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.     

A PV installation framework concerning electricity variable rates

This paper assesses building integrated photovoltaic (BIPV) installation parameters based on the profit generated by a photovoltaic system. It takes into consideration a home building case study and it investigates its monthly energy demand based on a specific location and a typical occupancy. The capability of a photovoltaic (PV) system to generate more profit occurs when solar intensity is maximum while the electric energy price is at its highest rate. The paper traces a framework that encompasses different aspects such as energy demand, energy price, and solar intensity. This framework identifies profit alternatives according to different installation parameters. A tool that predicts a PV installation hourly electric energy production is developed. The profit generated is simulated for home buildings located in Beirut (Lebanon) and Xihua (China), both at 33.8° latitude north. The paper highlights a new approach for BIPV installations, taking into account weather conditions, energy demand, and electric energy utility rates.     

Designed damping controller for SSSC to improve stability of a hybrid offshore wind farms considering time delay

This paper presents the stability improvement results of hybrid doubly fed induction generator (DFIG)-based and permanent magnet generator (PMG)-based offshore wind farms (OWFs) using a static synchronous series compensator (SSSC). An adaptive-network-based fuzzy inference system (ANFIS) controller of the proposed SSSC is designed to render adequate damping characteristics to the studied system. A frequency-domain approach based on a linearized system model using eigenvalue technique analysis is performed. A time-domain scheme based on a nonlinear system model subject to a three-phase short circuit fault at infinite bus with variations in the signal transmission delays has also been investigated to compare the damping of the studied system in cases of with and without controller. The simulation results with MATLAB/SIMULINK toolbox have been presented. It can be concluded from the simulation results that the proposed SSSC joined with the designed ANFIS damping controller can offer adequate damping performance to the studied hybrid DFIG-based and PMG-based OWFs under severe disturbance.     

水力旋冲钻井工具破岩影响因素模拟及应用

常规的冲击钻井工具不能满足井眼轨迹控制要求、使用寿命有限、缓解脱压不显著等问题,影响了在定向井钻井中的推广应用。建立ø215.9 mm PDC钻头和岩石的有限元模型,分析钻井参数对破岩效率的影响规律,结果表明:冲击频率为17.5 Hz和35 Hz时,破岩效率最优; 破岩效率随钻压增大而增加,而后变化逐渐平缓; 破岩效率随钻头转速增大而增加; 破岩效率随冲击载荷的增加变化平缓。据此研制了新型水力旋冲钻井工具。现场试验表明,该工具符合定向水平井“一趟钻”工艺要求,使机械钻速提高56%,使用寿命达150 h,MWD信号正常。     

Local toolpath smoothing for five-axis machine tools

When five axis CNC machine tools follow series linear toolpath segments, the drives experience velocity, acceleration and jerk discontinuities at the block transition points. The discontinuities result in fluctuations on machine tool motions which lead to poor surface quality. This paper proposes to insert quintic and septic micro-splines for the tool tip and tool-orientation, respectively, at the adjacent linear toolpath segments. Optimal control points are calculated for position and orientation splines to achieve C³ continuity at the junctions while respecting user-defined tolerance limits. The geometrically smoothed corners are traveled at a smoothly varying feed with cubic acceleration trajectory profile. The proposed method is experimentally demonstrated to show improvements in motion smoothness and tracking accuracy in five-axis machining of free-form surfaces found in dies, molds and aerospace parts.     

Friction compensation controller for load varying machine tool feed drive

The load applied to a machine tool feed drive changes during the machining process as material is removed. This load change alters the Coulomb friction of the feed drive. Because Coulomb friction accounts for a large part of the total friction the friction compensation control accuracy of the feed drives is limited if this nonlinear change in the applied load is not considered. This paper presents a new friction compensation method that estimates the machine tool load in real time and considers its effect on friction characteristics. A friction observer based on a Kalman filter with load estimation is proposed for friction compensation control considering the applied load change. A specially designed feed drive testbed that enables the applied load to be modified easily was constructed for experimental verification. Control performance and friction estimation accuracy are demonstrated experimentally using the testbed.     

