High-speed Production Research Articles

Causal Modelling for Predicting Machine Tools Degradation in High Speed Production Process

A dynamic health indicator based on regressive event-tracker algorithm is proposed to accurately interpret the condition of critical components of machine tools in a production system and to predict their potential sudden breakdown based on future trends. Through sensors/actuators data acquisition, the algorithm predicts the causal links between various monitored parameters of the system and offers a diagnosis of the health state of the system. A safety and operational robustness regime determines the acceptable thresholds of the operational boundaries of the electro-mechanical components of the machines. The proposed model takes into account the possibilities of sensor values being a piecewise-linear models or a pair of exponential functions with restricted model parameters, which can predict the runs-to-failure or remaining useful life until a safety threshold. The events caused by sensors passing through sub levels of safety threshold are used as a re-enforcement learning for the models. Each remaining useful life estimation diagnosis and prognosis analysis can be conducted on individual or an interconnected network of components within a machine. The overall health indicator based on individual useful life estimation is calculated by deriving the weights from event-clustering algorithm. The work can be extended to a network of machines representing a process. The outcome of the continuously learning real-time condition monitoring modus-operandi is to accurately measure the remaining useful life of the network of critical components of a machine.

Mechanical Properties and Formaldehyde Emission of Rubberwood Particleboard Using Emulsified Methylene Diphenyl Diisocyanate (EMDI) Binder at Different Press Factor Continuous Press

Rubberwood particleboard with low formaldehyde emission is a must in wood based paneling industry especially for export market such as in Japan, Korean, European countries and North America Region. Avoiding of urea formaldehyde binder and substitute it with emulsion isocyanate resin is an alternative in particleboard production. However, the low tackiness and sticking to steel belt during transferring and pressing in actual particleboard production contributes to surface defects as well as variation in mechanical properties of the final product. The results revealed that a correlation speed and press factor is necessary in order to improve mechanical properties and to keep the physical performance of boards within a limited range of values. Various speeds of press factors were studied at 15.0, 14.5, 14.0, 13.5 sec/mm to study the effect to the bending, internal bonding, screw withdrawal, surface soundness, thickness swelling, moisture content properties and formaldehyde emission of particleboard. At higher production speed (lower press factor), bending, internal bonding, MOE and edge screw withdrawals properties of particleboard was decrease by 3% to 13%. Thickness swelling and moisture content were increased in final particleboard production. Emission of formaldehyde was below than 0.15 mg/L (JIS A 1460) at all speeds of press factor which is extremely low.

Roll-to-roll wax transfer for rapid and batch fabrication of paper-based microfluidics

This study proposed a novel method for the rapid fabrication of paper-based microfluidic devices using a roll-to-roll wax transfer method. In this approach, a custom-made device was designed and fabricated for the direct roll-to-roll wax transfer from commercially available wax ribbon to the surface of paper substrate. After wax transfer, a thermal reflow process was conducted to enable the melt wax penetration through the whole thickness of the hydrophilic paper substrate to form hydrophobic wax barriers. Compared with the conventional approaches for paper-based microfluidics (wax printing, photolithography, and inkjet printing), the proposed fabrication technique for paper-based microfluidic devices is suitable for the batch fabrication of paper-based microfluidic chips at high production speed. Additional advantages including simple fabrication process, low material and fabrication cost, low-energy consumption, and without the requirement of cleanroom environment or facilities. The paper-based microfluidics fabricated with the proposed roll-to-roll wax transfer method is widely adaptable for microfluidic applications in biological and chemical fields.

On computer modelling of operations, geometric characteristics and methods of pulsed optical tomography of nuclear fuel microobjects

The paper refers to the area of morphological processing of projection images and its goal is to design some computer models of basic operations, geometric properties and methods of pulsed optical tomography which provide a high-speed production operational control and sorting of each microobjet (MO) of nuclear fuel in their flow according to their size and shape. Based on the proposed computer models, a precision laser method of industrial differential control and quality control of an MO flow of nuclear fuel was developed and experimentally tested. The method uses the statistical reconstruction of the size (D) and shape (K) of each microobject and takes into account the overall dimensions of the outlines of three mutually orthogonal two-dimensional pulsed discrete projection images of a microobject. The processing speed of this method is 100 MO/s in the diameter range of 400–1500 µm. The relative error of an MO diameter control is no more than 0.25% (at the reliability of PD = 0.7 and K = 1.3 relative units), and the relative error of the non-sphericity coefficient control lies in the range of 2.3% (PK = 0.7 and K = 1.3) to 0.6% (PK = 0.96 and K = 1.05).

