Digital twin-based analysis of volumetric error mapping procedures

The evaluation of the volumetric accuracy of a machine tool is an open challenge in the industry, and a wide variety of technical solutions are available in the market and at research level. All solutions have advantages and disadvantages concerning which errors can be measured, the achievable uncertainty, the ease of implementation, possibility of machine integration and automation, the equipment cost and the machine occupation time, and it is not always straightforward which option to choose for each application. The need to ensure accuracy during the whole lifetime of the machine and the availability of monitoring systems developed following the Industry 4.0 trend are pushing the development of measurement systems that can be integrated in the machine to perform semi-automatic verification procedures that can be performed frequently by the machine user to monitor the condition of the machine. Calibrated artefact based calibration and verification solutions have an advantage in this field over laser based solutions in terms of cost and feasibility of machine integration, but they need to be optimized for each machine and customer requirements to achieve the required calibration uncertainty and minimize machine occupation time.This paper introduces a digital twin-based methodology to simulate all relevant effects in an artefact-based machine tool calibration procedure, from the machine itself with its expected error ranges, to the artefact geometry and uncertainty, artefact positions in the workspace, probe uncertainty, compensation model, etc. By parameterizing all relevant variables in the design of the calibration procedure, this simulation methodology can be used to analyse the effect of each design variable on the error mapping uncertainty, which is of great help in adapting the procedure to each specific machine and user requirements. The simulation methodology and the analysis possibilities are illustrated by applying it on a 3-axis milling machine tool.     

Authenticity green coffee bean species and geographical origin using near-infrared spectroscopy combined with chemometrics

To prevent the adulteration of agricultural resources and provide a solution to enhance the green coffee bean supply chain, authentication using the near-infrared spectroscopy (NIRS) technique was investigated. Partial least square with discrimination analysis (PLS-DA) models combined with various preprocessing methods were built from NIR spectra of 153 Vietnamese green coffee samples. The model combined with the standard normal variate and the first order of derivative yielded excellent performance in predicting coffee species with the error cross-validation of 0.0261. PLS-DA model of mean centre and first-order derivative spectra also yielded good performance in verifying geographical indication of green coffee with the error of 0.0656. By contrast, the predicting abilities of post-harvest methods were poor. The overall results showed a high potential of the NIRS in online authentication practices.     

Influence of temperature on acoustic emission source location accuracy in underground structure

An acoustic emission (AE) experiment was carried out to explore the AE location accuracy influenced by temperature. A hollow hemispherical specimen was used to simulate common underground structures. In the process of heating with the flame, the pulse signal of constant frequency was stimulated as an AE source. Then AE signals received by each sensor were collected and used for comparing localization accuracy at different temperatures. Results show that location errors of AE keep the same phenomenon in the early and middle heating stages. In the later stage of heating, location errors of AE increase sharply due to the appearance of cracks. This provides some beneficial suggestions on decreasing location errors of structural cracks caused by temperature and improves the ability of underground structure disaster prevention and control.     

Automatic design for shop scheduling strategies based on hyper-heuristics: A systematic review

Against the background of smart manufacturing and Industry 4.0, how to achieve real-time scheduling has become a problem to be solved. In this regard, automatic design for shop scheduling based on hyper-heuristics has been widely studied, and a number of reviews and scheduling algorithms have been presented. Few studies, however, have specifically discussed the technical points involved in algorithm development. This study, therefore, constructs a general framework for automatic design for shop scheduling strategies based on hyper-heuristics, and various state-of-the-art technical points in the development process are summarized. First, we summarize the existing types of shop scheduling strategies and classify them using a new classification method. Second, we summarize an automatic design algorithm for shop scheduling. Then, we investigate surrogate-assisted methods that are popular in the current algorithm field. Finally, current problems and challenges are discussed, and potential directions for future research are proposed.     

Identifying catalyst layer compositions of proton exchange membrane fuel cells through machine-learning-based approach

Membrane electrode assembly (MEA) is considered a key component of a proton exchange membrane fuel cell (PEMFC). However, developing a new MEA to meet desired properties, such as operation under low-humidity conditions without a humidifier, is a time- and cost-consuming process. This study employs a machine-learning-based approach using K-nearest neighbor (KNN) and neural networks (NN) in the MEA development process by identifying a suitable catalyst layer (CL) recipe in MEA. Minimum redundancy maximum relevance and principal component analysis were implemented to specify the most important predictor and reduce the data dimension. The number of predictors was found to play an essential role in the accuracy of the KNN and NN models although the predictors have self-correlations. The KNN model with a K of 7 was found to minimize the model loss with a loss of 11.9%. The NN model constructed by three corresponding hidden layers with nine, eight, and nine nodes can achieve the lowest error of 0.1293 for the Pt catalyst and 0.031 for PVA as a good additive blending in the CL of the MEA. However, even if the error is low, the prediction of PVA seems to be inaccurate, regardless of the model structure. Therefore, the KNN model is more appropriate for CL recipe prediction.     

