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Satish Bukkapatnam

Publications and source records attributed to Satish Bukkapatnam.

13 recordsLinked to original sources

DynaMark: A Reinforcement Learning Framework for Dynamic Watermarking in Industrial Machine Tool Controllers

Industry 4.0's highly networked Machine Tool Controllers (MTCs) are prime targets for replay attacks that use outdated sensor data to manipulate actuators. Dynamic watermarking can reveal such tampering, but current schemes assume linear-Gaussian dynamics and use constant watermark statistics, making them vulnerable to the time-varying, partly proprietary behavior of MTCs. We close this gap with DynaMark, a reinforcement learning framework that models dynamic watermarking as a Markov decision process (MDP). It learns an adaptive policy online that dynamically adapts the covariance of a zero-mean Gaussian watermark using available measurements and detector feedback, without needing system knowledge. DynaMark maximizes a unique reward function balancing control performance, energy consumption, and detection confidence dynamically. We develop a Bayesian belief updating mechanism for real-time detection confidence in linear systems. This approach, independent of specific system assumptions, underpins the MDP for systems with linear dynamics. On a Siemens Sinumerik 828D controller digital twin, DynaMark achieves a reduction in watermark energy by 70% while preserving the nominal trajectory, compared to constant variance baselines. It also maintains an average detection delay equivalent to one sampling interval. A physical stepper-motor testbed validates these findings, rapidly triggering alarms with less control performance decline and exceeding existing benchmarks.

eess.SY

The Internet of Things for Smart Manufacturing: A Review

The modern manufacturing industry is investing in new technologies such as the Internet of Things (IoT), big data analytics, cloud computing and cybersecurity to cope with system complexity, increase information visibility, improve production performance, and gain competitive advantages in the global market. These advances are rapidly enabling a new generation of smart manufacturing, i.e., a cyber-physical system tightly integrating manufacturing enterprises in the physical world with virtual enterprises in cyberspace. To a great extent, realizing the full potential of cyber-physical systems depends on the development of new methodologies on the Internet of Manufacturing Things (IoMT) for data-enabled engineering innovations. This paper presents a review of the IoT technologies and systems that are the drivers and foundations of data-driven innovations in smart manufacturing. We discuss the evolution of internet from computer networks to human networks to the latest era of smart and connected networks of manufacturing things (e.g., materials, sensors, equipment, people, products, and supply chain). In addition, we present a new framework that leverages IoMT and cloud computing to develop a virtual machine network. We further extend our review to IoMT cybersecurity issues that are of paramount importance to businesses and operations, as well as IoT and smart manufacturing policies that are laid out by governments around the world for the future of smart factory. Finally, we present the challenges and opportunities arising from IoMT. We hope this work will help catalyze more in-depth investigations and multi-disciplinary research efforts to advance IoMT technologies.

eess.SY

Towards Futuristic Autonomous Experimentation--A Surprise-Reacting Sequential Experiment Policy

An autonomous experimentation platform in manufacturing is supposedly capable of conducting a sequential search for finding suitable manufacturing conditions by itself or even for discovering new materials with minimal human intervention. The core of the intelligent control of such platforms is a policy to decide where to conduct the next experiment based on what has been done thus far. Such policy inevitably trades off between exploitation and exploration. Currently, the prevailing approach is to use various acquisition functions in the Bayesian optimization framework. We discuss whether it is beneficial to trade off exploitation versus exploration by measuring the element and degree of surprise associated with the immediate past observation. We devise a surprise-reacting policy using two existing surprise metrics, known as the Shannon surprise and Bayesian surprise. Our analysis shows that the surprise-reacting policy appears to be better suited for quickly characterizing the overall landscape of a response surface under resource constraints. We do not claim that we have a fully autonomous experimentation system but believe that the surprise-reacting capability benefits the automation of sequential decisions in autonomous experimentation.

cs.LG

Machine Learning-Enhanced Prediction of Surface Smoothness for Inertial Confinement Fusion Target Polishing Using Limited Data

In Inertial Confinement Fusion (ICF) process, roughly a 2mm spherical shell made of high density carbon is used as target for laser beams, which compress and heat it to energy levels needed for high fusion yield. These shells are polished meticulously to meet the standards for a fusion shot. However, the polishing of these shells involves multiple stages, with each stage taking several hours. To make sure that the polishing process is advancing in the right direction, we are able to measure the shell surface roughness. This measurement, however, is very labor-intensive, time-consuming, and requires a human operator. We propose to use machine learning models that can predict surface roughness based on the data collected from a vibration sensor that is connected to the polisher. Such models can generate surface roughness of the shells in real-time, allowing the operator to make any necessary changes to the polishing for optimal result.

