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At least 91 records · Page 5

Experimental Verification of Electric Drive Technologies Based on Artificial Intelligence Tools

In this report, a fully integrated prototype of a flight servo control system is successfully developed and implemented using brushless dc motors. The control system is developed by the fuzzy logic theory, and implemented with a multilayer neural network. First, a neural network-based architecture is introduced for fuzzy logic control. The characteristic rules and their membership functions of fuzzy systems are represented as the processing nodes in the neural network structure. The network structure and the parameter learning are performed simultaneously and online in the fuzzy-neural network system. The structure learning is based on the partition of input space. The parameter learning is based on the supervised gradient decent method, using a delta adaptation law. Using experimental setup, the performance of the proposed control system is evaluated under various operating conditions. Test results are presented and discussed in the report. The proposed learning control system has several advantages, namely, simple structure and learning capability, robustness and high tracking performance and few nodes at hidden layers. In comparison with the PI controller, the proposed fuzzy-neural network system can yield a better dynamic performance with shorter settling time, and without overshoot. Experimental results have shown that the proposed control system is adaptive and robust in responding to a wide range of operating conditions. In summary, the goal of this study is to design and implement-advanced servosystems to actuate control surfaces for flight vehicles, namely, aircraft and helicopters, missiles and interceptors, and mini- and micro-air vehicles.

Rubaai, Ahmed↗

Using Selection Pressure as an Asset to Develop Reusable, Adaptable Software Systems

The Goddard Earth Sciences Data and Information Services Center (GES DISC) at NASA has over the years developed and honed several reusable architectural components for supporting large-scale data centers with a large customer base. These include a processing system (S4PM) and an archive system (S4PA) based upon a workflow engine called the Simple Scalable Script based Science Processor (S4P) and an online data visualization and analysis system (Giovanni). These subsystems are currently reused internally in a variety of combinations to implement customized data management on behalf of instrument science teams and other science investigators. Some of these subsystems (S4P and S4PM) have also been reused by other data centers for operational science processing. Our experience has been that development and utilization of robust interoperable and reusable software systems can actually flourish in environments defined by heterogeneous commodity hardware systems the emphasis on value-added customer service and the continual goal for achieving higher cost efficiencies. The repeated internal reuse that is fostered by such an environment encourages and even forces changes to the software that make it more reusable and adaptable. Allowing and even encouraging such selective pressures to software development has been a key factor In the success of S4P and S4PM which are now available to the open source community under the NASA Open source Agreement

Berrick, Stephen↗

Online model-based diagnosis to support autonomous operation of an advanced life support system

This article describes methods for online model-based diagnosis of subsystems of the advanced life support system (ALS). The diagnosis methodology is tailored to detect, isolate, and identify faults in components of the system quickly so that fault-adaptive control techniques can be applied to maintain system operation without interruption. We describe the components of our hybrid modeling scheme and the diagnosis methodology, and then demonstrate the effectiveness of this methodology by building a detailed model of the reverse osmosis (RO) system of the water recovery system (WRS) of the ALS. This model is validated with real data collected from an experimental testbed at NASA JSC. A number of diagnosis experiments run on simulated faulty data are presented and the results are discussed.

Non-NASA Center↗

Case studies in configuration control for redundant robots

A simple approach to configuration control of redundant robots is presented. The redundancy is utilized to control the robot configuration directly in task space, where the task will be performed. A number of task-related kinematic functions are defined and combined with the end-effector coordinates to form a set of configuration variables. An adaptive control scheme is then utilized to ensure that the configuration variables track the desired reference trajectories as closely as possible. Simulation results are presented to illustrate the control scheme. The scheme has also been implemented for direct online control of a PUMA industrial robot, and experimental results are presented. The simulation and experimental results validate the configuration control scheme for performing various realistic tasks.

