Deep hole drilling with twist drills: aspects of the CNC process and its real time monitoring and adaptive control

Deep hole drilling is one of the most complicated metal cutting processes and one of the most difficult to perform on CNC machine-tools or machining centres under conditions of limited manpower or unmanned operation. This research work investigates aspects of the deep hole drilling process with small diameter twist drills and presents a prototype system for real time process monitoring and adaptive control; two main research objectives are fulfilled in particular : First objective is the experimental investigation of the mechanics of the deep hole drilling process, using twist drills without internal coolant supply, in the range of diarneters Ø 2.4 to Ø4.5 mm and working length up to 40 diameters. The definition of the problems associated with the low strength of these tools and the study of mechanisms of catastrophic failure which manifest themselves well before and along with the classic mechanism of tool wear. The relationships between drilling thrust and torque with the depth of penetration and the various machining conditions are also investigated and the experimental evidence suggests that the process is inherently unstable at depths beyond a few diameters. Second objective is the design and implementation of a system for intelligent CNC deep hole drilling, the main task of which is to ensure integrity of the process and the safety of the tool and the workpiece. This task is achieved by means of interfacing the CNC system of the machine tool to an external computer which performs the following functions: On-line monitoring of the drilling thrust and torque, adaptive control of feed rate, spindle speed and tool penetration (Z-axis), indirect monitoring of tool wear by pattern recognition of variations of the drilling thrust with cumulative cutting time and drilled depth, operation as a data base for tools and workpieces and finally issuing of alarms and diagnostic messages.

Reaction Kinetics and Viscosity Modelling in the Fusion Syntheses of Ca- and Ca/Mg-resinates

Rosin is a natural product from pine forests and it is used as a raw material in resinate syntheses. Resinates are polyvalent metal salts of rosin acids and especially Ca- and Ca/Mg- resinates find wide application in the printing ink industry. In this thesis, analytical methods were applied to increase general knowledge of resinate chemistry and the reaction kinetics was studied in order to model the non linear solution viscosity increase during resinate syntheses by the fusion method. Solution viscosity in toluene is an important quality factor for resinates to be used in printing inks. The concept of critical resinate concentration, c crit, was introduced to define an abrupt change in viscosity dependence on resinate concentration in the solution. The concept was then used to explain the non-inear solution viscosity increase during resinate syntheses. A semi empirical model with two estimated parameters was derived for the viscosity increase on the basis of apparent reaction kinetics. The model was used to control the viscosity and to predict the total reaction time of the resinate process. The kinetic data from the complex reaction media was obtained by acid value titration and by FTIR spectroscopic analyses using a conventional calibration method to measure the resinate concentration and the concentration of free rosin acids. A multivariate calibration method was successfully applied to make partial least square (PLS) models for monitoring acid value and solution viscosity in both mid-infrared (MIR) and near infrared (NIR) regions during the syntheses. The calibration models can be used for on line resinate process monitoring. In kinetic studies, two main reaction steps were observed during the syntheses. First a fast irreversible resination reaction occurs at 235 °C and then a slow thermal decarboxylation of rosin acids starts to take place at 265 °C. Rosin oil is formed during the decarboxylation reaction step causing significant mass loss as the rosin oil evaporates from the system while the viscosity increases to the target level. The mass balance of the syntheses was determined based on the resinate concentration increase during the decarboxylation reaction step. A mechanistic study of the decarboxylation reaction was based on the observation that resinate molecules are partly solvated by rosin acids during the syntheses. Different decarboxylation mechanisms were proposed for the free and solvating rosin acids. The deduced kinetic model supported the analytical data of the syntheses in a wide resinate concentration region, over a wide range of viscosity values and at different reaction temperatures. In addition, the application of the kinetic model to the modified resinate syntheses gave a good fit. A novel synthesis method with the addition of decarboxylated rosin (i.e. rosin oil) to the reaction mixture was introduced. The conversion of rosin acid to resinate was increased to the level necessary to obtain the target viscosity for the product at 235 °C. Due to a lower reaction temperature than in traditional fusion synthesis at 265 °C, thermal decarboxylation is avoided. As a consequence, the mass yield of the resinate syntheses can be increased from ca. 70% to almost 100% by recycling the added rosin oil.

