Software sensor for activity-time monitoring and fault detection in production lines

Tamas Ruppert, J. Abonyi

Research output: Contribution to journalArticle

2 Citations (Scopus)

Abstract

Industry 4.0-based human-in-the-loop cyber-physical production systems are transforming the industrial workforce to accommodate the ever-increasing variability of production. Real-time operator support and performance monitoring require accurate information on the activities of operators. The problem with tracing hundreds of activity times is critical due to the enormous variability and complexity of products. To handle this problem a software-sensor-based activity-time and performance measurement system is proposed. To ensure a real-time connection between operator performance and varying product complexity, fixture sensors and an indoor positioning system (IPS) were designed and this multi sensor data merged with product-relevant information. The proposed model-based performance monitoring system tracks the recursively estimated parameters of the activity-time estimation model. As the estimation problem can be ill-conditioned and poor raw sensor data can result in unrealistic parameter estimates, constraints were introduced into the parameter-estimation algorithm to increase the robustness of the software sensor. The applicability of the proposed methodology is demonstrated on a well-documented benchmark problem of a wire harness manufacturing process. The fully reproducible and realistic simulation study confirms that the indoor positioning system-based integration of primary sensor signals and product-relevant information can be efficiently utilized in terms of the constrained recursive estimation of the operator activity.

Original languageEnglish
Article number2346
JournalSensors (Switzerland)
Volume18
Issue number7
DOIs
Publication statusPublished - Jul 19 2018

Fingerprint

fault detection
Fault detection
Software
computer programs
Monitoring
sensors
Sensors
products
operators
positioning
operator performance
Systems Integration
Benchmarking
harnesses
fixtures
tracing
Robustness (control systems)
Industry
Parameter estimation
Mathematical operators

Keywords

  • Early warning systems
  • Indoor positioning system
  • Paced conveyor
  • Performance monitoring
  • Recursive estimation

ASJC Scopus subject areas

  • Analytical Chemistry
  • Atomic and Molecular Physics, and Optics
  • Biochemistry
  • Instrumentation
  • Electrical and Electronic Engineering

Cite this

Software sensor for activity-time monitoring and fault detection in production lines. / Ruppert, Tamas; Abonyi, J.

In: Sensors (Switzerland), Vol. 18, No. 7, 2346, 19.07.2018.

Research output: Contribution to journalArticle

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