Utilizing the Internet of Things to promote energy awareness and efficiency at discrete production processes: Practices and methodology

El actual contexto de fabricación, con incrementos en los precios de la energía, una creciente preocupación medioambiental y cambios continuos en los comportamientos de los consumidores, fomenta que los responsables prioricen la fabricación respetuosa con el medioambiente. El paradigma del Internet de las Cosas (IoT) promete incrementar la visibilidad y la atención prestada al consumo de energía gracias tanto a sensores como a medidores inteligentes en los niveles de máquina y de línea de producción. En consecuencia es posible y sencillo obtener datos de consumo de energía en tiempo real proveniente de los procesos de fabricación, pero además es posible analizarlos para incrementar su importancia en la toma de decisiones. Esta tesis pretende investigar cómo utilizar la adopción del Internet de las Cosas en el nivel de planta de producción, en procesos discretos, para incrementar la capacidad de uso de la información proveniente tanto de la energía como de la eficiencia energética. Para alcanzar este objetivo general, la investigación se ha dividido en cuatro sub-objetivos y la misma se ha desarrollado a lo largo de cuatro fases principales (en adelante estudios). El primer estudio de esta tesis, que se apoya sobre una revisión bibliográfica comprehensiva y sobre las aportaciones de expertos, define prácticas de gestión de la producción que son energéticamente eficientes y que se apoyan de un modo preeminente en la tecnología IoT. Este primer estudio también detalla los beneficios esperables al adoptar estas prácticas de gestión. Además, propugna un marco de referencia para permitir la integración de los datos que sobre el consumo energético se obtienen en el marco de las plataformas y sistemas de información de la compañía. Esto se lleva a cabo con el objetivo último de remarcar cómo estos datos pueden ser utilizados para apalancar decisiones en los niveles de procesos tanto tácticos como operativos. Segundo, considerando los precios de la energía como variables en el mercado intradiario y la disponibilidad de información detallada sobre el estado de las máquinas desde el punto de vista de consumo energético, el segundo estudio propone un modelo matemático para minimizar los costes del consumo de energía para la programación de asignaciones de una única máquina que deba atender a varios procesos de producción. Este modelo permite la toma de decisiones en el nivel de máquina para determinar los instantes de lanzamiento de cada trabajo de producción, los tiempos muertos, cuándo la máquina debe ser puesta en un estado de apagada, el momento adecuado para rearrancar, y para pararse, etc. Así, este modelo habilita al responsable de producción de implementar el esquema de producción menos costoso para cada turno de producción. En el tercer estudio esta investigación proporciona una metodología para ayudar a los responsables a implementar IoT en el nivel de los sistemas productivos. Se incluye un análisis del estado en que se encuentran los sistemas de gestión de energía y de producción en la factoría, así como también se proporcionan recomendaciones sobre procedimientos para implementar IoT para capturar y analizar los datos de consumo. Esta metodología ha sido validada en un estudio piloto, donde algunos indicadores clave de rendimiento (KPIs) han sido empleados para determinar la eficiencia energética. En el cuarto estudio el objetivo es introducir una vía para obtener visibilidad y relevancia a diferentes niveles de la energía consumida en los procesos de producción. El método propuesto permite que las factorías con procesos de producción discretos puedan determinar la energía consumida, el CO2 emitido o el coste de la energía consumida ya sea en cualquiera de los niveles: operación, producto o la orden de fabricación completa, siempre considerando las diferentes fuentes de energía y las fluctuaciones en los precios de la misma. Los resultados muestran que decisiones y prácticas de gestión para conseguir sistemas de producción energéticamente eficientes son posibles en virtud del Internet de las Cosas. También, con los resultados de esta tesis los responsables de la gestión energética en las compañías pueden plantearse una aproximación a la utilización del IoT desde un punto de vista de la obtención de beneficios, abordando aquellas prácticas de gestión energética que se encuentran más próximas al nivel de madurez de la factoría, a sus objetivos, al tipo de producción que desarrolla, etc. Así mismo esta tesis muestra que es posible obtener reducciones significativas de coste simplemente evitando los períodos de pico diario en el precio de la misma. Además la tesis permite identificar