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Level 2 Model Improvement Case Study: Oregon Steel


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Limitation of Adaptive Learning

Studies on the relationship between C3 and C4 revealed the following tendencies:

  • FIT3A (C4=0) results in large values of C3; FIT3B (C3=0) also led to high values of C4.
  • In the four-parameter learning (FIT4), calculated C3 and C4 were not stable. The cases for C3 and C4 pairs were:
    • Low C3 plus high C4. C3 was much lower than the medium value and C4 much higher than the medium value.
    • High C3 plus low C4. The high value of C3 was much higher than the medium value and the low value of C4 much lower than the medium.
    • Medium C3 plus medium C4. This was the perfect condition with both C3 and C4 in the similar range of the medium values. However, the occurence of this case was low; C3 and C4 were more or less away from the medium value.

Further studies indicated that for most grades, C3 and C4 may be roughly described in a linear relationship:

C3 = m * C4 + n                                 (2)

In which m and n are empirical factors derived from the large number of data, varied from grade to grade. This finding indicated C3 and C4 have great influence on each other. As long as a C3 and a C4 satisfy equation (2), a relatively good fit for learning should be achieved, even though C3 and C4 might spread in a large range, from negative value, zero and a very high value. The problem is, even though each [C3, C4] pair may have a good fit, the C3ALL produced from combining so many widely scattered C3 values, and C4ALL from so many totally different C4 values, may not fit each other well. This leads to the limitation of the long-term learning. As long as each of qualified C3 and C4 in a pair depends on each other and thus scatters widely, the long-term learning by combining them would hardly reach high accuracy. Therefore, a blind long-term learning can reach only a limited level of accuracy, but cannot go further. Human intervention is necessary to determine the right C3, C4 value pair.

Discussion from the Data Analysis

In this project, quite a portion of the time was spent in an attempt to understand the data in the existing Level 2 system. There were many confusing questions, for example:

  • Why were the values of C3 and C4 scattered in so big a range? It did not look like a measurement problem.

  • Why were the C3 from the log data consistently much higher than the theoretical value?

  • Different researchers published quite different results on C3. Who is right?

  • Further studies were also needed to identify which temperature region should have higher C3 and C4, the higher-temperature region or the lower-temperature. The lower-temperature region did have higher retained strain.

  • Without an understanding to the problems, any change to the system would put it at risk. After all those questions were answered and the problems understood, repairing the system actually was not very difficult.

    Answer for (1) was due to the dependence of C3 and C4 on each other as discussed in the Limitation of Adaptive Learning. Reason for (2) was considered to be the effect of the retained strain. Both the German and Japanese colleagues are right and their data are consistent. If the value from the Japanese colleagues (C3=0.21) is used, the pass strain should be used; while if the German colleagues?data (C3=0.18) is accepted, the actual strain (the pass strain plus the retained strain) should be applied. Besides retained strain, there are other factors that affect the C3 and C4.

    <To Be Continued>

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