CERN openlab Whitepaper on Future IT Challenges in Scientific Research

This whitepaper describes the major IT challenges in scientific research at CERN and several other European and international research laboratories and projects. Each challenge is exemplified through a set of concrete use cases drawn from the requirements of large-scale scientific programs. The paper is based on contributions from many researchers and IT experts of the participating laboratories and also input from the existing CERN openlab industrial sponsors. The views expressed in this document are those of the individual contributors and do not necessarily reflect the view of their organisations and/or affiliates

Evaluating maintenance policies by quantitative modeling and analysis

International audienceThe growing importance of maintenance in the evolving industrial scenario and the technological advancements of the recent years have yielded the development of modern maintenance strategies such as the condition-based maintenance (CBM) and the predictive maintenance (PrM). In practice, assessing whether these strategies really improve the maintenance performance becomes a funda-mental issue. In the present work, this is addressed with reference to an example concerning the stochastic crack growth of a generic mechanical component subject to fatigue degradation. It is shown that modeling and analysis provide information useful for setting a maintenance policy

A Comprehensive Review of Digital Twin -- Part 1: Modeling and Twinning Enabling Technologies

As an emerging technology in the era of Industry 4.0, digital twin is gaining unprecedented attention because of its promise to further optimize process design, quality control, health monitoring, decision and policy making, and more, by comprehensively modeling the physical world as a group of interconnected digital models. In a two-part series of papers, we examine the fundamental role of different modeling techniques, twinning enabling technologies, and uncertainty quantification and optimization methods commonly used in digital twins. This first paper presents a thorough literature review of digital twin trends across many disciplines currently pursuing this area of research. Then, digital twin modeling and twinning enabling technologies are further analyzed by classifying them into two main categories: physical-to-virtual, and virtual-to-physical, based on the direction in which data flows. Finally, this paper provides perspectives on the trajectory of digital twin technology over the next decade, and introduces a few emerging areas of research which will likely be of great use in future digital twin research. In part two of this review, the role of uncertainty quantification and optimization are discussed, a battery digital twin is demonstrated, and more perspectives on the future of digital twin are shared

Prognostic Algorithms for Condition Monitoring and Remaining Useful Life Estimation

To enable the benets of a truly condition-based maintenance philosophy to be realised, robust, accurate and reliable algorithms, which provide maintenance personnel with the necessary information to make informed maintenance decisions, will be key. This thesis focuses on the development of such algorithms, with a focus on semiconductor manufacturing and wind turbines. An introduction to condition-based maintenance is presented which reviews dierent types of maintenance philosophies and describes the potential benets which a condition- based maintenance philosophy will deliver to operators of critical plant and machinery. The issues and challenges involved in developing condition-based maintenance solutions are discussed and a review of previous approaches and techniques in fault diagnostics and prognostics is presented. The development of a condition monitoring system for dry vacuum pumps used in semi- conductor manufacturing is presented. A notable feature is that upstream process mea- surements from the wafer processing chamber were incorporated in the development of a solution. In general, semiconductor manufacturers do not make such information avail- able and this study identies the benets of information sharing in the development of condition monitoring solutions, within the semiconductor manufacturing domain. The developed solution provides maintenance personnel with the ability to identify, quantify, track and predict the remaining useful life of pumps suering from degradation caused by pumping large volumes of corrosive uorine gas. A comprehensive condition monitoring solution for thermal abatement systems is also presented. As part of this work, a multiple model particle ltering algorithm for prog- nostics is developed and tested. The capabilities of the proposed prognostic solution for addressing the uncertainty challenges in predicting the remaining useful life of abatement systems, subject to uncertain future operating loads and conditions, is demonstrated. Finally, a condition monitoring algorithm for the main bearing on large utility scale wind turbines is developed. The developed solution exploits data collected by onboard supervisory control and data acquisition (SCADA) systems in wind turbines. As a result, the developed solution can be integrated into existing monitoring systems, at no additional cost. The potential for the application of multiple model particle ltering algorithm to wind turbine prognostics is also demonstrated

A SITUATION AWARENESS DRIVEN DESIGN FOR PREDICTIVE MAINTENANCE SYSTEMS: THE CASE OF OIL AND GAS PIPELINE OPERATIONS

The acquisition and processing of events from sensors or enterprise applications in real-time represent an essential part of many application domains such as the Internet of Things (IoT), offering benefits to predict the future condition of equipment to prevent the occurrence of failures. Many organisations already use some form of predictive maintenance to monitor performance or keep track of emerging business situations. However, the optimal design of applications to allow an effective Predictive Mainte-nance System (PMS) capable of analysing and processing large amounts of data is only scarcely exam-ined by Information Systems (IS) research. Due to the number, frequency, and the need for near-real-time evaluation systems must be capable of detecting complex event patterns based on spatial, temporal, or causal relationships on data streams (i.e. via Complex Event Processing). At the same time, however, due to the technical complexity, available systems today are static, since the creation and adaptation of recognisable situations results in slow development cycles. In addition, technical feasibility is only one prerequisite for predictive maintenance. Users must be capable of processing this vast amount of data presented without considerable cognitive effort. Precisely this challenge is even more daunting as op-erational maintenance personnel have to manage business-critical decisions with increasing frequency and short time. Research in Human Factors (HF) suggests Situation Awareness (SA) as a crucial sys-tem’s design paradigm allowing human beings to understand and anticipate the information available effectively. Building on this concept, this paper proposes a PMS for promoting operational decision makers’ Situation Awareness by three design principles (DP): Sensing, Acting, and Tracking. Based on these DPs, we implemented a PMS prototype for a scenario in Oil and Gas pipeline operations. Our finding suggest that the use of SA is of particular interest in realizing effective PMS