cómo el nivel de monitorización del consumo energético (es decir al nivel de máquina), el intervalo temporal, y el nivel del análisis de los datos son factores determinantes a la hora de localizar oportunidades para mejorar la eficiencia energética. Adicionalmente, la integración de datos de consumo energético en tiempo real con datos de producción (cuando existen altos niveles de estandarización en los procesos productivos y sus datos) es esencial para permitir que las factorías detallen la energía efectivamente consumida, su coste y CO2 emitido durante la producción de un producto o componente. Esto permite obtener una valiosa información a los gestores en el nivel decisor de la factoría así como a los consumidores y reguladores. ABSTRACT In today‘s manufacturing scenario, rising energy prices, increasing ecological awareness, and changing consumer behaviors are driving decision makers to prioritize green manufacturing. The Internet of Things (IoT) paradigm promises to increase the visibility and awareness of energy consumption, thanks to smart sensors and smart meters at the machine and production line level. Consequently, real-time energy consumption data from the manufacturing processes can be easily collected and then analyzed, to improve energy-aware decision-making. This thesis aims to investigate how to utilize the adoption of the Internet of Things at shop floor level to increase energy–awareness and the energy efficiency of discrete production processes. In order to achieve the main research goal, the research is divided into four sub-objectives, and is accomplished during four main phases (i.e., studies). In the first study, by relying on a comprehensive literature review and on experts‘ insights, the thesis defines energy-efficient production management practices that are enhanced and enabled by IoT technology. The first study also explains the benefits that can be obtained by adopting such management practices. Furthermore, it presents a framework to support the integration of gathered energy data into a company‘s information technology tools and platforms, which is done with the ultimate goal of highlighting how operational and tactical decision-making processes could leverage such data in order to improve energy efficiency. Considering the variable energy prices in one day, along with the availability of detailed machine status energy data, the second study proposes a mathematical model to minimize energy consumption costs for single machine production scheduling during production processes. This model works by making decisions at the machine level to determine the launch times for job processing, idle time, when the machine must be shut down, ―turning on‖ time, and ―turning off‖ time. This model enables the operations manager to implement the least expensive production schedule during a production shift. In the third study, the research provides a methodology to help managers implement the IoT at the production system level; it includes an analysis of current energy management and production systems at the factory, and recommends procedures for implementing the IoT to collect and analyze energy data. The methodology has been validated by a pilot study, where energy KPIs have been used to evaluate energy efficiency. In the fourth study, the goal is to introduce a way to achieve multi-level awareness of the energy consumed during production processes. The proposed method enables discrete factories to specify energy consumption, CO2 emissions, and the cost of the energy consumed at operation, production and order levels, while considering energy sources and fluctuations in energy prices. The results show that energy-efficient production management practices and decisions can be enhanced and enabled by the IoT. With the outcomes of the thesis, energy managers can approach the IoT adoption in a benefit-driven way, by addressing energy management practices that are close to the maturity level of the factory, target, production type, etc. The thesis also shows that significant reductions in energy costs can be achieved by avoiding high-energy price periods in a day. Furthermore, the thesis determines the level of monitoring energy consumption (i.e., machine level), the interval time, and the level of energy data analysis, which are all important factors involved in finding opportunities to improve energy efficiency. Eventually, integrating real-time energy data with production data (when there are high levels of production process standardization data) is essential to enable factories to specify the amount and cost of energy consumed, as well as the CO2 emitted while producing a product, providing valuable information to decision makers at the factory level as well as to consumers and regulators.

