Diagnosis of Missed Ductile Iron Melts with Process Modelling

• Autorzy: Perzyk M. , Werlaty M.

Identyfikatory

DOI

10.1515/afe-2017-0142

• Języki publikacji: EN

Abstrakty

EN

The paper presents an application of advanced data-driven (soft) models in finding the most probable particular causes of missed ductile iron melts. The proposed methodology was tested using real foundry data set containing 1020 records with contents of 9 chemical elements in the iron as the process input variables and the ductile iron grade as the output. This dependent variable was of discrete (nominal) type with four possible values: ‘400/18’, ‘500/07’, ‘500/07 special’ and ‘non-classified’, i.e. the missed melt. Several types of classification models were built and tested: MLP-type Artificial Neural Network, Support Vector Machine and two versions of Classification Trees. The best accuracy of predictions was achieved by one of the Classification Tree model, which was then used in the simulations leading to conversion of the missed melts to the expected grades. Two strategies of changing the input values (chemical composition) were tried: content of a single element at a time and simultaneous changes of a selected pair of elements. It was found that in the vast majority of the missed melts the changes of single elements concentrations have led to the change from the non-classified iron to its expected grade. In the case of the three remaining melts the simultaneous changes of pairs of the elements’ concentrations appeared to be successful and that those cases were in agreement with foundry staff expertise. It is concluded that utilizing an advanced data-driven process model can significantly facilitate diagnosis of defective products and out-of-control foundry processes.

Słowa kluczowe

EN

quality management; information technology; foundry industry; process fault diagnosis; ductile iron melting; data driven model

PL

zarządzanie jakością; technologia informacyjna; przemysł odlewniczy; diagnostyka uszkodzeń; topienie żeliwa

• Wydawca: Komisja Odlewnictwa Polskiej Akademii Nauk Oddział w Katowicach
• Czasopismo: Archives of Foundry Engineering
• Rocznik: 2017
• Tom: Vol. 17, iss. 4
• Strony: 123--126
• Opis fizyczny: Bibliogr. 11 poz., tab., wykr.

Twórcy

autor

Perzyk M.

• Institute of Manufacturing Technologies, Warsaw University of Technology, Narbutta 85, 02-524 Warszawa, Poland

autor

Werlaty M.

• Institute of Manufacturing Technologies, Warsaw University of Technology, Narbutta 85, 02-524 Warszawa, Poland

Bibliografia

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• [4] Tsang, K.F., Lau, H.C.W. & Kwok, S.K. (2007). Development of a data mining system for continual process quality improvement. Proc Inst Mech Eng Part B: J Eng Manuf, 221, 179–193.
• [5] Tseng, T.L., Jothishankar, M.C., Wu, T., Xing, G. & Jiang, F. (2004). Applying data mining approaches for defect diagnosis in manufacturing industry. In IIE Annual Conference and Exhibition, Institute of Industrial Engineers, 2004 (pp. 1441-1447). Houston, USA.
• [6] Vazan, P., Tanuska, P., Kebisek, M., Moravcik, O. (2012). Data Mining Model Building as a Support for Decision Making in Production Management. In Advances in Computer Science, Engineering & Applications, Proc. Second International Conference on Computer Science, Engineering and Applications (ICCSEA 2012), Vol. 1, (pp. 695–701). New Delhi, India, May 25 27, 2012.
• [7] Ghosh, S. & Maiti, J. (2014). Data mining driven DMAIC framework for improving foundry quality – a case study. Production Planning & Control. 25, 478-493.
• [8] Perzyk, M. & Kochanski, A. (2003). Detection of causes of casting defects assisted by artificial neural networks. Journal of Engineering Manufacture, Proceedings of the Institution of Mechanical Engineers, Part B. 217, 1279-1284.
• [9] Zhang, G. (1990). A new diagnosis theory with two kinds of quality. Total Quality Management. 1(2), 249-257.
• [10] Perzyk, M. & Kozlowski, J. (2016). Methodology of Fault Diagnosis in Ductile Iron Melting Process. Archives of Foundry Engineering, 16(4), 101-108.
• [11] Breiman, L., Friedman, J.H., Olshen, R.A., & Stone, C.J. (1984). Classification and regression trees. Monterey, CA: Wadsworth & Brooks/Cole Advanced Books & Software.

Uwagi

PL

Opracowanie ze środków MNiSW w ramach umowy 812/P-DUN/2016 na działalność upowszechniającą naukę (zadania 2017).