Handbook Of Industrial Automation

Handbook of Industrial Automation edited by Richard L. Shell Ernest L. Hall University of Cincinnati Cincinnati, Ohio ...

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Handbook of Industrial Automation edited by

Richard L. Shell Ernest L. Hall University of Cincinnati Cincinnati, Ohio

Marcel Dekker, Inc. TM

Copyright © 2000 by Marcel Dekker, Inc. All Rights Reserved.

Copyright © 2000 Marcel Dekker, Inc.

New York • Basel

ISBN: 0-8247-0373-1 This book is printed on acid-free paper. Headquarters Marcel Dekker, Inc. 270 Madison Avenue, New York, NY 10016 tel: 212-696-9000; fax: 212-685-4540 Eastern Hemisphere Distribution Marcel Dekker AG Hutgasse 4, Postfach 812, CH-4001 Basel, Switzerland tel: 41-61-261-8482; fax: 41-61-261-8896 World Wide Web http://www.dekker.com The publisher offers discounts on this book when ordered in bulk quantities. For more information, write to Special Sales/ Professional Marketing at the headquarters address above. Copyright # 2000 by Marcel Dekker, Inc. All Rights Reserved. Neither this book nor any part may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, micro®lming, and recording, or by any information storage and retrieval system, without permission in writing from the publisher. Current printing (last digit): 10 9 8 7 6 5 4 3 2 1 PRINTED IN THE UNITED STATES OF AMERICA


Preface

This handbook is designed as a comprehensive reference for the industrial automation engineer. Whether in a small or large manufacturing plant, the industrial or manufacturing engineer is usually responsible for using the latest and best technology in the safest, most economic manner to build products. This responsibility requires an enormous knowledge base that, because of changing technology, can never be considered complete. The handbook will provide a handy starting reference covering technical, economic, certain legal standards, and guidelines that should be the ®rst source for solutions to many problems. The book will also be useful to students in the ®eld as it provides a single source for information on industrial automation. The handbook is also designed to present a related and connected survey of engineering methods useful in a variety of industrial and factory automation applications. Each chapter is arranged to permit review of an entire subject, with illustrations to provide guideposts for the more complex topics. Numerous references are provided to other material for more detailed study. The mathematical de®nitions, concepts, equations, principles, and application notes for the practicing industrial automation engineer have been carefully selected to provide broad coverage. Selected subjects from both undergraduate- and graduate-level topics from industrial, electrical, computer, and mechanical engineering as well as material science are included to provide continuity and depth on a variety of topics found useful in our work in teaching thousands of engineers who work in the factory environment. The topics are presented in a tutorial style, without detailed proofs, in order to incorporate a large number of topics in a single volume. The handbook is organized into ten parts. Each part contains several chapters on important selected topics. Part 1 is devoted to the foundations of mathematical and numerical analysis. The rational thought process developed in the study of mathematics is vital in developing the ability to satisfy every concern in a manufacturing process. Chapters include: an introduction to probability theory, sets and relations, linear algebra, calculus, differential equations, Boolean algebra and algebraic structures and applications. Part 2 provides background information on measurements and control engineering. Unless we measure we cannot control any process. The chapter topics include: an introduction to measurements and control instrumentation, digital motion control, and in-process measurement. Part 3 provides background on automatic control. Using feedback control in which a desired output is compared to a measured output is essential in automated manufacturing. Chapter topics include distributed control systems, stability, digital signal processing and sampled-data systems. Part 4 introduces modeling and operations research. Given a criterion or goal such as maximizing pro®t, using an overall model to determine the optimal solution subject to a variety of constraints is the essence of operations research. If an optimal goal cannot be obtained, then continually improving the process is necessary. Chapter topics include: regression, simulation and analysis of manufacturing systems, Petri nets, and decision analysis. iii


iv

Preface

Part 5 deals with sensor systems. Sensors are used to provide the basic measurements necessary to control a manufacturing operation. Human senses are often used but modern systems include important physical sensors. Chapter topics include: sensors for touch, force, and torque, fundamentals of machine vision, low-cost machine vision and three-dimensional vision. Part 6 introduces the topic of manufacturing. Advanced manufacturing processes are continually improved in a search for faster and cheaper ways to produce parts. Chapter topics include: the future of manufacturing, manufacturing systems, intelligent manufacturing systems in industrial automation, measurements, intelligent industrial robots, industrial materials science, forming and shaping processes, and molding processes. Part 7 deals with material handling and storage systems. Material handling is often considered a necessary evil in manufacturing but an ef®cient material handling system may also be the key to success. Topics include an introduction to material handling and storage systems, automated storage and retrieval systems, containerization, and robotic palletizing of ®xed- and variable-size parcels. Part 8 deals with safety and risk assessment. Safety is vitally important, and government programs monitor the manufacturing process to ensure the safety of the public. Chapter topics include: investigative programs, government regulation and OSHA, and standards. Part 9 introduces ergonomics. Even with advanced automation, humans are a vital part of the manufacturing process. Reducing risks to their safety and health is especially important. Topics include: human interface with automation, workstation design, and physical-strength assessment in ergonomics. Part 10 deals with economic analysis. Returns on investment are a driver to manufacturing systems. Chapter topics include: engineering economy and manufacturing cost recovery and estimating systems. We believe that this handbook will give the reader an opportunity to quickly and thoroughly scan the ®eld of industrial automation in suf®cient depth to provide both specialized knowledge and a broad background of speci®c information required for industrial automation. Great care was taken to ensure the completeness and topical importance of each chapter. We are grateful to the many authors, reviewers, readers, and support staff who helped to improve the manuscript. We earnestly solicit comments and suggestions for future improvements. Richard L. Shell Ernest L. Hall


Contents

Preface iii Contributors Part 1

ix

Mathematics and Numerical Analysis

1.1

Some Probability Concepts for Engineers Enrique Castillo and Ali S. Hadi

1.2

Introduction to Sets and Relations Diego A. Murio

1.3

Linear Algebra William C. Brown

1.4

A Review of Calculus Angelo B. Mingarelli

1.5

Ordinary Differential Equations Jane Cronin

1.6

Boolean Algebra Ki Hang Kim

1.7

Algebraic Structures and Applications J. B. Srivastava

Part 2

1

Measurements and Computer Control

2.1

Measurement and Control Instrumentation Error-Modeled Performance Patrick H. Garrett

2.2

Fundamentals of Digital Motion Control Ernest L. Hall, Krishnamohan Kola, and Ming Cao v


vi

2.3

Contents

In-Process Measurement William E. Barkman

Part 3

Automatic Control

3.1

Distributed Control Systems Dobrivoje Popovic

3.2

Stability Allen R. Stubberud and Stephen C. Stubberud

3.3

Digital Signal Processing Fred J. Taylor

3.4

Sampled-Data Systems Fred J. Taylor

Part 4

Modeling and Operations Research

4.1

Regression Richard Brook and Denny Meyer

4.2

A Brief Introduction to Linear and Dynamic Programming Richard B. Darst

4.3

Simulation and Analysis of Manufacturing Systems Benita M. Beamon

4.4

Petri Nets Frank S. Cheng

4.5

Decision Analysis Hiroyuki Tamura

Part 5

Sensor Systems

5.1

Sensors: Touch, Force, and Torque Richard M. Crowder

5.2

Machine Vision Fundamentals Prasanthi Guda, Jin Cao, Jeannine Gailey, and Ernest L. Hall

5.3

Three-Dimensional Vision Joseph H. Nurre

5.4

Industrial Machine Vision Steve Dickerson

Part 6 6.1

Manufacturing

The Future of Manufacturing M. Eugene Merchant


Contents

vii

6.2

Manufacturing Systems Jon Marvel and Ken Bloemer

6.3

Intelligent Manufacturing in Industrial Automation George N. Saridis

6.4

Measurements John Mandel

6.5

Intelligent Industrial Robots Wanek Golnazarian and Ernest L. Hall

6.6

Industrial Materials Science and Engineering Lawrence E. Murr

6.7

Forming and Shaping Processes Shivakumar Raman

6.8

Molding Processes Avraam I. Isayev

Part 7

Material Handling and Storage

7.1

Material Handling and Storage Systems William Wrennall and Herbert R. Tuttle

7.2

Automated Storage and Retrieval Systems Stephen L. Parsley

7.3

Containerization A. Kader Mazouz and C. P. Han

7.4

Robotic Palletizing of Fixed- and Variable-Size/Content Parcels Hyder Nihal Agha, William H. DeCamp, Richard L. Shell, and Ernest L. Hall

Part 8

Safety, Risk Assessment, and Standards

8.1

Investigation Programs Ludwig Benner, Jr.

8.2

Government Regulation and the Occupational Safety and Health Administration C. Ray Asfahl

8.3

Standards Verna Fitzsimmons and Ron Collier

Part 9

Ergonomics

9.1

Perspectives on Designing Human Interfaces for Automated Systems Anil Mital and Arunkumar Pennathur

9.2

Workstation Design Christin Shoaf and Ashraf M. Genaidy


viii

9.3

Contents

Physical Strength Assessment in Ergonomics Sean Gallagher, J. Steven Moore, Terrence J. Stobbe, James D. McGlothlin, and Amit Bhattacharya

Part 10

Economic Analysis

10.1 Engineering Economy Thomas R. Huston 10.2 Manufacturing-Cost Recovery and Estimating Systems Eric M. Malstrom and Terry R. Collins Index

863


Contributors

Hyder Nihal Agha C. Ray Asfahl

Research and Development, Motoman, Inc., West Carrollton, Ohio

University of Arkansas, Fayetteville, Arkansas

William E. Barkman Tennessee

Fabrication Systems Development, Lockheed Martin Energy Systems, Inc., Oak Ridge,

Benita M. Beamon

Department of Industrial Engineering, University of Washington, Seattle, Washington

Ludwig Benner, Jr.

Events Analysis, Inc., Alexandria, Virginia

Amit Bhattacharya

Environmental Health Department, University of Cincinnati, Cincinnati, Ohio

Ken Bloemer

Ethicon Endo-Surgery Inc., Cincinnati, Ohio

Richard Brook

Off Campus Ltd., Palmerston North, New Zealand

William C. Brown Jin Cao Ohio

Department of Mathematics, Michigan State University, East Lansing, Michigan

Department of Mechanical, Industrial, and Nuclear Engineering, University of Cincinnati, Cincinnati,

Ming Cao Ohio


Enrique Castillo

Applied Mathematics and Computational Sciences, University of Cantabria, Santander, Spain

Frank S. Cheng Industrial and Engineering Technology Department, Central Michigan University, Mount Pleasant, Michigan Ron Collier Ohio


Terry R. Collins Jane Cronin

Department of Industrial Engineering, University of Arkansas, Fayetteville, Arkansas

Department of Mathematics, Rutgers University, New Brunswick, New Jersey

Richard M. Crowder Department of Electronics and Computer Science, University of Southampton, Southampton, England Richard B. Darst

Department of Mathematics, Colorado State University, Fort Collins, Colorado ix


x

Contributors

William H. DeCamp Steve Dickerson

Motoman, Inc., West Carrollton, Ohio

Department of Mechanical Engineering, Georgia Institute of Technology, Atlanta, Georgia

Verna Fitzsimmons Cincinnati, Ohio

Department of Mechanical, Industrial, and Nuclear Engineering, University of Cincinnati,

Jeannine Gailey Department of Mechanical, Industrial, and Nuclear Engineering, University of Cincinnati, Cincinnati, Ohio Sean Gallagher Pittsburgh Research Laboratory, National Institute for Occupational Safety and Health, Pittsburgh, Pennsylvania Patrick H. Garrett Department of Electrical and Computer Engineering and Computer Science, University of Cincinnati, Cincinnati, Ohio Ashraf M. Genaidy Cincinnati, Ohio


Wanek Golnazarian

General Dynamics Armament Systems, Burlington, Vermont

Prasanthi Guda Department of Mechanical, Industrial, and Nuclear Engineering, University of Cincinnati, Cincinnati, Ohio Ali S. Hadi

Department of Statistical Sciences, Cornell University, Ithaca, New York

Ernest L. Hall Department of Mechanical, Industrial, and Nuclear Engineering, University of Cincinnati, Cincinnati, Ohio C. P. Han

Department of Mechanical Engineering, Florida Atlantic University, Boca Raton, Florida

Thomas R. Huston Cincinnati, Ohio Avraam I. Isayev Ki Hang Kim

Department of Mechanical, Industrial, and Nuclear Engineering, University of Cincinnati, Department of Polymer Engineering, The University of Akron, Akron, Ohio

Mathematics Research Group, Alabama State University, Montgomery, Alabama

Krishnamohan Kola Department of Mechanical, Industrial, and Nuclear Engineering, University of Cincinnati, Cincinnati, Ohio Eric M. Malstromy Department of Industrial Engineering, University of Arkansas, Fayetteville, Arkansas John Mandel Jon Marvel

National Institute of Standards and Technology, Gaithersburg, Maryland

Padnos School of Engineering, Grand Valley State University, Grand Rapids, Michigan

A. Kader Mazouz

Department of Mechanical Engineering, Florida Atlantic University, Boca Raton, Florida

James D. McGlothlin

Purdue University, West Lafayette, Indiana

M. Eugene Merchant

Institute of Advanced Manufacturing Sciences, Cincinnati, Ohio

Denny Meyer Institute of Information and Mathematical Sciences, Massey University±Albany, Palmerston North, New Zealand Angelo B. Mingarelli Anil Mital

School of Mathematics and Statistics, Carleton University, Ottawa, Ontario, Canada

Department of Industrial Engineering, University of Cincinnati, Cincinnati, Ohio

J. Steven Moore Department of Occupational and Environmental Medicine, The University of Texas Health Center, Tyler, Texas *

Retired. y Deceased.


Contributors

Diego A. Murio

xi

Department of Mathematical Sciences, University of Cincinnati, Cincinnati, Ohio

Lawrence E. Murr Paso, Texas

Department of Metallurgical and Materials Engineering, The University of Texas at El Paso, El

Joseph H. Nurre

School of Electrical Engineering and Computer Science, Ohio University, Athens, Ohio

Stephen L. Parsley

ESKAY Corporation, Salt Lake City, Utah

Arunkumar Pennathur Dobrivoje Popovic

University of Texas at El Paso, El Paso, Texas

Institute of Automation Technology, University of Bremen, Bremen, Germany

Shivakumar Raman

Department of Industrial Engineering, University of Oklahoma, Norman, Oklahoma

George N. Saridis Professor Emeritus, Electrical, Computer, and Systems Engineering Department, Rensselaer Polytechnic Institute, Troy, New York Richard L. Shell Cincinnati, Ohio


Christin Shoaf Department of Mechanical, Industrial, and Nuclear Engineering, University of Cincinnati, Cincinnati, Ohio J. B. Srivastava

Department of Mathematics, Indian Institute of Technology, Delhi, New Delhi, India

Terrence J. Stobbe

Industrial Engineering Department, West Virginia University, Morgantown, West Virginia

Allen R. Stubberud California

Department of Electrical and Computer Engineering, University of California Irvine, Irvine,

Stephen C. Stubberud Hiroyuki Tamura

ORINCON Corporation, San Diego, California

Graduate School of Engineering Science, Osaka University, Toyonaka, Osaka, Japan

Fred J. Taylor Department of Electrical and Computer Engineering and Department of Computer and Information Science Engineering, University of Florida, Gainesville, Florida Herbert R. Tuttle

Graduate Engineering Management, University of Kansas, Lawrence, Kansas

William Wrennall

The Leawood Group Ltd., Leawood, Kansas


Chapter 1.1 Some Probability Concepts for Engineers Enrique Castillo

University of Cantabria, Santander, Spain

Ali S. Hadi

Cornell University, Ithaca, New York

1.1

Section 1.7 discusses some characteristics of random variables, such as the moment-generating function and the characteristic function. Section 1.8 treats the techniques of variable transformations, that is, how to obtain the probaiblity distribution function of a set of transformed variables when the probability distribution function of the initial set of variables is known. Section 1.9 uses the transformation techniques of Sec. 1.8 to simulate univariate and multivariate data. Section 1.10 is devoted to order statistics, giving methods for obtaining the joint distribution of any subset of order statistics. It also deals with the problem of limit or asymptotic distribution of maxima and minima. Finally, Sec. 1.11 introduces probability plots and how to build and use them in making inferences from data.

INTRODUCTION

Many engineering applications involve some element of uncertainty [1]. Probability is one of the most commonly used ways to measure and deal with uncertainty. In this chapter we present some of the most important probability concepts used in engineering applications. The chapter is organized as follows. Section 1.2 ®rst introduces some elementary concepts, such as random experiments, types of events, and sample spaces. Then it introduces the axioms of probability and some of the most important properties derived from them, as well as the concepts of conditional probability and independence. It also includes the product rule, the total probability theorem, and Bayes' theorem. Section 1.3 deals with unidimensional random variables and introduces three types of variables (discrete, continuous, and mixed) and the corresponding probability mass, density, and distribution functions. Sections 1.4 and 1.5 describe the most commonly used univariate discrete and continuous models, respectively. Section 1.6 extends the above concepts of univariate models to the case of bivariate and multivariate models. Special attention is given to joint, marginal, and conditional probability distributions.

1.2

In this section we introduce some basic probability concepts and de®nitions. These are easily understood from examples. Classic examples include whether a machine will malfunction at least once during the ®rst month of operation, whether a given structure will last for the next 20 years, or whether a ¯ood will 1


BASIC PROBABILITY CONCEPTS

2

Castillo and Hadi

occur during the next year, etc. Other examples include how many cars will cross a given intersection during a given rush hour, how long we will have to wait for a certain event to occur, how much stress level a given structure can withstand, etc. We start our exposition with some de®nitions in the following subsection. 1.2.1

2.

Random Experiment and Sample Space

Each of the above examples can be described as a random experiment because we cannot predict in advance the outcome at the end of the experiment. This leads to the following de®nition: De®nition 1. Random Experiment and Sample Space: Any activity that will result in one and only one of several well-de®ned outcomes, but does not allow us to tell in advance which one will occur is called a random experiment. Each of these possible outcomes is called an elementary event. The set of all possible elementary events of a given random experiment is called the sample space and is usually denoted by .

3.

4.

Therefore, for each random experiment there is an associated sample space. The following are examples of random experiments and their associated sample spaces: Rolling a six-sided fair die once yields

f1; 2; 3; 4; 5; 6g. Tossing a fair coin once, yields fHead; Tailg. Waiting for a machine to malfunction yields

fx : x > 0g. How many cars will cross a given intersection yields

f0; 1; . . .g. De®nition 2. Union and Intersection: If C is a set containing all elementary events found in A or in B or in both, then write C A [ B to denote the union of A and B, whereas, if C is a set containing all elementary events found in both A and B, then we write C A \ B to denote the intersection of A and B. Referring to the six-sided die, for example, if A f1; 3; 5g, B f2; 4; 6g, and C f1; 2; 3g, then A [ B and A [ C f1; 2; 3; 5g, whereas A \ C f1; 3g and A \ B , where denotes the empty set. Random events in a sample space associated with a random experiment can be classi®ed into several types: 1.

Elementary vs. composite events. A subset of

which contains more than one elementary event is called a composite event. Thus, for example,


1.2.2

observing an odd number when rolling a sixsided die once is a composite event because it consists of three elementary events. Compatible vs. mutually exclusive events. Two events A and B are said to be compatible if they can simultaneously occur, otherwise they are said to be mutually exclusive or incompatible events. For example, referring to rolling a sixsided die once, the events A f1; 3; 5g and B f2; 4; 6g are incompatible because if one event occurs, the other does not, whereas the events A and C f1; 2; 3g are compatible because if we observe 1 or 3, then both A and C occur. Collectively exhaustive events. If the union of several events is the sample space, then the events are said to be collectively exhaustive. For example, if f1; 2; 3; 4; 5; 6g, then A f1; 3; 5g and B f2; 4; 6g are collectively exhaustive events but A f1; 3; 5g and C f1; 2; 3g are not. Complementary events. Given a sample space

and an event A 2 , let B be the event consisting of all elements found in but not in A. Then A and B are said to be complementary events or B is the complement of A (or vice versa). The complement of A is usually denoted For example, in the six-sided die example, by A. if A f1; 2g, A f3; 4; 5; 6g. Note that an event and its complement are always de®ned with respect to the sample space . Note also that A and A are always mutually exclusive and col lectively exhaustive events, hence A \ A and A [ A . Probability Measure

To measure uncertainty we start with a given sample space , in which all mutually exclusive and collectively exhaustive outcomes of a given experiment are included. Next, we select a class of subsets of which are closed under the union, intersection, complementary and limit operations. Such a class is called a algebra. Then, the aim is to assign to every subset in a real value measuring the degree of uncertainty about its occurrence. In order to obtain measures with clear physical and practical meanings, some general and intuitive properties are used to de®ne a class of measures known as probability measures. De®nition 3. Probability Measure: A function p mapping any subset A into the interval 0; 1 is called a probability measure if it satis®es the following axioms:

Some Probability Concepts for Engineers

3

Axiom 1. Boundary: p 1. Axiom 2. Additivity: For any (possibly in®nite) sequence, A1 ; A2 ; . . . ; of disjoint subsets of , then p

[

X pAi Ai

Axiom 1 states that despite our degree of uncertainty, at least one element in the universal set will occur (that is, the set is exhaustive). Axiom 2 is an aggregation formula that can be used to compute the probability of a union of disjoint subsets. It states that the uncertainty of a given subset is the sum of the uncertainties of its disjoint parts. From the above axioms, many interesting properties of the probability measure can be derived. For example: Property 1. Boundary: p 0. Property 2. Monotonicity: If A B , then pA pB. Property 3. Continuity±Consistency: For every increasing sequence A1 A2 . . . or decreasing sequence A1 A2 . . . of subsets of we have i!1

pA \ B

1

Property 1 states that the evidence associated with a complete lack of information is de®ned to be zero. Property 2 shows that the evidence of the membership of an element in a set must be at least as great as the evidence that the element belongs to any of its subsets. In other words, the certainty of an element belonging to a given set A must not decrease with the addition of elements to A. Property 3 can be viewed as a consistency or a continuity property. If we choose two sequences converging to the same subset of , we must get the same limit of uncertainty. Property 4 states that the probabilities of the sets A; B; A \ B, and A [ B are not independent; they are related by Eq. (1). Note that these properties respond to the intuitive notion of probability that makes the mathematical model valid for dealing with uncertainty. Thus, for example, the fact that probabilities cannot be larger than one is not an axiom but a consequence of Axioms 1 and 2.


pA \ B pB

2

Equation (2) implies that the probability of A \ B can be written as pA \ B pBpA j B

3

This can be generalized to several events as follows: pA j B1 ; . . . ; Bk 1.2.3

pA; B1 ; . . . ; Bk pB1 ; . . . ; Bk

4

Dependence and Independence

De®ntion 5. Independence of Two Events: Let A and B be two events. Then A is said to be independent of B if and only if 5

otherwise A is said to be dependent on B.

Property 4. Inclusion±Exclusion: Given any pair of subsets A and B of , the following equality always holds: pA [ B pA pB

pA j B

pA j B pA

lim pAi p lim Ai

i!1

De®nition 4. Conditional Probability: Let A and B be two subsets of variables such that pB > 0. Then, the conditional probability distribution (CPD) of A given B is given by

Equation (5) means that if A is independent of B, then our knowledge of B does not affect our knowledge about A, that is, B has no information about A. Also, if A is independent of B, we can then combine Eqs. (2) and (5) and obtain pA \ B pA pB

6

Equation (6) indicates that if A is independent of B, then the probability of A \ B is equal to the product of their probabilities. Actually, Eq. (6) provides a de®nition of independence equivalent to that in Eq. (5). One important property of the independence relation is its symmetry, that is, if A is independent of B, then B is independent of A. This is because pB j A

pA \ B pA pB pB pA pA

Because of the symmetry property, we say that A and B are independent or mutually independent. The practical implication of symmetry is that if knowledge of B is relevant (irrelevant) to A, then knowledge of A is relevant (irrelevant) to B. The concepts of dependence and independence of two events can be extended to the case of more than two events as follows:

4

Castillo and Hadi

De®nition 6. Independence of a Set of Events: The events A1 ; . . . ; Am are said to be independent if and only if pA1 \ . . . \ Am

m Y i1

pAi

7

otherwise they are said to be dependent. In other words, fA1 ; . . . ; Am g are said to be independent if and only if their intersection probability is equal to the product of their individual probabilities. Note that Eq. (7) is a generalization of Eq. (6). An important implication of independence is that it is not worthwhile gathering information about independent (irrelevant) events. That is, independence means irrelevance. From Eq. (3) we get pA1 \ A2 pA1 j A2 pA2 pA2 j A1 pA1 This property can be generalized, leading to the socalled product or chain rule: pA1 \ . . . \ An pA1 pA2 j A1 . . . pAn j A1 \ . . . \ An 1 1.2.4

Total Probability Theorem

Theorem 1. Total Probability Theorem: Let fA1 ; . . . ; An g be a class of events which are mutually incompatible and such that [ Ai . Then we have 1in

pB

X 1in

pB j Ai pAi

A graphical illustration of this theorem is given in Fig. 1. 1.2.5

Bayes' Theorem

Theorem 2. Bayes' Theorem: Let fA1 ; . . . ; An g be a class of events which are mutually incompatible and such that \ Ai . Then, 1in

pB j Ai pAi pAi j B X pB j Ai pAi 1in

Probabilities pAi are called prior probabilities, because they are the probabilities before knowing the information B. Probabilities pAi j B, which are the probabilities of Ai after the knowledge of B, are called posterior probabilities. Finally, pB j Ai are called likelihoods.

1.3

In this section we de®ne random variables, distinguish among three of their types, and present various ways of presenting their probability distributions. De®nition 7. Random Variable: A possible vectorvalued function X : ! Rn , which assigns to each element ! 2 one and only one vector of real numbers X! x, is called an n-dimensional random variable. The space of X is fx : x X!; ! 2 g. The space of a random variable X is also known as the support of X. When n 1 in De®nition 7, the random variable is said to be unidimensional and when n > 1, it is said to be multidimensional. In this and Secs 1.4 and 1.5, we deal with unidimensional random variables. Multidimensional random variables are treated in Sec. 1.6. Example 1. Suppose we roll two dice once. Let A be the outcome of the ®rst die and B be the outcome of the second. Then the sample space f1; 1; . . . 6; 6g consists of 36 possible pairs (A,B), as shown in Fig. 2. Suppose we de®ne a random variable X A B, that is, X is the sum of the two numbers observed when we roll two dice once. Then X is a unidimensional random variable. The support of this random variable is the set f2; 3; . . . ; 12g consisting of 11 elements. This is also shown in Fig. 2.

1.3.1

Figure 1 Graphical illustration of the total probability rule.


UNIDIMENSIONAL RANDOM VARIABLES

Types of Random Variables

Random variables can be classi®ed into three types: discrete, continuous, and mixed. We de®ne and give examples of each type below.


5

Figure 2 Graphical illustration of an experiment consisting of rolling two dice once and an associated random variable which is de®ned as the sum of the two numbers observed.

De®nition 8. Discrete Random Variables: A random variable is said to be discrete if it can take a ®nite or countable set of real values. As an example of a discrete random variable, let X denote the outcome of rolling a six-sided die once. Since the support of this random variable is the ®nite set f1; 2; 3; 4; 5; 6g, then X is discrete random variable. The random variable X A B in Fig. 2 is another example of discrete random variables. De®nition 9. Continuous Random Variables: A random variable is said to be continuous if it can take an uncountable set of real values. For example, let X denote the weight of an object, then X is a continuous random variable because it can take values in the set fx : x > 0g, which is an uncountable set. De®nition 10. Mixed Random Variables: A random variable is said to be mixed if it can take an uncountable


set of values and the probability of at least one value of x is positive. Mixed random variables are encountered often in engineering applications which involve some type of censoring. Consider, for example, a life-testing situation where n machines are put to work for a given period of time, say 30 days. Let Xi denotes the time at which the ith machine malfunctions. Then Xi is a random variable which can take the values fx : 0 < x 30g. This is clearly an uncountable set. But at the end of the 30-day period some machines may still be functioning. For each of these machines all what we know is that Xi 30g. Then the probability that Xi 30 is positive. Hence the random variable Xi is of the mixed type. The data in this example is known as censored data. Censoring can be of two types: right censoring and left censoring. The above example is of the former type. An example of the latter type occurs when we measure say, pollution, using an instrument which cannot detect polution below a certain limit. In this case we have left censoring because only small values are cen-

6

Castillo and Hadi

sored. Of course, there are situations where both right and left censoring are present. 1.3.2

Probability Distributions of Random Variables

So far we have de®ned random variables and their support. In this section we are interested in measuring the probability of each of these values and/or the probability of a subset of these values. We know from Axiom 1 that p 1; the question is then how this probability of 1 is distributed over the elements of . In other words, we are interested in ®nding the probability distribution of a given random variable. Three equivalent ways of representing the probability distributions of these random variables are: tables, graphs, and mathematical functions (also known as mathematical models). 1.3.3

Probability Distribution Tables

As an example of a probability distribution that can be displayed in a table let us ¯ip a fair coin twice and let X be the number of heads observed. Then the sample space of this random experiment is fTT; TH; HT ; HHg, where TH, for example, denotes the outcome: ®rst coin turned up a tail and second a head. The sample space of the random variable X is then f0; 1; 2g. For example, X 0 occurs when we observe TT. The probability of each of these possible values of X is found simply by counting how many elements of

are associated with each value in the support of X. We can see that X 0 occurs when we observe the outcome TT, X 1 occurs when we observe either HT or TH, and X 2 occurs when we observe HH. Since there are four equally likely elementary events in

, each element has a probability of 1/4. Hence, pX 0 1=4, pX 1 2=4, and pX 2 1=4. This probability distribution of X can be displayed in a table as in Table 1. For obvious reasons, such tables are called probability distribution tables. Note that to

denote the random variable itself we use an uppercase letter (e.g., X), but for its realizations we use the corresponding lowercase letter (e.g., x). Obviously, it is possible to use tables to display the probability distributions of only discrete random variables. For continuous random variables, we have to use one of the other two means: graphs or mathematical functions. Even in discrete random variables with large number of elements in their support, tables are not the most ef®cient way of displaying the probability distribution. 1.3.4

Graphical Representation of Probabilities

The probability distribution of a random variable can equivalently be represented graphically by displaying values in the support of X on a horizontal line and erecting a vertical line or bar on top of each of these values. The height of each line or bar represents the probability of the corresponding value of X. For example, Fig. 3 shows the probability distribution of the random variable X de®ned in Example 1. For continuous random variables, we have in®nitely many possible values in their support, each of which has a probability equal to zero. To avoid this dif®culty, we represent the probability of a subset of values by an area under a curve (known as the probability density curve) instead of heights of vertical lines on top of each of the values in the subset. For example, let X represent a number drawn randomly from the interval 0; 10. The probability distribution of X can be displayed graphically as in Fig. 4. The area under the curve on top of the support of X has to equal 1 because it represents the total probability. Since all values of X are equally likely, the curve is a horizontal line with height equal to 1/10. The height of 1/10 will make the total area under the curve equal to 1. This type of random variable is called a contin-

Table 1 The Probability Distribution of the Random Variable X De®ned as the Number of Heads Resulting from Flipping a Fair Coin Twice x

px

0 1 2

0.25 0.50 0.25


Figure 3 Graphical representation of the probability distribution of the random variable X in Example 1.


7

f x

Figure 4 Graphical representation of the pdf of the U0; 10 random variable X.

uous uniform random variable and is dentoed by Ua; b, where in this example a 0 and b 10. If we wish, for example, to ®nd the probability that X is between 2 and 6, this probability is represented by the shaded area on top of the interval (2, 6). Note here that the heights of the curve do not represent probabilities as in the discrete case. They represent the density of the random variable on top of each value of X. 1.3.5

Probability Mass and Density Functions

Alternatively to tables and graphs, a probability distribution can be displayed using a mathematical function. For example, the probability distribution of the random variable X in Table 1 can be written as 8 if x 2 f0; 2g < 0:25 pX x 0:50 if x 1 8 : 0 otherwise A function like the one in Eq. (8) is known as a probability mass function (pmf). Examples of the pmf of other popular discrete random variables are given in Sec. 1.4. Sometimes we write pX x as px for simplicity of notation. Note that every pmf px must satisfy the following conditions: X px 1 px > 0; 8x 2 A; px 0; 8x 2 = A; x2A

where A is the support of X. As an example of representing a continuous random variable using a mathematical function, the graph of the continuous random variable X in Fig. 4 can be represented by the function 0:1 if 0 x 10 f x 0 otherwise The pdf for the general uniform random variable Ua; b is


8
0; 8x 2 A; f x 0; 8x 2 = A; x2A

where A is the support of X. Probability distributions of mixed random variables can also be represented graphically and using probability mass±density functions (pmdf). The pmdf of a mixed random variable X is a pair of functions px and f x such that they allow determining the probabilities of X to take given values, and X to belong to given intervals, respectively. Thus, the probability of X to take values in the interval a; b is given by b xa

a

The interpretation of each of these functions coincides with that for discrete and continuous random variables. The pmdf has to satisfy the following conditions: 1 x 1

1

which are an immediate consequence of their de®nitions. 1.3.6

Cumulative Distribution Function

An alternative way of de®ning the probability mass± density function of a random variable is by means of the cumulative distribution function (cdf). The cdf of a random variable X is a function that assigns to each real value x the probability of X having values less than or equal to x. Thus, the cdf for the discrete case is X px Px pX x ax

and for the continuous case is

8

Castillo and Hadi

Fx pX x

x 1

f x dx

A

Note that the cdfs are denoted by the uppercase letters Px and Fx to distinguish them from the pmf px and the pdf f x. Note also that since pX x 0 for the continuous case, then pX x pX < x. The cdf has the following properties as a direct consequence of the de®nitions of cdf and probability: F1 1 and F 1 0. Fx is nondecreasing and right continuous. f x dFx=dx. pX x Fx Fx 0, where Fx 0 lim"!0 Fx ". pa < X b Fb Fa. The set of discontinuity points of Fx is ®nite or countable. Every distribution function can be written as a linear convex combination of continuous distributions and step functions. 1.3.7

Moments of Random Variables

The pmf or pdf of random variables contains all the information about the random variables. For example, given the pmf or the pdf of a given random variable, we can ®nd the mean, the variance, and other moments of the random variable. The results in this section are presented for the continuous random variables using the pdf and cdf, f x and Fx, respectively. For the discrete random variables, the results are obtained by replacing f x, Fx, and the integration symbol by px, Px, and the summation symbol, respectively. De®nition 11. Moments of Order k: Let X be a random variable with pdf f x, cdf Fx, and support A. Then the kth moment mk around a 2 A is the real number

A

x

ak f x dx

Theorem 3. Existence of Moments of Lower Order: If the tth moment around a of a random variable X exists, then the sth moment around a also exists for 0 < s t. The ®rst central moment is called the mean or the expected value of the random variable X, and is denoted by or EX. Let X and Y be random variables, then the expectation operator has the following important properties: Ec c, where c is a constant. EaX bY c aEX bEY c; 8a; b; c 2 A. a Y b ) a EY b: jEYj Ej yj: The second moment around the mean is called the variance of the random variable, and is denoted by VarX or 2 . The square root of the variance, , is called the standard deviation of the random variable. The physical meanings of the mean and the variance are similar to the center of gravity and the moment of inertia, used in mechanics. They are the central and dispersion measures, respectively. Using the above properties we can write 2 EX

2

EX 2

2X 2

EX 2

2EX 2 E1

EX 2

22 2

EX 2

2

11

which gives an important relationship between the mean and variance of the random variable. A more general expression can be similarly obtained: a2 2

a2

10

The moments around a 0 are called the central moments. Note that the Stieltjes±Lebesgue integral, Eq. (10), does not always exist. In such a case we say that the corresponding moment does not exist. However, Eq. (10) implies the existence of


ajk f x dx

which leads to the following theorem:

EX

mk

jx

1.4

UNIVARIATE DISCRETE MODELS

In this section we present several important discrete probability distributions that often arise in engineering applications. Table 2 shows the pmf of these distributions. For additional probability distributions, see Christensen [2] and Johnson et al. [3].


9

Table 2 Some Discrete Probability Mass Functions that Arise in Engineering Applications Distribution

Bernoulli

Binomial

p 1

Parameters and support

pn

Nonzero binomial

n x p 1 pn x 1 1 pn

Geometric

p1

px

1 r p 1 1

Hypergeometric

Poisson

x r D x

0 s; Y > t exp 1 s

where lY and DYY are the mean vector and covariance matrix of Y, lZ and DZZ are the mean vector and cov-


The Marshall±Olkin Distribution

exp 1 s

Theorem 6. Conditional Mean and Covariance Matrix: Let Y and Z be two sets of random variables having a multivariate Gaussian distribution with mean vector and covariance matrix given by ly lZ

1.6.8

pfZ1 s; 1 0; Z2 t; 2 0; g Z12 maxs; t; 12 0; g

The following theorem gives the conditional mean and variance±covariance matrix of any conditional variable, which is normal.

For other properties of the multivariate normal distribution, see any multivariate analysis book, such as Rencher [8].

ti

Let X be an n-dimensional normal random variable, which is denoted by Nl; D, where l and D are the mean vector and covariance matrix, respectively. The pdf of X is given by n=2

18

Fs; t pX > s; Y > t

The Multinormal Distribution

f x

lz

DYZ DZZ1 DZY

i1

!

...

i1 1

n Y i1

j1

lYjZz lY DYZ DZZ1 z DYjZz DYY

otherwise

Then, the moment-generating function is ! 1 1 n n X Y MX t1 ; . . . ; tn ... exp ti xi i 0

ariance matrix of Z, and DYZ is the covariance of Y and Z. Then the CPD of Y given Z z is multivariate Gaussian with mean vector lYjZz and covariance matrix DYjZz , where

2 t

12 maxs; t

where 1 1 p1 12 p01 ; 12 12 p00

2 2 p2 12 p10 ;

20

Castillo and Hadi

This two-dimensional model admits an obvious generalization to n dimensions: X n X Fx1 ; . . . ; xn exp i xi ij maxxi xj X

i<j < i e i xi i1 > : 0

if 0 xi < 1; i 1; . . . ; n otherwise

Its characteristic function is

Some Probability Concepts for Engineers X t

1

23

1

eit1 x1 tn xn dFX x1 ; . . . ; xn 1 1 ! 1 1 n n X Y ... exp i ti xi i e i xi

...

0

0

i1

dx1 . . . dxn 1 1 Y n ... i exi iti 0

n Y i1 n Y i1

0

i

i

1 0

i

iti

i1

exi iti

i

n Y

i1

i

dx1 . . . dxn

i1

iti i

1

where X1 h1 Y1 ; . . . ; Yn

n X

6 BX 6B n B 't1 ; . . . ; tn exp6 t k k 6i B 4 @ k1

k;j1

13 kj tk tj C7 C7 C7 C7 2 A5

Example 15. The characteristic function of the multinominal random variable, Mn; p1 ; . . . ; pk , can be written as

't1 ; . . . ; tk

exp

j1

! itj xj

px1 ; x2 ; . . . ; xk X n! x1 !x2 ! . . . xk !

p1 e

TRANSFORMATIONS OF RANDOM VARIABLES One-to-One Transformations

Theorem 7. Transformations of Continuous Random Variables: Let X1 ; . . . ; Xn be an n-dimensional random variable with pdf f x1 ; . . . ; xn de®ned on the set A and let


Xn hn Y1 ; . . . ; Yn is the inverse transformation of Eq. (21) and j detJj the absolute value of the determinant of the Jacobian matrix J of the transformation. The ijth element of J is given by @Xi =@Yj . Example 16. Let X and Y be two independent normal N0; 1 random variables. Then the joint pdf is 2 1 1 fX;Y x; y p e x =2 p e 2 2 1 < x; y < 1

y2 =2

U X Y it1 x1

j1

1.8.1

X2 h2 Y1 ; . . . ; Yn .. .

Consider the transformation

p2 eit2 x2 . . . pk eitk xk !n k X itj pj e

1.8

be a one-to-one continuous transformation from the set A to the set B. Then, the pdf of the random variable Y1 ; . . . ; Yn on the set B, is f h1 y1 ; . . . ; yn ; h2 y1 ; . . . ; yn ; . . . ;

20

k X

21

hn y1 ; y2 ; . . . ; yn j detJj

Example 14. The characteristic function of the multinormal random variable is

X

Y2 g2 X1 ; . . . ; Xn .. . Yn gn X1 ; . . . ; Xn

dxi

1

Y1 g1 X1 ; . . . ; Xn

VX

Y

which implies that X U V=2 Y U V=2 Then the Jacobian matrix is @X=@U @X=@V 1=2 J @Y=@U @Y=@V 1=2

1=2 1=2

with j detJj 1=2. Thus, the joint density of U and V becomes 1 1 u v2 u v2 gu; v exp 4 2 2 2 1 u2 =4 v2 =4 e e 1 < u; v < 1 4

24

Castillo and Hadi

which is the product of a function of u and a function of v de®ned in a rectangle. Thus, U and V are independent N0; 2 random variables. 1.8.2

Other Transformations

If the transformation Eq. (21) is not one-to-one, the above method is not applicable. Assume that for each point x1 ; . . . ; xn in A there is one point in B, but each point in B, has more than one point in A. Assume further that there exists a ®nite partition A1 ; . . . ; An , of A, such that the restriction of the given transformation to each Ai , is a one-to-one transformation. Then, there exist transformations of B in Ai de®ned by X1 h1i Y1 ; . . . ; Yn X2 h2i Y1 ; . . . ; Yn .. . Xn hni Y1 ; . . . ; Yn with jacobians Ji i 1; . . . ; m. Then, taking into account that the probability of the union of disjoint sets is the sum of the probabilities of the individual sets, we obtain the pdf of the random variable Y1 ; . . . ; Yn : gy1 ; . . . ; yn

1.9

m X i1

f h1i ; . . . ; hni j detJi j

1

f x dx

We then generate a sequence of random numbers fu1 ; . . . ; un g from U0; 1 and obtain the corresponding values fx1 ; . . . ; xn g by solving Fxi ui ; i 1; . . . n; which gives xi H 1 ui , where H 1 ui is the inverse of the cdf evaluated at ui . For example, Fig. 16 shows the cdf Fx and two values x1 and x2 corresponding to the uniform U0; 1 numbers u1 and u2 . Theorem 9. Simulating Normal Random Variables: Let X and Y be independent standard uniform random variables U0; 1. Then, the random variables U and V de®ned by U 2 log X1=2 sin2Y V 2 log X1=2 cos2Y are independent N0; 1 random variables. 1.9.2

The Multivariate Case

In the multivariate case X1 ; . . . ; Xn , we can simulate using the conditional cdfs: Fx1 ; Fx2 jx1 ; . . . ; Fxn jx1 ; . . . ; xn 1 as follows. First we simulate X1 with Fx1 obtaining x1 . Once we have simulated Xk 1 obtaining xk 1 , we simulate Xk using Fxk jx1 ; . . . ; xk 1 , and we continue the process until we have simulated all X's. We repeat the whole process as many times as desired.

SIMULATION OF RANDOM VARIABLES

A very useful application of the change-of-variables technique discussed in the previous section is that it provides a justi®cation of an important method for simulating any random variable using the standard uniform variable U0; 1. 1.9.1

Fx pX x

x

1.10

ORDER STATISTICS AND EXTREMES

Let X1 ; . . . ; Xn be a random sample coming from a pdf f x and cdf Fx. Arrange X1 ; . . . ; Xn in an

The Univariate Case

Theorem 8. Let X be a univariate random variable with cdf Fx. Then, the random variable U Fx is distributed as a standard uniform variable U0; 1. Example 17. Simulating from a Probability Distribution: To generate a sample from a probability distribution f x, we ®rst compute the cdf,


Figure 16 Sampling from a probability distribution f x using the corresponding cdf Fx:


25

increasing order of magnitude and let X1:n Xn:n be the ordered values. Then, the rth element of this new sequence, Xr:n , is called the rth order statistic of the sample. Order statistics are very important in practice, especially so for the minimum, X1:n and the maximum, Xn:n because they are the critical values which are used in engineering, physics, medicine, etc. (see, e.g., Castillo and Hadi [9±11]). In this section we study the distributions of order statistics.

