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  1. 6 Journal of Machine Engineering
  2. 3 Advances in Manufacturing Science and Technology
  3. 3 Eksploatacja i Niezawodność
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  5. 2 Archives of Civil and Mechanical Engineering
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  1. 2 Cechowicz R.
  2. 2 Czyżewski P.
  3. 2 Gnyba M.
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  5. 2 O'Donell G. E.
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  1. 1 2024
  2. 4 2022
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1
Content available Reconstruction-based stacked sparse auto-encoder for nonlinear industrial process fault diagnosis
Weng Qihang, Ren Shaojun, Zhu Baoyu, Jin Yinfeng, Si Fengqi
Eksploatacja i Niezawodność
|
2024
|
Vol. 26, no. 1
art. no. 175873
EN
The reconstruction-based (RB) approach can effectively suppress the misdiagnosis problem due to the smearing effect in fault isolation. However, the current exploration of the RB approach for large-scale nonlinear systems is still limited. Therefore, this paper proposes a reliable and effective fault diagnosis method based on a reconstruction-based stacked sparse autoencoder (RBSSAE) for high-dimensional industrial systems. In RBSSAE, a reconstruction-based index achieved by the Steffensen iterative method is developed to check whether the given variable(s) are responsible for the faults efficiently. However, the number of possible faulty variable combinations grows exponentially with the system dimensionor actual abnormal variables, causing an unbearable computational burden for variable combination optimization. Hence, the proposed RBSSAE utilizes a sequential floating forward selection approach to rapidly isolate the most decisive combination of fault variables, meeting a requirement of online fault diagnosis. Finally, the effectiveness of the RBSSAE is verified on a numerical example and a real industrial case. Comparisons with other state-of-the-art methods are also presented.
2
Content available Analysis of the maturity of process monitoring in manufacturing companies
Czerwińska Karolina, Pacana Andrzej
Production Engineering Archives
|
2022
|
Vol. 28, Iss. 3
245--251
EN
The economic progress of recent years has contributed to the fact that both the quality of products and services offered and ISO standardization have become priority criterion that determines the success of manufacturing enterprises. Therefore, the monitoring and supervision of processes carried out in manufacturing companies is a key issue. These aspects support the achievement of key economic and quality objectives. The paper presents the results of a study on manufacturing enterprises in the context of process monitoring maturity. The research objective of the study was to determine the level of maturity in the use of process monitoring techniques and methods in manufacturing enterprises. The subject of the research were the techniques and methods used by the surveyed enterprises in such areas as: production management, machinery park management, warehouse management, transport management, inventory and supply management and IT tools. In order to determine the level of maturity, the author’s model was used, according to which the level of maturity of a manufacturing enterprise in the area of process monitoring depends on the instrumentation that is used in it.
3
Content available Method of monitoring of the grinding process with lapping kinematics using audible sound analysis
Deja Mariusz
Journal of Machine Engineering
|
2022
|
Vol. 22, No. 4
71--81
EN
Utilising microphones as audible sound sensors for monitoring a single-side grinding process with lapping kinematics is presented in the paper. The audible sound generated during grinding depended on the cutting properties of electroplated tools with D107 diamond grains and different thicknesses of the nickel bond. The tool wear affected the obtained technological effects such as material removal rate and the surface roughness of Al2O3 ceramic samples. The relationship between the quantities that characterise the sound signal and the surface roughness of machined surfaces was examined with the use of spectral analysis of the sound signal in the frequency domain with a focus on the Ra parameter. The decreasing amplitude indicated a better surface finish, down to Ra = 0.23 μm. The developed method and the obtained results will facilitate the practical use of the electroplated tools in the lap-grinding technology without interrupting the process before obtaining the required surface roughness.
4
Content available Assessment of the modernized production system through selected TPM method indicators
Michlowicz Edward
Eksploatacja i Niezawodność
|
2022
|
Vol. 24, no. 4
677--686
EN
The subject of the studies is the evaluation of the operation of a production system after modernization. The analysed case concerns the modernization forced by the end of the product lifetime. The proposed methodology is that of a multicriterial evaluation of the system operation after modernization. The evaluation criteria are selected TPM indices: availability of machinery and equipment, production process capacity, product quality and overall equipment effectiveness (OEE). The additional criteria are reliability indices MTBF and MTTR of studied production lines and the MTTR of the most unreliable equipment in each analysed line. A yearly monitoring of production process was proposed for obtaining the statistical credibility of the evaluation results. Additionally, a fuzzy indicator of acceptability of the modernization assessment was proposed. The paper presents the results of studies of the system for production of zinc concentrate from post-production waste. The obtained values of OEE, MTBF and MTTR indicators for the three tested lines make it possible to state that the modernization carried out is acceptable.