Multivariate quality control studies applied to Ca(II) and Mg(II) determination by a portable method

A portable or field test method for simultaneous spectrophotometric determination of calcium and magnesium in water using multivariate partial least squares (PLS) calibration methods is proposed. The method is based on the reaction between the analytes and methylthymol blue at pH 11. The spectral information was used as the X-block, and the Ca(II) and Mg(II) concentrations obtained by a reference technique (ICP-AES) were used as the Y-block. Two series of analyses were performed, with a month's difference between them. The first series was used as the calibration set and the second one as the validation set. Multivariate statistical process control (MSPC) techniques, based on statistics from principal component models, were used to study the features and evolution with time of the spectral signals. Signal standardization was used to correct the deviations between series. Method validation was performed by comparing the predictions of the PLS model with the reference Ca(II) and Mg(II) concentrations determined by ICP-AES using the joint interval test for the slope and intercept of the regression line with errors in both axes. (C) 1998 John Wiley & Sons, Ltd.

Artificial neural network associated to UV/Vis spectroscopy for monitoring bioreactions in biopharmaceutical processes

Currently, mammalian cells are the most utilized hosts for biopharmaceutical production. The culture media for these cell lines include commonly in their composition a pH indicator. Spectroscopic techniques are used for biopharmaceutical process monitoring, among them, UV–Vis spectroscopy has found scarce applications. This work aimed to define artificial neural networks architecture and fit its parameters to predict some nutrients and metabolites, as well as viable cell concentration based on UV–Vis spectral data of mammalian cell bioprocess using phenol red in culture medium. The BHK-21 cell line was used as a mammalian cell model. Off-line spectra of supernatant samples taken from batches performed at different dissolved oxygen concentrations in two bioreactor configurations and with two pH control strategies were used to define two artificial neural networks. According to absolute errors, glutamine (0.13 ± 0.14 mM), glutamate (0.02 ± 0.02 mM), glucose (1.11 ± 1.70 mM), lactate (0.84 ± 0.68 mM) and viable cell concentrations (1.89 105 ± 1.90 105 cell/mL) were suitably predicted. The prediction error averages for monitored variables were lower than those previously reported using different spectroscopic techniques in combination with partial least squares or artificial neural network. The present work allows for UV–VIS sensor development, and decreases cost related to nutrients and metabolite quantifications.

Mikrobielle Prozesskontrolle in Biogasanlagen durch Monitoring der Kohlenstoff-Isotopenverhältnisse im Gasbereich

Der zunehmende Anteil von Strom aus erneuerbaren Energiequellen erfordert ein dynamisches Konzept, um Spitzenlastzeiten und Versorgungslücken aus der Wind- und Solarenergie ausgleichen zu können. Biogasanlagen können aufgrund ihrer hohen energetischen Verfügbarkeit und der Speicherbarkeit von Biogas eine flexible Energiebereitstellung ermöglichen und darüber hinaus über ein „Power-to-Gas“-Verfahren bei einem kurzzeitigen Überschuss von Strom eine Überlastung des Stromnetzes verhindern. Ein nachfrageorientierter Betrieb von Biogasanlagen stellt jedoch hohe Anforderungen an die Mikrobiologie im Reaktor, die sich an die häufig wechselnden Prozessbedingungen wie der Raumbelastung im Reaktor anpassen muss. Eine Überwachung des Fermentationsprozesses in Echtzeit ist daher unabdingbar, um Störungen in den mikrobiellen Gärungswegen frühzeitig erkennen und adäquat entgegenwirken zu können. rnBisherige mikrobielle Populationsanalysen beschränken sich auf aufwendige, molekularbiologische Untersuchungen des Gärsubstrates, deren Ergebnisse dem Betreiber daher nur zeitversetzt zur Verfügung stehen. Im Rahmen dieser Arbeit wurde erstmalig ein Laser-Absorptionsspektrometer zur kontinuierlichen Messung der Kohlenstoff-Isotopenverhältnisse des Methans an einer Forschungsbiogasanlage erprobt. Dabei konnten, in Abhängigkeit der Raumbelastung und Prozessbedingungen variierende Isotopenverhältnisse gemessen werden. Anhand von Isolaten aus dem untersuchten Reaktor konnte zunächst gezeigt werden, dass für jeden Methanogenesepfad (hydrogeno-troph, aceto¬klastisch sowie methylotroph) eine charakteristische, natürliche Isotopensignatur im Biogas nachgewiesen werden kann, sodass eine Identifizierung der aktuell dominierenden methanogenen Reaktionen anhand der Isotopen-verhältnisse im Biogas möglich ist. rnDurch den Einsatz von 13C- und 2H-isotopen¬markierten Substraten in Rein- und Mischkulturen und Batchreaktoren, sowie HPLC- und GC-Unter¬suchungen der Stoffwechselprodukte konnten einige bislang unbekannte C-Flüsse in Bioreaktoren festgestellt werden, die sich wiederum auf die gemessenen Isotopenverhältnisse im Biogas auswirken können. So konnte die Entstehung von Methanol sowie dessen mikrobieller Abbauprodukte bis zur finalen CH4-Bildung anhand von fünf Isolaten erstmalig in einer landwirtschaftlichen Biogasanlage rekonstruiert und das Vorkommen methylotropher Methanogenesewege nachgewiesen werden. Mithilfe molekularbiologischer Methoden wurden darüber hinaus methanoxidierende Bakterien zahlreicher, unbekannter Arten im Reaktor detektiert, deren Vorkommen aufgrund des geringen O2-Gehaltes in Biogasanlagen bislang nicht erwartet wurde. rnDurch die Konstruktion eines synthetischen DNA-Stranges mit den Bindesequenzen für elf spezifische Primerpaare konnte eine neue Methode etabliert werden, anhand derer eine Vielzahl mikrobieller Zielorganismen durch die Verwendung eines einheitlichen Kopienstandards in einer real-time PCR quantifiziert werden können. Eine über 70 Tage durchgeführte, wöchentliche qPCR-Analyse von Fermenterproben zeigte, dass die Isotopenverhältnisse im Biogas signifikant von der Zusammensetzung der Reaktormikrobiota beeinflusst sind. Neben den aktuell dominierenden Methanogenesewegen war es auch möglich, einige bakterielle Reaktionen wie eine syntrophe Acetatoxidation, Acetogenese oder Sulfatreduktion anhand der δ13C (CH4)-Werte zu identifizieren, sodass das hohe Potential einer kontinuierlichen Isotopenmessung zur Prozessanalytik in Biogasanlagen aufgezeigt werden konnte.rn

