Using Krylov‐Padé model order reduction for accelerating design optimization of structures and vibrations in the frequency domain

In many engineering problems, the behavior of dynamical systems depends on physical parameters. In design optimization, these parameters are determined so that an objective function is minimized. For applications in vibrations and structures, the objective function depends on the frequency response function over a given frequency range, and we optimize it in the parameter space. Because of the large size of the system, numerical optimization is expensive. In this paper, we propose the combination of Quasi‐Newton type line search optimization methods and Krylov‐Padé type algebraic model order reduction techniques to speed up numerical optimization of dynamical systems. We prove that Krylov‐Padé type model order reduction allows for fast evaluation of the objective function and its gradient, thanks to the moment matching property for both the objective function and the derivatives towards the parameters. We show that reduced models for the frequency alone lead to significant speed ups. In addition, we show that reduced models valid for both the frequency range and a line in the parameter space can further reduce the optimization time. Copyright © 2012 John Wiley & Sons, Ltd.     

Smart Manufacturing for the Oil Refining and Petrochemical Industry

Smart manufacturing will transform the oil refining and petrochemical sector into a connected, information-driven environment. Using real-time and high-value support systems, smart manufacturing enables a coordinated and performance-oriented manufacturing enterprise that responds quickly to customer demands and minimizes energy and material usage, while radically improving sustainability, productivity, innovation, and economic competitiveness. In this paper, several examples of the application of so-called “smart manufacturing” for the petrochemical sector are demonstrated, such as the fault detection of a catalytic cracking unit driven by big data, advanced optimization for the planning and scheduling of oil refinery sites, and more. Key scientific factors and challenges for the further smart manufacturing of chemical and petrochemical processes are identified.     

Real-time performance evaluation and improvement of assembly systems with Bernoulli machines and finite production runs

Extensive research has been investigated in the past several decades to evaluate the performance of manufacturing systems under rigid production mode. Based on the deployment of the new manufacturing strategies (e.g. smart manufacturing), real-time performance analysis, continuous improvement and efficient production management of flexible production systems are urgently to be investigated. Therefore, we study the problems of real-time performance evaluation and bottleneck of assembly systems in this paper. The system is assumed to have Bernoulli machines and finite production runs. We first derive the mathematical model of the system and then, derive the analytical formulas for performance evaluation of systems with three Bernoulli machines. In addition, we propose a decomposition and aggregation-based algorithm to approximate the system performances with high accuracy and computational efficiency. The idea is then extended to generalised assembly systems. Finally, the method of bottleneck analysis by using completion time bottleneck indicator is introduced and evaluated by numerical justification.     

Exploring self-organization and self-adaption for smart manufacturing complex networks

Trends toward the globalization of the manufacturing industry and the increasing demands for small-batch, short-cycle, and highly customized products result in complexities and fluctuations in both external and internal manufacturing environments, which poses great challenges to manufacturing enterprises. Fortunately, recent advances in the Industrial Internet of Things (IIoT) and the widespread use of embedded processors and sensors in factories enable collecting real-time manufacturing status data and building cyber–physical systems for smart, flexible, and resilient manufacturing systems. In this context, this paper investigates the mechanisms and methodology of self-organization and self-adaption to tackle exceptions and disturbances in discrete manufacturing processes. Specifically, a general model of smart manufacturing complex networks is constructed using scale-free networks to interconnect heterogeneous manufacturing resources represented by network vertices at multiple levels. Moreover, the capabilities of physical manufacturing resources are encapsulated into virtual manufacturing services using cloud technology, which can be added to or removed from the networks in a plug-and-play manner. Materials, information, and financial assets are passed through interactive links across the networks. Subsequently, analytical target cascading is used to formulate the processes of self-organizing optimal configuration and self-adaptive collaborative control for multilevel key manufacturing resources while particle swarm optimization is used to solve local problems on network vertices. Consequently, an industrial case based on a Chinese engine factory demonstrates the feasibility and efficiency of the proposed model and method in handling typical exceptions. The simulation results show that the proposed mechanism and method outperform the event-triggered rescheduling method, reducing manufacturing cost, manufacturing time, waiting time, and energy consumption, with reasonable computational time. This work potentially enables managers and practitioners to implement active perception, active response, self-organization, and self-adaption solutions in discrete manufacturing enterprises.     

