Modelling, simulation and optimization of maintenance considerations on condition based maintenance

Globalization has increased the pressure on organizations and companies to operate in the most efficient and economic way. This tendency promotes that companies concentrate more and more on their core businesses, outsource less profitable departments and services to reduce costs. By contrast to earlier times, companies are highly specialized and have a low real net output ratio. For being able to provide the consumers with the right products, those companies have to collaborate with other suppliers and form large supply chains. An effect of large supply chains is the deficiency of high stocks and stockholding costs. This fact has lead to the rapid spread of Just-in-Time logistic concepts aimed minimizing stock by simultaneous high availability of products. Those concurring goals, minimizing stock by simultaneous high product availability, claim for high availability of the production systems in the way that an incoming order can immediately processed. Besides of design aspects and the quality of the production system, maintenance has a strong impact on production system availability. In the last decades, there has been many attempts to create maintenance models for availability optimization. Most of them concentrated on the availability aspect only without incorporating further aspects as logistics and profitability of the overall system. However, production system operator���s main intention is to optimize the profitability of the production system and not the availability of the production system. Thus, classic models, limited to represent and optimize maintenance strategies under the light of availability, fail. A novel approach, incorporating all financial impacting processes of and around a production system, is needed. The proposed model is subdivided into three parts, maintenance module, production module and connection module. This subdivision provides easy maintainability and simple extendability. Within those modules, all aspect of production process are modeled. Main part of the work lies in the extended maintenance and failure module that offers a representation of different maintenance strategies but also incorporates the effect of over-maintaining and failed maintenance (maintenance induced failures). Order release and seizing of the production system are modeled in the production part. Due to computational power limitation, it was not possible to run the simulation and the optimization with the fully developed production model. Thus, the production model was reduced to a black-box without higher degree of details.

Manutenzione su condizione e analisi dei ricambi per macchine automatiche nell���ottica industria 4.0. Il caso SACMI S.C.

In questo elaborato di tesi si affronta uno studio inerente alla Manutenzione su Condizione (CBM), applicata ad una macchina automatica adibita alla produzione di capsule in plastica, in collaborazione con il gruppo SACMI S.C. di Imola. Nel Capitolo 1 viene fornita una introduzione sul tema della manutenzione e sulla sua evoluzione dalla prima rivoluzione industriale ad oggi. Nel Capitolo 2 vengono descritti i principi teorici della manutenzione predittiva e se ne analizza lo stato dell���arte. Nel Capitolo 3 viene fornita una introduzione sull���azienda SACMI S.C. e in seguito vengono descritte nel dettaglio le macchine sulle quali si sono concentrate le successive analisi. Nel Capitolo 4 viene approfondito l���estrusore, uno dei componenti principali delle macchine analizzate. Nel Capitolo 5 viene presentato un esempio di valutazione dell���efficienza di alcune macchine collegate in serie attraverso il calcolo di un indicatore chiamato Overall Equipment Effectiveness (OEE). Il Capitolo 6 rappresenta il cuore della tesi e contiene tutte le analisi di CBM effettuate durante il periodo di tirocinio. Vengono analizzati i principali gruppi funzionali della macchina a partire da quelli pi�� critici per tempi o costi di manutenzione. Le analisi sono state condotte ricercando all���interno di tutto il parco macchine quelle che presentavano delle condizioni di funzionamento sospette. Nel Capitolo 7 vengono presentate alcune analisi relative ai tempi di fermo macchina dovuti alle manutenzioni preventive e ai costi dei ricambi previsti dal manuale di manutenzione. Queste analisi vengono poi declinate su un caso reale nel quale si calcola il costo dei ricambi negli ultimi cinque anni distinguendo tra costi dovuti ad azioni preventive o correttive. Nel Capitolo 8 vengono presentate le conclusioni, mentre nel Capitolo 9 sono presentati gli sviluppi futuri di questo lavoro.

Analisi dei guasti di un termovalorizzatore

L���obiettivo del presente lavoro di tesi �� stato quello di effettuare, tramite l���applicazione di una metodologia RBM ��� Risk Based Maintenance, l���analisi dei guasti avvenuti nel biennio 2012-2013 nel termovalorizzatore di rifiuti solidi urbani di Modena gestito dalla societ�� Herambiente.

