Non-destructive quality control of carbon anodes using modal analysis, acousto-ultrasonic and latent variable methods

La performance des cuves d’électrolyse utilisées dans la production d’aluminium primaire par le procédé Hall-Héroult est fortement influencée par la qualité des anodes de carbone. Celles-ci sont de plus en plus variables en raison de la qualité décroissante des matières premières (coke et braie) et des changements de fournisseurs qui deviennent de plus en plus fréquents afin de réduire le coût d’achat et de rencontrer les spécifications des usines. En effet, les défauts des anodes, tels les fissures, les pores et les hétérogénéités, causés par cette variabilité, doivent être détectés le plus tôt possible afin d’éviter d’utiliser des anodes défectueuses dans les cuves et/ou d’apporter des ajustements au niveau du procédé de fabrication des anodes. Cependant, les fabricants d’anodes ne sont pas préparés pour réagir à cette situation afin de maintenir une qualité d'anode stable. Par conséquent, il devient prioritaire de développer des techniques permettant d’inspecter le volume complet de chaque anode individuelle afin d’améliorer le contrôle de la qualité des anodes et de compenser la variabilité provenant des matières premières. Un système d’inspection basé sur les techniques d’analyse modale et d’acousto-ultrasonique est proposé pour contrôler la qualité des anodes de manière rapide et non destructive. Les données massives (modes de vibration et signaux acoustiques) ont été analysées à l'aide de méthodes statistiques à variables latentes, telles que l'Analyse en Composantes Principales (ACP) et la Projection sur les Structures Latentes (PSL), afin de regrouper les anodes testées en fonction de leurs signatures vibratoires et acousto-ultrasoniques. Le système d'inspection a été premièrement investigué sur des tranches d'anodes industrielles et ensuite testé sur plusieurs anodes pleine grandeur produites sous différentes conditions à l’usine de Alcoa Deschambault au Québec (ADQ). La méthode proposée a permis de distinguer les anodes saines de celles contenant des défauts ainsi que d’identifier le type et la sévérité des défauts, et de les localiser. La méthode acousto-ultrasonique a été validée qualitativement par la tomographie à rayon-X, pour les analyses des tranches d’anodes. Pour les tests réalisés sur les blocs d’anode, la validation a été réalisée au moyen de photos recueillies après avoir coupé certaines anodes parmi celles testées.The performance of the Hall-Héroult electrolysis reduction process used for the industrial aluminium smelting is strongly influenced by the quality of carbon anodes, particularly by the presence of defects in their internal structure, such as cracks, pores and heterogeneities. This is partly due to the decreasing quality and increasing variability of the raw materials available on the market as well as the frequent suppliers changes made in order to meet the smelter’s specifications and to reduce purchasing costs. However, the anode producers are not prepared to cope with these variations and in order to maintain consistent anode quality. Consequently, it becomes a priority to develop alternative methods for inspecting each anode block to improve quality control and maintain consistent anode quality in spite of the variability of incoming raw materials.A rapid and non-destructive inspection system for anode quality control is proposed based on modal analysis and acousto-ultrasonic techniques. The large set of vibration and acousto-ultrasonic data collected from baked anode materials was analyzed using multivariate latent variable methods, such as Principal Component Analysis (PCA) and Partial Least Squares (PLS), in order to cluster the tested anodes based on vibration and their acousto-ultrasonic signatures. The inspection system was investigated first using slices collected from industrial anodes and then on several full size anodes produced under different conditions at the Alcoa Deschambault in Québec (ADQ). It is shown that the proposed method allows discriminating defect-free anodes from those containing various types of defects. In addition, the acousto-ultrasonic features obtained in different frequency ranges were found to be sensitive to the defects severities and were able to locate them in anode blocks. The acousto-ultrasonic method was validated qualitatively using X-ray computed tomography, when studying the anode slices. The results obtained on the full size anode blocks were validated by means of images collected after cutting some tested anodes

Power Quality Management and Classification for Smart Grid Application using Machine Learning

The Efficient Wavelet-based Convolutional Transformer network (EWT-ConvT) is proposed to detect power quality disturbances in time-frequency domain using attention mechanism. The support of machine learning further improves the network accuracy with synthetic signal generation and less system complexity under practical environment. The proposed EWT-ConvT can achieve 94.42% accuracy which is superior than other deep learning models. The detection of disturbances using EWT-ConvT can also be implemented into smart grid applications for real-time embedded system development

Advances and Trends in Non-conventional, Abrasive and Precision Machining

The work included in this book pertains to advanced abrasive and nonconventional machining processes. These processes are at the forefront of modern technology, with significant practical significance. Their importance is also made clear by the case studies that are included in the research that is presented in the book, pertaining to important materials and high-end applications. However, the particularities of these manufacturing processes need to be further investigated and the processes themselves need to be optimized. This is conducted in the presented works with significant experimental and modeling work, incorporating modern tools of analysis and measurements

Deep Learning-Based Machinery Fault Diagnostics

This book offers a compilation for experts, scholars, and researchers to present the most recent advancements, from theoretical methods to the applications of sophisticated fault diagnosis techniques. The deep learning methods for analyzing and testing complex mechanical systems are of particular interest. Special attention is given to the representation and analysis of system information, operating condition monitoring, the establishment of technical standards, and scientific support of machinery fault diagnosis

