Autonomous Load Profile Recognition in Industrial DC-Link Using an Audio Search Algorithm

Industrial manufacturing plants, including machine tools, robots, and elevators, perform dynamic acceleration and braking processes. Recuperative braking results in an increased voltage in the machines' direct current (DC) links. In the case of a diode rectifier, a braking resistor turns the surplus of energy into lost heat. In contrast, active rectifiers can feed the braking energy back to the AC grid, though they are more expensive than diode rectifiers. DC link-coupled energy storage systems are one possible solution to downsize the supply infrastructure by peak shaving and to harvest braking energy. However, their control heavily depends on the applied load profiles that are not known in advance. Especially for retrofitted energy storage systems without connection to the machine control unit, load profile recognition imposes a major challenge. A self-tuning framework represents a suitable solution by covering system identification, proof of stability, control design, load profile recognition, and forecasting at the same time. This paper introduces autonomous load profile recognition in industrial DC links using an audio search algorithm. The method generates fingerprints for each measured load profile and saves them in a database. The control of the energy storage system then has to be adapted within a critical time range according to the identified load profile and constraints given by the energy storage system. Three different load profiles in four case studies validate the methodology

Minimisation of Energy Consumption Variance in Manufacturing through Production Schedule Manipulation

In the manufacturing sector, despite the vital role it plays, the consumption of energy is rarely considered as a manufacturing process variable during the scheduling of production jobs. Due to both physical and contractual limits, the local power infrastructure can only deliver a finite amount of electrical energy at any one time. As a consequence of not considering the energy usage during the scheduling process, this limited capacity can be inefficiently utilised or exceeded, potentially resulting in damage to the infrastructure. To address this, this thesis presents a novel schedule optimisation system. Here, a Genetic Algorithm is used to optimise the start times of manufacturing jobs such that the variance in production line energy consumption is minimised, while ensuring that typical hard and soft schedule constraints are maintained. Prediction accuracy is assured through the use of a novel library-based system which is able to provide historical energy data at a high temporal granularity, while accounting for the influence of machine conditions on the energy consumption. In cases where there is insufficient historical data for a particular manufacturing job, the library-based system is able to analyse the available energy data and utilise machine learning to generate temporary synthetic profiles compensated for probable machine conditions. The performance of the entire proposed system is optimised through significant experimentation and analysis, which allows for an optimised schedule to be produced within an acceptable amount of time. Testing in a lab-based production line demonstrates that the optimised schedule is able to significantly reduce the energy consumption variance produced by a production schedule, while providing a highly accurate prediction as to the energy consumption during the schedules execution. The proposed system is also demonstrated to be easily expandable, allowing it to consider local renewable energy generation and energy storage, along with objectives such as the minimisation of peak energy consumption, and energy drawn from the National Grid

Infrastructure systems modeling using data visualization and trend extraction

“Current infrastructure systems modeling literature lacks frameworks that integrate data visualization and trend extraction needed for complex systems decision making and planning. Critical infrastructures such as transportation and energy systems contain interdependencies that cannot be properly characterized without considering data visualization and trend extraction. This dissertation presents two case analyses to showcase the effectiveness and improvements that can be made using these techniques. Case one examines flood management and mitigation of disruption impacts using geospatial characteristics as part of data visualization. Case two incorporates trend analysis and sustainability assessment into energy portfolio transitions. Four distinct contributions are made in this work and divided equally across the two cases. The first contribution identifies trends and flood characteristics that must be included as part of model development. The second contribution uses trend extraction to create a traffic management data visualization system based on the flood influencing factors identified. The third contribution creates a data visualization framework for energy portfolio analysis using a genetic algorithm and fuzzy logic. The fourth contribution develops a sustainability assessment model using trend extraction and time series forecasting of state-level electricity generation in a proposed transition setting. The data visualization and trend extraction tools developed and validated in this research will improve strategic infrastructure planning effectiveness”--Abstract, page iv