Interactive Graphic Simulation: An Advanced Methodology to Improve the Teaching-Learning Process in Nuclear Engineering Education and Training

Nowadays, computer simulators are becoming basic tools for education and training in many engineering fields. In the nuclear industry, the role of simulation for training of operators of nuclear power plants is also recognized of the utmost relevance. As an example, the International Atomic Energy Agency sponsors the development of nuclear reactor simulators for education, and arranges the supply of such simulation programs. Aware of this, in 2008 Gas Natural Fenosa, a Spanish gas and electric utility that owns and operate nuclear power plants and promotes university education in the nuclear technology field, provided the Department of Nuclear Engineering of Universidad Politécnica de Madrid with the Interactive Graphic Simulator (IGS) of “José Cabrera” (Zorita) nuclear power plant, an industrial facility whose commercial operation ceased definitively in April 2006. It is a state-of-the-art full-scope real-time simulator that was used for training and qualification of the operators of the plant control room, as well as to understand and analyses the plant dynamics, and to develop, qualify and validate its emergency operating procedures.

Teaching Magnetic Design using CAD tools

Design of magnetic components is a multivariable problem. There are many different combinations of shapes, sizes and materials for the core with many diameters for the wires. So it is difficult to find the optimum design without a great number of iterations. Analytically only a few combinations are usually studied but it is very easy to take into account all the combinations using a CAD tool [1]. In this work the CAD tool used is PExprt (ANSYS [2]) which is being developed at UPMCEI.

Using Virtual Reality in the teaching of manufacturing processes with material removal in CNC Machine-Tools

This paper presents a methodology for the incorporation of a Virtual Reality development applied to the teaching of manufacturing processes, namely the group of machining processes in numerical control of machine tools. The paper shows how it is possible to supplement the teaching practice through virtual machine-tools whose operation is similar to the 'real' machines while eliminating the risks of use for both users and the machines.

The Experience of Helicopters subject-course in the OCW-UPM Project. A Proposal on Technology Dissemination.

An experience developed by the authors in the design of educational tools, funded on multimedia support for using in teaching, will be presented. These tools have been used on the subject of Helicopters, http://ocw.upm.es/ingenieriaaeroespacial/ helicopteros at the Universidad Politécnica de Madrid (E.U.I.T. Aeronáutica). Throughout more than ten years, these didactical and educational elements have been defined and developed. It has the singularity that most of them have been designed for undergraduate students, as a part of their end of degree projectwork. This peculiarity has led to a wide range of proposals and solutions, as well as an appropriate approach. depending on the level of knowledge. The evolution of tools for developing these materials will be presented, discussing advantages and disadvantages. Finally, we will advance the new materials which are being prepared at present.

The online case study development for the teaching of building structures reinforcement

The Reinforcement of Building Structures is one of the topics of the Master in Building Innovation Technology (MBIT) of Universidad Politécnica de Madrid (UPM). Since the beginning of the delivery of this master, case studies have been chosen as the teaching methodology. For the 2011-2012 course the online education of this subject was implemented, instead of the classical learning based on attendance. Through ICT’s (Information and Communication Technologies) students are provided with much more and more selective information than through the classical learning. ICT’s can be used for search, enquiries and reporting. Using the online tools has been proved, through the results obtained and based on the surveys made amongst students, to be a successful experience.

Las Infraestructuras de Datos Espaciales (IDE) como un recurso educativo TIC . Estrategias de formación y difusión para el profesorado de la Educación Secundaria Obligatoria