cs.LG

EBLIME: Enhanced Bayesian Local Interpretable Model-agnostic Explanations

We propose EBLIME to explain black-box machine learning models and obtain the distribution of feature importance using Bayesian ridge regression models. We provide mathematical expressions of the Bayesian framework and theoretical outcomes including the significance of ridge parameter. Case studies were conducted on benchmark datasets and a real-world industrial application of locating internal defects in manufactured products. Compared to the state-of-the-art methods, EBLIME yields more intuitive and accurate results, with better uncertainty quantification in terms of deriving the posterior distribution, credible intervals, and rankings of the feature importance.

stat.ML

Unsupervised spectral-band feature identification for optimal process discrimination

Changes in real-world dynamic processes are often described in terms of differences in energies $\textbf{E}(\underlineα)$ of a set of spectral-bands $\underlineα$. Given continuous spectra of two classes $A$ and $B$, or in general, two stochastic processes $S^{(A)}(f)$ and $S^{(B)}(f)$, $f \in \mathbb{R}^+$, we address the ubiquitous problem of identifying a subset of intervals of $f$ called spectral-bands $\underlineα \subset \mathbb{R}^+$ such that the energies $\textbf{E}(\underlineα)$ of these bands can optimally discriminate between the two classes. We introduce EGO-MDA, an unsupervised method to identify optimal spectral-bands $\underlineα^*$ for given samples of spectra from two classes. EGO-MDA employs a statistical approach that iteratively minimizes an adjusted multinomial log-likelihood (deviance) criterion $\mathcal{D}(\underlineα,\mathcal{M})$. Here, Mixture Discriminant Analysis (MDA) aims to derive MLE of two GMM distribution parameters, i.e., $\mathcal{M}^* = \underset{\mathcal{M}}{\rm argmin}~\mathcal{D}(\underlineα, \mathcal{M})$ and identify a classifier that optimally discriminates between two classes for a given spectral representation. The Efficient Global Optimization (EGO) finds the spectral-bands $\underlineα^* = \underset{\underlineα}{\rm argmin}~\mathcal{D}(\underlineα,\mathcal{M})$ for given GMM parameters $\mathcal{M}$. For pathological cases of low separation between mixtures and model misspecification, we discuss the effect of the sample size and the number of iterations on the estimates of parameters $\mathcal{M}$ and therefore the classifier performance. A case study on a synthetic data set is provided. In an engineering application of optimal spectral-banding for anomaly tracking, EGO-MDA achieved at least 70% improvement in the median deviance relative to other methods tested.

cs.LG

Ripple formation and its effect on the multi-scale microstructure of Directed Energy Deposition (DED)-printed 316L components

An experimental study is presented to characterize the ripple formations in the directed energy deposition (DED) process and study the influence of the ripples on the heterogenous microstructure in the scan direction of a DED-printed 316L components. While considerable studies on ripple formations exist in the welding literature, these formations in DED process have not received much attention. Also, little prior efforts exist on the microstructure along the scan direction (or the scan surface) as compared with the build direction. Experiments consisted of printing 10 mm x 10 mm x 10 mm cubical components on a Optomec LENS 500 Hybrid Machine Tool under different laser power, scan speed and dwell time combinations, chosen according to a Latin hypercube design. The surface of the scan face of the prints were finished to an Ra < 30 nm, and etched with Aqua regia for 90 sec. An optical microscope was employed to observe the microstructure at 4 difference scales. The studies suggest a significant influence of ripple formations as well as the scan width on the solidification front, the dendritic patterns as well as the heterogenous microstructure.

physics.app-ph

Hypothesis Tests with Functional Data for Surface Quality Change Detection in Surface Finishing Processes

This work is concerned with providing a principled decision process for stopping or tool-changing in a surface finishing process. The decision process is supposed to work for products of non-flat geometry. The solution is based on conducting hypothesis testing on the bearing area curves from two consecutive stages of a surface finishing process. In each stage, the bearing area curves, which are in fact the nonparametric quantile curves representing the surface roughness, are extracted from surface profile measurements at a number of sampling locations on the surface of the products. The hypothesis test of these curves informs the decision makers whether there is a change in surface quality induced by the current finishing action. When such change is detected, the current action is deemed effective and should thus continue, while when no change is detected, the effectiveness of the current action is then called into question, signaling possibly some change in the course of action. Application of the hypothesis testing-based decision procedure to both spherical and flat surfaces demonstrates the effectiveness and benefit of the proposed method and confirms its geometry-agnostic nature.

stat.ME

A Review of the Anomalies in Directed Energy Deposition (DED) Processes and Potential Solutions

