Intelligent decision support for maintenance: an overview and future trends

The changing nature of manufacturing, in recent years, is evident in industry’s willingness to adopt network-connected intelligent machines in their factory development plans. A number of joint corporate/government initiatives also describe and encourage the adoption of Artificial Intelligence (AI) in the operation and management of production lines. Machine learning will have a significant role to play in the delivery of automated and intelligently supported maintenance decision-making systems. While e-maintenance practice provides aframework for internet-connected operation of maintenance practice the advent of IoT has changed the scale of internetworking and new architectures and tools are needed. While advances in sensors and sensor fusion techniques have been significant in recent years, the possibilities brought by IoT create new challenges in the scale of data and its analysis. The development of audit trail style practice for the collection of data and the provision of acomprehensive framework for its processing, analysis and use should be avaluable contribution in addressing the new data analytics challenges for maintenance created by internet connected devices. This paper proposes that further research should be conducted into audit trail collection of maintenance data, allowing future systems to enable ‘Human in the loop’ interactions

An Edge-Cloud based Reference Architecture to support cognitive solutions in Process Industry

Process Industry is one of the leading sectors of the world economy, characterized however by intense environmental impact, and very high-energy consumption. Despite a traditional low innovation pace in PI, in the recent years a strong push at worldwide level towards the dual objective of improving the efficiency of plants and the quality of products, significantly reducing the consumption of electricity and CO2 emissions has taken momentum. Digital Technologies (namely Smart Embedded Systems, IoT, Data, AI and Edge-to-Cloud Technologies) are enabling drivers for a Twin Digital-Green Transition, as well as foundations for human centric, safe, comfortable and inclusive workplaces. Currently, digital sensors in plants produce a large amount of data, which in most cases constitutes just a potential and not a real value for Process Industry, often locked-in in close proprietary systems and seldomly exploited. Digital technologies, with process modelling-simulation via digital twins, can build a bridge between the physical and the virtual worlds, bringing innovation with great efficiency and drastic reduction of waste. In accordance with the guidelines of Industrie 4.0 this work proposes a modular and scalable Reference Architecture, based on open source software, which can be implemented both in brownfield and greenfield scenarios. The ability to distribute processing between the edge, where the data have been created, and the cloud, where the greatest computational resources are available, facilitates the development of integrated digital solutions with cognitive capabilities. The reference architecture is being validated in the three pilot plants, paving the way to the development of integrated planning solutions, with scheduling and control of the plants, optimizing the efficiency and reliability of the supply chain, and balancing energy efficiency

An artificial intelligence-based collaboration approach in industrial IoT manufacturing : key concepts, architectural extensions and potential applications

The digitization of manufacturing industry has led to leaner and more efficient production, under the Industry 4.0 concept. Nowadays, datasets collected from shop floor assets and information technology (IT) systems are used in data-driven analytics efforts to support more informed business intelligence decisions. However, these results are currently only used in isolated and dispersed parts of the production process. At the same time, full integration of artificial intelligence (AI) in all parts of manufacturing systems is currently lacking. In this context, the goal of this manuscript is to present a more holistic integration of AI by promoting collaboration. To this end, collaboration is understood as a multi-dimensional conceptual term that covers all important enablers for AI adoption in manufacturing contexts and is promoted in terms of business intelligence optimization, human-in-the-loop and secure federation across manufacturing sites. To address these challenges, the proposed architectural approach builds on three technical pillars: (1) components that extend the functionality of the existing layers in the Reference Architectural Model for Industry 4.0; (2) definition of new layers for collaboration by means of human-in-the-loop and federation; (3) security concerns with AI-powered mechanisms. In addition, system implementation aspects are discussed and potential applications in industrial environments, as well as business impacts, are presented

