Security aspects in cloud based condition monitoring of machine tools

In the modern competitive environments companies must have rapid production systems that are able to deliver parts that satisfy highest quality standards. Companies have also an increased need for advanced machines equipped with the latest technologies in maintenance to avoid any reduction or interruption of production. Eminent therefore is the need to monitor the health status of the manufacturing equipment in real time and thus try to develop diagnostic technologies for machine tools. This paper lays the foundation for the creation of a safe remote monitoring system for machine tools using a Cloud environment for communication between the customer and the maintenance service company. Cloud technology provides a convenient means for accessing maintenance data anywhere in the world accessible through simple devices such as PC, tablets or smartphones. In this context the safety aspects of a Cloud system for remote monitoring of machine tools becomes crucial and is, thus the focus of this pape

Machine Learning Applications for Predictive Maintenance in Mechanical Systems: Case Studies, Algorithms, and Performance Evaluation

Predictive maintenance is a critical aspect of ensuring the reliability and efficiency of mechanical systems in various industries. Machine learning (ML) techniques have emerged as powerful tools for predictive maintenance, enabling early detection of equipment failures and facilitating timely interventions to prevent costly downtime and repairs. This paper provides an overview of machine learning applications for predictive maintenance in mechanical systems, presenting case studies, algorithms, and performance evaluation metrics. We discuss the significance of predictive maintenance in enhancing operational efficiency, reducing maintenance costs, and minimizing unplanned downtime. Furthermore, we review various machine learning algorithms commonly employed for predictive maintenance, including supervised and unsupervised learning techniques, deep learning models, and ensemble methods. Additionally, we delve into real-world case studies that highlight the successful implementation of machine learning for predictive maintenance across different industries, such as manufacturing, automotive, aerospace, and energy. Finally, we discuss performance evaluation metrics and methodologies used to assess the effectiveness and reliability of predictive maintenance models, considering factors such as accuracy, precision, recall, and F1-score. Through this comprehensive exploration, this paper aims to provide insights into the practical application of machine learning for predictive maintenance and its potential impact on optimizing the performance and longevity of mechanical systems

Reliability analysis of an ultra-reliable fault tolerant control system

This report analyzes the reliability of NASA's Ultra-reliable Fault Tolerant Control System (UFTCS) architecture as it is currently envisioned for helicopter control. The analysis is extended to air transport and spacecraft control using the same computational and voter modules applied within the UFTCS architecture. The system reliability is calculated for several points in the helicopter, air transport, and space flight missions when there are initially 4, 5, and 6 operating channels. Sensitivity analyses are used to explore the effects of sensor failure rates and different system configurations at the 10 hour point of the helicopter mission. These analyses show that the primary limitation to system reliability is the number of flux windings on each flux summer (4 are assumed for the baseline case). Tables of system reliability at the 10 hour point are provided to allow designers to choose a configuration to meet specified reliability goals

A Modeling and Analysis Framework To Support Monitoring, Assessment, and Control of Manufacturing Systems Using Hybrid Models

The manufacturing industry has constantly been challenged to improve productivity, adapt to continuous changes in demand, and reduce cost. The need for a competitive advantage has motivated research for new modeling and control strategies able to support reconfiguration considering the coupling between different aspects of plant floor operations. However, models of manufacturing systems usually capture the process flow and machine capabilities while neglecting the machine dynamics. The disjoint analysis of system-level interactions and machine-level dynamics limits the effectiveness of performance assessment and control strategies. This dissertation addresses the enhancement of productivity and adaptability of manufacturing systems by monitoring and controlling both the behavior of independent machines and their interactions. A novel control framework is introduced to support performance monitoring and decision making using real-time simulation, anomaly detection, and multi-objective optimization. The intellectual merit of this dissertation lies in (1) the development a mathematical framework to create hybrid models of both machines and systems capable of running in real-time, (2) the algorithms to improve anomaly detection and diagnosis using context-sensitive adaptive threshold limits combined with context-specific classification models, and (3) the construction of a simulation-based optimization strategy to support decision making considering the inherent trade-offs between productivity, quality, reliability, and energy usage. The result is a framework that transforms the state-of-the-art of manufacturing by enabling real-time performance monitoring, assessment, and control of plant floor operations. The control strategy aims to improve the productivity and sustainability of manufacturing systems using multi-objective optimization. The outcomes of this dissertation were implemented in an experimental testbed. Results demonstrate the potential to support maintenance actions, productivity analysis, and decision making in manufacturing systems. Furthermore, the proposed framework lays the foundation for a seamless integration of real systems and virtual models. The broader impact of this dissertation is the advancement of manufacturing science that is crucial to support economic growth. The implementation of the framework proposed in this dissertation can result in higher productivity, lower downtime, and energy savings. Although the project focuses on discrete manufacturing with a flow shop configuration, the control framework, modeling strategy, and optimization approach can be translated to job shop configurations or batch processes. Moreover, the algorithms and infrastructure implemented in the testbed at the University of Michigan can be integrated into automation and control products for wide availability.PHDMechanical EngineeringUniversity of Michigan, Horace H. Rackham School of Graduate Studieshttps://deepblue.lib.umich.edu/bitstream/2027.42/147657/1/migsae_1.pd

