Patent Description:
<CIT> discloses a state observation unit that observes manufacturing operation data which is data relating to the operation at the time of manufacturing a product.

In "<NPL>) multi-sourced heterogenous monitoring data (vibration and IR signal) is used to monitor the mechanical health condition.

In pressing sheets or plates of different materials (e. steel, copper, polymer etc.) cracks in a sheet/plate (or rather manufactured workpiece), ripples of the sheet/plate or rather manufactured workpiece) and other failures of the manufacturing process regularly occur. These failures of the manufacturing process are not detected during the pressing process, but only after several pressing cycles during an automatically or manually conducted visual inspection. Further, during the pressing process micro-cracks can occur, which are not detected during the visual inspection, but only much later during final assembly or even operation.

The later such failures of the manufacturing process are detected the more expensive their correction becomes.

It is therefore an objective of the present invention to provide a reliable and fast automatic indication of a failure of a manufacturing process.

The present invention provides a computer-implemented method of indicating a failure of a manufacturing process according to independent claim <NUM> and a corresponding data processing system and a corresponding computer program product as well as a corresponding manufacturing system. Refinements of the present invention are subject of the respective dependent claims.

According to a first aspect of the present invention a computer-implemented method of indicating a failure of a manufacturing process comprises the steps a) receiving at least one input signal, b) transforming the at least one input signal, c) deriving latent features, d) mapping the derived latent features and e) optionally indicating a failure of the manufacturing process. In step a) at least one input signal is received. The received at least one input signal is based on at least one physical quantity, which is monitored during the manufacturing process by means of at least one sensor. In step b) the received at least one input signal is transformed into at least one parameter. The at least one parameter has a different domain and additionally or alternatively a different reference value than the received at least one input signal. In step c) latent features are derived based on the at least one parameter by means of a machine learning system (MLS). The MLS is trained on deriving latent features based on the at least one parameter indicative of specific states of the manufacturing process. In step d) the derived latent features are mapped into one of several distinct clusters in a twodimensional (2D) cluster space, wherein the clusters represent different sates of the manufacturing process. In step e) a failure of the manufacturing process is indicated based on the different states of the manufacturing process.

According to a second aspect of the present invention a data processing system for indicating a failure of a manufacturing process comprises means for carrying out the steps of the method according to the first aspect of the present invention.

According to a third aspect of the present invention a computer program product for indicating a failure of a manufacturing process comprises instructions which, when the program is executed by a computer, cause the computer to carry out the steps of the method according to the first aspect of the present invention.

According to a fourth aspect of the present invention a manufacturing system comprises the data processing system according to the second aspect of the present invention and at least one sensor. The at least one sensor generates at least one input signal by monitoring at least one physical quantity during conducting a manufacturing process. The generated at least one input signal is provided to the data processing system.

At least one physical quantity like vibrations, temperature, force, torque, rotational/angular/linear speed/acceleration, and/or the like occurring during the manufacturing process is monitored by the at least one sensor. Therefore, at least one appropriate sensor is provided, such as a temperature sensor, a vibration sensor, an acceleration sensor, a position sensor, a force sensor etc. The sensor is positioned at a corresponding position where the respective physical quantity can be monitored by the sensor.

More than one physical quantity may be monitored with appropriate sensors, for example vibrations (e.g. vibrations of a machine part or a workpiece) may be monitored with a vibration sensor. A temperature during the manufacturing process (e.g. a temperature of a machine part, of a chamber or of a workpiece) may be monitored with a temperature sensor. A rotational speed may be monitored with a rotation sensor. An acceleration or force (or speed derived from the acceleration/force) may be monitored with an acceleration or force sensor.

The respective sensor generates a corresponding input signal based on the respective monitored physical quantity. In step a) the generated input signal is provided to and received by the data processing system (e.g. at an interface of a receiver).

In step b) the received at least one input signal is transformed into at least one parameter. For example, the input signal may be normalized and additionally or alternatively KPIs like RMS, crest factor, and/or standard deviation may be derived as features of the input signal. Further the input signal may (additionally) be transformed into another domain, for example a vibration signal may be transformed from the time domain (F(t)) into the frequency domain (F(f)) e.g. by means of a Fast Fourier Transformation (FFT). An input signal based on a measured acceleration may be transformed from the time domain (F(t)) into the 3D-domain (F(x,y,z)). Further, the input signal may be transformed such that the feature has a different reference value than the input signal, like an input signal based on a measured temperature may be transformed from degree Celsius (°C) into Kelvin (K) or an input signal base on a measured speed which is a relative speed has to be transformed (superimposed) into an absolute speed (e.g. rotating element moved by an arm of a machine of the manufacturing system). Further, statistical values may be determined in the step of transforming. For example, in transforming the input signal may first be transformed into another domain and then statistical features may be derived therefrom. All these transformations may be referred to as parameter engineering.

