Application of Nonlinear PCA for Fault Detection in Polymer Extrusion Processes

This paper describes the application of an improved nonlinear principal component analysis (PCA) to the detection of faults in polymer extrusion processes. Since the processes are complex in nature and nonlinear relationships exist between the recorded variables, an improved nonlinear PCA, which incorporates the radial basis function (RBF) networks and principal curves, is proposed. This algorithm comprises two stages. The first stage involves the use of the serial principal curve to obtain the nonlinear scores and approximated data. The second stage is to construct two RBF networks using a fast recursive algorithm to solve the topology problem in traditional nonlinear PCA. The benefits of this improvement are demonstrated in the practical application to a polymer extrusion process.

Improved Nonlinear PCA for Process Monitoring Using Support Vector Data Description

Nonlinear principal component analysis (PCA) based on neural networks has drawn significant attention as a monitoring tool for complex nonlinear processes, but there remains a difficulty with determining the optimal network topology. This paper exploits the advantages of the Fast Recursive Algorithm, where the number of nodes, the location of centres, and the weights between the hidden layer and the output layer can be identified simultaneously for the radial basis function (RBF) networks. The topology problem for the nonlinear PCA based on neural networks can thus be solved. Another problem with nonlinear PCA is that the derived nonlinear scores may not be statistically independent or follow a simple parametric distribution. This hinders its applications in process monitoring since the simplicity of applying predetermined probability distribution functions is lost. This paper proposes the use of a support vector data description and shows that transforming the nonlinear principal components into a feature space allows a simple statistical inference. Results from both simulated and industrial data confirm the efficacy of the proposed method for solving nonlinear principal component problems, compared with linear PCA and kernel PCA.

Two-stage RBF network construction based on particle swarm optimization

The conventional radial basis function (RBF) network optimization methods, such as orthogonal least squares or the two-stage selection, can produce a sparse network with satisfactory generalization capability. However, the RBF width, as a nonlinear parameter in the network, is not easy to determine. In the aforementioned methods, the width is always pre-determined, either by trial-and-error, or generated randomly. Furthermore, all hidden nodes share the same RBF width. This will inevitably reduce the network performance, and more RBF centres may then be needed to meet a desired modelling specification. In this paper we investigate a new two-stage construction algorithm for RBF networks. It utilizes the particle swarm optimization method to search for the optimal RBF centres and their associated widths. Although the new method needs more computation than conventional approaches, it can greatly reduce the model size and improve model generalization performance. The effectiveness of the proposed technique is confirmed by two numerical simulation examples.

Non-parametric nonlinear system identification: A data-driven orthogonal basis function approach

In this paper, a data driven orthogonal basis function approach is proposed for non-parametric FIR nonlinear system identification. The basis functions are not fixed a priori and match the structure of the unknown system automatically. This eliminates the problem of blindly choosing the basis functions without a priori structural information. Further, based on the proposed basis functions, approaches are proposed for model order determination and regressor selection along with their theoretical justifications. © 2008 IEEE.

A new self-learning TLBO algorithm for RBF neural modelling of batteries in electric vehicles

One of the main purposes of building a battery model is for monitoring and control during battery charging/discharging as well as for estimating key factors of batteries such as the state of charge for electric vehicles. However, the model based on the electrochemical reactions within the batteries is highly complex and difficult to compute using conventional approaches. Radial basis function (RBF) neural networks have been widely used to model complex systems for estimation and control purpose, while the optimization of both the linear and non-linear parameters in the RBF model remains a key issue. A recently proposed meta-heuristic algorithm named Teaching-Learning-Based Optimization (TLBO) is free of presetting algorithm parameters and performs well in non-linear optimization. In this paper, a novel self-learning TLBO based RBF model is proposed for modelling electric vehicle batteries using RBF neural networks. The modelling approach has been applied to two battery testing data sets and compared with some other RBF based battery models, the training and validation results confirm the efficacy of the proposed method.

Forward and backward least angle regression for nonlinear system identification

A forward and backward least angle regression (LAR) algorithm is proposed to construct the nonlinear autoregressive model with exogenous inputs (NARX) that is widely used to describe a large class of nonlinear dynamic systems. The main objective of this paper is to improve model sparsity and generalization performance of the original forward LAR algorithm. This is achieved by introducing a replacement scheme using an additional backward LAR stage. The backward stage replaces insignificant model terms selected by forward LAR with more significant ones, leading to an improved model in terms of the model compactness and performance. A numerical example to construct four types of NARX models, namely polynomials, radial basis function (RBF) networks, neuro fuzzy and wavelet networks, is presented to illustrate the effectiveness of the proposed technique in comparison with some popular methods.

