Automated Monitoring of Manufacturing Processes, Part 1: Monitoring Methods

1995 ◽  
Vol 117 (2) ◽  
pp. 121-132 ◽  
Author(s):  
R. Du ◽  
M. A. Elbestawi ◽  
S. M. Wu
Keyword(s):  
Spectral Analysis ◽  
System Modeling ◽  
Process Condition ◽  
Process Conditions ◽  
Manufacturing Processes ◽  
Monitoring Methods ◽  
Time Frequency ◽  
Automated Monitoring ◽  
Two Phases ◽  
Analysis System

This paper presents a systematic study of various monitoring methods suitable for automated monitoring of manufacturing processes. In general, monitoring is composed of two phases: learning and classification. In the learning phase, the key issue is to establish the relationship between monitoring indices (selected signature features) and the process conditions. Based on this relationship and the current sensor signals, the process condition is then estimated in the classification phase. The monitoring methods discussed in this paper include pattern recognition, fuzzy systems, decision trees, expert systems and neural networks. A brief review of signal processing techniques commonly used in monitoring, such as statistical analysis, spectral analysis, system modeling, bi-spectral analysis and time-frequency distribution, is also included.

Automated Monitoring of Manufacturing Processes, Part 2: Applications

1995 ◽  
Vol 117 (2) ◽  
pp. 133-141 ◽  
Author(s):  
R. Du ◽  
M. A. Elbestawi ◽  
S. M. Wu
Keyword(s):  
Condition Monitoring ◽  
Rate Sensitivity ◽  
Index Selection ◽  
Manufacturing Processes ◽  
Test Results ◽  
Monitoring Methods ◽  
Decision Under Uncertainty ◽  
Automated Monitoring ◽  
Tool Condition ◽  
Monitoring Index

In Part 2 of this paper, three applications of automated monitoring of manufacturing processes are presented to demonstrate the use of monitoring methods discussed in Part 1 of the paper. These applications are: (1) tool condition monitoring in turning, (2) machining condition monitoring in tapping, and (3) metallographic condition monitoring in arc welding. For each application, a background review, monitoring index selection and experimental setup are first presented. Then, monitoring methods discussed in Part 1 of the paper were applied and the test results are investigated. Discussions of the monitoring success rate, sensitivity, robustness, monitoring index selection, and decision under uncertainty are also included.

scholarly journals Indicative Marker Microbiome Structures Deduced from the Taxonomic Inventory of 67 Full-Scale Anaerobic Digesters of 49 Agricultural Biogas Plants

2021 ◽  
Vol 9 (7) ◽  
pp. 1457
Author(s):  
Julia Hassa ◽  
Johanna Klang ◽  
Dirk Benndorf ◽  
Marcel Pohl ◽  
Benedikt Hülsemann ◽  
...  
Keyword(s):  
Stable Process ◽  
Process Condition ◽  
Full Scale ◽  
Process Models ◽  
Process Efficiency ◽  
Process Conditions ◽  
Rrna Gene ◽  
General Process ◽  
Specific Distribution ◽  
Biogas Plants

There are almost 9500 biogas plants in Germany, which are predominantly operated with energy crops and residues from livestock husbandry over the last two decades. In the future, biogas plants must be enabled to use a much broader range of input materials in a flexible and demand-oriented manner. Hence, the microbial communities will be exposed to frequently varying process conditions, while an overall stable process must be ensured. To accompany this transition, there is the need to better understand how biogas microbiomes respond to management measures and how these responses affect the process efficiency. Therefore, 67 microbiomes originating from 49 agricultural, full-scale biogas plants were taxonomically investigated by 16S rRNA gene amplicon sequencing. These microbiomes were separated into three distinct clusters and one group of outliers, which are characterized by a specific distribution of 253 indicative taxa and their relative abundances. These indicative taxa seem to be adapted to specific process conditions which result from a different biogas plant operation. Based on these results, it seems to be possible to deduce/assess the general process condition of a biogas digester based solely on the microbiome structure, in particular on the distribution of specific indicative taxa, and without knowing the corresponding operational and chemical process parameters. Perspectively, this could allow the development of detection systems and advanced process models considering the microbial diversity.

scholarly journals Two Current-Based Methods for the Detection of Bearing and Impeller Faults in Variable Speed Pumps

Energies ◽  
2021 ◽  
Vol 14 (15) ◽  
pp. 4514
Author(s):  
Vincent Becker ◽  
Thilo Schwamm ◽  
Sven Urschel ◽  
Jose Alfonso Antonino-Daviu
Keyword(s):  
Condition Monitoring ◽  
False Alarms ◽  
Signature Analysis ◽  
Variable Speed ◽  
Monitoring Methods ◽  
Time Frequency ◽  
Motor Current ◽  
Load Point ◽  
Bearing Defects ◽  
Current Signature