1.10.1

Distributions of Order Statistics

The cdf of the rth order statistic Xr:n is [12, 13] Fr:n x PXr:n x 1 Fmx r 1 ! n n X F k x1 Fxn k k kr ! n Fx r ur 1 1 un r du 0 r IFx r; n

r 1

22

where mx is the number of elements in the sample with value Xj x and Ip a; b is the incomplete beta function, which is implicitly de®ned in Eq. (22). If the population is absolutely continuous, then the pdf of Xrn is given by the derivative of Eq. (22) with respect to x: n fXr:n x r F r 1 x1 Fxn r f x r 23 Fr 1 x1 Fxn r f x r; n r 1 where a; b is the beta function.

Example 19. Distribution of the maximum order statistic. Letting r n in Eqs (22) and (23) we obtain the cdf and the pdf of the maximum order statistic: FXn:n x Fxn and fXn:n x nF n 1 xf x.

1.10.2

Distributions of Subsets of Order Statistics

Let Xr1 :n ; . . . ; Xrk :n , be the subset of k order statistics of orders r1 < . . . < rk , of a random sample of size n coming from a population with pdf f x and cdf Fx. With the aim of obtaining the joint distribution of this set, consider the event xj Xrj :n < xj xj ; 1 j k for small values of xj , 1 j k (see Fig. 17). That is, k values in the sample belong to the intervals xj ; xj xj for 1 j k and the rest are distributed in such a way that exactly rj rj 1 1 belong to the interval xj 1 xj 1 ; xj for 1 j k, where x0 0, r0 0, rk1 n 1, x0 1 and xk1 1. Consider the following multinomial experiment with the 2k 1 possible outcomes associated with the 2k 1 intervals illustrated in Fig. 17. We obtain a sample of size n from the population and determine to which of the intervals they belong. Since we assume independence and replacement, the numbers of elements in each interval is a multinomial random variable with parameters fn; f x1 x1 ; . . . ; f xk xk ; Fx1 Fx0 ; Fx2 Fx1 ; . . . ; Fxk1 Fxk g where the parameters are n (the sample size) and the probabilities associated with the 2k 1 intervals. Consequently, we can use the results for multinomial random variables to obtain the joint pdf of the k order statistics and obtain

Example 18. Distribution of the minimum order statistic. Letting r 1 in Eqs (22) and (23) we obtain the cdf and pdf of the minimum order statistic: n X n F k x1 FX1:n x k k1

1

1

k

Fxn

and fX1:n x n1

Fxn

Fxn 1 f x


Figure 17 An illustration of the multinomial experiment used to determine the joint pdf of a subset of k order statistics.

26

Castillo and Hadi

fr1 ;...;rk :n x1 ; . . . ; xk n!

k Y i1

f xi

k 1 Y

1.10.4

j1

Fxj Fxj 1 rj rj rj rj 1 1!

1

1

24

1.10.3

Distributions of Particular Order Statistics

1.10.3.1

lim Ln x lim 1

Setting k 2, r1 1 and r2 n in Eq. (24), we obtain the joint distribution of the maximum and the minimum of a sample of size n, which becomes

1.10.3.2

We have seen that the cdf of the maximum Zn and minimum Wn of a sample of size n coming from a population with cdf Fx are Hn x PZn x and Ln x PWn x 1 1 Fxn . F n x When n tends to in®nity we have 1 if Fx 1 n lim Hn x lim F x n!1 n!1 0 if Fx < 1 and

Joint Distribution of Maximum and Minimum

f1;n:n x1 ; x2 nn 1 f x1 f x2 Fx2 x1 x2

Fx1 n

2

n!1

n!f x1 f x2 F x1 1 Fx2 i 1!n i 1! x1 x2

1

Fx

0 if Fx 0 1 if Fx > 0

lim Hn an bn x lim F n an bn x Hx

n!1

n!1

8x 25

Setting k 2, r1 i and r2 i 1 in Eq. (24), we get the joint density of the statistics of orders i and i 1: fi;i1:n x1 ; x2

n!1

n

which means that the limit distributions are degenerate. With the aim of avoiding degeneracy, we look for linear transformations Y an bn x, where an and bn are constants, depending on n, such that the limit distributions

Joint Distribution of Two Consecutive Order Statistics

i 1

Limiting Distributions of Order Statistics

and lim Ln cn dn x lim 1

n i 1

n!1

n!1

Lx

1

Fcn dn xn

8x 26

are not degenerate. 1.10.3.3

Joint Distribution of Any Two Order Statistics

The joint distribution of the statistics of orders r and s r < s is fr;s:n xr ; xs

n!f xr f xs F r 1 xr Fxs Fxr s r 1 1 r 1!s r 1!n s! xr xs

1.10.3.4

Fxs n

s

Joint Distribution of all Order Statistics

The joint density of all order statistics can be obtained from Eq. (24) setting k n and obtain f1;...;n:n x1 ; . . . ; xn n!

n Y i1


f xi

x1 x n

De®nition 13. Domain of Attraction of a Given Distribution: A given distribution, Fx, is said to belong to the domain of attraction for maxima of Hx, if Eq. (25) holds for at least one pair of sequences fan g and fbn > 0g. Similarly, when Fx satis®es (26) we say that it belongs to the domain of attraction for minima of Lx. as:

The problem of limit distribution can then be stated 1. 2. 3.

Find conditions under which Eqs (25) and (26) are satis®ed. Give rules for building the sequences fan g; fbn g; fcn g, and fdn g. Find what distributions can occur as Hx and Lx.

The answer of the third problem is given by the following theorem [14±16].


27

Theorem 10. Feasible Limit Distribution for Maxima: The only nondegenerate distributions Hx satisfying Eq. (25) are

Frechet: H1;g x Weibull: H2;g x

exp x g 0 1 exp xg

if x > 0 otherwise if 0 otherwise

and Gumbel: H3;0 x exp exp x

1<x 0

1 1 1 0

otherwise

and Gumbel: L3;0 x 1

exp exp x

1<x 0, Fx belongs to the Frechet domain of attraction for minima. Table 7 shows the domains of attraction for maxima and minima of some common distributions.

1.11

PROBABILITY PLOTS

One of the graphical methods commonly used by engineers is the probability plot. The basic idea of probability plots, of a biparametric family of distributions, consists of modifying the random variable and the probability drawing scales in such a manner that the cdfs become a family of straight lines. In this way, when the cdf is drawn a linear trend is an indication of the sample coming from the corresponding family. In addition, probability plots can be used to estimate the parameters of the family, once we have checked that the cdf belongs to the family. However, in practice we do not usually know the exact cdf. We, therefore, use the empirical cdf as an approximation to the true cdf. Due to the random character of samples, even in the case of the sample

28

Castillo and Hadi

Table 7 Domains of Attraction of the Most Common Distributions Domain of attraction Distribution Normal Exponential Log-normal Gamma GumbelM Gumbelm Rayleigh Uniform WeibullM Weibullm Cauchy Pareto FrechetM Frechetm a

a

for maxima

for minima

Gumbel Gumbel Gumbel Gumbel Gumbel Gumbel Gumbel Weibull Weibull Gumbel Frechet Frechet Frechet Gumbel

Gumbel Weibull Gumbel Weibull Gumbel Gumbel Weibull Weibull Gumbel Weibull Frechet Weibull Gumbel Frechet

M for maxima; m for minima.

coming from the given family, the corresponding graph will not be an exact straight line. This complicates things a little bit, but if the trend approximates linearity, we can say that the sample comes from the associated family. In this section we start by discussing the empirical cdf and de®ne the probability graph, then give examples of the probability graph for some distributions useful for engineering applications. 1.11.1

Empirical Cumulative Distribution Function

Let xi:n denote the ith observed order statistic in a random sample of size n. Then the empirical cumulative distribution function (ecdf) is de®ned as 8 if x < x1:n xn:n This is a jump (step) function. However, there exist several methods that can be used to smooth this function, such as linear interpolation methods [18].

become the set of straight lines with positive slope (see Castillo [19], pp. 131±173). Let Fx; a; b be a biparametric family of cdfs, where a and b are the parameters. We look for a transformation gx

hy

such that the family of curves y Fx; a; b after transformation (27) becomes a family of straight lines. Note that this implies hy hFx; a; b agx b

Fundamentals of Probability Plots

A probability plot is simply a scatter plot with transformed scales for the two-dimensional family to


,

a b 28

where the variable is called the reduced variable. Thus, for the existence of a probabilistic plot associated with a given family of cdfs Fx; a; b it is necessary to have Fx; a; b h 1 agx b. As we mentioned above, in cases where the true cdf is unknown we estimate the cdf by the ecdf. But the ecdf has steps 0; 1=n; 2=n; . . . ; 1. However, the two extremes 0 and 1, when we apply the scale transformation become 1 and 1, respectively, in the case of many families. Thus, they cannot be drawn. Due to the fact that in the order statistic xi:n the probability jumps from i 1=n to i=n, one solution, which has been proposed by Hazen [20], consists of using the value i 1=2=n; thus, we draw on the probability plot the points xi:n ; i

0:5=n

i 1; . . . ; n

Other alternative plotting positions are given in Table 8. (For a justi®cation of these formulas see Castillo [13], pp. 161±166.) In the following subsection we give examples of probability plots for some commonly used random variables. 1.11.3

The Normal Probability Plot

The cdf Fx; ; of a normal random variable can be written as Table 8

Plotting Positions Formulas

Formula

1.11.2

27

xi:n ; i=n 1 xi:n ; i 0:375=n 0:25 xi:n ; i 0:5=n xi:n ; i 0:44=n 0:12

Source Ð Blom [21] Hazen [20] Gringorten [22]


x Fx; ;

29

29

where and are the mean and the standard deviation, respectively, and x is the cdf of the standard normal variable N0; 1. Then, according to Eqs (27) and (28), Eq. (29) gives hy 1 y

gx x

a

1

b

and the family of straight lines becomes a b

30

Once the normality assumption has been checked, estimation of the parameters and is straightforward. In fact, setting 0 and 1 in Eq. (30), we obtain 0 1

) )

0 1

= =

) )

31

Figure 18 shows a normal probability plot, where the ordinate axis has been transformed by 1 y, whereas the abscissa axis remains untransformed. Note that we show the probability scale Y and the reduced scale .

1.11.4

The Log-Normal Probability Plot

The case of the log-normal probability plot can be reduced to the case of the normal plot if we take into account that X is log-normal iff Y logX is normal. Consequently, we transform X into logx and obtain a normal plot. Thus, the only change consists of transforming the X scale to a logarithmic scale (see Fig. 19). The mean and the standard deviation of the lognormal distribution can then be estimated by 2 2 2 2 e2 e2 e e =2 where and are the values obtained according to Eq. (31). 1.11.5

The Gumbel Probability Plot

The Gumbel cdf for maxima is x Fx; ; exp exp

32 Let p Fx; ; . Then taking logarithms of 1=p twice we get

Figure 18 An example of a normal probability plot.


1<x 0, no matter how small, one can ®nd a corresponding number > 0 with the property that whenever jx aj < we have jf x Lj < ". In the same spirit, we say that f has a limit, L, from the right (resp. left) as x approaches a if for any given " > 0, no matter how small, one can ®nd a corresponding number > 0 with the property that whenever 0 < x a < (resp. < x a < 0), we have j f x Lj < ". The symbols for the limit, limit from the right, and limit from the left at a are denoted respectively by lim f x L

x!a

lim f x L

x!a

lim f x L

x!a

Fundamental in the theory of limits is the fact that a function f has the limit L as x approaches a, if and only if each of the left- and right-hand limits exist and are each equal to L. Furthermore, the limit of a sum (resp. difference, product) of two limits is the sum (resp. difference, product) of the individual limits. In the case of a quotient, the limit of a quotient of two functions is the quotient of the limits of each function if the limit of the denominator is nonzero. For example, if H denotes the Heaviside function (Fig. 1) where Hx 1 when x is in 0; 1 and Hx 1 when x is in 1; 0, then lim Hx 1

x!0

lim Hx

x!0

1

but the actual limit as x approaches 0 does not exist (since the left- and right-hand limits are unequal). On the other hand, the limit of xHx as x approaches 0 is 0. Note that xHx jxj, the absolute value of x. Fundamental limits:

Figure 1

The Heaviside function.


cos x 0 x

lim

x!0

sin x 1 x

11

More generally, if the function f has the limit 0 as x approaches 0, then lim

x!0

1

cos f x 0 f x

lim

x!0

sin f x 1 f x

12

For example, it follows that p 1 cos x sinx3 p 0 lim 1 lim x!0 x!0 x x3 If a is any number and b 6 0 then lim

x!0

4.1.3

sinax a bx b

lim

sinax

x!0 sinbx

a b

13

In®nite Limits and Limits at In®nity

Let f be a function de®ned to the left (resp. right) of x a. We say that the function f has the limit 1 as x approaches a from the left (resp. right) [or the limit of f as x approaches a from the left (resp. right) exists and is equal to 1] if for every given X > 0, there is a > 0 such that whenever <x a X. A similar de®nition applies to the case where the limit of f as x approaches a is 1. Explicitly, we say that the function f has the limit 1 as x approaches a from the left (resp. right) [or the limit of f as x approaches a from the left (resp. right) exists and is equal to 1] if, for every given X > 0, there is a > 0 such that whenever < x a < 0 (resp. 0 < x a < ) we have f x < X. The symbols used to denote each one of these limits are, respectively, lim f x 1

x!a

lim f x

x!a

1

lim f x 1

x!a

lim f x

x!a

1

If any one (or more) of the above limits exists, we call the line x a a vertical asymptote of the graph of f . Thus, the function f de®ned by f x 1=x has a vertical asymptote at x 0, while gx x 3=x2 4 has two vertical asymptotes (at x 2). In the preceding example, the limit of g as x approaches 2 from the left is 1 while, if x approaches 2 from the right, its limit is 1. Now, let f be a real-valued function whose domain is an interval I of the form 1; a or a; 1 where a is unspeci®ed, and let L be a real number. We say that the function f has the limit L as x approaches 1 (resp. 1) [or the limit of f as x approaches 1 (resp. 1)

68

Mingarelli

exists and is equal to L] if, for any given " > 0, there is a value of x, say X, such that whenever x > X > 0 (resp. x < X < 0) we have j f x Lj < ". The symbols used to denote these limits are respectively, lim f x L

x!1

lim f x L

x! 1

If either one (or both) of the above limits exists, and y f x, we call the line y L a horizontal asymptote of the graph of f . Thus, once again, the function f de®ned by f x 1=x has the line y 0 as a horizontal asymptote, while if f x x2 4=x2 4 then the graph of f has the two vertical asymptotes at x 2 and the line y 1 as a horizontal asymptote. The Euler exponential function, expx, or ex , may be de®ned by means of the following limits: xn lim 1 xh1=h lim 1 n!1 h!0 n 14 x e 1<x 0 and f b < 0 then there must be a root of f , say c, inside a; b, that is, if f a > 0 and f b < 0 then there is a point c such that f c 0, a result which is very useful in the practical problem of ®nding the roots of various functions (see Sec. 4.2.3). Every polynomial of degree n 0 with real coef®cients, that is, every expression of the form f x an xn an 1 xn

1

a1 x a 0

where a0 ; a1 ; . . . ; an are real numbers, is continuous on the real line (i.e., at every point of the real line). Sums, differences, and products/quotients (with a nonzero denominator) of continuous functions give continuous functions, while every rational function (a quotient of any two polynomials) is continuous at every point where the denominator is nonzero. Thus, f x x 3=x2 4 is continuous at every point x except when x 2. On the other hand, the slightly modi®ed function f x x 3=x2 4 is continuous at every point x or, more simply put, continuous everywhere. The composition of two continuous functions (see Sec. 4.1.1) is also continuous, so that, for instance hx sin cos x is continuous for each x, since hx f gx where f x sin x and gx cos x. Euler's exponential function, ex , is continuous on 1; 1, while its inverse function, the natural logarithm ln x, is continuous on 0; 1. The same is true of all other exponential functions of the form ax where a > 0. Figure 3 is a generic graph of points of continuity and discontinuity.

4.2

DIFFERENTIABILITY AND THE CHAIN RULE

4.2.1

The Derivative

One of the most important de®nitions involving limits is that of the derivative. The derivative of a function f at the point x a, denoted by f 0 a, or df =dxa, is de®ned by the two equivalent de®nitions df f a h f a a f 0 a lim h!0 dx h f x f a lim x!a x a


19

Figure 3 A discontinuous function.

whenever either limit exists (in which case so does the other). The right derivative (resp. left derivative) is de®ned by the right-hand (resp. left-hand) limits f0 a lim

h!0

f a h h

f a

lim

x!a

f x x

f a a 20

and f 0 a lim h!0

f a h h

f a

lim x!a

f x x

f a a

21

A function f is said to be differentiable at the point a if its derivative f 0 a exists there. This is equivalent to saying that both the left- and right-hand derivatives exist at a and are equal. A function f is said to be differentiable everywhere if it is differentiable at every point a of the real line. For example, the function f de®ned by the absolute value of x, namely f x jxj, is differentiable at every point except at x 0 where f 0 0 1 and f0 0 1. On the other hand, the function g de®ned by gx xjxj is differentiable everywhere. The derivative of the derivative of a given function f at x a is called the second derivative of f at x a and is denoted by f 00 a. The derivative of the second derivative is called the third derivative [denoted by f 000 a] and so on. The function g de®ned above by gx xjxj does not have a second derivative at x 0 [i.e., f 00 0 does not exist] even though it is differentiable there. It is a fundamental fact that if f 0 a exists then f is continuous at a. First derivatives may be thought of as the velocity or as the slope of the tangent line to the graph

70

Mingarelli

of the function y f x at the point x a, while second derivatives appear in physical applications under the name of acceleration. The binomial theorem states that if n is a positive integer, n

x y

n X r0

Cn;r x

n r r

y

22

where Cn;r denotes the binomial coef®cients de®ned by Cn;0 1 and, for r > 0, Cn;r

n! r!n r!

23

As usual, r! denotes the factorial symbol, that is, it is the product of the ®rst r numbers, 1; 2; . . . ; r 1. The binomial theorem allows one to prove the power rule, namely, that if k is any real number, d k x kxk dx

1

24

The derivative has the following properties (whenever it exists). Let f ; g be any two given differentiable functions at the point x and let k be any real number; then, f g 0 x f 0 x g 0 x

(sum/difference rule) 25

kf 0 x kf 0 x

26

fg 0 x f 0 x gx f x g 0 x (product rule) 27 0 f f 0 x gx f x g 0 x x g gx2

(quotient rule 28

The most useful of all the rules is the chain rule, which is used to ®nd the derivative of the composition (see Sec. 4.1.1) of two or more functions. It states that if f ; g are two given functions with f differentiable at the point ga and g itself differentiable at x a, then their composition f g is also differentiable at a and its value there is given by f g 0 a f 0 ga g 0 a

29

It is sometimes written in the form d f gx f 0 gx g 0 x (chain rule) dx

30

For example, if f x sin ux where u is differentiable at x, then f 0 x cos ux u 0 x. The generalized power rule states that for any differentiable function u,


d uxk k uxk dx

du ; dx

1

k constant

31

If f and F are inverse functions then the relation f Fx x and the chain rule shows that F 0 x

1 f

0 Fx

In the next set of logarithmic and exponential expressions let u; v each be differentiable functions and a a constant; then d ux du eux e dx dx d 1 du ln ux dx ux dx

if ux > 0

d ux du aux lna a dx dx d 1 du loga ux dx ux lna dx

if ux > 0

d ux dv du vxux vxux lnvx dx vx dx dx

32

33

34

if vx > 0 If u is a differentiable function then d du sin ux cos ux dx dx d du cos ux sin ux dx dx

35

d du tan ux sec2 ux dx dx d du 2 cot ux csc ux dx dx

36

d du sec ux sec ux tan ux dx dx d du csc ux csc ux cot ux dx dx

37

while, if juxj < 1 then d 1 du arcsin ux q dx 2 dx 1 ux d arccos ux dx

1 du q dx 1 ux2

or, for any function u,

38

Review of Calculus

71

d 1 du arctan ux 2 dx dx 1 ux d 1 du arccot ux 2 dx dx 1 ux

39

d arccsc ux dx

1 du q dx juxj ux2 1 1 du q dx 2 juxj ux 1

40

sinh x

e 2

x

ex e cosh x 2

x

41

with the remaining functions being de®ned by rules similar to the circular (trigonometric) functions; for example, sech x 1= cosh x, tanh x sinh x= cosh x, etc. For these functions we have the following differentiation formulae: d du sinh ux cosh ux dx dx d du cosh ux sinh ux dx dx

42

d du tanh ux sech2 ux dx dx d du 2 coth ux csch ux dx dx

43

4.2.2

L'Hospital's Rule

lim

x!a

f x gx

is called an indeterminate form if the expression f a=g a is one of the following types: 1=1 or 0=0. In either case it is sometimes possible to determine the limit by appealing to L'Hospital's rule. Before describing this rule, we de®ne the notion of a neighborhood of a point a. Brie¯y stated, if a is ®nite, a neighborhood of a consists of an open interval (see Sec. 4.1.1) containing a. In the same vein, a left-neighborhood of x a consists of an open interval with a has its right endpoint [or an interval of the form a ; a where > 0]. Similarly, a right-neighborhood of x a consists of an open interval with a has its left endpoint (or an interval of the form a; a where > 0). A punctured neighborhood of a is a set of points which is the union of two open intervals of the form a ; a and a; a

Figure 4 The hyperbolic sine and cosine functions.


44

We begin by de®ning the notion of an indeterminate form. A limit problem of the form

We de®ne the hyperbolic functions by setting ex

du dx du csch ux coth ux dx sech ux tanh ux

The graphs of the hyperbolic sine and cosine functions are shown in Fig. 4, and those of the hyperbolic cotangent and cosecant functions in Fig. 5.

and if juxj > 1, d arcsec ux dx

d sech ux dx d csch ux dx

72

Mingarelli

Figure 5 The hyperbolic contangent and cosecant.

where > 0; > 0 are not necessarily given. Notice that a punctured neighborhood does not include the point itself. Thus, for example, the union of the intervals 0:5; 0 and 0; 0:2 is a punctured neighborhood of the point 0 while the interval 0:5; 0:2 is a neighborhood of 0. Now, L'Hospital's rule may be stated as follows: let f ; g be two functions de®ned and differentiable in a punctured neighborhood of a, where a is ®nite. If g 0 x6 0 in this punctured neighborhood of a and f a =ga is one of the following types: 1=1 or 0=0, then lim

x!a

f x f 0 x lim 0 gx x!a g x

45

provided the limit on the right of Eq. (45) exists (or is 1, or 1). The rule also holds if, instead of assuming that f a=ga is of the type 1=1 or 0/0 we only have that limx!a f x 0 and limx!a gx 0 or limx!a f x 1 and limx!a gx 1. The rule is also valid when the quantity a is replaced by 1, or even if the limits are one-sided limits (i.e., limit as x approaches a from the right or left, see Sec. 4.1.2). For example, the limits (11)±(13) can all be found using this rule. Other indeterminate forms such as 01 , 11 , and 1 1 can sometimes be converted to indeterminate forms of the type 1=1 or 0/0 by algebraic manipulation, taking logarithms, etc. In addition,


lim

p ax b

x!1

lim

ex

1 x

x!0

p ax d 0

if a > 0

1

47

abx eab lim 1 x!1 x lim

x!1

ax b a cx d c

48 if c 6 0

lim x1=x 1

lim

tanx x

1 1 1 lim 1 n!1 2 3 n

49 50

x!0

x!0

46

51 ln n 0:57721 . . . 52

For example, in the case of Eq. (51), tanx sec2 x lim x!0 x!0 x 1 lim

since the derivative of tanx is sec2 x, the derivative of x is 1, and sec 0 1.

Review of Calculus

4.2.3

73

Newton's Method for Finding Roots

In the event that one wants to ®nd the roots of an equation of the form f x 0, where f is given and differentiable in an open interval containing the root sought, there is a powerful technique which approximates the value of the root(s) to arbitrary precision. It is easily programmable and many subroutines exist on the market which do this for you. The idea is as follows: choose a point x0 as a starting point (hopefully it is close to the desired root). With this value of x0 de®ne x1 by setrting x1 x0 f x0 =f 0 x0 . We can now de®ne x2 by setting x2 x1 f x1 =f 0 x1 . This gives us the three values x0 ; x1 ; x2 , the last of which (namely, x2 ) is closer to the desired root than the ®rst (i.e., x0 ). We de®ne xn , the nth term of this sequence of numbers, by xn xn

1

f xn 1 f 0 xn 1

for n 1

53

If the sequence, xn of numbers converges to a limit, say L, then the limit, L, of the sequence de®ned by Eq. (53) is a root of the equation f x 0 in the required interval, that is, f L 0. This is the basic idea of Newton's method. For example, if f x x3 2x 1 and we want to ®nd a root of the equation f x 0 near the point 1.5, then we ®nd f 0 x set up the iteration Eq. (53) for this function, and then check for convergence of the resulting sequence xn ; n 1; 2; 3; . . . So we set x0 1:5, from which the form of the iterative procedure given by Eq. (53) can be derived, namely, xn xn

1

f xn 1 xn f 0 xn 1

1

x3n

1

2xn

3x2n 1

1

2

1

;

for n 1 In this case, x1 1:6315789 . . . ; x2 1:6181835 . . . ; x3 1:6180340 . . . ; x4 1:618033989 . . . ; x5 1:6180 33989 . . . ; with rapid convergence to the root closest to the initial value, 1.5, namely, the root whose value is approximately 1.618033989. On the other hand, had we chosen x0 1:2, then x1 ; 1:9206896 . . . ; x2 1:6731874 . . . ; x3 1:6203940 . . . ; x4 1:61803 85 . . . ; x5 1:618033989 . . . : Even in this case we get very good convergence after only a few terms. 4.2.4

Curve Sketching

We outline here the basic steps required in sketching a given planar curve de®ned by a function. A function f is said to be increasing (resp. decreasing) if given any


pair of points x1 < x2 in its domain, we have f x1 < f x2 [resp. f x1 > f x2 ]. If f is differentiable on its domain then f is increasing on a given interval if its derivative is positive there, i.e., f is increasing (resp. decreasing) whenever f 0 x > 0 [resp. f 0 x < 0]. In each of these cases the slope of the tangent line at any point on the graph of y f x is positive (resp. negative). For example, if f is de®ned by f x x2 then f is increasing when x > 0 and decreasing when x < 0. The graph of a differentiable function f is said to be concave up (resp. concave down) if given any pair of points x1 < x2 in the domain of its derivative, we have f 0 x1 < f 0 x2 [resp. f 0 x1 > f 0 x2 ]. If f is twice differentiable on its domain then f is concave up on a given interval if its second derivative is positive there, i.e., f is concave up (resp. concave down) whenever f 00 x > 0 [resp. f 00 x < 0]. For example, the graph of the function de®ned by f x x3 is concave up whenever x > 0 and concave down when x < 0. A point c is called a critical point of a function f de®ned on an interval I (containing c) if either f 0 c 0 or f 0 c does not exist (either as a ®nite number, or as a twosided limit). Examples of critical points are furnished by the following two examples: f x 1=x at x 0 and f x x2 at x 0. The continuous function de®ned by f x jxj has a critical point at x 0 since it is not differentiable there (i.e., no two-sided limit of f 0 exists at x 0). A function f is said to have a local maximum at a point x a if there is a neighborhood of a in which f x < f a. In this case, the value of f a is called the local maximum value. It is said to have a global maximum at x a if f x < f a for every x in the domain of f . In this case the value of f a is called the global maximum value. For example, if f x x2 then f has a global maximum at x 0 and this global maximum value is equal to 0. If we set f x x 1x 2x 3 and Dom pf 0; 5, then f has a local maximum at x 2 1= 3, which is not a global maximum, since this occurs at x 5. It f is differentiable we can check the nature of a critical point, a, of f by using the ®rst derivative test for a maximum; that is, if f 0 x > 0 for x in a left neighborhood (Sec. 4.2.2) of a and f 0 x < 0 for x in a right neighborhood (Sec. 4.2.2) of a, then f has a local maximum at x a. In the event that f is twice differentiable on its domain, there is the second derivative test for a maximum, which states that if x a is a critical point of f and f 00 a < 0 then it is a local maximum. The global maximum (and its value) is determined by taking that critical point c where f c has the largest maximum value.

74

Mingarelli

The function f is said to have a local minimum at a point x a if there is a neighborhood of a in which f x > f a. In this case, the value of f a is called the local minimum value. It is said to have a global minimum at x a if f x > f a for every x in the domain of f . In this case, the value of f a is called the global minimum value. For example, if f x x2 then f has a global minimum at x 0 and this global minimum value is equal to 0. If we set f x x 1x 2x 3 and Dom f p 0; 5, then f has a local minimum at x 2 1= 3 which is not a global minimum since this occurs at x 0. If f is differentiable we can check the nature of a critical point, a, of f by using the ®rst derivative test for a minimum; that is, if f 0 x < 0 for x in a left neighborhood (Sec. 4.2.2) of a and f 0 x > 0 for x in a right neighborhood of a, then f has a local minimum at x a. In the event that f is twice differentiable on its domain, there is the second derivative test for a minimum which states that if x a is a critical point of f and f 00 a > 0 then it is a local minimum. The global minimum (and its value) is determined by taking that critical point c where f c has the smallest minimum value. A function f is said to have a point of in¯ection at x a if it changes its concavity around x a, that is, if there is a left neighborhood of x a in which the graph of f is concave down and a right neighborhood of x a in which the graph of f is concave up, or if there is a left neighborhood of x a in which the graph of f is concave up and a right neighborhood of x a in which the graph of f is concave down. For example, if f x x3 , the graph of f has a point of in¯ection at x 0 but the graph of f x x2 does not (because the graph is always concave up around x 0). If f is twice differentiable, a necessary (but not suf®cient) condition for x a to be a point of in¯ection is that f 00 a 0. In this case, we must then check around x a for a change in concavity. We recall the de®nitions of asymptotes as presented in Sec. 1.3. The usual rules for ®nding the graph of a function f now follow. Find the intervals where f is increasing and decreasing. Determine the critical points. Find all local maxima and minima and points of in¯ection. Find the roots of f (use may be made of Newton's method, Sec. 4.2.3). Locate the intervals where the graph of f is concave up or down.


Find the vertical and horizontal asymptotes of f , if any (one may have to use L'Hospital's rule, Sec. 4.2.2). We give an example of a typical graph in Fig. 6, this one for the function f de®ned by f x 4x=1 x2 : 4.2.5

Implicit Differentiation

Implicit relations (Sec. 4.1.1) are useful because they de®ne a curve in the xy-plane, a curve which is not, generally speaking, the graph of a function. For example, the circle of radius equal to 2 de®ned by the implicit relation x2 y2 4 is not the graph of a unique function. In this case, assuming that y is some function of x, the derivative is found by repeated applications of the chain rule, and possibly all the other rules in this section as well. The basic idea is best described by an example. Assume that y can be written as a differentiable function of x and that there is some implicit relation like y3 7y x3 We take the derivative of both sides. We see that 3y2

dy dy 7 3x2 dx dx

since d 3 dy y 3y2 dx dx

Figure 6 The function f x 4x=1 x2 .

Review of Calculus

by the generalized power rule. We can now solve for the expression dy=dx and ®nd a formula for the derivative, namely, dy 3x2 2 dx 3y 7 Now we can ®nd the derivative easily at any point x; y on the curve y3 7y x3 . For instance, the derivative at the point 2; 1 on this curve is given by substituting the values x 2; y 1 in the formula for the derivative just found, so that dy=dx 6=5. As usual, this represents the value of the slope of the tangent line to the curve y3 7y x3 at the point 2; 1. The graph of an implicit relation is then found by solving the relation for all possible pairs x; y satisfying the equation de®ning the relation, along with the derivative information gathered through implicit differentiation.

75

An antiderivative of f Fx f x dx x f x dx a

where a is some point of the domain of f . The difference between two values of an antiderivative, say, Fb Fa, is denoted by the symbol b f x dx Fb Fa 54 a

b Thus, for example, a x dx b2 a2 =2, since Fx x2 =2 for f x x. Various antiderivatives are displayed below. Note that, in every case, C denotes a constant. dx ln jxj C 55 ex dx ex C x

4.3 4.3.1

sin x dx

ANTIDERIVATIVES AND INTEGRATION Antiderivatives

One can think of the antiderivative of a given function as a kind of inverse to the operation of differentiation, which we saw in Sec. 4.2. This notion is motivated by the so-called fundamental theorem of calculus which we will see below. Given a function f , whose domain is an interval I a; b, we de®ne its antiderivative as another function, F, also de®ned and continuous on a; b, differentiable on a; b and with the property that F 0 x f x for every point x in I (except possibly the endpoints). Not every function has an antiderivative. For example, it is known that the function f de®ned by 2 f x ex has no antiderivative that can be written as a sum of a ®nite number of algebraic expressions. Its antiderivative is, in fact given by an in®nite series. Basic to this section is the fact that any continuous function or, more generally, any function which is continuous except for countably many points does have an antiderivative. For example, the function Fx x4 is an antiderivative of f x 4x3 , since F 0 x f x by the power rule. Although the derivative of a given function is unique when it is de®ned, this is not the case for antiderivatives. All antiderivatives differ by a constant. Thus if F is an antiderivative of f , then F c is also an antiderivative of f if c is a constant, by de®nition. Since the antiderivative of a function f depends on f its symbol is denoted universally by


cos x C

cos x dx sin x C 56

Use of the chain rule, Eq. (30), gives the more general formulae, analogous to those in Sec. 4.2.1, du eux dx eux C dx 57 1 du dx ln ux C; if ux > 0 ux dx

du dx sin ux C dx du sin ux dx cos ux C dx cos ux

58

du dx ln j cos uxj C dx du sec ux dx ln j sec ux tan uxj C dx tan ux

1 p 2 1 x 1 1 ux2

aux

du dx arcsin ux C dx du dx arctan ux C dx

du aux C dx ln a dx

if a > 0

59

60

61

with similar formulae for the rest of the functions in Sec. 4.2.1.

76

Mingarelli

4.3.2

The Integral and Its Properties

Let I a; b be an interval. By a partition, denoted by , of the interval I we mean a subdivision of I into n subintervals : a; x1 ; x1 ; x2 ; x2 ; x3 ; . . . ; xn 1 ; b where, by de®nition, x0 a; xn b. The points xi can be chosen in any fashion whatsoever and do not have to be equally spaced within I. The norm of the partition , denoted by kk, is de®ned to be the length of the largest subinterval making up the partition . For example, if we let I 0; 1 and de®ne to be the partition 0; 1=5; 1=5; 1=3; 1=3; 1=2; 1=2; 7=8, 7=8; 1 then the norm of this partition is equal to 7=8 1=2 3=8 0:375, which is the length of the largest subinterval contained within . Given a partition of I and f a function de®ned on I, we de®ne a Riemann sum as follows. Let i be a point in the subinterval xi 1 ; xi and consider the sum f 1 x1 x0 f 2 x2 n X f i xi xi 1

x1 . . . f n xn

xn 1

i1

Geometrically, this value can be thought of as representing an approximation of the area under the graph of the curve y f x, if f x 0, between the vertical lines x a and x b. We now de®ne the notion of a limit of the Riemann sum as the norm of approaches 0, denoted by the symbol lim

kk!0

n X i1

f i xi

xi 1

as follows. If given any number " > 0 we can ®nd a > 0 such that whenever is any partition with kk < , it follows that n X f i xi xi 1 L < " i1 then we say that the limit of the Riemann sum as the norm of the partition approaches 0 is L. Note that the numerical value of the limit, L, just de®ned generally depends on the choice of f and of the quantities i and the partition . If this limit, L, is independent of the choice of the partition and the choice of the i within each subdivision of , then we call this value of L the de®nite integral of f from a to b. When this happens we simply say that f is integrable over I and f is called the integrand of this integral. One of the consequences of this de®nition is that the de®-


nite integral of a function f which is continuous on I a; b exists. This limit also exists under much more general conditions but it is not necessary to delve into these matters here. The mean value theorem states that if f is differentiable on a; b and continuous on a; b then there exists some point c inside a; b with the property that f b f a f 0 cb a. Using this theorem it is not dif®cult to show that, in fact, The definite integral of f from a to b Fb

Fa

where F is any antiderivative of f . So, we can write b n X f x dx lim f i xi xi 1 Fb Fa a

kk!0

i1

62 and, in particular, b 1 dx b a a

Now, if f x 0, we can also de®ne the area under the graph of the curve y f x between the lines x a and x b by the de®nite integral of f from a to b, that is Eq. (62). Let x be a generally unspeci®ed point in a given interval a; b on which we de®ne f . Assuming that the de®nite integral of f from a to b exists, one can then write the equality x f t dt Fx Fa 63 a

where, as usual, F is some antiderivative of f . The fact that we changed the symbol x within the integral to a t is of no consequence to the value of the integral. These changes re¯ect the fact that these inner variables can be denoted by any symbol you want. This means that we can think of the quantity on the left of Eq. (63) as a function of x, and this equality is valid for every x in a; b. The quantity on the left of Eq. (63) is also called an inde®nite integral of f. This identi®es the notions of an inde®nite integral with that of an antiderivative. These two notions are equivalent on account of Eqs. (62) and (63). The following properties of the integral now follow easily: c b b f t dt f t dt f t dt acb a

a

c

If k is any constant, then b b k f t dt k f t dt a

a

Review of Calculus

77

from which follows the fact that b b k dt k 1 dt kb a a

d dx

x1

e

t2

dt e

a

a

a

Other properties of the integral that follow directly from its de®nition include b f x dx If f x gx over a; b then b a

a

gx dx

(monotonicity property)

from which we easily deduce that b If f x 0 over a; b then f x dx 0 a

and b b f x dx j f xj dx a a (triangle inequality for integrals) A consequence of the de®nition of antiderivative and Eq. (63) is the fundamental theorem of calculus which states that if f is continuous over a; b then f has an inde®nite integral and d x f t dt f x 64 dx a and, if f is differentiable over a; b and continuous over a; b, then b f 0 t dt f b f a 64 0 a

More generally, there is Leibniz's formula which follows from the chain rule and Eq. (64). If f is continuous over the real line and a; b are differentiable functions there, then d bx db da f ax f t dt f bx dx ax dx dx 65 (Leibniz's formula) For example, it follows from Eq. (63) that 2 d x t2 d x s2 e dt e ds e x dx a dx a and, from Eq. (65), that


x2 2

2xe

a

Generally, if f ; g are both integrable over I then b b b f t gt dt f t dt gt dt

x2

4.4

d 2 x dx

x4

e

e

x12 2

d x 1 dx

x14

TECHNIQUES OF INTEGRATION

4.4.1

Integration by Substitution

The evaluation of inde®nite and corresponding de®nite integrals is of major importance in calculus. In this section we introduce the method of substitution as a possible rule to be used in the evaluation of inde®nite or de®nite integrals. It is based on a change-of-variable formula, Eq. (67) below, for integrals which we now describe. Given a de®nite integral of f over I a; b we can write [see Eq. (62)], b f x dx Fb Fa 66 a

The substitution ux t, where we assume that u has a differentiable inverse function x u 1 t, inside the integral corresponds to the change-of-variable formula ub d 1 1 f u t 67 u t dt Fb Fa dt ua which is itself equivalent to the relation d d Fu 1 t F 0 u 1 t u 1 t dt dt d f u 1 t u 1 t dt

68

if F is an antiderivative of f , by the chain rule, Eq. (30). Integrating both sides of Eq. (68) over the interval ua; ub and using the fundamental theorem of calculus, we obtain Eq. (67). In practice, we proceed as follows. In order to evaluate the integral 2 b 2 f x dx 2xex dx a

0

we make the substitution ux x2 t, whose inverse p 1 is given by x t u t. Using this substitution we see that p u0 p t0, and u2 4. Since1 f t 2 t e , and the derivative of u f u 1 t p t is 1=2 t, Eq. (67) becomes, in this case, 2 4 p 2 1 2xex dx 2 t et p dt 2 t 0 0 4 et dt e4 1 0

78

Mingarelli

The shortcut to integration by substitution, which amounts to the same thing as an answer can be summarized by setting t x2 , dt 2x dx with the limits being changed according to the rule t 0 when x 0, t 4 when x 2. We ®nd 4 2 2 2xex dx et dt 0

0

as before, but more directly. 4.4.2

When every other technique fails try using integration by parts. This method is based on the product rule for derivatives (Sec. 4.2.1); in fact it is a sort of inverse of this method. Starting with the ordinary product rule, Eq. (27), namely,

e sin x dx

we can integrate both sides, say, from a to b. Use of Eq. (64 0 ) and some adjustments show that, when used with a de®nite integral, b b f x g 0 x dx fgb fga f 0 x gx dx a

69 However, it is more commonly written in the following inde®nite integral form: u dv uv v du 70 For example, in order to evaluate xex dx we set u x; dv ex . From this we obtain, du dx; v ex . Substituting these values into Eq. (70) we get xex dx xex ex dx xex ex C where C is a constant of integration. In the event where one of the terms is a simple trigonometric function (such as sin or cos), the method needs to be adapted, as the following shows. For example, the evaluation of ex sin x dx requires that we set u ex , dv sin x dx. Then du ex dx, v cos x. The method then gives us

x

e cos x ex cos x dx

We apply the same technique once again, except that now we set u ex ; dv cos x dx in the integral on the right of the last display. From this, du ex dx, v sin x and we now ®nd x x x e sin x dx e cos x e sin x ex sin x dx

ex cos x ex sin x 2

This method can always be used when one of the factors is either a sine or cosine and the other is an exponential. 4.4.3

fg 0 x f 0 x gx f x g 0 x


x

It follows that ex sin x dx

Integration by Parts

a

Trigonometric Integrals

A trigonometric integral is an integral whose integrand contains only trigonometric functions and their powers. These are best handled with the repeated use of trigonometric identities. Among those which are most commonly used we ®nd (here u or x is in radians): cos2 u

1 cos2u 2

cos2 u sin2 u 1 csc2 u

cot2 u 1

sin2u 2 sin u cos u

sin2 u sec2 u

1

cos2u 2

tan2 u 1

71

72 73

As an example, we consider the problem of ®nding an antiderivative of the function f x cos4 x. This problem is tackled by writing f x cos4 x cos2 x cos2 x 1 sin2 x cos2 x and then using the ®rst of Eqs (71), (73), and the second of Eq. (71) along with a simple change of variable. The details for evaluating integrals of the form 74 cosm x sinn x dx where m; n are positive integers are given here. Similar ideas apply in the case where the integral Eq. (74) involves other trigonometric functions. m is odd, n is even. Solve the ®rst of Eqs (72) for cos2 x and substitute the remaining in lieu of the cosine expression leaving one cosine term to the side. Follow this with a substitution of variable, namely, u sin x, du cos x dx, which now

Review of Calculus

79

reduces the integrand to a polynomial in u and this is easily integrated. m is odd, n is odd. Factor out a copy of each of sin x, cos x leaving behind even powers of both sin x, cos x. Convert either one of these even powers in terms of the other using Eq. (72), and then perform a simple substitution, as before. m is even, n is odd. Proceed as in the case where m is odd and n is even with the words sine and cosine interchanged. m is even, n is even. Remove all even powers of the sine and cosine by applying Eq. (71) repeatedly. In addition to Eqs (71)±(73) there are a few other formulae which may be useful as they untangle the products. For any two angles, A, B, these are sinA sinB sinA cosB cosA cosB

cosA sinA cosA

For example, 1 4 2 sin x cos x dx 1 8 1 1 8

B

cosA B 2 B sinA B 2 B cosA B 2

75 76 77

cos2x2 1 cos2x dx cos2x

cos2 2x

cos3 2x dx where the ®rst three integrals may be evaluated without much dif®culty. The last integral above reduces to the case where m is odd and n is even (actually, n 0 here). 4.4.4

Trigonometric Substitutions

A trigonometric substitution is particularly useful when the integrand has a particular form, namely, if it is the sum or difference of two squares, one of which is a constant. The substitutions can be summarized as follows. If the integrand contains a term of the form: p constant: set x a sin , a2 x2 , where a > 0 ispa if dx a cos d, a2 x2 a cos , =2 < < =2. p a2 x2 , where a > 0 is p a constant: set x a tan , a2 x2 a sec , if dx a sec2 d, =2 < < =2. p x2 a2 , where a > 0 is a constant: pset x a sec , dx a sec . tan d, x2 a2 a tan , if 0 < < =2.


