Online Analytics Framework of Sensor-Driven Prognosis and Opportunistic Maintenance for Mass Customization

2019 ◽  
Vol 141 (5) ◽  
Author(s):  
Tangbin Xia ◽  
Xiaolei Fang ◽  
Nagi Gebraeel ◽  
Lifeng Xi ◽  
Ershun Pan
Keyword(s):  
Real Time ◽  
Mass Customization ◽  
Maintenance Scheduling ◽  
System Level ◽  
Maintenance Cost ◽  
Time To Failure ◽  
Maintenance Policy ◽  
Opportunistic Maintenance ◽  
Product Demand ◽  
System Breakdown

In mass customization, a manufacturing line is required to be kept in reliable operation to handle product demand volatility and potential machine degradations. Recent advances in data acquisition and processing allow for effective maintenance scheduling. This paper presents a systematic framework that integrates a sensor-driven prognostic method and an opportunistic maintenance policy. The prognostic method uses degradation signals of each individual machine to predict and update its time-to-failure (TTF) distributions in real time. Then, system-level opportunistic maintenance optimizations are dynamically made according to real-time TTF distributions and variable product orders. The online analytics framework is demonstrated through the case study based on the collected reliability information from a production line of engine crankshaft. The results can effectively prove that the real-time degradation updating and the opportunistic maintenance scheduling can efficiently reduce maintenance cost, avoid system breakdown, and ensure product quality. Furthermore, this framework can be applied not only in an automobile line but also for a broader range of manufacturing lines in mass customization.

Real-Time Prognostic and Dynamic Maintenance Window Scheme for Reconfigurable Manufacturing Systems

2019 ◽  
Author(s):  
Yifan Dong ◽  
Tangbin Xia ◽  
Lei Xiao ◽  
Ershun Pan ◽  
Lifeng Xi
Keyword(s):  
Real Time ◽  
Manufacturing Systems ◽  
Manufacturing System ◽  
Degradation Process ◽  
Maintenance Cost ◽  
Time To Failure ◽  
Reconfigurable Manufacturing Systems ◽  
Reconfigurable Manufacturing ◽  
Reconfigurable Manufacturing System ◽  
Dynamic Maintenance

Abstract Real-time condition acquisition and accurate time-to-failure (TTF) prognostic of machines are both crucial in the condition based maintenance (CBM) scheme for a manufacturing system. Most of previous researches considered the degradation process as a population-specific reliability characteristics and ignored the hidden differences among the degradation process of individual machines. Moreover, existing maintenance scheme are mostly focus on the manufacturing system with fixed structure. These proposed maintenance scheme could not be applied for the reconfigurable manufacturing system, which is quite adjustable to the various product order and customer demands in the current market. In this paper, we develop a systematic predictive maintenance (PM) framework including real-time prognostic and dynamic maintenance window (DMW) scheme for reconfigurable manufacturing systems to fill these gaps. We propose a real-time Bayesian updating prognostic model using sensor-based condition information for computing each individual machine’s TTFs, and a dynamic maintenance window scheme for the maintenance work scheduling of a reconfigurable manufacturing system. This enables the real-time prognosis updating, the rapid decision making for reconfigurable manufacturing systems, and the notable maintenance cost reduction.

Maintenance cost assessment for heterogeneous multi-component systems incorporating perfect inspections and waiting time to maintenance

2021 ◽  
pp. 1748006X2110388
Author(s):  
Lucía Bautista ◽  
Inma T Castro ◽  
Luis Landesa
Keyword(s):  
Heuristic Algorithms ◽  
Cost Model ◽  
System Level ◽  
Maintenance Cost ◽  
Maintenance Policy ◽  
Industrial Systems ◽  
Inspection Strategy ◽  
Optimal Maintenance ◽  
Systems Maintenance ◽  
Safety Constraint

Most existing research about complex systems maintenance assumes they consist of the same type of components. However, systems can be assembled with heterogeneous components (for example degrading and non-degrading components) that require different maintenance actions. Since industrial systems become more and more complex, more research about the maintenance of systems with heterogeneous components is needed. For this reason, in this paper, a system consisting of two groups of components: degrading and non-degrading components is analyzed. The main novelty of this paper is the evaluation of a maintenance policy at system-level coordinating condition-based maintenance for the degrading components, delay time to the maintenance and an inspection strategy for this heterogeneous system. To that end, an analytic cost model is built using the semi-regenerative processes theory. Furthermore, a safety constraint related to the reliability of the degrading components is imposed. To find the optimal maintenance strategy, meta-heuristic algorithms are used.

scholarly journals Opportunistic Maintenance Policy for a Multi-Component System Subject to Random Failures

2017 ◽  
Vol 4 (2) ◽  
pp. 80-91
Author(s):  
H. Eldhadaf ◽  
R. Benmansour ◽  
H. Allaoui ◽  
M. Tkiouat ◽  
A. Artiba
Keyword(s):  
Optimization Procedure ◽  
Spare Part ◽  
Maintenance Cost ◽  
Maintenance Policy ◽  
Opportunistic Maintenance ◽  
Component System ◽  
Two Parameters ◽  
Scheduled Time ◽  
Random Failures ◽  
Multi Component System

In this paper, an opportunistic maintenance policy (OMP) for a multi-component system is studied. The objective is to minimize the maintenance cost while guaranteeing a minimum level of reliability for the system and for each of its components. Each component is subject to random failures and at most one spare part of it should be kept in stock or ordering at any time. The lifetime of this system will be divided into several periods. At the beginning of each period, the set of actions (among many others) must be determined in order to achieve the objective mentioned above. The policy OMP is characterized by two parameters; the first one is the scheduled time for spare ordering and the second one is the period of realization of the maintenance action (if any). These parameters will be derived from the joint optimization of maintenance cost and the inventory cost for each component. Finally, a numerical example to explain the proposed maintenance policy and the optimization procedure is provided.