Machine learning algorithms or MLS build a mathematical model based on sample data, known as "training data", in order to make predictions or decisions without being explicitly programmed to perform the task. The at least one "engineered" parameter is provided to the MLS in step c). The MLS has been trained such that it can derive latent features based on the provided at least one parameter indicative of specific states of the manufacturing process. Specific states such as failures of the manufacturing process (e.g. wrong manufacturing parameters, bad orientation of work pieces, malfunctioning machine parts etc.) manifest themselves in specific patterns of the at least one parameter or more than one parameter. Therefore, the MLS has been trained based on such patterns in a set of at least one training parameter indicative of at least one certain failure (state) of the manufacturing process.

The latent features derived by the MLS from the at least one provided parameter resemble one of several specific trained patterns. The MLS extracts latent information provided with the at least one parameter and connects this latent information internally (e.g. based on trained weights) into the latent features, which provide different information about states such as failures of the manufacturing process than the at least one provided parameter.

In step d) the derived latent features are mapped into one cluster. The cluster is one of several distinct clusters in the 2D cluster space. Thereto, the latent features derived by the MLS are mapped with a specific algorithm into two values (e.g. an X-coordinate and a Y-coordinate), which resemble their difference to other latent features derived by the MLS based on another provided at least one parameter. The latent features derived by the MLS form the at least one parameter have a specific pattern. The pattern can be transformed by the algorithm into the two values specific for the respective pattern of the latent features. Each of the distinct clusters resembles a different state of the manufacturing process, which states are idle, start-up phase, normal operation, and one or several different failures of the manufacturing process. Also a class and additionally or alternatively a severity of a failure of the manufacturing process may be derivable from the cluster.

In the step e) a failure of the manufacturing process (and its class and/or severity) is indicated based on the state of the manufacturing process resembled by the cluster. The failure of the manufacturing process, which is based on the pattern of the latent features derived by the MLS from the at least one parameter, may be reported to a user (e.g. technician, mechanic personnel, shift supervisor, facility engineer etc.) who can initiate the necessary steps for bringing the manufacturing process back to normal operation (eliminating the cause of the failure of the manufacturing process).

Additionally, the method may comprise a further step of automatically initiating appropriate counter measures, like repositioning of movable machine parts or workpieces, refilling of coolant or lubricant etc. to bring the manufacturing process back to normal operation.

The manufacturing system may comprise machines and machine parts by means of which the manufacturing process can be conducted. The at least one sensor generates the at least one input signal based on the at least one physical quantity monitored during the manufacturing process.

With the present invention it is possible to detect states of the manufacturing process and optionally to automatically indicate failures in the manufacturing process, such that the manufacturing process can be brought back to normal operation faster and more reliable.

According to a refinement of the present invention the at least one monitored physical quantity is a pressing force of a press and the at least one generated input signal is a force-over-time signal. Further, a failure in a pressed workpiece is indicated as the failure of the manufacturing process.

According to a further refinement of the present invention the manufacturing system further comprises a press.

According to the invention, the at least one sensor is a force sensor generating a force signal by monitoring a pressing force of the press.

At least one force sensor and preferably four force sensors equally distributed over the press is/are monitoring the pressing force of the press. The at least one force sensor may be a piezo-electric sensor or the like. The at least one force sensor measures the pressing force over time and produces the at least one corresponding input signal.

The at least one input signal based on the pressing force of the press is transformed into the at least one parameter. The at least one parameter is provided to the MLS which has been trained on respective training parameters based on training input signals based on pressing forces. The MLS derives the latent features which are mapped into one of the several respective clusters that represent states of the manufacturing process like a failure where a work piece formed by the press from a sheet or plate has cracks or ripples or micro-cracks etc..

With the present invention states and in particular failures of the manufacturing process like cracks, ripples, micro-cracks and the like in the manufactured workpieces can be reliably and fast detected.

According to a refinement of the present invention the monitored pressing force is a force of a plunger (or punch) of the press () and additionally or alternatively a force on a mould of the press ().

Preferably, at least four force sensors are positioned either at the mould or at the plunger. Each of the four force sensors is arranged in one of a front left portion, a front right portion, a rear left portion or a rear right portion of the mould or the plunger, respectively.

The pressing force of the plunger or on the mould can be particularly effectively measured and processed.

According to a refinement of the present invention the received at least one input signal is transformed by selecting a predefined time slice of the signal and additionally or alternatively a data cleansing and additionally or alternatively a normalization and/or a centring.