World Class Manufacturing : approccio ad un sistema di manutenzione predittiva (CBM)

L���oggetto di analisi del presente lavoro di tesi �� il modello di Operational Excellence noto come World Class Manufacturing in particolare l���approccio allo step 6 del pilastro Professional Maintenance, dove si richiede l���implementazione di un sistema di manutenzione PREDITTIVA, la cosiddetta CBM (Conditional Based Maintenance) . Il modello a cui si fa riferimento fu teorizzato dal professore giapponese H. Yamashina verso la met�� degli anni 2000 e giunse in Italia attorno al 2005, quando Fiat Group (oggi FCA) lo adott�� come approccio standard alla gestione della produzione. Questo tipo di analisi, orientata verso una prospettiva pratica pi�� che teorica, deriva direttamente da un���esperienza sul campo che ho svolto all���interno di un���azienda che ha aderito al World Class Manufacturing (WCM). Nel capitolo 1 verr�� proposto un excursus delle metodologie alla base del WCM e del percorso storico che ha portato alla formulazione del modello. Nel secondo capitolo verr�� proposto un caso di applicazione del WCM all'interno di un Gruppo, nella fattispecie Ariston Thermo Group (ATG). Dopo un���overview sul Gruppo e sulla storia della sua adesione al programma di miglioramento, la trattazione si focalizza sull'approccio di ATG al WCM. Nel terzo capitolo verr�� introdotta la Manutenzione Professionale secondo le principali politiche manutentive schematizzate dal WCM. Verranno presentate singolarmente per sottolineare i loro obiettivi seguiti dai vantaggi e svantaggi che si possono ottenere nell���implementare ogni singola politica. Nel quarto capitolo verranno specificate sotto un aspetto prettamente pratico le varie attivit�� svolte dalla PM cos�� da evidenziare lo sviluppo e il miglioramento continuo che essa sta ottenendo dall���introduzione del WCM; principalmente la presentazione delle varie attivit�� si riferiscono al passaggio allo step 6 della PM, dove verr�� presentata approfonditamente elencando e analizzando tutte le attivit�� svolte per approcciarsi alla CBM.

Space charge and dielectric response measurements to assess insulation aging of low-voltage cables used in nuclear power plants

The current design life of nuclear power plant (NPP) could potentially be extended to 80 years. During this extended plant life, all safety and operationally relevant Instrumentation & Control (I&C) systems are required to meet their designed performance requirements to ensure safe and reliable operation of the NPP, both during normal operation and subsequent to design base events. This in turn requires an adequate and documented qualification and aging management program. It is known that electrical insulation of I&C cables used in safety related circuits can degrade during their life, due to the aging effect of environmental stresses, such as temperature, radiation, vibration, etc., particularly if located in the containment area of the NPP. Thus several condition monitoring techniques are required to assess the state of the insulation. Such techniques can be used to establish a residual lifetime, based on the relationship between condition indicators and ageing stresses, hence, to support a preventive and effective maintenance program. The object of this thesis is to investigate potential electrical aging indicators (diagnostic markers) testing various I&C cable insulations subjected to an accelerated multi-stress (thermal and radiation) aging.

A Phase Space Box-counting based Method for Arrhythmia Prediction from Electrocardiogram Time Series