A new Kriging–Bat Algorithm for solving computationally expensive black-box global optimization problems

Many global optimization (GO) algorithms have been introduced in recent decades to deal with the Computationally Expensive Black-Box (CEBB) optimization problems. The high number of objective function evaluations, required by conventional GO methods, is prohibitive or at least inconvenient for practical design applications. In this work, a new Kriging–Bat algorithm (K–BA) is introduced for solving CEBB problems with further improved search efficiency and robustness. A Kriging surrogate model (SM) is integrated with the Bat Algorithm (BA) to find the global optimum using substantially reduced number of evaluations of the computationally expensive objective function. The new K–BA algorithm is tested and compared with other well-known GO algorithms, using a set of standard benchmark problems with 2 to 16 design variables, as well as a real-life engineering optimization application, to determine its search capability, efficiency and robustness. Results of the comprehensive tests demonstrated the suitability and superior capability of the new K–BA.     

Global optimization of a feature-based process sequence using GA and ANN techniques

Operation sequencing has been a key area of research and development for computer-aided process planning (CAPP). An optimal process sequence could largely increase the efficiency and decrease the cost of production. Genetic algorithms (GAs) are a technique for seeking to ‘breed’ good solutions to complex problems by survival of the fittest. Some attempts using GAs have been made on operation sequencing optimization, but few systems have intended to provide a globally optimized fitness function definition. In addition, most of the systems have a lack of adaptability or have an inability to learn. This paper presents an optimization strategy for process sequencing based on multi-objective fitness: minimum manufacturing cost, shortest manufacturing time and best satisfaction of manufacturing sequence rules. A hybrid approach is proposed to incorporate a genetic algorithm, neural network and analytical hierarchical process (AHP) for process sequencing. After a brief study of the current research, relevant issues of process planning are described. A globally optimized fitness function is then defined including the evaluation of manufacturing rules using AHP, calculation of cost and time and determination of relative weights using neural network techniques. The proposed GA-based process sequencing, the implementation and test results are discussed. Finally, conclusions and future work are summarized.     

Load Allocation Research in a Manufacturing System

Based on queuing theory, a nonlinear optimization model is proposed in this paper, which has the service load as its objective function and includes three inequality constraints of Work In Progress （WIP）. A novel transformation of optimization variables is also devised and the constraints are properly combined so as to make this model into a convex one from which the Lagrangian function and the Karurh Kuhn Tucker （KKT） conditions are derived. The interior-point method for convex optimization is presented here as a computationaUy efficient tool. Finally, this model is evaluated on a real example, from which such conclusions are reached that the optimum result can ensure the full utilization of machines and the least amount of WIP in manufacturing systems; the interior-point method needs fewer iterations with significant computational savings and it is possible to make nonlinear and complicated optimization problems convexified so as to obtain the optimum.     

离散生产系统车间设施布置优化

分析了离散生产系统车间平面布置的目标函数,生产单元之间的距离计算方法,提出了在非等面积生产单元布置条件下,缩减解空间的两阶段优化布置法。借助计算机的高速运算能力,采用智能最优化算法,对缩减的解空间进行优化搜索,确定出各生产单元的最优位置,在此基础上,根据各生产单元面积比例对车间面积分别按行和列进行分配,确定出初步布置方案,最后对各单元的面积形状进行规整化处理后,得到车间优化布置方案。     

考虑资源需求差异的印包设备网络协同制造资源匹配方法

目的 包装印刷装备行业存在制造资源分散、产业协同不足和效率低等问题,针对网络协同制造中的制造资源匹配问题提出一种有效方法。方法 从不同子任务资源需求差异视角出发,构建基于TQCS制造资源评价指标体系及制造任务约束体系,通过层次分析法计算不同子任务的权重,以资源与任务的匹配度最大为目标函数,提出基于莱维飞行–遗传算法的网络协同制造资源匹配方法。结果 改进的资源匹配方法相较于传统方法,能够得到成本更低、时间更短的方案,并且改进的遗传算法的寻优能力更高。结论 相较于传统方法,改进的制造资源匹配方法的目标函数更合理、权重取值更客观、寻优能力更好,能够得到更为合理的制造资源匹配方案。     