Only a predefined time slice of the at least one input signal can be selected and used as the at least one parameter. For example, a pressing force over time signal may be transformed by selecting only a time slice of said signal, where there is a measured an actual pressing force and preferably a time slice of said signal, from where the plunger makes contact to the sheet or plate until the pressing is finished and the plunger leaves the work piece pressed from the sheet or the plate.

The received at least one input signal may also be processed by a data cleansing. In the data cleansing gaps, jumps and the like in the at least one received input signal are filled, corrected and the like, such that a continuous and smooth signal is provided as parameter.

With normalization, the at least one input signal is normalised to a predefined value range (e.g. from <NUM> to <NUM>) and additionally or alternatively the metering time period is normalised. For example each input signal may be normalized to a predefined number of time steps of a predefined length, such that a too long signal is cut and a too short signal is extended.

The received at least one input signal may also be centred around a specific value or raise in the input signal. For example, the input signals based on the pressing force of the press may be centred by convolving each input signal with itself.

With the transformation the at least one input signal is prepared such that the MLS can optimally derive the latent features.

According to the present invention the MLS is a convolutional NN. This provides for storing specific coherent patterns of the timeseries in the latent space so that they can be distinguished.

Artificial neural networks (ANN) are systems, in particular computing systems, inspired by biological neural networks that constitute animal brains. ANNs "learn" to perform tasks by considering (labelled) examples or training data, generally without being designed with any task-specific rules. During an initial learning or training phase ANNs automatically generate identifying characteristics from the (labelled) training data. ANNs comprise a collection of connected nodes called artificial neurons, which loosely model the neurons in a biological brain. Each connection (synapses in the biological brain) can transmit a signal from one node to another. A node that receives a signal can process it and then signal to subsequent neurons connected to it. In common ANN implementations, the signal at a connection between nodes is a real number (e.g. <NUM>. <NUM>), and the output of each artificial neuron is computed by some non-linear function of the sum of its inputs (from other nodes). The connections between nodes are called "edges". The edges in ANNs may each have a weight that is adjusted during training of the ANNs. The weight increases or decreases the strength of the signal at the corresponding edge. Nodes may each have a threshold such that the signal is only sent if an aggregate signal exceeds that threshold. Typically, nodes are aggregated into layers. Different layers may perform different kinds of transformations on their inputs. Signals travel from a first layer or input layer to a last layer or output layer, possibly after traversing the layers multiple times.

In other words, an ANN is a network of simple elements, the so called nodes or artificial neurons, which receive input. After receiving input the nodes change their internal state (activation) according to that input, and produce output depending on the input and activation. The network forms by connecting the output of certain nodes to the input of other nodes forming a directed, weighted graph. The weights as well as the functions that compute the activation of each node can be modified during initial learning / training, which is governed by a learning rule or paradigm.

A node receiving an input from at least one predecessor neuron consists of the following components: an activation, the node's state, depending on a discrete time parameter, optionally a threshold, which stays fixed unless changed by a learning / training function, an activation function (e.g. hyperbolic tangent function, sigmoid function, softmax function, rectifier function etc.) that computes the new activation at a given time and the net input and an output function computing the output from the activation (often the output function is the identity function). An important characteristic of the activation function is that it provides a smooth transition as input values change, i.e. a small change in input produces a small change in output.

An input node has no predecessor but serves as input interface for the whole ANN. Similarly an output node has no successor and thus serves as output interface of the whole ANN. An ANN consists of edges / connections, each edge transferring the output of a node (predecessor) to the input of another, succeeding node (successor). Additionally to the assigned weight an edge may have a bias term added to a total weighted sum of inputs to serve as a threshold to shift the activation function. The propagation function computes the input to the succeeding node (successor) from the outputs of preceding nodes (predecessors) and may include the bias value.

The deep NN comprises more than one layer, preferably more than four layers, more preferably more than seven layers and most preferably ten or more layers. Each layer may comprise several neurons or nodes. Preferably each layer may contain ten or more, more preferably <NUM> or more and most preferably <NUM> or more neurons.

The convolutional NN is a deep NN with convolutional layers. In the convolutional layers, there are filters that are convolved with the input. Each filter is equivalent to a weights vector that has to be trained.

The accuracy of the mapped clusters and, thus, the certainty of the state of the manufacturing process based on the derived latent features of the deep or convolutional NN are increased.

According to a refinement of the present invention the MLS is deployed on a cloud-based system or on a local computer system of a premise where the manufacturing process is conducted.

The cloud-based system may be located at a side of a manufacturer of the manufacturing system, which conducts the manufacturing process, or at a side of the user of the manufacturing system.

In case the MLS is deployed on the cloud-based system the MLS can be used for several different manufacturing systems and manufacturing processes of the (exact) same type.

In case the MLS is deployed on the local computer system of a premise where the manufacturing process is conducted, the MLS is exclusively used for the respective manufacturing process.

