Machine Learning in Electric Motor Production - Potentials, Challenges and Exemplary Applications

Artificial intelligence entails a wide range of technologies, which provide great potential for tomorrow's electric motor production. Above all, data-driven techniques such as machine learning (ML) are increasingly moving into focus. ML provides systems the ability to automatically learn and improve from data without being explicitly programmed. However, the potential of ML has not yet been tapped by most electric motor manufacturers. Therefore, this paper aims to summarize potential applications of ML along the whole process chain. To do so, basic methods, potentials and challenges of ML are discussed first. Secondly, special characteristics of the application domain are outlined. Building on this, various ML approaches directly relating to electric motor production are presented. In addition, a selection of transferable approaches from related sectors is included, as many ML approaches can be used across industries. In conclusion, the given overview of different ML approaches helps practitioners to better assess the possibilities and limitations of ML. Moreover, it encourages the identification and exploitation of further ML use cases in electric motor production.

[1]  Nitin Ambhore,et al.  A Review on Tool Wear Monitoring System , 2016 .

[2]  Jörg Franke,et al.  Elektromotorenproduktion 4.0 , 2019, Zeitschrift für wirtschaftlichen Fabrikbetrieb.

[3]  Alexander Steinecker,et al.  Automated fault detection using deep belief networks for the quality inspection of electromotors , 2014 .

[4]  Hongzhi Cui,et al.  Quality assessment of resistance spot welding process based on dynamic resistance signal and random forest based , 2018 .

[5]  Sung-Hoon Ahn,et al.  Smart Machining Process Using Machine Learning: A Review and Perspective on Machining Industry , 2018, International Journal of Precision Engineering and Manufacturing-Green Technology.

[6]  Robert Tibshirani,et al.  The Elements of Statistical Learning: Data Mining, Inference, and Prediction, 2nd Edition , 2001, Springer Series in Statistics.

[7]  Ian H. Witten,et al.  Data mining: practical machine learning tools and techniques, 3rd Edition , 1999 .

[8]  Jörg Franke,et al.  I4.0-compliant integration of assets utilizing the Asset Administration Shell , 2019, 2019 24th IEEE International Conference on Emerging Technologies and Factory Automation (ETFA).

[9]  Katharina Morik,et al.  Quality Prediction in Interlinked Manufacturing Processes based on Supervised & Unsupervised Machine Learning , 2013 .

[10]  Jannes Slomp,et al.  A Proposal to Use Artificial Neural Networks for Process Control of Punching/Blanking Operations , 2004 .

[11]  Arthur L. Samuel,et al.  Some Studies in Machine Learning Using the Game of Checkers , 1967, IBM J. Res. Dev..

[12]  Alberto Tellaeche,et al.  Machine learning algorithms for quality control in plastic molding industry , 2013, 2013 IEEE 18th Conference on Emerging Technologies & Factory Automation (ETFA).

[13]  Hongtao Zhang,et al.  A study of welding process modeling based on Support Vector Machines , 2011, Proceedings of 2011 International Conference on Computer Science and Network Technology.

[14]  Bernardete Ribeiro,et al.  Support vector machines for quality monitoring in a plastic injection molding process , 2005, IEEE Transactions on Systems, Man, and Cybernetics, Part C (Applications and Reviews).

[15]  Achim Kampker,et al.  Potenziale und Hürden von Data Analytics in der Serienfertigung , 2019 .

[16]  Mojtaba Salehi,et al.  On-line analysis of out-of-control signals in multivariate manufacturing processes using a hybrid learning-based model , 2011, Neurocomputing.

[17]  Mika Liukkonen,et al.  Computational intelligence in mass soldering of electronics - A survey , 2012, Expert Syst. Appl..

[18]  Ken Goldberg,et al.  Learning ambidextrous robot grasping policies , 2019, Science Robotics.

[19]  Young-Jin Cha,et al.  Fully automated vision-based loosened bolt detection using the Viola–Jones algorithm , 2019 .

[20]  Marcello Colledani,et al.  Zero Defect Manufacturing Strategies for Reduction of Scrap and Inspection Effort in Multi-stage Production Systems , 2018 .

[21]  Ahmet Çalık,et al.  Failure load prediction of single lap adhesive joints using artificial neural networks , 2016 .

[22]  Bin Xu,et al.  Predict failures in production lines: A two-stage approach with clustering and supervised learning , 2016, 2016 IEEE International Conference on Big Data (Big Data).

[23]  Alessandro Goedtel,et al.  A comprehensive evaluation of intelligent classifiers for fault identification in three-phase induction motors , 2015 .

[24]  Andreas Mayr,et al.  Electric Motor Production 4.0 – Application Potentials of Industry 4.0 Technologies in the Manufacturing of Electric Motors , 2018, 2018 8th International Electric Drives Production Conference (EDPC).