The growing number of variable speed drives (VSDs) in industry has an impact on the future development of condition monitoring methods. In research, more and more attention is being paid to condition monitoring based on motor current evaluation. However, there are currently only a few contributions to current-based pump diagnosis. In this paper, two current-based methods for the detection of bearing defects, impeller clogging, and cracked impellers are presented. The first approach, load point-dependent fault indicator analysis (LoPoFIA), is an approach that was derived from motor current signature analysis (MCSA). Compared to MCSA, the novelty of LoPoFIA is that only amplitudes at typical fault frequencies in the current spectrum are considered as a function of the hydraulic load point. The second approach is advanced transient current signature analysis (ATCSA), which represents a time-frequency analysis of a current signal during start-up. According to the literature, ATCSA is mainly used for motor diagnosis. As a test item, a VSD-driven circulation pump was measured in a pump test bench. Compared to MCSA, both LoPoFIA and ATCSA showed improvements in terms of minimizing false alarms. However, LoPoFIA simplifies the separation of bearing defects and impeller defects, as impeller defects especially influence higher flow ranges. Compared to LoPoFIA, ATCSA represents a more efficient method in terms of minimizing measurement effort. In summary, both LoPoFIA and ATCSA provide important insights into the behavior of faulty pumps and can be advantageous compared to MCSA in terms of false alarms and fault separation.

Kinematics of rotation in place during defense turning in the crayfish Procambarus clarkii

2001 ◽  
Vol 204 (3) ◽  
pp. 471-486 ◽  
Author(s):  
N. Copp ◽  
M. Jamon
Keyword(s):  
Angular Velocity ◽  
Procambarus Clarkii ◽  
Angular Acceleration ◽  
The Body ◽  
Simple Variation ◽  
Freely Behaving ◽  
Leg Motion ◽  
Two Phases ◽  
Analysis System ◽  
Final Orientation

The kinematic patterns of defense turning behavior in freely behaving specimens of the crayfish Procambarus clarkii were investigated with the aid of a video-analysis system. Movements of the body and all pereiopods, except the chelipeds, were analyzed. Because this behavior approximates to a rotation in place, this analysis extends previous studies on straight and curve walking in crustaceans. Specimens of P. clarkii responded to a tactile stimulus on a walking leg by turning accurately to face the source of the stimulation. Angular velocity profiles of the movement of the animal's carapace suggest that defense turn responses are executed in two phases: an initial stereotyped phase, in which the body twists on its legs and undergoes a rapid angular acceleration, followed by a more erratic phase of generally decreasing angular velocity that leads to the final orientation. Comparisons of contralateral members of each pair of legs reveal that defense turns are affected by changes in step geometry, rather than by changes in the timing parameters of leg motion, although inner legs 3 and 4 tend to take more steps than their outer counterparts during the course of a response. During the initial phase, outer legs 3 and 4 exhibit larger stance amplitudes than their inner partners, and all the outer legs produce larger stance amplitudes than their inner counterparts during the second stage of the response. Also, the net vectors of the initial stances, particularly, are angled with respect to the body, with the power strokes of the inner legs produced during promotion and those of the outer legs produced during remotion. Unlike straight and curve walking in the crayfish, there is no discernible pattern of contralateral leg coordination during defense turns. Similarities and differences between defense turns and curve walking are discussed. It is apparent that rotation in place, as in defense turns, is not a simple variation on straight or curve walking but a distinct locomotor pattern.

Development of a sliding-leg tripod as an add-on device for manufacturing

Robotica ◽  
2001 ◽  
Vol 19 (3) ◽  
pp. 285-294 ◽  
Author(s):  
Fengfeng Xi ◽  
Wanzhi Han ◽  
Marcel Verner ◽  
Andrew Ross
Keyword(s):  
Laser Scanning ◽  
System Analysis ◽  
System Modeling ◽  
Kinematic Model ◽  
Joint Space ◽  
Cnc Machine Tools ◽  
System Control ◽  
System Modelling ◽  
Cnc Machine ◽  
Analysis System

This paper presents the work on developing a sliding-leg tripod as a programmable add-on device for manufacturing. The purpose is to enhance the capabilities of any machine by providing it with a more flexible range of motion. This device can be used as a toolhead for CNC machine tools and robots, or as a work stage for coordinate measuring machines and laser scanning systems. In this paper, system modelling, analysis and control of this device is presented. System modeling includes mobility study, kinematic model and inverse kinematics. System analysis includes workspace analysis, transmission ratio and stiffness analysis. System control includes path planning, joint space control and Cartesian space prediction. It is shown that the proposed device can provide flexibility and dexterity to machines.