Arrhythmia is one kind of cardiovascular diseases that give rise to the number of deaths and potentially yields immedicable danger. Arrhythmia is a life threatening condition originating from disorganized propagation of electrical signals in heart resulting in desynchronization among different chambers of the heart. Fundamentally, the synchronization process means that the phase relationship of electrical activities between the chambers remains coherent, maintaining a constant phase difference over time. If desynchronization occurs due to arrhythmia, the coherent phase relationship breaks down resulting in chaotic rhythm affecting the regular pumping mechanism of heart. This phenomenon was explored by using the phase space reconstruction technique which is a standard analysis technique of time series data generated from nonlinear dynamical system. In this project a novel index is presented for predicting the onset of ventricular arrhythmias. Analysis of continuously captured long-term ECG data recordings was conducted up to the onset of arrhythmia by the phase space reconstruction method, obtaining 2-dimensional images, analysed by the box counting method. The method was tested using the ECG data set of three different kinds including normal (NR), Ventricular Tachycardia (VT), Ventricular Fibrillation (VF), extracted from the Physionet ECG database. Statistical measures like mean (��), standard deviation (��) and coefficient of variation (��/��) for the box-counting in phase space diagrams are derived for a sliding window of 10 beats of ECG signal. From the results of these statistical analyses, a threshold was derived as an upper bound of Coefficient of Variation (CV) for box-counting of ECG phase portraits which is capable of reliably predicting the impeding arrhythmia long before its actual occurrence. As future work of research, it was planned to validate this prediction tool over a wider population of patients affected by different kind of arrhythmia, like atrial fibrillation, bundle and brunch block, and set different thresholds for them, in order to confirm its clinical applicability.

Laser shock peening treatment to control and moderate fatigue crack growth in aircraft structure based on residual stress engineering approach

Laser Shock Peening (LSP) is a surface enhancement treatment which induces a significant layer of beneficial compressive residual stresses of up to several mm underneath the surface of metal components in order to improve the detrimental effects of the crack growth behavior rate in it. The aim of this thesis is to predict the crack growth behavior in metallic specimens with one or more stripes which define the compressive residual stress area induced by the Laser Shock Peening treatment. The process was applied as crack retardation stripes perpendicular to the crack propagation direction with the object of slowing down the crack when approaching the peened stripes. The finite element method has been applied to simulate the redistribution of stresses in a cracked model when it is subjected to a tension load and to a compressive residual stress field, and to evaluate the Stress Intensity Factor (SIF) in this condition. Finally, the Afgrow software is used to predict the crack growth behavior of the component following the Laser Shock Peening treatment and to detect the improvement in the fatigue life comparing it to the baseline specimen. An educational internship at the ���Research & Technologies Germany ��� Hamburg��� department of AIRBUS helped to achieve knowledge and experience to write this thesis. The main tasks of the thesis are the following: ���To up to date Literature Survey related to ���Laser Shock Peening in Metallic Structures��� ���To validate the FE model developed against experimental measurements at coupon level ���To develop design of crack growth slowdown in Centered Cracked Tension specimens based on residual stress engineering approach using laser peened strip transversal to the crack path ���To evaluate the Stress Intensity Factor values for Centered Cracked Tension specimens after the Laser Shock Peening treatment via Finite Element Analysis ���To predict the crack growth behavior in Centered Cracked Tension specimens using as input the SIF values evaluated with the FE simulations ���To validate the results by means of experimental tests

Content and English Language Integrated Learning: The use of Moodle in Aircraft Maintenance Training Programs

The aim of this work is to develop a prototype of an e-learning environment that can foster Content and Language Integrated Learning (CLIL) for students enrolled in an aircraft maintenance training program, which allows them to obtain a license valid in all EU member states. Background research is conducted to retrace the evolution of the field of educational technology, analyzing different learning theories ��� behaviorism, cognitivism, and (socio-)constructivism ��� and reflecting on how technology and its use in educational contexts has changed over time. Particular attention is given to technologies that have been used and proved effective in Computer Assisted Language Learning (CALL). Based on the background research and on students��� learning objectives, i.e. learning highly specialized contents and aeronautical technical English, a bilingual approach is chosen, three main tools are identified ��� a hypertextbook, an exercise creation activity, and a discussion forum ��� and the learning management system Moodle is chosen as delivery medium. The hypertextbook is based on the technical textbook written in English students already use. In order to foster text comprehension, the hypertextbook is enriched by hyperlinks and tooltips. Hyperlinks redirect students to webpages containing additional information both in English and in Italian, while tooltips show Italian equivalents of English technical terms. The exercise creation activity and the discussion forum foster interaction and collaboration among students, according to socio-constructivist principles. In the exercise creation activity, students collaboratively create a workbook, which allow them to deeply analyze and master the contents of the hypertextbook and at the same time create a learning tool that can help them, as well as future students, to enhance learning. In the discussion forum students can discuss their individual issues, content-related, English-related or e-learning environment-related, helping one other and offering instructors suggestions on how to improve both the hypertextbook and the workbook based on their needs.