Directed Energy Deposition (DED) processes offer one of the most versatile current techniques to additively manufacture and repair metallic components that have generatively designed complex geometries, and with compositional control. When compared to powder bed fusion (PBF), its applicability and adoption has been limited because several issues innate to the process are yet to be suitably understood and resolved. This work catalogs and delineates these issues and anomalies in the DED process along with their causes and solutions, based on a state-of-the-art literature review. This work also serves to enumerate and associate the underlying causes to the detrimental effects which manifest as undesirable part/process outcomes. These DED-specific anomalies are categorized under groups related to the part, process, material, productivity, safety, repair, and functional gradients. Altogether, this primer acts as a guide to best prepare for and mitigate the problems that are encountered in DED, and also to lay the groundwork to inspire novel solutions to further advance DED into mainstream manufacturing.

physics.app-ph

Change detection in complex dynamical systems using intrinsic phase and amplitude synchronization

We present an approach for the detection of sharp change points (short-lived and persistent) in nonlinear and nonstationary dynamic systems under high levels of noise by tracking the local phase and amplitude synchronization among the components of a univariate time series signal. The signal components are derived via Intrinsic Time scale Decomposition (ITD)--a nonlinear, non-parametric analysis method. We show that the signatures of sharp change points are retained across multiple ITD components with a significantly higher probability as compared to random signal fluctuations. Theoretical results are presented to show that combining the change point information retained across a specific set of ITD components offers the possibility of detecting sharp transitions with high specificity and sensitivity. Subsequently, we introduce a concept of mutual agreement to identify the set of ITD components that are most likely to capture the information about dynamical changes of interest and define an InSync statistic to capture this local information. Extensive numerical, as well as real-world case studies involving benchmark neurophysiological processes and industrial machine sensor data, suggest that the present method can detect sharp change points, on an average 62% earlier (in terms of average run length) as compared to other contemporary methods tested.

physics.data-an

Towards Non-Contact Glucose Sensing in Aqueous Turbid Medium at ~1.1 Meters Distance

This work demonstrates a non-contact diffuse reflectance approach with a working distance of ~1.1 meters for the potential of glucose sensing. Non-contact diffuse reflectance over 1.1-1.3 micrometers was developed according to a center-illumination-area-detection (CIAD) geometry. The modeled response of diffuse reflectance in the CIAD geometry was examined with phantoms by altering independently the size of the collection geometry and the reduced scattering and absorption properties of the medium. When applied to aqueous turbid medium containing glucose control solutions with the cumulative volume varying over three orders of magnitude, a linear relationship expected for the diffuse reflectance as a function of the medium absorption/reduced-scattering property was observed for four conditions of the glucose-medium composition that differed either in the effective glucose concentration or the host medium scattering property. The cumulation of glucose up to 17.8mg/dL and 8.9mg/dL in the host medium having the same optical properties resulted in linear regression slopes of 0.0032 and 0.0030, respectively. The cumulation of the glucose up to 17.8mg/dL in an aqueous host medium that differed two folds in the reduced scattering property caused the linear regression slope to differ between 0.0032 and 0.0019. The R^2 values of all cases were all greater than 0.987. A provisional patent (US#63/053,004) has been obtained for this work.

physics.med-ph

Consistent estimation of the max-flow problem: Towards unsupervised image segmentation

Advances in the image-based diagnostics of complex biological and manufacturing processes have brought unsupervised image segmentation to the forefront of enabling automated, on the fly decision making. However, most existing unsupervised segmentation approaches are either computationally complex or require manual parameter selection (e.g., flow capacities in max-flow/min-cut segmentation). In this work, we present a fully unsupervised segmentation approach using a continuous max-flow formulation over the image domain while optimally estimating the flow parameters from the image characteristics. More specifically, we show that the maximum a posteriori estimate of the image labels can be formulated as a continuous max-flow problem given the flow capacities are known. The flow capacities are then iteratively obtained by employing a novel Markov random field prior over the image domain. We present theoretical results to establish the posterior consistency of the flow capacities. We compare the performance of our approach on two real-world case studies including brain tumor image segmentation and defect identification in additively manufactured components using electron microscopic images. Comparative results with several state-of-the-art supervised as well as unsupervised methods suggest that the present method performs statistically similar to the supervised methods, but results in more than 90% improvement in the Dice score when compared to the state-of-the-art unsupervised methods.

cs.CV

Surface plastic flow in polishing of rough surfaces

We report electron microscopy observations of the surface plastic flow in polishing of rough metal surfaces with a controlled spherical asperity structure. We show that asperity--abrasive sliding contacts exhibit viscous behavior, where the material flows in the form of thin fluid-like layers. Subsequent bridging of these layers among neighboring asperities result in progressive surface smoothening. Our study provides new phenomenological insights into the long-debated mechanism of polishing. The observations are of broad relevance in tribology and materials processing.

cond-mat.mtrl-sci