Desde mediados de los 90, gracias a las posibilidades de la World Wide Web, se liberó la cartografía de su dependencia del medio físico, posibilitando el acceso y visualización de millones de mapas almacenados en formatos gráficos a través de Internet. En este contexto, el papel de la Información Geográfica (IG) en la vida cotidiana adquirió relevancia en la medida que el acceso a la misma resultaba cada vez más fácil gracias a múltiples herramientas y aplicaciones para distribuir y acercar los mapas en distintos formatos a la sociedad en general. Sin embargo, dado que esa información enseguida pasaba a estar desactualizada, surgió una demanda desde distintos ámbitos (seguridad, medio ambiente transporte, servicios, etc.) y de la sociedad en general para disponer de la información más actual. Como respuesta a esta demanda, surgen las iniciativas denominadas Infraestructuras de Datos Espaciales (IDE). Estas iniciativas, mediante la acción coordinada de un conjunto de tecnologías, estándares, normas y políticas, brindan la posibilidad a los usuarios de acceder, a través de Internet, a IG actualizada producida por instituciones y organismos oficiales, en un marco colaborativo y sustentada en una estructura organizativa. En este contexto, el ámbito educativo no ha permanecido ajeno representando uno de los espacios más propicios para la difusión de las potencialidades y usos de las IDE. En esta tesis se propone la utilización de las IDE en el contexto educativo, específicamente en la Educación Secundaria Obligatoria (ESO). Utilizar las IDE en el contexto educativo implica asignarle un papel en el proceso de enseñanza-aprendizaje y en el marco de esta tesis se presentan los fundamentos teóricos que permiten afirmar que las IDE son un re-curso educativo que responde a las características de las Tecnologías de la Información y la Comunicación (TIC). Esto se explicita a través de un concepto más amplio que hemos denominado “recurso educativo TIC”. En este contexto se analizan las posibilidades que ofrece las IDE para alcanzar los objetivos de aprendizaje de asignaturas de la ESO relacionadas con IG y se identifican contenidos susceptibles de ser abordados utilizándolas. Por otra parte, atendiendo al modelo educativo del aprendizaje basado en competencias, se exponen las posibilidades y potencialidades que ofrecen las IDE para desarrollar la competencia digital. Una vez planteado el marco teórico se desarrollaron dos estrategias de formación y difusión de las IDE orientadas al profesorado de la ESO. En primer lugar, utilizando el Modelo de Diseño Instruccional ADDIE, se diseñaron, desarrollaron, implementaron y evaluaron tres cursos e-learning para el profesorado de ESO de las asignaturas Ciencias Sociales, Ciencias de la Naturaleza y Tecnología. En segundo lugar, con objetivo de complementar los resultados obtenidos de los cursos e-learning, se realizó una actividad en dos Institutos de Educación Secundaria orientada a difundir las IDE. La puesta en práctica de estas estrategias ofreció al profesorado la información necesaria sobre qué son las IDE y proporcionó ejemplos concretos de uso de las mismas en su asignatura, permitiéndoles disponer de los conocimientos e información para emitir una valoración sobre las posibilidades que ofrecen las IDE como un recurso educativo TIC. Since about the middle of the 1990 decade, owing to the potential of the World Wide Web, cartography freed itself from its dependence on its physical support, enabling the access and visualisation of millions of maps stored in graphical formats through the Internet. In this context, the role of Geographic Information (GI) in daily life became relevant in as much as its access turned out to be ever easier due to multiple tools and applications to distribute and bring maps in different formats closer to society in general. Yet, since the information available often became outdated, a demand for updated information arose from different specific fields (security, environment, transport, services, etc.) and from the general public. As a response to this demand, the so-called Spatial Data Infrastructure (SDI) initiatives arose which, through the coordinated action of a set of technologies, stan-dards, and policies, enabled users to access updated GI created by organisations and official institutions, through the Internet, within a cooperative framework and an organisational structure. In this context the educational world has not remained aloof, since it represented one of the most propitious scope for the dissemination of the potentials and uses of SDI. In this thesis the utilization of SDI in the educational context is proposed, specifically in the Spanish Compulsory Secondary Education (Educación Secundaria Obligatoria – ESO). This utilization implies assigning SDI a role in the teaching-learning process; here the theo-retical foundation is presented which allows asserting that SDI is an educational resource fitting in with the characteristics of the Information and Communication Technologies (ICT). This is made explicit by means of a broader concept we have called “ICT educa-tional resource”. The possibilities offered by SDI to reach the objective of learning ESO subjects related to GI are analyzed, and contents apt to be addressed by using them are identified. On the other hand, attending to the educational model of learning based on competences, the possibilities and potentials the SDI offer to develop the digital compe-tence are exposed. After having set forth the theoretical frame, two strategies of training and dissemination of SDI were developed, oriented to the ESO teaching staff. First, using the ADDIE Instruc-tional Design Model, three learning courses were designed, developed, implemented and evaluated for the ESO teaching staff in the subjects of Social Sciences, Natural Sciences and Technology. In the second place, with the purpose of supplementing the results ob-tained from the e-learning courses, an activity was carried out in two High Schools, ori-ented to disseminate the SDI. The implementation of these strategies offered the teaching staff the needed information concerning the SDI and provided specific instances of utilisa-tion thereof in their subject, thus enabling them to acquire the knowledge and information to issue an assessment of the possibilities the SDI offer as an ICT educational resource