[25]  Andreas Maier,et al.  Analysis of Forming Limits in Sheet Metal Forming with Pattern Recognition Methods. Part 1: Characterization of Onset of Necking and Expert Evaluation , 2018, Materials.

[26]  Ibrahim Masood,et al.  Recognition of unnatural variation patterns in metal-stamping process using artificial neural network and statistical features , 2016 .

[27]  Jörg Franke,et al.  Concept for Magnet Intra Logistics and Assembly Supporting the Improvement of Running Characteristics of Permanent Magnet Synchronous Motors , 2016 .

[28]  D. Coupek,et al.  Cloud-based control for downstream defect reduction in the production of electric motors , 2016, 2016 International Conference on Electrical Systems for Aircraft, Railway, Ship Propulsion and Road Vehicles & International Transportation Electrification Conference (ESARS-ITEC).

[29]  Jin Chun Song,et al.  Research on Hydraulic Control System of Straightening Machine with Nine Rolls for Plates Based on BP Neural Network PID Controller , 2013 .

[30]  Achim Kampker,et al.  Ex-Ante Process-FMEA for Hairpin Stator Production by Early Prototypical Production Concepts , 2018, 2018 8th International Electric Drives Production Conference (EDPC).

[31]  Meiabadi Mohammad Saleh,et al.  Optimization of Plastic Injection Molding Process by Combination of Artificial Neural Network and Genetic Algorithm , 2013 .

[32]  Manoj Kumar Tiwari,et al.  Data mining in manufacturing: a review based on the kind of knowledge , 2009, J. Intell. Manuf..

[33]  Claudia Brückner Qualitätsmanagement: Das Praxishandbuch für die Automobilindustrie , 2011 .

[34]  Haitao Zhou,et al.  Punching process monitoring using wavelet transform based feature extraction and semi-supervised clustering , 2018 .

[35]  Thomas G. Habetler,et al.  A Survey on Testing and Monitoring Methods for Stator Insulation Systems of Low-Voltage Induction Machines Focusing on Turn Insulation Problems , 2008, IEEE Transactions on Industrial Electronics.

[36]  J. Domińczuk,et al.  Modelling of adhesive joints and predicting their strength with the use of neural networks , 2008 .

[37]  Marco F. Huber,et al.  Enhancing Decision Tree Based Interpretation of Deep Neural Networks through L1-Orthogonal Regularization , 2019, 2019 18th IEEE International Conference On Machine Learning And Applications (ICMLA).

[38]  Ralf Böhm,et al.  Quo vehis, Elektromobilität? , 2018 .

[39]  Akbar Shojaei,et al.  Prediction and optimization of cure cycle of thick fiber-reinforced composite parts using dynamic artificial neural networks , 2012 .

[40]  S. Satorres Martínez,et al.  Quality inspection of machined metal parts using an image fusion technique , 2017 .

[41]  Kaspar Althoefer,et al.  Automated failure classification for assembly with self-tapping threaded fastenings using artificial neural networks , 2008 .

[42]  Jürgen Fleischer,et al.  Handbuch der Wickeltechnik für hocheffiziente Spulen und Motoren , 2016 .

[43]  อนิรุธ สืบสิงห์,et al.  Data Mining Practical Machine Learning Tools and Techniques , 2014 .

[44]  Andreas Mayr,et al.  Cross-Process Quality Analysis of X-ray Tubes for Medical Applications Using Machine Learning Techniques: Prozessübergreifende Qualitätsanalyse von Röntgenstrahlern für medizinische Anwendungen auf Basis maschineller Lernverfahren , 2019 .

[45]  Andreas Mayr,et al.  Towards a Data-Driven Process Monitoring for Machining Operations Using the Example of Electric Drive Production , 2018, 2018 8th International Electric Drives Production Conference (EDPC).

[46]  Joerg Franke,et al.  Process Reliable Laser Welding of Hairpin Windings for Automotive Traction Drives , 2019, 2019 International Conference on Engineering, Science, and Industrial Applications (ICESI).

[47]  Yuanyuan Liu,et al.  An Intelligent Decoupling Control Scheme for Vacuum Casting Process , 2009, 2009 WRI World Congress on Computer Science and Information Engineering.

[48]  Peter Vrancx,et al.  Model-free learning of wire winding control , 2013, 2013 9th Asian Control Conference (ASCC).

[49]  Patanjali Kashyap,et al.  Industrial Applications of Machine Learning , 2017 .

[50]  Yang Fei,et al.  Bolt force prediction using simplified finite element model and back propagation neural networks , 2016, 2016 IEEE Information Technology, Networking, Electronic and Automation Control Conference.