Consequently, the MLS can either be used (globally) for different manufacturing systems and for different manufacturing processes and, thus, the capacity of the MLS can be optimally used or the MLS can be locally used and, thus, the MLS can be more specialised for the respective manufacturing system or rather manufacturing process.

According to a refinement of the present invention a t-distributed Stochastic Neighbor Embedding (t-SNE) method is used to map the derived latent features into one of the several distinct clusters.

t-SNE is a machine learning algorithm for visualization. It is a nonlinear dimensionality reduction technique well-suited for embedding high-dimensional data for visualization in a low-dimensional space of two or three dimensions. Specifically, it models each high-dimensional object (here the latent features) by a 2D or three-dimensional (3D) point in such a way that similar objects are modelled by nearby points (clusters) and dissimilar objects are modelled by distant points with high probability. Here, the latent features derived by the MLS (e.g. several hundred values) are reduced or mapped into two values resembling points in the 2D cluster space, where the different states of the manufacturing process can be discriminated based on the distinct clusters in the 2d cluster space.

According to a fifth aspect of the present invention a computer-implemented method of training a machine learning system (MLS) for indicating states of a manufacturing process comprises the steps i) generating a set of at least one training parameter and of corresponding training results and ii) training the machine learning system. In step i) a set of at least one training parameter is generated based on training input signals based on at least one physical quantity monitored during several manufacturing processes by means of at least one sensor. Further corresponding training results of the respective manufacturing processes are included in the set. In step ii) the MLS is trained using the set of the at least one training parameter and of corresponding training results.

A learning or rather training rule or paradigm is an algorithm which modifies the parameters of a respective ANN, in order for a given input to the ANN to produce a favoured output. This training typically amounts to modifying the weights and thresholds of the variables within the ANN. Given a specific task to solve and a class of functions, learning means using a set of observations to find the one function of the class of functions, which solves the task in some optimal sense. This entails defining a cost function such that for the optimal solution the cost is minimal and no other solution has a cost less than the cost of the optimal solution. The cost function is an important concept in learning, as it is a measure of how far away a particular solution is from an optimal solution to the problem to be solved. Learning algorithms search through the solution space to find a function that has the smallest possible cost. For applications where the solution is data dependent, the cost must necessarily be a function of the observations, otherwise the model would not relate to the data. It is frequently defined as a statistic to which only approximations can be made. It is possible to define an arbitrary cost function, however, a particular cost function may be used either because it has desirable properties (e.g. convexity) or because it arises naturally from a particular formulation of the problem.

An ANN can be discriminatively trained with a standard backpropagation algorithm. Backpropagation is a method to calculate the gradient of a loss function (produces the cost associated with a given state) with respect to the weights in the ANN. The weight updates of backpropagation can be done via stochastic gradient descent. The choice of the cost function depends on factors such as the learning type (e.g. supervised, unsupervised, reinforcement etc.) and the activation function. Commonly, the activation function and cost function are the softmax function and cross entropy function, respectively.

In other words, training an ANN essentially means selecting one model from the set of allowed models (or, in a Bayesian framework, determining a distribution over the set of allowed models) that minimizes the cost. Commonly some form of gradient descent is deployed, using backpropagation to compute the actual gradients. This is done by simply taking the derivative of the cost function with respect to the network parameters and then changing those parameters in a gradient-related direction. Backpropagation training algorithms fall into three categories: steepest descent (with variable learning rate and momentum, resilient backpropagation), quasi-Newton (Broyden-Fletcher-Goldfarb-Shanno, one step secant), Leven-berg-Marquardt and conjugate gradient (Fletcher-Reeves update, Polak-Ribiére update, Powell-Beale restart, scaled conjugate gradient).

Common training paradigms include supervised learning, unsupervised learning and reinforcement learning. Supervised learning uses a set of example pairs and the aim is to find a function in the allowed class of functions that matches the examples. In other words, the mapping implied by the data is inferred; the cost function is related to the mismatch between the mapping of the ANN and the data and it implicitly contains prior knowledge about the problem domain. The cost may be the mean-squared error, which tries to minimize the average squared error between the ANN's output and a target value over all the example pairs. Minimizing this cost using gradient descent for the class of ANNs called multilayer per-ceptrons (MLP), produces the backpropagation algorithm for training ANNs. In unsupervised learning, some data is given and the cost function to be minimized that can be any function of the data and the ANN's output. The cost function is dependent on the task and any a priori assumptions (e.g. implicit properties or parameters of the model, observed variables etc.). In reinforcement learning, data is usually not given, but generated by an agent's interactions with the environment. At each point in time the agent performs an action and the environment generates an observation and an instantaneous cost according to some (usually unknown) dynamics. The aim is to discover a policy for selecting actions that minimizes some measure of a long-term cost, e.g. the expected cumulative cost. The environment's dynamics and the long-term cost for each policy are usually unknown, but may also be estimated. The environment is commonly modelled as a Markov decision process (MDP) with states and actions with the following probability distributions: the instantaneous cost distribution, the observation distribution and the transition, while a policy is defined as the conditional distribution over actions given the observations. Taken together, the two then define a Markov chain (MC). The aim is to discover the policy (i.e., the MC) that minimizes the cost.

