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.     

An industrial case study on variability handling in large enterprise software systems

ContextEnterprise software systems (e.g., enterprise resource planning software) are often deployed in different contexts (e.g., different organizations or different business units or branches of one organization). However, even though organizations, business units or branches have the same or similar business goals, they may differ in how they achieve these goals. Thus, many enterprise software systems are subject to variability and adapted depending on the context in which they are used.ObjectiveOur goal is to provide a snapshot of variability in large scale enterprise software systems. We aim at understanding the types of variability that occur in large industrial enterprise software systems. Furthermore, we aim at identifying how variability is handled in such systems.MethodWe performed an exploratory case study in two large software organizations, involving two large enterprise software systems. Data were collected through interviews and document analysis. Data were analyzed following a grounded theory approach.ResultsWe identified seven types of variability (e.g., functionality, infrastructure) and eight mechanisms to handle variability (e.g., add-ons, code switches).ConclusionsWe provide generic types for classifying variability in enterprise software systems, and reusable mechanisms for handling such variability. Some variability types and handling mechanisms for enterprise software systems found in the real world extend existing concepts and theories. Others confirm findings from previous research literature on variability in software in general and are therefore not specific to enterprise software systems. Our findings also offer a theoretical foundation for describing variability handling in practice. Future work needs to provide more evaluations of the theoretical foundations, and refine variability handling mechanisms into more detailed practices.     

Elitist clonal selection algorithm for optimal choice of free knots in B-spline data fitting

Data fitting with B-splines is a challenging problem in reverse engineering for CAD/CAM, virtual reality, data visualization, and many other fields. It is well-known that the fitting improves greatly if knots are considered as free variables. This leads, however, to a very difficult multimodal and multivariate continuous nonlinear optimization problem, the so-called knot adjustment problem. In this context, the present paper introduces an adapted elitist clonal selection algorithm for automatic knot adjustment of B-spline curves. Given a set of noisy data points, our method determines the number and location of knots automatically in order to obtain an extremely accurate fitting of data. In addition, our method minimizes the number of parameters required for this task. Our approach performs very well and in a fully automatic way even for the cases of underlying functions requiring identical multiple knots, such as functions with discontinuities and cusps. To evaluate its performance, it has been applied to three challenging test functions, and results have been compared with those from other alternative methods based on AIS and genetic algorithms. Our experimental results show that our proposal outperforms previous approaches in terms of accuracy and flexibility. Some other issues such as the parameter tuning, the complexity of the algorithm, and the CPU runtime are also discussed.     

土木工程施工课程线上平台教学实践

土木工程施工课程作为土木工程及工程管理专业的学科基础课和核心专业课程,在疫情防控期间"停课不停教""停课不停学"的要求下,通过线上平台进行授课。由于土木工程施工课程内容庞杂、综合性强、实践性强,且章节之间关联性较弱,探究既能使学生快速适应,又能保证教学质量的在线教学方法至关重要。以华南某高校土木工程施工课程为例,基于中国大学MOOC、建筑云课、腾讯课堂、QQ群等线上平台讲授教学内容,并运用问卷调查对课程线上教学效果进行评价。结果表明,线上教学为学生提供了丰富灵活的学习方式,显著提高了学生的自主学习能力,扩大了学生的知识面,达到了较好的学习效果。     

Crystal-field engineering of ultrabroadband mid-infrared emission in Co2+-doped nano-chalcogenide glass composites

Tunable and ultrabroadband mid-infrared (MIR) emissions in the range of 2.5–4.5 μm are firstly reported from Co²⁺-doped nano-chalcogenide (ChG) glass composites. The composites embedded with a variety of binary (ZnS, CdS, ZnSe) and ternary (ZnCdS, ZnSSe) ChG nanocrystals (NCs) can be readily obtained by a simple one-step thermal annealing method. They are highly transparent in the near- and mid-infrared wavelength region. Low-cost and commercially available Er³⁺-doped fiber lasers can be used as the excitation source. By crystal-field engineering of the embedded NCs through cation- or anion-substitution, the emission properties of Co²⁺ including its emission peak wavelength and bandwidth can be tailored in a broad spectral range. The phenomena can be accounted for by crystal-field theory. Such nano-ChG composites, perfectly filling the 3–4 μm spectral gap between the oscillations of Cr²⁺ and Fe²⁺ doped IIVI ChG crystals, may find important MIR photonic applications (e.g., gas sensing), or can be used directly as an efficient pump source for Fe²⁺: IIVI crystals which are suffering from lack of pump sources.     

Material design and development: From classical thermodynamics to CALPHAD and ICME approaches

This paper presents an overview and examples of material design and development using (1) classical thermodynamics; (2) CALPHAD (calculation of phase diagrams) modeling; and (3) Integrated Computational Materials Engineering (ICME) approaches. Although the examples are given in lightweight aluminum and magnesium alloys for structural applications, the fundamental methodology and modeling principles are applicable to all materials and engineering applications. The examples in this paper have demonstrated the effectiveness and limitations of classical thermodynamics in solving specific problems (such as nucleation during solidification and solid-state precipitation in aluminum alloys). Computational thermodynamics and CALPHAD modeling, when combined with critical experimental validation, have been used to guide the selection and design of new magnesium alloys for elevated-temperature applications. The future of material design and development will be based on a holistic ICME approach. However, key challenges exist in many aspects of ICME framework, such as the lack of diffusion/mobility databases for many materials systems, limitation of current microstructural modeling capability and integration tools for simulation codes of different length scales.     

A scalable architecture for geometric correction of multi-projector display systems

Multi-projector displays allow the realization of large and immersive projection environments by allowing the tiling of projections from multiple projectors. Such tiled displays require real time geometrical warping of the content that is being projected from each projector. This geometrical warping is a computationally intensive operation and is typically applied using high-end graphics processing units (GPUs) that are able to process a defined number of projector channels. Furthermore, this limits the applicability of such multi-projector display systems only to the content that is being generated using desktop based systems. In this paper we propose a platform independent FPGA based scalable hardware architecture for geometric correction of projected content that allows addition of each projector channel at a fractional increase in logic area. The proposed scheme provides real time correction of HD quality video streams and thus enables the use of this technology for embedded and standalone devices.     

Producing fully-lamellar microstructure for wrought beta-gamma TiAl alloys without single α-phase field

Fine-grained fully-lamellar (FL) microstructure is desired for TiAl components to serve as compressor/turbine blades and turbocharger turbine wheels. This study deals with the process and phase transformation to produce FL microstructure for Mo stabilized beta-gamma TiAl alloys without single α-phase field. Unlike the α + γ two-phased TiAl or beta-gamma TiAl with single α-phase field, the wrought multi-phase TiAl–4/6Nb–2Mo–B/Y alloys exhibit special annealing process to obtain FL microstructure. Short-term annealing at temperatures slightly above β-transus is recommended to produce the desired FL microstructure. The related mechanism is to guarantee the sufficient diffusion homogenization of β stabilizers during single β-phase annealing, and further avoid α decomposition by α → γ + β when cooling through α + β + γ phase field. The colony boundary β phase contributes to fine-grained nearly FL microstructure, by retarding the coarsening of the α phase grains.