of deep learning and enhance the implementation of iterative algorithms in software. The hyperparameters include the weights used in deep learning, and the number of clusters in Bayesian mixture models that characterize data heterogeneity. The big data analytics research also requires computer systems and software that are capable of storing, retrieving, processing, and analyzing big data that are generally large, complex, heterogeneous, unstructured, unpredictable, and exposed to scalability problems. Therefore, it is appropriate to introduce a new research topic—transformative knowledge discovery—that provides a research ground to study and develop smart machine learning models and algorithms that are automatic, adaptive, and cognitive to address big data analytics problems and challenges. The new research domain will also create research opportunities to work on this interdisciplinary research space and develop solutions to support research in other disciplines that may not have expertise in the research area of big data analytics. For example, the research, such as detection and characterization of retinal diseases in medical sciences and the classification of highly interacting species in environmental sciences can benefit from the knowledge and expertise in big data analytics

Factories of the Future

Engineering; Industrial engineering; Production engineerin