Advancing Net-Zero Manufacturing: Digital Twin-based Fault Diagnosis and Prognosis in Nonlinear Mechatronic Systems

In the context of the Industrial 4.0 revolution, the shift towards smart manufacturing is not only redefining how we approach industrial processes but also emphasizing the urgent need for sustainable practices to achieve Net-Zero goals. As factories become smarter, with machines, robots, and Automated Guided Vehicles (AGVs) seamlessly integrated within Cyber-Physical Systems (CPS), the focus on minimizing the environmental footprint of these advancements grows increasingly important. However, the challenges of wear and tear in mechanical parts or errors in electronic modules present obstacles to maintaining efficient, sustainable operations. These issues can lead to increased maintenance costs, reduced production efficiency, and compromised product quality, all of which can detract from the goal of achieving Net-Zero emissions by exacerbating resource waste and energy consumption.

This Ph.D. project aims to propose a fundamental solution to the challenges faced by current technologies and develop innovative digital twin-based techniques that can diagnose and prognose mechatronic systems in real-time. The supervisor team has recently developed a digital twin diagnostic framework based on an innovative data and systems science approach derived at Newcastle University [1]. This method has been validated through extensive experimental research at an industrial scale, earning recognition from leading entities in the advanced manufacturing sector, such as AMRC, BAE Systems, Sandvik, and Mitsubishi. Inspired by insights from these industry giants, the PhD projects will work closely with Power Electronics, Machines & Drives (PEMD) and Institute of Electrification and Sustainable Advanced Manufacturing (IESAM) groups at Newcastle and their industrial partners, aiming to elevate the developed FDP technique to greater Technology Readiness Level (TRL) levels, ensuring it meets the complex demands of mechatronic systems operating under varied environmental conditions.

Newcastle University is committed to being a fully inclusive Global University which actively recruits, supports and retains colleagues from all sectors of society. We value diversity as well as celebrate, support and thrive on the contributions of all our employees and the communities they represent.  We are proud to be an equal opportunities employer and encourage applications from everybody, regardless of race, sex, ethnicity, religion, nationality, sexual orientation, age, disability, gender identity, marital status/civil partnership, pregnancy and maternity, as well as being open to flexible working practices.

Application enquires: 

Dr Zepeng Liu

Zepeng.liu@newcastle.ac.uk

https://www.ncl.ac.uk/engineering/staff/profile/zepengliu.html