Innovative tools to address drought risk in grazing lands

Drought spells can impose severe impacts in most vulnerable farms. It is well known that uninsured exposure exacerbates income inequality in farming systems. However, high administrative costs of traditional insurance hinder small farmers? access to risk management tools. The existence of moral hazard and systemic risk prevents the implementation of traditional insurance programs to address drought risk in rural areas. Innovative technologies like satellite images are being used to derive vegetation index which are highly correlated with drought impacts. The implementation of this technology in agricultural insurance may help to overcome some of the limitations of traditional insurance. However, basis risk has been identified as one of the main problems that hinder the acceptance of index insurance. In this paper we focus on the analyses of basis risk under different contract options in the grazing lands of the Araucanía region. A vegetation index database is used to develop an actuarial insurance model and estimate risk premiums for moderate and severe drought coverage. Risk premium sharply increases with risk coverage. In contrast with previous findings in the literature, our results are not conclusive and show that lowering the coverage level does not necessarily imply a reduction in basis risk. Further analyses of the relation between contract design and basis risk is a promising area of research that may render an important social utility for most vulnerable farming systems.

A new way of teaching different subjects in a foreign language in the Building Engineering Degree at the Universidad Politécnica.

The European Union has been promoting linguistic diversity for many years as one of its main educational goals. This is an element that facilitates student mobility and student exchanges between different universities and countries and enriches the education of young undergraduates. In particular, a higher degree of competence in the English language is becoming essential for engineers, architects and researchers in general, as English has become the lingua franca that opens up horizons to internationalisation and the transfer of knowledge in today’s world. Many experts point to the Integrated Approach to Contents and Foreign Languages System as being an option that has certain benefits over the traditional method of teaching a second language that is exclusively based on specific subjects. This system advocates teaching the different subjects in the syllabus in a language other than one’s mother tongue, without prioritising knowledge of the language over the subject. This was the idea that in the 2009/10 academic year gave rise to the Second Language Integration Programme (SLI Programme) at the Escuela Arquitectura Técnica in the Universidad Politécnica Madrid (EUATM-UPM), just at the beginning of the tuition of the new Building Engineering Degree, which had been adapted to the European Higher Education Area (EHEA) model. This programme is an interdisciplinary initiative for the set of subjects taught during the semester and is coordinated through the Assistant Director Office for Educational Innovation. The SLI Programme has a dual goal; to familiarise students with the specific English terminology of the subject being taught, and at the same time improve their communication skills in English. A total of thirty lecturers are taking part in the teaching of eleven first year subjects and twelve in the second year, with around 120 students who have voluntarily enrolled in a special group in each semester. During the 2010/2011 academic year the degree of acceptance and the results of the SLI Programme have been monitored. Tools have been designed to aid interdisciplinary coordination and to analyse satisfaction, such as coordination records and surveys. The results currently available refer to the first and second year and are divided into specific aspects of the different subjects involved and into general aspects of the ongoing experience.