Exploring the impact of detection physics in X-ray CCD imagers and spectrometers

This thesis is concerned with exploring the way in which the physics of the detection process affects the quality of a CCD-based X-ray detector system. The physical processes which lead to the final images and spectra achieved with a CCD-based camera system are investigated through a combination of simulations and experimental techniques with the aim of improving the detector performance and allowing future detectors to be designed with optimal characteristics. Techniques developed throughout the study and the results of the simulations have wide-ranging impacts on the areas concerned. The study is split into two main sections, the first regarding a high-resolution, high-energy, photon-counting X/γ-ray camera. In medical imaging, X-rays and gamma-rays are often used for the purposes of diagnostic imaging. In many synchrotron based research programmes, such as protein crystallography and X-ray diffraction imaging, X-rays are used, once again, for imaging purposes. In both cases, a high-resolution detector with a high frame-rate is required such that images can be taken with a spatial resolution of the order of micrometers to tens of micrometers. If one is able to distinguish the energy of the incident X-rays and gamma-rays (with energies of 20-200 keV) then these spectral capabilities add to the functionality of the detector, allowing, for example, the removal of fluorescence X-rays. Chapter 2 reviews the relevant detector physics and theory before providing a critical review of current gammacameras. Chapter 3 outlines the feasibility study for the scintillator-coupled EM-CCD detailing the development of a new energy discrimination methodology. Also described is the development of a full system simulation which can be used to troubleshoot problems found when calibrating and optimising the device. Chapter 4 details the characterisation and optimisation of the detector making use of the aforementioned simulations where appropriate. Chapter 5 presents the results of the study, showing how the resolution can be dramatically improved and how energy discrimination can be implemented. The second section of the thesis regards instrument background. The use of CCDs for space borne X-ray detection in scientific satellites is wide-spread. Whilst in-orbit the CCDs are subjected to an incident flux of high energy particles. These particles may be detected, both as the primaries themselves and by means of secondaries produced in the detector shielding, and will produce a background level formed by components indistinguishable from the X-rays for which the mission was designed to detect. Chapter 6 presents an introduction to the theory behind the instrument background experienced by CCD-based detector systems in orbit. A simulation has been developed which is in very good agreement with data received from the spacecrafts, described in Chapter 7. Finally, Chapter 8 summarises the outcomes of these studies and provides insight into future work which will further aid the improvement of gamma-cameras for medical imaging and synchrotron-based research and will allow future CCD-based camera systems to be designed for increased sensitivity in-orbit

The Public Service Media and Public Service Internet Manifesto

This book presents the collectively authored Public Service Media and Public Service Internet Manifesto and accompanying materials.The Internet and the media landscape are broken. The dominant commercial Internet platforms endanger democracy. They have created a communications landscape overwhelmed by surveillance, advertising, fake news, hate speech, conspiracy theories, and algorithmic politics. Commercial Internet platforms have harmed citizens, users, everyday life, and society. Democracy and digital democracy require Public Service Media. A democracy-enhancing Internet requires Public Service Media becoming Public Service Internet platforms – an Internet of the public, by the public, and for the public; an Internet that advances instead of threatens democracy and the public sphere. The Public Service Internet is based on Internet platforms operated by a variety of Public Service Media, taking the public service remit into the digital age. The Public Service Internet provides opportunities for public debate, participation, and the advancement of social cohesion. Accompanying the Manifesto are materials that informed its creation: Christian Fuchs’ report of the results of the Public Service Media/Internet Survey, the written version of Graham Murdock’s online talk on public service media today, and a summary of an ecomitee.com discussion of the Manifesto’s foundations

Structural Health Monitoring Damage Detection Systems for Aerospace

This open access book presents established methods of structural health monitoring (SHM) and discusses their technological merit in the current aerospace environment. While the aerospace industry aims for weight reduction to improve fuel efficiency, reduce environmental impact, and to decrease maintenance time and operating costs, aircraft structures are often designed and built heavier than required in order to accommodate unpredictable failure. A way to overcome this approach is the use of SHM systems to detect the presence of defects. This book covers all major contemporary aerospace-relevant SHM methods, from the basics of each method to the various defect types that SHM is required to detect to discussion of signal processing developments alongside considerations of aerospace safety requirements. It will be of interest to professionals in industry and academic researchers alike, as well as engineering students. This article/publication is based upon work from COST Action CA18203 (ODIN - http://odin-cost.com/), supported by COST (European Cooperation in Science and Technology). COST (European Cooperation in Science and Technology) is a funding agency for research and innovation networks. Our Actions help connect research initiatives across Europe and enable scientists to grow their ideas by sharing them with their peers. This boosts their research, career and innovation

30th International Conference on Condition Monitoring and Diagnostic Engineering Management (COMADEM 2017)

Proceedings of COMADEM 201

Improvement of acoustic emission technology for stress corrosion cracking

This thesis was submitted for the award of Doctor of Philosophy and was awarded by Brunel University LondonThis thesis investigates the advancement of Acoustic emission (AE) monitoring techniques and analysis methods that could be applied in the field of Structural Health Monitoring (SHM), with an emphasis on the use of advanced AE techniques to detect and locate damage and their application on the monitoring of corrosion and Stress corrosion cracking (SCC) in complex metallic structures. The work was divided into three main areas of research, which are an investigation into using FE (Finite Element) generated delta-T mapping to locate experimental AE signals on complex structures, source location of AE signals generated by corrosion and an experimental investigation into SCC damage locations on a metallic specimen.Lloyd's Register Foundation, Brunel University London and the National Structural Integrity Research Centre (NSIRC