16-10-2021

Manufacturing and
Automation in Industry
Tegoeh Tjahjowidodo

Telephone: +32 15 68 81 43
Email: tegoeh.tjahjowidodo@kuleuven.be

About Me
• Tegoeh Tjahjowidodo, PhD
• Graduated from Katholieke Universiteit Leuven, Belgium, in 2006
• Working Experiences:
• 2006 – 2009 : Senior Researcher at Flanders Mechatronics Technology Center, Belgium
• 2009 – 2019 : Associate Professor at School of Mechanical and Aerospace Engineering, Nanyang Technological
University, Singapore
• 2017 – 2019 : Collaboration Director at Advanced Remanufacturing and Technology Centre A-Star (ARTC)
• 2018 – 2019 : Assistant Chair of Research at School of Mechanical and Aerospace Engineering, Nanyang Technological
University, Singapore
• 2019 - … : Associate Professor at Mechanical Department, KU Leuven, Belgium
• 2019 - … : Adjunct Professor at School of Mechanical and Aerospace Engineering, Nanyang Technological
University, Singapore

• Research interests:
• Nonlinear mechanics (modeling, identification and control)
• Measurements and Sensing Systems
• Diagnostics and Prognostics

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Industry 4.0
Industry 4.0 or IoT?

INDUSTRY 4.0

AUTOMATION CONNECTION CLOUD IoT BIG DATA SYSTEM

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Industry 4.0: more than ‘just’ connectivity

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What is Industry 4.0?

Conventional industry approach:

Production processes are delivered in sequential way.

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What is Industry 4.0? (cont’d)

Modern industry approach:

• There exist one central mind that knows how the final product will look like.
• This mind is a central control unit, communicating with and giving instructions to individual module.
• Each module releases its own results back to the central hub until the final product is completed

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What is Industry 4.0? (cont’d)

Industry 4.0

• Each individual module has its own mind, this means, they have a certain degree of self control.
• This is possible because the instruction for the single work step is tagged on the product, so each module knows what to do,
with less communication with the central hub.
• In addition, the modules in smart factory are able to communicate to each other, so the product can be passed on to the
proper module.
YI6898/YI6899  faster with distributed control

Manufacturing
Industry 4.0… floor
System Integration & Cyber Security

• Big data
Industry 4.0 involves Monitoring • AI
multidisciplinary knowledge
that includes mechanical,
electrical, computer science,
Logistics/optimization
…
Smart Manufacturing

Process feedback:
- Robotics/Automation
- Augmented Reality
- 3D Printing
- Monitoring
-…

Preparing adaptable workforces Mechanical

Engineering
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Sensor Enable Industry 4.0

Similar to the four phases of industrial development,
sensors can be classified similarly.

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Schütze A. et al., (2018), Sensors 4.0 – smart sensors and measurement technology enable
Industry 4.0, J. Sens. Sens. Syst. (7), 359-371
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MONITORING IN MACHINERIES

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On-Line Monitoring
Continuous quality inspection of critical items in aerospace industry and
silicon devices in microelectronic fabrication are done by on-line
systems.

100% inspection ensures a quality standard for all products with no

sampling error.

By linking the process data and quality data, automatic fault correction
is achieved. Quality monitoring provides the industrial plants with an
ability to take quick corrective actions at the problem source.

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Condition Monitoring
• Condition monitoring (CM) is a process of monitoring a parameter of condition
in machinery (vibration, temperature etc.), in order to identify a significant
change which is indicative of a developing fault.
• The ultimate goal is to reduce the time required to identify and rectify the fault
which further increases the efficiency of the machine.
• Condition monitoring provides us the real time information about the condition
of the machine which gives us the ability to minimize or to eliminate the factors
responsible for occurrence of faults .

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Condition Monitoring
… is a process of monitoring a parameter of condition in machinery (vibration,
temperature etc.), in order to identify a significant change which is indicative of
a developing fault. It is a major component of predictive maintenance.

Direct Indirect
e.g. surface roughness
measurement using
profilometer Physics based Data driven
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Condition Monitoring
… is a process of monitoring a parameter of condition in machinery (vibration,
temperature etc.), in order to identify a significant change which is indicative of
a developing fault. It is a major component of predictive maintenance.

Direct Indirect
e.g. surface roughness
measurement using
profilometer Data driven Physics based
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Direct Measurement
Simply defined as: “measuring exactly the thing that you are looking to measure”

Example: shaft misalignment

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Physic-based Monitoring 0
o

Measurement of an entity based 90

o

on some governing laws of nature shaft 1

Poros I shaft II
Poros 2
11rotation
putaran
180
o 11siklus
cycle

d 270
o

o
360

shaft 1I
Poros Poros
shaft II
2

x x

half
turn Based on centripetal effect, a
shaft 1 force spike will be observed
Two force spikes will be full every single turn.
rotation
shaft 2
observed every single turn.
half
turn

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Data-Driven-based Monitoring
Data-driven monitoring represents a major departure from traditional monitoring.
The monitoring strategy is compelled by data, rather than by physics, by intuition
or by personal experience.

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Multi-modal Monitoring
A technique for exploiting the synergy in the information acquired from multiple
sources: sensors, database, intelligence sources, humans, etc.

