Exploring the role of system operation modes in failure analysis in the context of first generation cyber-physical systems

Typically, emerging system failures have a strong impact on the performance of industrial systems as well as on the efficiency of their operational and servicing processes. Being aware of these, maintenance and repair researchers have developed multiple failure detection and diagnosis techniques that allow early recognition of system or component failures and maintaining continuous system operation in a cost-effective way. However, these techniques have many deficiencies in the case of self-tuning first generation cyber-physical systems (1G-CPSs). The reason is that these systems compensate for the effects of emerging system failures until their resources are exhausted, and the compensatory actions not only mask the failures, but also make their recognition difficult. Late recognition of failures is however in contrast with the principles of preventive maintenance. Therefore, the promotion research concentrated on the issue of recognizing and forecasting failures under dynamic and adaptive behavior of 1G-CPSs. CPSs are enabled to compensate for failure symptoms by changing their system operation modes (SOMs). It was also observed that transitions of SOMs reduce the reliability of a signal-based failure diagnosis. It was hypothesized that the frequency and the duration of the changes of the operational states of the 1G-CPS may be strong indicators of the failure emergence phenomenon and that investigation of SOMs facilitates early detection of failures. Therefore, the completed exploratory studies were aimed at exploring how the frequency and duration of transitions of SOMs can be brought into correlation with specific types of failures, and how they can be computed as measures of failure occurrence. The obtained results revealed that system failures tend to induce unusual system operation modes that can be used as basis for failure characterization, and even for failure forecasting. The empirical research made use of a cyber-physical greenhouse testbed to get experimental data and was completed by the development of computational model. A failure injection strategy was implemented in order to induce failure occurrence in a controlled manner. The proposed approach can be applied as a basis of forecasting system failures of 1G-CPSs, but additional research seems to be necessary

Continuous maintenance and the future – Foundations and technological challenges

High value and long life products require continuous maintenance throughout their life cycle to achieve required performance with optimum through-life cost. This paper presents foundations and technologies required to offer the maintenance service. Component and system level degradation science, assessment and modelling along with life cycle ‘big data’ analytics are the two most important knowledge and skill base required for the continuous maintenance. Advanced computing and visualisation technologies will improve efficiency of the maintenance and reduce through-life cost of the product. Future of continuous maintenance within the Industry 4.0 context also identifies the role of IoT, standards and cyber security

State-of-the-Art Review and Synthesis: A Requirement-based Roadmap for Standardized Predictive Maintenance Automation Using Digital Twin Technologies

Recent digital advances have popularized predictive maintenance (PMx), offering enhanced efficiency, automation, accuracy, cost savings, and independence in maintenance. Yet, it continues to face numerous limitations such as poor explainability, sample inefficiency of data-driven methods, complexity of physics-based methods, and limited generalizability and scalability of knowledge-based methods. This paper proposes leveraging Digital Twins (DTs) to address these challenges and enable automated PMx adoption at larger scales. While we argue that DTs have this transformative potential, they have not yet reached the level of maturity needed to bridge these gaps in a standardized way. Without a standard definition for such evolution, this transformation lacks a solid foundation upon which to base its development. This paper provides a requirement-based roadmap supporting standardized PMx automation using DT technologies. A systematic approach comprising two primary stages is presented. First, we methodically identify the Informational Requirements (IRs) and Functional Requirements (FRs) for PMx, which serve as a foundation from which any unified framework must emerge. Our approach to defining and using IRs and FRs to form the backbone of any PMx DT is supported by the track record of IRs and FRs being successfully used as blueprints in other areas, such as for product development within the software industry. Second, we conduct a thorough literature review spanning fields to determine the ways in which these IRs and FRs are currently being used within DTs, enabling us to point to the specific areas where further research is warranted to support the progress and maturation of requirement-based PMx DTs.Comment: (1)This work has been submitted to the IEEE for possible publication. Copyright may be transferred without notice, after which this version may no longer be accessibl

Smart Manufacturing

This book is a collection of 11 articles that are published in the corresponding Machines Special Issue “Smart Manufacturing”. It represents the quality, breadth and depth of the most updated study in smart manufacturing (SM); in particular, digital technologies are deployed to enhance system smartness by (1) empowering physical resources in production, (2) utilizing virtual and dynamic assets over the Internet to expand system capabilities, (3) supporting data-driven decision-making activities at various domains and levels of businesses, or (4) reconfiguring systems to adapt to changes and uncertainties. System smartness can be evaluated by one or a combination of performance metrics such as degree of automation, cost-effectiveness, leanness, robustness, flexibility, adaptability, sustainability, and resilience. This book features, firstly, the concepts digital triad (DT-II) and Internet of digital triad things (IoDTT), proposed to deal with the complexity, dynamics, and scalability of complex systems simultaneously. This book also features a comprehensive survey of the applications of digital technologies in space instruments; a systematic literature search method is used to investigate the impact of product design and innovation on the development of space instruments. In addition, the survey provides important information and critical considerations for using cutting edge digital technologies in designing and manufacturing space instruments

