Data-Driven Ergonomic Risk Assessment of Complex Hand-intensive Manufacturing Processes

Hand-intensive manufacturing processes, such as composite layup and textile draping, require significant human dexterity to accommodate task complexity. These strenuous hand motions often lead to musculoskeletal disorders and rehabilitation surgeries. We develop a data-driven ergonomic risk assessment system with a special focus on hand and finger activity to better identify and address ergonomic issues related to hand-intensive manufacturing processes. The system comprises a multi-modal sensor testbed to collect and synchronize operator upper body pose, hand pose and applied forces; a Biometric Assessment of Complete Hand (BACH) formulation to measure high-fidelity hand and finger risks; and industry-standard risk scores associated with upper body posture, RULA, and hand activity, HAL. Our findings demonstrate that BACH captures injurious activity with a higher granularity in comparison to the existing metrics. Machine learning models are also used to automate RULA and HAL scoring, and generalize well to unseen participants. Our assessment system, therefore, provides ergonomic interpretability of the manufacturing processes studied, and could be used to mitigate risks through minor workplace optimization and posture corrections.

Statistical Mechanics of Dynamical System Identification

Recovering dynamical equations from observed noisy data is the central challenge of system identification. We develop a statistical mechanical approach to analyze sparse equation discovery algorithms, which typically balance data fit and parsimony through a trial-and-error selection of hyperparameters. In this framework, statistical mechanics offers tools to analyze the interplay between complexity and fitness, in analogy to that done between entropy and energy. To establish this analogy, we define the optimization procedure as a two-level Bayesian inference problem that separates variable selection from coefficient values and enables the computation of the posterior parameter distribution in closed form. A key advantage of employing statistical mechanical concepts, such as free energy and the partition function, is in the quantification of uncertainty, especially in in the low-data limit; frequently encountered in real-world applications. As the data volume increases, our approach mirrors the thermodynamic limit, leading to distinct sparsity- and noise-induced phase transitions that delineate correct from incorrect identification. This perspective of sparse equation discovery, is versatile and can be adapted to various other equation discovery algorithms.

Data-Induced Interactions of Sparse Sensors

Large-dimensional empirical data in science and engineering frequently has low-rank structure and can be represented as a combination of just a few eigenmodes. Because of this structure, we can use just a few spatially localized sensor measurements to reconstruct the full state of a complex system. The quality of this reconstruction, especially in the presence of sensor noise, depends significantly on the spatial configuration of the sensors. Multiple algorithms based on gappy interpolation and QR factorization have been proposed to optimize sensor placement. Here, instead of an algorithm that outputs a singular "optimal" sensor configuration, we take a thermodynamic view to compute the full landscape of sensor interactions induced by the training data. The landscape takes the form of the Ising model in statistical physics, and accounts for both the data variance captured at each sensor location and the crosstalk between sensors. Mapping out these data-induced sensor interactions allows combining them with external selection criteria and anticipating sensor replacement impacts.

Optimal Sensor Placement with Adaptive Constraints for Nuclear Digital Twins

Given harsh operating conditions and physical constraints in reactors, nuclear applications cannot afford to equip the physical asset with a large array of sensors. Therefore, it is crucial to carefully determine the placement of sensors within the given spatial limitations, enabling the reconstruction of reactor flow fields and the creation of nuclear digital twins. Various design considerations are imposed, such as predetermined sensor locations, restricted areas within the reactor, a fixed number of sensors allocated to a specific region, or sensors positioned at a designated distance from one another. We develop a data-driven technique that integrates constraints into an optimization procedure for sensor placement, aiming to minimize reconstruction errors. Our approach employs a greedy algorithm that can optimize sensor locations on a grid, adhering to user-defined constraints. We demonstrate the near optimality of our algorithm by computing all possible configurations for selecting a certain number of sensors for a randomly generated state space system. In this work, the algorithm is demonstrated on the Out-of-Pile Testing and Instrumentation Transient Water Irradiation System (OPTI-TWIST) prototype vessel, which is electrically heated to mimic the neutronics effect of the Transient Reactor Test facility (TREAT) at Idaho National Laboratory (INL). The resulting sensor-based reconstruction of temperature within the OPTI-TWIST minimizes error, provides probabilistic bounds for noise-induced uncertainty and will finally be used for communication between the digital twin and experimental facility.

PySensors: A Python Package for Sparse Sensor Placement

PySensors is a Python package for selecting and placing a sparse set of sensors for classification and reconstruction tasks. Specifically, PySensors implements algorithms for data-driven sparse sensor placement optimization for reconstruction (SSPOR) and sparse sensor placement optimization for classification (SSPOC). In this work we provide a brief description of the mathematical algorithms and theory for sparse sensor optimization, along with an overview and demonstration of the features implemented in PySensors (with code examples). We also include practical advice for user and a list of potential extensions to PySensors. Software is available at https://github.com/dynamicslab/pysensors.