To each at least one training parameter in the generated set belongs a corresponding result. There may be at least <NUM>, preferably at least <NUM> and most preferably at least <NUM> pairs of training parameter and corresponding training result included in the set. The at least one training parameter corresponds to the at least one parameter described above for the first to fourth aspect of the present invention. The training input signals, which correspond to the at least one input signal described above for the first to fourth aspect of the present invention, is transformed into the at least one training parameter. The transformation is the same as described above for the first to fourth aspect of the present invention (cf. For example, at least one physical quantity (e.g. a pressing force or four pressing forces at different locations of a press) is monitored with at least one respective sensor during several cycles (e.g. <NUM> cycles) of a manufacturing process. At each cycle the at least one sensor generates a training input signal corresponding to the monitored physical quantity (e.g. a force-over-time signal). Further, in each cycle the state of the manufacturing process is determined (e.g. normal operation, failure of the manufacturing process (cracks in a workpiece etc.) and the like). The determined state of the manufacturing process is the trainings result for the respective trainings input signal or rather trainings parameter.

Based on the generated set of the at least one training parameter and of corresponding training results the MLS is trained. Thereto, the MLS is provided with one training parameter of the set and the MLS is optimised until the training result can be identified in a cluster space into which the latent features generated by the MLS have been mapped (e.g. by a t-SNE method).

The MLS used for deriving the latent features needs to learn cues in patterns of the provided at least one parameter. Therefore, the generated set contains training parameters based on training input signals generated during a certain failure of the manufacturing process and also based on training input signals generated during normal operation. Further, the set may contain training parameters based on training input signals generated during idle times and/or a start-up phase. The set of the at least one training parameter is "labelled" with the respective states of the manufacturing process (trainings results) present while the corresponding training input signal was generated (by the respective sensor (s) ).

According to a refinement of the present invention the training input signals are real input signals from a real machine of the manufacturing system or manufacturing process or simulated input signals from an artificial model of the machine of the manufacturing system or manufacturing process or a combination of both.

Thus, only a small set of "real" training parameters and corresponding training results needs to be generated from real (test) cycles of the manufacturing process. This significantly reduces the cost for generating the set. Further, "incomplete" sets (e.g. training signals during a specific state of the manufacturing process like a certain failure of the manufacturing process are missing) can be complemented with virtually generated training signals during specific states of the manufacturing process adjusted in the model.

According to the present invention the MLS is a neural network (NN) and preferably a pre-trained NN.

Especially by training a pre-trained neural network that has been generally conditioned for deriving information from industrial data the time and amount of sets of training feature(s) can be significantly reduced.

According to a refinement of the present invention the training input signals are transformed into the at least one training parameter of the set by selecting a predefined time slice of the training input signals and/or a data cleansing and/or a normalization and/or a centring and/or using parts of predefined length of the training input signals, where preferably, the parts of the predefined length of the training input signals are selected according to a Gaussian distribution.

The selecting of the predefined time slice of the signal, the data cleansing, the normalization and the centring are the same as for the at least one input signal as described above for the first to fourth aspect of the present invention.

Instead of the whole training input signal only parts of the predefined length may be used as parameters for training the MLS. Preferably, the predefined length of the parts is equal to or smaller than <NUM>% and most preferably equal to or smaller than <NUM>% of the length of the training signal. For example, a training input signal (e.g. a force-over-time-signal) that has been normalised to <NUM> time steps, where each time step has the same predefined time length, is divided into the parts of the predefined length. For example the normalised training input signal is divided into parts of a length of <NUM> time steps. For training the MLS only those "important" parts of the training input signal are used as training parameter, which contain the most information about the state of the manufacturing process or rather the trainings result.

Preferably, the parts of one single training input signal may be used several times for training the MLS.

Further preferably, the parts of the training input signals may be selected according to a Gaussian distribution and used as the training parameter. In selecting the parts of the training input signals based on the Gaussian distribution the maximum of the Gaussian distribution may be placed at the part of the input training signals, where the most information about the state of the manufacturing process is contained. Thereby, the training of the MLS can be accelerated and the accuracy of the trained MLS may also be improved.

