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.     

On recommendation problems beyond points of interest

Recommendation systems aim to recommend items or packages of items that are likely to be of interest to users. Previous work on recommendation systems has mostly focused on recommending points of interest (POI), to identify and suggest top-k items or packages that meet selection criteria and satisfy compatibility constraints on items in a package, where the (packages of) items are ranked by their usefulness to the users. As opposed to prior work, this paper investigates two issues beyond POI recommendation that are also important to recommendation systems. When there exist no sufficiently many POI that can be recommended, we propose (1) query relaxation recommendation to help users revise their selection criteria, or (2) adjustment recommendation to guide recommendation systems to modify their item collections, such that the users׳ requirements can be satisfied.We study two related problems, to decide (1) whether the query expressing the selection criteria can be relaxed to a limited extent, and (2) whether we can update a bounded number of items, such that the users can get desired recommendations. We establish the upper and lower bounds of these problems, all matching, for both combined and data complexity, when selection criteria and compatibility constraints are expressed in a variety of query languages, for both item recommendation and package recommendation. To understand where the complexity comes from, we also study the impact of variable sizes of packages, compatibility constraints and selection criteria on the analyses of these problems. Our results indicate that in most cases the complexity bounds of query relaxation and adjustment recommendation are comparable to their counterparts of the basic recommendation problem for testing whether a given set of (resp. packages of) items makes top-k items (resp. packages). In other words, extending recommendation systems with the query relaxation and adjustment recommendation functionalities typically does not incur extra overhead.     

Lagrangian relaxation hybrid with evolutionary algorithm for short-term generation scheduling

Short-term generation scheduling is an important function in daily operational planning of power systems. It is defined as optimal scheduling of power generators over a scheduling period while respecting various generator constraints and system constraints. Objective of the problem includes costs associated with energy production, start-up cost and shut-down cost along with profits. The resulting problem is a large scale nonlinear mixed-integer optimization problem for which there is no exact solution technique available. The solution to the problem can be obtained only by complete enumeration, often at the cost of a prohibitively computation time requirement for realistic power systems. This paper presents a hybrid algorithm which combines Lagrangian Relaxation (LR) together with Evolutionary Algorithm (EA) to solve the problem in cooperative and competitive energy environments. Simulation studies were carried out on different systems containing various numbers of units. The outcomes from different algorithms are compared with that from the proposed hybrid algorithm and the advantages of the proposed algorithm are briefly discussed.     

SiC/SiC mini-composites with multilayer ZrSiO4 interphase: Room-temperature properties and toughening mechanism

SiC/SiC mini-composites reinforced with SiC fibers coated with different numbers of ZrSiO₄ sublayers prepared via a non-hydrolytic sol-gel process were fabricated. The tensile strength and work of fracture of the prepared SiC/SiC mini-composites were determined, and the relationship between their mechanical properties and fracture morphologies was discussed. The toughening mechanism and the variation tendency of their mechanical properties were further elaborated by analyzing the interfacial debonding morphologies of the SiC/SiC mini-composites with 1 and 4 layers of ZrSiO₄ interphase as well as the results of prior studies. A relatively rare phenomenon—the delamination of the multilayer ZrSiO₄ interphase in the SiC/SiC mini-composites but not on the SiC fibers—was observed, which clearly demonstrated the weak bonding between the ZrSiO₄ sublayers in the SiC/SiC mini-composites. The ZrSiO₄ sublayer delamination mechanism was then explained based on the high-magnification morphologies found in and beside the ZrSiO₄ interphase.     

Biological Water Treatment by a Hybrid Fluidized-Bed Bioreactor: Theoretical Study

A hybrid fluidized-bed bioreactor for water purification was proposed and analyzed. It is a novel type of bioreactor characterized by hitherto unknown stationary and dynamic features. Steady-state characteristics of this hybrid bioreactor with external liquid circulation are presented. A quantitative analysis of steady-state properties of the bioreactor was performed with the aid of an original mathematical model developed for a double-substrate aerobic microbiological process. A steady-state analysis of aerobic processes characterized by different oxygen demand was performed. The effect of essential parameters was evaluated, including carbonaceous substrate concentration in the feed stream to the apparatus, aeration intensity, total residence time of a liquid in the bioreactor, and height of the bed of fine carrier particles.     

Enhanced relative permittivity in niobium and europium co-doped TiO2 ceramics

The appearance of colossal permittivity materials broadened the choice of materials for energy-storage applications. In this work, colossal permittivity in ceramics of TiO₂ co-doped with niobium and europium ions ((Eu_0.5Nb_0.5)_xTi_1-xO₂ ceramics) was reported. A large permittivity (ε_r ～ 2.01?×?10⁵) and a low dielectric loss (tanδ ～ 0.095) were observed for (Eu_0.5Nb_0.5)_xTi_1-xO₂ (x?=?1%) ceramics at 1?kHz. Moreover, two significant relaxations were observed in the temperature dependence of dielectric properties for (Eu, Nb) co-doped TiO₂ ceramics, which originated from defect dipoles and electron hopping, respectively. The low dielectric loss and high relative permittivity were ascribed to the electron-pinned defect-dipoles and electrons hopping. The (Eu_0.5Nb_0.5)_xTi_1-xO₂ ceramic with great colossal permittivity is one of the most promising candidates for high-energy density storage applications.     

A Distribution‐freeCUSUMChart for Monitoring Variability of AutocorrelatedProcesses

We present a distribution‐free tabular cumulative sum chart for monitoring the variability of an autocorrelated process. A quantity known as the asymptotic variance parameter is employed as a measure of the variability, and a distribution‐free tabular cumulative sum chart is applied to variance estimates calculated from batches of nonoverlapping samples. The proposed chart is applicable to a stationary process with a general marginal distribution and a general autocorrelation structure. It also determines control limits analytically without trial‐and‐error simulations. The performance of the proposed chart is tested on stationary processes with both normal and nonnormal marginals with various autocorrelation structures. Copyright © 2014 John Wiley & Sons, Ltd.     

Robust nonlinear feedback–feedforward control of a coupled kinetic Monte Carlo–finite difference simulation

Robust nonlinear feedforward–feedback controllers are designed for a multiscale system that dynamically couples kinetic Monte Carlo (KMC) and finite difference (FD) simulation codes. The coupled codes simulate the copper electrodeposition process for manufacturing on-chip copper interconnects in electronic devices. The control objective is to regulate the current density subject to the condition that the steady-state fluctuation of the overpotential remains bounded within ±0.01 V. The controller designs incorporate a low-order stochastic model that captures the input–output behavior of the coupled KMC–FD code. The controllers achieve the objectives and the closed-loop responses implemented on the low-order model and the coupled KMC–FD code match well within stochastic variations. The nonlinear feedforward control reduces the rise time of the controller response while the feedback control ensures robustness in the presence of model uncertainty.