Data-Driven Aerospace Engineering: Reframing the Industry with Machine Learning

Data science, and machine learning in particular, is rapidly transforming the scientific and industrial landscapes. The aerospace industry is poised to capitalize on big data and machine learning, which excels at solving the types of multi-objective, constrained optimization problems that arise in aircraft design and manufacturing. Indeed, emerging methods in machine learning may be thought of as data-driven optimization techniques that are ideal for high-dimensional, non-convex, and constrained, multi-objective optimization problems, and that improve with increasing volumes of data. In this review, we will explore the opportunities and challenges of integrating data-driven science and engineering into the aerospace industry. Importantly, we will focus on the critical need for interpretable, generalizeable, explainable, and certifiable machine learning techniques for safety-critical applications. This review will include a retrospective, an assessment of the current state-of-the-art, and a roadmap looking forward. Recent algorithmic and technological trends will be explored in the context of critical challenges in aerospace design, manufacturing, verification, validation, and services. In addition, we will explore this landscape through several case studies in the aerospace industry. This document is the result of close collaboration between UW and Boeing to summarize past efforts and outline future opportunities.

Kernel Analog Forecasting: Multiscale Test Problems

Data-driven prediction is becoming increasingly widespread as the volume of data available grows and as algorithmic development matches this growth. The nature of the predictions made, and the manner in which they should be interpreted, depends crucially on the extent to which the variables chosen for prediction are Markovian, or approximately Markovian. Multiscale systems provide a framework in which this issue can be analyzed. In this work kernel analog forecasting methods are studied from the perspective of data generated by multiscale dynamical systems. The problems chosen exhibit a variety of different Markovian closures, using both averaging and homogenization; furthermore, settings where scale-separation is not present and the predicted variables are non-Markovian, are also considered. The studies provide guidance for the interpretation of data-driven prediction methods when used in practice.

Sparse Principal Component Analysis via Variable Projection

Sparse principal component analysis (SPCA) has emerged as a powerful technique for data analysis, providing improved interpretation of low-rank structures by identifying localized spatial structures in the data and disambiguating between distinct time scales. We demonstrate a robust and scalable SPCA algorithm by formulating it as a value-function optimization problem. This viewpoint leads to a flexible and computationally efficient algorithm. It can further leverage randomized methods from linear algebra to extend the approach to the large-scale (big data) setting. Our proposed innovation also allows for a robust SPCA formulation which can obtain meaningful sparse components in spite of grossly corrupted input data. The proposed algorithms are demonstrated using both synthetic and real world data, showing exceptional computational efficiency and diagnostic performance.

Predicting shim gaps in aircraft assembly with machine learning and sparse sensing

A modern aircraft may require on the order of thousands of custom shims to fill gaps between structural components in the airframe that arise due to manufacturing tolerances adding up across large structures. These shims are necessary to eliminate gaps, maintain structural performance, and minimize pull-down forces required to bring the aircraft into engineering nominal configuration for peak aerodynamic efficiency. Gap filling is a time-consuming process, involving either expensive by-hand inspection or computations on vast quantities of measurement data from increasingly sophisticated metrology equipment. Either case amounts to significant delays in production, with much of the time spent in the critical path of aircraft assembly. This work presents an alternative strategy for predictive shimming, based on machine learning and sparse sensing to first learn gap distributions from historical data, and then design optimized sparse sensing strategies to streamline data collection and processing. This new approach is based on the assumption that patterns exist in shim distributions across aircraft, which may be mined and used to reduce the burden of data collection and processing in future aircraft. Specifically, robust principal component analysis is used to extract low-dimensional patterns in the gap measurements while rejecting outliers. Next, optimized sparse sensors are obtained that are most informative about the dimensions of a new aircraft in these low-dimensional principal components. We demonstrate the success of the proposed approach, called PIXel Identification Despite Uncertainty in Sensor Technology (PIXI-DUST), on historical production data from 54 representative Boeing commercial aircraft. Our algorithm successfully predicts $99\%$ of shim gaps within the desired measurement tolerance using $3\%$ of the laser scan points typically required; all results are cross-validated.

Sparse-TDA: Sparse Realization of Topological Data Analysis for Multi-Way Classification

Topological data analysis (TDA) has emerged as one of the most promising techniques to reconstruct the unknown shapes of high-dimensional spaces from observed data samples. TDA, thus, yields key shape descriptors in the form of persistent topological features that can be used for any supervised or unsupervised learning task, including multi-way classification. Sparse sampling, on the other hand, provides a highly efficient technique to reconstruct signals in the spatial-temporal domain from just a few carefully-chosen samples. Here, we present a new method, referred to as the Sparse-TDA algorithm, that combines favorable aspects of the two techniques. This combination is realized by selecting an optimal set of sparse pixel samples from the persistent features generated by a vector-based TDA algorithm. These sparse samples are selected from a low-rank matrix representation of persistent features using QR pivoting. We show that the Sparse-TDA method demonstrates promising performance on three benchmark problems related to human posture recognition and image texture classification.