Objectives:
• to obtain a better understanding of Sight Hearing
complex phenomena Smell
• to enhance intelligence and system Taste
Touch
control functions

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Process monitoring and condition monitoring

Key elements of monitoring:

1. Data acquisition
2. Feature representation and feature extraction
3. Feature selection
4. Classifier and Decision

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1. Data Acquisition
Data acquisition is the process of sampling signals that measure real world
physical conditions and converting the resulting samples into digital numeric
values that can be manipulated by a computer.

Selecting a Proper Measure!

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2. Feature Extraction
The features can be characteristic values (statistical), colors, etc.
The features must contain and keep information at highest level, so it can
represent the machine condition.
Frequency

Amplitude

type sedan Mean value

color red …

attribute plain

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3. Feature Selection

type sedan sedan truck truck bus

color red red blue blue yellow

attribute plain sticker plain sticker plain

The vehicles are characterized by three features, i.e. type, color and
attribute.
But in this case, only two of them are needed to identify the vehicle.

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type and color are redundant

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4. Classifier and Decision

Classification is the process of predicting the

class of given data points. Classes are sometimes
called as targets/ labels or categories.
Classification predictive modelling is the task of
approximating a mapping function from input
variables (x) to discrete output variables (y).

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Real-Time Surface Quality

Monitoring

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Machining Process
manual
Conventional Finishing Cell

• Automated finishing but not

OK
Machining
Process Measurement
automated control strategy.
• Operator dependency still
Not OK exists.
• Manual measurement will
Rework
slow down the cycle

In-process sensing Finishing Cell

vibration
• Automated finishing with closed
force
loop strategy.
Machining acoustic
Process • Minimum operator dependency.
• Improved production cycle.
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Indirect In-Process Sensing

Approach
• Monitoring measurable signals from the finishing process
• Correlating the signals with output values through Artificial Intelligent techniques
• Adapting the control process based on the diagnosis

measurable
signals

process indirect monitoring output

signals (machine learning) values

acoustic wafer conditioner

vibration torque emission temperature … quality wear
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Artificial Intelligence
Nothing more than a regression.

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acoustic level
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y = 2.003x - 0.5642
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15

10

0
0 5 10 15 20 vibration level

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In-process sensing for thickness measurement

Proposed Solution:
Machine Surface Quality
Learning

Data Acquisition Intelligent Polishing Process Prediction Results

Machine Learning

YI6898/YI6899 Feature Extraction Training Process Testing Process

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Demo

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US Patent: Tjahjowidodo, T., Barai, R.K., Pappachan, B.K. and Wijaya, T. (2018). Method and apparatus for
29 monitoring abrasive machining, US Application, US20180056480A1.

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Monitoring of Wire-Arc
Additive Manufacturing (WAAM)

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Background
A twin-wire WAAM setup Examples of WAAM use in industry

Chen, et. al. 2021

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Adapted from Fronius International Gmbh

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WAAM monitoring system

COBOT system Spectrometer

Workstation

Gas flow meter

Current/Voltage sensors

DAQ
[1] AE Structural
200 ~ 1000 kHz

Validation sensors
AE Airborne • Pyrometer
~20 kHz • Thermocouples
YI6898/YI6899 • Welding camera

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Sample experiment plan X-ray and microscope scans

Good weld
Acceptable porosity
Unacceptable porosity

Weld line

Sensor data
Validation data
Optical spectrum signal

Zhang, et. al. 2019

Acoustic time-frequency signal
Photos after grinding

Zhang, et. al. 2020

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Adapted from Yusof, et. al. 2017

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Experiments and setup

WAAM
component

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IR sensor Thermocouple

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Data processing and analysis

V = 10cm/18 sec = 0.55 cm/sec
Decrease of peak temperature
with more passes can be related Pass 1,3,5
to the additional mass deposited
Pass 2,4,6

IR sensor area

Capacitive effect
metal AM wall

What causes
this increase?

Base

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Torch on

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Modeling by PDE solver

Top left
Middle left

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Twin-wire welding cobot - monitoring current and AE

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Twin-wire welding cobot - monitoring current and AE

• Mistras AE sensor product testing, different sensitivity settings of pre-amplifier

AE sensor
with Pre-amplifier
magnetic gain switch
mount
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Twin-wire welding cobot - monitoring current and AE

• Mistras AE sensor product testing, different sensitivity

1500 Hz
settings of pre-amplifier 60dB preamp
-40 40dB preamp
20dB preamp
60dB preamp
2 40dB preamp -60
20dB preamp
1.5 -80

1 -100

0.5
0 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5
5 10 15 20 25 Frequency (Hz)
50 Hz 104
time (s)
40 1670 Hz
300 Start of welding 60dB preamp
60dB preamp 3000 Hz 40dB preamp
40dB preamp 20dB preamp
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200 20dB preamp

0
100

-20
0 0 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5
5 10 15 20 25
Frequency (Hz) 104
time (s)
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Twin-wire welding cobot -

monitoring current and AE
Bad weld

• Good weld and bad weld frequency spectrum

4 -40
good weld good weld
bad weld bad weld
-50
2
-60

0
-70

-80
-2
0 5 10 15 20 25 30 0 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5
time (s) Frequency (Hz) 104

400 40
good weld good weld
300 bad weld bad weld
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200
0
100

0 -20
0 5 10 15 20 25 30 0 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5
time (s) Frequency (Hz) 104

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