The present invention and its technical field are subsequently explained in further detail by exemplary embodiments shown in the drawings. The exemplary embodiments only conduce better understanding of the present invention and in no case are to be construed as limiting for the scope of the present invention. Particularly, it is possible to extract aspects of the subject-matter described in the figures and to combine it with other components and findings of the present description or figures, if not explicitly described differently. Equal reference signs refer to the same objects, such that explanations from other figures may be supplementarily used.

In <FIG> the computer-implemented method of indicating a failure of a manufacturing process is schematically depicted.

Here the manufacturing process is forming work pieces by pressing of sheets or plates (e.g. made of steel).

The computer-implemented method comprises the steps a) receiving <NUM> at least one input signal, b) transforming <NUM> the at least one input signal, c) deriving <NUM> latent features, d) mapping <NUM> the derived latent features and e) optionally indicating <NUM> a failure of the manufacturing process.

In step a) the at least one input signal is received. Here, five input signals I1. I5 are received. Four of the five input signals I1. I4 are force-over-time signals based on a pressing force over time of a plunger of a press on a mould of the press measured by four respective force sensors. The last of the five input signals I5 is a position-over-time signal based on a position over time of the plunger measured by a respective position sensor.

In step b) the five input signals I1. I5 are transformed. The step b) comprises for each input signal I1. I5 the sub-steps:.

The sub-steps <NUM>. <NUM> may be applied in any order to the signals I1. Each input signal I1. I5 is appropriately cut by selecting <NUM> the predefined time slice of the signal. Only the time slice of the input signals I1. I5 where a pressing force or movement is present is selected. Then the time slices are cleansed, whereby gaps or jumps in the curve progression of the signals or rather selected time slices are filled or corrected such that a continuous and smooth curve progression is present in the signals/selected time slices. The time slices are further normalised. The in the normalizing <NUM> the values may be normalised to a predefined range (e.g. <NUM>. <NUM>) or the time scale may be normalised to a predefined number of time steps or both. Here, the time slices are all normalised to <NUM> time steps of predefined length (e.g. a time step has a time length of <NUM> [Millisecond]). Also the curve progressions of the signals/time slices are centred, such that in each signal/time slice the pressing force or position starts to change at the same time step. The centring <NUM> is done by convolving each signal or rather time slice with itself. The selected, cleansed, normalised and centred signals/time slices are forwarded as the parameters P1.

In step c) the latent features LF are derived from the parameters P1. P5 of step b). The five parameters P1. P5 (four force-based and one position-based parameter) are provided to a convolutional neural network (NN). The convolutional NN has one input layer, five hidden layers and one output layer. The parameters P1. P5 are provided to the input layer. The convolutional NN has been trained to derive latent features LF based on the parameters P1. P5, which latent features LF provide information about a state of the manufacturing process (e.g. normal operation or a certain failure of the manufacturing process). The information about the manufacturing process contained in the parameters P1. P5 is extracted and newly combined into the latent features LF by the convolutional NN. Thereto, in each layer of the convolutional NN trained weights are applied. The derived latent features LF have a specific pattern indicative of the state of the manufacturing process. According to the invention, the latent features LF are provided by of the hidden layers.

In step d) the derived latent features LF are mapped with a t-SNE algorithm to two values resembling a point in a twodimensional (2D) cluster space. With the t-SNE algorithm similar patterns of the latent features LF of different cycles of the manufacturing process are grouped together and different patterns of the latent features LF are put into other groups in the 2D cluster space. Thereby, clusters C1. C3 of latent features LF are generated, where each cluster C1. C3 resembles one specific state of the manufacturing process.

With the mapped cluster C1. C3 the state of the manufacturing process becomes apparent.

In step e) a failure of the manufacturing process is indicated, for example, to a user like a technician, mechanic personnel, shift supervisor, facility engineer etc. The failure is determined based on the respective cluster C1. C3, which indicates the respective state of the manufacturing process and to which the pattern of latent features LF derived by the convolutional NN belongs.

The computer-implemented method of indicating a failure of a manufacturing process may be provided in form of the computer program product for indicating a failure of a manufacturing process.

In <FIG> the data processing system <NUM> for indicating a failure of a manufacturing process is schematically depicted. The data processing system <NUM> is arranged and configured to execute the computer-implemented method of indicating a failure of a manufacturing process of <FIG>.