TRANSFORMING A CIRCULAR ECONOMY INTO A HELICAL ECONOMY FOR ADVANCING SUSTAINABLE MANUFACTURING

The U.N. projects the world population to reach nearly 10 billion people by 2050, which will cause demand for manufactured goods to reach unforeseen levels. In order for us to produce the goods to support an equitable future, the methods in which we manufacture those goods must radically change. The emerging Circular Economy (CE) concept for production systems has promised to drastically increase economic/business value by significantly reducing the world’s resource consumption and negative environmental impacts. However, CE is inherently limited because of its emphasis on recycling and reuse of materials. CE does not address the holistic changes needed across all of the fundamental elements of manufacturing: products, processes, and systems. Therefore, a paradigm shift is required for moving from sustainment to sustainability to “produce more with less” through smart, innovative and transformative convergent manufacturing approaches rooted in redesigning next generation manufacturing infrastructure. This PhD research proposes the Helical Economy (HE) concept as a novel extension to CE. The proposed HE concepts shift the CE’s status quo paradigm away from post-use recovery for recycling and reuse and towards redesigning manufacturing infrastructure at product, process, and system levels, while leveraging IoT-enabled data infrastructures and an upskilled workforce. This research starts with the conceptual overview and a framework for implementing HE in the discrete product manufacturing domain by establishing the future state vision of the Helical Economy Manufacturing Method (HEMM). The work then analyzes two components of the framework in detail: designing next-generation products and next-generation IoT-enabled data infrastructures. The major research problems that need to be solved in these subcomponents are identified in order to make near-term progress towards the HEMM. The work then proceeds with the development and discussion of initial methods for addressing these challenges. Each method is demonstrated using an illustrative industry example. Collectively, this initial work establishes the foundational body of knowledge for the HE and the HEMM, provides implementation methods at the product and IoT-enabled data infrastructure levels, and it shows a great potential for HE’s ability to create and maximize sustainable value, optimize resource consumption, and ensure continued technological progress with significant economic growth and innovation. This research work then presents an outlook on the future work needed, as well as calls for industry to support the continued refinement and development of the HEMM through relevant prototype development and subsequent applications

Research and Education in Computational Science and Engineering

Over the past two decades the field of computational science and engineering (CSE) has penetrated both basic and applied research in academia, industry, and laboratories to advance discovery, optimize systems, support decision-makers, and educate the scientific and engineering workforce. Informed by centuries of theory and experiment, CSE performs computational experiments to answer questions that neither theory nor experiment alone is equipped to answer. CSE provides scientists and engineers of all persuasions with algorithmic inventions and software systems that transcend disciplines and scales. Carried on a wave of digital technology, CSE brings the power of parallelism to bear on troves of data. Mathematics-based advanced computing has become a prevalent means of discovery and innovation in essentially all areas of science, engineering, technology, and society; and the CSE community is at the core of this transformation. However, a combination of disruptive developments---including the architectural complexity of extreme-scale computing, the data revolution that engulfs the planet, and the specialization required to follow the applications to new frontiers---is redefining the scope and reach of the CSE endeavor. This report describes the rapid expansion of CSE and the challenges to sustaining its bold advances. The report also presents strategies and directions for CSE research and education for the next decade.Comment: Major revision, to appear in SIAM Revie

Challenges and Prospects of Steelmaking Towards the Year 2050

The world steel industry is strongly based on coal/coke in ironmaking, resulting in huge carbon dioxide emissions corresponding to approximately 7% of the total anthropogenic CO2 emissions. As the world is experiencing a period of imminent threat owing to climate change, the steel industry is also facing a tremendous challenge in next decades. This themed issue makes a survey on the current situation of steel production, energy consumption, and CO2 emissions, as well as cross-sections of the potential methods to decrease CO2 emissions in current processes via improved energy and materials efficiency, increasing recycling, utilizing alternative energy sources, and adopting CO2 capture and storage. The current state, problems and plans in the two biggest steel producing countries, China and India are introduced. Generally contemplating, incremental improvements in current processes play a key role in rapid mitigation of specific emissions, but finally they are insufficient when striving for carbon neutral production in the long run. Then hydrogen and electrification are the apparent solutions also to iron and steel production. The book gives a holistic overview of the current situation and challenges, and an inclusive compilation of the potential technologies and solutions for the global CO2 emissions problem

