Chenang Liu

Zhangyue Shi, Yuxuan Li, Chenang Liu

In advanced manufacturing, the incorporation of sensing technology provides an opportunity to achieve efficient in-situ process monitoring using machine learning methods. Meanwhile, the advances of information technologies also enable a connected and decentralized environment for manufacturing systems, making different manufacturing units in the system collaborate more closely. In a decentralized manufacturing system, the involved units may fabricate same or similar products and deploy their own machine learning model for online process monitoring. However, due to the possible inconsistency of task progress during the operation, it is also common that some units have more informative data while some have less informative data. Thus, the monitoring performance of machine learning model for each unit may highly vary. Therefore, it is extremely valuable to achieve efficient and secured knowledge sharing among the units in a decentralized manufacturing system for enhancement of poorly performed models. To realize this goal, this paper proposes a novel knowledge distillation-based information sharing (KD-IS) framework, which could distill informative knowledge from well performed models to improve the monitoring performance of poorly performed models. To validate the effectiveness of this method, a real-world case study is conducted in a connected fused filament fabrication (FFF)-based additive manufacturing (AM) platform. The experimental results show that the developed method is very efficient in improving model monitoring performance at poorly performed models, with solid protection on potential data privacy.

Yuxuan Li, Chaoyue Zhao, Chenang Liu

The optimal power flow (OPF) problem, as a critical component of power system operations, becomes increasingly difficult to solve due to the variability, intermittency, and unpredictability of renewable energy brought to the power system. Although traditional optimization techniques, such as stochastic and robust optimization approaches, could be leveraged to address the OPF problem, in the face of renewable energy uncertainty, i.e., the dynamic coefficients in the optimization model, their effectiveness in dealing with large-scale problems remains limited. As a result, deep learning techniques, such as neural networks, have recently been developed to improve computational efficiency in solving OPF problems with the utilization of data. However, the feasibility and optimality of the solution may not be guaranteed, and the system dynamics cannot be properly addressed as well. In this paper, we propose an optimization model-informed generative adversarial network (MI-GAN) framework to solve OPF under uncertainty. The main contributions are summarized into three aspects: (1) to ensure feasibility and improve optimality of generated solutions, three important layers are proposed: feasibility filter layer, comparison layer, and gradient-guided layer; (2) in the GAN-based framework, an efficient model-informed selector incorporating these three new layers is established; and (3) a new recursive iteration algorithm is also proposed to improve solution optimality and handle the system dynamics. The numerical results on IEEE test systems show that the proposed method is very effective and promising.

Yuxuan Li, Chenang Liu

Machine learning (ML) has been extensively adopted for the online sensing-based monitoring in advanced manufacturing systems. However, the sensor data collected under abnormal states are usually insufficient, leading to significant data imbalanced issue for supervised machine learning. A common solution is to incorporate data augmentation techniques, i.e., augmenting the available abnormal states data (i.e., minority samples) via synthetic generation. To generate the high-quality minority samples, it is vital to learn the underlying distribution of the abnormal states data. In recent years, the generative adversarial network (GAN)-based approaches become popular to learn data distribution as well as perform data augmentation. However, in practice, the quality of generated samples from GAN-based data augmentation may vary drastically. In addition, the sensor signals are collected sequentially by time from the manufacturing systems, which means sequential information is also very important in data augmentation. To address these limitations, inspired by the multi-head attention mechanism, this paper proposed an attention-stacked GAN (AS-GAN) architecture for sensor data augmentation of online monitoring in manufacturing system. It incorporates a new attention-stacked framework to strengthen the generator in GAN with the capability of capturing sequential information, and thereby the developed attention-stacked framework greatly helps to improve the quality of the generated sensor signals. Afterwards, the generated high-quality sensor signals for abnormal states could be applied to train classifiers more accurately, further improving the online monitoring performance of manufacturing systems. The case study conducted in additive manufacturing also successfully validated the effectiveness of the proposed AS-GAN.

Yuxuan Li, Ying Lin, Chenang Liu

Investigating the causal relationships between characteristics and expressions plays a critical role in healthcare analytics. Effective synthesis for expressions using given characteristics can make great contributions to health risk management and medical decision-making. For example, predicting the resulting physiological symptoms on patients from given treatment characteristics is helpful for the disease prevention and personalized treatment strategy design. Therefore, the objective of this study is to effectively synthesize the expressions based on given characteristics. However, the mapping from characteristics to expressions is usually from a relatively low dimension space to a high dimension space, but most of the existing methods such as regression models could not effectively handle such mapping. Besides, the relationship between characteristics and expressions may contain not only deterministic patterns, but also stochastic patterns. To address these challenges, this paper proposed a novel selective ensemble characteristic-to-expression synthesis (SE-CTES) approach inspired by generative adversarial network (GAN). The novelty of the proposed method can be summarized into three aspects: (1) GAN-based architecture for deep neural networks are incorporated to learn the relatively low dimensional mapping to high dimensional mapping containing both deterministic and stochastic patterns; (2) the weights of the two mismatching errors in the GAN-based architecture are proposed to be different to reduce the learning bias in the training process; and (3) a selective ensemble learning framework is proposed to reduce the prediction bias and improve the synthesis stability. To validate the effectiveness of the proposed approach, extensive numerical simulation studies and a real-world healthcare case study were applied and the results demonstrated that the proposed method is very promising.

