Abstract: The embodiments of present disclosure herein address unresolved problems of handwritten notes or digital diaries for logging defects during quality inspection. Also, these kinds of inspections in the industries are time bound. In certain sensitive inspection cases inspectors are required to use gloves while inspecting which leads to added overhead of working with gloves while noting down the defects. Sharing of these defect logs also becomes difficult as they first must be digitized to be shared across the different units in the industry. Embodiments herein provide a method and system which logs the defects identified by inspectors using inspector's voice. The system identifies defect type, location and sub-section from inspector speech and marks the defect in an orthogonal view, a two-dimensional (2D) view, a three-dimensional (3D) view of the artifact being inspected for verification. The system also allows for marking the defects as resolved during the repair or rework process.

Abstract: Existing question answering approaches have the disadvantages that they possess limited contextual understanding due to which the retrieval process they use is inefficient in nature. Embodiments disclosed herein provide a method and system for domain-driven knowledge augmented question answering. The system receives a raw corpus data as input, wherein the raw corpus data is a domain specific data. Further, an indexed corpus is generated from the raw corpus data, during which a document chunking approach is used. The indexed corpus is then used for processing received queries received, in order to generate response to the received user queries.

Abstract: Early-stage design for complex engineering systems is a difficult task with significant impact on the final design and is performed under time constraints which restricts the number of options being considered. Present disclosure provides a framework for an early-stage generative design of engineering systems by performing systematic design space exploration and targeted design space exploration. Diverse design configurations are generated for given requirements following a systematic design space exploration of the entire architectural design space of the early-stage problem. In the targeted design space exploration stage, potential regions of the design space are identified to generate different alternatives to the diverse design configurations already generated during the systematic design space exploration stage for early-stage generative design of a given engineering system.

Abstract: This disclosure relates generally to recommending tool configurations in machining. The machining tool configuration selection involves the selection of several tool specification parameters concerning the material, geometry and composition of the machining tool. The state-of-the-art methods uses a rule and knowledge-based system to select tool configuration, however these methods do not recommend tool configurations which satisfy customer requirement. Embodiments of the present disclosure uses a hierarchical model which is trained to predict acceptable tool specification parameters for a given requirement by learning the patterns from past tool selection data. Further a probabilistic approach is used to predict the top set of recommendations of tool configurations with a probability score for each prediction. The disclosed method is used for recommending tool configurations in a cylindrical grinding wheel process.

Abstract: Conventional approaches of physical experiments for the effects of cure kinetics in composites materials may lack in capturing lower length scale effects at bulk level. The computational state of the art approaches has not focused on the issue of scale bridging between multiple length scales for manufacturing effects in composites. This limits its usability for specific materials or situations. Embodiments of the present disclosure provide systems and methods that implement a multiscale analysis for determining residual stress and deformation profiles in molded parts comprising composite material. More specifically, present disclosure implements the multiscale analysis wherein a thermal chemical analysis and thermal mechanical analysis are linked to achieve two-way coupling for curing effects at each node/point of molded parts having composite material to provide flexibility and versatility in terms of exploring multiple material combinations without major modification in the approach.

Abstract: This disclosure relates generally to systems and methods for monitoring and controlling a manufacturing process using contextual hybrid digital twin. Data pertaining to the manufacturing process is obtained from a plurality of data generation sources which is further inputted to one or more physics based models and train machine learning models such that simulated data and real time tata is obtained. Further, a gap between the simulated data and the real time data is determined and learnt. The learnt gap is further minimized and an augmented set of models are obtained. The augmented set of models along with a set of soft-sensing data is used to create the contextual hybrid digital twin for the manufacturing process. The performance of the manufacturing process is monitored and controlled using a performance analytics and decision making enablers of the contextual hybrid digital twin respectively in real time.

Abstract: The present disclosure addresses the technical problem of prediction of a preheat refractory temperature profile of a ladle furnace. Operational temperature of the ladle furnace, stability of sensors and placement make sensors not feasible. Computational Fluid Dynamics (CFD) simulations require large computation time and cannot be used for runtime applications in plants. The method and system of the present disclosure uses CFD modeling to carry out parametric study to generate data which is further processed to train an Artificial Neural Network (ANN) model that serves as a prediction model for predicting the preheat refractory temperature profile for at least a portion of the side refractory and at least a portion of the bottom refractory layer separately for which a new set of input data is obtained. The trained prediction model of the present disclosure provides a quick runtime prediction in plants.