Seraji, H.↗

30 years of adaptive neural networks - Perceptron, Madaline, and backpropagation

Fundamental developments in feedforward artificial neural networks from the past thirty years are reviewed. The history, origination, operating characteristics, and basic theory of several supervised neural-network training algorithms (including the perceptron rule, the least-mean-square algorithm, three Madaline rules, and the backpropagation technique) are described. The concept underlying these iterative adaptation algorithms is the minimal disturbance principle, which suggests that during training it is advisable to inject new information into a network in a manner that disturbs stored information to the smallest extent possible. The two principal kinds of online rules that have developed for altering the weights of a network are examined for both single-threshold elements and multielement networks. They are error-correction rules, which alter the weights of a network to correct error in the output response to the present input pattern, and gradient rules, which alter the weights of a network during each pattern presentation by gradient descent with the objective of reducing mean-square error (averaged over all training patterns).

Widrow, Bernard↗

Community-Based Services that Facilitate Interoperability and Intercomparison of Precipitation Datasets from Multiple Sources

Over the past 12 years, large volumes of precipitation data have been generated from space-based observatories (e.g., TRMM), merging of data products (e.g., gridded 3B42), models (e.g., GMAO), climatologies (e.g., Chang SSM/I derived rain indices), field campaigns, and ground-based measuring stations. The science research, applications, and education communities have greatly benefited from the unrestricted availability of these data from the Goddard Earth Sciences Data and Information Services Center (GES DISC) and, in particular, the services tailored toward precipitation data access and usability. In addition, tools and services that are responsive to the expressed evolving needs of the precipitation data user communities have been developed at the Precipitation Data and Information Services Center (PDISC) (http://disc.gsfc.nasa.gov/precipitation or google NASA PDISC), located at the GES DISC, to provide users with quick data exploration and access capabilities. In recent years, data management and access services have become increasingly sophisticated, such that they now afford researchers, particularly those interested in multi-data set science analysis and/or data validation, the ability to homogenize data sets, in order to apply multi-variant, comparison, and evaluation functions. Included in these services is the ability to capture data quality and data provenance. These interoperability services can be directly applied to future data sets, such as those from the Global Precipitation Measurement (GPM) mission. This presentation describes the data sets and services at the PDISC that are currently used by precipitation science and applications researchers, and which will be enhanced in preparation for GPM and associated multi-sensor data research. Specifically, the GES-DISC Interactive Online Visualization ANd aNalysis Infrastructure (Giovanni) will be illustrated. Giovanni enables scientific exploration of Earth science data without researchers having to perform the complicated data access and match-up processes. In addition, PDISC tool and service capabilities being adapted for GPM data will be described, including the Google-like Mirador data search and access engine; semantic technology to help manage large amounts of multi-sensor data and their relationships; data access through various Web services (e.g., OPeNDAP, GDS, WMS, WCS); conversion to various formats (e.g., netCDF, HDF, KML (for Google Earth)); visualization and analysis of Level 2 data profiles and maps; parameter and spatial subsetting; time and temporal aggregation; regridding; data version control and provenance; continuous archive verification; and expertise in data-related standards and interoperability. The goal of providing these services is to further the progress towards a common framework by which data analysis/validation can be more easily accomplished.

Liu, Zhong↗

Integrated Component-based Data Acquisition Systems for Aerospace Test Facilities

The Multi-Instrument Integrated Data Acquisition System (MIIDAS), developed by the NASA Langley Research Center, uses commercial off the shelf (COTS) products, integrated with custom software, to provide a broad range of capabilities at a low cost throughout the system s entire life cycle. MIIDAS combines data acquisition capabilities with online and post-test data reduction computations. COTS products lower purchase and maintenance costs by reducing the level of effort required to meet system requirements. Object-oriented methods are used to enhance modularity, encourage reusability, and to promote adaptability, reducing software development costs. Using only COTS products and custom software supported on multiple platforms reduces the cost of porting the system to other platforms. The post-test data reduction capabilities of MIIDAS have been installed at four aerospace testing facilities at NASA Langley Research Center. The systems installed at these facilities provide a common user interface, reducing the training time required for personnel that work across multiple facilities. The techniques employed by MIIDAS enable NASA to build a system with a lower initial purchase price and reduced sustaining maintenance costs. With MIIDAS, NASA has built a highly flexible next generation data acquisition and reduction system for aerospace test facilities that meets customer expectations.

