On monitoring fretting fatigue damage in solid railway axles by acoustic emission with unsupervised machine learning and comparison to non-destructive testing techniques

Railway axles are safety-critical components of the rolling stock and the consequences of possible in-service failures can have dramatic effects. Although this element is traditionally designed against such failures, the initiation and propagation of service cracks are still occasionally observed, requiring an effective application of non-destructive testing and structural health monitoring approaches. This paper investigates the application of structural health monitoring by acoustic emission to the case of solid railway axles subject to fretting fatigue damage. A full-scale test was performed on a specimen in which artificial notches were suitably manufactured in order to cause the initiation and evolution of fretting fatigue damage up to the stage of relevant propagating fatigue cracks. During the test, both periodical phased array ultrasonic inspections and continuous acquisition of acoustic emission data have been carried out. Moreover, at the end of the test, the specimen was inspected, analyzed and evaluated by visual inspection and magnetic particles testing, while acoustic emission raw data were post-processed by a special unsupervised machine learning algorithm based on an Artificial Neural Network. It is demonstrated that the proposed methodology is very effective to detect the onset of crack initiation in a non-invasive and safe way

Nonparametric time series modelling for industrial prognostics and health management.

International audiencePrognostics and health management (PHM) methods aim at detecting the degradation, diagnosing the faults and predicting the time at which a system or a component will no longer perform its desired function. PHM is based on access to a model of a system or a component using one or combination of physical or data driven models. In physical based models one has to gather a lot of knowledge about the desired system, and then build analytical model of the system function of the degradation mechanism that is used as a reference during system operation. On the other hand data-driven models are based on the exploitation of symptoms or indicators of degradations using statistical or Artifcial Intelligence (AI) methods on the monitored system once it is operational and learn the normal behaviour. Trend extraction is one of the methods used to extract important information contained in the sensory signals, which can be used for data driven models. However, extraction of such information from collected data in a practical working environment is always a great challenge as sensory signals are usually multidimensional and obscured by noise. Also, the extracted trends should represent the nominal behaviour of the system as well as should represent the health status evolution. This paper presents a method for nonparametric trend modelling from multidimensional sensory data so as to use such trends in machinery health prognostics. The goal of this work is to develop a method that can extract features representing the nominal behaviour of the monitored component and from these features extract smooth trends to represent the critical component's health evolution over the time. The proposed method starts by multidimensional feature extraction from machinery sensory signals. Then, unsupervised feature selection on the features domain is applied without making any assumptions concerning the number of the extracted features. The selected features can be used to represent the nominal behaviour of the system and hence detect any deviation. Then, empirical mode decomposition algorithm (EMD) is applied on the projected features with the purpose of following the evolution of data in a compact representation over time. Finally, ridge regression is applied to the extracted trend for modelling and can be used later for remaining useful life prediction. The method is demonstrated on accelerated degradation dataset of bearings acquired from PRONOSTIA experimental platform and another dataset downloaded form NASA repository where it is shown to be able to extract signal trends

CNC Machine Tool's wear diagnostic and prognostic by using dynamic bayesian networks.

International audienceThe failure of critical components in industrial systems may have negative consequences on the availability, the productivity, the security and the environment. To avoid such situations, the health condition of the physical system, and particularly of its critical components, can be constantly assessed by using the monitoring data to perform on-line system diagnostics and prognostics. The present paper is a contribution on the assessment of the health condition of a Computer Numerical Control (CNC) tool machine and the estimation of its Remaining Useful Life (RUL). The proposed method relies on two main phases: an off-line phase and an on-line phase. During the first phase, the raw data provided by the sensors are processed to extract reliable features. These latter are used as inputs of learning algorithms in order to generate the models that represent the wear's behavior of the cutting tool. Then, in the second phase, which is an assessment one, the constructed models are exploited to identify the tool's current health state, predict its RUL and the associated confidence bounds. The proposed method is applied on a benchmark of condition monitoring data gathered during several cuts of a CNC tool. Simulation results are obtained and discussed at the end of the paper

Walking together: behavioural signatures of psychological crowds

Research in crowd psychology has demonstrated key differences between the behaviour of physical crowds where members are in the same place at the same time, and the collective behaviour of psychological crowds where the entire crowd perceive themselves to be part of the same group through a shared social identity. As yet, no research has investigated the behavioural effects that a shared social identity has on crowd movement at a pedestrian level. To investigate the direction and extent to which social identity influences the movement of crowds, 280 trajectories were tracked as participants walked in one of two conditions: 1) a psychological crowd primed to share a social identity; 2) a naturally occurring physical crowd. Behaviour was compared both within and between the conditions. In comparison to the physical crowd, members of the psychological crowd i) walked slower, ii) walked further, and iii) maintained closer proximity. In addition, pedestrians who had to manoeuvre around the psychological crowd behaved differently to pedestrians who had to manoeuvre past the naturally occurring crowd. We conclude that the behavioural differences between physical and psychological crowds must be taken into account when considering crowd behaviour in event safety management and computer models of crowds