The state of semantic technology today - overview of the first SEALS evaluation campaigns

This paper describes the first five SEALS Evaluation Campaigns over the semantic technologies covered by the SEALS project (ontology engineering tools, ontology reasoning tools, ontology matching tools, semantic search tools, and semantic web service tools). It presents the evaluations and test data used in these campaigns and the tools that participated in them along with a comparative analysis of their results. It also presents some lessons learnt after the execution of the evaluation campaigns and draws some final conclusions.

Teaching digital control of switch mode power supplier

This paper explains the methodology followed to teach the subject `Digital control of power converters'. This subject belongs to the research master on `Industrial Electronics' of the Universidad Politécnica de Madrid. The subject is composed of several theoretical lessons plus the development of an actual digital control. For that purpose an ad hoc dc-dc converter has been designed and built. The use of this board together with some software tools seems a very powerful way for the students to learn the concepts from the design to the real world

Student Reciprocal Peer Teaching as a Method for Active Learning: An Experience in an Electrotechnical Laboratory

Active learning is one of the most efficient mechanisms for learning, according to the psychology of learning. When students act as teachers for other students, the communication is more fluent and knowledge is transferred easier than in a traditional classroom. This teaching method is referred to in the literature as reciprocal peer teaching. In this study, the method is applied to laboratory sessions of a higher education institution course, and the students who act as teachers are referred to as ‘‘laboratory monitors.’’ A particular way to select the monitors and its impact in the final marks is proposed. A total of 181 students participated in the experiment, experiences with laboratory monitors are discussed, and methods for motivating and training laboratory monitors and regular students are proposed. The types of laboratory sessions that can be led by classmates are discussed. This work is related to the changes in teaching methods in the Spanish higher education system, prompted by the Bologna Process for the construction of the European Higher Education Area

CP debugging needs and tools

Conventional programming techniques are not well suited for solving many highly combinatorial industrial problems, like scheduling, decision making, resource allocation or planning. Constraint Programming (CP), an emerging software technology, offers an original approach allowing for efficient and flexible solving of complex problems, through combined implementation of various constraint solvers and expert heuristics. Its applications are increasingly elded in various industries.

TELMA: Technology enhanced learning environment for minimally invasive surgery

Background: Cognitive skills training for minimally invasive surgery has traditionally relied upon diverse tools, such as seminars or lectures. Web technologies for e-learning have been adopted to provide ubiquitous training and serve as structured repositories for the vast amount of laparoscopic video sources available. However, these technologies fail to offer such features as formative and summative evaluation, guided learning, or collaborative interaction between users. Methodology: The "TELMA" environment is presented as a new technology-enhanced learning platform that increases the user's experience using a four-pillared architecture: (1) an authoring tool for the creation of didactic contents; (2) a learning content and knowledge management system that incorporates a modular and scalable system to capture, catalogue, search, and retrieve multimedia content; (3) an evaluation module that provides learning feedback to users; and (4) a professional network for collaborative learning between users. Face validation of the environment and the authoring tool are presented. Results: Face validation of TELMA reveals the positive perception of surgeons regarding the implementation of TELMA and their willingness to use it as a cognitive skills training tool. Preliminary validation data also reflect the importance of providing an easy-to-use, functional authoring tool to create didactic content. Conclusion: The TELMA environment is currently installed and used at the Jesús Usón Minimally Invasive Surgery Centre and several other Spanish hospitals. Face validation results ascertain the acceptance and usefulness of this new minimally invasive surgery training environment.

Initiatives and facilities for E&T in the nuclear science and technology master at UPM

The present Master/Doctorate in Nuclear Science and Technology programme implemented in the Department of Nuclear Engineering of the Universidad Politécnica de Madrid (NED-UPM) has the excellence qualification by the Spanish Ministry of Education. One of the main of this programme is the training for the development of methodologies of simulation, design and advanced analysis, including experimental tools, necessary in research and in professional work in the nuclear field.