Knowledge-Based Virtual Modeling and Simulation of Manufacturing Processes for Industry 4.0

Abstract

Industry 4.0 aims at providing a digital representation of a production landscape, but the challenges in building, maintaining, optimizing, and evolving digital models in inter-organizational production chains have not been identified yet in a systematic manner. In this paper, various Industry 4.0 research and technical challenges are addressed, and their present scenario is discussed. Moreover, in this article, the novel concept of developing experience-based virtual models of engineering entities, process, and the factory is presented. These models of production units, processes, and procedures are accomplished by virtual engineering object (VEO), virtual engineering process (VEP), and virtual engineering factory (VEF), using the knowledge representation technique of Decisional DNA. This blend of the virtual and physical domains permits monitoring of systems and analysis of data to foresee problems before they occur, develop new opportunities, prevent downtime, and even plan for the future by using simulations. Furthermore, the proposed virtual model concept not only has the capability of Query Processing and Data Integration for Industrial Data but also real-time visualization of data stream processing.     

Reliability of complex chemical engineering processes

This paper presents a stochastic performance modelling approach that can be used to optimise design and operational reliability of complex chemical engineering processes. The framework can be applied to processes comprising multiple units, including the cases where closed form process performance functions are unavailable or difficult to derive from first principles, which is often the case in practice. An interface that facilitates automated two-way communication between Matlab^® and process simulation environment is used to generate large process responses. The resulting constrained optimisation problem is solved using both Monte Carlo Simulation (MCS) and First Order Reliability Method (FORM); providing a wide range of stochastic process performance measures. Adding such capabilities to traditional deterministic process simulators provides a more informed basis for selecting optimum design factors; giving a simple way of enhancing overall process reliability and cost-efficiency. Two case study systems are considered to highlight the applicability and benefits of the approach.     

Evolving an Accurate Decision Tree-Based Model for Predicting Carbon Dioxide Solubility in Polymers

Solubility is one of the most indispensable physicochemical properties determining the compatibility of components of a blending system. Research has been focused on the solubility of carbon dioxide in polymers as a significant application of green chemistry. To replace costly and time-consuming experiments, a novel solubility prediction model based on a decision tree, called the stochastic gradient boosting algorithm, was proposed to predict CO₂ solubility in 13 different polymers, based on 515 published experimental data lines. The results indicate that the proposed ensemble model is an effective method for predicting the CO₂ solubility in various polymers, with highly satisfactory performance and high efficiency. It produces more accurate outputs than other methods such as machine learning schemes and an equation of state approach.     

Control theory for stochastic distributed parameter systems,an engineering perspective

The main purpose of this paper is to survey some recent progresses on control theory for stochastic distributed parameter systems, i.e., systems governed by stochastic differential equations in infinite dimensions, typically by stochastic partial differential equations. We will explain the new phenomenon and difficulties in the study of controllability and optimal control problems for one dimensional stochastic parabolic equations and stochastic hyperbolic equations. In particular, we shall see that both the formulation of corresponding stochastic control problems and the tools to solve them may differ considerably from their deterministic/finite-dimensional counterparts. More importantly, one has to develop new tools, say, the stochastic transposition method introduced in our previous works, to solve some problems in this field.     

Adaptive backstepping repetitive learning control design for nonlinear discrete‐time systems with periodic uncertainties

This paper addresses a tracking problem for uncertain nonlinear discrete‐time systems in which the uncertainties, including parametric uncertainty and external disturbance, are periodic with known periodicity. Repetitive learning control (RLC) is an effective tool to deal with periodic unknown components. By using the backstepping procedures, an adaptive RLC law with periodic parameter estimation is designed. The overparameterization problem is overcome by postponing the parameter estimation to the last backstepping step, which could not be easily solved in robust adaptive control. It is shown that the proposed adaptive RLC law without overparameterization can guarantee the perfect tracking and boundedness of the states of the whole closed‐loop systems in presence of periodic uncertainties. In addition, the effectiveness of the developed controller is demonstrated by an implementation example on a single‐link flexible‐joint robot. Copyright © 2014 John Wiley & Sons, Ltd.     

Optimal resilient power grid operation during the course of a progressing wildfire

We study a two-stage stochastic and nonlinear optimization model for operating a power grid exposed to a natural disaster. Although this approach can be generalized to any natural hazard of continuous (and not instantaneous) nature, our focus is on wildfires. We assume that an approaching wildfire impacts the power grid by reducing the transmission capacity of its overhead lines. At the time when proactive decisions have to be taken, the severity of the wildfire is not known. This introduces uncertainty. In this paper, we extend previous work by more realistically capturing this uncertainty and by strengthening the mathematical programming formulation through standard reformulation techniques. With these reformulation techniques, the resulting two-stage, convex mixed-integer quadratically constrained programming formulation can be efficiently solved using commercial quadratic programming solvers as demonstrated on a case study on a modified version of the IEEE 123-bus test system with 100 scenarios. We also quantify the uncertainties through a second case study using the following three standard metrics of two-stage stochastic optimization: the expected value of perfect information, the expected result of using the expected value solution and the value of the stochastic solution.     

SiC/SiC mini-composites with multilayer ZrSiO4 interphase: Room-temperature properties and toughening mechanism

SiC/SiC mini-composites reinforced with SiC fibers coated with different numbers of ZrSiO₄ sublayers prepared via a non-hydrolytic sol-gel process were fabricated. The tensile strength and work of fracture of the prepared SiC/SiC mini-composites were determined, and the relationship between their mechanical properties and fracture morphologies was discussed. The toughening mechanism and the variation tendency of their mechanical properties were further elaborated by analyzing the interfacial debonding morphologies of the SiC/SiC mini-composites with 1 and 4 layers of ZrSiO₄ interphase as well as the results of prior studies. A relatively rare phenomenon—the delamination of the multilayer ZrSiO₄ interphase in the SiC/SiC mini-composites but not on the SiC fibers—was observed, which clearly demonstrated the weak bonding between the ZrSiO₄ sublayers in the SiC/SiC mini-composites. The ZrSiO₄ sublayer delamination mechanism was then explained based on the high-magnification morphologies found in and beside the ZrSiO₄ interphase.     

Biological Water Treatment by a Hybrid Fluidized-Bed Bioreactor: Theoretical Study

A hybrid fluidized-bed bioreactor for water purification was proposed and analyzed. It is a novel type of bioreactor characterized by hitherto unknown stationary and dynamic features. Steady-state characteristics of this hybrid bioreactor with external liquid circulation are presented. A quantitative analysis of steady-state properties of the bioreactor was performed with the aid of an original mathematical model developed for a double-substrate aerobic microbiological process. A steady-state analysis of aerobic processes characterized by different oxygen demand was performed. The effect of essential parameters was evaluated, including carbonaceous substrate concentration in the feed stream to the apparatus, aeration intensity, total residence time of a liquid in the bioreactor, and height of the bed of fine carrier particles.