Knowledge-driven Artificial Intelligence in Steelmaking: Towards Industry 4.0

With the ongoing emergence of the Fourth Industrial Revolution, often referred to as Indus-try 4.0, new innovations, concepts, and standards are reshaping manufacturing processes and production, leading to intelligent cyber-physical systems and smart factories. Steel production is one important manufacturing process that is undergoing this digital transfor-mation. Realising this vision in steel production comes with unique challenges, including the seamless interoperability between diverse and complex systems, the uniformity of het-erogeneous data, and a need for standardised human-to-machine and machine-to-machine communication protocols. To address these challenges, international standards have been developed, and new technologies have been introduced and studied in both industry and academia. However, due to the vast quantity, scale, and heterogeneous nature of industrial data and systems, achieving interoperability among components within the context of Industry 4.0 remains a challenge, requiring the need for formal knowledge representation capabilities to enhance the understanding of data and information. In response, semantic-based technologies have been proposed as a method to capture knowledge from data and resolve incompatibility conflicts within Industry 4.0 scenarios. We propose utilising fundamental Semantic Web concepts, such as ontologies and knowledge graphs, specifically to enhance semantic interoperability, improve data integration, and standardise data across heterogeneous systems within the context of steelmaking. Addition-ally, we investigate ongoing trends that involve the integration of Machine Learning (ML)techniques with semantic technologies, resulting in the creation of hybrid models. These models capitalise on the strengths derived from the intersection of these two AI approaches.Furthermore, we explore the need for continuous reasoning over data streams, presenting preliminary research that combines ML and semantic technologies in the context of data streams. In this thesis, we make four main contributions: (1) We discover that a clear under-standing of semantic-based asset administration shells, an international standard within the RAMI 4.0 model, was lacking, and provide an extensive survey on semantic-based implementations of asset administration shells. We focus on literature that utilises semantic technologies to enhance the representation, integration, and exchange of information in an industrial setting. (2) The creation of an ontology, a semantic knowledge base, which specifically captures the cold rolling processes in steelmaking. We demonstrate use cases that leverage these semantic methodologies with real-world industrial data for data access, data integration, data querying, and condition-based maintenance purposes. (3) A frame-work demonstrating one approach for integrating machine learning models with semantic technologies to aid decision-making in the domain of steelmaking. We showcase a novel approach of applying random forest classification using rule-based reasoning, incorporating both meta-data and external domain expert knowledge into the model, resulting in improved knowledge-guided assistance for the human-in-the-loop during steelmaking processes. (4) The groundwork for a continuous data stream reasoning framework, where both domain expert knowledge and random forest classification can be dynamically applied to data streams on the fly. This approach opens up possibilities for real-time condition-based monitoring and real-time decision support for predictive maintenance applications. We demonstrate the adaptability of the framework in the context of dynamic steel production processes. Our contributions have been validated on both real-world data sets with peer-reviewed conferences and journals, as well as through collaboration with domain experts from our industrial partners at Tata Steel

Data Spaces

This open access book aims to educate data space designers to understand what is required to create a successful data space. It explores cutting-edge theory, technologies, methodologies, and best practices for data spaces for both industrial and personal data and provides the reader with a basis for understanding the design, deployment, and future directions of data spaces. The book captures the early lessons and experience in creating data spaces. It arranges these contributions into three parts covering design, deployment, and future directions respectively. The first part explores the design space of data spaces. The single chapters detail the organisational design for data spaces, data platforms, data governance federated learning, personal data sharing, data marketplaces, and hybrid artificial intelligence for data spaces. The second part describes the use of data spaces within real-world deployments. Its chapters are co-authored with industry experts and include case studies of data spaces in sectors including industry 4.0, food safety, FinTech, health care, and energy. The third and final part details future directions for data spaces, including challenges and opportunities for common European data spaces and privacy-preserving techniques for trustworthy data sharing. The book is of interest to two primary audiences: first, researchers interested in data management and data sharing, and second, practitioners and industry experts engaged in data-driven systems where the sharing and exchange of data within an ecosystem are critical

