Design methodology for smart actuator services for machine tool and machining control and monitoring

This paper presents a methodology to design the services of smart actuators for machine tools. The smart actuators aim at replacing the traditional drives (spindles and feed-drives) and enable to add data processing abilities to implement monitoring and control tasks. Their data processing abilities are also exploited in order to create a new decision level at the machine level. The aim of this decision level is to react to disturbances that the monitoring tasks detect. The cooperation between the computational objects (the smart spindle, the smart feed-drives and the CNC unit) enables to carry out functions for accommodating or adapting to the disturbances. This leads to the extension of the notion of smart actuator with the notion of agent. In order to implement the services of the smart drives, a general design is presented describing the services as well as the behavior of the smart drive according to the object oriented approach. Requirements about the CNC unit are detailed. Eventually, an implementation of the smart drive services that involves a virtual lathe and a virtual turning operation is described. This description is part of the design methodology. Experimental results obtained thanks to the virtual machine are then presented

Five-Axis Machine Tool Condition Monitoring Using dSPACE Real-Time System

This paper presents the design, development and SIMULINK implementation of the lumped parameter model of C-axis drive from GEISS five-axis CNC machine tool. The simulated results compare well with the experimental data measured from the actual machine. Also the paper describes the steps for data acquisition using ControlDesk and hardware-in-the-loop implementation of the drive models in dSPACE real-time system. The main components of the HIL system are: the drive model simulation and input – output (I/O) modules for receiving the real controller outputs. The paper explains how the experimental data obtained from the data acquisition process using dSPACE real-time system can be used for the development of machine tool diagnosis and prognosis systems that facilitate the improvement of maintenance activities

Methods of Technical Prognostics Applicable to Embedded Systems

Hlavní cílem dizertace je poskytnutí uceleného pohledu na problematiku technické prognostiky, která nachází uplatnění v tzv. prediktivní údržbě založené na trvalém monitorování zařízení a odhadu úrovně degradace systému či jeho zbývající životnosti a to zejména v oblasti komplexních zařízení a strojů. V současnosti je technická diagnostika poměrně dobře zmapovaná a reálně nasazená na rozdíl od technické prognostiky, která je stále rozvíjejícím se oborem, který ovšem postrádá větší množství reálných aplikaci a navíc ne všechny metody jsou dostatečně přesné a aplikovatelné pro embedded systémy. Dizertační práce přináší přehled základních metod použitelných pro účely predikce zbývající užitné životnosti, jsou zde popsány metriky pomocí, kterých je možné jednotlivé přístupy porovnávat ať už z pohledu přesnosti, ale také i z pohledu výpočetní náročnosti. Jedno z dizertačních jader tvoří doporučení a postup pro výběr vhodné prognostické metody s ohledem na prognostická kritéria. Dalším dizertačním jádrem je představení tzv. částicového filtrovaní (particle filtering) vhodné pro model-based prognostiku s ověřením jejich implementace a porovnáním. Hlavní dizertační jádro reprezentuje případovou studii pro velmi aktuální téma prognostiky Li-Ion baterii s ohledem na trvalé monitorování. Případová studie demonstruje proces prognostiky založené na modelu a srovnává možné přístupy jednak pro odhad doby před vybitím baterie, ale také sleduje možné vlivy na degradaci baterie. Součástí práce je základní ověření modelu Li-Ion baterie a návrh prognostického procesu.The main aim of the thesis is to provide a comprehensive overview of technical prognosis, which is applied in the condition based maintenance, based on continuous device monitoring and remaining useful life estimation, especially in the field of complex equipment and machinery. Nowadays technical prognosis is still evolving discipline with limited number of real applications and is not so well developed as technical diagnostics, which is fairly well mapped and deployed in real systems. Thesis provides an overview of basic methods applicable for prediction of remaining useful life, metrics, which can help to compare the different approaches both in terms of accuracy and in terms of computational/deployment cost. One of the research cores consists of recommendations and guide for selecting the appropriate forecasting method with regard to the prognostic criteria. Second thesis research core provides description and applicability of particle filtering framework suitable for model-based forecasting. Verification of their implementation and comparison is provided. The main research topic of the thesis provides a case study for a very actual Li-Ion battery health monitoring and prognostics with respect to continuous monitoring. The case study demonstrates the prognostic process based on the model and compares the possible approaches for estimating both the runtime and capacity fade. Proposed methodology is verified on real measured data.