For example, x2 3 sin 2 3 cos d p dx 9 sin2 d 3 cos 9 x2 and the last one is handled by means of Eq. (71) and a substitution. Thus, 9 9 9 2 sin2 C 9 sin d 1 cos2 d 2 2 4 But x 3 sin means that arcsinx=3. Moreover, by trigonometry, p9=4 sin2 9=4 sin2 arcsin x=3 1=2x 9 x2 . Hence, x xp x2 9 9 x2 p dx arcsin C 2 2 3 9 x2 4.4.5

Partial Fractions

The method of partial fractions applies to the case where the integrand is a rational function (see Sec. 4.1.4). It is known from algebra that every polynomial with real coef®cients can be factored into a product of linear factors [e.g., products of factors of the form x rp ], and a product of quadratic factors called quadratic irreducibles (e.g., ax2 bx c where b2 4ac < 0, i.e., it has no real roots). For example, x4 1 x2 1x 1x 1. It follows that the numerator and denominator of every rational function can also be factored in this way. In order to factor a given polynomial in this way one can use Newton's method (Sec. 4.2.3) in order to ®nd all its real roots successively. Now, in order to evaluate an expression of the form an xn an 1 xn 1 a1 x a0 dx 78 bm xm bm 1 xm 1 b1 x b0 where m; n are integers and the coef®cients are assumed real, there are two basic cases. n m. In this case we apply the classical method of long division which indicates that we divide the numerator into the denominator resulting in a polynomial and a remainder term which is a rational function whose numerator has degree one (or more) less than the denominator. For example, long division gives us that x4 1 x2 1 2 x2 1 1 x Here, the remainder is the rational function on the right of the last display (whose numerator has degree 0 and whose denominator has degree 2).

80

Mingarelli

The remainder may be integrated using the idea in the next case. n < m. We factor the denominator completely into a product of linear and irreducible factors. Next, we decompose this quotient into a partial fraction in the following sense. To each factor (of the denominator) of the form x rp , there corresponds a sum of terms of the form

It follows that x 1 dx 1 dx dx 4 x 1 4 x1 x4 1 1 x dx 2 x2 1 1 1 ln jx 1j ln jx 1j 4 4 1 lnx2 1 4

Ap A1 A2 A3 2 3 x r x r x rp x r where the A's are to be found. To every quadratic irreducible factor (of the denominator) of the form ax2 bx cq where b2 4ac < 0, there corresponds, in its partial fraction decomposition, a sum of terms of the form B1 x C1 B2 x C2 2 ax bx c ax2 bx c2 Bq x Cq ax2 bx cq where the B's and C's are to be found, as well. The method for ®nding the A's, B's, and C's is best described using an example. In order to evaluate x dx 4 1 x which is a rational function, we ®nd its partial fraction decomposition, which looks like x x4

1

x

A1

1

A2 B x C1 12 x1 x 1

since the factors of the denominator are x 1 x 1x2 1 and each such factor is simple (i.e., p 1; q 1. We multiply both sides of the last display by the denominator, x4 1 and we proceed formally, canceling out as many factors as possible in the process. In this case, we get x A1 x 1x2 1 A2 x 1x2 1 B1 x C1 x 1x 1 Since the last relation must be true for every value of x, we can set x 1; 1 and then any two other values of x, say, x 0; 2 in order to get a system of equations (four of them) in the four given unknowns, A1 ; A2 ; B1 ; C1 . Solving this system, we get the values A1 1=4; A2 1=4; B1 1=2; C1 0 so that x x4

1=4 1=4 1 x 1 x1


1=2x x2 1

4.4.6

Numerical Integration

When the evaluation of a de®nite integral is required and every possible method of ®nding an antiderivative fails, one resorts to numerical integration, that is, the numerical approximation of the value of the de®nite integral. The two principal techniques here are the trapezoidal rule and Simpson's rule. Many other methods (midpoint rule, quadrature formulae, etc.) exist as well and the reader may consult any manual in numerical analysis for further details. In the trapezoidal rule the value of the de®nite integral of a given integrable function f on an interval a; b is approximated by b b a f x dx Tn f x0 2f x1 2n a 2f x2 2f xn 1 f xn where x0 a, xn b and xi a ib a=n, if i 0; 1; 2; 3; . . . ; n. This method uses line segments to mimic the curvature of the graph of the function f . The larger the value of n the better the approximation and one is limited only by computing power. For example, if n 30, 1 2 ex dx 1:4631550 0

whereas if we choose n 40 the value is approximately 1.46293487, while for n 50 the value is 1.462832952 with accuracy to three decimal places. In general, the error obtained in using the trapezoidal rule on a twice differentiable function f which is continuous on a; b is given by Kb a3 b f x dx Tn a 12n2 if jf 00 xj K for x in a; b. Simpson's rule states that, if we choose n to be an even number,

Review of Calculus

b a

81

f x dx Sn

b

a

f x0 4f x1 2f x2

3n 4f x3 4f xn 1 f xn

where the coef®cients on the right alternate between 4 and 2 except in the initial and ®nal positions. This particular method uses parabolic segments to mimic the curvature of the graph of the function f and usually results in a better approximation (in contrast to the trapezoidal rule) for small values of n. For example, if we choose n 30 as before, we ®nd 1 2 ex dx 1:462652118 0

with accuracy to ®ve decimal places already. In this case, the error obtained in using Simpson's rule on a four-times differentiable function f which is continuous on a; b is given by Kb a3 b f x dx Sn a 180n4 if j f 4 xj K for x in a; b. 4.4.7

Improper Integrals

In some cases a de®nite integral may have one or both of its limits in®nite, in which case we need to de®ne the meaning of the integral. The natural de®nition involves interpreting the de®nite integral as a limit of a de®nite integral with ®nite limits. In the evaluation of the resulting limit use may be made of L'Hospital's rule (Sec. 4.2.2) in conjunction with the various techniques presented in Sec. 4.3. Given a function f de®ned and integrable on every ®nite interval on the real line, we de®ne an improper integral with in®nite limit(s) in a limiting sense, as follows: T 1 f x dx lim f x dx T!1 a a a a f x dx lim f x dx 1

T! 1 T

whenever this limit exists and is ®nite, in which case we say that the improper integral converges. In the event that the limit does not exist as a ®nite number, we say the improper integral diverges. A similar de®nition applies when both limits are in®nite, e.g., 1 a 1 f x dx f x dx f x dx 1

a


1

provided this limit exists and is ®nite. For example, the evaluation of T 1 x x e dx lim xe x dx T!1 0

0

requires integration by parts after which T lim x e x dx lim T 1 e T 1 1 T!1 0

T!1

by L'Hospital's rule. If an antiderivative cannot be found using any method, one resorts to numerical integration (Sec. 4.4.6). 4.5

APPLICATIONS OF THE INTEGRAL

4.5.1

The Area Between Two Curves

In this section we outline the main applications of the integral and its main interpretation, namely, as the area under two given curves. Let y f x, y gx denote the graph of two curves de®ned on a common domain a; b and we assume each function f ; g is integrable over a; b. The area between the two curves is de®ned to be the expression The area between the two curves b j f x gxj dx

79

a

where the absolute value function was de®ned in Sec. 4.1.1. In the event that f x 0 the area under that part of the graph of f lying above the x-axis and between a, b is given simply by the de®nite integral, b f x dx a

For example, the area between the curves y x2 1, 2 the interval 1; 1 is given by y1 x 2 1 above 2 jx 1 x 1jdx 4. This area is depicted 1 graphically in Fig. 7. 4.5.2

Volume and Surface Area of a Solid of Revolution

Next, let y f x; y gx denote the graph of two curves de®ned on a common domain a; b and assume each function f ; g is integrable over a; b, as above. In addition, we assume that f x gx, a x b. Now, consider the planar region de®ned by the curves x a, x b, y f x, y gx. This region is a closed region and it can be rotated (out of the plane) about an arbitrary line x L where L < a, or L > b, thus forming a

82

Mingarelli

provided f x 0 and f is differentiable. For example, if we rotate the region bounded by the two curves y 1 x2 ; y x2 1 about the line x 2, say, we get (from Eq. (81)), the integral 1 32 2 j2 xj1 x2 x2 1 dx 3 1 The surface area of the solid of revolution obtained by revolving that part of the curve y 1 x2 with y 0 about the x-axis is given by p p 1 p 7 5 17 ln 5 2 1 x2 1 4x2 dx 2 8 16 1 Figure 7 The area between y x2 the interval 1; 1.

1 and y x2 1 above

solid of revolution. The volume of the solid of revolution obtained by revolving this region about the line x L is given by b 80 2 jL xj f x gx dx a

On the other hand, if we revolve this region about the line y M where M exceeds the largest value of f x, a x b or is smaller than the smallest value of gx, a x b, then the volume of the solid of revolution thus obtained by revolving the region about the line y M is given by b f x gx M f x gx dx 2 2 a Similar formulae may be derived in case the planar region under discussion is bounded by curves of the form x hy, x ky where c y d and we are revolving about an arbitrary vertical or horizontal line. We point out a theorem of Pappus which states that if a closed region in the plane is rotated about a line which does not intersect the region, then the volume of the resulting solid is the product of the area of the region and the distance traveled by the center of mass (Sec. 4.5.4). If we set gx 0, then the surface area of the solid of revolution obtained by revolving the region about the x-axis, also called a surface of revolution is given by the expression b q 2 f x 1 f 0 x2 dx a


4.5.3

The Length of a Curve

The length of a segment of a curve given by the graph of a differentiable function f on the interval a; b is given by b q 1 f 0 x2 dx 81 a

where, as usual, f 0 x denotes the derivative. The methods of Sec. 4.4 (trigonometric substitutions) may prove useful in the evaluation of an integral of the type Eq. (81). If these should fail, one can always resort to numerical integration (Sec. 4.4.6). For example, the length of the arc of the curve given by the function f where f x a2=3 x2=3 3=2 , between the points x 0 and x a, is given by a q a q 1 f 0 x2 dx 1 a2=3 x 2=3 1 dx 0 0 a 3a a1=3 x 1=3 dx 2 0 If the differentiable curve is given parametrically by a set of points x; y where x xt, y yt, a t b, are each differentiable functions of t, then its length is given by b q x 0 t2 y 0 t2 dt 82 a

For example, the parametric equations of a circle of radius R centered at a point P x0 ; y0 , are given by x x0 R cos t, y y0 R sin t where 0 t 2. In this case, the circumference of the circle is given by Eq. (82) where x 0 t2 y 0 t2 R2 resulting in the value 2R, as expected.

Review of Calculus

4.5.4

83

Moments and Centers of Mass

Let y f x, y gx denote the graph of two curves de®ned on a common domain a; b and assume each function f ; g is integrable over a; b, as above. In addition, we assume that f x gx, a x b. Then the center of mass or centroid of the region of uniform mass density de®ned by the curves x a; x b, y where y f x, y gx is given by the point x; b My 1 x f x gx dx x m m a b m f x gx dx a

M 1 y x m m

b a

f x2

gx2 2

dx

where Mx ; My represent the moment about the x-axis (resp. y-axis). For example, the centroid of the region bounded by the intersection of the line y f x x has mass and the parabola y gx x2 1 m 0 x x2 dx 1=6. In this case, 1 1 x 6 x2 x3 dx 2 0 1 2 4 x x 2 dx y 6 2 5 0

4.6 4.6.1

DIFFERENTIAL EQUATIONS First-Order Equations

The essence of most practical physical applications of calculus includes differential equations. By a differential equation of order n we mean an equation involving some unknown function say, yx, and its derivatives up to order n. By a classical solution of a differential equation of order n we mean a function, y, which has continuous derivatives up to and including that of order n and whose values satisfy the equation at every point x under consideration. For example, the function yx ex is a solution of the differential equation of order 1, y 0 x yx. By the general solution of a differential equation of order n is meant a solution which has the property that it contains every other solution of the same equation for particular choices of parameters appearing in it. For example the general solution of the equation y 0 x yx is given by yx cex where c is an arbitrary constant. Every other solution of this equation must agree with a particular choice of the parameter, c, in the general solution


just written. It is a general fact that the general solution of a differential equation of order n must contain n parameters. The simplest form of all differential equations of the ®rst order is known as a separable equation. It has the simple form dy f x gy dx

83

Dividing both sides by gy, assumed nonzero, and integrating both sides with respect to x gives the general solution in implicit form yx x 1 f t dt C 84 dt ya gt a where C is a constant, and a is a prescribed point. For example, the general solution of the separable equation dy x2 y dx y e is given by yx t et dt ya

x a

t2 dt C

or, upon integration, yx eyx

eyx

x3 C 3

where C includes all the quantities, ya; a etc., being constant, they can all be absorbed in some new constant, denoted again by C. This equation can also be written in the form yey

x3 C 3

ey

where the dependence of y on the independent variable x is suppressed. As such it becomes an implicit relation and it de®nes y as a function of x under some conditions (derived from a general result called the implicit function theorem). A linear differential equation of the ®rst order has the special form dy Pxy Qx dx

85

and its general solution may be written explicitly as yx

1 x exp Pt dt a x t Qt exp Pu du dt C a

a

86

84

Mingarelli

where C is a parameter (constant). For example, the general solution of the equation dy dx

y x2

is given by yx

1 e

x x

t2 e t dt C

a

ex e x x2 Ce

x

2

x

2x 2x

@f @ xexy xyexy exy @x @x

2 C; 2

and the particular solution for which y 1 when x 0 is given by yx 3ex x2 2x 2. 4.6.2

Partial Derivatives of Functions of Two Variables and Exact Equations

We turn brie¯y to a de®nition of a partial derivative, that is, the extension of the notion of derivative, also called an ordinary derivative, to functions of two or more variables. A function of two variables is a function, f , whose domain is a set of points in a plane, usually considered as the xy-plane. Its values are denoted by f x; y and it acts on two arguments, instead of one. For example, the function de®ned by f x; y xexy is such a function and f 1; 0 1. The values f x h; y are de®ned as usual by replacing every occurrence of the symbol x in the expression for f x; y by the new symbol x h and then simplifying this new expression. For example, with f de®ned earlier, f x h; y x hexhy x hexy ehy . In a similar way one can de®ne the meaning of, say, f x; y k. In our case, this implies that, for example, f x; y k xexyk . This then enables us to de®ne the notion of a partial derivative as a limit, as we did in Sec. 4.2. For functions of two variables, we de®ne the partial derivative of f with respect to x at the point (a,b) as @f f a h; b lim @x h!0 h

f a; b

87

whenever this limit exists and is ®nite. In the same way we can de®ne the partial derivative of f with respect to y at the point (a,b) as @f f a; b k lim @y k!0 k

f a; b

88

These two quantities represent the rate of change of the function f in the direction of the two principal axes, the x- and y-axes. In practice, these partial derivatives are found by thinking of one variable as a constant and


taking the ordinary derivative of the f with respect to the other variable. The operation of taking a partial derivative can be thought of as being an operation on a function of one variable, and so all the rules and properties that we know of in Sec. 2 apply in this case as well. For example, for f de®ned earlier,

by the product rule, since every occurrence of the variable y in the value of f x; y triggers the rule that it be thought of as a constant. A function of two variables is called differentiable at a; b if each one of its two partial derivatives exists at a; b and is ®nite. As usual it is differentiable in a region if it is differentiable at every point of the region. The notion of continuity for a function of two variables is similar to the one presented in Sec. 4.1.4, except that the notion of a limit needs to be updated to take into account the fact that there are now two variables, x; y, approaching a speci®ed point, a; b. In this case, we say that a function f of two variables is continuous at a; b if it is de®ned at a; b, i.e., f a; b is a ®nite number, and if lim

x;y!a;b

f x; y f a; b

where, by the symbol on the left, we mean the following. For each given " > 0, we can ®nd a number , generally depending on " > 0, with the property that whenever q x a2 y b2 < we also have j f x; y

f a; bj < "

Every polynomial function in two variables is continuous, for example, f x; y 1 x x2 y 3x2 y3 is such a function. More generally, the product of any two polynomials of one variable, say, px; qy gives a polynomial of two variables. As in Secs. 4.1 and 4.2, the composition of continuous functions is also continuous, and so forth. We can now turn to the solution of a so-called exact differential equation. We assume that the functions Px; y; Qx; y appearing below are each differentiable functions of two variables, in the sense above. A ®rstorder (ordinary) differential equation of the form Px; y Qx; y

dy 0 dx

89

is called an exact differential equation if the functions of two variables, P, Q satisfy the equations

Review of Calculus

@P @Q @y @x

85

90

in the region which is the intersection of the domains of each function. In this case the differential equation Eq. (89) can be solved and a general solution may be found as an implicit relation. However, before writing down the general solution, we need to have some working knowledge of the meaning of an expression like Px; y dx By this we mean that we integrate the function Px; y with respect to x and we think of every occurrence of the symbol y as being a constant (as before). For example, exy (some function of y exy dx y Another example is furnished by exy exy dy (some function of x x The last two terms which are functions of x and or y are the two-dimensional equivalent of the constant of integration which appears after we evaluate an inde®nite integral for a function of one variable. In the next formula, we will set them both to zero. The general solution of the exact equation Eq. (89) is given implicitly by the relation f x; y c where c is an ordinary constant, and f x; y Px; y dx @ Px; y dx dy Qx; y @y For example, we solve the equation x dy 2 lny 3y 6xy 0 y dx by noting that here, Px; y lny 3y2 and Qx; y x=y 6xy with the exactness criterion Eq. (90) being veri®ed, since @ @ x 1 2 lny 3y 6xy 6y @y @x y y Next, Px; y dx lny 3y2 dx xlny 3y2


and so @ 1 Px; y dx x 6y @y y Finally we note that @ Px; y dx 0 Qx; y @y and it follows that f x; y xlny 3y2 or the general solution is given implicitly by xlny 3y2 c where c is an arbitrary constant. It is dif®cult to isolate the y variable in the last expression but, nevertheless, this does give a general solution and one which is practical, since, given any initial condition, we can determine c, and therefore the locus of all points in the xyplane making up the graph of the required solution. 4.6.3

Integrating Factors

By an integrating factor of a ®rst-order differential equation of the form Eq. (89) is meant a function of one variable, call it I, with the property that I Px; y I Qx; y

dy 0 dx

is exact. Of course the original equation is not assumed to be exact, but, in some cases, it can be turned into an exact equation by multiplying throughout by this integrating factor. We describe two cases in which Eq. (89) can be transformed into an exact equation. If the quotient 1 @P @Q a function of x alone 91 Qx; y @y @x then an integrating factor is given by the exponential function 1 @P @Q dx Ix exp Qx; y @y @x On the other hand, if 1 @P @Q a function of y alone Px; y @y @x

92

then an integrating factor is given by the exponential function (note the minus sign), 1 @P @Q dy Iy exp Px; y @y @x

86

Mingarelli

In both cases the general solution may be written as f x; y c where c is a constant and, in the case where Ix is a function of x alone, f is given by " @ f x; y Ix Px; y dx Ix Qx; y @y # Ix Px; y dx dy 93 while in the case where Iy is a function of y alone, f is given by " @ f x; y Iy Px; y dx Iy Qx; y @y # Iy Px; y dx dy 94 For example, if we wish to solve the differential equation 1

xy xy

x

dy 0 dx

we note that Px; y 1 1 @P @Q Qx; y @y @x

xy; Qx; y xy 1 x


so that Ix 1=x, if x > 0. In this case, Ix Px; y dx ln x xy @ @y

Ix Qx; y

Ix Px; y dx y

and it follows that the general solution is given by f x; y c where f x; y ln x

xy

y2 2

In particular, the solution which passes through the point 1; 0 is given implicitly by ln x

xy

y2 0 2

since c 0 in this case. More techniques for ®nding the solutions of various ®rst-order differential equations and those of higher order as well, may be found in Refs. 1 and 2.

REFERENCES x and

1. D Zwillinger. Handbook of Differential Equations. New York: Academic Press, 1989. 2. M Abramowitz, I Stegun. Handbook of Mathematical Functions. New York: Dover, 1965.

Chapter 1.5 Ordinary Differential Equations Jane Cronin

Rutgers University, New Brunswick, New Jersey

5.1

INTRODUCTION

more extensive tables, see Refs 1, 2, or 3. There are also integral tables in some computer software systems (see, e.g., Ref. 4). Few of the differential equations encountered in physics, engineering, or chemistry are as simple as (E). Many involve second or higher derivatives of the unknown function and the expression on the right usually involves y as well as x. Thus it is clear from the start that there are serious problems in solving differential equations. Differential equations have been studied since Newton invented the calculus, which means that people have worked on them for more than 300 years. Our purpose here is to describe, in brief form, some techniques for studying solutions of differential equations. Before proceeding to this description, we mention some general properties of solutions. In solving equation (E) we obtained actually an in®nite set of solutions because C is an arbitrary constant. Very often we are concerned with ®nding a solution which satis®es an initial condition, that is, a solution which has a given value for a given value of the independent value. For example, to ®nd the solution of (E) which equals 0 if x 2, we write

A differential equation is an equation which involves an unknown function and its derivatives. We will consider ordinary differential equations which concern only functions of one independent variable. (If the unknown function is a function of two or more variables and partial derivatives with respect to two variables occur, the differential equation is called a partial differential equation.) Solving the differential equation means determining a function which satis®es it. For example, suppose we are given the differential equation dy sin 2x dx

E

then a solution of the differential equation is yx

1 2

cos 2x C

where C is an arbitrary constant. This equation is particularly easy to solve because on the left, we have only dy=dx and on the right we have an expression involving only the independent variable x. However, even an equation as simple as (E) requires ®nding an integral or antiderivative of sin 2x, and if the right-hand side were more complicated, say,

1 2 cos 22

x15 sinx2

Thus

then ®nding the antiderivative or integral might present more serious problems. It is for this reason that we must often resort to using a table of integrals. Short tables can be found in most calculus textbooks. For

C 12 and the desired solution is 87


C 0

88

Cronin

yx

1 2 cos 2x

12

Under quite general conditions, the solution which satis®es an initial condition is unique, and this has important practical and theoretical consequences. In most of the discussion which follows, we concern ourselves with the question of how to ®nd or to approximate the solution. Thus we are assuming implicitly that there is a solution to be found. This is not always true. (For examples of nonuniqueness and nonexistence, see Ref. 5, p. 27 and p. 29). Moreover, there is the allied question of the domain of the solution, i.e., the values of the independent value for which the solution is de®ned. As we shall see, even simple-looking equations present dif®culties along this line. Finally, there is the question of relationships among the various solutions of an equation. Important aspects of this question are linear independence (especially for solutions of linear equations) and stability (for solutions of all classes of equations). Roughly speaking, a given solution is stable if solutions which are near it for some value of the independent variable stay close to the given solution for all larger values of the independent value. We shall return later to a description of these properties. In describing methods for solving differential equations, we will use informal descriptions and exhibit examples. We will not be concerned with proofs, but will simply give references for further development or more rigorous treatment. The references given are intended to provide only a minimal sampling of available material. The literature on differential equations is huge. A few words about notation and numbering: ®rst, in the examples during the discussion of calculations it is sometimes necessary to refer just once or twice to an immediately preceding equation. Instead of using an unnecessary numbering system for these equations we refer to such equations with (*). Second, the examples are numbered consecutively, independent of the section in which they appear. We begin by describing some of the classical techniques which are sometimes very effective but apply only to special classes of equations. Then we proceed to an account of second-order linear equations, with constant coef®cients and also with nonconstant coef®cients. (An equation of nth order is one in which d n y=dxn appears but no derivative or order higher than n appears.) Then we treat ®rst-order linear systems with constant coef®cients. After that, we describe brie¯y a couple of the major topics in nonlinear equations. Because these topics are large and because of limitations of space, our treatment is indeed brief.


Finally, we consider the very important question of whether to use numerical analysis, i.e., whether to `put the differential equation on the computer' rather than try to solve it by `pencil-and-paper' methods.

5.2

SOME CLASSICAL TECHNIQUES

First we will describe some techniques which were developed mainly in the 1700s and 1800s but which are still often useful. 5.2.1

Separable Equations

Regard dy=dx as the ratio of two differentials and multiply through by dx. If the equation can be written so that the variable x appears only on one side and the variable y on the other, then integrate the two sides separately. Example 1 1 x2

dy xy dx

dy x dx y 1 x2 p ln jyj 12 ln1 x2 C ln 1 x2 C where C is a constant of integration. p jyj eC 1 x2 obtain two solu(Since C is real, then eC > 0.) Thuspwe p C tions: y e 1 x2 and y eC 1 x2 . Example 2 y3

dy y4 2 cos x dx

y3 dy cos x dx y4 2 1 4

lny4 2 sin x C

lny4 2 4 sin x C

A solution of the differerntial equation is obtained by solving the equation for y as a function of x. We say that yields an implicit solution of the differential equation. In this case, we can solve as follows: elny

4

2

e4 sin xC e4 sin x eC

y4 2 Ke4 sin x

Ordinary Differential Equations

89

where K is a positive constant. y4 Ke4 sin x

Qx ex

2

ye

then

If Ke

x

e e

4x

dx C 4x 3x e dx C e 1 3x 4x e C e 3 1 x e Ce4x 3 1 y0 C 1 3 4 C 3 1 x 4 4x yx e e 3 3

1 sin x 1

4

Since

e

4x

e4 sin x e4 4

> 2, then

Ke4 sin x

2>0

and y Ke4 sin x

5.2.3

21=4

(If Ke4 sin x < 2, then y would not be real.)

Exact Differential Equations

The differential equation Mx; y Nx; y

5.2.2

Linear Equation of First Order

is exact if there is a function Fx; y such that

A linear differential equation is an equation in which the dependent variable and its derivatives are all of degree 1 (have exponent 1). The general formula for the solution of the linear equation of ®rst order dy Pxy Qx dx

Pxdx

Qxe

@F M @x

@F N @y

and

Then the differential equation can be written @F @F dy 0 @x @y dx But if yx is a solution of the differential equation, we have

is ye

dy 0 dx

Pxdx

dx C

d @F @F dy Fx; yx x; yx x; yx 0 dx @x @y dx Integrating, we have Fx; yx 0

Example 3 dy dx

4y ex

Px

y0 1

where we have, for convenience, chosen the constant of integration to be zero. It can be proved that the differential equation Mx; y Nx; y

4

is exact if and only if

Pxdx

4x


dy 0 dx

Pxdx 4x

@M @N @y @x

90

Cronin

Example 4 2xy 1 y x dy 2 0 y y dx M

2xy 1 y

N

@F M @x

and

y

x y

@F N @y

M dx

Nx; y g 0 y

Since the right-hand side of is a function of y only, then the left-hand side of must be a function of y only. This is, in fact, true because taking the partial derivative of the left-hand side with respect to x, we obtain @ @ x @N @ @ x @N M dx M dx @x @y @x @y @x @x @M @N 0 @y @x In this problem, @ x @ x 0 2 x M dx N g y @y @y y x 1 x 1 y y2 y y2 Hence gy

is not exact, there exists a function x; y such that if the equation is multiplied by x; y, the result is an exact differential equation. Such a function x; y is called an integrating factor. Example 5 x


dy dx

x3 0

y

y

M

x3

y

and

Nx

so that @M @y

1

and

@N 1 @x

If we multiply by the integrating factor x; y 1=x2 , the equation becomes y 1 dy x 0 x dx x2 in which M @M @y

1 x2

y=x2 @N @x

x, N 1=x and 1 x2

Thus we have obtained an exact equation which can be solved as follows: x y x2 M dx x 2 " # @ y x2 1 @y x 2 x @ x 1 1 M dx N g 0 y 0 @y x x gy C Fx; y

x y2

y

x3 2

y x

x2 C 0 2

Cx

We may also solve as follows. Rewrite as y dx x2

ln jyj

and the implicit solution is

dy 0 dx

The equation is not exact since

where gy is an arbitrary function of y. (Function g is arbitrary because if we differentiate with respect to x, any function of y only can be regarded as a constant during the differentiation.) Thus we require that @F @ x M dx g 0 y N @y @y x

ln jyj 0

Mx; y Nx; y

2

Since @F=@x M, then integrating with respect to x, we obtain x Fx; y M dx gy

@ @y

x y

Sometimes even if the equation

The equation is exact because @M @ 1 1 @N 2x @y @y y @x y2 x Mx; y dx be the antiderivative of M regarded Let as a function of x. We seek a function Fx; y such that

or

x2

Fx; y

or

1 x dx dy 0 x


xdy

y dx x2

or d

y x

91

or e

x dx

v

e

2

y x C 2 x

y x

y=x

ln e x3 Cx 2

Substitution Methods Homogeneous Equations

A homogeneous ®rst-order equation is an equation which can be written in the form y dy F dx x

y

Bernoulli's Equation

This is dy Pxy Qxyk dx where P, Q are functions of x only and k is any ®xed real number. Divide by yk : y

k

dy Pxy dx

Let v y

k1

x

1 1 1

Let y or y vx x

Qx

k

dy dx

Substitution yields

dy 0 dx

dy y ey=x dx x

k1

. Then

dv k 1y dx

Divide by x and obtain the homogeneous equation

v

x lnlnK=jxj

5.2.4.2

Example 6 xey=x y

y lnlnK=jxj x

Therefore

(Since C is an arbitrary constant, its sign has no signi®cance.) A strategic choice of an integrating factor can simplify signi®cantly the problem of solving a differential equation, but ®nding an integrating factor may require skill, experience, and luck.

5.2.4.1

ln jxj ln K lnK=jxj

or

or

5.2.4

ln jxj C

If C ln K, then this equation becomes

Integrating each side, we obtain

y

dx x

e v dv

x dx 0

dv Pxv Qx k dx

or dv 1 dx

kPxv 1

kQx

2

This is a linear ®rst-order equation and we have already described a general formula for its solution.

3

Example 7. y 0 y y2 . (We use sometimes y 0 and y 00 to denote dy=dx and d 2 y=dx2 , respectively.) Divide by y2 :

Then dy dv vx dx dx Substituting (2) and (3) in (1) yields dv ev v vx dx dv ev x dx This is a separable equation.


y0 y2

1 y

Let v y dv dx

1

21

y

2

1=y. Then dy dx

92

Cronin

dy C1 xe dx

and becomes dv dx

v

1

y C1 e dv v1 dx

x

x

e e Ce 1 1 Ce y 1 y 1 Ce

x

1 Ce

x

x

2

1y

0

xp x p

0

p

0

p

1

p

1

x

1j jxj

jp

1j jxj

2

x 2

x

x =2C

x2 =2

yy 00 y 0 2 1 0. Let y 0 p. Then

yp

dp p2 1 0 dy

dp 1 p 0 dy p

dp dy 0 p 1=p y p dp dy 0 2 p 1 y 1 ln jyj C

lnp 1 ln y2 C C1 e

2

x =2

lnp2 1y2 C where C1 > 0

p2 1

x2 =2

p2

1

If x > 0, x2 =2

x C2

2

If p > 1, dy C1 jxje dx

x2 =2

dp dp dy dp p dx dy dx dy

2 1 2 lnp

x C 2

e

C1 e

1

1 dx 0 x

2

1j C1 jxje

y

dp

ln jxj C

2

C1 e

The equation becomes

y

p

x C2

If x < 0,

y 00

0 or

x2 =2

Example 9.

1 0

1 0 x

1j

jp

jp

1

x

ln jp ln

x

y C1 e

The procedure is to take y to be the independent variable and let y 0 be the new dependent variable.

1 0

1p 2

1

5.2.4.4 Independent Variable Absent

ex x e C

The dependent variable y is absent. Let p y 0 ; then p 0 y 00 and the equation becomes 2

x2 =2

and if x > 0,

x

Example 8

0

x C2

dy C1 jxje dx

y

Dependent Variable Absent

xy x

x2 =2

If p < 1,

This is a ®rst-order linear equation for which we have a general formula for the solution. We have here Px 1 and Qx 1. Hence y 1 v e x ex dx C

00

1

and

or

5.2.4.3

x2 =2

x C2

If x < 0,


K y2

K y2 1

where K ec > 0 y2

K

y p K y2 dy p y dx

2

y dy p dx K y2 K

y2 1=2 x C


K

93

y2 x C2

y2 K

x C2

In the preceding pages, we have given a sampling of the many ingenious techniques which have been developed to study particular classes of ®rst-order differential equations. More complete discussions including extensions of the techniques we have described and other techniques can be found in standard textbooks. There is an excellent discussion in Ref. 5, Chap. 1. Very extensive and thorough treatments are given in Refs 6± 8. Each of these references presents a large number of ordinary differential equations and then solutions. Reference 8 is a more extensive compilation than Refs 6 or 7, but Refs 6 and 7 contain more theory and references. 5.3

A GEOMETRICAL APPROACH

We have been describing methods for obtaining explicit formulas for solutions of differential equations. There are, however, other ways of obtaining useful information about solutions. A geometrical approach yields a good qualitative (nonnumerical) understanding not only of particular solutions but also of the relationships among the solutions. If we consider a ®rst-order equation

Figure 1

x ! 1, i.e. as x increases without bound, then each solution yx approaches the solution yx 0 for all x. (If this occurs then we say that the solution yx 0 is asymptotically stable.) Of course, it is easy to verify the conjectures we have made about the solutions because the differential equation in this case is easy to solve: dy y ln jyj

dy f x; y dx then each solution yx represents a curve in the xyplane. If this curve passes through a point x0 ; y0 the slope of the curve at x0 ; y0 is f x0 ; y0 . Thus to get an idea of how the solutions behave, we indicate by an arrow with initial point x0 ; y0 the slope f x0 ; y0 at that point. A solution which passes through x0 ; y0 must be tangent at x0 ; y0 to the arrow with initial point x0 ; y0 . If we look at the entire collection of arrows, this will, in many cases, give considerable information about the solutions even if we do not calculate any of the solutions. Example 10. dy=dx 2y. As shown in Fig. 1, all the arrows on a horizontal line y k, a constant, have the same slope. If k > 0, then as k increases the slope becomes more and more negative. If k < 0 then as k decreases, the slope becomes increasingly positive. Thus a reasonable guess at the appearance of two typical solutions are the curves sketched in Fig. 1. Notice that yx 0 for all x is a solution of the differential equation and that the sketch suggests that as


2 dx 2x C c

jyj e e

2x

Thus all the solutions have the form yx Ke

2x

where K is a positive constant or a negative constant. However, the geometrical description that we have given is often enlightening if the problem of solving the differential equation is more dif®cult. 5.4

SECOND-ORDER LINEAR EQUATIONS WITH CONSTANT COEFFICIENTS

The techniques described so far are, in the main, unrelated. They are effective with special classes of equations, but there is no logical structure which relates them. Now we begin a more systematic study. We have already obtained a formula for the solution of a ®rst-order linear equation. Now we consider secondorder linear equations with constant coef®cients, i.e., equations of the form y 00 by 0 cy gx

L

94

Cronin

where b, c are constants, and g is a given function of x. If gx 0, for all x, the equation is homogeneous. (Note that this is a different de®nition of the word homogeneous from the de®nition used in Example 6.) The procedure for solving the homogeneous equation is as follows. Find the roots r1 ; r2 of the quadratic equation 2

r br c 0 Then the general solution has the form Aer1 x ber2 x where A, B are constants. The only exception is the case r1 r2 , which will be discussed below. y 00

Example 11. r2

3y 0 2y 0

3r 2 r

r1 2

2r

r2 1

r2

6y 0 25y 0

Ae

Bxe

3x

(Later, we shall indicate how this result comes about.) If (L) is not homogeneous, i.e., if gx is not identically zero, then the procedures for solving the differential equation become more complicated and, in some cases, less effective. First we observe by a straightfor ward calculation that if yx is a given solution of (L), then if Aer1 x Ber2 x

y 00 4y x2 cos x is 1 2 4x

The general solution is x Ae3x e4ix Be3x e 3x

e Ae

4ix

Be

4ix

4ix

3x

e Acos 4x i sin 4x Bcos 4x i sin 4x

Here we have used the facts that cos x cos x sin x

and the Euler formula eaib ea cos b i sin b Finally, we consider the case in which the quadratic equation has a multiple root.


1 8

13 cos x

The corresponding homogeneous equation is y 00 4y 0 and its general solution is Ae2ix Be

e3x A B cos 4x iA B sin 4x

sin x

3x

3. The general solution in this case is

Example 14. Straightfoward calculation shows that one solution of

By the quadratic formula p 6 36 100 3 4i r1 ; r2 are 2 4i

Thus, r1 r2

is a solution of (L). In fact, every solution of (L) can be written in this form by a strategic choice of constants A and B.

6r 25 0

Ae34i Be3

r2 6r 9 r 32 0

Aer1 x Ber2 x yx

Ae2x Bex y 00

y 00 6y 0 9y 0

is the general solution of the corresponding homogeneous equation [i.e., equation (L) with gx 0 for all x] it follows that

1 0

The general solution is

Example 12.

Example 13.

2ix

Acos 2x i sin 2x Bcos 2x A Bcos 2x iA

i sin 2x B sin 2x

A1 cos 2x B1 sin 2x Then any solution of the differential equation may be written as 1 2 x 4

1 1 cos x A1 cos 2x B1 sin 2x 8 3

Thus the practical problem of solving (L) becomes that of ®nding the general solution of the corresponding homogeneous equation and just one solution (with no given initial conditions) of equation (L) itself. This conclusion is clearly of practical importance in


95

solving (L), but it is also of considerable general importance because it holds for many other linear equations, for example, partial differential equations, integral equations, and abstract functional equations. Now we consider the problem of ®nding one solution of the inhomogeneous equation. We describe ®rst the method of undetermined coef®cients which is simple but not always applicable. We suppose that gx in equation (L) has a simple form, i.e., that gx is a sum of products of polynomials, exponential functions ekx , and trigonometric functions cos kx and sin kx. Then, looking at gx, we make a guess at the form of the solution. Example 15. y 00 4y x2 cos x. A reasonable guess at a solution is Ax2 Bx C D cos x E sin x and we try to determine the constant coef®cients A, B, C, D, E. The derivative and second derivative of the guessed solution are 2AX B 2A

D sin x E cos x

D cos x

E sin x

Substituting into the differential equation, we get 2A

D cos x

E sin x 4Ax2 4Bx 4C

4D cos x 4E sin x x2 cos x or 4A 1x2 4Bx 4C 2A 3D 3E sin x 0

1 cos x

Setting the coef®cients equal to zero yields A 14 B0 C D 13 E0

1 2A

1 8

1 8

13 cos x 1 8

13 cos x

where a, b are constants. Notice that if we consider the equation y 00 4y x2 cos 2x


then the procedure used above fails because suppose we make the `reasonable' guess at a solution as Ax2 Bx C D cos 2x E sin 2x then we arrive at the equation 4A

1x2 4Bx 2A 4C

cos 2x 0

But no matter what values we use for A, B, C, this equation cannot be satis®ed for all x because then cos 2 x would be identically equal to a polynomial, which is certainly not true. For this case, it is necessary to use a more complicated `guess' obtained by multiplying the terms by an appropriate power of x [5, p. 155]. We have seen that the method of undetermined coef®cients, although simple and straightforward, has serious limitations, especially on the function gx. There is a far more powerful and general method, called the method of variation of constants or variation of parameters. (It must be acknowledged that the price of this power and generality is a considerable amount of calculation.) The method of variation of parameters has the additional virtue that it can be used in a much more general context. Consequently we will postpone describing it until we consider more general problems (systems of linear ®rst-order equations) in Sec. 5.6. 5.5

LINEAR EQUATIONS WITH NONCONSTANT COEFFICIENTS

xr eaibx xr eax cos bx i sin bx

and the general solution is a cos 2x b sin 2x 14 x2

y 00 4y 0

It would seem reasonable that if we consider a linear equation with coef®cients which are not constant but are simple functions of x (e.g., a function like x2 ) that such an equation would not be too dif®cult to solve. This is, however, not true. The reason is that as long as we deal with equations with constant coef®cients, the solutions are composed of sums of terms of the form

So a solution is 1 2 4x

where gx contains the term cos 2x, which is a solution of the corresponding homogeneous equation

where r is a nonnegative integer and a and b are real. Thus the solutions are ®nite sums and products of integer powers of x, exponential functions eax , and trigonometric functions sin bx, cos bx. (This is shown in the general case in Sec. 5.6.) But as soon as we venture into the realm of equations with nonconstant coef®cients, the solutions become less familiar (e.g.,

96

Cronin

Bessel functions) or are completely unknown. There is no easy answer to the question of how to proceed if confronted by a linear equation in which the coef®cients are functions of x. Part of the reason for this is that certain equations with nonconstant coef®cients often arise in physical and engineering applications. Consequently these equations have been studied extensively and for a long time. Among the most important of these equations are the Bessel equation, the Legendre equation, and the Laguerre equation. (For an introduction to these equations and further references, see Ref. 5.) One may have the good fortune or technical insight to recognize that the given equation is or can be transformed into one of these much studied equations. (See, for example, the beautiful discussions in Ref. 5, pp. 277±283, of the SchroÈdinger equation for the hydrogen atom.) But if the given equation cannot be treated in this way, there is no alternative but to use a numerical method, i.e., put the equation on a computer. Much of the study of such important equations as the Bessel equation is based on the method of power series solutions. We describe this technique as follows: Example 16.