A Framework for Industry 4.0

The potential of the Industry 4.0 will allow the national industry to develop all kinds of procedures, especially in terms of competitive differentiation. The prospects and motivations behind Industry 4.0 are related to the management that is essentially geared towards industrial internet, to the integrated analysis and use of data, to the digitalization of products and services, to new disruptive business models and to the cooperation within the value chain. It is through the integration of Cyber-Physical Systems (CPS), into the maintenance process that it is possible to carry out a continuous monitoring of industrial machines, as well as to apply advanced techniques for predictive and proactive maintenance. The present work is based on the MANTIS project, aiming to construct a specific platform for the proactive maintenance of industrial machines, targeting particularly the case of GreenBender ADIRA Steel Sheet. In other words, the aim is to reduce maintenance costs, increase the efficiency of the process and consequently the profit. Essentially, the MANTIS project is a multinational research project, where the CISTER Research Unit plays a key role, particularly in providing the communications infrastructure for one MANTIS Pilot. The methodology is based on a follow-up study, which is jointly carried with the client, as well as within the scope of the implementation of the ADIRA Pilot. The macro phases that are followed in the present work are: 1) detailed analysis of the business needs; 2) preparation of the architecture specification; 3) implementation/development; 4) tests and validation; 5) support; 6) stabilization; 7) corrective and evolutionary maintenance; and 8) final project analysis and corrective measures to be applied in future projects. The expected results of the development of such project are related to the integration of the industrial maintenance process, to the continuous monitoring of the machines and to the application of advanced techniques of preventive and proactive maintenance of industrial machines, particularly based on techniques and good practices of the Software Engineering area and on the integration of Cyber-Physical Systems.O potencial desenvolvido pela Indústria 4.0 dotará a indústria nacional de capacidades para desenvolver todo o tipo de procedimentos, especialmente a nível da diferenciação competitiva. As perspetivas e as motivações por detrás da Indústria 4.0 estão relacionadas com uma gestão essencialmente direcionada para a internet industrial, com uma análise integrada e utilização de dados, com a digitalização de produtos e de serviços, com novos modelos disruptivos de negócio e com uma cooperação horizontal no âmbito da cadeia de valor. É através da integração dos sistemas ciber-físicos no processo de manutenção que é possível proceder a um monitoramento contínuo das máquinas, tal como à aplicação de técnicas avançadas para a manutenção preditiva e pró-ativa das mesmas. O presente trabalho é baseado no projeto MANTIS, objetivando, portanto, a construção de uma plataforma específica para a manutenção pró-ativa das máquinas industriais, neste caso em concreto das prensas, que serão as máquinas industriais analisadas ao longo do presente trabalho. Dito de um outro modo, objetiva-se, através de uma plataforma em específico, reduzir todos os custos da sua manutenção, aumentando, portanto, os lucros industriais advindos da produção. Resumidamente, o projeto MANTIS consiste num projeto de investigação multinacional, onde a Unidade de Investigação CISTER desenvolve um papel fundamental, particularmente no fornecimento da infraestrutura de comunicação no Piloto MANTIS. A metodologia adotada é baseada num estudo de acompanhamento, realizado em conjunto com o cliente, e no âmbito da implementação do Piloto da ADIRA. As macro fases que são compreendidas por esta metodologia, e as quais serão seguidas, são: 1) análise detalhada das necessidades de negócio; 2) preparação da especificação da arquitetura; 3) implementação/desenvolvimento; 4) testes e validação; 5) suporte; 6) estabilização; 7) manutenção corretiva e evolutiva; e 8) análise final do projeto e medidas corretivas a aplicar em projetos futuros. Os resultados esperados com o desenvolvimento do projeto estão relacionados com a integração do processo de manutenção industrial, a monitorização contínua das máquinas e a aplicação de técnicas avançadas de manutenção preventiva e pós-ativa das máquinas, especialmente com base em técnicas e boas práticas da área de Engenharia de Software

Data Spaces

This open access book aims to educate data space designers to understand what is required to create a successful data space. It explores cutting-edge theory, technologies, methodologies, and best practices for data spaces for both industrial and personal data and provides the reader with a basis for understanding the design, deployment, and future directions of data spaces. The book captures the early lessons and experience in creating data spaces. It arranges these contributions into three parts covering design, deployment, and future directions respectively. The first part explores the design space of data spaces. The single chapters detail the organisational design for data spaces, data platforms, data governance federated learning, personal data sharing, data marketplaces, and hybrid artificial intelligence for data spaces. The second part describes the use of data spaces within real-world deployments. Its chapters are co-authored with industry experts and include case studies of data spaces in sectors including industry 4.0, food safety, FinTech, health care, and energy. The third and final part details future directions for data spaces, including challenges and opportunities for common European data spaces and privacy-preserving techniques for trustworthy data sharing. The book is of interest to two primary audiences: first, researchers interested in data management and data sharing, and second, practitioners and industry experts engaged in data-driven systems where the sharing and exchange of data within an ecosystem are critical

USE OF DIGITAL TWINS TO MITIGATE COMMUNICATION FAILURES IN MICROGRIDS

This work investigates digital twin (DT) applications for electric power system (EPS) resilience. A novel DT architecture is proposed consisting of a physical twin, a virtual twin, an intelligent agent, and data communications. Requirements for the virtual twin are identified. Guidelines are provided for generating, capturing, and storing data to train the intelligent agent. The relationship between the DT development process and an existing controller hardware-in-the-loop (CHIL) process is discussed. To demonstrate the proposed DT architecture and development process, a DT for a battery energy storage system (BESS) is created based on the simulation of an industrial nanogrid. The creation and validation of the BESS DT virtual twin and intelligent agent are emphasized, including a discussion of the design choices made during the process. The use of data communication for nanogrid coordination is introduced, including the possible detrimental effects of degraded or failed communication. The BESS DT is demonstrated during nominal and off-nominal events in the nanogrid, highlighting the DT’s ability to make decisions using only local measurements rather than relying on a data communication network for coordination. The results show that the BESS DT can increase nanogrid resilience by recommending actions in response to transient events in the nanogrid, even while the data communication network has degraded or failed