Soft Computing Techniques and Their Applications in Intel-ligent Industrial Control Systems: A Survey

Soft computing involves a series of methods that are compatible with imprecise information and complex human cognition. In the face of industrial control problems, soft computing techniques show strong intelligence, robustness and cost-effectiveness. This study dedicates to providing a survey on soft computing techniques and their applications in industrial control systems. The methodologies of soft computing are mainly classified in terms of fuzzy logic, neural computing, and genetic algorithms. The challenges surrounding modern industrial control systems are summarized based on the difficulties in information acquisition, the difficulties in modeling control rules, the difficulties in control system optimization, and the requirements for robustness. Then, this study reviews soft-computing-related achievements that have been developed to tackle these challenges. Afterwards, we present a retrospect of practical industrial control applications in the fields including transportation, intelligent machines, process industry as well as energy engineering. Finally, future research directions are discussed from different perspectives. This study demonstrates that soft computing methods can endow industry control processes with many merits, thus having great application potential. It is hoped that this survey can serve as a reference and provide convenience for scholars and practitioners in the fields of industrial control and computer science

A hybrid prognostics approach for motorized spindle-tool holder remaining useful life prediction

The quality and efficiency of high-speed machining are restricted by the matching performance of the motorized spindle-tool holder. In high speed cutting process, the mating surface is subjected to alternating torque, repeated clamping wear and centrifugal force, which results in serious degradation of mating performance. Therefore, for the purpose of the optimum maintenance time, periodic evaluation and prediction of remaining useful life (RUL) should be carried out. Firstly, the mapping model between the current of the motorized spindle and matching performance was extracted, and the degradation characteristics of spindle-tool holder were emphatically analyzed. After the original current is de-noised by an adaptive threshold function, the extent of degradation was identified by the amplitudes of wavelet packet entropy. A hybrid prognostics combining Relevance Vector Machine (RVM) i.e. AI-model with power regression i.e. statistical model was proposed to predict the RUL. Finally, the proposed scheme was verified based on a motorized spindle reliability test platform. The experimental results show that the current signal processing method based on wavelet packet and entropy can reflect the change of the degradation characteristics sensitively. Compared with other two similar models, the hybrid model proposed can accurately predict the RUL. This model is suitable for complex and high reliability equipment when Condition Monitoring (CM) data is scarcer

Depth Data Denoising in Optical Laser Based Sensors for Metal Sheet Flatness Measurement: A Deep Learning Approach

Surface flatness assessment is necessary for quality control of metal sheets manufactured from steel coils by roll leveling and cutting. Mechanical-contact-based flatness sensors are being replaced by modern laser-based optical sensors that deliver accurate and dense reconstruction of metal sheet surfaces for flatness index computation. However, the surface range images captured by these optical sensors are corrupted by very specific kinds of noise due to vibrations caused by mechanical processes like degreasing, cleaning, polishing, shearing, and transporting roll systems. Therefore, high-quality flatness optical measurement systems strongly depend on the quality of image denoising methods applied to extract the true surface height image. This paper presents a deep learning architecture for removing these specific kinds of noise from the range images obtained by a laser based range sensor installed in a rolling and shearing line, in order to allow accurate flatness measurements from the clean range images. The proposed convolutional blind residual denoising network (CBRDNet) is composed of a noise estimation module and a noise removal module implemented by specific adaptation of semantic convolutional neural networks. The CBRDNet is validated on both synthetic and real noisy range image data that exhibit the most critical kinds of noise that arise throughout the metal sheet production process. Real data were obtained from a single laser line triangulation flatness sensor installed in a roll leveling and cut to length line. Computational experiments over both synthetic and real datasets clearly demonstrate that CBRDNet achieves superior performance in comparison to traditional 1D and 2D filtering methods, and state-of-the-art CNN-based denoising techniques. The experimental validation results show a reduction in error than can be up to 15% relative to solutions based on traditional 1D and 2D filtering methods and between 10% and 3% relative to the other deep learning denoising architectures recently reported in the literature.This work was partially supported by by FEDER funds through MINECO project TIN2017-85827-P, and ELKARTEK funded projects ENSOL2 and CODISAVA2 (KK-202000077 and KK-202000044) supported by the Basque Governmen

Design of an electrochemical micromachining machine

Electrochemical micromachining (μECM) is a non-conventional machining process based on the phenomenon of electrolysis. μECM became an attractive area of research due to the fact that this process does not create any defective layer after machining and that there is a growing demand for better surface integrity on different micro applications including microfluidics systems, stress-free drilled holes in automotive and aerospace manufacturing with complex shapes, etc. This work presents the design of a next generation μECM machine for the automotive, aerospace, medical and metrology sectors. It has three axes of motion (X, Y, Z) and a spindle allowing the tool-electrode to rotate during machining. The linear slides for each axis use air bearings with linear DC brushless motors and 2-nm resolution encoders for ultra precise motion. The control system is based on the Power PMAC motion controller from Delta Tau. The electrolyte tank is located at the rear of the machine and allows the electrolyte to be changed quickly. This machine features two process control algorithms: fuzzy logic control and adaptive feed rate. A self-developed pulse generator has been mounted and interfaced with the machine and a wire ECM grinding device has been added. The pulse generator has the possibility to reverse the pulse polarity for on-line tool fabrication.The research reported in this paper is supported by the European Commission within the project “Minimizing Defects in Micro-Manufacturing Applications (MIDEMMA)” (FP7-2011-NMPICT- FoF-285614)