Neural network based control for synchronous generators

In this paper, a Radial Basis Function neural network based AVR is proposed. A control strategy which generates local linear models from a global neural model on-line is used to derive controller feedback gains based on the Generalised Minimum Variance technique. Testing is carried out on a micromachine system which enables evaluation of practical implementation of the scheme. Constraints imposed by gathering training data, computational load, and memory requirements for the training algorithm are addressed.

Advanced Modelling and Optimization of Infared Oven in Injection Stretch Blow-moulding for Energy Saving

In the production process of polyethylene terephthalate (PET) bottles, the initial temperature of preforms plays a central role on the final thickness, intensity and other structural properties of the bottles. Also, the difference between inside and outside temperature profiles could make a significant impact on the final product quality. The preforms are preheated by infrared heating oven system which is often an open loop system and relies heavily on trial and error approach to adjust the lamp power settings. In this paper, a radial basis function (RBF) neural network model, optimized by a two-stage selection (TSS) algorithm combined with partial swarm optimization (PSO), is developed to model the nonlinear relations between the lamp power settings and the output temperature profile of PET bottles. Then an improved PSO method for lamp setting adjustment using the above model is presented. Simulation results based on experimental data confirm the effectiveness of the modelling and optimization method.

Modelling the fresh properties of self-compacting concrete using support vector machine approach

The main objective of the study presented in this paper was to investigate the feasibility using support vector machines (SVM) for the prediction of the fresh properties of self-compacting concrete. The radial basis function (RBF) and polynomial kernels were used to predict these properties as a function of the content of mix components. The fresh properties were assessed with the slump flow, T50, T60, V-funnel time, Orimet time, and blocking ratio (L-box). The retention of these tests was also measured at 30 and 60 min after adding the first water. The water dosage varied from 188 to 208 L/m3, the dosage of superplasticiser (SP) from 3.8 to 5.8 kg/m3, and the volume of coarse aggregates from 220 to 360 L/m3. In total, twenty mixes were used to measure the fresh state properties with different mixture compositions. RBF kernel was more accurate compared to polynomial kernel based support vector machines with a root mean square error (RMSE) of 26.9 (correlation coefficient of R2 = 0.974) for slump flow prediction, a RMSE of 0.55 (R2 = 0.910) for T50 (s) prediction, a RMSE of 1.71 (R2 = 0.812) for T60 (s) prediction, a RMSE of 0.1517 (R2 = 0.990) for V-funnel time prediction, a RMSE of 3.99 (R2 = 0.976) for Orimet time prediction, and a RMSE of 0.042 (R2 = 0.988) for L-box ratio prediction, respectively. A sensitivity analysis was performed to evaluate the effects of the dosage of cement and limestone powder, the water content, the volumes of coarse aggregate and sand, the dosage of SP and the testing time on the predicted test responses. The analysis indicates that the proposed SVM RBF model can gain a high precision, which provides an alternative method for predicting the fresh properties of SCC.

Data-Driven Dynamic Modeling of Coupled Thermal and Electric Outputs of Microturbines

Microturbines are among the most successfully commercialized distributed energy resources, especially when they are used for combined heat and power generation. However, the interrelated thermal and electrical system dynamic behaviors have not been fully investigated. This is technically challenging due to the complex thermo-fluid-mechanical energy conversion processes which introduce multiple time-scale dynamics and strong nonlinearity into the analysis. To tackle this problem, this paper proposes a simplified model which can predict the coupled thermal and electric output dynamics of microturbines. Considering the time-scale difference of various dynamic processes occuring within microturbines, the electromechanical subsystem is treated as a fast quasi-linear process while the thermo-mechanical subsystem is treated as a slow process with high nonlinearity. A three-stage subspace identification method is utilized to capture the dominant dynamics and predict the electric power output. For the thermo-mechanical process, a radial basis function model trained by the particle swarm optimization method is employed to handle the strong nonlinear characteristics. Experimental tests on a Capstone C30 microturbine show that the proposed modeling method can well capture the system dynamics and produce a good prediction of the coupled thermal and electric outputs in various operating modes.