5
Content available Intelligent Visual Quality Control System Based on Convolutional Neural Networks for Holonic Shop Floor Control of Industry 4.0 Manufacturing Systems
Oborski Przemysław, Wysocki Przemysław
Advances in Science and Technology. Research Journal
|
2022
|
Vol. 16, no 2
89--98
EN
The article presents research on industrial quality control system based on AI deep learning method. They are a part of larger project focusing on development of Holonic Shop Floor Control System for integration of machines, machine operators and manufacturing process monitoring with information flow in whole production process according to Industry 4.0 requirements. A system connecting together machine operators, machine control, process and machine monitoring with companywide IT systems is developed. It is an answer on manufacture of airplane industry requirements. The main aim of the system is full automation of information flow between a management level and manufacturing process level. Intelligent, flexible quality control system allowing for active manufacturing optimization on the base of achieved results as well as a historical data collection for further Big Data analysis is the main aim of the current research. During research number of selected AI algorithms were tested for assessing their suitability for performing tasks identified in real manufacturing environment. As a result of the conducted analyzes, Convolutional Neural Networks were selected for further study. Number of built Convolutional Neural Networks algorithms were tested using sets of data and photos from the production line. A further step of research will be focused on testing a system in real manufacturing process for able possible construct a fully functional quality control system based on the use of Convolutional Neural Networks.
6
Content available The identification method of the coal mill motor power model with the use of machine learning techniques
Łabęda-Grudziak Zofia Magdalena, Lipiński Mariusz
Bulletin of the Polish Academy of Sciences. Technical Sciences
|
2021
|
Vol. 69, nr 1
art. no. e135842
EN
The article presents an identification method of the model of the ball-and-race coal mill motor power signal with the use of machine learning techniques. The stages of preparing training data for model parameters identification purposes are described, as well as these aimed at verifying the quality of the evaluated model. In order to meet the tasks of machine learning, additive regression model was applied. Identification of the additive model parameters was performed on the basis of iterative backfitting algorithm combined with nonparametric estimation techniques. The proposed models have predictive nature and are aimed at simulation of the motor power signal of a coal mill during its regular operation, startup and shutdown. A comparative analysis has been performed of the models structured differently in terms of identification quality and sensitivity to the existence of an exemplary disturbance in the form of overhangs in the coal bunker. Tests carried out on the basis of real measuring data registered in the Polish power unit with a capacity of 200 MW confirm the effectiveness of the method.
7
Content available Process monitoring in end milling using polar figures
Goetz Sven, Schraknepper Daniel, Faustini Gabriel, Bergs Thomas
Journal of Machine Engineering
|
2020
|
Vol. 20, No. 3
95--105
EN
Knowledge of the tool wear state in machining has become an important issue in research and industrial application. Current systems use the spindle power or cutting force as measured variable and refer it to a taught set point. However, this method lacks the ability to adapt to new work piece geometries. A new approach focusses on the tool instead of the work piece, and uses a sensory tool holder with integrated strain gauges. This tool holder provides polar figures whose shapes relate to the engagement conditions and whose area is a function of the tool load. As the tool load increases with tool wear, the area of the polar figures provides information about the tool wear status, and with knowledge about the engagement conditions, the model can be calibrated.
8
Monitorowanie procesu fermentacji alkoholowej metodami instrumentalnymi
Trawczyńska Aleksandra, Ima Krzysztof, Jeleń Henryk
Analityka : nauka i praktyka
|
2020
|
nr 4
42--51
PL
Szybkie przeprowadzenie analiz wpływa bezpośrednio na optymalizację, wydajność i jakość produktu. Dlatego zastosowanie technik analitycznych jest jedynym i skutecznym rozwiązaniem kontroli procesu fermentacji alkoholowej.
9
Dlaczego warto się mierzyć? : poprawa procesu produkcyjnego poprzez wizualne zarządzanie miarami
Milewski K., Czerwiński K.