Abstract: Conventionally, root cause analysis and process documentation in process industries has been manually performed resulting in time consuming effort, cost, and human resources. Moreover, in the event of failure, looking at such document and searching for possible root causes is practically impossible in the interest of time and cost associated. Systems and methods of the present disclosure systematically curate knowledge of industrial process(es) from various sources and generate process ontology via meta model(s). Root cause graph (RCG) is created wherein the RCG corresponds to process and root cause and failure modes in the process. The RCG is then transformed to machine instructions which are executed for root cause analysis in real time. The created graphs/knowledge also help in identifying conflicting knowledge or redundant knowledge. Present disclosure enables root cause analysis as soon as a failure occurs or as the systems show or indicate a tendency towards failure.

Abstract: Failure analysis of industrial plants are stored in various types of documents associated with industrial plant. The documents are used by operators of plant to address any deviation that is active in plant. The operator generally has prior knowledge of relevant processes, equipment and sensors described in a deviation scenario in these documents. However, a system that is envisaged to aid operator in real-time does not have this information readily available as this knowledge is spread across documents. Currently available systems manually curate failure knowledge thereby making the process time consuming and prone to human errors. Present disclosure provides method and system for performing extracting and collating failure knowledge from diverse sources in industrial plant.

Abstract: The disclosure generally relates to methods and systems for generating synthetic microstructure images of a material with desired features. Conventional techniques that make use of unsupervised deep generative models has no control on the generated microstructure images with specific, desired set of features. The present disclosure generates the synthetic microstructure images of the material with desired feature, by using a variational autoencoder defined with a style loss function. In the first step, the variational autoencoder is trained to learn latent representation of microstructure image of the material. In the second step, some of the dimensions of learned latent representation is interpreted as physically significant features. In the third and last step, the latent representation required for getting the desired features is appropriately sampled based on the interpretation to generate the synthetic microstructure images of the material with desired features.

Abstract: All the model-driven systems may not have capability to perform designing and execution of experiments, which limits functionality of such model-driven systems. The disclosure herein generally relates to Design of Experiments (DOE), and, more particularly, to a model driven sub-system for design and execution of experiments. The sub-system when plugged into the model driven system, uses legacy components as well components of the sub-system to perform designing and execution of the design of experiments.

Abstract: This disclosure relates generally to a system and method to estimate an operational risk associated with one or more failures in at least one unit of a process plant. There is a continuous stream of operational data of several variables such as temperature, pressure, etc. Detections are defined in terms of acceptable/unacceptable ranges of parameters over a finite period and operating load of the unit. Often, these predefined parameters must be within a specified range based on operating condition of the process plant and when the measured parameters go beyond, a failure is detected. A risk priority number is estimated from number of occurrences of failure mode, average percentage change from dynamic limits with severity and degree of correlation with detectability from operational data and dynamic limits. Herein, operational risk associated with failure modes can be calculated and updated from time to time automatically from the stream of operational data.

Abstract: Currently solutions for early detection of failures in manufacturing utilize predefined threshold levels of the process variables associated with equipment in manufacturing unit/industry plants. The pre-defined threshold and levels thereof are compared with the real values obtained from the manufacturing unit to check behavior of process variables (also referred as ‘process parameters’) and thus are prone to error. The present disclosure provides systems and method for predicting early warning of operating mode of equipment operating in industry plants which is based on transforming conditions on process parameters into conditions on corresponding fuzzy indices based on their thresholds. The fuzzy indices (concordance index, discordance index) of individual conditions are combined into a composite fuzzy index (composite index or degree of credibility) that describes the failure scenario in the process parameter space.

Abstract: This disclosure relates generally to method and system for designing the formulated products. Conventional techniques for designing the formulated products, meeting final functional properties, are limited. Further, understanding user requirements and active incorporation of the user requirements during design phase is quite challenging. The present disclosure herein provides method and system that solve the technical problem of extracting the functional requirement by establishing continuous conversation with the user. An optimal prediction function for each functional requirement is determined by using a plurality of prediction models. An optimization technique along with an objective function is employed to determine optimized solutions comprising list of ingredients, possible concentration level of each ingredient, the process parameters, and the operating parameters for obtaining the desired formulation based on the user requirement.