Events Recognition System for Water Treatment Works

The supply of drinking water in sufficient quantity and required quality is a challenging task for water companies. Tackling this task successfully depends largely on ensuring a continuous high quality level of water treatment at Water Treatment Works (WTW). Therefore, processes at WTWs are highly automated and controlled. A reliable and rapid detection of faulty sensor data and failure events at WTWs processes is of prime importance for its efficient and effective operation. Therefore, the vast majority of WTWs operated in the UK make use of event detection systems that automatically generate alarms after the detection of abnormal behaviour on observed signals to ensure an early detection of WTW’s process failures. Event detection systems usually deployed at WTWs apply thresholds to the monitored signals for the recognition of WTW’s faulty processes. The research work described in this thesis investigates new methods for near real-time event detection at WTWs by the implementation of statistical process control and machine learning techniques applied for an automated near real-time recognition of failure events at WTWs processes. The resulting novel Hybrid CUSUM Event Recognition System (HC-ERS) makes use of new online sensor data validation and pre-processing techniques and utilises two distinct detection methodologies: first for fault detection on individual signals and second for the recognition of faulty processes and events at WTWs. The fault detection methodology automatically detects abnormal behaviour of observed water quality parameters in near real-time using the data of the corresponding sensors that is online validated and pre-processed. The methodology utilises CUSUM control charts to predict the presence of faults by tracking the variation of each signal individually to identify abnormal shifts in its mean. The basic CUSUM methodology was refined by investigating optimised interdependent parameters for each signal individually. The combined predictions of CUSUM fault detection on individual signals serves the basis for application of the second event detection methodology. The second event detection methodology automatically identifies faults at WTW’s processes respectively failure events at WTWs in near real-time, utilising the faults detected by CUSUM fault detection on individual signals beforehand. The method applies Random Forest classifiers to predict the presence of an event at WTW’s processes. All methods have been developed to be generic and generalising well across different drinking water treatment processes at WTWs. HC-ERS has proved to be effective in the detection of failure events at WTWs demonstrated by the application on real data of water quality signals with historical events from a UK’s WTWs. The methodology achieved a peak F1 value of 0.84 and generates 0.3 false alarms per week. These results demonstrate the ability of method to automatically and reliably detect failure events at WTW’s processes in near real-time and also show promise for practical application of the HC-ERS in industry. The combination of both methodologies presents a unique contribution to the field of near real-time event detection at WTW

Modern approaches to control of a multiple hearth furnace in kaolin production

The aim of this thesis is to improve the overall efficiency of the multiple hearth furnace (MHF) in kaolin calcination by developing control strategies which incorporate machine learning based soft sensors to estimate mineralogy related constraints in the control strategy. The objective of the control strategy is to maximize the capacity of the furnace and minimize energy consumption while maintaining the product quality of the calcined kaolin. First, the description of the process of interest is given, highlighting the control strategy currently implemented at the calciner studied in this work. Next, the state of the art on control of calcination furnaces is presented and discussed. Then, the description of the mechanistic model of the MHF, which plays a key role in the testing environment, is provided and an analysis of the MHF dynamic behavior based on the industrial and simulated data is presented. The design of the mineralogy-driven control strategy for the multiple hearth furnace and its implementation in the simulation environment are also outlined. The analysis of the results is then presented. Furthermore, the extensive sampling campaign for testing the soft sensors and the control strategy logic of the industrial MHF is reported, and the results are analyzed and discussed. Finally, an introduction to Model Predictive Control (MPC) is presented, the design of the Linear MPC framework for the MHF in kaolin calcination is described and discussed, and future research is outlined

A Feasibility Study for the Automated Monitoring and Control of Mine Water Discharges

The chemical treatment of mine-influenced waters is a longstanding environmental challenge for many coal operators, particularly in Central Appalachia. Mining conditions in this region present several unique obstacles to meeting NPDES effluent limits. Outlets that discharge effluent are often located in remote areas with challenging terrain where conditions do not facilitate the implementation of large-scale commercial treatment systems. Furthermore, maintenance of these systems is often laborious, expensive, and time consuming. Many large mining complexes discharge water from numerous outlets, while using environmental technicians to assess the water quality and treatment process multiple times per day. Unfortunately, this treatment method when combined with the lower limits associated with increased regulatory scrutiny can lead to the discharge of non-compliant water off of the mine permit. As an alternative solution, this thesis describes the ongoing research and development of automated protocols for the treatment and monitoring of mine water discharges. In particular, the current work highlights machine learning algorithms as a potential solution for pH control.;In this research, a bench-scale treatment system was constructed. This system simulates a series of ponds such as those found in use by Central Appalachian coal companies to treat acid mine drainage. The bench-scale system was first characterized to determine the volumetric flow rates and resident time distributions at varying flow rates and reactor configurations. Next, data collection was conducted using the bench scale system to generate training data by introducing multilevel random perturbations to the alkaline and acidic water flow rates. A fuzzy controller was then implemented in this system to administer alkaline material with the goal of automating the chemical treatment process. Finally, the performance of machine learning algorithms in predicting future water quality was evaluated to identify the critical input variables required to build these algorithms. Results indicate the machine learning controllers are viable alternatives to the manual control used by many Appalachian coal producers