Model based tampering for improved process performance - An application to grinding of shafts
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This paper presents the Model Based Tampering (MBT) methodology to address performance degradation in complex nonlinear processes. MBT involves characterizing the dynamics of a process through experiments to derive Nonlinear Stochastic Differential Equation (n-SDE) models that can accurately and compactly represent a process, and using these models to dynamically compensate for the effects of process degradation on the performance. This research has yielded a new method to derive n-SDE models of complex processes through a signal-based reconstruction of Fokker-Plank equations. MBT was applied to control surface finish during cylindrical grinding of shafts of Air Bearings used in aircraft Environmental Control Systems (ECS) - a core competency of Honeywell- We have proved that the n-SDE models help capture patterns in process outputs that cannot be captured using any simpler models, and that MBT reduces the surface finish variation by 62% over the current industry practice.