To ®nd the solutions of

y 00 y 0 such that y 0 0 1

y0 0

It is easy to show by the earlier method that the solution of this problem is yx sin x. However, let us suppose that we do not have this answer and start by assuming that the solution can be represented as an in®nite series, i.e., yx a0 a1 x a2 x2 an xn Since y 0 x a1 2a2 x nan xn

1

and y 00 x 2a2 nn

1an xn

2

2a2 nn n 2

an 2 x

1an xn

0

2

a0 a 1 x

Since must hold for all x, then the coef®cient of each power of x must be zero. Thus we obtain


a3 .. .

an 2 nn 1

an

Since y0 a0 0, then if n is even an 0 Since y 0 0 a1 1, then a3

1 32

and if n is odd, i.e., if n 2p 1, then an

1p n!

and the solution is x

x3 x5 3! 5!

x7 7!

which is a power series (the Maclaurin series) for yx sin x. Two serious questiosn arise immediately about this procedure. First, if we manage to get a power series in this way, how do we determine whether the series converges or diverges for various values of x? This question is readily answered by application of some classical theory. (See, e.g., Ref. 5, Chap. 3.) But even if we can show that the power series converges, this gives us no practical knowledge of how the function represented by the series behaves. One can try approximating the function by using the ®rst few terms of the power series, but we would not know, in general, how good this approximation is. On the other hand, it should be emphasized that the power series approach has been and remains very important in the study of the particular equations mentioned earlier: Bessel's equation, the Legendre equation, and others. 5.6

then substituting in the equation we have

a0 2 a1 32

a2

SYSTEMS OF LINEAR FIRST-ORDER DIFFERENTIAL EQUATIONS

So far, we have dealt only with second-order linear equations. It is easy to guess how some of the methods we have described might be carried over to third-order or higher-order equations. However, instead of pursuing this direction we proceed at once to the study of


97

systems of ®rst-order linear equations. There are several reason for choosing this direction. First, a single nth-order equation can be regarded as a system of n linear ®rst-order equations. Thus the investigation of linear ®rst-order systems is a broadening of our study. Secondly, by taking the ®rst-order system viewpoint, we can utilize matrix theory to obtain a coherent and complete description of how to treat the problems. Finally, systems of ®rst-order linear equations are important for many applications. A system of linear ®rst-order differential equations is a set of equations dx1 a11 x1 a12 x2 a1n xn b1 dt dx2 a21 x1 a22 x2 a2n xn b2 dt .. . dxn an1 x1 an2 x2 ann xn bn dt

S

where aij i 1; . . . ; n; j 1; . . . ; n will be assuemd to be constant and b1 ; . . . ; bn are functions of t. If bi t 0

i 1; . . . ; n

the system is said to be homogeneous. In system (S) the t is the independent variable and solving system (S) means ®nding functions x1 t; . . . ; xn t which satisfy system (S). Specifying an initial condition for the solution means specifying initial values x1 t0 ; . . . ; xn t0 , all at the same value t0 of the independent variable. Each of the equations in (S) is a ®rst-order equation, and we show ®rst how to write a single nth-order linear equation as a system of ®rst-order equations. We consider the equation d nx d n 1x d n 2x d2x a a a n n 1 3 dtn dtn 1 dtn 2 dt2 dx a2 a1 x bt 0 dt Let x1 x dx dx1 x2 dt dt 2 d x d dx dx x3 2 2 dt dt dt dt .. . " # d n 1x d d n 2x dx n xn n 1 n 2 dt dt dt dt


E

Then equation (E) can be written as the system dx1 x2 dt dx2 x3 dt .. . dxn 1 xn dt n d x dxn a1 x1 dt dtn an xn

an 1 x n

1

bt

Although it is by no means obvious at this stage, it turns out that it is better to treat the single nth-order equation as a special case of a system of ®rst-order equations. We shall see why later. But in order to develop the theory for systems of ®rst-order equations, we need a few facts about matrices. 5.6.1

Some Theory of Matrices

A matrix is a rectangular array (m rows, n columns) of numbers 2 3 a11 . . . a1n 6 .. 7 4 . 5 am1

. . . amn

Sometimes the matrix is denoted by aij . 5.6.1.1

Sums, Determinants, and Products of Matrices

The sum of two matrices is de®ned for two matrices with the same number of rows and columns as follows: 2 3 2 3 a11 a12 . . . a1n b11 b12 . . . b1n 6a 7 6 7 6 21 a22 . . . a2n 7 6 b21 b22 . . . b2n 7 6 . 76 . 7 6 . 7 6 . 7 4 . 5 4 . 5 am1 am2 . . . amn bm1 bm2 . . . bmn 2 3 a11 b11 a12 b12 . . . a1n b1n 6 a b a22 b22 . . . a2n b2n 7 21 6 21 7 7 6 .. 6 7 4 5 . am1 bm1

1

a2 x2

am2 bm2

. . . amn bmn

Multiplication of a matrix by a number (or scalar) is de®ned as follows: if c is a number then the product of c and the matrix aij is

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2

...

a11

6 6 a21 c6 6 4

3

a1n

amn ...

cam1

a11

7 6 7 6 a21 76 7 6 5 4

a2n

am1 2 ca11 6 6 ca21 6 6 4

2

ca1n

3

am1

...

a1n a2n

3 7 7 7c 7 5

amn

a11 6 .. A4 . am1

162

camn

a12

...

am2

a1m

b11

6b 6 21 B6 6 .. 4 . bm1

...

b22

...

bm2

0

4 7 5

7 5

242 239 84 78 162

b1m

3

b2m 7 7 7 7 5

. . . bmm

n X 1ij bij Bi; j j1

where i is a ®xed integer with 1 i m or det B can be de®ned as det B

5

3

Let Bi; j be the m 1 m 1 matrix obtained by deleting the ith row and the jth column of matrix B. Then det B can be de®ned to be det B

Expansion by the second column: 2 3 1 2 7 6 7 2 6 5 1 212 30 24 4 3

amm

b12

m X 1ij bij Bi; j i1

where j is ®xed with 1 j m. All these expressions for det B yield the same result. The ®rst equation is called expansion by the ith row. The second equation is called expansion by the jth column.


2 5

8 84 70

the determinant of A, denoted by det A, is de®ned inductively as follows. If m 2, det A a11 a22 a12 a21 . If det A is de®ned for A, an m 1 m 1 matrix, let B be an m m matrix, 2

6 5 730 8 242 710

7 ca2n 7 7 7 5

We will need to consider only square matrices m n and single column matrices n 1. (A single column matrix is a vector.) If A is a square matrix 2

Example 17. Expansion by the ®rst row: 2 3 1 2 7 6 7 2 6 5 124 60 1 234 4 3 5 0 4

If A and B are two square matrices, their products are de®ned to be 2 32 3 b11 b12 . . . b1m a11 a12 . . . a1m 6a 76 b 7 6 21 a22 . . . 7 6 21 b22 7 AB 6 76 7 4 54 5 2 4

am1

...

...

amm

c11

c12

...

x1m

cm1

cm2

bm1

bm2

bmm

3 5

cmm

where c11 a11 b11 a12 b21 a1m bm1 m X a1j bj1 j1

That is, c11 is the dot product of the ®rst row of A with the ®rst column of B. Also c12 a11 b12 a12 b22 a1m bm2 m X a1j bj2 j1

That is, c12 is the dot product of the ®rst row of A with the second column of B. Generally, if k 1; . . . ; m and ` 1; . . . ; m, then ck`

m X j1

akj bj`


2

Similarly 2 b11 6b 6 21 BA 6 6 .. 4 .

b12 b22

bm1

bm2

...

d11 6 d21 6 4 dm1 where

d12 d22 ... dm2

... ...

2

dk`

m X j1

99

3 b1m 2 a11 b2m 7 76 a21 76 76 54

... ...

am1

bmm

a12 a22 ... am2

... ...

3

a1m a2m 7 7 7 5

. . . amm

5.6.1.2

bkj aj`

AB

4 10

11 25

... ...

Exponent of a Matrix

ex 1 x

x2 xn 2! n!

If A is a square matrix, we de®ne the exponent of A as

Example 18 1 2 A 3 4

a1 jbj 7 32 b 3 6 6 j1 7 1 a1m 6 m 7 6 6 7 7 X b2 7 6 a2m 7 76 a2j bj 7 6 6 7 7 . 54 . 5 6 7 . 6 j1 7 m . . . amm 6X 7 bm 4 amj bj 5

a12 a22 ... am2

The exponent of a matrix is a very useful concept in systems of linear differential equations. It is de®ned by using the in®nite series for the familiar exponential function, i.e.,

WARNING. In general AB 6 BA. That is, multiplication of matrices is not commutative, as the following example shows.

Then

a11 6 a21 6 4 am1

3

j1

3 d1m d2m 7 7 5 dmm

...

2

m X

2 3 B 1 4

The m m matrix 2 1 6 1 I 6 .. 4 .

BA

11 16 13 18

eA I A

A2 An 2! n!

For this de®nition to make sense it is necessary to say what we mean by convergence of an in®nite series of matrices and to show that the above in®nite series of matrices converges. In order to de®ne the convergence, we must introduce a de®nition of distance between matrices A and B, denoted by jA Bj. This distance is de®ned as

3 7 7 5

jA

1

Bj

m X i;j1

in which all the diagonal entries, aii , are equal to 1 and every entry off the diagonal, aij with i 6 j, is equal to 0, is called the identity matrix because if A is any m m matrix then

jaij

bij j

The formal de®nition of convergence is based on this distance and using the convergence of the familiar exponential series , it can be proved that converges.

AI IA A If A has an inverse A 1 , i.e., if there exists a matrix A such that AA 1 I, the identity matrix, then A and A commute: AA

1

1

A 1A I

It can be proved that A has an inverse if and only if det A 6 0. Multiplication of a square matrix and a vector is de®ned as follows:


5.6.1.3

1

Eigenvalues and Eigenvectors of a Matrix

An important concept for matrices is an eigenvalue of a matrix. Given a matrix A aij , then an eigenvalue of A is a number such that 2

a11 6 a21 det6 4 am1

a12 a22 am2

...

3

a1m a2m amm

7 70 5

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Example 19. Find the eigenvalues of 2 3 4 2 8 A 4 1 13=3 16=3 5 1 4=3 7=3 The eigenvalues are the solutions of the polynomial equation 2 3 4 2 8 6 7 det4 1 13=3 16=3 5 1 4=3 7=3 16 4 13 7 4 3 3 4 3 3 0 2 93 8 43 13 3 3 62

11 6 0

or 3

62 11

60

The number 6 must be divisible by any integer solution of this polynomial equation. So the possible integer solutions include 2 and 3. Using synthetic division, we have 1

6 3

11 9

1

3

2

6 b3 6

That is: 3 62 11 6 32 3 2. So the solutions are 1; 2; 3. The eigenvalues are the solutions of a polynomial equation, that is, if A is an m m matrix, the eigenvalues of A are the solutions of a polynomial equation of degree m. Hence by a theorem from algebra, the matrix A has m eigenvalues if each eigenvalue is counted with its multiplicity. It is straightforward to prove that the product of the eigenvalues is det A. Thus 0 is an eigenvalue of A if and only if det A 0. Later we will need the concept of an eigenvector. If is an eigenvalue of matrix A, then detA

I 0

As will be shown later (after Example 25), it follows that there is a nonzero vector x such that A

Ix 0

Vector x is called an eigenvector of A. Note that if x is an eigenvector and c is a nonzero constant, then cx is also an eigenvector.


5.6.1.4 Canonical Forms of a Matrix With one more bit of matrix theory, we reach the result which is used to given an explicit formula for the solutions of a system of m ®rst-order homogeneous equations with constant coef®cients. If A is an m m matrix with entries aij which are real or complex, then there is a constant matrix P with an inverse P 1 such that P 1 AP J where J is a matrix called the Jordan canonical form and J has the form 2 3 J1 6 7 J2 6 7 6 7 .. 4 5 . Js where all the entries not written in are zero and Jj j 1; . . . ; s has the form 2 3 j 1 6 7 j 1 6 7 6 7 . .. Jj 6 7 6 7 4 15 j where j is an eigenvalue of A. (All the entries not written in are zero.) Each eigenvalue of A appears in at least one of the matrices Jj . (The eigenvalues j are, in general, not distinct.) If all the entries of A are real, then there is a real constant matrix P with an inverse P 1 such that P 1 AP J~ where J~ is a matrix called the real canonical form, all the entries of J~ are real, and J~ has the form 2 3 J~1 6 7 J~2 6 7 J~ 6 7 . .. 4 5 ~ Js and J~j is associated with eigenvalue j and has one of the two following forms: if j is real, 2 3 j 1 6 7 j 1 6 7 6 7 . . .. .. J~j 6 7 6 7 4 15 j


Each j appears in at least one J~j . If j is a complex eigenvalue, j j i j where j and j are real and j > 0. (Note that since A is real, then if j i j is an eigenvalue, so is j i j .) Then 2 3 j j 1 0 6 j j 0 1 7 6 7 6 7 .. 6 7 . 6 7 ~ Jj 6 1 07 j j 6 7 6 0 17 j j 6 7 4 j j 5 j j Corresponding to each j j i j , there is at least one J~j . Example 20. The eigenvalues of 2 3 19 30 0 4 15 23 0 5 0 0 3 are the solutions of the polynomial equation 2 3 19 30 0 det4 15 23 0 50 0 0 8 or, expanding the determinant by the third column, 8

19

23

450 0

8

1923 19

8

2

4

8

2

4 13 0

437 450 0

The eigenvalues are 8 and p 4 16 52 2 or 4 6i 2

4

2 3i

2

23 2 450 0

6i 2

101

2

2 J~ 4 3 0

3 2 0

3 0 05 8

In general, ®nding the Jordan canomical form or the real canonical form can be a lengthy process even if m is fairly small. (For a more detailed description of the canonical forms, a description of how to calculate them, and an example with m 7, see Ref. 9, Chap. 2.) 5.6.2

Solutions of a Homogeneous System of Linear Differential Equations

With these facts about matrices, we return to the study of systems of linear differential equations. We consider a linear homogeneous system with constant coef®cients dx1 a11 x1 a12 x2 a1m xm dt dx2 a21 x1 a22 x2 a2m xm dt .. . dxm am1 x1 am2 x2 amm xm dt We may rewrite (L) in matrix form as 2 3 2 dx1 =dt a11 a12 . . . a1m 6 dx =dt 7 6 a 6 2 7 6 21 a22 . . . a2m 6 76 . .. 6 7 6 .. 4 5 4 . dxm =dt

am1

3i

Then


am2

. . . amm

If we introduce the notation 2 3 x1 6x 7 6 27 7 x6 6 .. 7 4 . 5 xm 3 dx1 =dt 6 dx =dt 7 2 7 dx 6 7 6 .. 7 dt 6 4 5 . 2

dxm =dt a11 a12 6a 6 21 a22 A6 6 4 2

or

L

am1

am2

... ... .. .

3 a1m a2m 7 7 7 7 5 amm

32

x1

76 x 76 2 76 . 76 . 54 . xm

3 7 7 7 7 5

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2

3 2 3 2 3 a2 x12 t an x1n t a1 x11 t 6 a x t 7 6 a x t 7 6 a x t 7 6 1 21 7 6 2 22 7 6 n 2n 7 6 7 6 7 6 7 .. .. .. 6 7 6 7 6 7 4 5 4 5 4 5 . . .

then the linear system (L) can be written in the much briefer form dx Ax dt

Lm

a1 xm1 t 2 3 0 607 6 7 7 6 6 .. 7 4.5 0

Before discussing the problem of solving (L) or (Lm ), we state a couple of facts about the set of solutions of (L). These facts are stated in terms of the notion of linear independence. We will then discuss the meaning of linear independence. The basic facts are: 1. 2.

System (L) has m linearly independent solutions. Every solution of (L) can be expressed as a linear combination of m linearly independent solutions.

(For proofs of these statements, see Ref. 9, Chap. 2.) The notion of linear independence is of crucial importance throughout the study of linear equations of all sorts. Unfortuantely, it has an elusive quality that is dif®cult to deal with, at least at ®rst. Part of this dif®culty stems from the fact that the de®nition of linear independence is given in negative terms. First we de®ne linear dependence. Functions f1 t; . . . ; fn t are linearly dependent if there exist constants a1 ; . . . ; an , not all zero, such that for all t a1 f1 t a2 f2 t an fn t 0 (Speaking informally, we would say that f1 ; . . . ; fn are linearly dependent if one of them can be written as a linear combination of the others.) The vectors 2 3 2 3 2 3 x11 t x12 t x1n t 6 x21 t 7 6 x22 t 7 6 x2n t 7 6 7 6 7 6 7 6 .. 7; 6 .. 7; . . . ; 6 .. 7 4 . 5 4 . 5 4 . 5 xm1 t xm2 t xmn t are linearly dependent if there exist constants a1 ; . . . ; an , not all zero, such that for all t, 2 2 3 3 2 3 x12 t x1n t x11 t 6 x t 7 6 x t 7 6 x t 7 6 22 7 6 2n 7 6 21 7 6 . 7 7 a1 6 a 7 a2 6 n6 . 6 7 7 4 5 4 .. 5 4 .. 5 xm1 t xm2 t xmn t 2 3 0 607 6 7 7 6 6 .. 7 4.5 0 or


a2 xm2 t

an xmn t

(The zero vector on the right is sometimes denoted simply by 0.) This last vector equation is equivalent to the scalar equations a1 x11 t a2 x12 t an x1n t 0 a1 x21 t a2 x22 t an x2n t 0 .. . a1 xm1 t a2 xm2 t an xmn t 0 (Note that in these de®nitions, any or all of the functions fj t, xij t may be constant functions.) Example 21. The constant vectors 3 12 and 2 8 are linearly dependent because 3 12 0 4 2 8 0 Example 22. To show that the vectors 17 3 1 ; ; 2 4 18 are linearly dependent, we show that there are numbers a1 , a2 , such that 1 3 17 a1 a2 0 2 4 18 or a1 3a2 2a1 4a2

17 18

These simultaneous equations have a unique solution for a1 and a2 because 1 3 det 2 6 0 2 4


(Actually it can be proved that if n is any integer, then a set of n 1 constant n-vectors must be linearly dependent.) Functions f1 t; . . . ; fn t are linearly independent if they are not linearly dependent. Similarly, vectors are linearly independent if they are not linearly dependent. Thus if we want to show that a set of functions or vectors is linearly independent then we must show that there is no set of numbers a1 ; . . . ; an with the properties described in the de®nition of linear dependence. It is by no means obvious how to go about this. Example 23.

The functions

f1 t 1 f2 t t f3 t t2 are linearly independent because if a1 ; a2 ; a3 are ®xed numbers, then the equation 2

a1 a 2 t a 3 t 0 holds for at most two values of t (the solutions of the quadratic equation) unless a1 0, a2 0, and a3 0. Example 24.

Similarly the functions

f1 t 1 f2 t t12 f3 t3 t17 are linearly independent because the equation 12

a1 a 2 t a 3 t

17

0

holds for, at most, 17 values of t (the solutions of the polynomial equation of degree 17) unless a1 0; a2 0; and a3 0. Example 25. The vectors 2 3 2 3 2 3 1 1 5 4 2 5; 4 3 5; 4 0 5 4 6 2 are linearly independent because if 2 3 2 3 2 3 1 1 5 a 1 4 2 5 a2 4 3 5 a 3 4 0 5 0 4 6 2 then


103

a1 a2 5a3 0

2a1 3a2 0 4a1 6a2 2a3 0 But since the coef®cient determinant is 2 3 1 1 5 6 7 det4 2 3 0 5 5 12 12 23 2 4 6 2

120 10 6 0

then the system of equations has the unique solution a1 a2 a3 0. The same kind of argument shows that more generally, we have: n constant n-vectors are linearly independent if the corresponding determinant is nonzero. Also if the n-vectors are linearly independent, then the corresponding determinant is nonzero. Finally, it is easy to show that eigenvectors exist: since detA

I 0

then the columns of A I are linearly dependent. That is, there exists a nonzero vector x such that A

Ix 0

Example 26. Suppose we have two 3-vectors 2 3 2 3 x12 x11 4 x21 5; 4 x22 5 x31 x32 then if x det 11 x21

x12 x22

6 0

the vectors are linearly independent. To prove this suppose that 2 3 2 3 x11 x12 a1 4 x21 5 a2 4 x22 5 0 x31 x32 that is a1 x11 a2 x12 0 a1 x21 a2 x22 0 a1 x31 a2 x32 0 Then the equations a1 x11 a2 x12 0 a1 x21 a2 x22 0

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where J~ is the real canonical form described in Sec. 5.6.1.3. Multiplying this equation on the left by P and on the right by P 1 , we obtain

can be solved for a1 , a2 . Since x12 x det 11 6 0 x21 x22

~ A PJP

the solution is a1 0, a2 0. The basic facts stated earlier essentially tell us that in order to ®nd the solutions of system (L), it is suf®cient to ®nd m linearly independent solutions. The ®rst step in such a search is to observe that the matrix equation dx Ax dt

LM

which is another form of (L), is a generalization of the simple scalar equation dx ax dt and we know that a solution of this equation is eta . This suggests that the exponential etA I tA

t2 A 2 tn A n 2! n

F

is, in some sense, a solution of (LM ). In fact it is not dif®cult to prove that the m columns of the matrix etA are m linearly independent solutions of (LM ). [A matrix with this property is called a fundamental matrix of LM .] Indeed, for t 0, we have e0A I and hence the solution xt of LM such that x0 x where x is a given vector, is xt etA x A glance at equation (F) is enough to suggest that these statements have no practical value. If A is, say, a 3 3 matrix, how can the powers of A be calculated? That is, how can an explicit form for the in®nite series be obtained? Also how can we determine what this in®nite series converges to for various values of t? These would seem to be dif®cult problems, but they are fairly easy to solve if we use the Jordan canonical form or the real canonical form described earlier. Since we are interested mainly in the case in which all the entries in A are real and in ®nding real solutions we will use the real canonical form. We stated earlier that there exists a real matrix P with inverse P 1 such that P 1 AP J~


1

and 1 ~ 1 PJP ~ 1 PJP ~ ~ A2 PJP PJP ~ 2P 1 PJ

1

and for any integer n ~ nP An PJ

1

Then by equation (F), ~ 2P 1 t2 PJ 2! ~ nP 1 tn PJ n! " # 2 ~ 2 n ~ n t J t J P 1 tJ~ P 2! n!

~ etA I tPJP

~

PetJ P

1

1

1

~ n is not dif®cult and with some simCalculating J ple, although rather lengthy, computations the expres~ sion etJ can be explicitly determined. (For a detailed description of this, see Ref. 9, Chap. 2.) Here we will just sketch the results. First, we have 2 ~ 3 etJ1 ~ 6 7 etJ2 ~ 6 7 etJ 6 7 .. 4 5 . tJ~s e ~

So it is suf®cient to exhibit etJ where J~ has the form, if the eigenvalue is complex, 2 3 1 0 6 0 1 7 6 7 .. 6 7 6 7 . 6 7 J~ 6 7 1 0 6 7 6 7 0 1 6 7 4 5 or, if is real, 2 1 6 1 6 .. .. ~ 6 J6 . . 4

3 7 7 7 7 15


105

Simple calculations show that if is real and J is such an m m matrix, then 2 3 tm 1 t t t e t . . . e 6 m 1! 7 6 7 6 7 t t tJ e te . . . e 6 7 6 7 . .. 4 5 et

If is complex, then simple but lengthier calculations show that etJ has the following form, which we indicate only brie¯y: 2

et cos t et sin t 6 et sin t et cos t 6 6 etJ 6 6 4

tet cos t tet sin t et cos t et sin t .. .

tet sin t tet cos t et sin t et cos t

3 ...7 7 7 7 ...7 5

(These expressions appear to be rather complicated, but it is important to notice that each term is simply an integer power of t multiplied by a real exponential or a sine or a cosine.) Finally, it is not dif®cult to show that since ~

etA PetJ P

1 ~

is a fundamental matrix, so is PetJ . [An m m matrix whose m columns are linearly independent solutions of LM is a fundamental matrix of (LM ).] Example 27.

Find the solution of

dx 4x 2y 8z dt dy 13 16 x y z dt 3 3 dz 4 7 x y z dt 3 3 which satis®es the initial condition x0 1 y0 1 z0 4 By Example 19, the eigenvalues of the coef®cient matrix 2 3 4 2 8 A 4 1 13=3 16=3 5 1 4=3 7=3 are the number 1, 2, 3. Hence the Jordan canonical form of A is


2

1 J 40 0

3 0 05 3

0 2 0

It is easy to see that if n is a positive integer, then 2 n 3 t 0 0 tJn 4 0 2tn 0 5 0 0 3tn and it follows 2 t e etJ 4 0 0

that 0 e2t 0

3 0 0 5 e3t

As remarked above, a fundamental matrix of the system of differential equation is PetJ . It remains to determine the matrix P. As is shown in a detailed discussion of canonical forms (e.g., Ref. 9, Chap. 2), the columns of P are eigenvectors associated with the eigenvalues. If 1, we solve the following equation in order to ®nd an eigenvector: 3 2 32 4 1 2 8 p11 4 1 13=3 1 16=3 54 p21 5 0 p31 1 4=3 7=3 1 or

2

3 4 1 1

3 32 8 p11 16=3 54 p21 5 0 p31 10=3

2 10=3 4=3

or 3p11 2p21 8p31 0 p11

10 3 p21

p11

4 3 p21

16 3 p31

1

0

10 3 p31

2

0

3

Adding 2 and 3 yields 2p21 2p31 0

or

p21

p31

Multiplying 3 by 5/2 and adding to 2 yields 3 2 p11

9 3 p31

3p11

6p31 0

p11

0

2p31

So an eigenvector associated with eigenvector 1 is (if we take p31 1) 2 3 2 4 15 1 If 2, we solve

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4

2

1 1

3 32 8 p12 16=3 54 p22 5 0 p32 7=3 2

2 13=3 2 4=3

2p12 2p22 8p32 0 p12

7 3 p22

16 3 p32

4 3 p22

p12

5

0

6

Adding 5 and 6, we obtain p22 p32 0

or

p32

3p32

If 3 we solve 2 4 3 2 4 1 13=3 3 1 4=3

3 32 8 p13 16=3 54 p23 5 1 p33 7=3 3

p13 2p23 8p33 0

7

p13 43 p23 16 3 p33 0

8

16 3 p33

0

9

Subtracting 8 from 7 yields 83 p33 0

or

p23

4p33

Substituting in 9 yields p13 43 4p33

2

16 3 p33

0

or

p13 0

So an eigenvalue associated with eigenvalue 3 is (if we take p33 1) 2 3 0 4 45 1 Now let matrix P have these three eigenvectors as its columns. That is, 2 3 2 3 0 P4 1 1 45 1 1 1 Then since the columns of P are eigenvectors, we have


0 21 0

3 2 0 1 0 5 40 31 0

0 2 0

3 0 05 3

3 0 0 2 05 0 3

1 J 40 0

So an eigenvector associated with the eigenvalue 2 is (if we take p32 1) 2 3 3 4 15 1

2 3 p23

1 P 1 AP 4 0 0

where

or

4 3 p23

2

PetJ

2p12 6p32 0

p13

and

A fundamental matrix of our system is

p22

Substituting in 4 yields

p12

3 2 3 30 2 1 3 4 5 21 31

2 AP 4 1 1 4

0

13 3 p32

2

but

2

et tJ 4 e 0 0

0 e2t 0

3 0 0 5 e3t

and hence the fundamental matrix is 2 32 t 2 3 0 e 0 6 76 PetJ 4 1 1 4 54 0 e2t 1 1 1 0 0 2 3 t 2t 3e 0 2e 6 7 4 et e2t 4e3t 5 et

e2t

3 0 7 0 5 e3t

e3t

Since PetJ is a fundamental matrix then the desired solution is a linear combination of the columns of PetJ . That is, there exist constants a, b, c such that at t 0 2 3 2 3 2 3 2 3 0 1 2et 3e2t a4 et 5 b4 e2t 5 c4 4e3t 5 4 1 5 e3t 4 et e2t Taking t 0, we have 2a a b

3b 1 4c 1

abc4 Solving these three equations for a, b, c, we obtain: c 1, b 11, a 16. Hence the desired solution is xt 16 2et yt

11 3e2t

16et 11e2t 4e3t

zt 16et

11e2t

e3t

These calculations show that even for a simple, lowdimensional example, the solutions are not quickly


107

obtained. It is clear that the dif®culties increase if n is much larger. Also we have not described at all how to deal with the case of eigenvalues of multiplicity greater than 1 [9, Chap. 2]. To do so, we must introduce generalized eigenvectors in order to ®nd the matrix P. There is one cheering note in this welter of complications. If we deal with a system which stems from a single nth-order equation, and if is a multiple eigenvalue, then appears in just one `box' Jj in the Jordan canonical form [9, Chap. 2]. Thus we obtain a straightforward algebraic explanation of the form of the solutions of the single nth-order equation. (The form of the solutions for the single second-order equation with a multiple eigenvalue was described in Example 13.) 5.6.3

Solutions of Nonhomogeneous Linear Systems

Finally, we turn to the problem of solving a nonhomogeneous linear system with constant coef®cients, i.e., a system dx1 a11 x1 a12 x2 a1m xm b1 t dt dx2 a21 x1 a22 x2 a2m xm b2 t dt .. . dxm am1 x1 am2 x2 amm xm bm t dt Using the matrix notation introduced earlier and letting bt denote the vector 2 3 b1 t 6 b2 t 7 6 7 6 .. 7 4 . 5 bm t

then we may rewrite this system as dx Ax bt dt

1

Let Mt be a fundamental matrix of the corresponding homogeneous equation dx Ax dt

2

Then we have the following result: Variation-of-Constants Formula (also called the variation-of-parameters formula). The solution xt of 1 such that xt satis®es the initial condition


xt0 x0 is given by the formula t xt yt Mt Ms 1 bs ds t0

where yt is the solution of 2 such that yt0 x0 The proof of this formula is a straightforward calculation [9, Chap. 2]. It is worth noting that this is a generalization of the formulation for the solutions of a single ®rst-order linear equation, i.e., the formula given in Sec. 5.2.2. We have looked only at linear systems with constant coef®cients. If we permit the coef®cients aij to be functions of t, the problems become far more dif®cult. This is to be expected because if we consider a singlesecond-order linear homogeneous equation whose coef®cients are not constants, then we move from the realm where all the solutions are sums of terms of the familiar form ert or tk ert into another country where the solutions are entirely novel: Bessel functions, Legendre functions, etc. In fact there is very little general theory of linear systems with coef®cients aij which are functions of t. One exception is the Floquet theory for systems in which each aij t has period T [9, Chap. 2]. Although useful, the Floquet theory is limited in scope and yields few explicit results. 5.7

NONLINEAR EQUATIONS

A second direction of generalization is to consider equations or systems which have terms in which the unknown functions appear with exponent different from 1. Such equations are termed nonlinear equations. (Examples 2, 4, 6, and 7 are nonlinear equations.) In some rough sense, most equations are nonlinear. More precisely, the class of linear equations is highly specialized. As this suggests, there are many applications in which we must deal with nonlinear equations. Among these applications is celestial mechanics, which was the motivation for the remarkable work of PoincareÂ and Lyapunov. Later impetus for study came from the intensive study of radio circuits, which began in the 1920s. More recent applications have arisen in chemistry and biology: for example, population models and mathematical descriptions of electrically excitable cells (neurons, cardiac components). These applications have inspired a lot of study of nonlinear differential equations in the last hundred years. But although tremendous strides have been made in our knowledge, the

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results remain somewhat fragmentary. There is no general theory like that for linear systems, which is embodied in the variation-of-constants formula. That is, we have no convenient general formulas which automatically yield solutions. There are, of course, many special cases which can be dealt with, such as Examples 2, 4, 6, and 7. But all of these examples satisfy some very special hypotheses. (Examples, 2, 4, 6, and 7 were all ®rstorder equations.) Besides the lack of general formulas for the solutions of nonlinear equations, there is another serious complication which arises in nonlinear equations. We have seen that the solutions of linear equations with constant coef®cients are de®ned for all values of the independent variable, i.e., the domain of the solution includes all the real numbers. (The reason for this is that each component of each solution consists of a sum of terms of the form ctk eaibt where a, b, c and k are constants.) However, even a very simple example reveals the unpleasant fact that there may be strong limitations on the domain of the solution of a nonlinear equation. Example 28.

Find the solution of

dx x2 dt such that x0 1. (Since the dependent variable x appears with exponent 2, this equation is certainly nonlinear.) Solution: using separation of variables, we have dx dt x2 1 tC x 1 x tC 1 x0 1 C Therefore C 1 and xt 1=t 1. But then xt is de®ned for t < 1; however, as t approaches 1, the solution xt increases without bound. 5.7.1

Classical Techniques

By the end of the 1800s, mathematicians had, largely by struggling with nonlinear equations in celestial mechanics, become aware of the deep problems inherent in the study of nonlinear equations. The result was that various techniques were introduced which are


used to investigate different aspects or properties of solutions. Our next step is to describe brie¯y some of these techniques. 5.7.1.1 Perturbation Theory One of the oldest techniques for dealing with nonlinear equations is the perturbation method. The basic idea of the perturbation method is to represent the problem as a simple problem which is perturbed by the addition of a small but more complicated term. For example, the equation d 2x x "x3 0 dt2 where " is a small parameter is a special case of Duf®ng's equation, which arises in nonlinear mechanics. The unperturbed equation is d 2x x0 dt2 which is by now a familiar equation and easy to solve. The idea is then to look for solutions of the perturbed equation near solutions of the unperturbed equation. This idea is the basis for a large amount of important theory. It was developed extensively by PoincareÂ in his studies of celestial mechanics and used widely in studies of radio circuitry in the 1920s. It is also widely used in other ®elds: sound, mechanics, and quantum mechancis. However, a description of the subject is far beyond the reach of this chapter. (For an interesting introductory discussion of perturbation theory, see Ref. 10, Chap. 25; see also Ref. 9, Chap. 7, and Ref. 11.) 5.7.1.2 PoincareÂ±Bendixson Theory The geometrical viewpoint was developed largely by PoincareÂ and has been used and extended ever since. The most complete development is for systems of the form dx Px; y dt dy Qx; y dt

NL

Let us assume that P and Q have continuous partial derivatives of second order for all x; y. Each solution of the system is a pair of functions xt; yt which describes a curve in the xy-plane. From the standard existence and uniqueness theorem is follows that there is one such curve through each point in the xy-plane. Thus no two curves intersect each other and no curve crosses itself. To get an idea of how the curves behave


109

we use a viewpoint introduced earlier in the study of ®rst-order equations (see Example 10). If a solution curve passes through a point x0 ; y0 , then the slope of the curve at x0 ; y0 is dy dy=dt Qx0 ; y0 dx dx=dt Px0 ; y0 Thus we can associate with each point x0 ; y0 an arrow which indicates the slope of the curve at x0 ; y0 . As earlier, if enough of these arrows are sketched, then a picture of the solution curves begins to emerge. This picture becomes clearer if we investigate the solutions which are single points. Suppose y is a point such that x; y Qx; y 0 Px; Then the pair of constant functions xt x for all t yt y is a solution of (NL). Such a single-point solution is called a critical point, a singular point, or an equilibrium point. The behavior of solutions near the critical point can be determined if the determinant of the matrix 2 3 @P @P x; y x; y 6 @x 7 @y 7 M6 4 @Q 5 @Q y y x; x; @x @y is nonzero. The solutions of the linear approximation to (NL), i.e., the system dx=dt x M LA dy=dt y can be described in detail and these results can then be used to obtain considerable information about the y of the system (NL). Here we will solutions near x; y of the solujust describe brie¯y the behavior near x; tions of (LA). If both the eigenvalues of M (i.e., both the solutions of the quadratic equation detM

I 0

y move are positive, all the solutions of (LA) near x; y. Typical such behavior is shown in away from x; Fig. 2(a). If both the eigenvalues are negative, all the y move toward x; y as indicated solutions near x; typically in Fig. 2(b). If one eigenvalue is positive and the other negative, the behavior is more compli y, cated. Most of the solutions move away from x; y. Such an equilibrium but two of them approach x;


Figure 2

point is called a saddle point; a typical saddle point is shown in Fig. 2(c). If the eigenvalues are complex, then since the entries in matrix M are real the two eigenvalues will be complex conjugates a ib and a ib. If a y > 0 a < 0 the solutions spiral outward from x; y] as shown in Fig. 2(d) [(e)]. If [inward toward x; a 0, the solutions describe closed curves as shown in Fig. 2(f). The analysis by which these pictures are obtained is quite simple [9, Chap. 3]. But other seemingly simple questions present more serious problems. Having used the equilibrium points to help get a picture of the solution curves, we turn to a question which arises very often in applications: Does the system (NL) have a periodic solution? In geometrical terms, this question becomes: Is there a solution which describes a closed curve? A solution xt; yt describes a closed curve if there is a number T such that for all t xt T; yt T xt; yt An answer to this question is given by the PoincareÂ± Bendixson theorem which can be stated informally as follows. If xt; yt is a solution of (NL) with the following properties:

110

1.

2.

Cronin

For t beyond some value, the solution xt; y t is bounded. (More precisely, there is a value t0 and a positive number M such that if t t0 , then jxjtj jytj M.) y is an equilibrium point of (NL), then If x; y as t xt; yt does not approach x; increases without bound. [More precisely, there is a disc D in the xy-plane with center x; and a value t1 , such that if t > t1 , then xt; y yt is outside D.]

Then either: 1. 2.

xt; yt is a periodic solution, or xt; yt spirals toward a periodic solution as indicated in Fig. 3.

The PoincareÂ±Bendixson theorem is intuitively very reasonable. Roughly speaking, it says that if a solution is bounded and does not `pile up' on an equilibrium point, then either D `piles up' on a periodic solution or is itself a periodic solution. However, a rigorous proof of the theorem is surprisingly complicated. Some of the geometrical theory described above for the system (NL) can be extended to systems of n equations where n > 2. Generally speaking, studying the solution curves in n-space turns out to be a fruitful approach for many problems. But it has drawbacks. If n > 3, we lose the possibility of completely visualizing the solution curve. Also the PoincareÂ±Bendixson theorem is no longer valid if n > 2. 5.7.1.3

Stability Theory

The equilibrium points of (LA) described in the preceding section illustrate the simplest aspects of the concept of stability, a subject largely developed by the great Russian mathematician Lyapunov. Speaking informally, we say that a solution of a differential equation is stable if every solution which gets close to the solution stays close to the solution. The solution is asymptotically stable if every solution which gets close

to the solution actually approaches the solution. If neither of these conditions holds, the solution is unstable. The equilibrium points in Fig. 2(b) and (e) are asymptotically stable; the equilibrium points in Fig. 2(a), (c), and (d) are unstable. The equilibrium point in Fig. 2(f) is stable. For applications, stability is a very important property because in many cases we can expect that only the solutions which have some stability will predict the actual behavior of the physical system that is modeled by the differential equations. The reason for this is that the physical system is often subject to small disturbances which are not included in the description given by the differential equation. Such disturbances can be interpreted as `kicking' the system a small distance from the solution that the system is òn.' If the system were at equilibrium and described by one of the asymptotically stable equilibrium points, then after a `kick' the system would tend to return to the equilibrium point. But if the equilibrium point were unstable then after even a very small `kick,' the system would tend to move away from the equilibrium point. Stability theory has been studied extensively for many years, and a good deal of theory has been developed. Here we will merely point out one fundamental results for linear systems. Let dx Ax dt be a linear homogeneous system with constant coef®cients. Then the solution x 0 has the following stability properties: if the eigenvalues of A all have negative real parts, then x 0 is asymptotically stable; if at least one eigenvalue of A has positive real part then x 0 is unstable; if all the eigenvalues of A are pure imaginary, then x 0 is stable but it is not asymptotically stable. These results can be proved by looking at the fundamental matrix etA PetJ P

1

which we discussed earlier. 5.7.2

Figure 3


Modern Techniques

More recent approaches to the study of nonlinear equations include qualitative or topological studies and chaos theory. The topological studies, which use results such as ®xed point theory, had their start in the work of PoincareÂ and Lyapunov. They provide useful informa-


tion about the existence and properties of solutions and are a useful complement to the more conventional studies. However, a description of topological techniques is beyond the scope of this chapter. The basic idea of chaos theory lies in the following observation. We consider a system of nonlinear equations: dx1 f1 x1 ; . . . ; xn dt ... dxn fn x1 ; . . . ; xn dt with n 3, in which all the functions f1 ; . . . ; fn are fairly simple and are `well behaved' (say, have derivatives of all orders) so that the usual existence and uniqueness theorems are applicable. Then it may happen that the solutions of the system display complicated behavior and also that solutions which have almost the same initial condition may behave very differently. This observation was already formulated by PoincareÂ before 1900 but it did not receive the attention it deserved until the advent of computers which made possible extensive and detailed numerical studies. The nummerical studies illustrate vividly the complicated and disorderly solution behavior which sometimes occurs. This behavior is called deterministic chaos. A particularly striking example of deterministic chaos is displayed by the solutions of the famous Lorenz system of three nonlinear differential equations. A meterological model, the Lorenz system was introduced and studied in the 1960s. 5.8

NUMERICAL OR COMPUTER ANALYSIS

There are many software programs which can be used to obtain accurate numerical approximations to the solutions of a given differential equation. Such numerical analysis can be used even if one has no idea how to analyze the differential equation by using one of the techniques described earlier. Moreover, even if one of those techniques can be applied there is, sooner or later, numerical analysis that must be carried out. An example would be to ®nd the solutions of an n-dimensional homogeneous linear system dx Ax dt where n is not small, e.g., n 11. To ®nd the eigenvalues, one must ®nd the solutions of a polynomial equa-


111

tion of degree 11. Also the eigenvectors must be calculated, and ®nally one must calculate Petj . If the linear equation is inhomogeneous, then if the variation-of-constants formula is used, we must also calculate an integral, which calculation may itself be a nontrivial chore. In some important applications, we are wholly dependent on the use of numerical techniques. For example, the orbits of satellites are determined accurately by numerical calculations of the solutions of the appropriate differential equations. In view of these remarks, the natural question that arises is: Why not just `put the differential equation on the computer' rather than attempt to use one of the ``pencil-and-paper'' techniques that we described earlier? This is a valid question and deserves a detailed answer. Before attempting to answer this question, we discuss a little further the kind of results that can be obtained by using a computer program. We have already referred to the numerical approximations to solutions that can be obtained with the computer. In addition some software programs (e.g., Maple [4]) do symbolic work, i.e., the program can be used to obtain a formula for the general solution. Thus we have a quick way to solve the differential equation provided that the equation can be treated symbolically by the program. On the other hand, the program may not have the resources to deal with a given differential equation even though the differential equation has a closed solution, i.e., a solution which can be represented explicitly or implicitly in terms of known functions. Then the computer program can be used only to obtain a numerical approximation to a solution of the differential equation. Thus if one is confronted with a differential equation, the ®rst step is to try to apply whatever penciland-paper techniques one knows; then, if this fails, to seek a formula for the solution by using the symbol resources of whatever computer program is available. If neither of these directions yields the desired solution, then one must make a decision whether to search further for a pencil-and-paper technique or settle for a numerical approximation to the solution which can be obtained from the computer. The further search for a pencil-and-paper method can be started by consulting a textbook such as Ref. 5 and then continued in the collections of differential equations [6±8]. This procedure may yield a closed solution. But the danger is that time may be invested in a vain search.

112

On the other hand, the numerical approximation is not a wholly satisfactory description of the solution. Also the computer analysis yields only information about single solutions of the differential equation. Little or no information is obtained about the structure of the set of solutions. For example, the stability properties of the solutions remain unknown. An example of this is shown in the study of differential equations which model electrically excitable cells (nerve ®bers, neurons, cardiac ®bers). These differential equations are messy-looking nonlinear systems, and their study has been largely limited to numerical studies. However, an analytical study of some of these equations reveals that the structure of the set of solutions of the differential equation is quite simple, surprisingly so in view of the appearance of the equations.

REFERENCES 1. Mathematical Tables from Handbook of Chemistry and Physics. 10th ed. Cleveland: Chemical Rubber Publishing Co., 1954.


Cronin 2. HB Dwight. Tables of Integrals and Other Mathematical Data. 4th ed. New York: Macmillan, 1961. 3. W Grobner, N Hafreiter. Integraltafel: erste Teil, Unbestimmte Integrale; zweiter Teil, Bestimmte Integrale. Wien: Springer-Verlag, 1965. 4. Maple U Release 4, copyright 1981±1996 by Waterloo Maple Inc. 5. CH Edwards Jr, DE Penney. Elementary Differential Equations with Boundary Value Problems. 2nd ed. Englewood Cliffs, NJ: Prentice-Hall, 1989. 6. E Kamke. Differentialgleichungen LoÈsungsmethoden und LoÈsungen. Band 1, GewoÈhnliche Differentialgleichungen, 3. Au¯age. New York: Chelsea Publishing Company, 1959. 7. GM Murphy. Ordinary Differential Equations and Their Solutions. New York: Van Nostrand, 1960. 8. AD Polyanin, VF Zaitsev. Handbook of Exact Solutions for Ordinary Differential Equations. Boca Raton, FL: CRC Press, 1995. 9. J Cronin. Differential Equations: Introduction and Qualitative Theory, 2nd ed. New York: Marcel Dekker, 1994. 10. MD Greenberg. Foundations of Applied Mathematics. Englewood Cliffs, NJ: Prentice-Hall, 1978. 11. RE O'Malley Jr. Singular Perturbation Methods for Ordinary Differential Equations. New York: SpringerVerlag, 1991.