[51]  Franz Dietrich,et al.  DEVELOPMENT OF AN AUTOMATED ASSEMBLY PROCESS SUPPORTED WITH AN ARTIFICIAL NEURAL NETWORK , 2018 .

[52]  Richard S. Sutton,et al.  Reinforcement Learning: An Introduction , 1998, IEEE Trans. Neural Networks.

[53]  Johannes Seefried,et al.  Challenges in the manufacturing of hairpin windings and application opportunities of infrared lasers for the contacting process , 2017, 2017 7th International Electric Drives Production Conference (EDPC).

[54]  Thomas Reinartz,et al.  CRISP-DM 1.0: Step-by-step data mining guide , 2000 .

[55]  Jörg Franke,et al.  Towards an inline quick reaction system for actuator manufacturing using data mining , 2016, 2016 6th International Electric Drives Production Conference (EDPC).

[56]  Yu Zhang,et al.  Machine Learning-Based Fault Diagnosis for Single- and Multi-Faults in Induction Motors Using Measured Stator Currents and Vibration Signals , 2019, IEEE Transactions on Industry Applications.

[57]  Hua Lu,et al.  Research on precision tension control system based on neural network , 2004, IEEE Transactions on Industrial Electronics.

[58]  Klaus-Dieter Thoben,et al.  Changing States of Multistage Process Chains , 2016 .

[59]  Jörg Franke,et al.  Conceptual design of an intelligent ultrasonic crimping process using machine learning algorithms , 2018 .

[60]  Ashutosh Kumar Singh,et al.  The Elements of Statistical Learning: Data Mining, Inference, and Prediction , 2010 .

[61]  Prasad Krishna,et al.  Back propagation genetic and recurrent neural network applications in modelling and analysis of squeeze casting process , 2017, Appl. Soft Comput..

[62]  Laura Palagi,et al.  Modelling the Electrostatic Fluidised Bed (EFB) coating process using Support Vector Machines (SVMs) , 2014 .

[63]  Jörg Franke,et al.  6DoF Pose-Estimation Pipeline for Texture-less Industrial Components in Bin Picking Applications , 2019, 2019 European Conference on Mobile Robots (ECMR).

[64]  Marieke Rohde,et al.  POTENTIAL OF ARTIFICIAL INTELLIGENCE IN GERMANY’S PRODUCING SECTOR , 2018 .

[65]  Klaus Bauer,et al.  Big Data in manufacturing systems engineering – close up on a machine tool , 2016, Autom..

[66]  Jörg Franke,et al.  Distributed condition monitoring systems in electric drives manufacturing , 2016, 2016 6th International Electric Drives Production Conference (EDPC).

[67]  Mauridhi Hery Purnomo,et al.  Welding defect classification based on convolution neural network (CNN) and Gaussian kernel , 2017, 2017 International Seminar on Intelligent Technology and Its Applications (ISITIA).

[68]  Bernardete Ribeiro,et al.  Model Prediction of Defects in Sheet Metal Forming Processes , 2018, EANN.

[69]  Armin Lechler,et al.  Cloud-Based Control Strategy: Downstream Defect Reduction in the Production of Electric Motors , 2017, IEEE Transactions on Industry Applications.

[70]  Arun Kumar Pandey,et al.  Neuro Fuzzy Modeling of Laser Beam Cutting Process , 2011 .

[71]  A. Pandey,et al.  Intelligent Modeling of Laser Cutting of Thin Sheet , 2011 .

[72]  Taghi M. Khoshgoftaar,et al.  A survey on Image Data Augmentation for Deep Learning , 2019, Journal of Big Data.

[73]  Jörg Franke,et al.  Sustainability Aspects of Current Market Developments, Different Product Types and Innovative Manufacturing Processes of Electric Motors , 2018 .

[74]  Andreas Mayr,et al.  Evaluation of Machine Learning for Quality Monitoring of Laser Welding Using the Example of the Contacting of Hairpin Windings , 2018, 2018 8th International Electric Drives Production Conference (EDPC).

[75]  Sehyeok Oh,et al.  Deep learning model for predicting hardness distribution in laser heat treatment of AISI H13 tool steel , 2019, Applied Thermal Engineering.

[76]  María Teresa García-Ordás,et al.  Tool wear monitoring using an online, automatic and low cost system based on local texture , 2018, Mechanical Systems and Signal Processing.

[77]  Achimaş Gheorghe,et al.  INVESTIGATIONS ON SPRINGBACK OF BENT TUBES USING DESIGN OF EXPERIMENT AND ARTIFICIAL NEURAL NETWORKS , 2007 .

[78]  Jörg Franke,et al.  Application Scenarios of Artificial Intelligence in Electric Drives Production , 2018 .

[79]  Pedro Pedrosa Rebouças Filho,et al.  New approach to evaluate a non-grain oriented electrical steel electromagnetic performance using photomicrographic analysis via digital image processing , 2019, Journal of Materials Research and Technology.