Synthesis, characterization and crystallization of bionanocomposites based on PLLA, PCL and nanocellulose

In recent years, environmental concerns and the expected shortage in the fossil reserves have increased further development of biomaterials. Among them, poly(lactide) PLA possess some potential properties such as good ability process, excellent tensile strength and stiffness equivalent to some commercial petroleum-based polymers (PP, PS, PET, etc.). This biobased polymer is also biodegradable and biocompatible However, one great disadvantage of commercial PLA is slow crystallization rate, which restricts its use in many fields. Using of nanofillers is viewed as an efficient strategy to overcome this problem. In this thesis, the effect of bionanofillers in neat PLA and in blends of poly (L-lactide)(PLA)/poly(��-Caprolactone) (PCL) has been investigated. The used nanofillers are: poly(L-lactide-co-��-caprolactone) and poly(L-lactide-b-��-caprolactone) grafted on cellulose nanowhiskers and neat cellulose nanowhiskers (CNW). The grafting reaction of poly(L-lactide-co-caprolactone) and poly (L-lactide-b-caprolactone) on the nanocellulose has been performed by the grafting from technique. In this way the polymerization reaction it is directly initiated on the substrate surface. The condition of the reaction were chosen after a temperature and solvent screening. By non-isothermal an isothermal DSC analysis the effect of bionanofillers on PLA and 80/20 PLA/PCL was evaluated. Non-isothermal DSC scans show a nucleating effect of the bionanofillers on PLA. This effect is detectable during PLA crystallization from the glassy state. Cold crystallization temperature is reduced upon the addition of the poly(L-lactide-b-caprolactone) grafted on cellulose nanowhiskers that is most performing bionanofiller in acting as a nucleating agent. On the other hand, DSC isothermal analysis on the overall crystallization rate indicate that cellulose nanowhiskers are best nucleating agents during isothermal crystallization from the melt state. In conclusion, nanofillers have different behavior depending on the processing conditions. However, the efficiency of our nanofillers as nucleating agent was clearly demonstrated in both isothermal as in non-isothermal condition.

Sensor-based evaluation of Circadian motor behavior in people with Dementia. Development and validation of analysis strategies

[ITA]La demenza consiste nel deterioramento, spesso progressivo, dello stato cognitivo di un individuo. Chi �� affetto da demenza, presenta alterazioni a livello cognitivo, comportamentale e motorio, ad esempio compiendo gesti ossessivi, ripetitivi, senza uno scopo preciso. La condizione dei pazienti affetti da demenza �� valutata clinicamente tramite apposite scale e le informazioni relative al comportamento vengono raccolte intervistando chi se ne occupa, come familiari, il personale infermieristico o il medico curante. Spesso queste valutazioni si rivelano inaccurate, possono essere fortemente influenzate da considerazioni soggettive, e sono dispendiose in termini di tempo. Si ha quindi l'esigenza di disporre di metodiche oggettive per valutare il comportamento motorio dei pazienti e le sue alterazioni patologiche; i sensori inerziali indossabili potrebbero costituire una valida soluzione, per questo scopo. L'obiettivo principale della presente attivit�� di tesi �� stato definire e implementare un software per una valutazione oggettiva, basata su sensori, del pattern motorio circadiano, in pazienti affetti da demenza ricoverati in un'unit�� di terapia a lungo termine, che potrebbe evidenziare differenze nei sintomi della malattia che interessano il comportamento motorio, come descritto in ambito clinico. Lo scopo secondario �� stato quello di verificare i cambiamenti motori pre- e post-intervento in un sottogruppo di pazienti, a seguito della somministrazione di un programma sperimentale di intervento basato su esercizi fisici. --------------- [ENG]Dementia involves deterioration, often progressive, of a person's cognitive status. Those who suffer from dementia, present alterations in cognitive and motor behavior, for example performing obsessive and repetitive gestures, without a purpose. The condition of patients suffering from dementia is clinically assessed by means of specific scales and information relating to the behavior are collected by interviewing caregivers, such as the family, nurses, or the doctor. Often it turns out that these are inaccurate assessments that may be heavily influenced by subjective evaluations and are costly in terms of time. Therefore, there is the need for objective methods to assess the patients' motor behavior and the pathological changes; wearable inertial sensors may represent a viable option, so this aim. The main objective of this thesis project was to define and implement a software for a sensor-based assessment of the circadian motor pattern in patients suffering from dementia, hospitalized in a long-term care unit, which could highlight differences in the disease symptoms affecting the motor behavior, as described in the clinical setting. The secondary objective was to verify pre- and post-intervention changes in the motor patterns of a subgroup of patients, following the administration of an experimental program of intervention based on physical exercises.