Surowce i Maszyny Budowlane
|
2018
|
nr 5
34--35
PL
Czy wyobrażasz sobie prowadzenie pojazdu bezpiecznie i zgodnie z przepisami bez deski rozdzielczej? Co w przypadku, gdy prowadzisz swoje procesy? Skąd wiesz, że wszystko jest wykonane poprawnie. Jeżeli jesteśmy po wdrożeniu w przedsiębiorstwie działań 6S i chcemy nadal pracować nad usprawnieniami naszych procesów w firmie, a co za tym idzie - ograniczeniem kosztów związanych z profilem naszej działalności - powinniśmy zacząć się "mierzyć".
10
Content available remote Modernizacja gniazda produkcyjnego zgodnie z koncepcją Industry 4.0 na przykładzie stanowiska do realizacji procesu wykrawania
Czyżewski P., Ernt M.
Przegląd Spawalnictwa
|
2018
|
R. 90, nr 1
21--24
PL
Koncepcja czwartej rewolucji przemysłowej sprowadza się do zwiększenia wydajności i elastyczności procesów produkcyjnych oraz poprawy jakości życia ludzi. Industry 4.0 dysponuje szeregiem narzędzi technicznych, które między innymi realizują funkcje komunikacji za pośrednictwem sieci Internet z elementami składowymi maszyny. Do realizacji pilotażowej modernizacji stanowiska produkcyjnego wykorzystano prasę mimośrodową Instytutu Technik Wytwarzania Politechniki Warszawskiej. Układ napędowy i sterownia zmodernizowano, zakładając wymianę kluczowych danych diagnostycznych z systemem sterowania nadrzędnego. Kolejno uruchomiono system akwizycji danych procesowych oparty o urządzenia Kistler maXYmos TL. Całość dopełnia system SCADA wraz z aplikacją administracyjną, które za pośrednictwem odpowiedniego aparatu matematycznego, dążą do realizacji koncepcji predyktywnego utrzymania ruchu i określenia zużycia narzędzia.
EN
The concept of the Industry 4.0 revolution is related to increasing efficiency, elasticity of production and improving the quality of life. Industry 4.0 has several technical tools that, implements communication between components of machine via the Internet. The mechanical press of the Institute of Manufacturing Technologies at Warsaw University of Technology was used to implement the pilot modernization to Industry 4.0 standard. The control and drive system were upgraded assuming exchange of key diagnostic data with the master control system. The process data acquisition system based on Kistler maXYmos TL was launched. The whole is complemented by SCADA system and administrative application, which using appropriate mathematical calculations realize the concept of predictive maintenance and calculates the tool wear.
11
Content available Integration of machine operators with shop floor control system for Industry 4.0
Oborski P.
Management and Production Engineering Review
|
2018
|
Vol. 9, No. 4
48--55
EN
Research focused on integration of machine operators with information flow in manufacturing process according to Industry 4.0 requirements are presented in this paper. A special IT system connecting together machine operators, machine control, process and machine monitoring with companywide IT systems is developed. It is an answer on manufacture of airplane industry requirements. The main aim of the system presented in the article is full automation of information flow between a management level represented by Integrated Management IT System and manufacturing process level. From the management level an information about particular orders are taken, back an on-line information about manufacturing process and manufactured parts are given. System allows automatic identification of tasks for machine operator and particular currently machined part. Operator can verify information about process and tasks. System allows on-line analyzing process data. It is based on information from machining acquired: machine operator, process and machine monitoring systems and measurement devices handled by operator. Process data is integrated with related order as a history of particular manufactured part. System allows for measurement data analysis based on Statistical Process Control algorithm dedicated for short batches. It supports operator in process control. Measurement data are integrated with order data as a part of history of manufactured product. Finally a conception of Cyber-Physical Systems applying in integrated Shop Floor Control and Monitoring systems is presented and discussed.
12
Modelowanie parametrów procesu wykrawania dla różnych stanów zużycia stempla
Czyżewski P., Kochański A., Moszczyński L.
Przegląd Mechaniczny
|
2016
|
nr 5
23--26
PL
W pracy przedstawiono wyniki modelowania numerycznego procesu wykrawania blach elektrotechnicznych dla różnych stanów zużycia narzędzia. Uzyskane wyniki modelowania zestawiono z wynikami pomiarów dla procesu rzeczywistego. Wyznaczone przebiegi sił działających na stempel posłużyły do ustalenia wskaźnika przyrostu zużycia (WPZ), który może zostać wykorzystany w autonomicznych systemach nadzorowania procesu wykrawania.