Ross, Richard W.↗

A Reinforcement Learning Framework for Space Missions in Unknown Environments

A land-and-traverse mission to icy worlds such as Europa and Enceladus is challenging due to lack of prior knowledge regarding the terrain conditions. Previous work [1] showed that rovers with high degrees of freedom (DoF) can achieve robust traversal by leveraging redundant modes for mobility to counter terrain uncertainty (e.g. walking, driving, or inch-worming). This paper presents a generic and scalable reinforcement learning scheme for enabling on-board decision making on rovers to automatically switch between modes of traversal based on online performance feedback. The objective is to maximize energy efficiency, minimize operator input and successfully negotiate unstructured terrain conditions without relying on exhaustive prior knowledge. The proposed methodology is well grounded in the literature on reinforcement learning and has been adapted to address conformance to validation and verification requirements and JPL flight operations history of using per-sol prescribed sequences for a space mission.

Tavallali, Peyman↗

Online Rapid Analysis of Laser Heterodyne Radiometer (LHR) Data Using the Planetary Spectrum Generator (PSG)

One of the biggest challenges in developing scientific instruments is not just the build and testing of an instrument, but the method for processing the data and producing a consistent, well characterized data product that can be confidently used by the public and scientific community. Raw data products are frequently an array of numbers that are a read-out of voltages. The challenge is to convert these arrays into meaningful information as well as remove noise and interferences. Because this can be a tedious and time-consuming, the goal is to automate the process so that data ca be processed rapidly and be available in real-time for event monitoring. Here we present a rapid analysis method for Laser Heterodyne Radiometer (LHR) data that can be used to analyze data taken from a range of LHR observation modes (column, limb, etc.). This online tool uses the versatile Planetary Spectrum Generator (PSG) and allows LHR users to quickly analyze their own data using a NASA Goddard Space Flight Center (GSFC) monitored capability to ensure quality and reproducibility in the data products. Background: Development of a miniaturized LHR (mini-LHR) as a ground instrument for measuring carbon dioxide (CO 2 ) and methane (CH 4 ) in the atmospheric column started in 2009 with the commercial availability of distributive feedback lasers (DFB) in wavelengths that could measure absorption of gases in the near-IR. As new DFB lasers, detectors and hardware emerged at different wavelengths, additional gases were added to the capability. The mini-LHR was adapted into an occultation-viewing CubeSat with Lawrence Livermore National Laboratory (LLNL) for observing CO 2 , CH 4 , and H 2 O in the limb and was launched in 2019. Other versions of the LHR technology have been designed for observation of water vapor in the lunar exosphere as well as observations of trace gases in planetary atmospheres and plumes from icy moons. The PSG is an online tool developed at GSFC that can be used for synthesizing Earth and planetary spectra (atmospheres and surfaces) over a broad range of wavelengths (0.1 μm to 100 mm) for any observatory, orbiter or lander. Spectra are simulated by combining several state-of-the-art radiative transfer models, spectroscopic databases, planetary databases, as well as modern-era retrospective analysis for research and applications, version 2 (MERRA-2) data set which provides meteorological inputs such as modeled surface pressure for calculating dry-air columns.