Study on the non-uniform contact during ELID groove grinding

This paper introduces the potential feasibility that ELID (electrolytic in-process dressing) grinding replaces superfinishing in bearing manufacturing, but ELID grinding will bring new challenges. Different regions present distinguish surface profile due to the non-uniform contact in ELID groove grinding. However, few reports explaining the non-uniform contact are available. This article explores the mechanisms of the non-uniform contact during ELID groove grinding. Experiments on the non-uniform contact between bearing raceway and grinding wheel have been carried out under different conditions. The results show that non-uniform contact exists in ELID groove grinding process and it exerts influence on the profile of the raceway surface. Non-uniform contact influences the Rsk and Rku value all the time, but it influences the Ra value occasionally. Improvement strategies of eliminating the non-uniform contact are also discussed based on the experimental study.     

Accurate ensemble pruning with PL-bagging

Ensemble pruning deals with the selection of base learners prior to combination in order to improve prediction accuracy and efficiency. In the ensemble literature, it has been pointed out that in order for an ensemble classifier to achieve higher prediction accuracy, it is critical for the ensemble classifier to consist of accurate classifiers which at the same time diverse as much as possible. In this paper, a novel ensemble pruning method, called PL-bagging, is proposed. In order to attain the balance between diversity and accuracy of base learners, PL-bagging employs positive Lasso to assign weights to base learners in the combination step. Simulation studies and theoretical investigation showed that PL-bagging filters out redundant base learners while it assigns higher weights to more accurate base learners. Such improved weighting scheme of PL-bagging further results in higher classification accuracy and the improvement becomes even more significant as the ensemble size increases. The performance of PL-bagging was compared with state-of-the-art ensemble pruning methods for aggregation of bootstrapped base learners using 22 real and 4 synthetic datasets. The results indicate that PL-bagging significantly outperforms state-of-the-art ensemble pruning methods such as Boosting-based pruning and Trimmed bagging.     

Fault handling in large water networks with online dictionary learning

Fault detection and isolation in water distribution networks is an active topic due to the nonlinearities of flow propagation and recent increases in data availability due to sensor deployment. Here, we propose an efficient two-step data driven alternative: first, we perform sensor placement taking the network topology into account; second, we use incoming sensor data to build a network model through online dictionary learning. Online learning is fast and allows tackling large networks as it processes small batches of signals at a time. This brings the benefit of continuous integration of new data into the existing network model, either in the beginning for training or in production when new data samples are gathered. The proposed algorithms show good performance in our simulations on both small and large-scale networks.     

A hybrid multiple feature construction approach for classification using Genetic Programming

The purpose of feature construction is to create new higher-level features from original ones. Genetic Programming (GP) was usually employed to perform feature construction tasks due to its flexible representation. Filter-based approach and wrapper-based approach are two commonly used feature construction approaches according to their different evaluation functions. In this paper, we propose a hybrid feature construction approach using genetic programming (Hybrid-GPFC) that combines filter’s fitness function and wrapper’s fitness function, and propose a multiple feature construction method that stores top excellent individuals during a single GP run. Experiments on ten datasets show that our proposed multiple feature construction method (Fcm) can achieve better (or equivalent) classification performance than the single feature construction method (Fcs), and our Hybrid-GPFC can obtain better classification performance than filter-based feature construction approaches (Filter-GPFC) and wrapper-based feature construction approaches (Wrapper-GPFC) in most cases. Further investigations on combinations of constructed features and original features show that constructed features augmented with original features do not improve the classification performance comparing with constructed features only. The comparisons with three state-of-art methods show that in majority of cases, our proposed hybrid multiple feature construction approach can achieve better classification performance.     

ACCUGRAM: A novel approach based on classification to frequency band selection for rotating machinery fault diagnosis

Frequency band selection (FBS) in rotating machinery fault diagnosis aims to recognize frequency band location including a fault transient out of a full band spectrum, and thus fault diagnosis can suppress noise influence from other frequency components. Impulsiveness and cyclostationarity have been recently recognized as two distinctive signatures of a transient. Thus, many studies have focused on developing quantification metrics of the two signatures and using them as indicators to guide FBS. However, most previous studies almost ignore another aspect of FBS, i.e. health reference, which significantly affect FBS performance. To address this issue, this paper investigates importance of a health reference and recognize it as the third critical aspect in FBS. With help of the health reference, the frequency band where the fault transient exists could be located. A novel approach based on classification is proposed to integrate all three aspects (impulsiveness, cyclostationarity, and health reference) for FBS. Classification accuracy is developed as a novel indicator to select the most sensitive frequency band for rotating machinery fault diagnosis. The proposed method (coined by accugram) has been validated on benchmark and experiment datasets. Comparison results show its effectiveness and robustness over conventional envelope analysis, the kurtogram, and the infogram.