EN
Paper was presented the results of numerical modeling of blanking electrical sheet for different state of wear of the tools. Achieved modeling result was compared with the results of obtained for the real process. The designated process forces interacting with the punch was used to determine W index (coefficient intense of tool wear). It can be used in the autonomic monitoring system of blanking processes.
13
Content available remote Zastosowanie analizy sygnału emisji akustycznej do oceny jakości powierzchni uzyskiwanej w procesie przecinania strugą wodno-ścierną
Sutowski P., Sutowska M.
Mechanik
|
2016
|
R. 89, nr 8-9
1046--1047
PL
W artykule opisano możliwość zastosowania analizy sygnału emisji akustycznej do oceny jakości powierzchni uzyskiwanej w procesie cięcia wysokociśnieniową strugą wodno-ścierną. Otrzymane wyniki badań potwierdziły wyraźny wpływ warunków obróbki na strukturę geometryczną przecięć oraz zarejestrowane wartości emitowanych fal naprężeń.
EN
The article describes the possibility of using acoustic emission signal for the purpose of evaluation of the surface obtained in high-pressure abrasive waterjet cutting process. The obtained results showed a clear influence of the machining conditions on the geometric structure of the obtained cuts and the registered values of the stress waves.
14
Content available remote Wykorzystanie sieci Profibus-DP do określania stanu obrabiarki i procesu
Szulewski P., Kapeluszny T., Fularski R.
Mechanik
|
2016
|
R. 89, nr 8-9
1142--1143
PL
Wewnętrzna magistrala komunikacyjna obrabiarki może być interesującym źródłem aktualnych i precyzyjnych informacji o stanie maszyny i realizowanej obróbki. Omówiono samodzielnie wykonane oprogramowanie pozwalające na przechwytywanie informacji z wewnętrznej sieci Profibus-DP oraz zaprezentowano wyniki eksperymentu związanego z analizą pozyskanych danych. Poprawnie zinterpretowane dane zasilają zakładowy system informatyczny i ułatwiają skuteczne zarządzanie realizowanym procesem wytwarzania.
EN
For the purpose of accurate monitoring of production, there is necessary to use every available source of information. The internal communication bus machine can be an interesting, accurate and timely source of information about the machine state and process. The article discusses the self made software that allows to capture information from internal Profibus-DP and presents the results of an experiment related to the analysis of the acquired data.
15
Content available Integrated monitoring system of production processes
Oborski P.
Management and Production Engineering Review
|
2016
|
Vol. 7, No. 4
86--96
EN
Integrated monitoring system for discrete manufacturing processes is presented in the paper. The multilayer hardware and software reference model was developed. Original research are an answer for industry needs of the integration of information flow in production process. Reference model corresponds with proposed data model based on multilayer data tree allowing to describe orders, products, processes and save monitoring data. Elaborated models were implemented in the integrated monitoring system demonstrator developed in the project. It was built on the base of multiagent technology to assure high flexibility and openness on applying intelligent algorithms for data processing. Currently on the base of achieved experience an application integrated monitoring system for real production system is developed. In the article the main problems of monitoring integration are presented, including specificity of discrete production, data processing and future application of Cyber-Physical-Systems. Development of manufacturing systems is based more and more on taking an advantage of applying intelligent solutions into machine and production process control and monitoring. Connection of technical systems, machine tools and manufacturing processes monitoring with advanced information processing seems to be one of the most important areas of near future development. It will play important role in efficient operation and competitiveness of the whole production system. It is also important area of applying in the future CyberPhysical-Systems that can radically improve functionally of monitoring systems and reduce the cost of its implementation.
16
Content available Decision support and maintenance system for natural hazards, processes and equipment monitoring
Kozielski M., Sikora M., Wróbel Ł.
Eksploatacja i Niezawodność
|
2016
|
Vol. 18, no. 2
218--228
EN
This paper presents the DISESOR integrated decision support system and its applications. The system integrates data from different monitoring and dispatching systems and contains such modules as data preparation and cleaning, analytical, prediction and expert system. Architecture of the system is presented in the paper and a special focus is put on the presentation of two issues: data integration and cleaning, and creation of prediction model. The work contains also two case studies presenting the examples of the system application.