OPPORTUNISTIC MAINTENANCE OPTIMIZATION FOR WIND TURBINE SYSTEMS CONSIDERING IMPERFECT MAINTENANCE ACTIONS

2011 ◽  
Vol 18 (05) ◽  
pp. 463-481 ◽  
Author(s):  
FANGFANG DING ◽  
ZHIGANG TIAN
Keyword(s):  
Wind Power ◽  
Preventive Maintenance ◽  
Wind Farm ◽  
Power Industry ◽  
Maintenance Cost ◽  
Maintenance Optimization ◽  
Imperfect Maintenance ◽  
Maintenance Policy ◽  
Opportunistic Maintenance ◽  
Wind Power Industry

Currently corrective maintenance and time-based preventive maintenance strategies are widely used in wind power industry. However, few methods are applied to optimize these strategies. This paper aims to develop opportunistic maintenance approaches for an entire wind farm rather than individual components that most of the existing studies deal with. Furthermore, we consider imperfect actions in the preventive maintenance tasks, which address the issue that preventive maintenance do not always return components to the as-good-as-new status in practice. In this paper we propose three opportunistic maintenance optimization models, where the preventive maintenance is considered as perfect, imperfect and two-level action, respectively. Simulation methods are developed to evaluate the costs of the proposed opportunistic maintenance policies. Numerical examples are provided to demonstrate the advantage of the proposed opportunistic maintenance methods in reducing the maintenance cost. The two-level action method demonstrates to be the most cost-effective in different cost situations, while the imperfect maintenance policy, which is a simpler method, is a close second. The developed methods are expected to bring immediate benefits to wind power industry.

scholarly journals Opportunistic Maintenance Policy for A Multi-Component System Subject To Random Failures

2021 ◽  
Vol 4 (1) ◽  
pp. 15-27
Author(s):  
H. Elhadaf ◽  
R. Benmansour ◽  
H. Allaoui ◽  
M. Tkiouat ◽  
A. Artiba
Keyword(s):  
Optimization Procedure ◽  
Spare Part ◽  
Maintenance Cost ◽  
Maintenance Policy ◽  
Opportunistic Maintenance ◽  
Component System ◽  
Two Parameters ◽  
Scheduled Time ◽  
Random Failures ◽  
Multi Component System

In this paper we study an opportunistic maintenance policy (OMP) for a multi-component system. The objective is to minimize the maintenance cost while guaranteeing a minimum level of reliability for the system and for each of its components. We suppose that each component is subject to random failures and at most one spare part of it should be kept in stock or ordering at any time. The lifetime of this system will be divided into several periods. At the beginning of each period we must determine the set of actions (among many others) that will achieve the objective mentioned above. The policy OMP is characterized by two parameters; the first one is the scheduled time for spare ordering and the second one is the period of realization of the maintenance action (if any). These parameters will be derived from the joint optimization of maintenance cost and the inventory cost for each component. Finally, we will give a numerical example to explain the proposed maintenance policy and the optimization procedure.

Availability analysis and maintenance optimization for multiple failure mode systems considering imperfect repair

2021 ◽  
pp. 1748006X2110127
Author(s):  
Qingan Qiu ◽  
Baoliang Liu ◽  
Cong Lin ◽  
Jingjing Wang
Keyword(s):  
Failure Modes ◽  
Maintenance Cost ◽  
Imperfect Maintenance ◽  
Maintenance Policy ◽  
Cost Rate ◽  
Availability Analysis ◽  
Long Run ◽  
Optimal Maintenance ◽  
Maintenance Policies ◽  
Periodic Inspections

This paper studies the availability and optimal maintenance policies for systems subject to competing failure modes under continuous and periodic inspections. The repair time distribution and maintenance cost are both dependent on the failure modes. We investigate the instantaneous availability and the steady state availability of the system maintained through several imperfect repairs before a replacement is allowed. Analytical expressions for system availability under continuous and periodic inspections are derived respectively. The availability models are then utilized to obtain the optimal inspection and imperfect maintenance policy that minimizes the average long-run cost rate. A numerical example for Remote Power Feeding System is presented to demonstrate the application of the developed approach.

scholarly journals System Level Simulation of Microgrid Power Electronic Systems

Electronics ◽  
2021 ◽  
Vol 10 (6) ◽  
pp. 644
Author(s):  
Michal Frivaldsky ◽  
Jan Morgos ◽  
Michal Prazenica ◽  
Kristian Takacs
Keyword(s):  
Smart Grid ◽  
Simulation Model ◽  
Real Time ◽  
Power Converter ◽  
System Level ◽  
Time Behavior ◽  
Operational Parameters ◽  
System Level Simulation ◽  
Time Operation ◽  
The Impact

In this paper, we describe a procedure for designing an accurate simulation model using a price-wised linear approach referred to as the power semiconductor converters of a DC microgrid concept. Initially, the selection of topologies of individual power stage blocs are identified. Due to the requirements for verifying the accuracy of the simulation model, physical samples of power converters are realized with a power ratio of 1:10. The focus was on optimization of operational parameters such as real-time behavior (variable waveforms within a time domain), efficiency, and the voltage/current ripples. The approach was compared to real-time operation and efficiency performance was evaluated showing the accuracy and suitability of the presented approach. The results show the potential for developing complex smart grid simulation models, with a high level of accuracy, and thus the possibility to investigate various operational scenarios and the impact of power converter characteristics on the performance of a smart gird. Two possible operational scenarios of the proposed smart grid concept are evaluated and demonstrate that an accurate hardware-in-the-loop (HIL) system can be designed.

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