Real-world products and physics-based simulations are becoming interconnected. In particular, real-time capable dynamic simulation has made it possible for simulation models to run in parallel and simultaneously with operating machinery. This capability combined with state observer techniques such as Kalman filtering have enabled the synchronization between simulation and the real world. State estimator techniques can be applied to estimate unmeasured quantities, also referred as virtual sensing, or to enhance the quality of measured signals. Although synchronized models could be used in a number of ways, value creation and business model development are currently defining the most practical and beneficial use cases from a business perspective. The research reported here reveals the communication and collaboration methods that lead to economically relevant technology solutions. Two case examples are given that demonstrate the proposed methodology. The work benefited from the broad perspective of researchers from different backgrounds and the joint effort to drive the technology development towards business relevant cases.

AI is one of the biggest megatrends towards the 4th industrial revolution. Although these technologies promise business sustainability as well as product and process quality, it seems that the ever-changing market demands, the complexity of technologies and fair concerns about privacy, impede broad application and reuse of Artificial Intelligence (AI) models across the industry. To break the entry barriers for these technologies and unleash its full potential, the knowlEdge project will develop a new generation of AI methods, systems, and data management infrastructure. Subsequently, as part of the knowlEdge project we propose several major innovations in the areas of data management, data analytics and knowledge management including (i) a set of AI services that allows the usage of edge deployments as computational and live data infrastructure as well as a continuous learning execution pipeline on the edge, (ii) a digital twin of the shop-floor able to test AI models, (iii) a data management framework deployed along the edge-to-cloud continuum ensuring data quality, privacy and confidentiality, (iv) Human-AI Collaboration and Domain Knowledge Fusion tools for domain experts to inject their experience into the system, (v) a set of standardisation mechanisms for the exchange of trained AI models from one context to another, and (vi) a knowledge marketplace platform to distribute and interchange trained AI models. In this paper, we present a short overview of the EU Project knowlEdge –Towards Artificial Intelligence powered manufacturing services, processes, and products in an edge-to-cloud-knowledge continuum for humans [in-the-loop], which is funded by the Horizon 2020 (H2020) Framework Programme of the European Commission under Grant Agreement 957331. Our overview includes a description of the project’s main concept and methodology as well as the envisioned innovations.

In vibration-based structural health monitoring damage in structure is tried to detect from damage-sensitive features. Because neither prior information nor data about expected damage are normally available, damage detection problem must be solved by using a novelty detection approach. Features, which are sensitive to damage, are often sensitive to environmental and operational variations. Therefore elimination of these variations is essential for reliable damage detection. At present many of the damage detection methods are linear, though it has been shown that many of the vibration changes in structures are bilinear or nonlinear. This paper proposes to use nonlinear factor analysis to detect damage via elimination of external effects from damage features. The effectiveness of the proposed method is demonstrated by analyzing the experimental Z24 Bridge data with a comparison to a linear method. It is shown that elimination of adverse effects and damage detection are feasible.

Rotating machines are typically equipped with vibration sensors at the bearing location and the information from these sensors is used for condition monitoring. Installing additional sensors may not be possible due to limitations of the installation and cost. Thus, the internal condition of machines might be difficult to evaluate. This study presents a numerical and experimental study on the case of a rotor supported by four rolling element bearings (REBs). As such, the study resembles a complex real-life industrial multi-fault scenario: a lack of information, uncertainties, and nonlinearities increase the overall complexity of the system. The study provides a methodology for modeling and analyzing complicated systems without prior information. First, the unknown model parameters of the system are approximated using measurement data and the linearized model. Thereafter, the Unscented Kalman Filter (UKF) is applied to the estimation of the vibration characteristics in unmeasured locations. As a result, the estimation of unmeasured vibration characteristics has a reasonable agreement with the rotor whirling, and the estimated results are within a 95% confidence interval. The proposed methodology can be considered as a transfer learning method that can be further used in other identification problems in the field of rotating machinery.