Automated manufacturing system discovery and digital twin generation

The latest developments in industry involved the deployment of digital twins for both long and short term decision making, such as supply chain management, production planning and control. Modern production environments are frequently subject to disruptions and consequent modifications. As a result, the development of digital twins of manufacturing systems cannot rely solely on manual operations. Recent contributions proposed approaches to exploit data for the automated generation of the models. However, the resulting representations can be excessively accurate and may also describe activities that are not significant for estimating the system performance. Generating models with an appropriate level of detail can avoid useless efforts and long computation times, while allowing for easier understanding and re-usability. This paper proposes a method to automatically discover manufacturing systems and generate adequate digital twins. The relevant characteristics of a production system are automatically retrieved from data logs. The proposed method has been applied on two test cases and a real manufacturing line. The experimental results prove its effectiveness in generating digital models that can correctly estimate the system performance.     

Toward in-situ flaw detection in laser powder bed fusion additive manufacturing through layerwise imagery and machine learning

Process monitoring in additive manufacturing may allow components to be certified cheaply and rapidly and opens the possibility of healing defects, if detected. Here, neural networks (NNs) and convolutional neural networks (CNNs) are trained to detect flaws in layerwise images of a build, using labeled XCT data as a ground truth. Multiple images were recorded after each layer before and after recoating with various lighting conditions. Classifying networks were given a single image or multiple images of various lighting conditions for training and testing. CNNs demonstrated significantly better performance than NNs across all tasks. Furthermore, CNNs demonstrated improved generalizability, i.e., the ability to generalize to more diverse data than either the training or validation data sets. Specifically, CNNs trained on high-resolution layerwise images from one build showed minimal loss in performance when applied to data from an independent build, whereas the performance of the NNs degraded significantly. CNN accuracy was also demonstrated to be a function of flaw size, suggesting that smaller flaws may be produced by mechanisms that do not alter the surface morphology of the build plate. CNNs demonstrated accuracies of 93.5 % on large (>200 μm) flaws when testing and training on components from the same build and accuracies of 87.3 % when testing on a previously unseen build. Finally, evidence linking the formation of large lack-of-fusion defects to the presence of process ejecta is presented.     

Digital twin modeling method based on biomimicry for machining aerospace components

High-performance aerospace component manufacturing requires stringent in-process geometrical and performance-based quality control. Real-time observation, understanding and control of machining processes are integral to optimizing the machining strategies of aerospace component manufacturing. Digital Twin can be used to model, monitor and control the machining process by fusing multi-dimensional in-context machining process data, such as changes in geometry, material properties and machining parameters. However, there is a lack of systematic and efficient Digital Twin modeling method that can adaptively develop high-fidelity multi-scale and multi-dimensional Digital Twins of machining processes. Aiming at addressing this challenge, we proposed a Digital Twin modeling method based on biomimicry principles that can adaptively construct a multi-physics digital twin of the machining process. With this approach, we developed multiple Digital Twin sub-models, e.g., geometry model, behavior model and process model. These Digital Twin sub-models can interact with each other and compose an integrated true representation of the physical machining process. To demonstrate the effectiveness of the proposed biomimicry-based Digital Twin modeling method, we tested the method in monitoring and controlling the machining process of an air rudder.     

Decision-based process planning for wire and arc additively manufactured and machined parts

The conventional manufacturing of aircraft components is based on the machining from bulk material and the buy-to-fly ratio is high. This, in combination with the often low machinability of the materials in use, leads to high manufacturing costs. To reduce the production costs for these components, a process chain was developed, which consists of an additive manufacturing process and a machining process. To fully utilize the process chain’s capabilities, an integrated process planning approach is necessary. As a result, the work sequence can be optimized to achieve the economically most suitable sequence. In this paper, a method for a joint manufacturing cost calculation and subsequent decision-based cost minimization is proposed for the wire and arc additive manufacturing (WAAM) & milling process chain. Furthermore, the parameters’ influence on the results and the magnitude of their influence are determined. These results make it possible to design an economically optimal work sequence and to automate the process planning for this process chain.     