Data analytics and optimization for smart industry

Industrial intelligence is a core technology in the upgrading of the production processes and management modes of traditional industries. Motivated by the major development strategies and needs of industrial intellectualization in China, this study presents an innovative fusion structure that encompasses the theoretical foundation and technological innovation of data analytics and optimization, as well as their application to smart industrial engineering. First, this study describes a general methodology for the fusion of data analytics and optimization. Then, it identifies some data analytics and system optimization technologies to handle key issues in smart manufacturing. Finally, it provides a four-level framework for smart industry based on the theoretical and technological research on the fusion of data analytics and optimization. The framework uses data analytics to perceive and analyze industrial production and logistics processes. It also demonstrates the intelligent capability of planning, scheduling, operation optimization, and optimal control. Data analytics and system optimization tech-nologies are employed in the four-level framework to overcome some critical issues commonly faced by manufacturing, resources and materials, energy, and logistics systems, such as high energy consumption, high costs, low energy efficiency, low resource utilization, and serious environmental pollution. The fusion of data analytics and optimization allows enterprises to enhance the prediction and control of unknown areas and discover hidden knowledge to improve decision-making efficiency. Therefore, industrial intelligence has great importance in China’s industrial upgrading and transformation into a true industrial power.     

Multidisciplinary Design Optimization with Quasiseparable Subsystems

Numerous hierarchical and nonhierarchical decomposition strategies for the optimization of large scale systems, comprised of interacting subsystems, have been proposed. With a few exceptions, all of these strategies lack a rigorous theoretical justification. This paper focuses on a class of quasiseparable optimization problems narrow enough for a rigorous decomposition theory, yet general enough to encompass many large scale engineering design problems. The subsystems for these problems involve local design variables and global system variables, but no variables from other subsystems. The objective function is a sum of a global system criterion and the subsystems' criteria. The essential idea is to give each subsystem a budget and global system variable values, and then ask the subsystems to independently maximize their constraint margins. Using these constraint margins, a system optimization then adjusts the values of the system variables and subsystem budgets. The subsystem margin problems are totally independent, always feasible, and could even be done asynchronously in a parallel computing context. An important detail is that the subsystem tasks, in practice, would be to construct response surface approximations to the constraint margin functions, and the system level optimization would use these margin surrogate functions. The purpose of the present paper is to present a decomposition strategy in a general context, provide rigorous theory justifying the decomposition, and give some simple illustrative examples.     

A Petri net-based decomposition approach in modelling of manufacturing systems

This paper discusses the decomposition problem in the modelling and simulation of manufacturing systems. Petri nets are chosen as the modelling tool in a manufacturing system control study. The parallelism properly in the manufacturing system operations are extracted by the developed decomposition procedure. A system can be divided into several subsystems based on this decomposition procedure. Subsystems then can be analysed or simulated concurrently. This process generates the parallel processing activity for modelling and simulating manufacturing systems.     

Fundamental Theories and Key Technologies for Smart and Optimal Manufacturing in the Process Industry

Given the significant requirements for transforming and promoting the process industry, we present the major limitations of current petrochemical enterprises, including limitations in decision-making, production operation, efficiency and security, information integration, and so forth. To promote a vision of the process industry with efficient, green, and smart production, modern information technology should be utilized throughout the entire optimization process for production, management, and marketing. To focus on smart equipment in manufacturing processes, as well as on the adaptive intelligent optimization of the manufacturing process, operating mode, and supply chain management, we put forward several key scientific problems in engineering in a demand-driven and application-oriented manner, namely: ① intelligent sensing and integration of all process information, including production and management information; ② collaborative decision-making in the supply chain, industry chain, and value chain, driven by knowledge; ③ cooperative control and optimization of plant-wide production processes via human-cyber-physical interaction; and ④ life-cycle assessments for safety and environmental footprint monitoring, in addition to tracing analysis and risk control. In order to solve these limitations and core scientific problems, we further present fundamental theories and key technologies for smart and optimal manufacturing in the process industry. Although this paper discusses the process industry in China, the conclusions in this paper can be extended to the process industry around the world.     

Machine Learning and Data-Driven Techniques for the Control of Smart Power Generation Systems: An Uncertainty Handling Perspective

Due to growing concerns regarding climate change and environmental protection, smart power generation has become essential for the economical and safe operation of both conventional thermal power plants and sustainable energy. Traditional first-principle model-based methods are becoming insufficient when faced with the ever-growing system scale and its various uncertainties. The burgeoning era of machine learning (ML) and data-driven control (DDC) techniques promises an improved alternative to these outdated methods. This paper reviews typical applications of ML and DDC at the level of monitoring, control, optimization, and fault detection of power generation systems, with a particular focus on uncovering how these methods can function in evaluating, counteracting, or withstanding the effects of the associated uncertainties. A holistic view is provided on the control techniques of smart power generation, from the regulation level to the planning level. The benefits of ML and DDC techniques are accordingly interpreted in terms of visibility, maneuverability, flexibility, profitability, and safety (abbreviated as the “5-TYs”), respectively. Finally, an outlook on future research and applications is presented.     