Chapter 1.6 Boolean Algebra Ki Hang Kim

Alabama State University, Montgomery, Alabama

6.1

INTRODUCTION

that is, a_0a

The theory of Boolean algebra is relatively simple but it is endowed with an elegant structure and rich in practical applications. Boolean algebra is named after the British mathematician George Boole (1815±1864). For Boole's pioneering work, see Refs 1 and 2. Boolean algebras have been extensively studied by SchroÈder [3], Huntington [4], Birkhoff [5], Stone [6], Halmos [7], Sikorski [8], and Hohn [9]. In this chapter, we present a concise summary of Boolean algebra and its applications. A Boolean algebra is a mathematical system ; _; ^ consisting of a nonempty set fa; b; c; . . .g and two binary operations _ (vee) and ^ (wedge) de®ned on such that: b1 .

b5 .

b3 .

Notice that there exists a complete symmetry in the postulates b1 b5 with respect to the operations _ and ^ and also in the identities of b4 . Therefore, we can state the following principle: Principle of Duality. If in any statement deduced from the ®ve postulates b1 b5 we interchange _ and ^, and 0 and 1, then we obtain a valid statement.

Both operations are commutative; that is,

Example 1. Let S fa; bg, a < b. We de®ne a _ b supfa; bg and a ^ b inffa; bg. (Accordingly, we can also de®ne the operations as a _ b maxfa; bg and a ^ b minfa; bg.) The tables for these operations are as Tables 1 and 2 . Clearly S; _; ^ is the simplest and most fundamental nontrivial Boolean algebra.

a^bbâ

Each operation is distributive with respect to the other; that is, a _ b _ c a _ b ^ a _ c a ^ b _ c a ^ b _ a ^ c

b4 .

contains an identity element 0 with respect to _ and an identity element 1 with respect to ^;

Example 2. Let D be the set of positive integral divisors of 6: that is, D f1; 2; 3; 6g. For all a, b 2 D, we 113


a ^ a 0

The element a is called a complement of a.

Both operations are associative; that is

a_bb_a

The element 0 is called the zero element and the element 1 is called the unit (or universal) element, respectively, of . For each a 2 , there exists an element a 2 such that a _ a 1

a _ b _ c a _ b _ c a ^ b ^ c a ^ b ^ c b2 .

a^1a

114

Kim Table 1 Multiplication for _ _

a

b

a a

a b

b b

^ is a Boolean algebra. The veri®cation is left as an exercise.

Table 2 Multiplication for ^ ^

a

b

a b

a a

a b

Four-Element _ Multiplication Table

_

a

b

c

d

a b c d

a b c d

b b d d

c d c d

d d d d

Table 6 Four-Element ^ Multiplication Table

de®ne a _ b and a ^ b to be respectively the least common multiple (lcm) and greatest common divisor (gcd) of a and b. In other words, a _ b lcm fa; bg and a ^ b gcd fa; bg. The tables for these operations are Tables 3 and 4. Table 3 Lowest Common Multiple Multiplication Table _

1

2

3

6

1 2 3 6

1 2 3 6

2 2 6 6

3 6 3 6

6 6 6 6

Table 4 Greatest Common Divisor Multiplication Table ^

1

2

3

6

1 2 3 6

1 1 1 1

1 2 1 2

1 1 3 3

1 2 3 6

A quick inspection of these tables yields the fact that the integer 1 plays the role of the zero element and the integer 6 plays the role of the unit element and the tables also yield the various complements as follows: for all a 2 D, a 6=a; 1 6, 2 3, 3 2, 6 1. Therefore, D; _; ^ is a Boolean algebra. Example 3. Let S fa; b; c; dg together with the operations de®ned in Tables 5 and 6. The system S; _;


Table 5

^

a

b

c

d

a b c d

a a a a

a b a b

a a c c

a b c d

Example 4. Let PX be the power set of a nonempty, ®nite set X. Then PX; [; \ is a Boolean algebra, taking _ and ^ as [ and \, respectively. Take ``±'' as complementation relative to X, 0 ;, 1 X, respectively. Therefore, the operations _ and ^ may be denoted by [ and \, respectively. In®nite Boolean algebras are not used much in the theory of switching circuits but do occur in other areas of mathematics such as measure theory, logic, probability, and topology. Since we are mainly interested in the applications of Boolean algebras, we will only concentrate on ®nite Boolean algebras. The simplest in®nite Boolean algebras are in®nite Cartesian products of f0; 1g. These act almost identically to ®nite Boolean algebras. Example 5. All measurable subsets of the real numbers form a Boolean algebra which allows not only ®nite union and intersection but also countable union and intersection. Example 6. All sets obtained from the open and closed sets of a topology by ®nite union and intersection form a Boolean algebra. Example 7. Given any set, a Boolean algebra is obtained by taking all its ®nite subsets and all the complements of ®nite subsets.

Boolean Algebra

115

We now present another characterization of Boolean algebra. For a comprehensive treatment of lattice theory, see Birkhoff [5]. A lattice is a mathematical system L; _; ^ consisting of a nonempty set L fa; b; c; . . .g and two binary operations _ (join) and ^ (meet) de®ned on L such that: l1 . l2 . l3 .

Associativity:

a _ b _ c a _ b _ c, a ^ b ^ c a ^ b ^ c: Commutativity: a _ b b _ a; a ^ b b ^ a: Absorption: a _ a ^ b a, a ^ a _ b a:

If in addition the distributive law: l4 .

a _ b ^ c a _ b ^ a _ c, a ^ b _ c a ^ b _ a ^ c holds, then L is called a distributive lattice.

L is said to be modular if and only if l5 .

a ^ b _ a ^ c a ^ b _ a ^ c:

Since l1 l3 hold in every Boolean algebra, every Boolean algebra is a lattice. Example 8. Let X f1; 2; 3g. Then PX f;; f1g; f2g; f3g; f1; 2g; f2; 3g; f1; 3g; Xg. The subset lattice of PX is shown in Fig. 1. Example 9. Let PX be the same as in Example 4. Then PX; _; ^ is a lattice. As a consequence of the above example the operations _ and ^ are frequently interchanged with settheoretical `ùnion'' (lattice-theoretical ``join'') and set-theoretical `ìntersection'' (lattice-theoretical ``meet''), respectively. However, some authors use ``+'' (addition and ``'' (multiplication) instead of _ ([) and ^ \, respectively. For brevity and simplicity, from now on we use ``+'' instead of _ and ``'' instead of ^, respectively. Furthermore, we usually suppress the dot ``'' of a b and simply write ab. We list some important properties of Boolean algebras which can be deduced from the ®ve postulates b 1 b5 . p1 . p2 . p3 . p4 . p5 . p6 .

The identities 0 and 1 are unique. Idempotency: for a 2 ; a a a; aa a. Dominant element: for a 2 , a 1 1, a0 0. Absorption: for a, b 2 , a ab a, aa b a. Complementation: 0 1; 1 0. Every a 2 has a unique complement.


Figure 1 Subset lattice of Pf1; 2; 3g.

p7 . p8 .

Involution: for a 2 ; a a. De Morgan's law: for a, b 2 , a b ab, ab a b.

A ring is called Boolean if all of its elements are idempotent under the second operation. Example 10. The ring of integers modulo 2, Z2 ; ; is a Boolean ring, since 0 0 0 and 1 1 1. Example 11. The ring PX; ; \ of subsets of a nonempty set X is a Boolean ring, where is the symmetrical difference of sets. The veri®cation is left as an exercise.

6.2

BOOLEAN FUNCTION

Let fx1 ; x2 ; . . . ; xn g be a Boolean algebra. A constant of is any symbol, such as ``0'' and ``1'', which represents a speci®ed element of . A variable is any symbol which represents an arbitrary element of . In the expression x1 x2 x3 we call x1 and x2 x3 monomials and the entire expression x1 x2 x3 a Boolean polynomial. Any expression such as x1 x2 , x1 x3 , x1 x2 x3 consisting of a ®nite number of elements of will be called a Boolean function and we will denote it by f x1 ; x2 ; x3 (for short f ). For example, x1 x2 x2 x3 x4 is a function of four variables x1 ; x2 ; x3 ; and x4 . A Boolean polynomial is said to be in disjunctive normal form (or canonical form) if it is a sum of monomials in which each variable or its complement appears exactly once.

116

Kim

Example 12. form

This polynomial is in disjunctive normal

f x 1 x2 x 3 x 1 x 2 x3 x1 x2 x3 In disjunctive normal form of a function f, a given monomial M will appear if and only if the function f is 1 when we make xi 1 whenever xi appears in M and xi 0 whenever x i appears in M. Example 13. In the above example the ®rst monomial is 1 provided x1 0; x2 1; x3 0. For then all of x 1 , x2 , x 3 are 1 and so is their product. But in all other cases at least one variable is zero and the product is zero. This argument shows that the disjunctive normal form is unique, and moreover that it exists since if we add one monomial to M whenever the function is 1 at some set of xi values then we get a function equal to that function at each set of xi values. Example 14. Suppose f has the truth table of Table 7. Then f 1 at the three triples 0; 0; 0, 0; 1; 0, and 0; 1; 1. Add the corresponding monomials to get f x 1 x 2 x 3 x 1 x2 x 3 x 1 x2 x3 We can also obtain the disjunctive normal form for general polynomial by expanding products of polynomials and replacing absent variables in monomials by xi x i . Example 15. Suppose f x1 x2 x 1 x3 Expand the products to get x1 x2 x3 . Now f x1 x 1 x2 x 1 x1 x3 x2 x3 x1 x2 x1 x3 . and combine terms to get x1 x 1 0, f x2 x 1 x1 x3 x2 x3 x1 x2 . Now since x3 is missing in the ®rst term, and x3 x 3 1, rewrite it as x 1 x2 x3 x 3 . Do the same for other terms: Table 7 Truth Table of Boolean Function f x1

x2

x3

f

0 0 0 1 1 1 0 1

0 0 1 0 1 0 1 1

0 1 0 0 0 1 1 1

1 0 1 0 0 0 1 0


x 1 x2 x3 x 3 x1 x2 x 2 x3 x1 x 1 x2 x3 x1 x2 x3 x 3 x 1 x2 x3 x 1 x2 x 3 x1 x2 x3 x1 x 2 x3 x1 x2 x3 x 1 x2 x3 x1 x2 x3 x1 x2 x 3 x1 x2 x3 x 1 x2 x3 x 1 x2 x 3 x1 x 2 x3 x1 x2 x 3 With n variables, the number of monomials is 2n , since for each variable we have two choices: complement it or not, give choices on previous variables. This means a Boolean function is determined by its 2n coef®cientsn which can each be 0 or 1. This means that there are 22 Boolean functions of n variables. Example 16. In two variables, there are 22 4 monomials: x1 x2 , x1 x 2 , x 1 x2 ; x 1 x 2 , and 24 16 functions. The conjuctive normal form is dual to the disjunctive normal form. It is a product of sums S such that each variable or its complement occurs just once as a summand in S. Example 17.

This is in conjunctive normal form

x1 x2 x 3 x 1 x2 x3 In the conjunctive normal form, if xi appears in a factor then set xi 0, if x i appears set xi 1. Then the factor and hence the whole expansion is zero. This indicates that a given factor appears in the conjunctive normal form for a function f if and only if when we make this substitution the function is zero. By considering those values which make f zero, we can expand any function in conjunctive normal form. Suppose f has the same values as in Table 7. Then f is zero at the triples 0; 0; 1, 1; 0; 0, 1; 0; 1, 1; 1; 0, 1; 1; 1. Therefore f is the product x1 x2 x 3 x 1 x2 x3 x 1 x2 x 3 x 1 x 2 x3 x 1 x 2 x 3 We may also expand the function using the dual distributive law and replacing summands 0 by xi x i . Example 18. Let f x1 x2 x 1 x3 x1 x2 x3 : f x1 x2 x 1 x3 x1 x1 x2 x 1 x3 x2 x3 x1 x2 x1 x 1 x3 x1 x1 x2 x2 x3 x 1 x3 x2 x3 x1 x2 1x1 x2 x3 x 1 x2 x3 x1 x2 x3 x 3 x1 x2 x3 x 1 x2 x3 x1 x2 x3 x1 x2 x 3 x 1 x2 x3

Boolean Algebra

117

Still another way to obtain the conjunctive normal form of f is to obtain the disjucntive normal form of f and take its dual. Example 19. Let f be as in the Example 14. The disjunctive normal form of f is x 1 x 2 x3 x1 x 2 x 3 x1 x 2 x3 x1 x2 x 3 x1 x2 x3 . Then f is its complement, a product of one factor for each summand in f. The summand x 1 x 2 x3 goes to x 1 x 2 x3 x1 x2 x 3 and so on. This gives once again the product x1 x2 x 3 x 1 x2 x3 x 1 x2 x 3 x 1 x 2 x3 x 1 x 2 x 3

6.3

SWITCHING FUNCTIONS

Shannon [10] was the ®rst one to apply Boolean algebra to digital circuitry. For an excellent account of the switching functions, see Hohn [11] and Dornhoff and Hohn [12]. In two-state circuits, a switch or contact may be in the open state or in the closed state. With an open contact (or open path) in a circuit we assign the symbol ``0'' and with a closed contact (or closed path) we assign the symbol ``1.'' That is, we assign the value 1 or 0 to any circuit according as current does or does not ¯ow through it. Therefore, we can construct a two-element Boolean algebra, which is also known as switching algebra as follows. Example 20. Let 0 f0; 1g. We de®ne +, by Tables 8 and 9. This system has applications in both switching theory and the algebra of propositions, where 0 is ``false'' and 1 is ``true.'' Table 8

Addition Table for 0

0

1

0 1

0 1

1 1

Table 9 Multiplication Table for 0 0

1

0 1

0 0

0 1

Let fx1 ; x2 ; . . . ; xn g where xi is either 0 or 1 for every i. Then the Boolean function 0 f x1 ; x2 ; . . . ; xn 1 is called a switching function. Example 21. Let x and y be the circuit variables which apply to a two-terminal circuit consisting of two contacts x and y. Thus, we have the parallel and series connection, shown in Figs. 2 and 3. The two circuits can be represented by switching functions (Table 10). The disjunctive normal form gives a way to represent any Boolean function by a switching circuit. z x yz xyz. This is Example 22. Let f x; y; z xy represented by Figs. 4 and 5 . In general, we have one series circuit for each monomial and then put all those circuits in parallel. However, in very many cases, this form will not be the simplest form. Example 23. The function f x; y; z x yz in dis xy z xyz, junctive normal form is xyz xyz xyz Table 10 Circuits

Values of Switching

x

y

xy

xy

0 1 0 1

0 0 1 1

0 1 1 1

0 0 0 1

Figure 2 Parallel connection: x y.


118

Kim

Figure 3 Series connection: xy.

as shown in Fig. 6, but the original function is as shown in Fig. 7, which is simpler. The terms appearing in the disjunctive normal form are known as minterms. In realizing Boolean functions by switching circuits, it is important to have as few switches as possible in order to save money, space, and time.

Figure 5 Second switching circuit for f x; y; z:

The basic way of simplifying an expression is to replace Mxi M x i by M where M is a monomial. A product P z1 z2 . . . zk of variables and complements which implies a function f is called an implicant of f . This is equivalent to P f or P f f . An implicant is prime if no subproduct of P is also an implicant. Example 26. implicant.

Any term of a Boolean polynomial is an

Example 27. x1 x2 is an implicant of x1 x2 x1 x 2 which is not prime, and x1 is an implicant which is prime. Figure 4 First switching circuit for f x; y; z.

We may consider minimizing a representation of a Boolean function as a sum of products of variables and its complements. We say that one polynomial P1 is shorter than another polynomial P2 if (1) P1 has no more terms than P2 , and (2) P1 has fewer total appearances of variables than P2 . Example 24. minimal.

x1 x2 x1 x 2 x1 so the former is not

Example 25. x1 x 2 x2 x 3 x3 x 1 x 1 x2 x 2 x3 x 3 x1 so minimal forms need not be unique.

Any minimal expression for a Boolean function f must be a sum of prime implicants, otherwise we can replace any nonprime implicant by a subproduct and get a shorter expression. Quine's method of ®nding prime implicants is ®rst to write in a column the terms in the disjunctive normal form of f . Examine each term to see whether it can be combined with a term below, i.e., the two terms differ by complementing a single variable. If so, check it and the term below and write the shortened term in a second column. Then repeat this procedure for the second and later columns. Example 28. Consider the Boolean polynomial with disjunctive normal form x1 x2 x3 x1 x 2 x3 x1 x2 x 3 x1 x 2 x 3 x 1 x2 x3 . The ®rst column is

Figure 6 Switching circuit before simpli®cation.


Boolean Algebra

119 Table 12 Computation of Prime Implicants, Third Stage

Figure 7

x1 x2 x3 p x1 x 2 x3 p x1 x2 x 3 p x1 x 2 x 3 p x 1 x2 x3 p

Switching circuit after simpli®cation.

x1 x2 x3 x1 x 2 x3 x1 x2 x 3

x1 x3 p x1 x2 p x2 x3 x1 x 2 p x1 x 3 p

x1

Next we give an example where not all prime implicants are used. Example 30. Let f x1 x2 x 3 x1 x 2 x3 x 1 x2 x3 x1 x 2 x 3 x 1 x2 x 3 x 1 x 1 x3 . Then the monomials are

x1 x 2 x 3 x 1 x2 x3 The ®rst term combines with the second to give x1 x3 , with the third to give x1 x2 , with the ®fth to give x2 x3 . The second combines with the fourth to give x1 x 2 . The third combines with the fourth to give x1 x 3 . So the new table is Table 11. In the second column, x1 x3 combines with x1 x 3 to give x1 , x1 x2 combines with x1 x 2 to give x1 . This gives Table 12. Then the unchecked terms are the prime implicants of f. Their sum is one formula for f, x1 x2 x3 , which in this case is minimal. In general, a shortest formula will use some but not all of the minimal implicants. To determine this we form a table with rows labeled by prime implicants and columns labeled by terms in the disjunctive normal form (Table 13). We put a ``T'' in a cell when the prime implicant implies the disjunctive term. Example 29. Now choose as few rows as possible such that every column has a check. Here we need both x1 and x2 x3 . For n large, these procedures will typically grow exponentially in the amount of time and space required to carry them out and in fact the last part of this method is an example of an NP-complete problem. Table 11 Computation of Prime Implicants, Second Stage x1 x2 x3 p x1 x 2 x3 p x1 x2 x 3 p x1 x 2 x 3 p x 1 x2 x3 p


x1 x3 x1 x2 x2 x3 x1 x 2 x1 x 3

x1 x2 x 3 x1 x 2 x3 x 1 x2 x3 x1 x 2 x 3 x 1 x2 x 3 x 1 x 2 x3 The ®rst combines with the fourth to give x1 x 3 , with the ®fth to give x2 x 3 . The second combines with the fourth to give x1 x 2 and with the sixth to give x 2 x3 . The third combines with the ®fth to give x 1 x2 and with the sixth to give x 1 x3 . So we have Table 14 (see pg. 120). All the second column are prime implicants (Table 15, see pg. 120). Any three disjoint rows give a minimal expression for f, x1 x 3 x 2 x3 x 1 x2

or x2 x 3 x1 x 2 x 1 x3

In practice often some values of Boolean functions are not important, for instance those combinations may never occur. These are called ``don't cares.'' They are dealt with by listing them when ®nding the prime implicants, but not in Table 15. Example 31. Suppose we add x1 x2 x3 as a don't care in Table 14 (Table 16, see pg. 120). Then across the top we list all but the last don't care (Table 17, see pg. 120). So x1 x2 x3 is the minimal Boolean polynomial. Table 13 Computation of Shortest Formula

x1 x2 x3

x1 x2 x3 p p

x1 x 2 x3 p

x2 x2 x 3 p

x1 x 2 x 3 p

x 1 x2 x3 p

120

Kim Table 14 Computation of Prime Implicants x1 x2 x 3 p x1 x 2 x3 p x 1 x2 x3 p x1 x 2 x 3 p x 1 x2 x 3 p x 1 x 2 x3 p

6.4

Table 16 Computation of Prime Implicants with ``Don't Care'' p p x1 x 3 p x1 x1 x2 x 3 p x2 x 3 p x2 x1 x 2 x3 p x1 x2 p x3 x 1 x2 x3 p x1 x 2 x 3 p x1 x 1 p x 1 x2 x 3 p x 2 x3 p x 1 x 2 x3 p x1 x3 p x1 x2 x3 x 1 x2 p x 1 x3 p x2 x3

x1 x 3 x2 x 3 x1 x 2 x 2 x3 x 1 x2 x 1 x3

BOOLEAN MATRICES

Let BVn denote the set of all n-tuples v1 ; v2 ; . . . ; vn over 0 f0; 1g. An element of BVn is called a Boolean vector of dimension n. The system BVn ; ; is a Boolean algebra by de®ning operations as elementwise sums and products. For elementary properties of Boolean vectors, see Kim [13]. Example 32. Let 1; 0; 1; 0, 0; 0; 1; 1 2 BV4 . Then 1; 0; 1; 0 0; 0; 1; 1 1; 0; 1; 1 1; 0; 1; 00; 0; 1; 1 0; 0; 1; 0:

A subspace of BVn is a subset containing the zero vector 0; 0; . . . ; 0 and closed under addition of vectors. The span of a set S of vectors, denoted hSi, is the intersection of all subspaces containing S. Example 33 1. 2.

1. 2.

Logical product: A B aij bij : Complement: AC a ij :

Example 34.

Let U f0; 0; 0; 1; 0; 0; 0; 1; 0; 1; 1; 0; 0; 1; 1; 1; 1; 1g 2 BV3 . Then U is a subspace of BV3 . Let V f0; 0; 0; 1; 0; 0; 0; 0; 1; 1; 1; 0; 0; 1; 1; 1; 1; 1g 2 BV3 . Since 1; 0; 0 0; 0; 1 1; 0; 1 2 = BV3 , V is not a subspace of BV3 .

Table 15

x1 x 3 x2 x 3 x1 x 2 x 2 x3 x 1 x2 x 1 x3

By a Boolean matrix we mean a matrix over 0 . One can also de®ne a Boolean matrix over an arbitrary Boolean algebra. The Boolean matrices behave quite differently from matrices over a ®eld. Let Bmn denote the set of all m n Boolean matrices. If m n, we just write Bn . For a comprehensive treatment of Boolean matrices and their applications, see Kim 13: Boolean matrix addition and multiplication are the same as in the case of matrices over a ®eld except the concerned sums and products are over 0 . There are two other operations on Boolean matrices.

2

1 0

6 60 1 6 A6 60 0 4 1 1

Let 1 0 1 0

1

3

2

7 07 7 7 17 5 0

0

6 61 6 B6 60 4 0

0 1 0 0 1 1 0 1

0

3

7 17 7 7 2 B4 07 5 1

Determination of Minimal Expression for f

x1 x2 x 3 p p

x1 x 2 x3 p p

x 1 x2 x3

x1 x 2 x 3 p p

p p


x 1 x2 x 3 x 1 x 2 x3 p p

p p

Table 17 Omission of ``Don't Care'' to Find Shortest Formula

x1 x2 x3

x1 x2 x 3 p p

x1 x 2 x3 p p

x 1 x2 x3 p p

x1 x 2 x 3 p

x 1 x2 x 3 x 1 x 2 x3 p

p

Boolean Algebra

121

Then 2

1 0

6 60 1 AB6 60 0 4

1 0 1

1 1

0

1 0 6 61 1 6 60 1 4

1

1 1

1

1 0

1

2

2

6 60 1 AB 6 60 0 4 2

0 1

0 1

1 1

0

0 1

1

6 61 0 6 60 1 4

0 1

1 0

1

1 0 6 60 1 A B6 60 0 4

1

1 1

0

0 0 6 60 0 6 60 0 4

1

0 0

0

2

2

2

1 6 60 AC 6 60 4 1 2 1 6 60 AT 6 60 4

0 1

0 1

0

1

1

0

0

1

1

0

0

1

1

0

0

1

1 1

0

1

3

2

0 0

1

0

3

7 6 7 07 61 0 0 17 76 7 6 7 17 5 40 1 1 05 0 0 0 1 1 3 1 7 17 7 17 5 1 32 3 1 0 0 1 0 76 7 0 76 1 0 0 1 7 76 7 6 7 17 54 0 1 1 0 5 0 0 0 1 1 3 1 7 17 7 17 5 1 3 2 3 1 0 0 1 0 7 6 7 07 61 0 0 17 7 6 7 6 7 17 5 40 1 1 05 0 0 0 1 1 3 0 7 07 7 07 5 0 3C 2 3 1 0 1 0 0 7 6 7 61 0 1 17 07 7 6 7 61 1 0 07 17 5 4 5 0 0 0 1 1 3T 2 3 1 1 0 0 1 6 7 7 60 1 0 17 07 7 6 7 61 0 1 07 17 5 4 5 0 1 0 1 0

AT aji The inequality of Boolean matrices is de®ned by A B if and only if aij bij for all i; j. This is a partial order relation. Similarly, one can de®ne a strict partial order relation A < B if and only if A B and aij < bij for some i and j.


Example 35. Let 1 0 1 1 1 ; ; 0 1 0 1 1

1 2 B2 1

Then 1 1 1 1 0 1 1 1 1 0 1 1 < 0 1 0 1 The row space of A 2 Bmn is the span of the set of all rows of A. Similarly, the column space of A is the span of the set of all columns of A. Let RA CA denote the row (column) space of A. Example 36. Let 2 3 1 0 0 A 4 1 1 0 5 2 B3 1 0 1 Then RAf0; 0; 0;1; 0; 0;1; 1; 0; 1; 0; 1,1; 1; 1g; and CA f0; 0; 0T ; 0; 1; 0T ; 0; 0; 1T , 0; 1; 1T ; 1; 1; 1T g. Let A 2 Bmn . Then both RA and CA are lattices, respectively. The join of two elements is their sum and the meet of two elements is the sum of the elements of RA which are less than or equal to both elements. Certainly, 0 is the universal lower bound while the sum of all the elements of RA is the universal upper bound. Here 0 denotes the zero vector. Example 37. Let A be the same as in the above example (Figs. 8, 9 see pg. 122). For a binary relation from X fx1 ; x2 ; . . . ; xm g to Y fy1 ; y2 ; . . . ; yn g, we can associate a m n Boolean matrix A aij to each binary relation R by the following rule: 1; xi ; yj 2 R aij =R 0; xi ; yj 2 This gives a one-to-one correspondence between binary relations from X to Y and m n Boolean matrices. Under this correspondence unions of binary relations become Boolean matrix sums and compositions of binary relations become Boolean matrix products. Example 38. Let X f1; 2; 3; 4g and Y f1; 2; 3g. Let R f1; 2; 2; 3; 3; 1; 3; 2; 4; 3g. Then the Boolean matrix corresponding to R is

122

Kim

Figure 8 Lattice of RA.

2

0 60 A6 41 0

1 0 1 0

3 0 17 7 05 1

A directed graph (for short digraph) consists of points called vertices, and line segments with arrows from certain vertices to certain others. The line segments are called edges. A digraph represents a binary relation R from a set X to a set Y if its vertices are labeled to correspond to the elements of X and Y and an edge is drawn from x to y if and only if x; y 2 R. For an excellent treatment of digraph theory, see Harary et al. [14].

Figure 10 Digraph of a binary relation.

We give an application of Boolean matrices to switching circuits due to Hohn and Schissler [9]. Switching circuits can be drawn by a variety of graphs which cannot always be analyzed into parallel and series components. The question of analysis is: Given a circuit in graphical form, when will current ¯ow between any pair of points? Example 40. Consider Fig. 11. Here x, y, u, and v are switches. We are interested in current ¯ows among pairs of vertices, 1, 2, 3, and 4.

Example 39. Let X f1; 2; 3; 4; 5g and Y f1; 2; 3; 4g. Let R f1; 1; 1; 4; 2; 2; 2; 3,3; 1; 3; 4; 4; 3; 4; 4; 5; 1; 5; 4g. Then the digraph corresponding to R is shown in Fig. 10.

The primitive connection matrix of a graph with vertex set V is the jVj jVj matrix whose i; jentry is labeled with the product of all switches going between vertex i and vertex j (assumed to be in series). Its i; j-entries are 1. Here jVj denotes the cardinality of V.

Figure 9 Lattice of CA.

Figure 11 A general switching circuit.


Boolean Algebra

Example 41. Example 40 is 2 1 x 0 6x 1 0 6 40 0 1 y u v

123

The primitive connection matrix in 3 y u7 7 v5 1

Our goal is to produce a matrix representing whether current will ¯ow between any set of vertices in a subset S of V. An output matrix of a circuit has i; j-entry some Boolean polynomial P such that for each setting of all switches P is 1 if and only if current ¯ows between those vertices. To obtain an output matrix, we may ®rst remove all vertices outside the set S. To remove a vertex vr , delete its row and column and then to every remaining entry i; j add the product of the i; r- and r; j-entries in the original matrix. Example 42. If we remove vertex 4 from the above example we obtain 2 3 1 yy x yu vy M 4 x yu 1 uu uv 5 vy uv 1 vv Note that the matrix M so obtained is symmetrical and re¯exive M I where I is an identity matrix. We may by Boolean algebra simplify this to 2 3 1 x yu vy M 4 x yu 1 uv 5 vy uv 1 Now take the least power of this matrix which is idempotent M 2 M. The reason is that nth powers of matrices have entries representing all products of entries of length n walks in their graphs. For a re¯exive Boolean matrix, M n M n 1 . So this eventually gives all possible routes for the current to take between any two given points.

2

1

x yu uvy

vy uvx yuv

6 7 1 xvy yuvy uv 5 4 x yu uvy vy xuv yuv xvy yuvy uv 1 2 3 1 x yu vy uvx 6 7 4 x yu 1 uv xvy 5 vy uvx

uv xvy

1

This is the required output function. Given a required output, circuits may be synthesized by reversing this sequence of steps. However, there are a very great number of ways to synthesize a given circuit and it is not obvious which synthesis will have the fewest circuit components. One could synthesize any circuit by adding a new vertex for every term but one, in every off-main-diagonal 1 entry. For example, synthesize 1 xy uv M xy uv 1 We add a new vertex 3 so that m13 m12 is the second term uv of m12 (see Fig. 12). In the following we give an application of Boolean matrices to automata [15]. A ®nite-state machine consists of a ®nite set S (internal states), an initial state 2 S, a ®nite set X (input symbols), a ®nite set Y (output symbols), and functions f :SX !S

transition function

g:SX !Y

output function

A ®nite-state nondeterministic machine differs in that f and g are binary relations instead of functions. That is, the next state and output are not uniquely determined by the previous state. Nondeterministic machines are of interest even though their behavior is not completely predictable. Sometimes deterministic machines can be modeled by nondeterministic machines with fewer states.

For a re¯exive n-square Boolean matrix its n 1 power will equal all subsequent powers, this corresponds to any matrix being reachable from another by a path of length at most n 1 if it is reachable at all. Powers of large Boolean matrices can be computed rapidly by repeatedly squaring them. Example 43. Here it is enough to take the second power of the 3 3 matrix in the last example. That is,


3

Figure 12 Equivalent connection graph.

124

Kim

Example 44. We can produce a deterministic ®nitestate machine which will add two numbers of any number of digits where the input set X Y is fa; b : a, b 2 f0; 1; 2; . . . ; 9gg. The set of internal states is f0; 1g, the possible carries. The transition function calculates the next carry from the previous carry c and the two input states: f a; b; c

0 1

if a b c < 10 if a b c 10

The output function produces the next digit of the output. Any deterministic machine is also a nondeterministic machine. A semigroup is a set G together with an associative binary operation de®ned on G. The semigroup of a deterministic ®nite automaton is the set of all functions from S to S which are ®nite compositions of the functions fx s f s; x. Its operation is composition of functions. The semigroup of a nondeterministic ®nite automaton is the set of all binary relations from S to S which are ®nite compositions of the binary relations fx s f s; x from S to S, under the operation composition of binary relations. Example 45. The semigroup of the machine in Example 44 consists of the three monotone functions f0 ; f1 ; f2 ; f0; 1g to itself: f0 s 0; f1 s 1, f2 s s. For instance, if x 0; 0 we never have a carry, giving f0 . If x 9; 9 we always have a carry, giving f1 . If x 0; 9 then we have a carry if and only if the previous carry is 1, giving f2 . Semigroups of machines can be used to tell something about the number of states used to produce a given output. For example, we can show there is no machine analogous to the adder above which can do arbitrary multiplication. Suppose it has n states. Consider the product of the two numbers 10 . . . 01, 10 . . . 01 with n zeros. The output will be 10 . . . 020 . . . 01 with two sequences of n zeros. It will be output in reverse order, and the ®nal 0 . . . 01 occur when both inputs are 0. Given the state sn2 after the last 1's are input, the function f00 must have the property that f00 sn2 lies in a state yielding output 0 for j 1; 2; . . . ; n and in a state yielding output 1 for j n 1. However, there does not exist any such transformaj sn for j 1; 2; tion on a set of n states because f00 . . . ; n will realize all states that could possibly occur for higher powers.


We can more precisely describe the asymptotic behavior of any function f on a set of n elements as follows: there is an integer k called the index, which is at most n 1, and an integer d called the period, such that for any j k, f kd f k . The integer d must divide n!. There is also an index and a period for the set f k s for each s 2 S, and its period is at most n. Example 46. On f0; 1; . . . ; 9g consider the function such that f x x 1 if x 1 and f 0 2. This has index 7, since f 7 is the least power mapping the whole set into f0; 1; 2g where it cycles, and the period is 3, since f 2 1, f 1 0, f 0 2. Boolean matrices A also have an index k and a period d such that Ajd Aj if j d. For n-square Boolean matrices, the index is at most n 12 1 and the period is the period of some permutation on n elements, a divisor of n!. Example 47. 2

0 60 A6 40 1

Consider the Boolean matrix 1 0 0 1

0 1 0 0

3 0 07 7 15 0

Its powers are the semigroup of a machine de®ned as follows: S f1; 2; 3; 4g, X f0g, Y f1; 2; 3; 4g, f i; x contains the element j if and only if aij 1 and gi; x i. We have 2

0 60 6 A2 6 41 2

0 1

60 6 A8 6 41

A10

1 2 1 61 6 6 41 1

0 1 0 0 1 0 1 1 1 1

3 0 17 7 7 05

1 1 1 1

0 3 0 17 7 7 15 1 3 1 17 7 7 15

1 1

1

1 1 1 1 1 1 1 1

2

1 1 60 1 6 A4 6 40 0 1 1 2 0 1 61 1 6 A9 6 41 1 1 1

0 1 1 0 1 1 1 1

3 0 07 7 7 15 1 3 1 17 7 7 15 1

Then A10 equals all larger powers and the index is 10 4 12 1.

Boolean Algebra

Example 48. 2 0 60 6 A6 61 40 0

125

The 5 5 Boolean matrix 3 1 0 0 0 0 1 0 07 7 0 0 0 07 7 0 0 0 15 0 0 1 0

is the direct sum of a 2-cycle and a 3-cycle. It can be made into the semigroup of a nondeterministic machine in the same way. Its period is the least common multiple of 2, 3, or 6.

6.5

GENERALIZATION OF BOOLEAN ALGEBRA

The two-element Boolean algebra 0 f0; 1g only expresses two extreme or opposite relationships such as ``negative'' and ``positive,'' ``no'' and ``yes,'' `òff'' and `òn,'' and ``false'' and ``true.'' Thus, in order to express degrees of relationships, we introduce a new algebra known as an incline algebra to expand 0 to a closed unit interval 0; 1. For a detailed account of incline algebra, see Cao et al. [16]. A semiring is a nonempty set S provided with two binary operations ``+'' and ``'' such that S is closed and associative under both operations, and commutative under +, satisfying also the distributive law. Example 49. Any Boolean algebra is a semiring under Boolean operations. In the following two examples, ``+'' stands for ordinary addition and ``'' stands for ordinary multiplication. Example 50. Let Z denote the set of all positive integers. Then Z ; ; is a semiring. Example 51. Let Mn Z denote the set of all n-square matrices over Z . Then Mn Z ; ; is a semiring. An incline is a semiring which also satis®es i1 . i2 .

Idempotence under : Absorption law:

a a a. a ab a; a ba a.

The absorption law implies that any product ab a or ab b. Therefore, these operations tend to make quantities ``slide downhill.'' Accordingly, we decided to call it incline. The ®rst letter of the Korean alphabet


is ``7'' (pronounced ``gee-yeok''), which looks like a slide downhill and so 7 denotes an arbitrary incline. Example 52. The two-element Boolean algebra 0 f0; 1g is an incline under Boolean operations. Example 53. Let Q R denote the set of all positive rationals (reals). Let Z Q ; R denote the set of all negative integers (rationals, reals). Then (1) Z Q ; R is not an incline under ordinary addition and ordinary multiplication. Similarly, (2) Z Q ; R is not an incline under ordinary addition and multiplication. However, Z Q ; R is an incline under the operations a b supfa; bg and ab a b (ordinary addition) for a, b 2 Z Q ; R . Let IVn for an incline 7 denote the Cartesian product incline 7 7 7 (n factors). An element of IVn is called an incline vector of dimension n. The system IVn ; ; is an incline under the operations u v ui vi and u v ui vi where u u1 ; . . . ; un , v v1 ; . . . ; vn 2 IVn . Example 54. Let 7 have operations supfa; bg and ab. Let 0:01; 0:9; 0:2, 0:5; 0:8; 0:12 2 IV3 . Then 0:01; 0:9; 0:2 0:5; 0:8; 0:12 0:5; 0:9; 0:2 and 0:01; 0:9; 0:2 0:5; 0:8; 0:12 0:005; 0:72; 0:024: The matrices over an incline 7 are called incline matrices. Let Mmn 7 Mn 7 denote the set of all m n n n incline matrices. The system Mmn 7; ; is an incline under the operations A B supfaij ; bij g and A B A B aij bij (elementwise product) for all A aij , B bij 2 Mmn 7. Example 55. Let 0:1 0:5 A 0:6 0:3 Then

AB AB

0:2 0:3 2 M2 7: 0:7 0:8

0:3

0:6 0:1

0:3 0:7 0:8 0:7 0:8 0:5 0:2 0:3 0:35 0:4 0:3 0:7 0:8 0:21 0:24 0:5 0:2 0:3 0:02 0:15 0:3 0:7 0:8 0:42 0:24

0:2

0:5

0:5

0:2

0:1

0:6 0:1 A B 0:6

B

The inequality of incline matrices is de®ned by A B if and only if aij bij for all i; j. Transpose is de®ned by AT aji .

126

Kim

Example 0:2 0:1 0:2 0:1

56

0:5 0:2 0:9 0:7 0:3 0:8 T 0:5 0:2 0:1 0:7 0:5 0:7

We introduce three basic and practical inclines. We expand 0 f0; 1g to a closed unit interval F 0; 1 and the operations are de®ned by a b supfa; bg and a b inffa; bg for all a, b 2 F. This is called a fuzzy algebra and vectors over F are called fuzzy sets, respectively. In fact, fuzzy sets were ®rst invented by Menger [17] in 1951 who called them hazy sets. However, they were independently rediscovered by Zadeh [18] who explored and popularized the subject. For basic facts and applications of fuzzy sets, see Dubois and Prade [19]. Example 57. The fuzzy algebra is an incline under the operations maximum and minimum. Let F be the ®rst basic incline, the fuzzy algebra, and denote it by 71 . The second basic incline 72 is de®ned on F by a b inffa; bg and a b inff1; a bg. The third basic incline 73 is denoted on F by a b supfa; bg and a b ab (ordinary multiplication). Since basic inclines essentially differ in their second operation, these determine the suitability of an incline to a particular application. (1) 71 with idempotent operation is suited to an application involving order properties only or a totally controlled system. (2) In 72 , for a 6 0, a a...a 1 |{z} n factors

for some n. Therefore, it is suited to applications having a strong convergence to a ®nite state. (3) 73 is suitable to applications in which constant proportionality between cause and effect holds. In the following we give an example dealing with application of 72 [20]. Fuzzy algebras and inclines have been used by many workers to model control systems. Here we model a simple industrial system which responds to disturbances by recovering to a satisfactory equilibrium. The use of maximum is natural in a control system because the controller wants to maximize his or her utility. The incline 72 is used here because (1) the situation is linear and (2) there is a cutoff point which should not be exceeded. A linear system is a dynamical system over time with


xht 1i xhtiA B where xhti x1 ; x2 ; . . . ; xn is the state at time t, A aij is a matrix describing transitions and B b1 ; b2 ; . . . ; bn is a vector describing some external factor. We assume aij is the desired balance between factor xi and factor xj . In this situation, the automatic controller is causing the transitions. Therefore, aij c means that factor xj should not exceed factor xi by more than c. In order for the process to be safe, we must impose b1 ; b2 ; . . . ; bn as upper limits on these n quantities. If xi > aij xj then the prevalence of factor xi over factor xj results in an inferior product. Subject to these conditions the quantity of production is maximized when all xi are as large as possible. Then xi inffaij xj ; bi g which is precisely an equilibrium in our system. Example 58. Consider an automated process of manufacturing in which x1 hti is pressure, x2 hti is temperature, and x3 hti acidity. Let xh0i 0; 0:1; 0:3, B 0:5; 0:5; 0:5; 2

1

6 A6 4 0:2 0:5

0:2 1 0:3

0:1

3

7 0:6 7 5 1

Then xh1i xh0iA B 8 2 1 > > < 6 0; 0:1; 0:36 4 0:2 > > : 0:5

0:2 1 0:3

39 0:1 > > 7= 0:6 7 5> > ; 1

0:5; 0:5; 0:5 0:3; 0:2; 0:1 0:5; 0:5; 0:5 0:3; 0:2; 0:1 xh2i 0:4; 0:4; 0:4 xh3i 0:5; 0:5; 0:5 xh4i 0:5; 0:5; 0:5 xh5i 0:5; 0:5; 0:5 xh6i 0:5; 0:5; 0:5 .. . xhki 0:5; 0:5; 0:5

k 2 Z

Boolean Algebra

127

REFERENCES

Figure 13 Inclines of various semirings.

Therefore, 0:5; 0:5; 0:5 is the equilibrium and so it is an ideal state. We conclude by illustrating the relationship between the various algebras and the distinct characteristics of the various algebras mentioned in the chapter (Fig. 13, Table 18). Table 18 Properties of Types of Semirings Algebras Properties

0

F

7i

Ordered structure Degree of intensity Real number operations Parameter of proportionality

ACKNOWLEDGMENTS The author is very grateful to Fred Roush for his very constructive criticism and suggestions on the various stages of rough drafts. Also, the author would like to thank Kay Roush for very carefully proofreading the manuscript.


1. G Boole. The Mathematical Analysis of Logic, Being an Essay Toward a Calculus of Deductive Reasoning. Cambridge, England: Mcmillan, 1847. 2. G Boole. An Investigation of the Laws of Thought, on Which are Founded the Mathematical Theories of Logic and Probabilities. Cambridge, England: Macmillan, 1854. 3. E SchroÈder. Algebra der Logik. Leipzig, 1880. 4. EV Huntington. Sets of independent postulates for the algebra of logic. Trans Math Soc 5: 288±309, 1904. 5. G Birkhoff. Lattice Theory, vol XXV. Providence, RI: Amer Math Soc Col Pub, 1967. 6. MH Stone. The theory of representations for Boolean algebras. Trans Am Math Soc 40: 37±111, 1936. 7. PR Halmos. Lecture on Boolean Algebra. Princeton, NJ: Van Nostrand, 1963. 8. R Sikorski. Boolean Algebra. Berlin: Springer-Verlag, 1964. 9. FE Hohn, LR Schissler. Boolean matrices and the design of combinatorial relay circuits. Bell Syst Tech J 34: 177±202, 1955. 10. CE Shannon. A symbolic analysis of relay and switching circuits. Trans Am Inst Elect Eng 57: 713±723, 1938. 11. FE Hohn. Applied Boolean Algebra. Toronto: Macmillan, 1969. 12. LL Dornhoff, FE Hohn. Applied Modern Algebra. New York: Macmillan, 1978. 13. KH Kim. Boolean Matrix Theory and Applications. New York: Dekker, 1982. 14. F Harary, RZ Norman, D Cartwright. Structural Models: An Introduction to the Theory of Directed Graph. New York: Wiley, 1965. 15. KH Kim, FW Roush. Automata on One Symbol. Studies in Pure Mathematics. Boston: Birkhauser, 1983, pp 423±425. 16. ZQ Cao, KH Kim, FW Roush. Incline Algebra and Applications. Chichester, England: Horwood; New York: Wiley, 1984. 17. K Menger. Selected Papers in Logic and Foundations, Didactics, Economics. New York: Reidel, 1979. 18. LA Zadeh. Fuzzy sets. Inform Control 8: 338±353, 1965. 19. D Dubois, H Prade. Fuzzy Sets and Systems Theory and Applications. New York: Academic Press, 1980. 20. KH Kim, FW Roush. Applications of inclines. Proceedings of International Conference on Information and Knowledge Engineering, Dalian, China, 1995, pp 190±196.