Emily Wilson↗

Serious Gaming for Test & Evaluation of Clean-Slate (Ab Initio) National Airspace System (NAS) Designs

Incremental approaches to air transportation system development inherit current architectural constraints, which, in turn, place hard bounds on system capacity, efficiency of performance, and complexity. To enable airspace operations of the future, a clean-slate (ab initio) airspace design(s) must be considered. This ab initio National Airspace System (NAS) must be capable of accommodating increased traffic density, a broader diversity of aircraft, and on-demand mobility. System and subsystem designs should scale to accommodate the inevitable demand for airspace services that include large numbers of autonomous Unmanned Aerial Vehicles and a paradigm shift in general aviation (e.g., personal air vehicles) in addition to more traditional aerial vehicles such as commercial jetliners and weather balloons. The complex and adaptive nature of ab initio designs for the future NAS requires new approaches to validation, adding a significant physical experimentation component to analytical and simulation tools. In addition to software modeling and simulation, the ability to exercise system solutions in a flight environment will be an essential aspect of validation. The NASA Langley Research Center (LaRC) Autonomy Incubator seeks to develop a flight simulation infrastructure for ab initio modeling and simulation that assumes no specific NAS architecture and models vehicle-to-vehicle behavior to examine interactions and emergent behaviors among hundreds of intelligent aerial agents exhibiting collaborative, cooperative, coordinative, selfish, and malicious behaviors. The air transportation system of the future will be a complex adaptive system (CAS) characterized by complex and sometimes unpredictable (or unpredicted) behaviors that result from temporal and spatial interactions among large numbers of participants. A CAS not only evolves with a changing environment and adapts to it, it is closely coupled to all systems that constitute the environment. Thus, the ecosystem that contains the system and other systems evolves with the CAS as well. The effects of the emerging adaptation and co-evolution are difficult to capture with only combined mathematical and computational experimentation. Therefore, an ab initio flight simulation environment must accommodate individual vehicles, groups of self-organizing vehicles, and large-scale infrastructure behavior. Inspired by Massively Multiplayer Online Role Playing Games (MMORPG) and Serious Gaming, the proposed ab initio simulation environment is similar to online gaming environments in which player participants interact with each other, affect their environment, and expect the simulation to persist and change regardless of any individual player's active participation.

Allen, B. Danette↗

Adaptive force and position control of manipulators

Systematic methods for the design of adaptive force and position controllers for robot manipulators within the hybrid control architecture are presented. The force controller tracks the desired force setpoints while the position controller tracks the desired position trajectories. The present control schemes are computationally efficient and suitable for implementation in online control with high sampling rates.

Seraji, H.↗

NASA's Space Launch System Begins Integration, Stacking in Preparation for Artemis I Launch