Preface

DAMSS-2018 is the jubilee 10th international workshop on data analysis methods for software systems, organized in Druskininkai, Lithuania, at the end of the year. The same place and the same time every year. Ten years passed from the first workshop. History of the workshop starts from 2009 with 16 presentations. The idea of such workshop came up at the Institute of Mathematics and Informatics. Lithuanian Academy of Sciences and the Lithuanian Computer Society supported this idea. This idea got approval both in the Lithuanian research community and abroad. The number of this year presentations is 81. The number of registered participants is 113 from 13 countries. In 2010, the Institute of Mathematics and Informatics became a member of Vilnius University, the largest university of Lithuania. In 2017, the institute changes its name into the Institute of Data Science and Digital Technologies. This name reflects recent activities of the institute. The renewed institute has eight research groups: Cognitive Computing, Image and Signal Analysis, Cyber-Social Systems Engineering, Statistics and Probability, Global Optimization, Intelligent Technologies, Education Systems, Blockchain Technologies. The main goal of the workshop is to introduce the research undertaken at Lithuanian and foreign universities in the fields of data science and software engineering. Annual organization of the workshop allows the fast interchanging of new ideas among the research community. Even 11 companies supported the workshop this year. This means that the topics of the workshop are actual for business, too. Topics of the workshop cover big data, bioinformatics, data science, blockchain technologies, deep learning, digital technologies, high-performance computing, visualization methods for multidimensional data, machine learning, medical informatics, ontological engineering, optimization in data science, business rules, and software engineering. Seeking to facilitate relations between science and business, a special session and panel discussion is organized this year about topical business problems that may be solved together with the research community. This book gives an overview of all presentations of DAMSS-2018.DAMSS-2018 is the jubilee 10th international workshop on data analysis methods for software systems, organized in Druskininkai, Lithuania, at the end of the year. The same place and the same time every year. Ten years passed from the first workshop. History of the workshop starts from 2009 with 16 presentations. The idea of such workshop came up at the Institute of Mathematics and Informatics. Lithuanian Academy of Sciences and the Lithuanian Computer Society supported this idea. This idea got approval both in the Lithuanian research community and abroad. The number of this year presentations is 81. The number of registered participants is 113 from 13 countries. In 2010, the Institute of Mathematics and Informatics became a member of Vilnius University, the largest university of Lithuania. In 2017, the institute changes its name into the Institute of Data Science and Digital Technologies. This name reflects recent activities of the institute. The renewed institute has eight research groups: Cognitive Computing, Image and Signal Analysis, Cyber-Social Systems Engineering, Statistics and Probability, Global Optimization, Intelligent Technologies, Education Systems, Blockchain Technologies. The main goal of the workshop is to introduce the research undertaken at Lithuanian and foreign universities in the fields of data science and software engineering. Annual organization of the workshop allows the fast interchanging of new ideas among the research community. Even 11 companies supported the workshop this year. This means that the topics of the workshop are actual for business, too. Topics of the workshop cover big data, bioinformatics, data science, blockchain technologies, deep learning, digital technologies, high-performance computing, visualization methods for multidimensional data, machine learning, medical informatics, ontological engineering, optimization in data science, business rules, and software engineering. Seeking to facilitate relations between science and business, a special session and panel discussion is organized this year about topical business problems that may be solved together with the research community. This book gives an overview of all presentations of DAMSS-2018

A systematic mapping of the advancing use of machine learning techniques for predictive maintenance in the manufacturing sector