PL
W pracy przedstawiono zintegrowany system wspomagania decyzji DISESOR oraz jego zastosowania. System pozwala na integrację danych pochodzących z różnych systemów monitorowania i systemów dyspozytorskich. Struktura systemu DISESOR składa się z modułów realizujących: przygotowanie i czyszczenie danych, analizę danych, zadania predykcyjne oraz zadania systemu ekspertowego. W pracy przedstawiono architekturę systemu DISESOR, a szczególny nacisk został położony na zagadnienia związane z integracją i czyszczeniem danych oraz tworzeniem modeli predykcyjnych. Działanie systemu przedstawione zostało na dwóch przykładach analizy dla danych rzeczywistych.
17
Content available remote Potentials of in situ monitoring of aluminum alloy forging by acoustic emission
Behrens B. A., Bouguecha A., Buse C., Wolki K., Santangelo A.
Archives of Civil and Mechanical Engineering
|
2016
|
Vol. 16, no. 4
724--733
EN
Deviations during forging processes lead to workpiece failure when the forming limits of the material are exceeded. In production processes an early detection of manufacturing faults is preferred. The acoustic emission (AE) technique is examined with respect to its ability to detect deviations in lubrication conditions and in the structural integrity of different aluminum part geometries and alloys during forming. In a first step, an upsetting of varying specimen shapes was performed in order to study correlations of occurring defects as well as changing friction conditions with acoustic emission response. Afterwards, a cross joint was forged and AE was analyzed. The results suggest that crack detection during forging is feasible but limited by material ductility. In addition, it is shown that the characteristics of the acoustic emission during forming strongly depend on the respective alloy. With respect to faultless warm forging it is found that different stages are reflected in the AE signal, facilitating the detection of process deviations.
18
Content available A service-oriented reconfigurable process monitoring system - enabling cyber physical systems
Morgan J., O'Donell G. E.
Journal of Machine Engineering
|
2014
|
Vol. 14, No. 2
116--129
EN
Communication is an essential requirement for collaborative manufacturing systems. However the diversity of communication media and protocols in machine tools, automation equipment, and associated proprietary software, presents a challenge for enabling capable, extensible and re-configurable process monitoring systems. Additionally, as process control systems evolve from centralised hierarchical structures to decentralised heterarchical communities, enabling media and tools are required to provide interoperability between systems and subsystems. The focus of this research is to introduce a manufacturing decentralised process monitoring architecture that utilises a service-oriented architecture framework for network-wide dynamic data acquisition and distribution. The system design is created using a combination of service-oriented architecture topology and technical modelling. Service-oriented communication structure and capability is given particular focus, resulting in a comparative study of message structures and communication speeds. The resultant system is modular in structure, reconfigurable, network-distributable, interoperable, efficient, and meets real-time requirements.
19
Content available Data interoperability for reconfigurable manufacturing process monitoring systems
Morgan J., O'Driscoll J., O'Donell G. E.
Journal of Machine Engineering
|
2013
|
Vol. 13, No. 1
64--79
EN
The ability for manufacturing organisation to be responsive to changing market conditions is imperative for sustainable market competitiveness, and enabling self preservation. Responsive behaviour requires the incorporation of not only robust sustainable manufacturing process chains, but the functional capacity to facilitate reconfiguration and adaption. Manufacturing process chains require process monitoring and condition based monitoring systems to achieve high accuracy manufacturing systems, sustainable production capability, and resource efficiency. The focus of this research is aimed at developing a novel data interoperability architecture to enable the creation of reconfigurable process monitoring systems. To achieve reconfigurable process monitoring capability an information communication paradigm known as agent based design is reviewed, and an emerging agent based standard known as MTConnect is also reviewed. Through this research a novel data interoperability system is developed and defined to enable dynamic data acquisition for reconfigurable process monitoring. A case study is carried out to demonstrate the validity of the architecture to achieve multi data stream unification. This case study demonstrates the ability to actively condition monitor a HURCO VM2 three axis CNC machine dynamically, through the measurement of machine energy requirements and vibration, which are examples of process variables associated with condition based machine monitoring.
20
Content available Random projections and Hotelling’s T2 statistics for change detection in high-dimensional data streams
Skubalska-Rafajłowicz E.
International Journal of Applied Mathematics and Computer Science
|
2013
|
Vol. 23, no. 2
447--461
EN
The method of change (or anomaly) detection in high-dimensional discrete-time processes using a multivariate Hotelling chart is presented. We use normal random projections as a method of dimensionality reduction. We indicate diagnostic properties of the Hotelling control chart applied to data projected onto a random subspace of Rn. We examine the random projection method using artificial noisy image sequences as examples.
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