The data processing system <NUM> may be a personal computer (PC), a laptop, a tablet, a server, a distributed system (e.g. cloud system) and the like. The data processing system <NUM> comprises a central processing unit (CPU) <NUM>, a memory having a random access memory (RAM) <NUM> and a non-volatile memory (MEM, e.g. hard disk) <NUM>, a human interface device (HID, e.g. keyboard, mouse, touchscreen etc.) <NUM> and an output device (MON, e.g. monitor, printer, speaker, etc.) <NUM>. The CPU <NUM>, RAM <NUM>, HID <NUM> and MON <NUM> are communicatively connected via a data bus. The RAM <NUM> and MEM <NUM> are communicatively connected via another data bus. The computer program product for indicating a failure of a manufacturing process can be loaded into the RAM <NUM> from the MEM <NUM> or another computer-readable medium. According to the computer program product the CPU executes the steps a) to d) and optionally e) of the computer-implemented method of indicating a failure of a manufacturing process of <FIG>. The execution can be initiated and controlled by a user via the HID <NUM>. The status and/or result of the executed computer program may be indicated to the user by the MON <NUM>. The result of the executed computer program may be permanently stored on the non-volatile MEM <NUM> or another computer-readable medium.

In particular, the CPU <NUM> and RAM <NUM> for executing the computer program may comprise several CPUs <NUM> and several RAMs <NUM> for example in a computation cluster or a cloud system. The HID <NUM> and MON <NUM> for controlling execution of the computer program may be comprised by a different data processing system like a terminal communicatively connected to the data processing system <NUM> (e.g. cloud system).

In <FIG> the computer-readable medium <NUM> having stored thereon the computer program product for indicating a failure of a manufacturing process is schematically depicted.

Here, exemplarily a computer-readable storage disc <NUM> like a Compact Disc (CD), Digital Video Disc (DVD), High Definition DVD (HD DVD) or Blu-ray Disc (BD) has stored thereon the computer program product for indicating a failure of a manufacturing process. However, the computer-readable medium may also be a data storage like a magnetic storage/memory (e.g. magnetic-core memory, magnetic tape, magnetic card, magnet strip, magnet bubble storage, drum storage, hard disc drive, floppy disc or removable storage), an optical storage/memory (e.g. holographic memory, optical tape, Tesa tape, Laserdisc, Phasewriter (Phasewriter Dual, PD) or Ultra Density Optical (UDO)), a magneto-optical storage/memory (e.g. MiniDisc or Magneto-Optical Disk (MO-Disk)), a volatile semiconductor/solid state memory (e.g. Random Access Memory (RAM), Dynamic RAM (DRAM) or Static RAM (SRAM)), a non-volatile semiconductor/solid state memory (e.g. Read Only Memory (ROM), Programmable ROM (PROM), Erasable PROM (EPROM), Electrically EPROM (EEPROM), Flash-EEPROM (e.g. USB-Stick), Ferroelectric RAM (FRAM), Magnetoresistive RAM (MRAM) or Phase-change RAM).

In <FIG> the manufacturing system <NUM> comprising the data processing system <NUM> for indicating a failure of a manufacturing process and a press <NUM> is schematically depicted. The manufacturing system <NUM> further comprises four force sensors S1. S4 and one position sensor (not depicted).

The press <NUM> comprises a plunger (or punch) <NUM> and a mould (or die) <NUM>. The four force sensors S1. S4 are arranged in a front left portion, a front right portion, a rear left portion and a rear right portion of the mould <NUM>. The plunger <NUM> may be driven by a motor via an eccentric or by a pneumatic or hydraulic drive. The plunger <NUM> is moved towards the mould <NUM> with a pressing force F such that a sheet or plate <NUM> (e.g. made of steel) is pressed into the mould <NUM> by the plunger <NUM>. Thereby, the sheet/plate <NUM> is deformed into a work piece by the pressing force F applied via the plunger <NUM>. After the work piece has been formed from the sheet/plate <NUM> the plunger <NUM> is retracted. During this operation of the plunger <NUM>, the four force sensors S1. S4 detect the pressing force F applied by the plunger <NUM> onto the mould <NUM> and generate corresponding force-over-time signals that are provided to the data processing system <NUM> for indicating a failure of a manufacturing process of <FIG> as the input signals I1. Further the position sensor determines the position of the plunger <NUM> relative to the mould <NUM> during the operation and generates a position-over-time signal that is provided to the data processing system <NUM> for indicating a failure of a manufacturing process of <FIG> as the input signal I5.

In <FIG> the computer-implemented method of training a machine learning system for indicating states of a manufacturing process is schematically depicted. The computer-implemented method of training a machine learning system for indicating states of a manufacturing process comprises the steps i) generating <NUM> a set of at least one training parameter and of corresponding training results and ii) training <NUM> the machine learning system.