The Artemis era of human lunar exploration is nearing take-off as NASA’s new super heavy-lift launch vehicle, the Space Launch System (SLS), begins stack-ing and integration operations in mid-2020 at Kennedy Space Center (KSC) in Florida. With a planned upgrade path to progressively more powerful vehicles and availability in crew and cargo configurations, SLS provides a unique and flexible launch solution to send crew, large-scale infrastructure and robotic probes to deep space. The SLS Block 1 vehicle, the initial variant to fly, is optimized for lunar missions with a proven propulsion system consisting of four liquid hydrogen (LH2)/liquid oxygen (LOX)-fed RS-25 engines and twin five-segment solid rocket boosters (SRBs). The Block 1 vehicle can also be outfitted with an industry-standard 5 m-class payload fairing (the “cargo” configuration) and will launch at least 27 metric tons (t) of mass to trans-lunar injection (TLI). SLS is the backbone of NASA’s Artemis program, which will return the agency’s human spaceflight program to the Moon for the first time since 1972. For the Artemis I mission, SLS will send an uncrewed Orion spacecraft to TLI, where it will enter a distant retrograde lunar orbit and fly 38,000 nmi past the Moon – farther than any spacecraft built for humans has ever traveled. The SLS Block 1 vehicle for Artemis I completed manufacturing in 2019. Several elements, including the upper stage, have been delivered to the Exploration Ground Systems (EGS) program at KSC and are being prepped for integration and stack-ing. The five-segment solid rocket boosters – the largest and most powerful ever built for flight – are also complete. The booster motor segments for the Artemis I flight are scheduled to ship from prime contractor Northrop Grumman’s Utah facilities and begin stacking and integration at KSC in June 2020. The SLS core stage is the largest rocket stage NASA has ever built in terms of volume and height, and includes the avionics and the tanks that feed cryogenic propellant to the four RS-25s (formerly Space Shuttle Main Engines [SSMEs]). They have been modified with an updated controller and nozzle insulation to protect them from the hotter launch environment. The SLS core stage is currently being test-ed at NASA’s Stennis Space Center (SSC) in a series of “green run” tests to verify it meets design and performance requirements. Following the green run test series, which is scheduled to culminate with a full-duration hot-fire of the four RS-25 engines, the core stage will ship to KSC and be stacked between the sol-id rocket boosters in the Vehicle Assembly Building (VAB). Integration of the vehicle will continue with the upper stage, known as the Interim Cryogenic Propulsion Stage (ICPS) and the Launch Vehicle Stage Adapter (LVSA) on the core stage. Another adapter, the Orion Stage Adapter (OSA), connects SLS to Orion and provides housing for 13 6U CubeSat payloads manifested on Artemis I. The CubeSats will be released in deep space after Orion separates from the vehicle, and the flight marks the first ride share opportunity for independent small-sats to deep space. The second major SLS variant to come online, Block 1B, replaces the single-engine ICPS with a four-engine LH2/LOX Exploration Upper Stage (EUS). This more powerful upper stage, along with other vehicle up-grades, will enable the Block 1B vehicle to launch 38-42 t to TLI, depending on crew or cargo configuration. The final evolution of the vehicle, Block 2, will onramp evolved solid rocket boosters to increase mass to TLI to 43-46 t, de-pending on crew or cargo configuration. The Block 1B/Block 2 vehicles can be outfitted with an 8.4 m-diameter payload fairing in 19.1 m or 27.4 m lengths, to provide unprecedented volume for payloads. With the initial Block 1 vehicle completely manufactured and the core stage in final testing before shipping to KSC, the SLS Program and its industry partners have made significant progress manufacturing subsequent vehicles. For the second Block 1 vehicle, the solid rocket motor segments are complete, as are the RS-25 engines with controllers. All five major components of the Artemis II core stage – the forward skirt, LOX and LH2 tanks, intertank and engine section – are manufactured and technicians are installing subsystems at NASA’s rocket factory, Michoud Assembly Facility. The RL-10 engine for the Artemis II ICPS is complete and panels have been machined for its LH2 tank. In addition, panels are machined for the vehicle’s two adapters, with welding scheduled to begin in summer 2020. Flight hard-ware is also in production for the third SLS vehicle, with several booster motor segments cast. The pace of development on the EUS has increased, with the goal to complete Critical Design Review (CDR) in December 2020. Several EUS test rings have been machined at Michoud. The EUS is designed to exe-cute a variety of missions – human spaceflight, deployment of deep-space infra-structure, or high-C3 missions to the outer solar system – with crew and cargo configurations available beginning in the mid-2020s. The near-term goal for the nation’s powerful new space exploration asset, however, is to launch the Arte-mis program, and send the first woman and the next man to the lunar surface. At the Astrodynamics Specialist Conference, the SLS program will update the community on the progress of the initial Block 1 vehicle in final green run test-ing, integration and stacking. In addition, this paper will provide an update to the community on the manufacturing status of subsequent Block 1 and Block 1B vehicles.