[80]  Armin Lechler,et al.  Selective rotor Assembly Using Fuzzy Logic in the Production of Electric Drives , 2015 .

[81]  Yi-Horng Lai,et al.  Analysis of Permanent Magnet Synchronous Motor Fault Diagnosis Based on Learning , 2019, IEEE Transactions on Instrumentation and Measurement.

[82]  Achim Kampker,et al.  Exhaustive Data- and Problem-Driven use Case Identification and Implementation for Electric Drive Production , 2018, 2018 8th International Electric Drives Production Conference (EDPC).

[83]  Andreas Mayr,et al.  Potentials of machine learning in electric drives production using the example of contacting processes and selective magnet assembly , 2017, 2017 7th International Electric Drives Production Conference (EDPC).

[84]  Franziska Schäfer,et al.  Synthesizing CRISP-DM and Quality Management: A Data Mining Approach for Production Processes , 2018, 2018 IEEE International Conference on Technology Management, Operations and Decisions (ICTMOD).

[85]  Marcello Colledani,et al.  A cyber-physical system for quality-oriented assembly of automotive electric motors , 2018 .

[86]  Jörg Franke,et al.  A novel approach for data-driven process and condition monitoring systems on the example of mill-turn centers , 2018, Prod. Eng..

[87]  Chun Lin,et al.  Resistance Welding Spot Defect Detection with Convolutional Neural Networks , 2017, ICVS.

[88]  Johannes Günther Machine intelligence for adaptable closed loop and open loop production engineering systems , 2018 .

[89]  Jörg Franke,et al.  Towards a Smart Electronics Production Using Machine Learning Techniques , 2019, 2019 42nd International Spring Seminar on Electronics Technology (ISSE).

[90]  Francesco Piazza,et al.  Unsupervised electric motor fault detection by using deep autoencoders , 2019, IEEE/CAA Journal of Automatica Sinica.

[91]  Braz de Jesus Cardoso Filho,et al.  Evaluation of electrical insulation in three-phase induction motors and classification of failures using neural networks , 2016 .

[92]  S. Rhee,et al.  An ANFIS based approach for predicting the weld strength of resistance spot welding in artificial intelligence development , 2017 .

[93]  K. Rameshkumar,et al.  Use of Machine Learning Algorithms for Weld Quality Monitoring using Acoustic Signature , 2015 .

[94]  Che Hassan Che Haron,et al.  Application of ANN in milling process: a review , 2011 .

[95]  Spiros Pantelakis,et al.  Assessing the quality of adhesive bonded joints using an innovative neural network approach , 2014 .

[96]  Andrés Bustillo,et al.  Artificial intelligence for automatic prediction of required surface roughness by monitoring wear on face mill teeth , 2017, Journal of Intelligent Manufacturing.

[97]  Giovanni De Magistris,et al.  Deep reinforcement learning for high precision assembly tasks , 2017, 2017 IEEE/RSJ International Conference on Intelligent Robots and Systems (IROS).

[98]  Petter Kyösti,et al.  Machine learning for detection of anomalies in press-hardening: Selection of efficient methods , 2018 .

[99]  Dalibor Petković,et al.  Prediction of laser welding quality by computational intelligence approaches , 2017 .

[100]  Jörg Franke,et al.  Challenges of the Hairpin Technology for Production Techniques , 2018, 2018 21st International Conference on Electrical Machines and Systems (ICEMS).

[101]  Stephen C. Adams,et al.  A Condition Monitoring System for Low Vacuum Plasma Spray using Computer Vision , 2018, 2018 IEEE International Conference on Prognostics and Health Management (ICPHM).

[102]  Srdjan Jovic,et al.  Evaluation of laser cutting process with auxiliary gas pressure by soft computing approach , 2018, Infrared Physics & Technology.

[103]  Andreas Mayr,et al.  Six Sigma 4.0 , 2019, Zeitschrift für wirtschaftlichen Fabrikbetrieb.

[104]  Thorsten Wuest,et al.  Holistic approach to machine tool data analytics , 2018, Journal of Manufacturing Systems.

[105]  J. Franke,et al.  Manufacturing Imperfections in Electric Motor Production with Focus on Halbach Array Permanent Magnet Rotor Assembly , 2018, 2018 8th International Electric Drives Production Conference (EDPC).

[106]  Varun Jampani,et al.  Training Deep Networks with Synthetic Data: Bridging the Reality Gap by Domain Randomization , 2018, 2018 IEEE/CVF Conference on Computer Vision and Pattern Recognition Workshops (CVPRW).

[107]  Chiun-Hsun Chen,et al.  Motor Fault Detection and Feature Extraction Using RNN-Based Variational Autoencoder , 2019, IEEE Access.