Stress distribution in thick-walled cylinder due to non-uniform radial pressure on the example of reinforcement corrosion in concrete

This paper presents an analytical solution to the non-uniform pressure on thick-walled cylinder. The formulation is based on the linear elasticity theory (plain strain) and stress function method. As an example, the proposed solution is used to model the stress distribution due to non-uniform steel reinforcement corrosion in concrete. The model is formulated considering different scenarios of corrosion pressure distribution. It is validated against the finite element model for different cases of non-uniform pressure distributions. The results show that the corrosion-induced cracks are likely to start just beyond the anodic zone. This is confirmed by the experimental tests on concrete cylinder exposed to non-uniform accelerated corrosion of steel reinforcement. The model can be effectively used to calculate the distribution of corrosion-induced stresses in concrete.     

Operational time-series data modeling via LSTM network integrating principal component analysis based on human experience

Today’s information technologies involve increasingly intelligent systems, which come at the cost of increasingly complex equipment. Modern monitoring systems collect multi-measuring-point and long-term data which make equipment health prediction a “big data” problem. It is difficult to extract information from such condition monitoring data to accurately estimate or predict health statuses. Deep learning is a powerful tool for big data processing that is widely utilized in image and speech recognition applications, and can also provide effective predictions in industrial processes. This paper proposes the Long Short-term Memory Integrating Principal Component Analysis based on Human Experience (HEPCA-LSTM), which uses operational time-series data for equipment health prognostics. Principal component analysis based on human experience is first conducted to extract condition parameters from the condition monitoring system. The long short-term memory (LSTM) framework is then constructed to predict the target status. Finally, a dynamic update of the prediction model with incoming data is performed at a certain interval to prevent any model misalignment caused by the drifting of relevant variables. The proposed model is validated on a practical case and found to outperform other prediction methods. It utilizes a powerful deep learning analysis method, the LSTM, to fully process big condition monitoring series data; it effectively extracts the features involved with human experience and takes dynamic updates into consideration.     

Detection of correlation characteristics between financial time series based on multi-resolution analysis

Interactions between financial time series are complex and changeable in both time and frequency domains. To reveal the evolution characteristics of the time-varying relations between bivariate time series from a multi-resolution perspective, this study introduces an approach combining wavelet analysis and complex networks. In addition, to reduce the influence the phase lag between the time series has on the correlations, we propose dynamic time-warping (DTW) correlation coefficients to reflect the correlation degree between bivariate time series. Unlike previous studies that symbolized the time series only based on the correlation strength, the second-level symbol is set according to the correlation length during the coarse-graining process. This study presents a novel method to analyze bivariate time series and provides more information for investors and decision makers when investing in the stock market. We choose the closing prices of two stocks in China’s market as the sample and explore the evolutionary behavior of correlation modes from different resolutions. Furthermore, we perform experiments to discover the critical correlation modes between the bull market and the bear market on the high-resolution scale, the clustering effect during the financial crisis on the middle-resolution scale, and the potential pseudo period on the low-resolution scale. The experimental results exactly match reality, which provides powerful evidence to prove that our method is effective in financial time series analysis.     

Improving weld formability by a novel dual-rotation bobbin tool friction stir welding

A novel dual-rotation bobbin tool friction stir welding (DBT-FSW) was developed, in which the upper shoulder (US) and lower shoulder (LS) have different rotational speeds. This process was tried to weld 3.2 mm thick aluminum-lithium alloy sheets. The metallographic analysis and torque measurement were carried out to characterize the weld formability. Experimental results show that compared to conventional bobbin tool friction stir welding, the DBT-FSW has an excellent process stability, and can produce the defect-free joints in a wider range of welding parameters. These can be attributed to the significant improvement of material flow caused by the formation of a staggered layer structure and the unbalanced force between the US and LS during the DBT-FSW process.