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In the Industry 4.0 era, a myriad of sensors of diverse nature (temperature, pressure, etc.) is spreading throughout the entire value chain of industries, being potentially exploitable for multiple purposes, such as Predictive Maintenance (PdM): the just-in-time maintenance of industrial assets, which results in reduced operating costs, increased operator safety, etc. Nowadays, industrial processes require to be highly configurable, in order to proactively adapt their operation to diverse factors such as user needs, product updates or supply chain uncertainties. This limits current Industry 4.0-PdM solutions, typically consisting of ad-hoc developments intended for specific scenarios, i.e. they are designed to operate under certain conditions (configurations, employed sensors, etc.), being unable to manage changes in their setup. This paper presents a general Deep Learning (DL) architecture, MachNet, which deals with such heterogeneity and is able to address PdM problems of a diverse nature. The modularity of the proposed architecture enables it to deal with an arbitrary number of sensors of different types, also allowing the integration of prior information (age of assets, material type, etc.), which clearly affects performance and is often neglected. In practice, our architecture effortlessly adapts to the assets' specifications and to different PdM problems. That is, MachNet becomes an architectural template that can be instantiated for a given scenario. We tested our proposal in two different PdM-related problems: Health State (HS) and Remaining-useful-Life (RuL) estimation, achieving in both cases comparable or superior performance to other state-of-the-art approaches, with the additional advantage of the generality that MachNet offers. [ABSTRACT FROM AUTHOR]

The wider availability of low-cost sensing and data acquisition technologies means that real-time sensing of tribological parameters is becoming increasingly viable. Consequently, the potential to use these technologies to monitor in-service tribological components has increased significantly. This paper presents a review of a number of state-of-the-art in sensors for measuring friction, wear and lubricant properties. It also elaborates on the use of sensor coatings as an emerging area for directly probing the tribological interface. It is concluded that sensors will find ever increasing uses in condition monitoring" applications. However, sensing and tribology is beginning to evolve towards "Tribotronics" where combining the sensing of machine elements that have conventionally been passive with computational capability, or even embedded intelligence, along with actuation can create active machine elements, optimised to operate with say minimum power loss in all situations of duty. Additionally, it is noted that by incorporating sensing and responsive capabilities, functional surfaces can also become part of a bigger connected systems particularly in association with Industry 4.0. Increased use of sensors in tribological components alongside machine learning and artificial intelligence, will also support the shift in industrial tribological analytics. [ABSTRACT FROM AUTHOR]

In the railway domain, rolling stock maintenance affects service operation time and efficiency. Minimizing train unavailability is essential for reducing capital loss and operational costs. To this aim, prediction of failures of rolling stock equipment is crucial to proactively trigger proper maintenance activities. Indeed, predictive maintenance is a golden example of the digital transformation within Industry 4.0, which affects several engineering processes in the railway domain. Nowadays, it may leverage artificial intelligence and machine learning algorithms to forecast failures and schedule the optimal time for maintenance actions. Generally, rail systems deteriorate gradually over time or fail directly, leading to data that vary extremely slowly. Indeed, ML approaches for predictive maintenance should consider this type of data to accurately predict and forecast failures. This paper proposes a methodology based on Long Short-Term Memory deep learning algorithms for predictive maintenance of railway rolling stock equipment. The methodology allows us to properly learn long-term dependencies for gradually changing data, and both predicting and forecasting failures of rail equipment. In the framework of an academic-industrial partnership, the methodology is experimented on a train traction converter cooling system, demonstrating its applicability and benefits. The results show that it outperforms state-of-the-art methods, reaching a failure prediction and forecasting accuracy over 99%, with a false alarm rate of ∼ 0. 4 % and a mean absolute error in the order of 1 0 − 4 , respectively. [ABSTRACT FROM AUTHOR]

• Process intensification 4.0 (PI4.0) framework allows system-level transformations. • PI4.0 incorporates a data approach based on the design principles of industry 4.0. • An iterative design strategy is presented as the backbone of PI4.0. • Machine Learning/advanced computing accelerate knowledge discovery, driving PI4.0. • Different case studies are reviewed that support the philosophy behind PI4.0. This paper reviews system-level transformations converging into the next generation of Process Intensification strategies defined as PI4.0. Process Intensification 4.0 uses data-driven algorithms to understand other physical and chemical processes that improve equipment design, predictive control, and optimization. Following this, an overview of the use of Artificial Intelligence techniques, particularly Machine Learning for the acceleration of equipment design, process optimization, and streamlining, is presented. This work will highlight and discuss the emerging framework of the integration between Circular Chemistry, Industry 4.0, and Process Intensification and how the data obtained from this integration is at the core of the next generation of Process Intensification strategies. This is supported by a discussion of different cases that apply data-driven models enabled by Machine Learning as a mean to enhance an intensified system (product synthesis, equipment or methods). [Display omitted] [ABSTRACT FROM AUTHOR]

Recent trends in intelligent manufacturing are transforming shop floor environments into digital factories, thanks to a pervasive integration of information and communication technologies in production lines. Industrial processes become the source of high-volume heterogeneous data, paving the way to create manufacturing intelligence by means of machine learning and data-driven methodologies. In such settings, predictive diagnostics play a crucial role, as they promise to predict future critical conditions in the production process. Unfortunately, the diffusion of data-driven predictive maintenance methodologies is limited by (i) the absence of timely ground-truth knowledge (i.e., class labels), required in the learning phase of data-driven supervised approaches, and (ii) the limited availability of data-mining expertise among application-domain experts, required to harness the power of machine learning techniques. Innovative data-driven services are needed to support domain experts in (i) applying powerful self-learning intelligent techniques with limited technical expertise and (ii) easily understanding results and choices operated by such intelligent techniques, to increase trust by means of transparency. To this aim, this paper presents UDaMP, an integrated platform to support manufacturing intelligence by providing a transparent, self-tuning, unsupervised discovery and assisted data labelling service for predictive maintenance, specifically targeted at cyclic industrial processes. UDaMP includes (i) production-cycle-aware feature engineering, (ii) unsupervised discovery of production-cycle categories, (iii) self-tuning of the optimal number of categories, (iv) human-readable characterisation of production-cycle categories, and (v) assisted data labelling for domain experts. Scalable clustering algorithms automatically discover groups of production cycles sharing common time-independent properties. A self-tuning strategy is integrated to automatically configure the specific input parameter and select the best approach for the data under analysis. Each cluster is then locally characterised through the data distribution of the top 10 most relevant features to support domain experts in uncovering its meaning. Experimental evaluation of UDaMP has been performed on real-world data collected in two different industrial settings. • Semi-supervised labelling of production cycles for predictive maintenance. • Wide applicability to any cycle-based production process without ground truth labels. • Exploitable by domain experts thanks to transparent self-tuning techniques. [ABSTRACT FROM AUTHOR]