Abstract: The disclosure generally relates to methods and systems for generating synthetic microstructure images of a material with desired features. Conventional techniques that make use of unsupervised deep generative models has no control on the generated microstructure images with specific, desired set of features. The present disclosure generates the synthetic microstructure images of the material with desired feature, by using a variational autoencoder defined with a style loss function. In the first step, the variational autoencoder is trained to learn latent representation of microstructure image of the material. In the second step, some of the dimensions of learned latent representation is interpreted as physically significant features. In the third and last step, the latent representation required for getting the desired features is appropriately sampled based on the interpretation to generate the synthetic microstructure images of the material with desired features.

Abstract: The present disclosure addresses the technical problem of prediction of a preheat refractory temperature profile of a ladle furnace. Operational temperature of the ladle furnace, stability of sensors and placement make sensors not feasible. Computational Fluid Dynamics (CFD) simulations require large computation time and cannot be used for runtime applications in plants. The method and system of the present disclosure uses CFD modeling to carry out parametric study to generate data which is further processed to train an Artificial Neural Network (ANN) model that serves as a prediction model for predicting the preheat refractory temperature profile for at least a portion of the side refractory and at least a portion of the bottom refractory layer separately for which a new set of input data is obtained. The trained prediction model of the present disclosure provides a quick runtime prediction in plants.

Abstract: Currently solutions for early detection of failures in manufacturing utilize predefined threshold levels of the process variables associated with equipment in manufacturing unit/industry plants. The pre-defined threshold and levels thereof are compared with the real values obtained from the manufacturing unit to check behavior of process variables (also referred as ‘process parameters’) and thus are prone to error. The present disclosure provides systems and method for predicting early warning of operating mode of equipment operating in industry plants which is based on transforming conditions on process parameters into conditions on corresponding fuzzy indices based on their thresholds. The fuzzy indices (concordance index, discordance index) of individual conditions are combined into a composite fuzzy index (composite index or degree of credibility) that describes the failure scenario in the process parameter space.

Abstract: This disclosure relates generally to a system and method to estimate an operational risk associated with one or more failures in at least one unit of a process plant. There is a continuous stream of operational data of several variables such as temperature, pressure, etc. Detections are defined in terms of acceptable/unacceptable ranges of parameters over a finite period and operating load of the unit. Often, these predefined parameters must be within a specified range based on operating condition of the process plant and when the measured parameters go beyond, a failure is detected. A risk priority number is estimated from number of occurrences of failure mode, average percentage change from dynamic limits with severity and degree of correlation with detectability from operational data and dynamic limits. Herein, operational risk associated with failure modes can be calculated and updated from time to time automatically from the stream of operational data.

Abstract: Conventional approaches of physical experiments for the effects of cure kinetics in composites materials may lack in capturing lower length scale effects at bulk level. The computational state of the art approaches has not focused on the issue of scale bridging between multiple length scales for manufacturing effects in composites. This limits its usability for specific materials or situations. Embodiments of the present disclosure provide systems and methods that implement a multiscale analysis for determining residual stress and deformation profiles in molded parts comprising composite material. More specifically, present disclosure implements the multiscale analysis wherein a thermal chemical analysis and thermal mechanical analysis are linked to achieve two-way coupling for curing effects at each node/point of molded parts having composite material to provide flexibility and versatility in terms of exploring multiple material combinations without major modification in the approach.

Abstract: This disclosure relates generally to recommending tool configurations in machining. The machining tool configuration selection involves the selection of several tool specification parameters concerning the material, geometry and composition of the machining tool. The state-of-the-art methods uses a rule and knowledge-based system to select tool configuration, however these methods do not recommend tool configurations which satisfy customer requirement. Embodiments of the present disclosure uses a hierarchical model which is trained to predict acceptable tool specification parameters for a given requirement by learning the patterns from past tool selection data. Further a probabilistic approach is used to predict the top set of recommendations of tool configurations with a probability score for each prediction. The disclosed method is used for recommending tool configurations in a cylindrical grinding wheel process.