The Effect Of Calender Temperature And Number Of Fabric Layers On Fabric Performans In Combining Nonwovens With Calender Method

Nonwoven kumaş endüstrisinde, son üründe istenen özelliklere göre lif esaslı tülbent tabakaları başlıca mekanik, ısı ve kimyasal yöntemlerle bağlanarak tekstil yüzeyi haline getirilmektedir. Çevre koruma konusundaki farkındalık, kimyasal maddelerle yapılan doku bağlamanın kullanımı yerine ısı ile bağlama yöntemleri tercih edilmeye başlanmıştır. Isı ile doku oluşturma (kalender) ile doku bağlama yönteminde yüksek üretim hızı, daha iyi fiziksel özellik (kopma ve yırtılma mukavemeti) ve çevre dostu üretim yapılabilmesi bu yöntemi ilgi çekici hale getirmiştir. Dokusuz kumaş üreticileri sürekli olarak üretim hızını arttırmaya ve aynı güç için daha yüksek güç, daha az ağırlık veya yüksek genişletilebilirlik gibi performansı artırmaya çalışıyor. Üretim hızını artırmak için, kalender silindir sıcaklığı yükseltilir, böylece daha az zamanda daha fazla ısı emilir. Nonwoven kumaşlara uygulanan sıcaklık ve basınç değeri kumaşların mukavemetlerine doğrudan etki etmektedir. Bu çalışmada, farklı kalender sıcaklıklarında, ısıl bağlanmanın lif üzerinde sebep olduğu bozunmalar sonucunda elde edilecek spunbond kumaşların yırtılma, kopma mukavemeti ve su sütunu değerleri karşılaştırılmıştır. Deneysel çalışma sonucunda hem nonwoven üreticilerine hem de tüketicilerine kalender yöntemi ile birleştirmede sıcaklık değerlerinin kumaş fiziksel özelliklerine etkisi hakkında yönlendirme yapılmıştır.

Polyvinyl Butyral (PVB) Nanofiber/Nanoparticle-Covered Yarns for Antibacterial Textile Surfaces

In this study, nanoparticle-incorporated nanofiber-covered yarns were prepared using a custom-made needle-free electrospinning system. The ultimate goal of this work was to prepare functional nanofibrous surfaces with antibacterial properties and realize high-speed production. As antibacterial agents, we used various amounts of copper oxide (CuO) and vanadium (V) oxide (V2O5) nanoparticles (NPs). Three yarn preparation speeds (100 m/min, 150 m/min, and 200 m/min) were used for the nanofiber-covered yarn. The results indicate a relationship between the yarn speed, quantity of NPs, and antibacterial efficiency of the material. We found a higher yarn speed to be associated with a lower reduction in bacteria. NP-loaded nanofiber yarns were proven to have excellent antibacterial properties against Gram-negative Escherichia coli (E. coli). CuO exhibited a greater inhibition and bactericidal effect against E. coli than V2O5. In brief, the studied samples are good candidates for use in antibacterial textile surface applications, such as wastewater filtration. As greater attention is being drawn to this field, this work provides new insights regarding the antibacterial textile surfaces of nanofiber-covered yarns.

High-speed production of antibacterial fabrics using liquid flame spray

Healthcare associated infections (HAIs) are known as one of the major problems of the modern healthcare system, which result in additional cost and mortality. It has also been shown that pathogenic bacteria are mostly transferred via surfaces in healthcare settings. Therefore, antibacterial surfaces, which include fabrics and textiles, can be used in a healthcare environment to reduce the transfer of pathogenic bacteria, hence reducing HAIs. Silver nanoparticles have been shown to have broad spectrum antibacterial properties, and therefore they have been incorporated into fabrics to provide antibacterial functionality. Liquid flame spray (LFS) nanoparticle synthesis allows nanoparticles to be produced and deposited on surfaces at speeds up to and beyond 300 m/min. Herein, LFS is used to deposit silver nanoparticles onto two fabrics that are commonly used in the hospital environment with the aim of producing antibacterial fabrics. A thin plasma coating on top of the fabrics after silver deposition is used to improve nanoparticle adhesion. Fabrics coated with silver nanoparticles demonstrated antibacterial properties against Escherichia coli. Nanoparticle imaging and surface chemical characterization are performed using scanning electron microscopy and X-ray photoelectron spectroscopy. The highlights of this research are as follows: • high-speed synthesis and deposition of silver nanoparticles on fabrics; • plasma coating onto fabrics with silver nanoparticles; • antibacterial fabrics for potential use in healthcare environments.