Bionanocomposites based on Plla, Pcl and montmorillonite: synthesis, characterization and crystallization

Poly(lactide) is one of the best candidate to replace conventional petroleum-based polymers, since it is biobased, biocompatible and biodegradable. However, commercial PLA materials typically have low crystallization rate resulting in long processing time and low production efficiency. In this work the effects of two nanofillers MMT30B and MMT30B-g-P(LA-co-CL) on the crystallization rate of neat PLA and PLA/PCL blend were investigated. MMT30B-g-P(LA-co-CL) was synthetized by in situ grafting reaction. The synthesis was carried in xylene at 140��C, upon the results of a screening. The grafted copolymers were evaluated by 1H-NMR ,ATR���IR and TGA. Solvent casted films were obtained by mixing MMT30B-g-P(LA-co-CL) at 5% (w/w) with neat PLA and PLA/PCL blend, comparing the properties with the corresponding blends with and without a 5% of (w/w) unmodified clay. SEM images on PLA based blends shows that MMT30B is aggregated into larger particles compared to MMT30B-g-P(LLA-co-CL). This behavior is correlated to the better exfoliation of MMT30B-g-P(LA-co-CL) clay layers. SEM images on PLA/PCL based blends exhibit the typical sea-island morphology, characteristic of immiscible blends. PLA is the matrix while PCL is finely dispersed in droplets. MMT30B does not reduce PCL droplets size, while MMT30B-g-P(LA-co-CL) reduces the size of PCL droplets. This means that MMT30B-g-P(LA-co-CL) can migrate to the PLA-PCL interface, acting as a compatibilizer. Non-isothermal DSC cooling scans show a fractionated crystallization of the PCL phase in PLA/PCL/MMT30B-g-P(LA-co-CL), confirming the compatibilizer effect of MMT30B-g-P(LA-co-CL). At the same timeMMT30B-g-P(LA-co-CL) can better nucleate the PLA phase, both in neat PLA and PLA/PCL blend, promoting the crystallization during the heating scans. In isothermal condition, both the nanofillers increase the crystallization rate of PLA phase in neat PLA, while in PLA/PCL blends the effect is covered by the nucleating effect of PCL.

Finite Element Modeling of Spiral Frequency Steerable Acoustic Transducers (FSATs) for guided waves based Structural Health Monitoring of plate-like structures

Structural Health Monitoring (SHM) is an emerging area of research associated to improvement of maintainability and the safety of aerospace, civil and mechanical infrastructures by means of monitoring and damage detection. Guided wave structural testing method is an approach for health monitoring of plate-like structures using smart material piezoelectric transducers. Among many kinds of transducers, the ones that have beam steering feature can perform more accurate surface interrogation. A frequency steerable acoustic transducer (FSATs) is capable of beam steering by varying the input frequency and consequently can detect and localize damage in structures. Guided wave inspection is typically performed through phased arrays which feature a large number of piezoelectric transducers, complexity and limitations. To overcome the weight penalty, the complex circuity and maintenance concern associated with wiring a large number of transducers, new FSATs are proposed that present inherent directional capabilities when generating and sensing elastic waves. The first generation of Spiral FSAT has two main limitations. First, waves are excited or sensed in one direction and in the opposite one (180 �� ambiguity) and second, just a relatively rude approximation of the desired directivity has been attained. Second generation of Spiral FSAT is proposed to overcome the first generation limitations. The importance of simulation tools becomes higher when a new idea is proposed and starts to be developed. The shaped transducer concept, especially the second generation of spiral FSAT is a novel idea in guided waves based of Structural Health Monitoring systems, hence finding a simulation tool is a necessity to develop various design aspects of this innovative transducer. In this work, the numerical simulation of the 1st and 2nd generations of Spiral FSAT has been conducted to prove the directional capability of excited guided waves through a plate-like structure.