Statistical Methods for Semiconductor Manufacturing

In this thesis techniques for non-parametric modeling, machine learning, filtering and prediction and run-to-run control for semiconductor manufacturing are described. In particular, algorithms have been developed for two major applications area: - Virtual Metrology (VM) systems; - Predictive Maintenance (PdM) systems. Both technologies have proliferated in the past recent years in the semiconductor industries, called fabs, in order to increment productivity and decrease costs. VM systems aim of predicting quantities on the wafer, the main and basic product of the semiconductor industry, that may be physically measurable or not. These quantities are usually ’costly’ to be measured in economic or temporal terms: the prediction is based on process variables and/or logistic information on the production that, instead, are always available and that can be used for modeling without further costs. PdM systems, on the other hand, aim at predicting when a maintenance action has to be performed. This approach to maintenance management, based like VM on statistical methods and on the availability of process/logistic data, is in contrast with other classical approaches: - Run-to-Failure (R2F), where there are no interventions performed on the machine/process until a new breaking or specification violation happens in the production; - Preventive Maintenance (PvM), where the maintenances are scheduled in advance based on temporal intervals or on production iterations. Both aforementioned approaches are not optimal, because they do not assure that breakings and wasting of wafers will not happen and, in the case of PvM, they may lead to unnecessary maintenances without completely exploiting the lifetime of the machine or of the process. The main goal of this thesis is to prove through several applications and feasibility studies that the use of statistical modeling algorithms and control systems can improve the efficiency, yield and profits of a manufacturing environment like the semiconductor one, where lots of data are recorded and can be employed to build mathematical models. We present several original contributions, both in the form of applications and methods. The introduction of this thesis will be an overview on the semiconductor fabrication process: the most common practices on Advanced Process Control (APC) systems and the major issues for engineers and statisticians working in this area will be presented. Furthermore we will illustrate the methods and mathematical models used in the applications. We will then discuss in details the following applications: - A VM system for the estimation of the thickness deposited on the wafer by the Chemical Vapor Deposition (CVD) process, that exploits Fault Detection and Classification (FDC) data is presented. In this tool a new clustering algorithm based on Information Theory (IT) elements have been proposed. In addition, the Least Angle Regression (LARS) algorithm has been applied for the first time to VM problems. - A new VM module for multi-step (CVD, Etching and Litography) line is proposed, where Multi-Task Learning techniques have been employed. - A new Machine Learning algorithm based on Kernel Methods for the estimation of scalar outputs from time series inputs is illustrated. - Run-to-Run control algorithms that employ both the presence of physical measures and statistical ones (coming from a VM system) is shown; this tool is based on IT elements. - A PdM module based on filtering and prediction techniques (Kalman Filter, Monte Carlo methods) is developed for the prediction of maintenance interventions in the Epitaxy process. - A PdM system based on Elastic Nets for the maintenance predictions in Ion Implantation tool is described. Several of the aforementioned works have been developed in collaborations with major European semiconductor companies in the framework of the European project UE FP7 IMPROVE (Implementing Manufacturing science solutions to increase equiPment pROductiVity and fab pErformance); such collaborations will be specified during the thesis, underlying the practical aspects of the implementation of the proposed technologies in a real industrial environment

Fuzzy-logic-based control, filtering, and fault detection for networked systems: A Survey

This paper is concerned with the overview of the recent progress in fuzzy-logic-based filtering, control, and fault detection problems. First, the network technologies are introduced, the networked control systems are categorized from the aspects of fieldbuses and industrial Ethernets, the necessity of utilizing the fuzzy logic is justified, and the network-induced phenomena are discussed. Then, the fuzzy logic control strategies are reviewed in great detail. Special attention is given to the thorough examination on the latest results for fuzzy PID control, fuzzy adaptive control, and fuzzy tracking control problems. Furthermore, recent advances on the fuzzy-logic-based filtering and fault detection problems are reviewed. Finally, conclusions are given and some possible future research directions are pointed out, for example, topics on two-dimensional networked systems, wireless networked control systems, Quality-of-Service (QoS) of networked systems, and fuzzy access control in open networked systems.This work was supported in part by the National Natural Science Foundation of China under Grants 61329301, 61374039, 61473163, and 61374127, the Hujiang Foundation of China under Grants C14002 andD15009, the Engineering and Physical Sciences Research Council (EPSRC) of the UK, the Royal Society of the UK, and the Alexander von Humboldt Foundation of Germany