A dynamic data dissemination mechanism for Cassandra NoSQL data store

Cassandra as a type of NoSQL databases has been put forward so as to surmount the hurdles of traditional relational databases in the scope of big data as well as real-time applications whose paramount traits are high-speed data production (volume) and miscellaneous data formats (variety). The dynamic nature of distributed data, distributed systems, and their concomitant applications results in skewed data access patterns, thereby causing imbalanced data issues, and in turn consecutive performance deterioration after all. In this study, we have proposed a dynamic data dissemination (D3) strategy well conforming to the dynamic behavior of distributed environment, including diversified as well as temporal popularity of data requests, and heterogeneous node capacity. The assessment results have shed light on performance improvement.

BigData Analysis in Healthcare: Apache Hadoop , Apache spark and Apache Flink

Introduction: Health care data is increasing. The correct analysis of such data will improve the quality of care and reduce costs. This kind of data has certain features such as high volume, variety, high-speed production, etc. It makes it impossible to analyze with ordinary hardware and software platforms. Choosing the right platform for managing this kind of data is very important. The purpose of this study is to introduce and compare the most popular and most widely used platform for processing big data, Apache Hadoop MapReduce, and the two Apache Spark and Apache Flink platforms, which have recently been featured with great prominence.Material and Methods: This study is a survey whose content is based on the subject matter search of the Proquest, PubMed, Google Scholar, Science Direct, Scopus, IranMedex, Irandoc, Magiran, ParsMedline and Scientific Information Database (SID) databases, as well as Web reviews, specialized books with related keywords and standard. Finally, 80 articles related to the subject of the study were reviewed.Results: The findings showed that each of the studied platforms has features, such as data processing, support for different languages, processing speed, computational model, memory management, optimization, delay, error tolerance, scalability, performance, compatibility, Security and so on. Overall, the findings showed that the Apache Hadoop environment has simplicity, error detection, and scalability management based on clusters, but because its processing is based on batch processing, it works for slow complex analyzes and does not support flow processing, Apache Spark is also distributed as a computational platform that can process a big data set in memory with a very fast response time, the Apache Flink allows users to store data in memory and load them multiple times and provide a complex Fault Tolerance mechanism Continuously retrieves data flow status.Conclusion: The application of big data analysis and processing platforms varies according to the needs. In other words, it can be said that each technology is complementary, each of which is applicable in a particular field and cannot be separated from one another and depending on the purpose and the expected expectation, and the platform must be selected for analysis or whether custom tools are designed on these platforms.

A high-speed additive manufacturing approach for achieving high printing speed and accuracy

The primary concern of the Industry 4.0 is the direct digital manufacturing of customized products on demand at high production speed, high accuracy with functional material property. Although the unique capabilities of existing additive manufacturing technologies make it suitable for direct digital manufacturing, there are numerous limitations which include low printing speed, less accuracy and repeatability, and a limited selection of materials for a particular application. Therefore, a high-speed additive manufacturing approach is proposed in this paper, that is capable of achieving high speed of production, high accuracy, and surface finish, and functional material property. For better understanding, authors describe those additive manufacturing technologies that are capable of achieving the aforementioned characteristics. For validation, samples of various dimensions were 3D printed on a selective laser sintering and a high-speed multijet fusion 3D printer. The results were compared in the context of printing speed, surface roughness (Ra), and hardness of printed parts. Results revealed that the multijet fusion process is significantly faster than its counterpart while sacrificing Ra to some extent but the hardness of printed parts is not changed significantly. The selective laser sintering-printed samples had a 15% lower Ra compared with multijet fusion samples. The results also revealed that the multijet fusion process might be able to print composite/multi-materials; however, more research needs to be done.

In situ construction of Ni enriched porous NiAl as long-lived electrode for hydrogen evolution at high current densities

Abstract The hydrogen evolution reaction (HER) is a key process in water electrolysis to produce hydrogen, but the development of highly active, stable and cost-effective monolith HER electrocatalysts by simple methods remains a great challenge. Here we report a compelling and powerful strategy to prepare a Ni enriched three-dimensional nanoporous NiAl catalyst which can be directly used as a highly active and long-lived HER electrode in acids. The electrode exhibits low onset overpotential of only −33 mV. Overpotentials of merely −157 mV and −226 mV are needed to reach current densites of −100 and −200 mA cm−2, respectively, superior to recently reported state-of-art Ni-based monolith HER catalysts. The high activity is likely due to in situ obtained nanoporous structure with high surface area and nanosized Ni. Under a medium overpotential of −335 mV, the electrode can sustain −350 mA cm−2 up to 60 h, showing good long-term stability at high current density. The favorable combination of the high activity, stability, facile preparation and low-cost makes the Ni enriched nanoporous NiAl a promising electrocatalyst for high-speed hydrogen production.

