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Context awareness in process monitoring of additive manufacturing using a digital twin
Technology Department, Siemens AG, 81739, Munich, Germany; Chair of Robotics, Artificial Intelligence and Real-Time Systems, Technical University of Munich, 80333, Munich, Germany.
Luleå University of Technology, Department of Engineering Sciences and Mathematics, Product and Production Development. Technology Department, Siemens AG, 81739, Munich, Germany.ORCID iD: 0000-0002-3403-5602
Technology Department, Siemens AG, 81739, Munich, Germany.
Chair of Robotics, Artificial Intelligence and Real-Time Systems, Technical University of Munich, 80333, Munich, Germany.
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2022 (English)In: The International Journal of Advanced Manufacturing Technology, ISSN 0268-3768, E-ISSN 1433-3015, Vol. 119, no 5-6, p. 3483-3500Article in journal (Refereed) Published
Abstract [en]

Wire Arc Additive Manufacturing allows the cost-effective manufacturing of customized, large-scale metal parts. As the post-process quality assurance of large parts is costly and time-consuming, process monitoring is inevitable. In the present study, a context-aware monitoring solution was investigated by integrating machine, temporal, and spatial context in the data analysis. By analyzing the voltage patterns of each cycle in the oscillating cold metal transfer process with a deep neural network, temporal context was included. Spatial context awareness was enabled by building a digital twin of the manufactured part using an Octree as spatial indexing data structure. By means of the spatial context awareness, two quality metrics—the defect expansion and the local anomaly density—were introduced. The defect expansion was tracked in-process by assigning detected defects to the same defect cluster in case of spatial correlation. The local anomaly density was derived by defining a spherical region of interest which enabled the detection of aggregations of anomalies. By means of the context aware monitoring system, defects were detected in-process with a higher sensitivity as common defect detectors for welding applications, showing less false-positives and false-negatives. A quantitative evaluation of defect expansion and densities of various defect types such as pore nests was enabled.

Place, publisher, year, edition, pages
Springer, 2022. Vol. 119, no 5-6, p. 3483-3500
Keywords [en]
Anomaly detection, Digital twin, Process monitoring, Smart manufacturing, Wire Arc Additive Manufacturing
National Category
Manufacturing, Surface and Joining Technology
Research subject
Manufacturing Systems Engineering
Identifiers
URN: urn:nbn:se:ltu:diva-88876DOI: 10.1007/s00170-021-08636-5ISI: 000739828400008Scopus ID: 2-s2.0-85122427749OAI: oai:DiVA.org:ltu-88876DiVA, id: diva2:1631861
Note

Validerad;2022;Nivå 2;2022-03-10 (johcin)

Available from: 2022-01-25 Created: 2022-01-25 Last updated: 2022-07-05Bibliographically approved

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Hauser, Tobias

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