Analysis of information exchange activities to actualize and validate situation awareness during shift changeovers in nuclear power plants

Shift work situations occur in almost all safety‐critical organizations, and the investigations of some catastrophes like Chernobyl, Exxon Valdez, and the Gol/Legacy mid‐air collision indicated that shift work information exchange played an important role during the evolution of the situation before the accidents. Inadequate communications during shift changeovers challenged operators' work in the moments that preceded these accidents, because they got inadequate information about the current situation. Our research focuses on the information exchange activities (verbal, written, and nonverbal) of nuclear power plant control operators during shift changeovers. Our aim is to investigate how verbal exchanges and other representations enable operator crews to share information regarding the events that occurred in the previous shift to achieve adequate situation awareness. Our findings indicated the importance and richness of the information exchange during the shift changeover process to update and validate individual and collective situation awareness, showing that information adequately shared enables the ad hoc configurations of regulation loops and a safer use of simplified strategies that can be understood and be validated by other operators, reducing the occurrence of cognitive overloads and contributing to the construction of a common cognitive ground that enhances system resilience. © 2010 Wiley Periodicals, Inc.     

Routing with multiple quality-of-services constraints: An approximation perspective

Finding a path that satisfies multiple Quality-of-Service (QoS) constraints is vital to the deployment of current emerged services. However, existing algorithms are not very efficient and effective at finding such a path. Moreover, few works focus on three or more QoS constraints. In this paper, we present an enhanced version of fully polynomial time approximation scheme (EFPTAS) for multiconstrainted path optimal (MCOP) problem. Specifically, we make four major contributions. We first allow the proposed algorithm to construct an auxiliary graph, through which the QoS parameters on each of the finding path can be guaranteed not to exceed the given constraints. Then we adopt a concept, called nonlinear definition of path constraints in EFPTAS for reducing both time and space complexity. Also, we enable EFPTAS to run iteratively to facilitate a progressive refinement of the finding result. In addition to these, we identify some “deployment” issues for proposed algorithm, the essential steps that how and when the EFPTAS takes place are presented. By analyzing the proposed algorithm theoretically, we find that the presented EFPTAS can find a (1+ε)-approximation path in the network with time complexity O(|E||V|/ε) (where |E| is the number of edges and |V| is the number of nodes), which outperforms the previous best-known algorithm for MCOP. We conduct an extensive comparison between the algorithm presented in this paper and previous best-known study experimentally, our results indicate that EFPTAS can find a path with low complexity and preferable quality.     

金选别工艺的发展与深化

本文阐述了充分考虑矿石性质,探索出混合浮选的分步流程,恰当的施用多元扑收剂所产出的“协同效应”,稳定和强化选别工艺,收到提高选金技术指标的效果。     

激光焊接对接拼缝测量的微景深方法

对于复杂微细、错边量小的激光焊接拼缝测量,现有的视觉传感器方法不能稳定、可靠地提取出拼缝的中心位置、拼缝宽度等信息。为此,提出了基于微景深的激光焊接对接拼缝测量方法,该方法采用高倍光学放大镜头、工业CCD(Charge Coupled Device)/CMOS(Complementary Metal-Oxide-Semiconductor Transistor)相机和LED(Light-Emitting Diode)外部照明装置,以光学成像光轴与被测表面法矢呈45°的方式,组成的对接拼缝的非接触测量系统,既解决了显微放大时景深很小、测量范围小的问题,又解决了狭窄拼缝高光学放大倍数拼缝检测的难题。实验结果表明,该系统可快速准确地提取出拼缝中心坐标、拼缝宽度以及拼缝局部表面法矢。拼缝宽度测量精度优于5 μm,拼缝中心测量精度优于6 μm,可识别的最小拼缝宽度为0.02 mm,完全满足激光焊接对接狭窄拼缝的检测与自动跟踪的要求。     

过程控制计算机系统在热轧中的应用

在冶金生产中,热轧是自动化程度高、各种高新技术应用最为广泛的领域.针对过程控制计算机系统在热轧中的应用情况,联系过程控制系统在宝钢热轧发展过程的实际情况,从系统功能的组成及模型、系统接口的实现等方面,对热轧过程控制系统的开发与应用情况,进行了详细的分析.