Wireless Sensor Technology Selection for I4.0 Manufacturing Systems

The term smart manufacturing has surfaced as an industrial revolution in Germany known as Industry 4.0 (I4.0); this revolution aims to help the manufacturers adapt to turbulent market trends. Its main scope is implementing machine communication, both vertically and horizontally across the manufacturing hierarchy through Internet of things (IoT), technologies and servitization concepts. The main objective of this research is to help manufacturers manage the high levels of variety and the extreme turbulence of market trends through developing a selection tool that utilizes Analytic Hierarchy Process (AHP) techniques to recommend a suitable industrial wireless sensor network (IWSN) technology that fits their manufacturing requirements.In this thesis, IWSN technologies and their properties were identified, analyzed and compared to identify their potential suitability for different industrial manufacturing system application areas. The study included the identification and analysis of different industrial system types, their application areas, scenarios and respective communication requirements. The developed tool’s sensitivity is also tested to recommend different IWSN technology options with changing influential factors. Also, a prioritizing protocol is introduced in the case where more than one IWSN technology options are recommended by the AHP tool.A real industrial case study with the collaboration of SPM Automation Inc. is presented, where the industrial systems’ class, communication traffic types, and communication requirements were analyzed to recommend a suitable IWSN technology that fits their requirements and assists their shift towards I4.0 through utilizing AHP techniques. The results of this research will serve as a step forward, in the transformation process of manufacturing towards a more digitalized and better connected cyber-physical systems; thus, enhancing manufacturing attributes such as flexibility, reconfigurability, scalability and easing the shift towards implementing I4.0

Flight deck automation: Promises and realities

Issues of flight deck automation are multifaceted and complex. The rapid introduction of advanced computer-based technology onto the flight deck of transport category aircraft has had considerable impact both on aircraft operations and on the flight crew. As part of NASA's responsibility to facilitate an active exchange of ideas and information among members of the aviation community, a NASA/FAA/Industry workshop devoted to flight deck automation, organized by the Aerospace Human Factors Research Division of NASA Ames Research Center. Participants were invited from industry and from government organizations responsible for design, certification, operation, and accident investigation of transport category, automated aircraft. The goal of the workshop was to clarify the implications of automation, both positive and negative. Workshop panels and working groups identified issues regarding the design, training, and procedural aspects of flight deck automation, as well as the crew's ability to interact and perform effectively with the new technology. The proceedings include the invited papers and the panel and working group reports, as well as the summary and conclusions of the conference

Reliability and Maintenance

Amid a plethora of challenges, technological advances in science and engineering are inadvertently affecting an increased spectrum of today’s modern life. Yet for all supplied products and services provided, robustness of processes, methods, and techniques is regarded as a major player in promoting safety. This book on systems reliability, which equally includes maintenance-related policies, presents fundamental reliability concepts that are applied in a number of industrial cases. Furthermore, to alleviate potential cost and time-specific bottlenecks, software engineering and systems engineering incorporate approximation models, also referred to as meta-processes, or surrogate models to reproduce a predefined set of problems aimed at enhancing safety, while minimizing detrimental outcomes to society and the environment