Chapter 1.7 Algebraic Structures and Applications J. B. Srivastava

Indian Institute of Technology, Delhi, New Delhi, India

7.1

GROUPS

3. For every x 2 G, there exists an element y 2 G with y ? x e.

In this section we study one of the most important and useful algebraic structures, that of a group. The recent developments in computer applications have made it possible to automate a wide range of systems and operations in the industry by building ever more intelligent systems to cope with the growing demands. Group theory and group theoretical methods have played a vital role in certain crucial areas in these developments. Group theory is a vast subject with wide applications both within mathematics and in the real-world problems. We present here some of the most basic concepts with special emphasis on permutation groups and matrix groups. Let S be a nonempty set. A binary operation on S is any function from S S to S. We shall denote an arbitrary operation on S by ``?.'' Thus ? : S S ! S sending x; y ! x ? y assigns to each ordered pair x; y of elements of S an element x ? y in S. Binary operation ? on S is said to be associative if x ? y ? z x ? y ? z for all x; y; z 2 S. S; ? is called a semigroup if S is a nonempty set and ? de®nes an associative binary operation on S. G; ? is said to be a group if G is nonempty set and ? is a binary operation on G satisfying the following properties (axioms): 1. 2.

If G; ? is a group, as above, then it can be proved that x ? e x for every x 2 G and in axiom 3, y ? x e if and only if x ? y e. Further, e in axiom 2 and y in axiom 3 are unique. In the group G; ?, the element e is called the identity of the group G and y is called the inverse of x in G. Axiom 1 says that every group is a semigroup. Thus a group is a semigroup in which there exists a unique identity element e with e ? x x x ? e and for every x there exists a unique y such that y ? x e x ? y. 7.1.1 7.1.1.1

Abelian Groups

A group G; ? is said to be Abelian or commutative if x ? y y ? x for all x; y 2 G. The following examples are well known: 1. 2. 3. 4.

x ? y ? z x ? y ? z for all x; y; z 2 G. There exists an element e 2 G such that e ? x x for every x 2 G.

5. 129


Examples of Groups

Z; the group of all integers (positive, negative and 0) under addition. R; the group of all real numbers under addition. C; the group of all complex numbers under addition. Mn R; the group of all n n real matrices under addition. (R? ; all nonzero real numbers under multiplication.

130

6.

7.

Srivastava

(C? ; all nonzero complex numbers under multiplication. 1 0 1 0 1 0 1 0 G ; ; ; 0 1 0 1 0 1 0 1

6.

7.

under multiplication.

7.1.1.2

Permutation Groups

Let X be a nonempty set. Any one-to-one, onto function from X to X is called a permutation on X. The set of all permutations on X form a group under multiplication which is by de®nition a composition of functions. Let SX denote the set of all permutations on X and let ; 2 SX . Then and are one-to-one, onto functions from X to X. Their product is de®ned by x x x for every x 2 X. Clearly is one-to-one, onto and hence 2 SX . Composition of functions is associative. The function e : X ! X de®ned by ex x for every x 2 X is the identity. Also every one-to-one, onto function has an inverse which is also one-to-one, onto. Thus SX under multiplication (which is composition) is a group. When X fx1 ; x2 ; . . . ; xn g is a ®nite set, a function from X to X is one-to-one if and only if it is onto. In this case the group of all permutations SX on X is denoted by Sn . In particular, if X f1; 2; 3; . . . ; ng, the group of all permutations on X under multiplication is denoted by Sn and is called the symmetrical group of degree n. It may be noted that the symmetrical group Sn is non-Abelian for all n 3. 7.1.1.3 1.

2. 3. 4. 5.

Matrix Groups GLn R GLn; R the group of all n n nonsingular real matrices under matrix multiplication. Here nonsingular means invertible or equivalently having nonzero determinant. GLn R is called the general linear group of degree n over the reals R. GLn C GLn; C the general linear group of degree n over the ®eld of all complex numbers. SLn R SLn; R fA 2 GLn R j detA 1g the special linear group of degree n over R. SLn C the special linear group of degree n over C. Un Un C the n-dimensional unitary group is the multiplicative group of all n n complex unitary matrices. A 2 GLn C is unitary if A 1 At the conjugate transpose of A.


8.

On On; R the n-dimensional real orthogonal group the group of all n n real orthogonal matrices under multiplication. A 2 On , At A I AAt , A 1 At . SUn the special unitary group of degree n fA 2 Un j detA 1g under matrix multiplication. SOn the special orthogonal group of degree n fA 2 On j detA 1g under matrix multiplication.

7.1.1.4 Miscellaneous 1.

Dihedral groups: D2n hx; y j xn 1; y2 1; y 1 xy x 1 i

2.

3. 4.

7.1.2

This is the group generated by two elements x and y with prdouct rules given by xn 1, y2 1, yx x 1 y, x 1 xn 1 , y 1 y having 1 as the identity. Quaternion groups: Q8 f1; i; j; kg with multiplication rules i2 j 2 k2 1, ij k ji, jk i kj, ki j ik and identity 1. f1; p1; i; ig under multiplication where i 1 is the complex number. multiplicative Gn fz 2 C j zn 1g the group of all nth roots of unity belonging to C. Here n is ®xed but arbitrary. Basic Concepts

Let G; ? be a group. A nonempty subset H of G is a subgroup of G if H is a group under the binary operation of G. This means (1) e 2 H, (2) x; y 2 H ) x ? y 2 H, (3) x 2 H ) x 1 2 H. It is easy to see that H is a subgroup of G if and only if x ? y 1 2 H for all x; y 2 H. A subgroup H of G is said to be a normal subgroup of G if g ? H H ? g for each g 2 G. Thus H is a normal subgroup of G if and only if g 1 ? H ? g H g ? H ? g 1 for all g 2 G. If x; y 2 G, then y is said to be a conjugate of x if y g ? x ? g 1 or y g 1 ? x ? g for some g 2 G. If H is a subgroup of G, then a conjugate of H is g ? H ? g 1 or g 1 ? H ? g for any g 2 G. If H is a subgroup of G, we de®ne g ? H fg ? h j h 2 Hg the left coset of H by g 2 G and H ? g fh ? g j h 2 Hg the right coset of H by g. Two cosets are either identical or disjoint. Further, H ? g H , g 2 H , g ? H H. Using this, we get H ? g1 H ? g2 , g1 ? g2 1 2 H. Similarly, g1 ? H g2 ? H , g1 1 ? g2 2 H.

Algebraic Structures and Applications

For a ®nite group G, we denote by jGj the order of the group G. Here jGj denotes the number of distinct elements in G. If H is a subgroup of G, then de®ne jG : Hj the index of H in G the number of distinct left cosets of H in G the number of distinct right cosets of H in G. If H is a normal subgroup of G, then the quotient group or factor group G=H is de®ned by G=H fH ? g g ? H j g 2 Gg the set of all right (left) cosets of H in G and H ? g1 ? H ? g2 H ? g1 ? g2 H ? g 1 H ? g 1 and identity G=H is H H ? e. Let G1 ; ?1 and G2 ; ?2 be groups which may be identical. Then a function f : G1 ! G2 is called a group homomorphism if f x ?1 y f x ?2 f y for all x; y 2 G1 . If f : G1 ! G2 is a homomorphism, then K Ker f the kernel of f is de®ned by Ker f fx 2 G1 j f x e2 the identity of G2 g It is not dif®cult to see that K Ker f is a normal subgroup of G1 . Also Im f ff x j x 2 G1 g is a subgroup of G2 . An isomorphism of groups is a one-to-one, onto group homomorphism. We write G1 G2 for G1 is isomorphic to G2 if there exists an isomorphism from G1 to G2 . If S is a subset of G, then hSi denotes the smallest subgroup of G containing the subset S. If G hSi, then we say that G is generated by the subset S. If S fxg is a singleton subset and G hxi, then G is called a cyclic group. Thus G is a cyclic group if and only if it is generated by a single element. G is a ®nite cyclic group if G hxi for some x 2 G and xn e for some positive integer n. The group G is called in®nite cyclic if G hxi for some x 2 G and xn 6 e for any positive integer n. If x is an element of a group G, then x has in®nite order if xn nee for any positive integer n. An element x of a group has ®nite order if xn e for some positive integer n. The least positive integer n such that xn e is called the order of x and is denoted by ox n the order of x. In fact, ox jhxij the order of the cyclic subgroup generated by x. 7.1.3

Main Theorems

Now onward, for the sake of convenience, we shall use xy for x ? y whenever there is no confusion. In this section, we state without proof some theorems in group theory and explain their importance. We start with the basic results on ®nite groups.


131

Lagrange's Theorem. group G. Then

Let H be a subgroup of a ®nite

jGj jHjjG : Hj Remarks: 1. From Lagrange's theorem it is clear that the order and the index of any subgroup divide the order of the whole group. 2. The converse of Lagrange's theorem is false in the sense that if jGj n and m divides n, then G need not have a subgroup of order m. A pivotal role is played by the following most famous theorems on ®nite groups. Sylow's Theorem. Let G be a ®nite group having jGj pn m, p a prime, p and m relatively prime. Then: 1. G has at least one subgroup of order pn . 2. Any two subgroups of G having order pn are conjugate in G. 3. The number np of Sylow p-subgroups (subgroups of order pn ) of G is of the form np 1 kp, k 0; 1; 2; . . . and np divides jGj. Remarks: 1. Subgroups of G of order pn in the above theorem are called Sylow p-subgroups of G. 2. Theorems 1, 2, and 3 above are called Sylow's ®rst, second, and third theorem respectively. 3. Sylow's theorems and Lagrange's theorem are the most basic theorems in the study of ®nite groups. 4. It is known that if jGj p, p a prime, then G is cyclic and if jGj p2 , then G is Abelian. For arbitrary groups, ®nite or in®nite, the following theorem is quite useful. Fundamental Theorem of Homomorphism. Let G1 and G2 be two groups and let f : G1 ! G2 be a group homomorphism. Then G1 =Ker f Im f Thus, if f is onto, then G1 =Ker f G2 . Remarks: 1. De®ne f : GLn R ! R? R\f0g by f A detA. Then f AB detAB detA detB f A f B. Thus f is a group homomorphism. Clearly, Ker f fA 2 GLn R j f a detA

132

Srivastava

2.

7.1.4

ag SLn R. By the above theorem GLn R= SLn R R? ; : De®ne f : R; ! R? ; by f x ex . Then f x y exy ex ey f x f y. Thus f is a homomorphism, Ker f 0. In fact f is an isomorphism. Here R? ; is the multiplicative group of all positive real numbers. Permutation Groups

Permutations arise naturally in several concrete problems. The symmetrical group Sn of degree n consists of all permutations on f1; 2; 3; . . . ; ng and the binary operation is product which is composition. We discuss in detail the permutations because of their importance in several practical problems. Let 2 Sn be any permutation. Then can be represented by displaying its values: 1 2 3 ... n 1 2 3 . . . n The order of the symmetrical group Sn is n!. 2 Sn ®xes k if k k. The most simple kind of permutations are transpositions. A permutation 2 Sn is called a transposition if i j; j i and k k for all k 6 i; j where 1 i; j; k n with i 6 j. We write this transposition as i; j. Thus r; s means r ! s, s ! r; k ! k for k 6 r; s; r 6 s, i.e., r s, s r, r 6 s, and k k for k 6 r; s. Clearly, every transposition has order 2, i.e., 2 e, where e is the identity permutation and hence 1 . A permutation 2 Sn is called a cycle of length r if there exist distinct integers i1 ; i2 ; . . . ; ir between 1 and n such that i1 i2

i2 i3 ; . . . ; ir 1 ir

ir i1

k k

for all other integers between 1 and n. It is denoted by i1 ; i2 ; . . . ; ir . Thus S3 is explicitly given by ( ! ! 1 2 3 1 2 3 ; 1 ; S3 e 1 2 3 2 1 3 ! ! 1 2 3 1 2 3 ; 3 ; 2 3 2 1 1 3 2 ! !) 1 2 3 1 2 3 ; 2 3 1 3 1 2 fe; 1; 2; 1; 3; 2; 3; 1; 2; 3; 1; 3; 2g


Now 1 2 1 21 3 1 3 2 but 2 1 1 3 1 2 1 2 3 . Thus 1 2 6 2 1 and hence S3 is non-Abelian. In fact Sn is non-Abelian for n 3. Two cycles, i1 i2 . . . ir and j1 ; j2 . . . js , in Sn are said to be disjoint if fi1 ; i2 ; . . . ; ir and f j1 ; j2 ; . . . ; js g are disjoint as sets, i.e., they do not have common indices. Disjoint cycles commute. It is a routine computation to verify that any nonidentity permutation can be written as a product of disjoint cycles and writing this way is unique except for the order in which the cycles are written. Since 1-cycles are identity permutations, we ignore them. This is best illustrated by an example:

1

2

3

4

5

6 7

8

9 10 11 12 13 14

7 10 4 6 11 9 3 2 1 1 7 3 4 6 92 10 85 1112 14

8

5

14 13 12

Here 2 S14 has been expressed as a product of disjoint cycles which commute. Remarks: 1. 2.

A 2-cycle is simply a transposition. An r-cycle i1 i2 . . . ir can be expressed as a product of r 1 transpositions as i1 i2 . . . ir i1 ir i1 ir 1 . . . i1 i2

3.

4.

5.

which are not disjoint. Any permutation in Sn ; n 2, can be written as a product of transpositions. It is a well-known result that while writing a permutation as a product of transpositions, the number of transpositions is either always even or always odd. It is never possible to write the same permutation as a product of even number of transpositions as well as a product of odd number of transpositions. 2 Sn is called an even permutation if is a product of even number of transpositions. is called an odd permutation if can be written as a product of odd number of transpositions. Let An f 2 Sn j is eveng. Then An is a subgroup of Sn and it is called the alternating group of degree n. The mapping f : Sn ! f1; 1g sending 1 if is even f 1 if is odd is an onto group homomorphism with Ker f An . Thus Sn =An f1; 1g. Here f1; 1g is a group under multiplication. Thus order jAn j n!=2 and index jSn : An j 2. Also An is a normal subgroup of Sn .


6. 7.1.5

Any subgroup of the symmetrical group Sn is called a permutation group. Group Actions

Let G be a group and let X be a nonempty set. A group action of G on X is a function from G X ! X sending g; x to g x 2 X satisfying the following: 1. 2.

g1 g2 x g1 g2 x for all g1 ; g2 2 G and all x 2 X. e x x for all x 2 X, where e is the identity of the group G.

Given a group action, there exists a group homomorphism : G ! SX de®ned by g ! g and g : X ! X maps x to g x. Conversely, every group homomorphism : G ! SX de®nes a unique group action where g x g x for g 2 G and x 2 X. Given a group action of the group G on a set X, we have the following concepts: 1.

2. 3.

The orbits of the group action are de®ned in a natural way. If x 2 X, then Ox Ox fg x j g 2 Gg the orbit of x under the given G-action. The stabilizer subgroup of x 2 X is Gx fg 2 G j g x xg the stabilizer subgroup of x. Points on the same orbit have conjugate stabilizers. Suppose x and y belong to the same orbit. Then there exists a g 2 G such that y g x. Then it can be shown that the stabilizers of x and y are conjugate as Gy gGx g 1 .

In this context, we have the following well-known theorems. Orbit-Stabilizer Theorem. Let G be a ®nite group acting on a ®nite nonempty set X. Then the size of the orbit jOx j jG : Gx j the index of the stabilizer subgroup for each x 2 X. Further, the size of each orbit divides the order jGj of the group. The next theorem gives the count. The Counting Orbit Theorem. If G and X are as in the previous theorem then the number of distinct orbits is given by 1 X g jX j jGj g2G where jX g j denotes the number of distinct elements of X left ®xed by g in the sense g x x.


133

7.1.6

Group of Rigid Motions

We brie¯y describe the group of all rigid motions (the Euclidean group). This is the group of all distancepreserving functions from Rn ! Rn . When n 2 or 3, these groups are of great practical importance and contain translations, rotations, and re¯ections. Here Rn fx1 ; x2 ; . . . ; xn j xi 2 R; 1 i ng consists of all ordered n-tuples of real numbers, and the distance between two points x x1 ; x2 ; . . . ; xn and y y1 ; q is de®ned by dx; y where y2 ; . . . ; y n Pn 2 . A function x y dx; y kx yk i i1 i T : Rn ! Rn is distance preserving if dTx; Ty kTx Tyk kx yk dx; y for all x; y 2 Rn . All distance-preserving functions from Rn to Rn form a group under composition of functions. Such functions are called rigid motions of Rn . When n 2, R2 de®nes a plane and when n 3, R3 de®nes the usual threedimensional space. If w 2 Rn ; Tw : Rn ! Rn given by Tw x x w for x 2 Rn de®nes a translation. SO2 the group of all 2 2 orthogonal matrices having determinant 1 de®ne the group of all rotations of the plane and SO3 similarly de®nes the group of all rotations of the threedimensional Euclidean space. Re¯ections can be represented by orthogonal matrices having determinant 1. Every rigid motion is the composite of a translation and an orthogonal transformation which may be a rotation or a re¯ection in the above sense. Geometrical applications help in understanding the physical phenomena.

7.2

RINGS AND FIELDS

In this section we deal with algebraic structures having two binary operations satisfying certain axioms. A ring R is a nonempty set together with two binary operations ``+'' and ``'' called addition and multiplication, which satisfy the following axioms: 1.

R; is an Abelian group with identity denoted by 0. 2. R; is a semigroup with identity denoted by 1. 3. Distributive laws hold: for all a; b; c 2 R, a b c a c b c a b c a b a c

Note: in axiom 2 some authors do not assume the identity. R is said to be a commutative ring if a b b a for all a; b 2 R. A commutative ring with identity 1 is

134

Srivastava

called an integral domain if for a; b 2 R; a 6 0; b 6 0 always implies a b 6 0. A ®eld is a commutative ring with identity 1 6 0 in which every nonzero element has a multiplicative inverse, i.e., R? ; is also an Abelian group where R? R\f0g all nonzero elements of R. 7.2.1

Examples

7.2.1.1 1. 2. 3.

Z; ; Z the ring of all integers under usual addition and multiplication. RX the ring of all real polynomials under usual addition and multiplication. R C0; 1 f f : 0; 1 ! Rj f is continousg, the ring of all continuous real-valued functions de®ned on the closed interval 0; 1 with addition and multiplication of functions de®ned pointwise

4.

Zi fa bi 2 Cja; b 2 Zg, the ring of gaussian integers consisting of all complex numbers having their real and imaginary parts integers, and addition and multiplication inherited from complex numbers. 5. Z n f0; 1; 2; . . . ; n 1g with addition and multiplication de®ned modulo n. Here r s mod(n) means r s is divisible by n. n 0 mod n. 7.2.1.2

2.

3.

1.

2.

Commutative Rings

f gx f x gx f gx f xgx for all x 2 0; 1

1.

7.2.1.3 Noncommutative Rings

Examples of Fields a.

R the ®eld of all real numbers with usual addition and multiplication. b. C the ®eld of all complex numbers with usual addition and multiplication. c. Q the ®eld of all rational numbers. Z p the ®eld of all integers modulo p, p a prime. Here Z p f0; 1; 2; . . . ; p 1g, p a prime and addition and multiplication is de®ned modulo p. KX the ®eld of all rational functions with coef®cients in a given ®eld K f X j f X; gX 2 KX gX polynomials with gX 6 0

By taking K R; C; Q, or Z p we get special examples of ®elds of rational functions.


7.2.2

Mn K the ring of all n n matrices with entries from the ®eld K with the usual addition and multiplication of matrices, n 2. Mn R, Mn C etc. give concrete examples of practical importance. H fa bi cj dk j a; b; c; d 2 Rg the ring of all real quaternions with addition a bi cj dk a 0 b 0 i c 0 j d 0 k a a 0 b b 0 i c c 0 j d d 0 k and multiplication ade®ned distributively using the rules: ij k; ji k; jk i, i2 j 2 k2 1, kj i; ki j, ik j. Basic Concepts

Since most of the rings from the application point of view are generally commutative, the emphasis will be on such rings. Let R be a ring. S is called a subring of R if a, b 2 S ) a b; a b; 1 2 S. Further, a nonempty set I is called an ideal of R ifs a; b 2 I ) a b 2 I and a 2 I; r 2 R ) a r; r a 2 I. In this situation I; is a subgroup of R; . If I is an ideal of a ring R, then the quotient ring or factor ring is given by R=I fI a j a 2 Rg with addition and multiplication de®ned by I a I b I a b I a I b I a b Let R1 and R2 be two rings which may be the same. A function f : R1 ! R2 is called a ring homomorphism if it preserves addition and multiplication, i.e., f a b f a f b

f ab f a f b

for all a; b 2 R1 . Here ``'' and ``'' denote and of R1 and R2 depending upon where the elements belong to. If f : R1 ! R2 is a ring homomorphism, then the kernel of f is de®ned as Ker f fa 2 R1 j f a 0 in R2 g It is easy to see that Ker f is an ideal of R1 and Im f f f a j a 2 R1 g is a subring of R2 . An isomorphism is a one-to-one, onto ring homomorphism. If f : R1 ! R2 is an isomorphism, then we saythat R1 is isomorphic to R2 via f . In general, we


write R1 R2 and read R1 is isomorphic to R2 if there exists an isomorphism from R1 to R2 . Note: in homomorphism, we always assume that f 1 1, i.e., the homomorphism maps 1 of R1 to 1 of R2 . Fundamental Homomorphism Theorem for Rings. Let f : R1 ! R2 be a ring homomorphism with kernel Ker f . Then R1 =Ker f Im f and if f is onto, R1 =Ker f R2 . 7.2.3

Polynomial Rings

In this section, we shall study polynomial rings over the ®eld R of all real numbers and the ®eld C of all complex numbers. The study of these rings leads to the understanding of algebraic and projective geometry which has a wide range of applications in such diverse areas as robotics and computer vision. Much of this material is very well presented in Cox et al. [1] and uses the computation of Grobner bases as a basic tool. RX and CX denote the polynomial rings in single variable X. Also RX1 ; X2 ; . . . ; Xn and CX1 ; X2 ; . . . ;


135

Xn for n 2 denote the polynomial rings in n commuting variables X1 ; X2 ; . . . ; Xn . Over the ®eld C of complex numbers, the following theorem plays the dominant role. The Fundamental Theorem of Algebra. Every nonconstant polynomial in C X has a root in C. Remark. If f X 2 C X is nonconstant, then repeated Q application of the above theorem gives f x cx ni1 X i ; c; 1 ; 2 ; . . . ; n 2 C and n degree of f X. The behavior of polynomials in several variables is much more dif®cult. Understanding of these polynomials requires the knowledge of commutative rings.

REFERENCES 1. D Cox, J Little, D O'Shea. Ideals, Varieties and Algorithms. Springer-Verlag, UTM, 1992. 2. M Artin. Algebra. Englewood Cliffs, NJ: Prentice Hall, 1991. 3. IN Herstein. Topics in Algebra, 2nd ed. New York: Wiley, 1975.

Chapter 2.1 Measurement and Control Instrumentation Error-Modeled Performance Patrick H. Garrett

University of Cincinnati, Cincinnati, Ohio

1.1

INTRODUCTION

A general convention is to provide sensor measurements in terms of signal amplitudes as a percent of full scale, or %FS, where minimum±maximum values correspond to 0 to 100%FS. This range may correspond to analog signal levels between 0 and 10 V (unipolar) with full scale denoted as 10 VFS . Alternatively, a signal range may correspond to 50%FS with signal levels between 5 V (bipolar) and full scale denoted at 5VFS .

Modern technology leans heavily on the science of measurement. The control of industrial processes and automated systems would be very dif®cult without accurate sensor measurements. Signal-processing functions increasingly are being integrated within sensors, and digital sensor networks directly compatible with computer inputs are emerging. Nevertheless, measurement is an inexact science requiring the use of reference standards and an understanding of the energy translations involved more directly as the need for accuracy increases. Seven descriptive parameters follow:

1.2

The acquisition of accurate measurement signals, especially low-level signals in the presence of interference, requires ampli®er performance beyond the typical capabilities of operational ampli®ers. An instrumentation ampli®er is usually the ®rst electronic device encountered by a sensor in a signal-acquisition channel, and in large part it is responsible for the data accuracy attainable. Present instrumentation ampli®ers possess suf®cient linearity, stability, and low noise for total error in the microvolt range even when subjected to temperature variations, and is on the order of the nominal thermocouple effects exhibited by input lead connections. High common-mode rejection ratio (CMRR) is essential for achieving the ampli®er performance of interest with regard to interference rejection, and for establishing a signal ground reference at the ampli®er

Accuracy: the closeness with which a measurement approaches the true value of a measurand, usually expressed as a percent of full scale. Error: the deviation of a measurement from the true value of a measurand, usually expressed as a precent of full scale. Tolerance: allowable error deviation about a reference of interest. Precision: an expression of a measurement over some span described by the number of signi®cant ®gures available. Resolution: an expression of the smallest quantity to which a quantity can be represented. Span: an expression of the extent of a measurement between any two limits. 137


INSTRUMENTATION AMPLIFIERS AND ERROR BUDGETS

138

Garrett

that can accommodate the presence of ground±return potential differences. High ampli®er input impedance is also necessary to preclude input signal loading and voltage divider effects from ®nite source impedances, and to accommodate source-impedance imbalances without degrading CMRR. The precision gain values possible with instrumentation ampli®ers, such as 1000.000, are equally important to obtain accurate scaling and registration of measurement signals. The instrumentation ampli®er of Fig. 1 has evolved from earlier circuits to offer substantially improved performance over subtractor instrumentation ampli®ers. Very high input impedance to 109 is typical with no resistors or their associated temperature coef®cients involved in the input signal path. For example, this permits a 1 k source impedance imbalance without degrading CMRR. CMRR values to 106 are achieved with Avdiff values of 103 with precision internal resistance trimming. When conditions exist for large potentials between circuits in a system an isolation ampli®er should be considered. Isolation ampli®ers permit a fully ¯oating sensor loop because these devices provide their own input bias current, and the accommodation of very high input-to-input voltages between a sensor input and the ampli®er output ground reference. Off-ground Vcm values to 10 V, such as induced by interference

Figure 1


coupled to signal leads, can be effectively rejected by the CMRR of conventional operational and instrumentation ampli®ers. However, the safe and linear accommodation of large potentials requires an isolation mechanism as illustrated by the transformer circuit of Fig. 2. Light-emitting diode (LED)-phototransistor optical coupling is an alternate isolation method which sacri®ces performance somewhat to economy. Isolation ampli®ers are especially advantageous in very noisy and high voltage environments and for breaking ground loops. In addition, they provide galvanic isolation typically on the order of 2 mA inputto-output leakage. The front end of an isolation ampli®er is similar in performance to the instrumentation ampli®er of Fig. 1 and is operated from an internal dc±dc isolated power converter to insure isolation integrity and for sensor excitation purposes. Most designs also include a 100 k series input resistor R to limit the consequences of catastrophic input fault conditions. The typical ampli®er isolation barrier has an equivalent circuit of 1011 shunted by 10 pF representing Riso and Ciso , respectively. An input-to-output Viso rating of 2500 V peak is common, and is accompanied by an isolation-mode rejection ratio (IMRR) with reference to the output. Values of CMRR to 104 with reference to the input common, and IMRR values of 108 with reference

High-performance instrumentation ampli®er.

Measurement and Control Instrumentation

139

Figure 2 Isolation instrumentation ampli®er.

to the output are available at 60 Hz. This dual rejection capability makes possible the accommodation of two sources of interference, Vcm and Viso , frequently encountered in sensor applications. The performance of this connection is predicted by Eq. (1), where nonisolated instrumentation ampli®ers are absent the Viso / IMRR term: 1 Vcm Viso V0 Avdiff Vdiff 1 IMRR CMRR Vdiff where (1) 2R0 Avdiff 1 RG The majority of instrumentation-ampli®er applications are at low frequencies because of the limited response of the physical processes from which measurements are typically sought. The selection of an instrumentation ampli®er involves the evaluation of


ampli®er parameters that will minimize errors associated with speci®c applications under anticipated operating conditions. It is therefore useful to perform an error evaluation in order to identify signi®cant error sources and their contributions in speci®c applications. Table 1 presents parameter speci®cations for example ampli®ers described in ®ve categories representative of available contemporary devices. These parameters consist of input voltage and current errors, interference rejection and noise speci®cations, and gain nonlinearity. Table 2 provides a glossary of ampli®er parameter de®nitions. The instrumentation ampli®er error budget tabulation of Table 3 employs the parameters of Table 1 to obtain representative ampli®er error, expressed both as an input-amplitude-threshold uncertainty in volts and as a percent of the full-scale output signal. These error totals are combined from the individual device parameter errors by

140 Table 1

Garrett Example Ampli®er Parameters Subtractor ampli®er OP-07

Vos dVos =dT Ios dIos =dT Sr fhi @Avdiff 103 CMRR (IMRR) Vn rms f AV dAV =dT Ricm Ridiff

60 mV 0:2 mV=8C 0.8 nA 5 pA/8C 0.17 V=ms 600 Hz 105 p 10 nV= Hz 0.01% Rtempco 1:2 1011

3 107

Three-ampli®er AD624 25 mV 0.2 mV=8C 10 nA 20 pA/8C 5 V/ms 25 kHz 106 p 4 nV= Hz 0.001% 5 ppm/8C 109

109

V "amp1RTI Vos Ios Rs f Av FS 2 Avdiff " 2 2 dVos Vcm dT dT CMRR IMRR #1=2 p 2 dAv VFS 2 dT 6:6 Vn fhi dT Avdiff "amp1%FS "amp1RTI

Avdiff 100% VFS

3

The barred parameters denote mean values, and the unbarred parameters drift and random values that are combined as the root-sum-square (RSS). Examination Table 2

Ampli®er Parameter Glossary

Vos dVos =dT Ios dIos =dT Ridiff Ricm Sr Vn In Avo Avcm Avdiff f Av dAv =dT fhi CMRR (IMRR)

Input offset voltage Input-offset-voltage temperature drift Input offset current Input-offset-current temperature drift Differential input impedance Common-mode input impedance Slew rate Input-referred noise voltage Input-referred noise current Open-loop gain Common-mode gain Closed-loop differential gain Gain nonlinearity Gain temperature drift 3 dB bandwidth Common-mode (isolation-mode) numerical rejection ratio


Isolation ampli®er BB3456 0.25 mV 1 mV=8C 10 mA 0.3 nA/8C 0.5 mV=ms 1 kHz 6 104 10p 7 nV= Hz 0.01% 10 ppm/8C 5 109

107

Low-bias ampli®er CAZ DC ampli®er OPA 103 ICL 7605 100 mV 1 mV=8C 0.2 pA 7%Ios =8C 1.3 V/ms 1 kHz 104 p 30 nV= Hz 0.01% Rtempco 1014

1013

2 mV 0.05 mV=8C 150 pA 1 pA/8C 0.5 V/ms 10 Hz 105 p 200 nV/ Hz 0.01% 15 ppm/8C 1012

1012

of these ampli®er error terms discloses that input offset voltage drift with temperature is a consistent error, and the residual Vcm error following upgrading by ampli®er CMRR is primarily signi®cant with the subtractor instrumentation ampli®er. Ampli®er referred-to-input internal rms noise Vn is converted to peak±peak at a 3.3 con®dence (0.1% error) with multiplication by 6.6 to relate it to the other dc errors in accounting for its crest factor. The effects of both gain nonlinearity and drift with temperature are also referenced to the ampli®er input, where the gain nonlinearity represents an average amplitude error over the dynamic range of input signals. The error budgets for the ®ve instrumentation ampli®ers shown in Table 3 include typical input conditions and consistent operating situations so that their performance may be compared. The total errors obtained for all of the ampli®ers are similar in magnitude and represent typical in-circuit expectations. Signi®cant to the subtractor ampli®er is that Vcm must be limited to about 1 V in order to maintain a reasonable total error, whereas the three-ampli®er instrumentation ampli®er can accommodate Vcm values to 10 V at the same or reduced total error. 1.3

INSTRUMENTATION FILTERS

Lowpass ®lters are frequently required to bandlimit measurement signals in instrumentation applications to achieve frequency-selective operation. The application of an arbitrary signal set to a lowpass ®lter can result in a signi®cant attenuation of higher frequency components, thereby de®ning a stopband whose boundary is in¯uenced by the choice of ®lter cutoff


141

Table 3 Ampli®er Error Budgets (Avdiff 103 ; VFS 10 V; T 208C; Rtol 1%; Rtempco 50 ppm=8C

Ampli®er parameters

Subtractor ampli®er OP-07

Threeampli®er AD624

Isolation ampli®er BB3456

Low-bias ampli®er OPA103

CAZ DC ampli®er ICL7605

Input conditions

Vcm Rs

1 V 1 k

10 V 1 k

1000 V 1 k

100 mV 10 M

100 mV 1 k

Offset group

Vos dVos T dT Ios Rs

Nulled

Nulled

Nulled

Nulled

2 mV

4 mV

5 mV

20 mV

1 mV

0:8 mV

10 mV

10 mV

20 mV 2 mV

Vcm CMRR IMRR inckt p 6:6Vn fh1

30 mV

10 mV

10 mV

12 mV

1 mV

1:6 mV

4:1 mV

1:5 mV

6:2 mV

4:1 mV

1 mV

0:1 mV

1 mV

1 mV

1 mV

dAv V T FS DT Avdiff

10 mV

1 mV

2 mV

10 mV

3 mV

ampi RTI ampi%FS

34 mV 0:34%

22 mV 0:22%

33 mV 0:33%

29 mV 0:29%

8 mV 0:08%

Interference group

Linearity group

Combined error

f Av

VFS Avdiff

frequency, with the unattenuated frequency components de®ning the ®lter passband. For instrumentation purposes, approximating the lowpass ®lter amplitude responses described in Fig. 3 is bene®cial in order to achieve signal bandlimiting with minimum alteration or addition of errors to a passband signal of interest. In fact, preserving the accuracy of measurement signals is of suf®cient importance that consideration of ®lter charcterizations that correspond to well-behaved functions such as Butterworth and Bessel polynomials are especially useful. However, an ideal ®lter is physically unrealizable because practical ®lters are represented by ratios of polynomials that cannot possess the discontinuities required for sharply de®ned ®lter boundaries. Figure 3 describes the Butterworth and Bessel lowpass amplitude response where n denotes the ®lter order or number of poles. Butterworth ®lters are characterized by a maximally ¯at amplitude response in the vicinity of dc, which extends toward its 3 dB cutoff frequency fc as n increases. Butterworth attenuation is rapid beyond fc as ®lter order increases with a slightly nonlinear phase response that provides a good approximation to an ideal lowpass ®lter. Butterworth ®lters are therefore preferred for bandlimiting measurement signals.


0:15 mV

Table 4 provides the capacitor values in farads for unity-gain networks tabulated according to the number of ®lter poles. Higher-order ®lters are formed by a cascade of the second- and third-order networks shown. Figure 4 illustrates the design procedure with a 1 kHz-cutoff two-pole Butterworth lowpass ®lter including frequency and impedance scaling steps. The choice of resistor and capacitor tolerance determines the accuracy of the ®lter implementation such as its cutoff frequency and passband ¯atness. Filter response is typically displaced inversely to passivecomponent tolerance, such as lowering of cutoff frequency for component values on the high side of their tolerance. Table 5 presents a tabulation of the example ®lters evaluated for their amplitude errors, by "filter%FS

f =0:1f 0:1 X c 1:0 f =fc 0

Af 100%

4

over the speci®ed ®lter passband intervals. One-pole RC and three-pole Bessel ®lters exhibit comparable errors of 0.3%FS and 0.2%FS, respectively, for signal bandwidths that do not exceed 10% of the ®lter cutoff frequency. However, most applications are better

142

Garrett

Figure 3 (a) Butterworth and (b) Bessel lowpass ®lters.

served by the three-pole Butterworth ®lter which offers an average amplitude error of 0.2%FS for signal passband occupancy up to 50% of the ®lter cutoff, plus good stopband attenuation. While it may appear inef®cient not to utilize a ®lter passband up to its cutoff frequency, the total bandwidth sacri®ced is usually small. Higher ®lter orders may also be evaluated when greater stopband attenuation is of interest with substitution of their amplitude response A f in Eq. (4).


1.4

MEASUREMENT SIGNAL CONDITIONING

Signal conditioning is concerned with upgrading the quality of a signal of interest coincident with measurement acquisition, amplitude scaling, and signal bandlimiting. The unique design requirements of a typical analog data channel, plus economic constraints of achieving necessary performance without incurring the costs of overdesign, bene®t from the instrumenta-


143

"measurement "2sensor "2amplifier "2filter "2random 1=2 "2coherent n 1=2

tion error analysis presented. Figure 5 describes a basic signal-conditioning structure whose performance is described by the following equations for coherent and random interference:

"coherent

" # 2n Vcm Rdiff 1=2 Avcm f 1 coh Vdiff Rcm Avdiff fc

1=2

5

100% Vcm Rdiff 1=2 Avcm p fc 1=2 2 100% "random Vdiff Rcm Avdiff fhi

6

7 Input signals Vdiff corrupted by either coherent or random interference Vcm can be suf®ciently enhanced by the signal-conditioning functions of Eqs. (5) and (6), based upon the selection of ampli®er and ®lter parameters, such that measurement error is principally determined by the hardware device residual errors derived in previous sections. As an option, averaged measurements offer the merit of sensor fusion whereby total measurement error may be further reduced by the

Table 4 Unity-Gain Filter Network Capacitor Values (Farads) Butterworth Poles 2 3 4 5 6 7 8

C1

C2

1.414 3.546 1.082 2.613 1.753 3.235 1.035 1.414 3.863 1.531 1.604 4.493 1.091 1.202 1.800 5.125

0.707 1.392 0.924 0.383 1.354 0.309 0.966 0.707 0.259 1.336 0.624 0.223 0.981 0.831 0.556 0.195


Bessel C3 0.202 0.421

0.488

C1

C2

0.907 1.423 0.735 1.012 1.009 1.041 0.635 0.723 1.073 0.853 0.725 1.098 0.567 0.609 0.726 1.116

0.680 0.988 0.675 0.390 0.871 0.310 0.610 0.484 0.256 0.779 0.415 0.216 0.554 0.486 0.359 0.186

C3 0.254 0.309

0.303

144

Garrett

Figure 4 Butterworth lowpass ®lter design example.

Table 5 Filter Passband Errors Frequency

Amplitude response A f

Average ®lter error "filter%FS

f fc

1-pole RC

3-pole Bessel

3-pole Butterworth

1-pole RC

3-pole Bessel

3-pole Butterworth

0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0

1.000 0.997 0.985 0.958 0.928 0.894 0.857 0.819 0.781 0.743 0.707

1.000 0.998 0.988 0.972 0.951 0.924 0.891 0.852 0.808 0.760 0.707

1.000 1.000 1.000 1.000 0.998 0.992 0.977 0.946 0.890 0.808 0.707

0% 0.3 0.9 1.9 3.3 4.7 6.3 8.0 9.7 11.5 13.3

0% 0.2 0.7 1.4 2.3 3.3 4.6 6.0 7.7 9.5 11.1

0% 0 0 0 0 0.2 0.7 1.4 2.6 4.4 6.9



145

Figure 5 Signal-conditioning channel.

factor n 1=2 for n identical signal conditioning channels combined. Note that Vdiff and Vcm may be present in any combination of dc or rms voltage magnitudes. External interference entering low-level instrumentation circuits frequently is substantial, especially in industrial environments, and techniques for its attenuation or elimination are essential. Noise coupled to signal cables and input power buses, the primary channels of external interference, has as its cause local electric and magnetic ®eld sources. For example, unshielded signal cables will couple 1 mV of interference per kilowatt of 60 Hz load for each lineal foot of cable run on a 1 ft spacing from adjacent power cables. Most interference results from near-®eld sources, primarily electric ®elds, whereby the effective attenuation mechanism is re¯ection by a nonmagnetic material such as copper or aluminum shielding. Both copperfoil and braided-shield twinax signal cables offer attenuation on the order of 90 voltage dB to 60 Hz interference. However, this attenuation decreases by 20 dB per decade of increasing frequency. For magnetic ®elds, absorption is the effective attenuation mechanism, and steel or mu-metal shielding is required. Magnetic-®eld interference is more dif®cult to shield against than electric-®eld interference, and shielding effectiveness for a given thickness diminishes with decreasing frequency. For example, steel at 60 Hz provides interference attenuation on the order of 30 voltage dB per 100 mils of thickness. Magnetic shielding of applications is usually implemented by the installation of signal cables in steel conduit of the necessary wall thickness. Additional


magnetic-®eld cancellation can be achieved by periodic transposition of a twisted-pair cable, provided that the signal return current is on one conductor of the pair and not on the shield. Mutual coupling between circuits of a computer input system, resulting from ®nite signal-path and power-supply impedances, is an additional source of interference. This coupling is minimized by separating analog signal grounds from noisier digital and chassis grounds using separate ground returns, all terminated at a single star-point chassis ground. Single-point grounds are required below 1 MHz to prevent circulating currents induced by coupling effects. A sensor and its signal cable shield are usually grounded at a single point, either at the sensor or the source of greatest intereference, where provision of the lowest impedance ground is most bene®cial. This also provides the input bias current required by all instrumentation ampli®ers except isolation types, which furnish their own bias current. For applications where the sensor is ¯oating, a bias-restoration path must be provided for conventional ampli®ers. This is achieved with balanced differential Rbias resistors of at least 103 times the source resistance Rs to minimize sensor loading. Resistors of 50 M , 0.1% tolerance, may be connected between the ampli®er input and the single-point ground as shown in Fig. 5. Consider the following application example. Resistance-thermometer devices (RTDs) offer commercial repeatability to 0.18C as provided by a 100

platinum RTD. For a 0±1008C measurement range the resistance of this device changes from 100.0 to

146

Garrett

138.5 with a nonlinearity of 0.00288C/8C. A constant-current excitation of 0.26 mA converts this resistance to a voltage signal which may be differentially sensed as Vdiff from 0 to 10 mV, following a 26 mV ampli®er offset adjustment whose output is scaled 0± 10 V by an AD624 instrumentation ampli®er differential gain of 1000. A three-pole Butterworth lowpass bandlimiting ®lter is also provided having a 3 Hz cutoff frequency. This signal-conditioning channel is evaluated for RSS measurement error considering an input Vcm of up to 10 V rms random and 60 Hz coherent interference. The following results are obtained: tolerance nonlinearity FS 100% FS 8C 0:18C 0:0028 1008C 8C 100% 1008C 0:38%FS

"RTD

"ampl 0:22%FS (Table 3) (Table 5) "filter 0:20%FS " #1=2 10 V 109

10 6 "coherent 10 mV 109

" # 1=2 60 Hz 6 1 100% 3 Hz

"random

"measurement

1:25 10 5 %FS " #1=2 10 V 109

10 6 10 mV 109

p 3 Hz 1=2 2 100% 25 kHz

appreciable intereference is a frequent requirement in data acquisition systems. Measurement error of 0.5% or less is shown to be readily available under these circumstances. 1.5

DIGITAL-TO-ANALOG CONVERTERS

Digital-to-analog (D/A) converters, or DACs, provide reconstruction of discrete-time digital signals into continuous-time analog signals for computer interfacing output data recovery purposes such as actuators, displays, and signal synthesizers. These converters are considered prior to analog-to-digital (A/D) converters because some A/D circuits require DACs in their implementation. A D/A converter may be considered a digitally controlled potentiometer that provides an output voltage or current normalized to a full-scale reference value. A descriptive way of indicating the relationship between analog and digital conversion quantities is a graphical representation. Figure 6 describes a 3-bit D/A converter transfer relationship having eight analog output levels ranging between zero and seven-eighths of full scale. Notice that a DAC full-scale digital input code produces an analog output equivalent to FS 1 LSB. The basic structure of a conventional D/A converter incudes a network of switched current sources having MSB to LSB values according to the resolution to be represented. Each switch closure adds a binary-weighted current increment to the output bus. These current contributions are then summed by a current-to-voltage converter

1:41 10 3 %FS "2RTD "2ampl "2filter "coherent 1=2 "2random 0:48%FS

An RTD sensor error of 0.38%FS is determined for this measurement range. Also considered is a 1.5 Hz signal bandwidth that does not exceed one-half of the ®lter passband, providing an average ®lter error contribution of 0.2%FS from Table 5. The representative error of 0.22%FS from Table 3 for the AD624 instrumentation ampli®er is employed for this evaluation, and the output signal quality for coherent and random input interference from Eqs. (5) and (6), respectively, is 1:25 10 5 %FS and 1:41 10 3 %FS. The acquisition of low-level analog signals in the presence of


Figure 6 Three-bit D/A converter relationships.


ampli®er in a manner appropriate to scale the output signal. Figure 7 illustrates such a structure for a 3-bit DAC with unipolar straight binary coding corresponding to the representation of Fig. 6. In practice, the realization of the transfer characteristic of a D/A converter is nonideal. With reference to Fig. 6, the zero output may be nonzero because of ampli®er offset errors, the total output range from zero to FS 1 LSB may have an overall increasing or decreasing departure from the true encoded values resulting from gain error, and differences in the height of the output bars may exhibit a curvature owing to converter nonlinearity. Gain and offset errors may be compensated for leaving the residual temperature-drift variations shown in Table 6, where gain temperature coef®cient represents the converter voltage reference error. A voltage reference is necessary to establish a basis for the DAC absolute output voltage. The majority of voltage references utilize the bandgap principle, whereby the Vbe of a silicon transistor has a negative temperature coef®cient of 2:5 mV=8C that can be extrapolated to approximately 1.2 V at absolute zero (the bandgap voltage of silicon). Converter nonlinearity is minimized through precision components, because it is essentially distributed throughout the converter network and cannot be eliminated by adjustment as with gain and offset error. Differential nonlinearity and its variation with temperature are prominent in data converters in that they describe the difference between the true and actual outputs for each of the 1-LSB code changes. A DAC with a 2-LSB output change for a 1-LSB input code change exhibits 1 LSB of differential nonlinearity as

Figure 7 Three-bit D/A converter circuit.