Optimal control of tension and thickness for tandem cold rolling process based on receding horizon control

ABSTRACT Tandem cold rolling is a high-speed, high-efficiency, and complex production process. In some cases, minor interference or disoperation may result in large economic losses. To improve control performance and enhance system robustness, an optimal tension and thickness control method is presented in this paper. The control method is designed based on the receding horizon control (RHC) strategy, which has good tracking performance and strong constraint handling capability. First, a state space model is constructed to describe the tension and thickness of the tandem cold rolling process. Then, according to the system model, a RHC controller is designed and introduced into the control system. Based on field data, model verification and a series of experiments are completed. The results show that the proposed RHC control strategy can effectively reduce the effects of disturbances and has excellent control performance compared with the conventional proportion and integration (PI) control strategy.

High Speed Roll-to-Roll Printable Transistor Enabled by a Pulsed Light Curable CNT Ink

This paper reports the first high speed roll-to-roll printable transistor using a carbon nanotube (CNT) semiconducting layer. The transistor is made possible through the development of a pulsed light curable CNT ink compatible with typical drop on demand inkjet cartridges. This CNT ink uses a xylene based solvent with methanol, glycerin, and Triton X-100 modifiers to create an evaporable solution with appropriate absorption spectra for a mercury or xenon flash lamp with strong energy transmission in the UVB to mid visible light range, allowing the solution to absorb the energy from the flash lamp and evaporate. Transistor dimensions were defined by the capabilities of a typical roll-to-roll drop on demand cartridge. The final device demonstrated an on/off ratio of 104, representing performance similar to gravure printed devices. This represents the first CNT ink which can be used in high speed production methods without long thermal curing steps in the workflow.

Research and Implementation of Partition Detection Algorithm Based on Defects of sanitary Products

In order to solve the problem of detecting the surface stains of the unfixed shading flexible sanitary Products, a new detection algorithm was proposed to realize the rapid and accurate detection of the unfixed shading flexible sanitary products.In the detection algorithm, the collected sample images are first pre-processed, and then the threshold image segmentation method is used in the sample images to perform partitioning, and different mathematical morphology processes are performed according to different partition regions; Then, the segmented image processed by mathematical morphology is subjected to defect detection of its suitable algorithm according to its different regional features; Finally, the stains are extracted by using the dilation, erosion, and connectivity of the region.The algorithm is implemented by Halcon operator of MVtec company in Germany. Experiments show that the algorithm can identify edge stains, cotton pad stains and cotton core stains well. The average time overhead is 92ms and the detection accuracy is 100%. Compared with the traditional method, the method in this paper is robust and fast, and can meet the needs of industrial high-speed production.

The Analysis of Weak Base ASP Flooding Injection-production Capacity

Weak base ASP flooding is an important technique to replace oil production. Field tests show that weak base ASP flooding achieves the good effect of EOR 18% in classIIreservoir, and has many other advantages such as strong injection-production capacity, high production speed and oil increasing multiples, light scaling and emulsion level and easy to clean. It has a broad prospect. This paper analyzes the changing characteristics of weak base ASP flooding injection-production capacity, compares two types of polymer flooding blocks with similar reservoir conditions, identifies key factors affecting injection-production capacity and provides insights for future development of weak base ASP flooding in classII reservoirs.

Algorithm-based Verification of Manufacturing Constraints for a Loadpath Reinforced Fabric

Lightweight construction has become increasingly important in recent decades. The fundamental idea of lightweight design is not to save weight at any price, but to use resources responsibly. Less waste and the right material in the right place can save costs and reduce energy consumption. Lightweight construction often increases design complexity. Algorithms can help to solve highly complicated design tasks effectively. This paper shows how load paths can be used to reinforce a component optimally. The load path method is an efficient way of structural reinforcement. It also fits perfectly to a new manufacturing method which will be shortly discussed: A textile machine for biaxial NCF (non crimp fabrics) with a special unit for offsetting warps of carbon fibers. This novel technology allows the reinforcing material to be placed at exactly the right place at high production speeds. The base material can be a cheaper fiber, such as glass fiber, the local reinforcement material can be a high performance fiber, such as carbon fiber. The manufacturing process is only considered to the extent that all relevant manufacturing restrictions can be extracted. Five key restrictions are being studied (e.g. minimal curvature radius or minimal and maximal stacking angle). All restriction can be broken down to geometrical information and formulated as various mathematical problems. These problems can be solved efficiently by known algorithms.