Data-Driven Dynamic Prediction of Interrelated Heat and Electric Outputs of Microturbines

Microturbines are among the most successfully commercialized distributed energy resources, especially when they are used for combined heat and power generation. However, the interrelated thermal and electrical system dynamic behaviors have not been fully investigated. This is technically challenging due to the complex thermo-fluid-mechanical energy conversion processes which introduce multiple time-scale dynamics and strong nonlinearity into the analysis. To tackle this problem, this paper proposes a simplified model which can predict the coupled thermal and electric output dynamics of microturbines. Considering the time-scale difference of various dynamic processes occuring within microturbines, the electromechanical subsystem is treated as a fast quasi-linear process while the thermo-mechanical subsystem is treated as a slow process with high nonlinearity. A three-stage subspace identification method is utilized to capture the dominant dynamics and predict the electric power output. For the thermo-mechanical process, a radial basis function model trained by the particle swarm optimization method is employed to handle the strong nonlinear characteristics. Experimental tests on a Capstone C30 microturbine show that the proposed modeling method can well capture the system dynamics and produce a good prediction of the coupled thermal and electric outputs in various operating modes.

Integrated structure selection and parameter optimisation for eng-genes neural models

The eng-genes concept involves the use of fundamental known system functions as activation functions in a neural model to create a 'grey-box' neural network. One of the main issues in eng-genes modelling is to produce a parsimonious model given a model construction criterion. The challenges are that (1) the eng-genes model in most cases is a heterogenous network consisting of more than one type of nonlinear basis functions, and each basis function may have different set of parameters to be optimised; (2) the number of hidden nodes has to be chosen based on a model selection criterion. This is a mixed integer hard problem and this paper investigates the use of a forward selection algorithm to optimise both the network structure and the parameters of the system-derived activation functions. Results are included from case studies performed on a simulated continuously stirred tank reactor process, and using actual data from a pH neutralisation plant. The resulting eng-genes networks demonstrate superior simulation performance and transparency over a range of network sizes when compared to conventional neural models. (c) 2007 Elsevier B.V. All rights reserved.

Molecular dynamics simulation model for the quantitative assessment of tool wear during single point diamond turning of cubic silicon carbide

Silicon carbide (SiC) is a material of great technological interest for engineering applications concerning hostile environments where silicon-based components cannot work (beyond 623 K). Single point diamond turning (SPDT) has remained a superior and viable method to harness process efficiency and freeform shapes on this harder material. However, it is extremely difficult to machine this ceramic consistently in the ductile regime due to sudden and rapid tool wear. It thus becomes non trivial to develop an accurate understanding of tool wear mechanism during SPDT of SiC in order to identify measures to suppress wear to minimize operational cost.

In this paper, molecular dynamics (MD) simulation has been deployed with a realistic analytical bond order potential (ABOP) formalism based potential energy function to understand tool wear mechanism during single point diamond turning of SiC. The most significant result was obtained using the radial distribution function which suggests graphitization of diamond tool during the machining process. This phenomenon occurs due to the abrasive processes between these two ultra hard materials. The abrasive action results in locally high temperature which compounds with the massive cutting forces leading to sp3–sp2 order–disorder transition of diamond tool. This represents the root cause of tool wear during SPDT operation of cubic SiC. Further testing led to the development of a novel method for quantitative assessment of the progression of diamond tool wear from MD simulations.

Molecular dynamics simulation of nanoindentation of Fe3C and tetrahedral Fe4C

Study of nanomechanical response of iron carbides is important because presence of iron carbides greatly influences the performance and longevity of steel components. This work contributes to the literature by exploring nanoindentation of nanocrystalline Fe3C and tetrahedral-Fe4C using molecular dynamics simulation. The chemical interactions of iron and carbon were described through an analytical bond order inter-atomic potential (ABOP) energy function. The indentations were performed at an indentation speed of 50 m/sec and a repeat trial was performed at 5 m/sec. Load-displacement (P-h) curve for both these carbides showed residual indentation depth and maximum indentation depth (hf/hmax) ratio to be higher than 0.7 i.e. a circumstance where Oliver and Pharr method was not appropriate to be applied to evaluate the material properties. Alternate evaluation revealed Fe3C to be much harder than Fe4C. Gibbs free energy of formation and radial distribution function, coupled with state of the average local temperature and von Mises stresses indicate the formation of a new phase of iron-carbide. Formation of this newer phase was found to be due to deviatoric strain rather than the high temperature induced in the substrate during nanoindentation

Can a carbon nano-coating resist metallic phase transformation in silicon substrate during nanoimpact?

Nanomechanical response of a silicon specimen coated with a sp3 crystalline carbon coating (1.8 nm thickness) was investigated using MD simulation. A sharp conical rigid tip was impacted at the speed of 50 m/sec up to a depth of ~80% of the coating thickness. Unlike pure silicon specimen, no metallic phase transformation was observed i.e. a thin coating was able to resist Si-I to Si-II metallic phase transformation signifying that the coating could alter the stress distribution and thereby the contact tribology of the substrate. The stress state of the system, radial distribution function and the load-displacement curve were all aligned with above observations