147 Table 6 Representative 12-Bit D/A Errors Differential nonlinearity (1/2 LSB) Linearity temp. coeff. (2 ppm/8C)(208C) Gain temp. coeff. (20 ppm/8C)(208C) Offset temp. coeff. (5 ppm/8C)(208C) D=A

0:012% 0:004 0:040 0:010 0.05%FS

shown. Nonlinearities greater than 1 LSB make the converter output no longer single valued, in which case it is said to be nonmonotonic and to have missing codes. 1.6

ANALOG-TO-DIGITAL CONVERTERS

The conversion of continuous-time analog signals to discrete-time digital signals is fundamental to obtaining a representative set of numbers which can be used by a digital computer. The three functions of sampling, quantizing, and encoding are involved in this process and implemented by all A/D converters as illustrated by Fig. 8. We are concerned here with A/D converter devices and their functional operations as we were with the previously described complementary D/A converter devices. In practice one conversion is performed each period T, the inverse of sample rate fs , whereby a numerical value derived from the converter quantizing levels is translated to an appropriate output code. The graph of Fig. 9 describes A/D converter input± output relationships and quantization error for prevailing uniform quantization, where each of the levels q is of spacing 2 n 1 LSB for a converter having an n-bit binary output wordlength. Note that the maximum output code does not correspond to a full-scale input value, but instead to 1 2 n FS because there exist only 2n 1 coding points as shown in Fig. 9. Quantization of a sampled analog waveform involves the assignment of a ®nite number of amplitude levels corresponding to discrete values of input signal Vi between 0 and VFS . The uniformly spaced quantization intervals 2 n represent the resolution limit for an n-bit converter, which may also be expressed as the quantizing interval q equal to VFS =2n 1V. These relationships are described by Table 7. It is useful to match A/D converter wordlength in bits to a required analog input signal span to be represented digitally. For example, a 10 mV-to10 V span (0.1%±100%) requires a minimum converter wordlength n of 10 bits. It will be shown that additional considerations are involved in the conversion

148

Garrett

Figure 8 Analog-to-digital converter functions.

of an input signal to an n-bit accuracy other than the choice of A/D converter wordlength, where the dynamic range of a digitized signal may be represented by an n-bit wordlength without achieving n-bit data accuracy. However, the choice of a long wordlength A/D converter will bene®cially minimize both quantization noise and A/D device error and provide increased converter linearity. The mechanization of all A/D converters is by either the integrating method or the voltage-comparison method. The successive-approximation voltage-comparison technique is the most widely utilized A/D converter for computer interfacing primarily because its constant conversion period T is independent of input

Figure 9 Three-bit A/D converter relationships.


signal amplitude, making its timing requirements conveniently uniform. This feedback converter operates by comparing the output of an internal D/A converter with the input signal at a comparator, where each bit of the converter wordlength n is sequentially tested during n equal time subperiods to develop an output code representative of the input signal amplitude. The conversion period T and sample/hold (S/H) acquisition time tacq determine the maximum data conversion throughput rate fs T tacq 1 shown in Fig. 10. Figure 11 describes the operation of a successiveapproximation converter. The internal elements are represented in the 12-bit converter errors of Table 8, where differential nonlinearity and gain temperature coef®cient are derived from the internal D/A converter and its reference, and quantizing noise as the 1/2 LSB uncertainty in the conversion process. Linearity temperature coef®cient and offset terms are attributable to the comparator, and long-term change is due to shifts occurring from component aging. This evaluation reveals a two-binary-bit derating in realizable accuracy below the converter wordlength. High-speed, successive-approximation A/D converters require high-gain fast comparators, particularly for accurate conversion at extended wordlengths. The comparator is therefore critical to converter accuracy, where its performance is ultimately limited by the in¯uence of internal and external noise effects on its decision threshold. Integrating converters provide noise rejection for the input signal at an attenuation rate of 20 dB/ decade of frequency. Notice that this noise improvement capability requires integration of the signal plus noise during the conversion period, and therefore is not provided when a sample-hold device precedes the converter. A conversion period of 16 2/3 ms will provide a useful null to the conversion of 60 Hz interference, for example. Only voltage-comparison converters actually need a S/H to satisfy the A/Dconversion process requirement for a constant input signal.

Measurement and Control Instrumentation Table 7 Bits, n 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

149

Decimal Equivalents of Binary Quantities Levels, 2n 2 4 8 16 32 64 128 256 512 1,024 2,048 4,096 8,192 16,384 32,768 65,536 131,072 262,144 524,288 1,048,576

LSB weight, 2

0.5 0.25 0.125 0.0625 0.03125 0.015625 0.0078125 0.00390625 0.001953125 0.0009763625 0.00048828125 0.000244140625 0.0001220703125 0.00006103515625 0.000030517578125 0.0000152587890625 0.00000762939453125 0.000003814697265625 0.0000019073486328125 0.00000095367431640625

Dual-slope integrating converters perform A/D conversion by the indirect method of converting an input signal to a representative time period that is totaled by a counter. Features of this conversion technique include self-calibration that makes it immune to component temperature drift, use of inexpensive components in its mechanization, and the capability for multiphasic integration yielding improved resolution

Figure 10 Timing relationships for S/H±A/D conversion.


n

"%FS (1 LSB) 50.0 25.0 12.5 6.25 3.12 1.56 0.78 0.39 0.19 0.097 0.049 0.024 0.012 0.006 0.003 0.0015 0.0008 0.0004 0.0002 0.0001

of the zero endpoint as shown in Fig. 12. Operation occurs in three phases. The ®rst is the autozero phase that stores the converter analog offsets on the integrator with the input grounded. During the second phase, the input signal is integrated for a constant time T1 . In the ®nal phase, the input is connected to a reference of opposite polarity. Integration then proceeds to zero during a variable time T2 while clock pulses are totaled to represent the amplitude of the input signal. The representative errors of Table 8 show slightly better performance for dual-slope compared with successive-approximation converters, but their speed differences belie this advantage. The selfcalibration, variable conversion time, and lower cost features of dual-slope converters make them especially attractive for instrumentation applications. Sample/hold component errors consist of contributions from acquisition time, capacitor charge droop and dielectric absorption, offset voltage drift, and hold-mode feedthrough. A representative S/H error budget is shown in Table 9. Hold-capacitor voltage droop dV=dt is determined primarily by the output ampli®er bias-current requirements. Capacitor values in the 0.01± 0.001 mF range typically provide a balance for reasonable droop and acquisition errors. Capacitor dielectric absorption error is evident as voltage creep following repetitive changes in capacitor charging

150

Garrett

Figure 11 Successive-approximation A/D conversion. Table 8

Representative 12-Bit A/D Errors 12-bit successive approximation

Differential nonlinearity (1/2 LSB) Quantizing uncertainty (1/2 LSB) Linearity temp. coeff. (2 ppm/8C)(208C) Gain temp. coeff. (20 ppm/8C)(208C) Offset (5 ppm/8C)(208C) Long-term change

0:012% 0:012 0.004 0.040 0.010 0.050

A=D

0.080%FS

1.7

12-bit dual slope Differential nonlinearity (1/2 LSB) Quantizing uncertainty (1/2 LSB) Gain temp. coeff. (25 ppm/8C)(208C) Offset temp.coeff. (2 ppm/8C)(208C)

0:012% 0.012 0.050 0.004

A=D

0.063%FS


resulting from incomplete dielectric repolarization. Polycarbonate capacitors exhibit 50 ppm dielectric absorption, polystyrene 20 ppm, and Te¯on 10 ppm. Hold-jump error is attributable to that fraction of the logic signal transferred by the capacitance of the switch at turnoff. Feedthrough is speci®ed for the hold mode as the percentage of an input sinusoidal signal that appears at the output.

SIGNAL SAMPLING AND RECONSTRUCTION

The provisions of discrete-time systems include the existence of a minimum sample rate for which theoretically exact signal reconstruction is possible from a sampled sequence. This provision is signi®cant in that signal sampling and recovery are considered


151

Figure 12

Dual-slope A/D conversion.

simultaneously, correctly implying that the design of real-time data conversion and recovery systems should also be considered jointly. The following interpolation ^ formula analytically describes this approximation xt

Table 9 Representative Sample/Hold Errors Acquisition error Droop (25 mV=ms)(2 ms hold) in 10VFS Dielectric absorption Offset (50 mV=8C208C in 10VFS Hold-jump error Feedthrough S=H


0.01% 0.0005 0.005 0.014 0.001 0.005 0.02%FS

of a continuous time signal xt with a ®nite number of samples from the sequence xnT as illustrated by Fig. 13: ^ F 1 f f xnT H f g xt x BW X T xnT e j2fnT ej2ft df n x x X

T

8

BW

xnT

n x

2TBW

x X n x

ej2BWt

xnT

nT

j2t

e

j2BWt nT

nT

sin 2BWt nT 2BWt nT

^ is obtained from the inverse Fourier transform of xt the input sequence and a frequency-domain convolution with an ideal interpolation function H f , result-

152 Signal Interpolation Functions

Interpolator D/A

D/A + 1-pole RC

D/A + Butterworth n-pole lowpass

Af sincf =fs 1 f =fc 2

Intersample error (%FS)

2 4 1=2

1 f =fc 2n

1=2

|{z}

Table 10

Garrett

2 6 6 6 6 4

VS2

( h

sinc2 1

h 1:644VS2 sinc2 1

BW fs

i 1

2 VFS BW fs

2 VFS 2n 1 fs BW fc

1=2

i5 sinc2 1 BW fs

h

i 1 sinc2 1 BW fs

100% 3 7 7 7 2n 1 7 5 fs BW

(fs BW substituted for f in Af

Figure 13 Ideal signal sampling and recovery.


3

fc

1=2

100%


ing in a time-domain sinc amplitude response owing to the rectangular characteristic of H f . Due to the orthogonal behavior of Eq. (8), however, only one nonzero term is provided at each sampling instant by a summation of weighted samples. Contributions of samples other than the ones in the immediate neighborhood of a speci®c sample, therefore, diminish rapidly because the amplitude response of H f tends to decrease. Consequently, the interpolation formula provides a useful relationship for describing recovered bandlimited sampled-data signals of bandwidth BW with the sampling period T chosen suf®ciently small to prevent signal aliasing where sampling frequency fs 1=T. It is important to note that an ideal interpolation function H f utilizes both phase and amplitude infor^ mation in reconstructing the recovered signal xt, and is therefore more ef®cient than conventional bandlimiting functions. However, this ideal interpolation function cannot be physically realized because its impulse response is noncausal, requiring an output that anticipates its input. As a result, practical interpolators for signal recovery utilize amplitude information that can be made ef®cient, although not optimum, by achieving appropriate weighting of the reconstructed signal. Of key interest is to what accuracy can an original continuous signal be reconstructed from its sampled values. It can be appreciated that the determination of sample rate in discrete-time systems and the accuracy with which digitized signals may be recovered requires the simultaneous consideration of data conversion and reconstruction parameters to achieve an ef®cient allocation of system resources. Signal to mean-squarederror relationships accordingly represent sampled and recovered data intersample error for practical interpolar functions in Table 10. Consequently, an intersample error of interest may be achieved by substitution of a selected interpolator function and solving for the sampling frequency fs by iteration, where asymptotic convergence to the performance provided by ideal interpolation is obtained with higher-order practical interpolators. The recovery of a continuous analog signal from a discrete signal is required in many applications. Providing output signals for actuators in digital control systems, signal recovery for sensor acquisition systems, and reconstructing data in imaging systems are but a few examples. Signal recovery may be viewed from either time-domain or frequency-domain perspectives. In time-domain terms, recovery is similar to


153

interpolation procedures in numerical analysis with the criterion being the generation of a locus that reconstructs the true signal by some method of connecting the discrete data samples. In the frequency domain, signal recovery involves bandlimiting by a linear ®lter to attenuate the repetitive sampled-data spectra above baseband in achieving an accurate replica of the true signal. A common signal recovery technique is to follow a D/A converter by an active lowpass ®lter to achieve an output signal quality of interest, accountable by the convergence of the sampled data and its true signal representation. Many signal power spectra have long time-average properties such that linear ®lters are especially effective in minimizing intersample error. Sampled-data signals may also be applied to control actuator elements whose intrinsic bandlimited amplitude response assist with signal reconstruction. These terminating elements often may be characterized by a single-pole RC response as illustrated in the following section. An independent consideration associated with the sampling operation is the attenuation impressed upon the signal spectrum owing to the duration of the sampled-signal representation xnT. A useful criterion is to consider the average baseband amplitude error between dc and the full signal bandwidth BW expressed as a percentage of departure from full-scale response. This average sinc amplitude error is expressed by "sinc%FS

1 1 2

sinBWT 100% BWT

9

and can be reduced in a speci®c application when it is excessive by increasing the sampling rate fs . This is frequently referred to as oversampling. A data-conversion system example is provided by a simpli®ed three-digit digital dc voltmeter (Fig. 14). A dual-slope A/D conversion period T of 16 2/3 ms provides a null to potential 60 Hz interference, which is essential for industrial and ®eld use, owing to sinc nulls occurring at multiples of the integration period T. A 12-bit converter is employed to achieve a nominal data converter error, while only 10 bits are required for display excitation considering 3.33 binary bits per decimal digit. The sampled-signal error evaluation considers an input-signal rate of change up to an equivalent bandwidth of 0.01 Hz, corresponding to an fs =BW of 6000, and an intersample error determined by zero-order-hold (ZOH) data, where Vs equals VFS :

154

Garrett

Figure 14 Three-digit digital voltmeter example. 3

2 6 "intersample 6 4

1:644 VS2 sinc2 1

2 82 6 6 > > 6 > 4 > > 1 :

"sinc

2 VFS

BW sinc2 fs

1=2

7 7 1 BW 5 fs

1 32 2

1 6000 1 6000

100% 3

32 97 7 > 1 > > sin 1 =7 7 7 6 6000 7 7 6 7 5 7 7 5 4 1 > 5 > > 1 ; 6000

100% 0:033%FS 1 sinBW= fs 100% 1 2 BW=fs 1 sin=6000 1 100% 2 =6000 0:000001%FS

(Table 8) "A=D 0:063%FS 2 1=2 2 "sampled "intersample "sinc "A=D signal

0:07=%FS

The RSS error of 0.07/% exceeds 10 bits required for a three-digit display with reference to Table 7.

1.8

DIGITAL CONTROL SYSTEM ERROR

The design of discrete-time control loops can bene®t from an understanding of the interaction of sample rate and intersample error and their effect on system performance. The choice of sample rate in¯uences stability through positioning of the closed-loop transfer function pole locations in the z-domain with respect to the origin. Separately, the decrease in intersample error from output interpolation provided by the closed-loop bandwidth of the control system reduces the uncertainty of the controlled variable. Since the choice of sample rate also in¯uences intersample error, an analysis of a digital control loop is instructive to illustrate these interrelationships.


1=2

Figure 15 describes an elementary discrete-time control loop with a ®rst-order process and unity feedback. All of the process, controller, and actuator gains are represented by the single constant K with the compensator presently that of proportional control. The D/A converter represents the in¯uence of the sampling period T, which is z-transformed in the closed-loop transfer function of the following equations: CZ

k1 e T Rz Z e T 1 K K (transfer function)

k1 e Z Z e 0:1 2 1 Z 1 (unit step input K 1; T 0:1 sec 0:5Z 0:5Z Z 0:8 Z 1 (by partial fractions)

10

0:1

n

11

12

n

Cn 0:50:8 0:51 Un (inverse transforming) 0:50 final value n large

13

The denominator of the transfer function de®nes the in¯uence of the gain K and sampling period T on the pole positions, and hence stability. Values are substituted to determine the boundary between stable and unstable regions for control loop performance evaluated at the z-plane unit circle stability boundary of z 1. This relationship is plotted in Fig. 15. Calculation of the 3dB closed-loop bandwidth BW for both ®rst- and second-order processes is necessary for the determination of interpolated intersample error of the controlled-variable C. For ®rst-order processes, the closed-loop BW is obtained in terms of the rise time tr between the 10% and 90% points of the controlled-variable amplitude response to a step input


155

Figure 15 Elementary digital control loop.

as de®ned in Table 11. The constant 0.35 de®nes the ratio of 2.2 time constants, required for the response to rise between 10% and 90% of the ®nal value, to 2 radians for normalization to frequency in Hertz. Validity for digital control loops is achieved by acquiring tr from a discrete-time plot of the controlled-variable amplitude response. Table 11 also de®nes the bandwidth for a second-order process which is calculated directly with knowledge of the natural frequency, sampling period, and damping ratio. In the interest of minimizing sensor-to-actuator variability in control systems the error of a controlled variable of interest is divisible into an analog measurement function and digital conversion and interpolation functions. Instrumentation error models provide a uni®ed basis for combining contributions from individual devices. The previous temperature measurement signal conditioning associated with Fig. 5 is included in this temperature control loop, shown by Fig. 16, with the averaging of two identical 0.48%FS error measurement channels to effectively reduce that error by n 1=2 or 2 1=2 , from Eq. (7), yielding 0.34%FS. This provides repeatable temperature measurements to

Table 11

within an uncertainty of 0.348C, and a resolution of 0.0248C provided by the 12-bit digital data bus wordlength. The closed-loop bandwidth is evaluated at conservative gain and sampling period values of K 1 and T 0:1 sec fs 10 Hz, respectively, for unit-step excitation at rt. The rise time of the controlled variable is evaluated from a discrete-time plot of Cn to be 1.1 sec. Accordingly, the closed-loop bandwidth is found from Table 11 to be 0.318 Hz. The intersample error of the controlled variable is then determined to be 0.143%FS with substitution of this bandwidth value and the sampling period TT 1=fs into the one-pole process-equivalent interpolation function obtained from Table 10. These functions include provisions for scaling signal amplitudes of less than full scale, but are taken as VS equalling VFS for this example. Intersample error is therefore found to be directly proportional to process closed-loop bandwidth and inversely proportional to sampling rate. The calculations are as follows: "measurement 0:48%x

" S/H 0:02%x "A=D 0:08%x "D=A 0:05%x "sinc

1 1 2

(Fig. 5) (Table 9) (Table 8) (Table 6)

! sin 0:318 Hz=10 Hz 100% } } 0:318 =10

0:08%FS 3 2 1 "intersample 6 2 32 7 7 6 " 6 sin 1 0:318 Hz 2 # 1 7 7 66 7 10 Hz 0:318 Hz 10 Hz 66 7 7 7 64 5 1 0:318 Hz 0:318 Hz 7 6 1 7 6 10 Hz 7 6 7 62 32 6 Hz " # 17 7 6 sin 1 0:318 2 7 66 7 10 Hz 0:318 Hz 10 Hz 7 7 66 1 7 64 5 0:318 Hz 0:318 Hz 5 4 1 10 Hz 100%

"controlled variable

0:143%FS " #1=2 "measurement 2 1:2 2 "2S=H "2A=D 2 2 2 "D=A "sinc "intersample 0:39%FS

Process Closed-Loop Bandwidth

Process First order Second order


3dB BW of controlled variable 0:35 Hz (tr from Cn) BW 1:1tr p1=2 1 a 12 a2 4!4n Hz where a 4 2 !2n 4!3n T BW 2 (natural frequency !n , sample period T sec, damping ratio )

2!2n

!4n T 2

1=2

156

Garrett

Figure 16 Process controlled-variable de®ned error.

The addition of interpolation, sinc, and device errors results in a total rss controlled-variable error of 0.39%FS, corresponding to 8-bit binary accuracy. This 0.39%FS de®ned error describes the baseline variability of the control loop and hence the process quality capability. It is notable that control-loop tracking cannot achieve less process disorder than this de®ned-error value regardless of the performance enabled by process identi®cation and tuning of the PID compensator.

BIBLIOGRAPHY 1. JW Gardner. Microsensors. New York: John Wiley, 1994. 2. G Tobey, J Graeme, L Huelsman. Operational Ampli®ers: Design and Applications. New York: McGraw-Hill, 1971. 3. J Graeme. Applications of Operational Ampli®ers: Third-Generation Techniques. New York: McGrawHill, 1973. 4. PH Garrett. Computer Interface Engineering for RealTime Systems. Englewood Cliffs, NJ: Prentice-Hall, 1987.


5. PR Geffe. Toward high stability in active ®lters. IEEE Spect 7(May): 1970. 6. P Allen, L Huelsman. Theory and Design of Active Filters. New York: McGraw-Hill, 1980. 7. PH Garrett. Optimize transducer/computer interfaces. Electron Des (May 24): 1977. 8. S Laube. Comparative analysis of total average ®lter component error. Senior Design Project, Electrical Engineering Technology, University of Cincinnati, 1983. 9. M Budai. Optimization of the signal conditioning channel. Senior Design Project, Electrical Engineering Technology, University of Cincinnati, 1978. 10. LW Gardenshire. Selecting sample rates. ISA J April: 1964. 11. AJ Terri. The Shannon sampling theorem ± its various extensions and applications: a tutorial review. Proc IEE 65 (11): 1977. 12. N Weiner, Extrapolation, Interpolation, and Smoothing of Stationary Time Series with Engineering Applications. Cambridge, MA: MIT Press, 1949. 13. E Zuch. Data Acquisition and Conversion Handbook. Mans®eld, MA: Datel-Intersil, 1977. 14. ER Hnatek. A User's Handbook of D/A and A/D Converters. New York: John Wiley, 1976. 15. PH Garrett. Advanced Instrumentation and Computer I/O Design. New York: IEEE Press, 1994.

Chapter 2.2 Fundamentals of Digital Motion Control Ernest L. Hall, Krishnamohan Kola, and Ming Cao University of Cincinnati, Cincinnati, Ohio

2.1

includes control systems as well as numerical methods used to design products with built-in intelligence.'' Motion control applications include the industrial robot [2] and automated guided vehicles [3±6]. Because of the introductory nature of this chapter, we will focus on digital position control; force control will not be discussed.

INTRODUCTION

Control theory is a foundation for many ®elds, including industrial automation. The concept of control theory is so broad that it can be used in studying the economy, human behavior, and spacecraft design as well as the design of industrial robots and automated guided vehicles. Motion control systems often play a vital part of product manufacturing, assembly, and distribution. Implementing a new system or upgrading an existing motion control system may require mechanical, electrical, computer, and industrial engineering skills and expertise. Multiple skills are required to understand the tradeoffs for a systems approach to the problem, including needs analysis, speci®cations, component source selection, and subsystems integration. Once a speci®c technology is selected, the supplier's application engineers may act as members of the design team to help ensure a successful implementation that satis®es the production and cost requirements, quality control, and safety. Motion control is de®ned [1] by the American Institute of Motion Engineers as: ``The broad application of various technologies to apply a controlled force to achieve useful motion in ¯uid or solid electromechanical systems.'' The ®eld of motion control can also be considered as mechatronics [1]: ``Mechatronics is the synergistic combination of mechanical and electrical engineering, computer science, and information technology, which

2.2

Motion control systems may operate in an open loop, closed-loop nonservo, or closed-loop servo, as shown in Fig. 1, or a hybrid design. The open-loop approach, shown in Fig. 1(a), has input and output but no measurement of the output for comparison with the desired response. A nonservo, on±off, or bang±bang control approach is shown in Fig. 1(b). In this system, the input signal turns the system on, and when the output reaches a certain level, it closes a switch that turns the system off. A proportion, or servo, control approach is shown in Fig. 1(c). In this case, a measurement is made of the actual output signal, which is fed back and compared to the desired response. The closed-loop servo control system will be studied in this chapter. The components of a typical servo-controlled motion control system may include an operator interface, motion control computer, control compensator, electronic drive ampli®ers, actuator, sensors and transducers, and the necessary interconnections. The actua157


MOTION CONTROL ARCHITECTURES

158

Hall et al.

2.3

MOTION CONTROL EXAMPLE

Consider the simple pendulum shown in Fig. 2 that has been studied for more than 2000 years. Aristotle ®rst observed that a bob swinging on a string would come to rest, seeking a lower state of energy. Later, Galileo Galilei made a number of incredible, intuitive inferences from observing the pendulum. Galileo's conclusions are even more impressive considering that he made his discoveries before the invention of calculus. 2.3.1

Figure 1 Motion control systems may operate in several ways such as (a) open loop, (b) closed-loop nonservo, or (c) closed-loop servo.

tors may be powered by electromechanical, hydraulic, or pneumatic power sources, or a combination. The operator interface may include a combination of switches, indicators, and displays, including a computer keyboard and a monitor or display. The motion control computer generates command signals from a stored program for a real-time operation. The control compensator is a special prgram in the motion control computer. Selecting the compensator parameters is often a critical element in the success of the overall system. The drive ampli®ers and electronics must convert the low power signals from the computer to the higher power signals required to drive the actuators. The sensors and transducers record the measurements of position or velocity that are used for feedback to the controller. The actuators are the main drive devices that supply the force or torque required to move the load. All of these subsystems must be properly interconnected in order to function properly.


Flexible-Link Pendulum

The pendulum may be described as a bob with mass, M, and weight given by W Mg, where g is the acceleration of gravity, attached to the end of a ¯exible cord of length, L as shown in Fig. 2. When the bob is displaced by an angle , the vertical weight component causes a restoring force to act on it. Assuming that viscous damping, from resistance in the medium, with a damping factor, D, causes a retarding force proportional to its angular velocity, !, equal to D!. Since this is a homogeneous, unforced system, the starting motion is set by the initial conditions. Let the angle at time t 0 be 458. For de®niteness let the weight, W 40 lb, the length, L 3 ft, D 0:1 lb sec and g 32:2 ft/s2 . The analysis is begun by drawing a free-body diagram of the forces acting on the mass. We will use the tangent and normal components to describe the forces acting on the mass. The free-body diagram shown in Fig. 2(b) and Newton's second law are then used to derive a differential equation describing the dynamic response of the system. Forces may be balanced in any direction; however, a particularly simple form of the

Figure 2 Pendulum as studied by Galileo Galilei.

Fundamentals of Digital Motion Control

159

equation for pendulum motion can be developed by balancing the forces in the tangential direction: X 1 Ft Mat

the principal of superposition must hold as demonstrated by the following equations:

This gives the following equation:

where

Mg sin

D

d Mat dt

at

dv d s dt dt2

3

Since the arc length, s, is given by s L

4

Substituting s into the differential in Eq. (3) yields at L

d2 dt2

5

Thus, combining Eqs. (2) and (5) yields Mg sin

D

d d 2 Mat ML 2 dt dt

6

Note that the unit of each term is force. In imperial units, W is in lbf , g is in ft/sec2 , D is in lb sec, L is in feet, is in radians, d=dt is in rad/sec and d 2 =dt2 is in rad/sec2 . In SI units, M is in kg, g is in m/sec2 , D is in kg m/sec, L is in meters, is in radians, d=dt is in rad/ sec, and d 2 =dt2 is in rad/sec2 . This may be rewritten as d2 D d g sin 0 dt2 ML dt L

7

This equation may be said to describe a system. While there are many types of systems, systems with no output are dif®cult to observe, and systems with no input are dif®cult to control. To emphasize the importance of position, we can describe a kinematic system, such as y Tx. To emphasize time, we can describe a dynamic system, such as g h f t. Equation (7) describes a dynamic response. The differential equation is nonlinear because of the sin term. For a linear system, y Tx, two conditions must be satis®ed: 1.

If a constant, a, is multiplied by the input, x, such that ax is applied as the input, then the output must be multiplied by the same constant: Tax ay

2.

8

If the sum of two inputs is applied, the output must be the sum of the individual outputs and


Tx1 y1

2

The tangential acceleration is given in terms of the rate of change of velocity or arc length by the equation 2

Tx1 x2 y1 y2

9

10

and Tx2 y2

11

Equation (7) is nonlinear because the sine of the sum of two angles is not equal to the sum of the sines of the two angles. For example, sin 458 0:707, while sin 908 1. Invariance is an important concept for systems. In an optical system, such as reading glasses, position invariance is desired, whereas, for a dynamic system time invariance is very important. Since an arbitrary input function, f t may be expressed as a weighted sum of impulse functions using the Dirac delta function, t . This sum can be expressed as 1

f t

f t

d

12

1

(Note that t is the time the output is observed and is the time the input is applied.) The response of the linear system to this arbitrary input may be computed by 2 1 3 f t d5 13 gt h4 1

Thus by the property of linearity we obtain 1

gt

f ht

d

14

1

Therefore, the response of the linear system is characterized by the response to an impulse function. This leads to the de®nition of the impulse response, ht; , as ht; ht

15

Since the system response may vary with the time the input is applied, the general computational form for the output of a linear system is the superposition integral called the Fredholm integral equation [7,8]:

160

Hall et al.

Gs Hs Fs

gt f ht; d

16

where 1

The limits of integration are important in determining the form of the computation. Without any assumptions about the input or system, the computation must extend over an in®nite interval. 1 f ht; d 17 gt 1

An important condition of realizability for a continuous system is that the response be nonanticipatory, or casual, such that no output is produced before an input is applied: ht; 0

for t

0

The mathematical de®nition for the discrete-time case is identical. The important consequence of the two previous de®nitions for stability is the location of the poles of the transfer function of a stable system. The transfer function is in the form of a ratio of polynomials as in Eq. (3). The denominator polynomial is called the characteristic polynomial of the system and if the characteristic polynomial is equated to zero, the resulting equation is called the characteristic equation. The roots of the characteristic equation are called the

Stability

poles of the transfer function. As shown in Kuo [3], a necessary and suf®cient condition for a system to be absolutely stable is that all of its poles must lie in the left half plane (the poles have negative real part) for continuous-time systems, or lie within the unit circle (pole magnitude less than 1) for discrete-time systems. For systems de®ned by the state space model, the poles are the eigenvalues of the state transition matrix A. 2.3.2

Marginal Stability

As with all de®nitions in engineering, there exist some exceptions to the rules of stability. Several important systems, such as the differentiation operator and the pure integrator as continuous-time systems, violate the rules of asymptotic stability and BIBO stability, respectively. Other cases exist in the set of systems that have resonant poles along the j!-axis (imaginary axis), for continuous-time systems, or on the unit circle, for discrete-time systems. While the differentiation operator violates the asymptotic stability de®nition, since the impulse response is not bounded, it does satisfy the BIBO de®nition. In any case, it is generally considered stable. For an integrator, the impulse response is a constant and thus bounded and in the limit is a constant, as described in Oppenheim et al. [4]; however, for a step input, which is bounded, the output grows without bound. The same would occur if the input is a sinusoid of the same frequency as any imaginary axis (unit circle for discrete-time systems) poles of a system. Since such systems only ``blow up'' for a countable ®nite number of bounded inputs, such systems are often considered stable. However, for any input along the imaginary axis (unit circle), the output of these systems will neither decay to zero nor even to a stable value. Systems such as these are referred to as marginally stable. For these systems the roots of the polynomial, or eigenvalues of the state transition matrix, that do not meet the criteria for absolute stability, lie on the imginary axis (zero real-value part) for a continuous-time system or lie on the unit circle (magnitude equal to 1) for a discretetime system. While some consider such systems as stable, others consider them unstable because they violate the de®nition of absolute stability.

221

To a design engineer such a measure provides valuable information. It indicates the allowable variation or uncertainty that can exist in the system. Such a measure is referred to as relative stability. Many different measures for relative stability are available so it is important to discuss desirable measures.

2.4

STABILITY CRITERIA AND TESTS

Now that we have de®ned stability, we need tools to test for stability. In this section, we discuss various criteria and tests for stability. This section follows the format from the preceding section in that we ®rst discuss the techniques for determining absolute stability, followed by those for marginal stability, and ®nally those for relative stability. 2.4.1

There exist two approaches for determining absolute stability. The ®rst is to use time-domain system models. The second, and the most usual, is to deal with the transfer function. Both types of techniques are presented here. 2.4.1.1

Relative Stability

Once we have determined that a system is absolutely stable, usually we desire to know ``How stable is it?''


Zero-Input Stability Criteria

Given a zero-input system in the time-domain form of Eq. (1) with all terms on the right-hand side equal to zero, stability is de®ned in terms of the impulse response function which, for stability, must satisfy the following conditions: 1. There exists a ®nite real number M such that jhtj M for all t t0 . 2. lim jhtj 0: l!1

Similar criteria for the impulse response sequence hkT can be used to determine stability for the discrete-time case. If a system is modeled by the state-space form of Eq. (9), the criteria become: 1. There exists a value M such that kxtk M for all t t0 . 2. lim kxtk 0: t!1

2.4.1.2 2.3.3

Absolute Stability Criteria

Bounded-Input±Bounded-Output Time Domain Criteria

When systems such as the continuous-time system, Eq. (1), or the discrete-time system, Eq. (2), are modeled by their impulse response functions, BIBO stability can be

222

Stubberud and Stubberud

demonstrated directly from the de®nition and the property of convolution. Since the input is bounded there exists a value N such that jutj N < 1 If the output yt is bounded, then there exists a value M such that

an xn an 1 xn

jytj M < 1 which implies that 1 1 jut hj d jut jytj 0 0 1 Njhj d < 1

characteristic equation, or poles, of the system lie in the right half plane or along the j!-axis. While they provide suf®cient conditions for unstable poles, they do not provide necessary conditions. However, they are fast and require no computation. Given a polynomial

j d

1

a 1 x a0 0

we may be able to determine if there exist any roots that lie outside the left half plane using the following table.

0

Since the input is bounded by a constant, all we need to show is that 1 jhj d < 1 0

For the discrete-time case, we similarly need to show 1 X

jhkTj < 1

Properties of polynomial coef®cients

Conclusion about roots from the coef®cient test

Differing algebraic signs

At least one root in right half plane

Zero-valued coef®cients

Imaginary axis root and/or a pole in right half plane

All algebraic signs same

No information

k0

For the state space form of the problem, Eq. (9), we use the formulation t xt t u d 0

which results in the following tests, for continuoustime and discrete-time systems, respectively: 1 kk d < 1 0

or 1 X

Example 1. 4x3 7x2

Given the polynomial 3x 1 0

we know that at least one root lies in the right half plane because there is at least one sign change in the coef®cients. If this were the characteristic equation of a system, the system would be unstable. However, we would not know about any of the root locations for the equation x5 3x4 12x3 x2 92x 14 0

kkTk < 1

k0

where t is the state-transition matrix of the continuous-time system and k k represents a matrix norm and similarly for the discrete-time system. 2.4.1.3

Polynomial Coef®cient Test (Continuous-Time Systems)

Polynomial coef®cient tests provide a quick method to determine if a system is unstable by looking for poles of the system's characteristic polynomial in the right half plane. These are typically the ®rst of several tests used to determine whether or not the roots of the


because all of the signs are the same and none of the coef®cients are zero. 2.4.1.4 Routh Test (Continuous-Time Systems) While the coef®cient tests can tell you if you have an unstable system, it cannot inform you whether or not you have a stable system or how many poles lie outside the left half plane. In order to overcome this dif®culty, we apply the Routh test. In much of the literature, this is also referred to as the Routh±Hurwitz test. Given an equation of the form an sn an 1 sn

1

a 1 s a0 0

Stability

223

the Routh test is performed using the Routh table: sn an an 2 an 4 . . . sn 1 an 1 an 3 an 5 . . . b2 b3 . . . sn 2 b1 c2 c3 ... sn 3 c1 .. . .. .. .. . . . . . . 0 s where the ai s are the coef®cients of the polynomial and an 1 an 2i an an 2i1 bl and an 1 b1 an 2i1 an 1 bi1 ci b1 A polynomial has all of its roots in the left half plane if, and only if, all of the elements in the ®rst column of Routh table have the same sign. If sign changes are present, then the number of roots with positive real parts is equal to the number of changes of sign of the elements in the ®rst column. Example 2.

Given the polynomial equation

s4 4s3 101s2 494s 600 0 we create the Routh table s4 1 101 600 s3 4 494 0 s2 s1 s0 We compute the third row from b1 b2

4 101

1 494 4

and

4 600 1 0 4

The resulting Routh table is 101 600 s4 1 494 0 s3 4 s2 90=4 600 s1 s0 Row four is computed similarly from rows two and three: 101 600 s4 1 494 0 s3 4 s2 90=4 600 s1 1802=3 s0


The completed Routh table becomes s4 1 s3 4 s2 90=4 s1 1802=3 s0 600

101 494 600

600 0

We note that we have two sign changes, rows two to three and three to four, which implies that two of our roots are in the right half plane and three are in the left half plane. As with all techniques there are problems that can occur with the Routh table. Polynomials do exist that can result in the computation of a zero in the left column in the Routh table. An excellent example can be found in Hostetter et al. [2]. A polynomial equation of the form s4 3s3 2s2 6s 4 0 will result in the following Routh table: s4 1 2 s3 3 6 s2 0 4 s1 s0

4 0

Note the zero in the third row of the table. There are two methods to alleviate this problem. The ®rst is to multiply the original polynomial by a ®rst-order known-root polynomial such as s 1. This produces a new polynomial s5 4s4 5s3 8s2 10s 4 0 whose computed Routh table is s5 s4 s3 s2 s1 s0

1 4 3 4 12 4

5 8 9 4 0

10 4

The second technique is to realize that a minor perturbation in any coef®cient would result in a nonzero entry in the third element of the ®rst column. For our example, the perturbed Routh table would be

224


s4 3 s s2 1 6" s 0 s

1 3 "

2 4 6 0 4

To implement this technique, we start with the term of the general input±output gain rule or Mason's gain formula [3,5]:

12 1 Fs 1

" 4

Once the Routh table is completed, we let " go to zero. This results in the Routh table of 2 4 s4 1 6 0 s3 3 4 s2 0 s1 1 s0 4 A ®nal note is that while " can be of any sign it should be taken to have the same sign as the previous column element. 2.4.1.5

Nyquist Stability Criterion

The Routh test provides information pertaining to stability and the number of unstable poles of a system. However, often when we are designing a control system, we want even more information. The Nyquist stability criterion is a quasigraphical frequency domain method for determining stability and can be used for design as well.

Nums Dens

This is the denominator of the closed-loop system transfer function Fs 1 Fs where we note that Fs is the ratio of the polynomials Nums to Dens. To generate a Nyquist plot, we let s j!, calculate the real and imaginary parts of Eq. (15) for all of the values along the j!-axis, and then plot the results on the complex plane. Example 3.

The curve for

1 Fs 1

s2 3s 2 s3 3s2 4

when s j!, 1 < ! < 1 is seen in Fig. 1. The dashed line indicates results for the negative frequency values.

Figure 1 The Nyquist curve does not encircle the point 1; 0.


15

Stability

225

A closed-loop system with

The system is said to be stable if, and only if,

Nums Dens 0 as the characteristic equation of its open-loop transfer function is stable if, and only if, the Nyquist plot encircles in the counterclockwise direction the point 1; 0 in the complex plane the same number of times as the number of poles of Fs which have a positive real parts. If there are no poles of Fs with positive real parts, then the Nyquist plot does not encircle the point 1; 0: The number of the unstable roots of the numerator of 1 Fs, which are the poles of the closed-loop system, is equal to the difference between the number of right half plane poles and the number of counterclockwise encirclements. For the example above, we have no encirclements and one right half plane pole. Therefore, we have one right half plane zero, which translates into one right half plane pole in our closed-loop system. For discrete-time systems, we change from using the imaginary axis for computing the Nyquist plot to the frequency values along the unit circle. The number of zeros in the system are related to those outside the unit circle. 2.4.1.6

Schur±Cohn Test (Discrete-Time Systems)

One of the earliest techniques used by control engineers to determine the stability of a discrete-time system is the Schur±Cohn test. For a given characteristic polynomial, an zn an 1 zn

1

a1 z a 0

we can determine the system stability by examining the determinants a0 a1 .. . a k k 1 an a n 1 . .. a

n k1

0 a0 .. .

ak 2 0 an .. .

an

k2

0 0 .. .

ak 3 0 0 .. .

an

k3

... ... .. . ... ... ... .. .

0 0 .. .

0 0 0 .. .