Development of New Structural Health Monitoring Techniques

During the past two decades, many researchers have developed methods for the detection of structural defects at the early stages to operate the aerospace vehicles safely and to reduce the operating costs. The Surface Response to Excitation (SuRE) method is one of these approaches developed at FIU to reduce the cost and size of the equipment. The SuRE method excites the surface at a series of frequencies and monitors the propagation characteristics of the generated waves. The amplitude of the waves reaching to any point on the surface varies with frequency; however, it remains consistent as long as the integrity and strain distribution on the part is consistent. These spectral characteristics change when cracks develop or the strain distribution changes. The SHM methods may be used for many applications, from the detection of loose screws to the monitoring of manufacturing operations. A scanning laser vibrometer was used in this study to investigate the characteristics of the spectral changes at different points on the parts. The study started with detecting a load on a plate and estimating its location. The modifications on the part with manufacturing operations were detected and the Part-Based Manufacturing Process Performance Monitoring (PbPPM) method was developed. Hardware was prepared to demonstrate the feasibility of the proposed methods in real time. Using low-cost piezoelectric elements and the non-contact scanning laser vibrometer successfully, the data was collected for the SuRE and PbPPM methods. Locational force, loose bolts and material loss could be easily detected by comparing the spectral characteristics of the arriving waves. On-line methods used fast computational methods for estimating the spectrum and detecting the changing operational conditions from sum of the squares of the variations. Neural networks classified the spectrums when the desktop – DSP combination was used. The results demonstrated the feasibility of the SuRE and PbPPM methods.

Development of New Structural Health Monitoring Techniques

During the past two decades, many researchers have developed methods for the detection of structural defects at the early stages to operate the aerospace vehicles safely and to reduce the operating costs. The Surface Response to Excitation (SuRE) method is one of these approaches developed at FIU to reduce the cost and size of the equipment. The SuRE method excites the surface at a series of frequencies and monitors the propagation characteristics of the generated waves. The amplitude of the waves reaching to any point on the surface varies with frequency; however, it remains consistent as long as the integrity and strain distribution on the part is consistent. These spectral characteristics change when cracks develop or the strain distribution changes. The SHM methods may be used for many applications, from the detection of loose screws to the monitoring of manufacturing operations. A scanning laser vibrometer was used in this study to investigate the characteristics of the spectral changes at different points on the parts. The study started with detecting a load on a plate and estimating its location. The modifications on the part with manufacturing operations were detected and the Part-Based Manufacturing Process Performance Monitoring (PbPPM) method was developed. Hardware was prepared to demonstrate the feasibility of the proposed methods in real time. Using low-cost piezoelectric elements and the non-contact scanning laser vibrometer successfully, the data was collected for the SuRE and PbPPM methods. Locational force, loose bolts and material loss could be easily detected by comparing the spectral characteristics of the arriving waves. On-line methods used fast computational methods for estimating the spectrum and detecting the changing operational conditions from sum of the squares of the variations. Neural networks classified the spectrums when the desktop – DSP combination was used. The results demonstrated the feasibility of the SuRE and PbPPM methods.