Early Damage State Criterion from a Fault-Seeded Helicopter Gear Using Acoustic Emission and Neural Networks

In response to five failures since 2008 of the tail gearbox of multiple models of Sikorsky\u27s H-60 helicopter, acoustic emission (AE) data collected from a rotating gearbox test stand at the Naval Air Station in Patuxtent River, MD, was used to monitor the initiation and propagation of a flaw from an electro-discharge machined (EDM) notch seeded on the face of a gear tooth. A period of testing was considered which spanned ~300,000 seconds or ~83 hours and culminates to a damage state such that a flaw has initiated on both ends of the EDM notch. AE data was analyzed for three separate channels which span a wide range of amplitude thresholds using clustering methods and verification algorithms developed at the Embry-Riddle Aeronautical University (ERAU) Structure Health Monitoring (SHM) and Nondestructive Evaluation (NDE) Laboratory. Energy, duration, amplitude, and average frequency of the AE signals were input into the Kohonen Self-Organizing Map (KSOM) artificial neural network (ANN) function in NeuralWorks Professional II/Plus software to separate cracking signals from other mechanisms such as noise and plastic deformation. Visual inspection and statistical analysis of the data in the AE plots created using the output ANN results was used to separate the cluster(s) which exhibited higher amplitude and energy, and lower duration and average frequency; hits typical to cracking. The similarities and differences in the progression of clusters sourced to cracking for each of the three channels is discussed. Cumulative testing time plots of AE parameters were compiled using both entire data sets and using clusters representative of cracking mechanisms. Replica cross sections which were taken throughout testing visually display, in chronological fashion, circumferential crack growth across gear splines adjacent to the spline with the EDM notch. Data analysis techniques are used in conjunction with replica cross sections to provide insight into the AE activity for crack initiation and crack propagation and define early damage state detection criterion for rotary components

Ono: an open platform for social robotics

In recent times, the focal point of research in robotics has shifted from industrial ro- bots toward robots that interact with humans in an intuitive and safe manner. This evolution has resulted in the subfield of social robotics, which pertains to robots that function in a human environment and that can communicate with humans in an int- uitive way, e.g. with facial expressions. Social robots have the potential to impact many different aspects of our lives, but one particularly promising application is the use of robots in therapy, such as the treatment of children with autism. Unfortunately, many of the existing social robots are neither suited for practical use in therapy nor for large scale studies, mainly because they are expensive, one-of-a-kind robots that are hard to modify to suit a specific need. We created Ono, a social robotics platform, to tackle these issues. Ono is composed entirely from off-the-shelf components and cheap materials, and can be built at a local FabLab at the fraction of the cost of other robots. Ono is also entirely open source and the modular design further encourages modification and reuse of parts of the platform

Approaches to hazard-oriented groundwater management based on multivariate analysis of groundwater quality

Drinking water extracted near rivers in alluvial aquifers is subject to potential microbial contamination due to rapidly infiltrating river water during high discharge events. The heterogeneity of river-groundwater interaction and hydrogeological characteristics of the aquifer renders a complex pattern of groundwater quality. The quality of the extracted drinking water can be managed using decision support and HACCP (Hazard Analysis and Critical Control Point) systems, but the detection of potential contamination remains a complex task to master. The methodology proposed herein uses a combination of high-resolution measurements and multivariate statistical analyses to characterise actual groundwater quality and detect potential contamination. The aim of this project was to improve the protection of riverine groundwater extraction wells and to increase the degrees of freedom available to the management of fluvial planes with drinking-water production and aquifer recharge by river-groundwater interaction. The monitoring network was set up in the Reinacherheide in North-west Switzerland and encompassed the depth-oriented installation of multiparameter instruments, a surface-water monitoring station and a flow-through cell with an automated sampler and high-precision measurement instruments. The parameters recorded included temperature, electrical conductivity, spectral absorption coefficient, particle density and turbidity. Two of the observation wells were equipped with a telemetry system and the flow cell could be controlled remotely. The well-field encompassed eight groundwater extraction wells. The optimal choice of observation wells and indicator parameters was assessed using principal component analysis of groundwater head, temperature and electrical conductivity time-series to detect the influence of, for example, river-water infiltration or river-stage fluctuations on the time-series recorded in the groundwater observation wells. Groundwater head was susceptible to pressure waves induced by both river-stage fluctuations and groundwater extraction. Temperature time-series showed only weak responses to high discharge events. Electrical conductivity, however, showed a distance-driven response pattern to high discharge events. To further assess the representative strength of individual groundwater quality indicator parameters for identifying microbial contamination, a bi-weekly and a high-resolution sampling campaign were carried out. The results showed high faecal-indicator bacteria densities (E. coli and Enterococcus sp.) at the beginning of high discharge events, followed by a rapid decrease, leading to a strong hit-and-miss characteristic in the bi-weekly sampling campaign. The third approach applied used the neural network-based combination of self-organizing maps and Sammon's projection (SOM-SM) to detect shifts in groundwater quality system states. The nonlinear analysis was carried out with groundwater head, temperature and electrical conductivity time-series from six observation wells. The subsequent shading of the projected trajectory of system states with independent time-series (spectral absorption coefficient and particle density) allowed the identification of critical system states, when actual groundwater quality decreased and contamination of the extraction wells was imminent. The time at which the changes in system state occurred and were detected were used as potential warning indicators for the water supplier. The effects of altered groundwater extraction (as a consequence of the SOM-SM warning) were then simulated using a groundwater flow model. The outcome of the SOM-SM analysis is, thus, proposed as an interface between the monitoring system and extraction-well management system. The proposed approach incorporates hydrogeological knowledge and the analysis of prevalent conditions concerning river-groundwater interaction with real-time telemetric data transfer, data-base management and nonlinear statistical analysis to detect deterioration in actual groundwater quality due to rapidly infiltrating river water. As the SOM-SM is not based on threshold values and independent of indicator parameters, the approach can be transferred to other sites with similar characteristics

