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In the context of Industry 4.0, smart factories use advanced sensing and data analytic technologies to understand and monitor the manufacturing processes. To enhance production efficiency and reliability, statistical Artificial Intelligence (AI) technologies such as machine learning and data mining are used to detect and predict potential anomalies within manufacturing processes. However, due to the heterogeneous nature of industrial data, sometimes the knowledge extracted from industrial data is presented in a complex structure. This brings the semantic gap issue which stands for the lack of interoperability among different manufacturing systems. Furthermore, as the Cyber-Physical Systems (CPS) are becoming more knowledge-intensive, uniform knowledge representation of physical resources and real-time reasoning capabilities for analytic tasks are needed to automate the decision-making processes for these systems. These requirements highlight the potential of using symbolic AI for predictive maintenance.
To automate and facilitate predictive analytics in Industry 4.0, in this paper, we present a novel Knowledge-based System for Predictive Maintenance in Industry 4.0 (KSPMI). KSPMI is developed based on a novel hybrid approach that leverages both statistical and symbolic AI technologies. The hybrid approach involves using statistical AI technologies such as machine learning and chronicle mining (a special type of sequential pattern mining approach) to extract machine degradation models from industrial data. On the other hand, symbolic AI technologies, especially domain ontologies and logic rules, will use the extracted chronicle patterns to query and reason on system input data with rich domain and contextual knowledge. This hybrid approach uses Semantic Web Rule Language (SWRL) rules generated from chronicle patterns together with domain ontologies to perform ontology reasoning, which enables the automatic detection of machinery anomalies and the prediction of future events’ occurrence. KSPMI is evaluated and tested on both real-world and synthetic data sets.
The rise of digital twins in the manufacturing industry is accompanied by new possibilities, like process automation and condition monitoring, real time simulations and quality and maintenance prediction are just a few advantages which can be realized. This paper takes a novel approach by extracting the fundamental knowledge of a data set from a production process and mapping it to an expert fuzzy rule set. Afterwards, new fundamental augmented data is generated by exploring the feature space of the previously generated fuzzy rule set. At the same time, a high number of artificial neural network (ANN)models with different hyperparameter configurations are created.
The best models are chosen, in line with the idea of survival of the fittest, and improved with the additional training data sets, generated by the fuzzy rule simulation. It is shown that ANN models can be improved by adding fundamental knowledge represented by the discovered fuzzy rules. Those models can represent digitized machines as digital twins. The architecture and effectiveness of the digital twin is evaluated within an industry 4.0 use case.