NIR-spectroscopy for bioprocess monitoring & control

The Ingold port adaption of a free beam NIR spectrometer is tailored for optimal bioprocess monitoring and control. The device shows an excellent signal to noise ratio dedicated to a large free aperture and therefore a large sample volume. This can be seen particularly in the batch trajectories which show a high reproducibility. The robust and compact design withstands rough process environments as well as SIP/CIP cycles. Robust free beam NIR process analyzers are indispensable tools within the PAT/QbD framework for realtime process monitoring and control. They enable multiparametric, non-invasive measurements of analyte concentrations and process trajectories. Free beam NIR spectrometers are an ideal tool to define golden batches and process borders in the sense of QbD. Moreover, sophisticated data analysis both quantitative and MSPC yields directly to a far better process understanding. Information can be provided online in easy to interpret graphs which allow the operator to make fast and knowledge-based decisions. This finally leads to higher stability in process operation, better performance and less failed batches.

Virtual Enterprise Process Management: An Application to Industrial Maintenance

Part 2: Behaviour and Coordination

Colonization and extinction of land planarians (Platyhelminthes, Tricladida) in a Brazilian Atlantic Forest regrowth remnant

Long-term assessments of species assemblages are valuable tools for detecting species ecological preferences and their dispersal tracks, as well as for assessing the possible effects of alien species on native communities. Here we report a 50-year-long study on population dynamics of the four species of land flatworms (Platyhelminthes, Tricladida, Terricola) that have colonized or become extinct in a 70-year-old Atlantic Forest regrowth remnant through the period 1955-2006. On the one hand, the two initially most abundant species, which are native to the study site, Notogynaphallia ernesti and Geoplana multicolor have declined over decades and at present do not exist in the forest remnant. The extinction of these species is most likely related with their preference for open vegetation areas, which presently do not exist in the forest remnant. On the other hand, the neotropical Geoplaninae 1 and the exotic Endeavouria septemlineata were detected in the forest only very recently. The long-term study allowed us to conclude that Geoplaninae 1 was introduced into the study area, although it is only known from the study site. Endeavouria septemlineata, an active predator of the exotic giant African snail, is originally known from Hawaii. This land flatworm species was observed repeatedly in Brazilian anthropogenic areas, and this is the first report of the species in relatively well preserved native forest, which may be evidence of an ongoing adaptive process. Monitoring of its geographic spread and its ecological role would be a good practice for preventing potential damaging effects, since it also feeds on native mollusk fauna, as we observed in lab conditions.

Reasoning about real-time repetitions: terminating and nonterminating

It is common for a real-time system to contain a nonterminating process monitoring an input and controlling an output. Hence, a real-time program development method needs to support nonterminating repetitions. In this paper we develop a general proof rule for reasoning about possibly nonterminating repetitions. The rule makes use of a Floyd-Hoare-style loop invariant that is maintained by each iteration of the repetition, a Jones-style relation between the pre- and post-states on each iteration, and a deadline specifying an upper bound on the starting time of each iteration. The general rule is proved correct with respect to a predicative semantics. In the case of a terminating repetition the rule reduces to the standard rule extended to handle real time. Other special cases include repetitions whose bodies are guaranteed to terminate, nonterminating repetitions with the constant true as a guard, and repetitions whose termination is guaranteed by the inclusion of a fixed deadline. (C) 2002 Elsevier Science B.V. All rights reserved.

Devolução de doses unitárias: análise de uma prática diária

A Distribuição Individual Diária em Dose Unitária deve assegurar o maior rigor no Processo de Distribuição de Medicamentos, o que nem sempre se verificou no Hospital Pedro Hispano, dado que as Doses Unitárias devolvidas pelos Serviços de Internamento, nem sempre seguiam os Parâmetros de Qualidade. Assim, desenvolveu-se um estudo quasi-experimental, longitudinal, prospetivo e analítico, entre 1 de Março a 30 de Junho de 2012, no qual se analisaram as Doses Unitárias, devolvidas pelos Serviços de Internamento da Unidade Local de Saúde de Matosinhos a funcionam com Distribuição Individual Diária em Dose Unitária, tendo-se recolhido as não conformes relativamente aos Parâmetros de Qualidade instituídos. Na 1.ª fase do estudo (Recolha de amostras), foram contabilizadas 337 amostras, correspondentes a uma perda de 471 €. Na 2.ª fase do estudo (Implementação de acções correctivas às amostras previamente recolhidas), foram rejeitadas definitivamente 129 amostras, correspondentes a uma perda de 198 €. Na 4.ª fase do estudo (Segunda recolha de amostras), foram contabilizadas 228 amostras, correspondentes a uma perda de 199 €. A 3.ª fase do estudo incluiu a divulgação dos resultados às enfermeiras chefes dos serviços envolvidos no estudo e a 5.ª fase a comparação dos resultados obtidos na 1.ª, 2.ª e 4.ª fase do estudo. As amostras foram recolhidas em 16 serviços de internamento, sendo os valores monetários mais relevantes associados ao Espessante para alimentos líquidos e ao Imipeno + Cilastatina. A prática observada e sujeita a estudo aumenta os riscos associados ao consumo do medicamento e os custos relativos ao Processo, sendo de eliminar. A sua monitorização deve constituir uma rotina, uma vez que houve mudança de comportamentos. A redução/eliminação desta prática não conforme conduz à integração de novas tarefas com valor acrescentado, com aumento da fiabilidade do Processo.

