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The Internet of Things and AI-based optimization within the Industry 4.0 paradigm

Mikołajewski Dariusz, Czerniak Jacek M., Piechowiak Maciej, Węgrzyn-Wolska Katarzyna, Kacprzyk Janusz

Bulletin of the Polish Academy of Sciences. Technical Sciences

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2024

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Vol. 72, nr 1

art. no. e147346

EN

By reviewing the current state of the art, this paper opens a Special Section titled “The Internet of Things and AI-driven optimization in the Industry 4.0 paradigm”. The topics of this section are part of the broader issues of integration of IoT devices, cloud computing, big data analytics, and artificial intelligence to optimize industrial processes and increase efficiency. It also focuses on how to use modern methods (i.e. computerization, robotization, automation, machine learning, new business models, etc.) to integrate the entire manufacturing industry around current and future economic and social goals. The article presents the state of knowledge on the use of the Internet of Things and optimization based on artificial intelligence within the Industry 4.0 paradigm. The authors review the previous and current state of knowledge in this field and describe known opportunities, limitations, directions for further research, and industrial applications of the most promising ideas and technologies, considering technological, economic, and social opportunities.

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A Concept of an SME Focused Edge Computing Self-managing Cyber-physical System

Stadnicka Dorota, Bonci Andrea, Longhi Sauro, Pirani Massimiliano, Dec Grzegorz

Management and Production Engineering Review

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2023

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Vol. 14, No. 3

3--15

EN

The dynamically changing environment forces companies to introduce changes in production processes and the need for employees to adapt quickly to new tasks. Therefore, it is expected to implement solutions to support employees. The system that will manage the work on a manufacturing line should work in real time to support the ongoing activities and, to be implemented in SMEs, must not be expensive. The authors identified important system components and expected functionalities. The methodology of the work is based on humancentered design. A concept of a cyber-physical system is proposed. The aim of the proposed edge computing-based system is to manage the work on the manufacturing line in which certain elements communicate with each other to achieve common goals. The paper presents what the system can consist of, how information and knowledge are managed in the system, and what can be the benefits for enterprises from its implementation.

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Cyber-physical test environment for the identification of interacting wear effects in feed axes

Bott Alexander, Stöbel Robin, Osen Gregor, Fleischer Jürgen

Journal of Machine Engineering

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2023

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Vol. 23, No. 1

123--132

EN

For a comprehensive optimization and control of production processes, cyber-physical systems are necessary to include machines' time-dependent properties. These wear effects in machine tools, especially the feed axes, can significantly influence the process quality and are a steady research focus. However, the interaction of wear effects between different feed axes has received little attention. Especially models that represent the combined wear influence of different interacting feed axes on the control parameters and machine dynamics hold great potential. To close this knowledge gap, this paper proposes a cyber-physical test environment to identify the interaction of wear effects in feed axes. For this test environment, the relevant boundary conditions of different feed axes in machine tools and their systematic interaction are presented. Through these conditions, a physical test setup is derived and, analogous to this, a virtual model is created. This holistic approach represents the physical and virtual interaction between different components.

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Fault diagnosis of induction motors: an architecture for real-time assessment as a cyber-physical system

Pal Ranjan Sasti Charan, Dewangan Nagesh, Mohanty Amiya Ranjan

Engineering Transactions

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2023

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Vol. 71, iss. 1

23--42

EN

Induction motors (IMs) have a crucial and significant role in various industrial sectors. With the prolonged operation of IMs, faults tend to develop that can be classified into five major categories, i.e., broken rotor bars, stator winding faults, air-gap eccentricity, bearing faults, and load torque fluctuations. If the faults go undetected, it may lead to catastrophic failure. Hence, the predictive-based condition monitoring technique has evolved as a real-time fault diagnosis that exploits the revolutionary idea of cyber-physical system (CPS). Furthermore, motor current signature analysis (MCSA) is a non-invasive fault diagnosis technique of a motor that can be used to investigate the presence of five fault types. However, the major constraint that industries face today is the on-field implementation of MCSA-based fault diagnosis involving CPS-based architecture, executed in an automated manner. Hence, the present article depicts algorithms that aim at real-time monitoring of IMs through a CPS framework. The proposed methodology is automated, does not involve any human intervention, and has been validated with real-time experiments, depicting its effectiveness and practicality.

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Disassembly-free metrological control of analog-to-digital converter parameters

Bubela Tetiana, Kochan Roman, Więcław Łukasz, Yatsuk Vasyl, Kuts Victor, Yatsuk Jurij

Metrology and Measurement Systems

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2022

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Vol. 29, nr 4

669--684

EN

The authors update the issue disassembly-free control and correction of all components of the error of measuring channels with multi-bit analog-to-digital converters (ADCs). The main disadvantages of existing methods for automatic control of the parameters of multi-bit ADCs, in particular their nonlinearity, are identified. Methods for minimizing instrumental errors and errors caused by limited internal resistances of closed switches, input and output resistances of active elements are investigated. The structures of devices for determining the multiplicative and nonlinear components of the error of multi-bit ADCs based on resistive dividers built on single-nominal resistors are proposed and analyzed. The authors propose a method for the correction of additive, multiplicative and nonlinear components of the error at each of the specified points of the conversion range during non-disassembly control of the ADC with both types of inputs. The possibility of non-disassembly control, as well as correction of multiplicative and nonlinear components of the error of multi-bit ADCs in the entire range of conversion during their on-site control is proven. ADC error correction procedures are proposed. These procedures are practically invariant to the non-informative parameters of active structures with resistive dividers composed of single-nominal resistors. In the article the prospects of practical implementation of the method of error correction during non-dismantling control of ADC parameters using the possibilities provided by modern microelectronic components are shown. The ways to minimize errors are proposed and the requirements to the choice of element parameters for the implementation of the proposed technical solutions are given. It is proved that the proposed structure can be used for non-disassembly control of multiplicative and nonlinear components of the error of precision instrumentation amplifiers.