OPTIMIZATION OF COMPOSITE LAMINATES WITH CUTOUTS USING GENETIC ALGORITHM,VARIABLE METRIC AND COMPLEX SEARCH METHODS

Optimization of composite laminates with cutouts is a complex problem, involving non-differentiable objective function and constraints. Choice of the optimization method is generally based on the nature and complexity of the objective function, constraints and how easily and/or accurately the first derivatives can be found. Many researchers have attempted and applied different classical optimization techniques for non-convex optimization problems. This paper clearly brings out the advantages of a non-traditional optimization method-Genetic algorithm (GA) over conventional techniques, the limitations of conventional techniques and GA's ability to approach the global optimum in an n-dimensional search space, for composite laminates.     

The elementary flux modes of a manufacturing system: a novel approach to explore the relationship of network structure and function

Elementary flux modes (EFMs) are a concept from Systems Biology, where they serve as an indicator of component relevance in metabolic networks. An elementary flux mode is a functionally relevant, non-decomposable path through a given network. In this paper, we apply elementary flux mode analysis to manufacturing systems, with the aim of using the number of EFMs as a predictor for resource significance in the manufacturing system. For this, we formulate a network representation of a manufacturing process, which allows us to define the manufacturing equivalent of a stoichiometric matrix to draw an analogy between metabolic and manufacturing systems. This, in turn, allows the computation of EFMs, which we conduct in a case-study for a real manufacturing system. We further show that the change of EFMs under resource breakdown is a good indicator of the average order lateness in the manufacturing system. In this way, EFMs provide insight into the relationship of network structure and function in manufacturing.     

A Perspective on Smart Process Manufacturing Research Challenges for Process Systems Engineers

The challenges posed by smart manufacturing for the process industries and for process systems engineering (PSE) researchers are discussed in this article. Much progress has been made in achieving plant- and site-wide optimization, but benchmarking would give greater confidence. Technical challenges confronting process systems engineers in developing enabling tools and techniques are discussed regarding flexibility and uncertainty, responsiveness and agility, robustness and security, the prediction of mixture properties and function, and new modeling and mathematics paradigms. Exploiting intelligence from big data to drive agility will require tackling new challenges, such as how to ensure the consistency and confidentiality of data through long and complex supply chains. Modeling challenges also exist, and involve ensuring that all key aspects are properly modeled, particularly where health, safety, and environmental concerns require accurate predictions of small but critical amounts at specific locations. Environmental concerns will require us to keep a closer track on all molecular species so that they are optimally used to create sustainable solutions. Disruptive business models may result, particularly from new personalized products, but that is difficult to predict.     

一种混合遗传算法在压电智能结构振动控制全局优化设计中的应用

本文针对采用压电作动器／传感器的智能结构,了振动控制中作动器／传动器的配置以及反馈增益的全局优化设计问题。     

Design search and optimization in aerospace engineering

In this paper, we take a design-led perspective on the use of computational tools in the aerospace sector. We briefly review the current state-of-the-art in design search and optimization (DSO) as applied to problems from aerospace engineering, focusing on those problems that make heavy use of computational fluid dynamics (CFD). This ranges over issues of representation, optimization problem formulation and computational modelling. We then follow this with a multi-objective, multi-disciplinary example of DSO applied to civil aircraft wing design, an area where this kind of approach is becoming essential for companies to maintain their competitive edge. Our example considers the structure and weight of a transonic civil transport wing, its aerodynamic performance at cruise speed and its manufacturing costs. The goals are low drag and cost while holding weight and structural performance at acceptable levels. The constraints and performance metrics are modelled by a linked series of analysis codes, the most expensive of which is a CFD analysis of the aerodynamics using an Euler code with coupled boundary layer model. Structural strength and weight are assessed using semi-empirical schemes based on typical airframe company practice. Costing is carried out using a newly developed generative approach based on a hierarchical decomposition of the key structural elements of a typical machined and bolted wing-box assembly. To carry out the DSO process in the face of multiple competing goals, a recently developed multi-objective probability of improvement formulation is invoked along with stochastic process response surface models (Krigs). This approach both mitigates the significant run times involved in CFD computation and also provides an elegant way of balancing competing goals while still allowing the deployment of the whole range of single objective optimizers commonly available to design teams.