Gestão integrada da doença : uma abordagem experimental de gestão em sa

RESUMO - Os sistemas de saúde deparam-se, actualmente, com novos paradigmas, ao nível da qualidade da prestação de cuidados de saúde, bem como no que se refere à necessidade de controlo dos custos com o sector da saúde, obrigando as organizações a adaptarem-se por forma a fornecerem a resposta mais adequada às crescentes necessidades dos indivíduos. O reconhecimento desta realidade tem levado os governos de muitos países a definir políticas orientadas para problemas de saúde específicos e a adoptar estratégias de intervenção que privilegiam uma abordagem integrada com o objectivo de melhorarem progressivamente o nível de saúde das populações, a qualidade dos cuidados prestados e a eficiência na utilização de recursos. Em Portugal, a aplicação dos princípios que estiveram na base dos modelos de gestão da doença, deu origem ao modelo experimental de Gestão Integrada da Doença, que incorpora a gestão clínica da doença, centrada no doente, com especial enfoque na sua autogestão e na clarificação das melhores práticas profissionais, visando a sua uniformização; a reorganização do modelo de prestação de cuidados, com a criação de Centros de Elevada Diferenciação e Centros de Tratamento, com especiais preocupações no que concerne à orientação do doente no sistema para que os cuidados lhe seja ministrados no nível mais adequado; um modelo de financiamento específico, indexado aos resultados, que reflicta a adopção das melhores práticas; um sistema de informação que permita a monitorização e avaliação constante deste processo. O desenvolvimento deste modelo organizacional tem-se revelado como uma estratégia inovadora e como uma ferramenta de elevado potencial para a melhoria da prestação de cuidados de saúde e para a promoção de uma maior efectividade e eficiência, tal como poderá, ainda, constituirse como um veículo, importante e permanente, de informação de apoio à decisão em Saúde. Este modelo visa, no fundo, promover uma acção concertada no sentido da obtenção de uma intervenção precisa, através da mobilização de recursos adequados, que permitam uma melhoria do estado de saúde, da qualidade de vida e do bem-estar global dos doentes. Esta abordagem passa pela colaboração e coordenação dos diferentes níveis de prestação de cuidados, no sentido de oferecerem cuidados integrados de saúde, com níveis de qualidade elevados em termos de prevenção, diagnóstico, tratamento, reabilitação e acompanhamento. ------------------------ --ABSTRACT – The health systems are faced with new paradigms, on one hand in the healthcare services delivered to the populations, and on the other hand, in the need to control costs in the health sector, forcing organizations to adapt and provide the most appropriate response to the individuals growing needs. The magnitude of this problem, in terms of public health, requires the adoption of a directed, targeted, planned and integrated action, based on clear and well defined strategies in order to obtain health gains, improving the quality of care and streamlining the costs. In Portugal, the application of those principles forming the basis of the disease management models, led to the Integrated Disease Management model which, apart from the clinical management of the disease, also incorporates the healthcare delivery structure reorganization, a specific financing model based on an information system that allows the process monitoring and evaluation. The development of Integrated Disease Management models is a central strategy and a tool for improving healthcare delivery, more effectively and efficiently, and can even be an important and permanent vehicle of information for health decision support. Therefore, it is important to promote a concerted action towards achieving a precise intervention, mobilizing the resources, improving the health status, quality of life and the overall patients’ wellbeing. This action means increasing collaboration and coordination of the different levels of care, offering integrated healthcare s

Ensino, aprendizagem e avaliação no Ensino Superior: Perspetivas e práticas

Tese de Doutoramento em Ciências da Educação - Especialidade de Desenvolvimento Curricular

Nanocomposites: the contribution of multiscale modelling to improve the dispersion levels

Tese de Doutoramento em Ciência e Engenharia de Polímeros e Compósitos