Amirul Islam Saimon, Emmanuel Yangue, Xiaowei Yue et al.

This paper presents the first comprehensive literature review of deep learning (DL) applications in additive manufacturing (AM). It addresses the need for a thorough analysis in this rapidly growing yet scattered field, aiming to bring together existing knowledge and encourage further development. Our research questions cover three major areas of AM: (i) design for AM, (ii) AM modeling, and (iii) monitoring and control in AM. We use a step-by-step approach following the Preferred Reporting Items for Systematic Reviews and Meta-Analyses (PRISMA) guidelines to select papers from Scopus and Web of Science databases, aligning with our research questions. We include only those papers that implement DL across seven major AM categories - binder jetting, directed energy deposition, material extrusion, material jetting, powder bed fusion, sheet lamination, and vat photopolymerization. Our analysis reveals a trend towards using deep generative models, such as generative adversarial networks, for generative design in AM. It also highlights an increasing effort to incorporate process physics into DL models to improve AM process modeling and reduce data requirements. Additionally, there is growing interest in using 3D point cloud data for AM process monitoring, alongside traditional 1D and 2D formats. Finally, this paper summarizes the current challenges and recommends some of the promising opportunities in this domain for further investigation with a special focus on (i) generalizing DL models for a wide range of geometry types, (ii) managing uncertainties both in AM data and DL models, (iii) overcoming limited, imbalanced, and noisy AM data issues by incorporating deep generative models, and (iv) unveiling the potential of interpretable DL for AM.

Yuxuan Li, Tianxin Xie, Chenang Liu et al.

The incorporation of advanced sensors and machine learning techniques has enabled modern manufacturing enterprises to perform data-driven classification-based anomaly detection based on the sensor data collected in manufacturing processes. However, one critical challenge is that newly presented defect category may manifest as the manufacturing process continues, resulting in monitoring performance deterioration of previously trained machine learning models. Hence, there is an increasing need for empowering machine learning models to learn continually. Among all continual learning methods, memory-based continual learning has the best performance but faces the constraints of data storage capacity. To address this issue, this paper develops a novel pseudo replay-based continual learning framework by integrating class incremental learning and oversampling-based data generation. Without storing all the data, the developed framework could generate high-quality data representing previous classes to train machine learning model incrementally when new category anomaly occurs. In addition, it could even enhance the monitoring performance since it also effectively improves the data quality. The effectiveness of the proposed framework is validated in three cases studies, which leverages supervised classification problem for anomaly detection. The experimental results show that the developed method is very promising in detecting novel anomaly while maintaining a good performance on the previous task and brings up more flexibility in model architecture.

Frida Cantu, Salomon Ibarra, Arturo Gonzales et al.

Online sensing plays an important role in advancing modern manufacturing. The real-time sensor signals, which can be stored as high-resolution time series data, contain rich information about the operation status. One of its popular usages is online process monitoring, which can be achieved by effective anomaly detection from the sensor signals. However, most existing approaches either heavily rely on labeled data for training supervised models, or are designed to detect only extreme outliers, thus are ineffective at identifying subtle semantic off-track anomalies to capture where new regimes or unexpected routines start. To address this challenge, we propose an matrix profile-based unsupervised anomaly detection algorithm that captures fabrication cycle similarity and performs semantic segmentation to precisely identify the onset of defect anomalies in additive manufacturing. The effectiveness of the proposed method is demonstrated by the experiments on real-world sensor data.

Yue Zhao, Yuxuan Li, Chenang Liu et al.

Machine learning (ML) methods are widely used in industrial applications, which usually require a large amount of training data. However, data collection needs extensive time costs and investments in the manufacturing system, and data scarcity commonly exists. Therefore, data-sharing is widely enabled among multiple machines with similar functionality to augment the dataset for building ML methods. However, distribution mismatch inevitably exists in their data due to different working conditions, while the ML methods are assumed to be built and tested on the dataset following the same distribution. Thus, an Active Data-sharing (ADs) framework is proposed to ensure the quality of the shared data among multiple machines. It is designed to simultaneously select the most informative data points benefiting the downstream tasks and mitigate the distribution mismatch among all selected data points. The proposed method is validated on anomaly detection on in-situ monitoring data from three additive manufacturing processes.