Cloud Computing cost and energy optimization through Federated Cloud SoS

2017 Fall.Includes bibliographical references.The two most significant differentiators amongst contemporary Cloud Computing service providers have increased green energy use and datacenter resource utilization. This work addresses these two issues from a system's architectural optimization viewpoint. The proposed approach herein, allows multiple cloud providers to utilize their individual computing resources in three ways by: (1) cutting the number of datacenters needed, (2) scheduling available datacenter grid energy via aggregators to reduce costs and power outages, and lastly by (3) utilizing, where appropriate, more renewable and carbon-free energy sources. Altogether our proposed approach creates an alternative paradigm for a Federated Cloud SoS approach. The proposed paradigm employs a novel control methodology that is tuned to obtain both financial and environmental advantages. It also supports dynamic expansion and contraction of computing capabilities for handling sudden variations in service demand as well as for maximizing usage of time varying green energy supplies. Herein we analyze the core SoS requirements, concept synthesis, and functional architecture with an eye on avoiding inadvertent cascading conditions. We suggest a physical architecture that diminishes unwanted outcomes while encouraging desirable results. Finally, in our approach, the constituent cloud services retain their independent ownership, objectives, funding, and sustainability means. This work analyzes the core SoS requirements, concept synthesis, and functional architecture. It suggests a physical structure that simulates the primary SoS emergent behavior to diminish unwanted outcomes while encouraging desirable results. The report will analyze optimal computing generation methods, optimal energy utilization for computing generation as well as a procedure for building optimal datacenters using a unique hardware computing system design based on the openCompute community as an illustrative collaboration platform. Finally, the research concludes with security features cloud federation requires to support to protect its constituents, its constituents tenants and itself from security risks

Big data reference architecture for industry 4.0: including economic and ethical Implications

El rápido progreso de la Industria 4.0 se consigue gracias a las innovaciones en varios campos, por ejemplo, la fabricación, el big data y la inteligencia artificial. La tesis explica la necesidad de una arquitectura del Big Data para implementar la Inteligencia Artificial en la Industria 4.0 y presenta una arquitectura cognitiva para la inteligencia artificial - CAAI - como posible solución, que se adapta especialmente a los retos de las pequeñas y medianas empresas. La tesis examina las implicaciones económicas y éticas de esas tecnologías y destaca tanto los beneficios como los retos para los países, las empresas y los trabajadores individuales. El "Cuestionario de la Industria 4.0 para las PYME" se realizó para averiguar los requisitos y necesidades de las pequeñas y medianas empresas. Así, la nueva arquitectura de la CAAI presenta un modelo de diseño de software y proporciona un conjunto de bloques de construcción de código abierto para apoyar a las empresas durante la implementación. Diferentes casos de uso demuestran la aplicabilidad de la arquitectura y la siguiente evaluación verifica la funcionalidad de la misma.The rapid progress in Industry 4.0 is achieved through innovations in several fields, e.g., manufacturing, big data, and artificial intelligence. The thesis motivates the need for a Big Data architecture to apply artificial intelligence in Industry 4.0 and presents a cognitive architecture for artificial intelligence – CAAI – as a possible solution, which is especially suited for the challenges of small and medium-sized enterprises. The work examines the economic and ethical implications of those technologies and highlights the benefits but also the challenges for countries, companies and individual workers. The "Industry 4.0 Questionnaire for SMEs" was conducted to gain insights into smaller and medium-sized companies’ requirements and needs. Thus, the new CAAI architecture presents a software design blueprint and provides a set of open-source building blocks to support companies during implementation. Different use cases demonstrate the applicability of the architecture and the following evaluation verifies the functionality of the architecture

Systems Engineering: Availability and Reliability

Current trends in Industry 4.0 are largely related to issues of reliability and availability. As a result of these trends and the complexity of engineering systems, research and development in this area needs to focus on new solutions in the integration of intelligent machines or systems, with an emphasis on changes in production processes aimed at increasing production efficiency or equipment reliability. The emergence of innovative technologies and new business models based on innovation, cooperation networks, and the enhancement of endogenous resources is assumed to be a strong contribution to the development of competitive economies all around the world. Innovation and engineering, focused on sustainability, reliability, and availability of resources, have a key role in this context. The scope of this Special Issue is closely associated to that of the ICIE’2020 conference. This conference and journal’s Special Issue is to present current innovations and engineering achievements of top world scientists and industrial practitioners in the thematic areas related to reliability and risk assessment, innovations in maintenance strategies, production process scheduling, management and maintenance or systems analysis, simulation, design and modelling