Steve Creech↗

Serious Gaming for Building a Basis of Certification via Trust and Trustworthiness of Autonomous Systems

Autonomous systems governed by a variety of adaptive and nondeterministic algorithms are being planned for inclusion into safety-critical environments, such as unmanned aircraft and space systems in both civilian and military applications. However, until autonomous systems are proven and perceived to be capable and resilient in the face of unanticipated conditions, humans will be reluctant or unable to delegate authority, remaining in control aided by machine-based information and decision support. Proving capability, or trustworthiness, is a necessary component of certification. Perceived capability is a component of trust. Trustworthiness is an attribute of a cyber-physical system that requires context-driven metrics to prove and certify. Trust is an attribute of the agents participating in the system and is gained over time and multiple interactions through trustworthy behavior and transparency. Historically, artificial intelligence and machine learning systems provide answers without explanation - without a rationale or insight into the machine “thinking”. In order to function as trusted teammates, machines must be able to explain their decisions and actions. This transparency is a product of both content and communication. NASA’s Autonomy Teaming & TRAjectories for Complex Trusted Operational Reliability (ATTRACTOR) project seeks to build a basis for certification of autonomous systems via establishing metrics for trustworthiness and trust in multi-agent team interactions, using AI (Artificial Intelligence) explainability and persistent modeling and simulation, in the context of mission planning and execution, with analyzable trajectories. Inspired by Massively Multiplayer Online Role Playing Games (MMORPG) and Serious Gaming, the proposed ATTRACTOR modeling and simulation environment is similar to online gaming environments in which player (aka agent) participants interact with each other, affect their environment, and expect the simulation to persist and change regardless of any individual agent’s active participation. This persistent simulation environment will accommodate individual agents, groups of self-organizing agents, and large-scale infrastructure behavior. The effects of the emerging adaptation and coevolution can be observed and measured to building a basis of measurable trustworthiness and trust, toward certification of safety-critical autonomous systems.

Allen, B. Danette↗

Online Control Design for Learn-To-Fly

Two methods were developed for online control design as part of a flight test e ort to examine the feasibility of the NASA Learn-to-Fly concept. The methods use an aerodynamic model of the aircraft that is being identified in real-time onboard the aircraft to adjust the control parameters. One method employs adaptive nonlinear dynamic inversion, whereas the other consists of a classical autopilot structure. E ects from the interaction between the realtime modeling and the developed control laws are discussed. The Learn-to-Fly concept has been deemed feasible based on successful flights of both a stable and unstable aircraft.

Snyder, Steven M↗

Perceptions of Climate Risk and Use of Climate Risk Information by Natural Resource Conservation Stakeholders Participating in ADVANCE Projects in Asia and Latin America

Integrating climate risk information into resilience-building activities in the field is important to ensure that adaptation is based on the best available science. Despite this, many challenges exist when developing, communicating, and incorporating climate risk information. There are limited resources on how stakeholders perceive risks, use risk information, and what barriers exist to limit knowledge integration. This paper seeks to define the following: 1) What do conservation stakeholders consider to be the most significant climate risks they face now and possibly in the future? 2) What have been the most significant barriers to their using climate risk information? 3) What sources and types of knowledge would be most useful for these managers to overcome these barriers? A survey was conducted among stakeholders (n = 224) associated with World Wildlife Fund projects in tropical and subtropical countries. A very high proportion of stakeholders used climate risk information and yet faced integration-related challenges, which included too much uncertainty and the lack of a relevant scale for planning. The main factors preventing the use of climate risk information in decision-making were unavailability of climate risk information, no or limited financial or human resources available to respond, lack of organizational mandate or support, and no or limited institutional incentives. Comparing perceived current and future risks revealed a decline in concern for some future climate hazards. Survey respondents identified scientific reports, climate scientists, and online sources as the most useful information sources of climate risk information, while (i) maps and illustrations; (ii) scenarios format; and (iii) data tables, graphs, and charts were identified as user-friendly formats.