Precipitation kinetics and structure of η precipitates in 7N01 aluminium alloy

ABSTRACT7N01 Al alloy is used extensively in high-speed train production. The mechanical properties of Al–Zn–Mg–Cu alloys are known to be closely related to the characteristics of their precipitates, which are greatly affected by the heat-treatment temperature. Herein, differential scanning calorimetry (DSC) and transmission electron microscopy (TEM) were used to investigate the precipitation kinetics and structure of η precipitates in 7N01 alloy. The solution temperature range of precipitation and the activation energy of η were determined using DSC analysis, and the chemical composition and crystal structure of the η precipitates were characterised using TEM. A relationship between the solution temperature and crystal structure was established, providing insight into the selection of the heat-treatment temperature for 7N01 alloy.

Surface Defect Classification for Hot-Rolled Steel Strips by Selectively Dominant Local Binary Patterns

Developments in defect descriptors and computer vision-based algorithms for automatic optical inspection (AOI) allows for further development in image-based measurements. Defect classification is a vital part of an optical-imaging-based surface quality measuring instrument. The high-speed production rhythm of hot continuous rolling requires an ultra-rapid response to every component as well as algorithms in AOI instrument. In this paper, a simple, fast, yet robust texture descriptor, namely selectively dominant local binary patterns (SDLBPs), is proposed for defect classification. First, an intelligent searching algorithm with a quantitative thresholding mechanism is built to excavate the dominant non-uniform patterns (DNUPs). Second, two convertible schemes of pattern code mapping are developed for binary encoding of all uniform patterns and DNUPs. Third, feature extraction is carried out under SDLBP framework. Finally, an adaptive region weighting method is built for further strengthening the original nearest neighbor classifier in the feature matching stage. The extensive experiments carried out on an open texture database (Outex) and an actual surface defect database (Dragon) indicates that our proposed SDLBP yields promising performance on both classification accuracy and time efficiency.

Printing pressure uniformization of a roll-to-roll system using roll runout

Printed electronics refers to the technology of fabricating electronic devices by applying the printing process method to thin films. Printed electronics is regarded as a promising industry of the future because of its relatively low cost, simple process, and high mass production capacity, which are all superior to existing manufacturing methods. Roll-to-roll printing is a suitable technology for printed electronics with large-scale and high-speed mass production. To commercialize roll-to-roll printing technology, it is necessary to develop technology for position control of the web, tension control of the web, printing pressure control, and functional ink development. Among them, the printing pressure uniformization by the printing pressure control is an important factor that significantly affects the printing quality. In the roll-to-roll printing process, the functional ink is transferred by the nip generated by the printing pressure. That is, if the nip can be kept uniform by applying the printing pressure uniformly, the uniformity of the line width and thickness of the printed pattern is improved. This nip occurs on a line connecting the geometric center of the two rolls, and the centers of the two rolls are on the orbit line by each roll runout. Therefore, the print pressure can be estimated through the change in the inter-center distance of the rolls caused by the roll runout. In this study, we propose a method of printing pressure uniformization using roll runout. After establishing initial conditions that minimize change in printing pressure, load cells are used to estimate and verify the initial conditions that minimized the change in the inter-center distance of rolls, and pressure sensitive paper is used to verify whether the actual printing pressure is minimized.

Research and Implementation of Signature Detection Based on Matching Algorithm

Errors such as wrong signature or upside down signature occur mostly during gathering in a bookbinding production line, and affect the quality of bookbinding. This paper presents a new algorithm for signature detection to detect these errors rapidly and accurately. The algorithm constructs scale space firstly by making use of pyramid method in morphology, then creates a region of interest by selecting a appropriate Pyramid image, extracts features from regions of interest, and make them matching templates, furthermore, filters the sample image and extracts the contour, finally selects the appropriate similarity coefficient for template matching, and obtain the matching results. This algorithm is implemented with MVtec Haclon software. Experiments show that the algorithm can anti-rotation, has strong robustness. The matching accuracy is 100%, meanwhile, the low time consumption of the algorithm can meet the demand of high-speed production.