Here, five training parameters are used. The training parameters are generated much like the parameters in the computer-implemented method of <FIG>. In a manufacturing system (e.g. the manufacturing system of <FIG>) several cycles of the manufacturing process are run in order to generate training input signals T1. Here, <NUM> training cycles are run, but the training input signals T1. T5 may also be acquired during productive operation. In each (training or productive) cycle of the manufacturing process the pressing force of a plunger on a mould while pressing a sheet or plate into a workpiece is detected by four force sensors. Further, the position of the plunger relative to the mould is detected by a position sensor during each cycle. The four force sensors generate force-over-time signals T1. T4 and the position sensor generates a position-over-time signal T5 in each cycle. The four force-over-time signals and the position-over-time signal of each of the <NUM> cycles are provided as the training input signals T1. T5 of the set. Further, the state of the manufacturing process at each cycle is determined. These states of the manufacturing process comprise idle phase, start-up phase, normal operation and one or more failures of the manufacturing process. The failures of the manufacturing process may comprise cracks in the sheet/plate or rather workpiece, ripples of the sheet/plate or rather workpiece, micro-cracks of the sheet/plate or rather workpiece and the like after the pressing. These states of the manufacturing process are included in the set as the corresponding training results. Thereby, respective five training input signals T1. T5 and the corresponding training result (state of the manufacturing process) form one pair of training data (the five training input signals as input data for the training and the corresponding training result as (desired) output data for the training). The five training input signals T1. T5 may be labelled or tagged with the corresponding training result.

The generating <NUM> comprises the sub-steps:.

The sub-steps <NUM>. <NUM> may be applied in any order to the training input signals T1. The five training input signals T1. T5 are transformed as described for the input signals in the computer-implemented method of <FIG>. The sub-steps <NUM>. <NUM> correspond to the sub-steps <NUM>. Further, the five input training signals T1. T5 or rather the selected time slices may not be used completely, but only parts of the predefined length may be used as training parameters. Thereto, the training input signals T1. T5 or rather selected time slices thereof may be divided into the parts of the predefined length. Here the time slices of <NUM> time steps are divided into parts of <NUM> time steps.

Further, the part of the time slice of each training input signal T1. T5 that is used as the respective training parameter is selected according to a Gaussian distribution. The maximum of the Gaussian distribution is placed in a region of the training input signals T1. T5/time slices, where a maximal pressing force is detected. This region of the training input signals T1. T5/time slices contains the most information about the state of the manufacturing process. The corresponding parts are therefore more often selected as the input parameters via the Gaussian distribution than the parts belonging to regions of the training input signals T1. T5/time slices, where the plunger applies a lower pressing force onto the mould (e.g. from the time point where the plunger contacts the sheet/plate until before the plunger exerts the maximal pressing force as well as from the time point where the plunger decreases the pressing force and is retracted from the mould).

In step ii) a convolutional NN is trained for indicating states of the manufacturing process. Iteratively the pairs of input data (five training parameters) and (desired) output data (corresponding training results) are used for training the convolutional NN. In each iteration, the five training parameters, which are based on the respective five training input signals T1. T5, are provided to the convolutional NN. The internal weights of the hidden layers of the convolutional NN are adjusted until the optimisation function converges to the corresponding training result. After the set of <NUM> pairs of input data and output data have been used for training, the convolutional NN is sufficiently trained for indicating states of the manufacturing process.

The convolutional NN trained by the computer-implemented method of training a machine learning system for indicating states of a manufacturing process of <FIG> may be used in the computer-implemented method of indicating a failure of a manufacturing process of <FIG> and/or integrated in the data processing system for indicating a failure of a manufacturing process of <FIG>, which may be included in the manufacturing system of <FIG>.

Claim 1:
Computer-implemented method of indicating a failure of a manufacturing process, comprising the steps:
a) receiving (<NUM>) at least one input signal (I1..I5) based on at least one physical quantity monitored during the manufacturing process by means of at least one sensor (S1..S4);
b) transforming (<NUM>) the received at least one input signal (I1..I5) into at least one parameter (P1..P5), having a different domain than the received at least one input signal (I1..I5);
c) deriving (<NUM>) latent features (LF) based on the at least one parameter (P1..P5) by means of a machine learning system (MLS) which is trained on deriving latent features (LF) based on the at least one parameter (P1..P5) indicative of specific states of the manufacturing process; wherein
states of the manufacturing process comprises idle phase, start-up phase, normal operation and at least one failure of the manufacturing process in a manufactured workpieces, wherein the MLS is a convolutional neural network,
d) mapping (<NUM>), using a nonlinear dimensionality reduction technique, the derived latent features (LF), provided by one of the hidden layers of the convolutional neural network, into one of several distinct clusters (C1..C3) in a two dimensional (2D) cluster space, wherein the clusters (c1..C3) represent different states of the manufacturing process; and
e) indicating a failure of the manufacturing process based on the different states of the manufacturing process, wherein the at least one monitored physical quantity is a pressing force (F) of a press (<NUM>) and the at least one generated input signal (I1..I5) is a force-over-time signal and wherein the failure in the pressed workpiece is indicated as the failure of the manufacturing process.