Climate risk↗

An Efficient Model-based Diagnosis Engine for Hybrid Systems Using Structural Model Decomposition

Complex hybrid systems are present in a large range of engineering applications, like mechanical systems, electrical circuits, or embedded computation systems. The behavior of these systems is made up of continuous and discrete event dynamics that increase the difficulties for accurate and timely online fault diagnosis. The Hybrid Diagnosis Engine (HyDE) offers flexibility to the diagnosis application designer to choose the modeling paradigm and the reasoning algorithms. The HyDE architecture supports the use of multiple modeling paradigms at the component and system level. However, HyDE faces some problems regarding performance in terms of complexity and time. Our focus in this paper is on developing efficient model-based methodologies for online fault diagnosis in complex hybrid systems. To do this, we propose a diagnosis framework where structural model decomposition is integrated within the HyDE diagnosis framework to reduce the computational complexity associated with the fault diagnosis of hybrid systems. As a case study, we apply our approach to a diagnostic testbed, the Advanced Diagnostics and Prognostics Testbed (ADAPT), using real data.

Structural Decomposition↗

Follow-up Imaging of Disk Candidates from the Disk Detective Citizen Science Project: New Discoveries and False Positives in WISE Circumstellar Disk Surveys

The Disk Detective citizen science project aims to find new stars with excess 22 m emission from circumstellar dust in the All WISE data release from the Wide-field Infrared Survey Explorer. We evaluated 261 Disk Detective objects of interest with imaging with the Robo-AO adaptive optics instrument on the 1.5 m telescope at Palomar Observatory and with RetroCam on the 2.5 m du Pont Telescope at Las Campanas Observatory to search for background objects at 0 15–12 separations from each target. Our analysis of these data leads us to reject 7% of targets. Combining this result with statistics from our online image classification efforts implies that at most7.9%±0.2% of All WISE-selected infrared excesses are good disk candidates. Applying our false-positive rates to other surveys, we find that the infrared excess searches of McDonald et al. and Marton et al. all have false-positiverates >70%. Moreover, we find that all 13 disk candidates in Theissen & West with W4 signal-to-noise ratio >3are false positives. We present 244 disk candidates that have survived vetting by follow-up imaging. Of these,213 are newly identified disk systems. Twelve of these are candidate members of comoving pairs based on Gaia astrometry, supporting the hypothesis that warm dust is associated with binary systems. We also note the discovery of 22 m excess around two known members of the Scorpius–Centaurus association, and we identifyknown disk host WISEA J164540.79-310226.6 as a likely Sco-Cen member. Thirty of these disk candidates arecloser than 125 pc (including 26 debris disks), making them good targets for both direct-imaging exoplanetsearches.

Wide-field Infrared Survey Explorer↗

Hybrid data-driven and model-informed online tool wear detection in milling machines

Precision machining tool wear is responsible for low product throughput and quality. Monitoring the tool wear online is vital to prevent degradation in machining quality. However, direct real-time tool wear measurement is not practical. This paper presents residual-based anomaly detection models, combining a hybrid model comprised of a physics-based model and a data-driven model (a decision tree or a neural network) to predict signals of interest (e.g., power or forces) under nominal conditions, followed by Page’s cumulative sum test for detecting tool wear on-line using the computer numerical control machine measurements. The most informative features are ranked using dynamic programming and its approximation variants from real-time measurements and machine settings, such as the width of cut, depth of cut, feed rate and spindle speed, that serve as inputs to the predictive models. The baseline nominal model is incrementally updated with experimental data via a gradient boosted adaptation model to generate the residuals that account for discrepancies between the actual machine data under normal conditions and the baseline nominal model predictions. The hybrid model is validated against 20 Mazak milling machine experimental tests and one Haas run-to-failure experiment. The proposed anomaly detector is applied to synthetic data from simulations of the physics-based model at different operating conditions, measurement noise levels, and tool wear levels, and the methods were able to achieve an overall 92% accuracy in data with 1% noise. The anomaly detection methods based on hybrid model reduced the false alarms of either the data-driven or physical-based models alone, and are found to be capable of good online detection of tool wear.

Online anomaly detection↗