VIRHUS: uma plataforma computacional para a simulação de sinais fisiológicos de humanos virtuais

The ability to access bio-signals of participants for research activity is limited specially for informal settings like academic projects. These limitations can be in part overcome it by using software to simulated good enough physiological data. In this work we propose and develop a computational platform to simulate (biological signals of ) virtual humans as a service. The system adopts the concept of digital twin to structure the simulation processes. In this case, the system is not sensing real participants, rather uses pre-recorded signals as inputs to auto-encoders that generate realistic synthetic signal for a virtual human, i.e., a digital twin. The pre-recorded signals used were the electrocardiogram, electrodermal activity and electromyography signals which were labeled with the ongoing emotion. The system, VIRHUS, offers an interactive web environment to create the required virtual humans and manage the simulation processes. A scalable backend takes care of the asynchronous generation of signals, that can be streamed to endpoints (and consumed by external applications) or exported as files, for convenience. As a proof of concept, the “virtual human” data can be parameterized to include emotional traits in the bio-signals (happy, sad,...), generating meaningful variations in data for applications developers.A capacidade de aceder aos biossinais de participantes para actividades de investigação é limitada, especialmente em contextos informais, tais como projectos académicos. Estas limitações podem ser parcialmente ultrapassadas através da utilização de software para simular dados fisiológicos suficientemente fidedignos. Neste trabalho, propomos e desenvolvemos uma plataforma computacional para simular (sinais biológicos de ) seres humanos virtuais como um serviço. O sistema adopta o conceito de réplica digital ("digital twin") para estruturar os processos de simulação. Neste caso, o sistema não está a monitorar participantes reais, mas utiliza sinais pré-gravados como entradas para autocodificadores que geram um sinal sintético realista para um ser humano virtual, ou seja, uma réplica digital. Os sinais pré-gravados utilizados foram o electrocardiograma, a actividade electrodérmica e os sinais electromiográficos que foram marcados com a emoção em progresso. O sistema, VIRHUS, fornece um ambiente web interactivo para criar os seres humanos virtuais necessários e gerir os processos de simulação. Um backend escalável cuida da geração assíncrona de sinais, que podem ser transmitidos para pontos de acesso programático (e consumidos por aplicações externas) ou exportados como ficheiros por conveniência. Como prova de conceito, os dados "humanos virtuais" podem ser parametrizados para incluir traços emocionais nos biossinais (feliz, triste,...), gerando variações significativas nos dados para os programadores de aplicações.Mestrado em Engenharia Informátic

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

Support vector machine based classification in condition monitoring of induction motors

Continuous and trouble-free operation of induction motors is an essential part of modern power and production plants. Faults and failures of electrical machinery may cause remarkable economical losses but also highly dangerous situations. In addition to analytical and knowledge-based models, application of data-based models has established a firm position in the induction motor fault diagnostics during the last decade. For example, pattern recognition with Neural Networks (NN) is widely studied. Support Vector Machine (SVM) is a novel machine learning method introduced in early 90's. It is based on the statistical learning theory presented by V.N. Vapnik, and it has been successfully applied to numerous classification and pattern recognition problems such as text categorization, image recognition and bioinformatics. SVM based classifier is built to minimize the structural misclassification risk, whereas conventional classification techniques often apply minimization of the empirical risk. Therefore, SVM is claimed to lead enhanced generalisation properties. Further, application of SVM results in the global solution for a classification problem. Thirdly, SVM based classification is attractive, because its efficiency does not directly depend on the dimension of classified entities. This property is very useful in fault diagnostics, because the number of fault classification features does not have to be drastically limited. However, SVM has not yet been widely studied in the area of fault diagnostics. Specifically, in the condition monitoring of induction motor, it does not seem to have been considered before this research. In this thesis, a SVM based classification scheme is designed for different tasks in induction motor fault diagnostics and for partial discharge analysis of insulation condition monitoring. Several variables are compared as fault indicators, and forces on rotor are found to be important in fault detection instead of motor current that is currently widely studied. The measurement of forces is difficult, but easily measurable vibrations are directly related to the forces. Hence, vibration monitoring is considered in more detail as the medium for the motor fault diagnostics. SVM classifiers are essentially 2-class classifiers. In addition to the induction motor fault diagnostics, the results of this thesis cover various methods for coupling SVMs for carrying out a multi-class classification problem.reviewe

Exploring Prognostic and Diagnostic Techniques for Jet Engine Health Monitoring: A Review of Degradation Mechanisms and Advanced Prediction Strategies

Maintenance is crucial for aircraft engines because of the demanding conditions to which they are exposed during operation. A proper maintenance plan is essential for ensuring safe flights and prolonging the life of the engines. It also plays a major role in managing costs for aeronautical companies. Various forms of degradation can affect different engine components. To optimize cost management, modern maintenance plans utilize diagnostic and prognostic techniques, such as Engine Health Monitoring (EHM), which assesses the health of the engine based on monitored parameters. In recent years, various EHM systems have been developed utilizing computational techniques. These algorithms are often enhanced by utilizing data reduction and noise filtering tools, which help to minimize computational time and efforts, and to improve performance by reducing noise from sensor data. This paper discusses the various mechanisms that lead to the degradation of aircraft engine components and the impact on engine performance. Additionally, it provides an overview of the most commonly used data reduction and diagnostic and prognostic techniques

prognostic health management of production systems new proposed approach and experimental evidences

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