Analysis ot the road barriers maintenance: the Bologna Case Study

This thesis deals with the topic of Road Safety when maintaining its road elements. The aim of the work is the prioritization of maintenance for each barrier that depends on some factors that are related to the topography of the site, deformations, degradation of the composing elements, and the compliance of the barrier installation with the original situation. Based on these components a final coefficient by which the maintenance priority was highlighted, calculated, and associated to each barrier. For easy study and visualization, information was uploaded and processed in a GIS environment, in order to create analyses and choropleth maps. Analyses were exploited by using free and open-source GIS software, namely QGIS. Information on the barriers' features was registered with both on-site and online (i.e., web mapping providers) inspections. With regards to the on-site inspections, a complete geotagged photos database was created, in order to improve the survey. GIS potentialities were fully exploited by applying some geoprocessing tools which allowed deep analyses.

Acquisition of Vibration Signals for Predictive Maintenance: a Practical Case

As predictive maintenance becomes more and more relevant in industrial environment, the possible range of applications for this maintenance strategy grows. The progresses in components technology and their reduction in price, together with the late years' advances in machine learning and in computational power, are making the implementation of predictive maintenance possible in plants where it would have previously been unreasonably costly. This is leading major pharmaceutical industries to explore the possibility of the application of condition monitoring systems on progressively less and less critical equipment. The focus of this thesis is on the implementation of a system to gather vibrational data from the motors installed in a pre-existing machine using off-the-shelf components. The final goal for the system is to provide the necessary vibration data, in the form of frequency spectra, to a machine learning system developed by IMA Digital, which will be leveraging such data to predict possible upcoming faults and to give the final client all the information necessary to plan maintenance activity according to the estimated machine condition.

Studio del comportamento meccanico e tribologico della lega AlSi10Mg prodotta mediante Laser-based Powder Bed Fusion sottoposta ad un ciclo tecnologico ottimizzato

AlSi10Mg alloy is one of the most widely used alloys for producing structural components by Laser-based Powder Fusion (L-PBF) technology due to the high mechanical and technological properties. The present work aims to characterize mechanically and tribologically the L-PBF AlSi10Mg alloy subjected to both heat treatment and surface modification cycles. Specifically, the effects of three heat treatments on the tribological and mechanical properties of the alloy were analyzed: T5 (artificial aging at 160 ��C for 4 h), T6 rapid solution heat treatment (solution heat treatment at 510 ��C for 1h and aging at 160 ��C for 6 h), and T6 benchmark (solution heat treatment at 540 ��C for 1h and aging at 160 ��C for 4 h), the latter used as a benchmark. The study highlighted how the better balance between strength and ductility properties induced by the introduction of heat treatments leads to lower wear resistance and not significant variations in the friction coefficient of the alloy. The tribological and mechanical behavior of the alloy coated with two different coating structures, consisting of (i) chemical Ni (Ni-P) and (ii) Ni-P + DLC, was also evaluated. The goal was the identification of a deposition cycle such as to guarantee the optimization of the mechanical and tribological behavior of the alloy. The Ni-P coating provided good wear resistance but an increase in the coefficient of friction. In contrast, using the DLC top coating resulted in excellent tribological performance in wear resistance and friction coefficient. The samples characterized by the Ni-P + DLC multilayer coating were subsequently subjected to mechanical characterization. The results obtained highlighted problems of adhesion and incipient breaking of the material due to the different mechanical behavior of the coating, considerably reducing the mechanical performance of the alloy coated with Ni-P+DLC multilayer solution compared to the specimens in the un-coated condition.