Sensor based real-time process monitoring for ultra-precision manufacturing processes with non-linearity and non-stationarity

This research investigates methodologies for real-time process monitoring in ultra-precision manufacturing processes, specifically, chemical mechanical planarization (CMP) and ultra-precision machining (UPM), are investigated in this dissertation.The three main components of this research are as follows: (1) developing a predictive modeling approaches for early detection of process anomalies/change points, (2) devising approaches that can capture the non-Gaussian and non-stationary characteristics of CMP and UPM processes, and (3) integrating multiple sensor data to make more reliable process related decisions in real-time.In the first part, we establish a quantitative relationship between CMP process performance, such as material removal rate (MRR) and data acquired from wireless vibration sensors. Subsequently, a non-linear sequential Bayesian analysis is integrated with decision theoretic concepts for detection of CMP process end-point for blanket copper wafers. Using this approach, CMP polishing end-point was detected within a 5% error rate.Next, a non-parametric Bayesian analytical approach is utilized to capture the inherently complex, non-Gaussian, and non-stationary sensor signal patterns observed in CMP process. An evolutionary clustering analysis, called Recurrent Nested Dirichlet Process (RNDP) approach is developed for monitoring CMP process changes using MEMS vibration signals. Using this novel signal analysis approach, process drifts are detected within 20 milliseconds and is assessed to be 3-7 times faster than traditional SPC charts. This is very beneficial to the industry from an application standpoint, because, wafer yield losses will be mitigated to a great extent, if the onset of CMP process drifts can be detected timely and accurately.Lastly, a non-parametric Bayesian modeling approach, termed Dirichlet Process (DP) is combined with a multi-level hierarchical information fusion technique for monitoring of surface finish in UPM process. Using this approach, signal patterns from six different sensors (three axis vibration and force) are integrated based on information fusion theory. It was observed that using experimental UPM sensor data that process decisions based on the multiple sensor information fusion approach were 15%-30% more accurate than the decisions from individual sensors. This will enable more accurate and reliable estimation of process conditions in ultra-precision manufacturing applications

CPS Data Streams Analytics based on Machine Learning for Cloud and Fog Computing: A Survey

Cloud and Fog computing has emerged as a promising paradigm for the Internet of things (IoT) and cyber-physical systems (CPS). One characteristic of CPS is the reciprocal feedback loops between physical processes and cyber elements (computation, software and networking), which implies that data stream analytics is one of the core components of CPS. The reasons for this are: (i) it extracts the insights and the knowledge from the data streams generated by various sensors and other monitoring components embedded in the physical systems; (ii) it supports informed decision making; (iii) it enables feedback from the physical processes to the cyber counterparts; (iv) it eventually facilitates the integration of cyber and physical systems. There have been many successful applications of data streams analytics, powered by machine learning techniques, to CPS systems. Thus, it is necessary to have a survey on the particularities of the application of machine learning techniques to the CPS domain. In particular, we explore how machine learning methods should be deployed and integrated in cloud and fog architectures for better fulfilment of the requirements, e.g. mission criticality and time criticality, arising in CPS domains. To the best of our knowledge, this paper is the first to systematically study machine learning techniques for CPS data stream analytics from various perspectives, especially from a perspective that leads to the discussion and guidance of how the CPS machine learning methods should be deployed in a cloud and fog architecture