The increasing availability of data, gathered by sensors and intelligent machines, is chang-ing the way decisions are made in the manufacturing sector. In particular, based on predictive approach and facilitated by the nowadays growing capabilities of hardware, cloud-based solutions, and new learning approaches, maintenance can be scheduled—over cell engagement and resource monitoring—when required, for minimizing (or managing) unexpected equipment failures, improving uptime through less aggressive maintenance schedules, shortening unplanned downtime, reducing excess (direct and indirect) cost, reducing long-term damage to machines and processes, and improve safety plans. With access to increased levels of data (and over learning mechanisms), companies have the capability to conduct statistical tests using machine learning algorithms, in order to uncover root causes of problems previously unknown. This study analyses the maturity level and contributions of machine learning methods for predictive maintenance. An upward trend in publications for predictive maintenance using machine learning techniques was identified with the USA and China leading. A mapping study—steady set until early 2019 data—was employed as a formal and well-structured method to synthesize material and to report on pervasive areas of research. Type of equipment, sensors, and data are mapped to properly assist new researchers in positioning new research activities in the domain of smart maintenance. Hence, in this paper, we focus on data-driven methods for predictive maintenance (PdM) with a comprehensive survey on applications and methods until, for the sake of commenting on stable proposal, 2019 (early included). An equal repartition between evaluation and validation studies was identified, this being a symptom of an immature but growing research area. In addition, the type of contribution is mainly in the form of models and methodologies. Vibrational signal was marked as the most used data set for diagnosis in manufacturing machinery monitoring; furthermore, supervised learning is reported as the most used predictive approach (ensemble learning is growing fast). Neural networks, followed by random forests and support vector machines, were identified as the most applied methods encompassing 40% of publications, of which 67% related to deep neural network with long short-term memory predominance. Notwithstanding, there is no robust approach (no one reported optimal performance over different case tests) that works best for every problem. We finally conclude the research in this area is moving fast to gather a separate focused analysis over the last two years (whenever stable implementations will appear)

Artificial intelligence for digital twins in energy systems and turbomachinery: development of machine learning frameworks for design, optimization and maintenance

The expression Industry4.0 identifies a new industrial paradigm that includes the development of Cyber-Physical Systems (CPS) and Digital Twins promoting the use of Big-Data, Internet of Things (IoT) and Artificial Intelligence (AI) tools. Digital Twins aims to build a dynamic environment in which, with the help of vertical, horizontal and end-to-end integration among industrial processes, smart technologies can communicate and exchange data to analyze and solve production problems, increase productivity and provide cost, time and energy savings. Specifically in the energy systems field, the introduction of AI technologies can lead to significant improvements in both machine design and optimization and maintenance procedures. Over the past decade, data from engineering processes have grown in scale. In fact, the use of more technologically sophisticated sensors and the increase in available computing power have enabled both experimental measurements and highresolution numerical simulations, making available an enormous amount of data on the performance of energy systems. Therefore, to build a Digital Twin model capable of exploring these unorganized data pools collected from massive and heterogeneous resources, new Artificial Intelligence and Machine Learning strategies need to be developed. In light of the exponential growth in the use of smart technologies in manufacturing processes, this thesis aims at enhancing traditional approaches to the design, analysis, and optimization phases of turbomachinery and energy systems, which today are still predominantly based on empirical procedures or computationally intensive CFD-based optimizations. This improvement is made possible by the implementation of Digital Twins models, which, being based primarily on the use of Machine Learning that exploits performance Big-Data collected from energy systems, are acknowledged as crucial technologies to remain competitive in the dynamic energy production landscape. The introduction of Digital Twin models changes the overall structure of design and maintenance approaches and results in modern support tools that facilitate real-time informed decision making. In addition, the introduction of supervised learning algorithms facilitates the exploration of the design space by providing easy-to-run analytical models, which can also be used as cost functions in multi-objective optimization problems, avoiding the need for time-consuming numerical simulations or experimental campaings. Unsupervised learning methods can be applied, for example, to extract new insights from turbomachinery performance data and improve designers’ understanding of blade-flow interaction. Alternatively, Artificial Intelligence frameworks can be developed for Condition-Based Maintenance, allowing the transition from preventive to predictive maintenance. This thesis can be conceptually divided into two parts. The first reviews the state of the art of Cyber-Physical Systems and Digital Twins, highlighting the crucial role of Artificial Intelligence in supporting informed decision making during the design, optimization, and maintenance phases of energy systems. The second part covers the development of Machine Learning strategies to improve the classical approach to turbomachinery design and maintenance strategies for energy systems by exploiting data from numerical simulations, experimental campaigns, and sensor datasets (SCADA). The different Machine Learning approaches adopted include clustering algorithms, regression algorithms and dimensionality reduction techniques: Autoencoder and Principal Component Analysis. A first work shows the potential of unsupervised learning approaches (clustering algorithms) in exploring a Design of Experiment of 76 numerical simulations for turbomachinery design purposes. The second work takes advantage of a nonsequential experimental dataset, measured on a rotating turbine rig characterized by 48 blades divided into 7 sectors that share the same baseline rotor geometry but have different tip designs, to infer and dissect the causal relationship among different tip geometries and unsteady aero-thermodynamic performance via a novel Machine-Learning procedure based on dimensionality reduction techniques. The last application proposes a new anomaly detection framework for gensets in DH networks, based on SCADA data that exploits and compares the performance of regression algorithms such as XGBoost and Multi-layer Perceptron