Effect of carburizing and annealing processes in improving the Ni/WC–Co adhesion strength

2017 ◽  
Vol 232 (3) ◽  
pp. 338-348 ◽  
Author(s):  
AW Hassan ◽  
MY Noordin ◽  
S Izman ◽  
K Denni
Keyword(s):  
Heat Treatment ◽  
Adhesion Strength ◽  
Positive Impact ◽  
Process Condition ◽  
Scratch Test ◽  
Process Conditions ◽  
X Ray ◽  
Treatment Processes ◽  
Before And After ◽  
Field Emission Electron Microscopy

Heat treatment processes have a positive impact in improving the adhesion strength of different interlayer/substrate materials. However, information regarding the effect of these processes in enhancing the adhesion strength of an electroplated nickel interlayer on tungsten carbide substrate for diamond deposition is lacking. In this study, the effect of carburizing and annealing process conditions in enhancing the adhesion strength of the electroplated nickel interlayer was investigated. The heat treatment processes were designed and modeled by the design of experiments technique. The heat-treated specimens were characterized by the field-emission electron microscopy, energy-dispersive X-ray spectroscopy, and X-ray diffraction techniques. The adhesion of the interlayer before and after the heat treatment was assessed by the scratch test. The results show that the adhesion of the electroplated nickel interlayer was remarkably improved by both processes. The mathematical models for predicting the adhesion strength of the carburized and annealed nickel interlayer within the specified ranges were developed. The maximum adhesion strength of 30 N was obtained from the nickel interlayer annealed at the highest process condition of temperature and time.

Ultrasonic Nondestructive Testing for In-Line Monitoring of Wire-Arc Additive Manufacturing (WAAM)

2020 ◽  
Author(s):  
Md Shahjahan Hossain ◽  
Hossein Taheri ◽  
Niraj Pudasaini ◽  
Alexander Reichenbach ◽  
Bishal Silwal
Keyword(s):  
Quality Assurance ◽  
Additive Manufacturing ◽  
Nondestructive Testing ◽  
Large Scale ◽  
Gas Flow ◽  
Complex Structure ◽  
Process Condition ◽  
Process Conditions ◽  
Ultrasonic Signals ◽  
Wire Arc Additive Manufacturing

Abstract The applications for metal additive manufacturing (AM) are expanding. Powder-bed, powder-fed, and wire-fed AM are the different kinds of AM technologies based on the feeding material. Wire-Arc AM (WAAM) is a wire-fed technique that has the potential to fabricate large-scale three-dimensional objects. In WAAM, a metallic wire is continuously fed to the deposition location and is melted by an arc-welding power source. As the applications for WAAM expands, the quality assurance of the parts becomes a major concern. Nondestructive testing (NDT) of AM parts is necessary for quality assurance and inspection of these materials. The conventional method of inspection is to perform testing on the finished parts. There are several limitations encountered when using conventional methods of NDT for as-built AM parts due to surface conditions and complex structure. In-situ process monitoring based on the ultrasound technology is proposed for WAAM material inspection during the manufacturing process. Ultrasonic inline monitoring techniques have the advantages of providing valuable information about the process and parts quality. Ultrasonic technique was used to detect the process condition deviations from the normal. A fixture developed by the authors holds an ultrasonic sensor under the build platform and aligned with the center of the base plate. Ultrasonic signals were measured for different process conditions by varying the current and gas flow rate. Features (indicators) from the radio frequency (RF) signal were used to evaluate the difference in signal clusters to identify and classify different build conditions. Results show that the indicator values of the ultrasonic signals in the region of interest (ROI) changes with different process conditions and can be used to classify them.

scholarly journals Conduction-Based Thermally Assisted Micromilling Process for Cutting Difficult-to-Machine Materials

2020 ◽  
Vol 4 (2) ◽  
pp. 34 ◽  
Author(s):  
Timo Platt ◽  
Alexander Meijer ◽  
Dirk Biermann
Keyword(s):  
Tool Wear ◽  
High Speed ◽  
End Milling ◽  
High Speed Steel ◽  
High Strength ◽  
Process Conditions ◽  
Manufacturing Processes ◽  
Central Process ◽  
Workpiece Temperature ◽  
Micro End Milling

The increasing demand for complex and wear-resistant forming tools made of difficult-to-machine materials requires efficient manufacturing processes. In terms of high-strength materials; highly suitable processes such as micromilling are limited in their potential due to the increased tool loads and the resulting tool wear. This promotes hybrid manufacturing processes that offer approaches to increase the performance. In this paper; conduction-based thermally assisted micromilling using a prototype device to homogeneously heat the entire workpiece is investigated. By varying the workpiece temperature by 20 °C < TW < 500 °C; a highly durable high-speed steel (HSS) AISI M3:2 (63 HRC) and a hot-work steel (HWS) AISI H11 (53 HRC) were machined using PVD-TiAlN coated micro-end milling tools (d = 1 mm). The influence of the workpiece temperature on central process conditions; such as tool wear and achievable surface quality; are determined. As expected; the temporary thermal softening of the materials leads to a reduction in the cutting forces and; thus; in the resulting tool wear for specific configurations of the thermal assistance. While only minor effects are detected regarding the surface topography; a significant reduction in the burr height is achieved.

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