. . . an

an 0 .. . 0 a 0 0 .. . 0

an 1 an .. . 0 a1 a0 .. . 0

. . . an k1 . . . an k2 .. .. . . ... an . . . ak 1 . . . ak 2 .. .. . . ... a

k < 0

k odd

k > 0

k even

Example 4. polynomial

4z2 2z 2 is stable. We form the determinants 2 1 4 2 2 2 4 2 4

2.4.1.7


0 2 0 4

16

12

4 2 0 4 2 2 0 2

162

42

42 144

16 128

Jury Test (Discrete-Time Systems)

The Jury test for determining the stability of discretetime systems is similar to the Routh criterion for continuous-time systems and is much simpler to implement than the Schur±Cohn test. Where the Routh test determines if the roots of a polynomial equation are in the left half plane, the Jury test determines whether the roots of a polynomial equation are inside the unit circle. The Jury test begins with the development of the Jury array:

0

k 1; 2; . . . ; n

a k complex conjugate ak

4 4 2

Since 1 < 0 and 2 > 0, the system is stable.

where

and

Determine if the system with characteristic

2n 2n 2n

1 2 3 4 5 6 .. .

a0 an b0 bn 1 c0 cn 2 . .. 5 r0 4 r3 3 s0

a1 an 1 b1 bn 2 c1 cn 3 .. . r1 r2 s1

a2 an 2 b2 bn 3 c2 cn 4 .. . r2 r1 s2

... ... ... ... ... ... ... ... . . . cn 2 . . . c0 .. . r3 r0

an 1 a1 bn 1 b0

an a0

226


where bk ck s0 s1

a0 an k an ak b0 bn 1 bn 1 bk r0 r3 r3 r0 r0 r2 r2 r1

and

r s2 0 r3

H 1 1

k

Construct the Jury array: 1 0:25 0:5 0:3 2 1 0:6 0:3 3 0:9375 0:725 0:225 4 0:65 0:225 0:725 5 0:4654 0:8259 0:6821

0:9375 > 0:65 0:4654 < 0:6821

1

a 1 z a0

The elements of the next two rows are computed using the determinants de®ned above. The process continues, with each new pair of rows having one less column than the prior pair of rows until row 2n 3 is computed. This last row has only three elements and does not have its reversed-order pair. Thus a seventh-order polynomial would have 11 rows. Once the Jury array is complete, we can perform the entire Jury test which provides necessary and suf®cient conditions for the roots of the polynomial equation to have magnitudes less than 1. Note that the ®rst two parts of the test can be completed without construction of the Jury array. 2. 3.

Hzjz1 > 0: > 0 for n even, Hzjz 1 < 0 for n odd. ja0 j < an jb0 j > jbn 1 j jc0 j > jcn 2 j

Given the characteristic polynomial

Hz z4 0:6z3 0:3z2

0:5z 0:25

is the system stable? Test 1: H1 1 0:6 0:3

Since the ®nal inequality violates Test 3, the system is unstable. We note that the element an is assumed to be positive and can always be made so without changing the roots of the system by multiplying the polynomial by 1. 2.4.1.8 w-Plane Transformation/Routh Test for Discrete-Time Systems While the Jury test informs us of stability, it does not tell us how many poles are outside the unit circle. If this is desired, we can employ the Routh test. We cannot perform the test directly on the polynomial because again we would only be able to determine whether or not the poles of the discrete-time system were in the right or left half planes, which is basically useless. In order to invoke this test, we perform the bilinear transformation [5] on the discrete-time based polynomial. The complex variable z is then transformed into the new complex variable w which is similar to the complex variable s in the familiar s-plane. The bilinear transformation is given by the equivalent expressions: z

jr0 j > jr3 j js0 j > js2 j. Example 5.

1 0:25

0:25 < 1

The terms ai are the coef®cients of the polynomial

1.

0:6 0:5 0:65 0:9375

Test 3:

r1 r2

Hz an zn an 1 zn

0:6 0:3 0:5 0:25 1:75 > 0

0:5 0:25 1:65 > 0

Test 2:


1w 1 w

w

z 1 z1

This transformation transforms roots of a polynomial equation inside the unit circle of the z-plane into the left half of the s-plane, transforms the roots outside the unit circle into the right half plane, and the roots on the unit circle onto the j-axis. We can examine the location of the roots of the polynomial equation Hz an zn an 1 zn

1

a 1 z a0 0

by letting z 1 w=1 equation

w, thus generating the

Stability

227

1w n 1w n 1 an 1 1 w 1 w 1w a1 a0 0 1 w

Hw an

We need only concern ourselves with the numerator of this equation to ®nd root locations: an 1 wn

an 1 1 wn 1 1 a1 1 w1

w

a0 1

n

w 0

and apply the Routh test to determine root locations. Example 6. nomial

Given the discrete-time characteristic poly-

Hz 4z2

4z 1

we want to determine stability and the number of any unstable poles. The transformed equation is given by w2 6w 9 0 Now we apply the Routh test which indicates that this is the characteristic polynomial of an absolutely stable system. 2.4.1.9

Eigenvalue Computation

If a system is modeled in the state-space form _ Axt But xt yt Cxt Dut the stability is determined by the location of the eigenvalues of the matrix A. For continuous time systems, the eigenvalues must be in the left half plane. Similarly, for discrete-time systems, the magnitude of the eigenvalues must be less than one. The question becomes how do we ®nd the eigenvalues. There are many techniques to compute the eigenvalues of a matrix. Several can be found in Wilkinson [6] and Golub and Van Loan [7]. New techniques are probably being developed as you read this. A computer implementation can be found in any numerical linear algebra package such as EISPACK. In this section we outline one technique, the real Schur decomposition. The real Schur form is a block triangular form 2 3 X X X D11 X 6 X X 7 D22 X 6 7 6 .. 7 .. .. 6 7 . . . 6 7 4 0 Dn 1n 1 X 5 Dnn


Dii i ji where

w n 1

where the diagonal block elements, Dii , are either 1 1 or 2 2 element blocks. The single-element blocks are the real eigenvalues of the system, while the 2 2 blocks represent the complex and imaginary eigenvalues via

Dii

i i

i i

The algorithm begins by reducing the matrix A to what is referred to as an upper Hessenberg form 2 3 X X X X X 6X X X X X 7 6 7 60 X X X X7 6 7 40 0 X X X5 0 0 0 X X We then use the iteration for k 1; 2; 3; . . . Hk 1 Uk Rk Hk Rk Uk end

where Hk 1 Uk Rk is a QR factorization, a technique that reduces a matrix to a product of an orthogonal matrix postmultiplied by an upper triangular matrix [7]. Once the algorithm is completed, you check for any eigenvalues whose real part is nonnegative. Each such eigenvalue is an unstable pole of the transfer function. 2.4.1.10

Kharatonov Polynomials

When actually designing a real system, you may ask questions about variations in the parameters of the physical system compared to the design parameters. Resistors and motors may be the ``same'' but no two are identical. Operating conditions and/or age can cause changes in operating parameters. Will these changes affect the system's stability? Hopefully not. However, in today's litigious society, we need a little more than hope. To check the stability for your system over a range of values for each coef®cient, we can use the Kharatonov polynomials [8]. Given a polynomial with a range of values for each coef®cient n an ; an sn a n 1 ; an 1 s

a 0 ; a0 0

1

a 1 ; a1 s

228


where a i ; ai indicates the bounds of a coef®cient, we can determine the stability of the system by determining the stability of the following four polynomials: 2 3 4 5 p1 s a 0 a1 s a2 s a 3 s a 4 s a5 s

a6 s 6 a7 s 7 2 3 4 5 p2 s a0 a1 s a 2 s a 3 s a 4 s a5 s 7 a6 s 6 a 7 s

p3 s

a 0

2

a1 s a2 s 6

a6 s

7 a 7s

3 a 3s

4 a 4s

a5 s

5

2 3 4 5 p4 s a0 a 1 s a2 s a 3 s a 4 s a5 s

a6 s 6 a7 s 7 Now all that needs to be shown is that the roots of each of these four equations are in the left half plane, and we have guaranteed stability over the entire range of all the coef®cients given. 2.4.2 2.4.2.1

Marginal Stability Polynomial Test (Continuous-Time Systems)

If our interest is not in absolute stability, the coef®cient test results change. If a coef®cient is zero, then we know that at least one root can lie on the imaginary axis. However, the location of the other roots, if the signs do not change, are not known. Thus, the result of a zero coef®cient is necessary but not suf®cient for marginal stability. The table below may give us information about relative stability. Properties of polynomial coef®cients

Conclusion about roots from the coef®cient test

Differing algebraic signs

At least one root in right half plane

Zero-valued coef®cients All algebraic signs same

No information No information

2.4.2.2

Routh Test (Continuous-Time Systems)

In the earlier section on the Routh test, we avoided asking the question what happens if the roots of the polynomial lie on the imaginary axis. If a system is marginally stable or just has imaginary roots, the Routh table can terminte prematurely. In this section, we provide a technique for dealing with this problem.


Given the polynomial Hs s4 5s3 10s2 20s 24 the computed Routh table is s4 1 10 24 s3 5 20 0 s2 6 24 s1 0 0 s0 As expected, it has terminated prematurely with a row of zeros. This implies that 6s2 24 is a factor of the original polynomial. We replace the zero row of the Routh table with the derivative of this factor, that is, d=ds6s2 24 12s, s4 1 10 24 s3 6 20 0 s2 6 24 s1 12 0 s0 24 and continue computing the Routh table. The result implies that we have two roots in the left half plane, and two imaginary roots, thus our system is marginally stable. If there were a change in signs between any row, then we would have a pole in the right half plane. Any time that an imaginary pair of roots exists, then the Routh table will contain a zero row. All of the roots will be contained in the factor polynomial. 2.4.2.3 Other Algorithms The w-plane, eigenvalue, and Kharatonov techniques can be expanded to look for marginally stable poles just by changing what we are looking for, nonpositive poles instead of nonnegative poles. 2.4.3

Relative Stability

Our ®nal discussion on stability for linear time-invariant systems is about relative stability. We have presented several techniques to determine whether or not a system is stable. However, we often like to know how stable a system is. To what degree can the system be changed before stability is lost. Relative stability techniques give this measure of the degree of stability. 2.4.3.1 Distance Measure of the Poles Relative stability is important in design because the locations of the poles have a great deal of effect on

Stability

229

the performance of the system. For instance, complex conjugate pole pairs that are close to the imaginary axis can cause ringing behavior in the system. Poles that have a real part whose magnitude is less than the imaginary part can show resonance behavior as the input frequency gets closer to the resonant frequency. Therefore, we should use a measure of distance from the imaginary axis as a measure of relative stability, right? Wrong! As seen in Oppenheim et al. [4], Butterworth poles can be close to the imginary axis but the system behavior is quite stable and without a resonant frequency. Also, in state space problems small changes in particular elements can cause major changes in the system behavior. For example, the state transition matrix 2 3 0 1 0 0 0 60 0 1 a 07 6 7 60 0 0 1 07 6 7 40 0 0 0 15 " 0 0 0 0 has its poles located at the origin if a and " are set to zero. If a is set to 100, the poles are still located at the origin. However, if " is set to 1, the system poles are distributed on the unit circle, which for both discretetime and continuous-time systems prevents absolute stability. The change of " is small compared to that of a, yet it changes the stability of the system substan-

tially. The same can happen when the parameters of the characteristic polynomial change. This is one reason for the development of Kharatonov's stability test. Pole location can tell us a great deal about the system behavior, but the simple measure of distance from the j-axis should not be used as a measure of relative stability. 2.4.3.2

Gain and Phase Margin

Gain and phase margin have long been used as a useful measure of relative stability. Both of these quantities are computed using the open-loop transfer function 1 Fs 1

Nums Dens

the same that was used for the Nyquist stability criterion. As with the Nyquist stability criterion, we note that the technique works as well for discrete-time systems. Simply replace all references to the imaginary axis with references to the unit circle. We de®ne gain margin as the magnitude of the reciprocal of the open-loop transfer function at the phase crossover frequency, ! phase 1808: Phase margin is de®ned as 1808 plus the phase angle of the open-loop transfer function at the frequency where the gain is equal to unity.

Figure 2 Magnitude and phase Bode plots demonstrate gain and phase margins.


230


Mathematically, we write gain margin as

x_ fxt; ut

1 gain margin jF! j

yt gxt; ut

and phase margin as PM 180 argF!1 degrees Note that we can also de®ne gain margin in decibels gain margin

20 log jF! j

To use these two quantities, we need to interpret them. Gain margin is measured as the number of decibels below 0 dB that the open-loop transfer function is at the phase crossover frequency. Phase margin is measured as the number of degrees above 1808 that the phase of the open-loop transfer is when its gain is equal to unity. While both a positive phase and gain margin can usually indicate stability of a system, there do exist cases where this is not true, thus care should be taken when determining absolute stability. If a system is not absolutely stable, then relative stability has no meaning. Example 7. Fs

Given the open-loop transfer function

4 s 3s 3s 1 3

2

determine the phase and gain margin. We shall use a Bode plot [2,5,8,9] to perform the analysis. As seen in Fig. 2, the phase crossover frequency is at 1.7348 rad/ sec. This implies that the gain margin is gain margin 1:9942 5:9954 dB The phase margin is measured at a frequency of 1.234 rad/sec. The phase margin is phase margin 27:08828

2.5

STABILITY OF NONLINEAR SYSTEMS

In this section we discuss the stability of nonlinear systems, both continuous-time and discrete-time. As for LTI systems, stability is a binary concept; however, beyond that, stability of nonlinear systems is much more complex, thus the stability criteria and tests are more dif®cult to apply than those for LTI systems. Two models will be used to represent nonlinear systems. For nonlinear, continuous-time systems the model is


16

where the nonlinear differential equation is in state variable form and the second equation is the output equation of the system. For nonlinear, discrete-time systems the model is xk 1 fxk; uk

17

yk gxk; uk

where the nonlinear difference equation is in state variable form and the second equation is the output equation of the system. In the following two sections, two different stability concepts will be presented for the nonlinear systems models de®ned above. 2.5.1

Linearization and Small Perturbation Stability

The small perturbation stability of a nonlinear, continuous-time system is de®ned in a small region near a ``point'' de®ned by a particular input vector u t and the corresponding output vector xt, the ordered pair fxt; u tg is called an operating point. The nonlinear continuous-time system de®ned in Eq. (16) is linearized about the operating point by de®ning the linear per turbations xt xt xt, ut ut u t, and yt yt y t, then expanding the functions fxt; ut and gxt; ut in a Taylor series expansion about the operating point fxt; u tg, retaining only the ®rst two terms of the Taylor series, and recognizing that _ fxt; xt u t and y t gxt; u t, the following two small perturbation equations result: @f @f xt ut @x xxt @u xxt uut uut @g @g yt xt ut @x xxt @u xxt

_ xt

uut

18

uut

where 2

@f1 6 @x1 @f 6 6 6 .. @x 6 . 4 @f n @x1

3 @f1 @xn 7 7 .. .. 7 . . 7 7 @fn 5 @xn

2

@f1 6 @u1 @f 6 6 6 .. @u 6 . 4 @f n @u1

..

.

3 @f1 @ur 7 7 .. 7 . 7 7 @fn 5 @ur

Stability

231

2

@g1 6 @x1 @g 6 6 ... @x 6 4 @gm @x1

2

3 @g1 @xn 7 7 .. 7 . 7 @gm 5 @xn

..

.

@g1 6 @u1 @g 6 6 ... @u 6 4 @gm @u1

3 @g1 @ur 7 7 .. 7 .. . 7 . @gm 5 @ur

Note that these equations are linear equations in the small perturbations, and further note that if the elements of the operating point are constants, that is, if x a constant u t u a constant vector and xt vector, then these equations are time invariant and Eq. (18) is an LTI, continuous-time system as given in Eq. (9). When these equations are time invariant, all of the criteria and tests for stability that are applicable to LTI, continuous-time systems in Sec. 2.4 are directly applicable to these equations. It should be remembered that stability of this type is valid only when the linear perturbations xt, ut, and yt are ``small.'' The problem with this requirement is that it is, in general, very dif®cult, if not impossible, to determine how small they must be. In spite of this, the stability of the linearized equations is a valuable tool in nonlinear control system design. Example 8. x_

x_ 1 x_ 2

The nonlinear system

fx; u

x2 sin x1 u

y y x1 is a simple model of a pendulum driven by a torque u. This system has two operating points of interest: fx 1 0, x 2 0, u 0g, which represents the case when the pendulum is at rest and hanging straight down, and fx 1 , x 2 0, u 0g, which represents the case when the pendulum is at rest and standing straight up. The linearized equations for the ®rst case are x_

x_ 1 x_ 2

0

1

1

0

x1 x2

0 1

u

A x b u y x1 c x1 The small perturbation stability is determined by the eigenvalues of the matrix A which are located at s j. Thus the system is marginally stable about the operating point fx 1 0; x 2 0; u 0g. For the operating point fx 1 ; x 2 0; u 0g, the linearized equations are


x_ 1 x_ x_ 2

0 1 1 0

x1 0 u x2 1

A x bu y x1 c x1 For this case, the eigenvalues of the matrix A are at s 1. The pole in the right half plane indicates the system is unstable, which certainly satis®es our intuition that a pendulum which is standing straight up is in an unstable position. Nonlinear, discrete-time systems described by Eq. (17) can be linearized similarly with the resulting linear perturbation equations given by @f @f xk uk xk 1 xxk @x uuk @u xxk uuk 19 @g @g xk uk yk xxk @x uuk @u xxk uuk

where fxk; u kg is the operating point and the notation is the same as in Eq. (18). As with the linearized equations for continuous-time systems, these equations are valid only for small perturbations, that is, xk, uk, and yk must be ``small.'' Even though determining how small is generally impossible, the stability analysis obtained from this linearized model can be a valuable tool in control system design. As is the case for the small-perturbation continuous-time model in Eq. (18), when u k u a constant vector and xk x a constant vector, the small perturbation system in Eq. (19) is an LTI, discrete-time system and all of the stability criteria and tests in Sec. 2.4 are applicable to this system. 2.5.2

Lyapunov Stability for Nonlinear Systems

In this section the stability of nonlinear systems with zero input will be examined using the Lyapunov stability criterion. Since u 0, the equations de®ning nonlinear systems, Eqs. (16) and (17), will be rewritten, respectively, as _ fxt xt y t gxt and xk 1 fxk yk gxk The stability for each of these systems is determined by the ®rst equation only, thus only the ®rst equations need to be considered, that is, the equations

232


x_ fxt

16 0

and xk 1 fxk

17 0

will be examined for stability. For both of these equations, a singular point is de®ned as a solution x0 for the equation fx0 0. Note that a solution is generally not unique for nonlinear systems. The stability of the system, whether it is continuous-time or discrete-time, is determined with respect to one or more of the singular points. A singular point is said to be stable if there exist two n-dimensional spheres of ®nite radii, r and R, each centered at the singular point and such that for any solution xt of the differential equation (any solution xk of the difference equation) that starts in the sphere of radius r remains in the sphere of radius R forever. A stable singular point is called asymptotically stable if all solutions xt of the differential equation xk for difference equation] approach the singular point as time approaches in®nity. If the origin of the state space is a singular point, that is, one solution of the equation fx0 0 is x0 0, then the Lyapunov stability criterion states that the origin is a stable singular point if a Lyapunov function (a scalar function) can be found such that: 1. 2.

Vx > 0 for all x 6 0. For a. Continuous-time systems, V_ 0 for all x. b. Discrete-time systems, Vk Vk 1 Vk 0 for all x.

For continuous-time systems, if in addition to the conditions above, V_ 0 if, and only if, x 0 then the origin is called asymptotically stable. For discretetime systems if in addition to the conditions above, Vk 0 if, and only if, x 0, then the origin is called asymptotically stable. Note that these conditions are suf®cient, but not necessary, for stability. Example 9. Consider the nonlinear differential equation x2 x_ 1 fx x_ 3 x_ 2 x2 x2 x1


Obviously, the origin, x1 x2 0, is a singular point and the Lyapunov stability criterion might be used to determine its stability. Consider the Lyapunov function de®ned by Vx1 ; x2 x21 x22 , which is positive unless Its derivative is given by x1 x2 0. _ 1 ; x2 2x1 x_ 1 2x2 x_ 2 2x22 2x42 , which is Vx never positive, thus the origin is stable. Note that since the derivative can be zero for x1 6 0, then the condition for asymptotic stability is not satis®ed. This does not mean that the system is not asymptotically stable, only that this Lyapunov function does not guarantee asymptotic stability. Another Lyapunov function might satisfy the condition for asymptotic stability. In using the Lyapunov stability theory, it should be noted that there is no suggestion as to the form of Lyapunov function for any particular system. Generally, the choice of a suitable Lyapunov function is left to the system analyst.

REFERENCES 1. MS Santina, AR Stubberud, GH Hostetter. Digital Control System Design, Second Edition. Fort Worth, TX: Saunders College Publishing, 1994. 2. GH Hostetter, CJ Savant, Jr, RT Stefani. Design of Feedback Control Systems, Second Edition. New York: Saunders College Publishing, 1989. 3. BC Kuo. Automatic Control Systems, 4th ed. Englewood Cliffs, NJ: Prentice-Hall, 1982. 4. AV Oppenheim, AS Willsky, IT Young. Signals and Systems. Englewood Cliffs, NJ: Prentice-Hall, 1983. 5. JJ Di Stefano, AR Stubberud, IJ Williams. Feedback and Control Systems, 2nd ed. New York: McGrawHill, 1990. 6. JH Wilkinson. The Algebraic Eigenvalue Problem. Oxford: Oxford University Press, 1992. 7. GH Golub, CF Van Loan. Matrix Computations, 2nd ed. Baltimore, MD: The Johns Hopkins University Press, 1989. 8. W Levine, ed. The Control Handbook. New York: CRC Press, 1996. 9. RC Dorf. Modern Control Systems, 3rd ed. Reading, MA: Addison-Wesley, 1980.

Chapter 3.3 Digital Signal Processing Fred J. Taylor

University of Florida, Gainesville, Florida

3.1

INTRODUCTION

Signal processing is as old as history itself. Early man relied on acoustic and optical signal processing for his very existence. Man is, in some respects, the quintessential signal processing machine. With a few exceptions, prior to the advent of digital electronics, signal processing technology was called analog (continuous-time). Analog electronic signal processing systems were historically designed using resistors, capacitors, inductors, and operational ampli®ers. By mid-century another technology emerged called sampled-data (discrete-time) systems (see Chap. 3.4). In general, all these technologies are in the process of being replaced by digial signal processing (DSP) systems. DSP is a relatively young branch of engineering which can trace its origins back to the mid-1960s with the introduction of the now-celebrated Cooley±Tukey fast Fourier transform (FFT) algorithm. The FFT algorithm was indeed a breakthrough in that it recognized both the strengths and weaknesses of a general-purpose digital computer and used this knowledge to craft an ef®cient computer algorithm for computing Fourier transforms. The popularity and importance of DSP has continued to grow ever since. Contemporary DSP applications areas include: 1.

2.

3.

4.

5.

General purpose Filtering (convolution) Detection (correlation) 233


Spectral analysis (Fourier transforms) Adaptive ®ltering Neural computing Instrumentation Waveform generation Transient analysis Steady-state analysis Biomedical instrumentation Information systems Speech processing Audio processing Voice mail Facsimile (fax) Modems Cellular telephones Modulators, demodulators Line equalizers Data encryption Spread-spectrum Digital and LAN communications Graphics Rotation Image transmission and compression Image recognition Image enhancement Control Servo control Disk control Printer control Engine control Guidance and navigation

234

6.

Taylor

Vibration (modal) control Power systems monitors Robots Others Radar and sonar Radio and television Music and speech synthesis Entertainment

The study of analog systems remains closely related to DSP at many levels. Classical digital ®lters are, in fact, simply digital manifestations of analog radio ®lters whose structures have been known for nearly 75 years. One of the principal differences between an analog and digital system is found in how they interface to the external world. Analog systems import analog signals and export the same without need of a domain conversion. Digital systems, alternatively, must change the domain of any analog signal to digital before processing and return the signal to the analog domain in some cases. A typical DSP signal processing stream is shown in Fig. 1. An analog antialiasing ®lter is introduced to eliminate aliasing (see Chap. 3.4) by heavily attenuating input signal energy above the Nyquist frequency fs =2, where fs is the sampling frequency. The conditioned signal is then passed to an analog-to-digital converter (ADC). Following the ADC is the DSP system which typically implements a set of instructions which are de®ned by a DSP algorithm (e.g., ®lter) whose output may or may not be converted back into the analog domain, depending on the application. An analog signal can be reconstructed from a digital signal using a digital-to-analog converter (DAC). The typical DSP system is characterized in Fig. 1. Digital ®lters initially made their appearance in the mid-1960s using discrete logic. Their expense and limited programmability restricted their use to narrowly de®ned applications. Digital ®lters are now regularly developed using commonly available commercial off-

the-shelf (COTS) DSP microprocessors and application-speci®c integrated circuits (ASICs). A vast array of CAD tools and products can now be found to support this technology. The struggle between analog and DSP will continue into the future with the race increasingly favoring DSP well into the 21st century. It is commonly assumed that the attributes of analog and digital signal processing systems compare as follows: The continued evolution of the semiconductor is being driven by digital devices and digital signal processing systems which provide a technological advantage over analog systems. This gap between digital and analog performance and price points is increasingly favoring digital. Digital systems can operate at extremely low frequencies which are unrealistic for an analog system. Digital systems can be designed with high precision and dynamic range, far beyond the ability of analog systems. Digital systems can be easily programmed to change their function; reprogramming analog systems is extremely dif®cult. Digital signals can easily implement signal delays which are virtually impossible to achieve in analog systems. Digital signals can easily implement nonlinear signal operations (e.g., compression), which are virtually impossible to implement with analog technology. Digital systems remain stable and repeatable results, whereas analog systems need periodic adjustment and alignment. Digital systems do not have impedance-matching requirements; analog systems do. Digital systems are less sensitive to additive noise as a general rule.

Figure 1 DSP signal train.


Digital Signal Processing

235

There are a few areas in which analog signal processing will remain competitive, if not supreme, for the following reasons: Analog systems can operate at extremely high frequencies [e.g., radio frequencies (RF)], whereas digital systems are limited by the maximum frequency of an ADC. Some low-level signal processing solutions can be achieved for the cost of a resistor, capacitor, and possibly operational ampli®er, which would establish a price point below the current minimum DSP solution of around $5.

3.2

The study of DSP usually begins with its progenitor, analog signal processing. Continuous-time or analog signals are de®ned on a continuum of points in both the independent and dependent variables. Electronic analog ®lters have existed throughout the 20th century and generally are assumed to satisfy an ordinary differential equation (ODE) of the form

m0

am

M d m yt X d m xt b m dtm dtm m0

1

The classic analog ®lter types, called Cauer, Butterworth, Bessel, and Chebyshev are well studied and have been reduced to standard tables. Analog ®lters are historically low order ( 4) and are often physically large devices. High-precision high-order analog ®lters are notoriously dif®cult to construct due to the inexactness of the analog building-block elements and inherent parameter sensitivity problems. Currently analog ®lters have been routinely reduced to electronic integrated circuits (IC) which adjust their frequency response using external resistors and capacitors.

Figure 2


DIGITAL SYSTEMS

Digital systems are generally modeled to be linear shiftinvariant (LSI) systems (see Chap. 3.4). The output of an LSI system, say yk, of an LSI having an impulse response hk to an input xk, is given by the convolution sum N X m0

am yk

m

M X m0

bm xk

m

2

Computing the convolution sum can be side-stepped by using the z-transform (see Chap. 3.4) and the convolution theorem, which states that if hk

ANALOG SIGNALS AND SYSTEMS

N X

3.3

xk yk

Z

! Hz

Z

3

! Xz

Z

! Yz

then Yz Zyk Zhk xk Xz Hz

4

The advantage provided by the convolution theorem is that the computationally challenging convolution sum can be replaced by a set of simple algebraic operations. A comparison of the computation requirements to produce a convolution sum using time- and z-transformdomain methods is shown in Fig. 2. The z-transform of the convolution sum de®ned in Eq. (2) is given by ! ! N M X X m m Yz Xz 5 am z bm z m0

m0

The ratio of input and output transforms, namely Hz Yz=Xz, is formally called the transfer function. Algebraically the transfer function of an LSI system satis®es

Convolution theorem.

236

Taylor M X

Hz

Yz Nz m0 N X Xz Dz m0

! bm z

m

! am z

6

m

The poles of the digital system are given by the roots of Dz found in Eq. (6), namely N X m0

am z m

N Y m0

pm

z 0

7

and are denoted pm . The zeros of a digital system are given by the roots of Nz found in Eq. (6), namely M X m0

bm z m

N Y m0

zm

z 0

8

and are dentoed zm . The location of the poles and zeros, relative to the periphery of the unit circle in the z-plane are important indicators of system performance. A class of stability, for example, can be assured if the poles are interior to the unit circle (see Chap. 3.4). If the system is asymptotically stable, then after a period of time any transient signal components (due to possible nonzero initial conditions) will decay to zero, leaving only externally forced (inhomogeneous) signal components at the output. If the input is a sinusoid, then after the transients have decayed, the signal found at the ®lter's output is called the steady-state sinusoidal response. If the input frequency is slowly swept from DC to the Nyquist frequency, the steady-state frequency response can be measured. Mathematically, the steady-state frequency response is equivalently given by A! jHej! j jHzjze j! (magnitude frequency response) ej! argHej! arctan

g

j!

ImHe ReHej!

dej! d!

3.4

10

where ! 2 ; . The amplitude response corresponds to the gain added to the input at frequency ! and the phase response speci®es what phase shift, or delay, has been applied to the input. Therefore, if the input is assumed to be given by xk Vej!k , then the output (after any transients have decayed) would be given by yk VA!ej!k . This simply restates a fundamental property of linear systems, namely that an LSI cannot create any new frequencies, but can

11

FOURIER ANALYSIS

The frequency-domain representation of a continuoustime signal is de®ned by the continuous-time Fourier transform (CTFT). The CTFT analysis equation satis®es 1

xte

X j

j t

dt

12

1

and the synthesis equation is given by 1

xt

!

(group delay)

From Eqs. (9) and (10) is can be noted that the spectral properties of Hz can be analytically computed if Hz is known in closed form. However, in many cases, signals and systems are only known from direct measurement or observation. In such cases the spectrum of a signal or system must be computed directly from timeseries data. Historically, this is the role of the discrete Fourier transform (DFT).

9

(phase response)


simply alter the magnitude and phase of the signal presented to the input. Another important steady-state property of an LSI is called the group delay. It has importance in communications and control systems where it is desired that a signal have a well-behaved propagation delay within a ®lter. In many design cases, it is important that the propagation delay through the system be frequency invariant. Such systems are said to be linear phase. The frequency-dependent propagation delay of an LSI is de®ned by the group delay measure which is given by

X j ej t d

13

1

where is called the analog frequency in radians per second and X j is called the spectrum of xt. Computing a CTFT with in®nite limits of integration with a digital computer is virtually impossible. A modi®cation of the Fourier transform, called the continuous-time Fourier series (CTFS) simpli®ed the computational problem by restricting the study to periodic continuous-time signals xp t where xp t xp t T for all time t. Regardless of the form that a continuous-time Fourier transform takes, it is again impractical to compute using a general-purpose digital computer. A computer expects data to be in a digital


237

Table 1 Properties of a DFT Discrete-time series xk

L X m0

am xm k

Discrete Fourier transform Xn

m0

XN n XnWNqn XN n X n mod N XN n Xn q mod N L X XN n am Xm n

xN k

XN n

m0 N X1

xk mod Nyk mod N

sampled format and be of ®nite duration. What is therefore needed is an algorithm which can operate on a time series. The discrete Fourier transform (DFT) is such a tool in that it maps an N-sample time series (possibly complex) into an N-harmonic array in the frequency domain. Since the harmonics are, in general, complex, the DFT is a mapping of complex space into a complex space (i.e., C N $ CN . The DFT of an N-sample time series, denoted xN k, is given by N X1

xN kWNnk

14

k0

for 0 n < N, WN e j2=N , and Xn is called the nth harmonic. The complex exponential WN is seen to be periodic with period N, which also de®nes the periodicity of the DFT. Therefore Xn Xn kN for any integer N. Equation (14) is called the DFT analysis equation and de®nes the N harmonics of xN k for 0 n < N. The inverse transform, called the DFT synthesis equation, is given by xN k

am Xm n

xN k xk q mod N xN k x k mod N xN k xkWN k L X xN k am xm k mod N

k0

Xn

L X

X1 1N XnWN nk N k0

15

for 0 k < N. The advantage of the DFT is its ability to compute a spectrum from the bounded sample values of xN k without regard to the established mathematical properties of xk. The DFT algorithm presented in Eq. (14) de®nes what is computationally called the direct method of producing a spectrum. The direct method computes the N harmonics of Xn by repeatedly performing complex multiply±accumulate (MAC) operations on the elements of the N-sample time series xN k. The MAC complexity of the direct


m0 N X1

1 N

Xn Yk

Remark Linearity Circular time shift Time reversal Modulation Linearity Parseval (power)

n0

method is classi®ed as being order N 2 . This translates to a ®nite, but possibly long, computation time. This condition was radically altered with the advent of the fast Fourier transform (FFT) algorithm. It should be appreciated, however, that ``fast'' has a relative meaning in this case. The FFT is a well known computer algorithm which converts an order N 2 calculation to an order N log2 N computation. The FFT, while being faster than a direct method, still remains computationally intensive. In addition, the FFT incurs some overhead penalty. Typically, as a general rule, the advantage of a software-based FFT over a direct DFT is not realized unless N 32. For high-speed applications, application-speci®c integrated circuits (ASICs), dedicated DFT chips, have been developed for general use. The list of DFT properties is found in Table 1 and the parameters of a DFT reviewed in Table 2. The fundamental parameters which de®ne the precision of a DFT are de®ned in terms of the sample rate fs and N, the number of samples to be transformed. The performance of a DFT (usually implemented as an FFT) is well known and understood. Variations of the basic algorithm have been developed to ef®ciently handle the case where the input data are known to be real. Called real FFTs, they offer a speed-up of a factor of two over their more general counterparts. Various methods have been developed to integrate short DFT units together to create a long DFT (viz., Cooley± Tukey, Good±Thomas, etc.), which can be useful in the hands of a skilled DSP engineer. Nevertheless, a DFT or FFT is rarely designed in a contemporary setting. Instead they are simply extracted from an abundance of math software libraries, CAD packages, or from a runtime executable supplied by a technology vendor.

238

Taylor Table 2 DFT Parameters Parameter Sample size Sample period Record length Number of harmonics Number of positive (negative) harmonics Frequency spacing between harmonics DFT frequency (one-sided baseband range) DFT frequency (two-sided baseband range) Frequency of the kth harmonic

While the DFT is well known, the interpretation of a DFT spectrum requires some care and experience. The DFT is a baseband signal analysis which means that it maps all spectral information into the frequency range f 2 fs =2; fs =2 Hz which is centered about DC. Obviously if a signal is not properly sampled in the context of the Nyquist sampling theorem, aliasing errors will occur introducing what are called artifacts. Artifacts are spectral lines which appear in the baseband spectra can be due to signal energy lying outside the baseband spectrum. If a signal at frequency f is

Notation or units N samples Ts sec T NTs sec N harmonics N=2 harmonics f 1=T 1=NTs fs =N Hz f 2 0; fs =2 Hz f 2 fs =2; fs =2 Hz fk kfs =N Hz

sampled at a rate fs , and f > fs =2 (below the Nyquist rate), then an artifact will occur at frequency f 0 f mod fs in the DFT spectrum where f 0 2 fs =2 fs =2 Hz. An example of aliasing is found in Fig. 3. Artifacts due to aliaising can be eliminated, or controlled, by placing an antialiasing ®lter before the ADC which will limit the highest frequency presented to the ADC to be bound by fs =2 Hz (i.e., Nyquist limiter). Artifacts can also result from an effect called leakage. Recall that a DFT assumes the signal to be trans-

Figure 3 Top left shows an EKG signal with 60 Hz distortion which is sampled at a 135 Hz rate. Top right is the one-sided (positive) spectrum showing a number of peaks over the baseband frequency range f 2 0; 67:5 Hz. The prominent high-frequency peak is attributed to 60 Hz contamination. Bottom center is the two-sided spectrum showing the location of the aliased contaminates at 120 Hz and 180 Hz. Notice that the aliased spectral components wrap the folding (Nyquist) frequency as de®ned by the rule fa f mod fs where fa 2 67:5; 67:5 Hz, f 120 and 180 Hz, and fs 135 Hz.



239

formed, namely xN k, is periodic N-sample time series with period N. Suppose the actual signal xk is not periodic. Then the DFT of xN k, which assumes periodicity, will differ from an in®nitely long DFT of the aperiodic parent xk. The difference between the Nsample spectra is due to energy found at the boundary of N-sample intervals leaking into the DFT spectrum. This phenomenon can be motivated by analyzing the data shown in Fig. 4. Shown are two time series of length N, along with their periodic extension. One time series completes an integer number of cycles in N samples and the other does not. The difference in their spectra is also shown in Fig. 4. The DFT of a signal completing an integer number of oscillations in N samples is seen to possess a well-de®ned and localized line spectrum. The other spectrum exhibits ``spreading'' of spectral energy about local spectral lines. The leaked energy from the jump discontinuity found at the N-sample boundary can be reduced by increasing the length of the time series (i.e., N) or through the use of a data window smoothing function. 3.5

produced by the N-sample gating function is given by xN k xk wk. The leakage artifacts can be suppressed by reducing the in¯uence of jump discontinuities at the window boundary. This can be achieved by having the leading and trailing tails of wk take on values at or near zero. A rectangular window, or gating function, obviously does not satisfy this criterion and, as previously seen, can introduce artifacts into the spectrum. Popular windows which do meet this criterion are shown below (rectangular included for completeness). Rectangular wk 1

Bartlett (triangular) 8 2k > > < N 1 wk 2k > > :2 N 1

1

17

N 1 k 2 0; 2 n 1 k2 ;N 1 2 18

Hann

WINDOWING

Figure 5 describes an arbitrary signal of in®nite length xk and its assumed spectrum. Also shown is a gating, or window function of length N denoted wk. The object of the window function is to reduce the presence of artifacts introduced by creating a ®nite duration signal xN k from an arbitrary parent time series xk. The potential dilatory effects of such action were graphically interpreted in Fig. 4. The ®nite-duration signal

1 wk 1 2

2k cos N 1

k 2 0; N

1 19

Hamming wk 0:54

Figure 4 Example of leakage and its cause.


k 2 0; N

2k 0:46 cos N 1

k 2 0; N

1 20

240

Taylor

Figure 5 The mechanics of windowing is modeled as a time-domain gating operating. Notice how the nonrectangular window suppresses leakage artifacts. Shown in the upper right is the DFT of a leaky sinusoid processed by a number of popular window functions. Notice that the resulting magnitude spectrum (in dBs) exhibits various tradeoffs between the width of the main lobe and sideband attenuation.

Blackman

2k 4k wk 0:42 0:5 cos 0:08 cos N 1 N 1 k 2 0; N 1 21

Kaiser k 2 0; N 1 wk I0 I0 is a 0th-order Bessel function)

22

All the above windows, except the rectangular window, have values near zero locally about k 0 and k N 1. The shape and spectrum of these windows are reported in Fig. 6. A good window is considered to be one which has a spectrum exhibiting a narrow main lobe along with deep sideband attenuation. The presented windows (except the rectangular window) achieve this to various degrees and with different tradeoffs.

Figure 6 Experimental study of windowing on a DFT showing the time-domain and frequency-domain envelope of basic window functions.



3.6

241

DIGITAL FILTERS

Digital ®lters can be grouped into three broad classes called (1) ®nite impulse response (FIR) ®lters, (2) in®nite impulse response (IIR) ®lters, and (3) multirate ®lters. Filters are also historically classi®ed in terms of their function with their most common being lowpass, highpass, bandpass, or bandstop ®ltering. However, it should not be forgotten that all digital ®lters which are based on common LSI models share a common mathematical framework and are often implemented with a common technology (i.e., DSP microprocessors). 3.6.1

In®nite Impulse Response Filters (IIR)

An IIR ®lter is sometimes called a recursive ®lter due to the fact that it contains feedback paths. An IIR ®lter is generally modeled by the LSI transfer function. M X

Nz i0 N Hz Dz X i0

bi z

i

ai z

i

M Y1

z

i0 KzN M N 1 Y

zi 23

z

i0

pi

The presence of the denominator terms [i.e., Dz] establishes the fact that the IIR contains feedback data paths. The numerator terms [i.e., Nz] in turn de®ne the ®lter's feedforward data paths. It is the presence of feedback, however, which allows IIRs to achieve high-frequency selectivity and near resonate behavior. The frequency response of an IIR is determined by evaluating Hz for z ej! . This act scans a continuous range of frequencies which is normally assumed to be bounded between plus or minus the Nyquist frequency or fs =2 f fs =2. It is often more convenient to interpret this frequency range to be normalized to ! rad/sec or 0:5 f < 0:5 Hz. Upon evaluation, one obtains M X

Hej!

i0

N X i0

bi e

M Y1

j!

ej!

Kej!N ai e

j!

M i0 N Y1 i0

zi 24

e

j!

pi

where ! . As a general rule, an IIR can meet very demanding magnitude frequency-response speci®cations with a reasonable ®lter order (i.e., N 8). The design of such ®lters has been highly re®ned and much is known about classical digital


®lters. The origins of classical ®lters can be traced back nearly a century to the early days of radio engineering. From the beginning of the radio era to today, frequency-selective ®lters have been extensively used to isolate the radio broadcast spectrum into distinct information bands. Radio engineers historically used tables and graphs to determine the parameters of a ®lter. The designer of digital ®lters relies on the use of computer program to support the design process. The task of the classical ®lter designer is one of creating a system whose magnitude frequency response emulates that of an ideal ®lter. Historically, classical design paradigms are based on the well-known models of Bessel, Butterworth, Chebyshev, and Cauer (elliptical). To standardize the design procedure, a set of normalized lowpass ®lter models for each of these classes was agreed upon and reduced to a standardized design model. The models, called analog prototypes, assumed a 1 dB or 3 dB passband deviation from an ideal ¯at passband which extends from 0 to 1 rad/sec. In a classical design environment, the analog prototype, denoted Hp s, is read from prepared tables, charts, and graphs and then mapped into the desired analog ®lter which has the magnitude frequency-response shape but a cutoff frequency other than 1 rad/sec. The resulting scaled ®lter is called the (desired) analog ®lter and is denoted Hs. The ®lter Hs meets or exceeds the magnitude frequency-response design constraints posed for an acceptable analog ®lter solution. The mapping rule which will take an analog prototype into its ®nal analog form is called a frequency-to-frequency transform, summarized in Table 3 and interpreted in Fig. 7. The analog prototype magnitude-squared frequency response, measured at the preagreed analog passband cutoff frequency of 1, is often interpreted as jHsj2sj1

1 1 "2

25

If "2 1:0, the prototype is said to be a 3 dB ®lter. Referring to Fig. 8, observe that the analog ®lter is to be mapped to an analog ®lter having target frequencies

p , p1 , p2 , a1 , and a2 , called critical frequencies. The passband and stopband gains are speci®ed in terms of the parameters " and A. The steepness of the ®lter skirt is measured in terms of the transition gain ratio which is given by "=A2 11=2 . The frequency transition ratio, denoted kd , measures the transition bandwidth. The possible values of kd , are given by

242

Taylor Table 3

Frequency-to-Frequency Transforms

th

N -order prototype Lowpass ... Lowpass Lowpass Lowpass

Transform

to lowpass to highpass to bandpass to bandstop

s

Lowpass:

kd

p

a

26

Highpass:

kd

a

p

27

Bandpass:

kd

Bandstop:

kd

k1 k2 1=k1 1=k2

where

if 2u 2v if 2u < 2v if 2u 2v if 2u < 2v

Order

s=

.. p . s

p =s s2 H L =s H 1 s H L =s2 H L

c

p1 p2

p2 p2

a1 k1

c

28 29

k2

N. .. N 2N 2N

a2

c

30 1

2a1

2v

1

!

1 1

2a2

2v

31

!

32

Figure 7 Frequency-to-frequency transforms showing the mapping of a prototype lowpass to (1) lowpass, (2) highpass, (3) bandpass, and (4) bandstop mappings.



Figure 8

243

Frequency-response speci®cations of a lowpass analog prototype ®lter.

2u a1 a2

33

2v p1 p2

34

From 2 A2 1, the gain ratio may be de®ned to be d =". From these parameters the order and transfer function of classical analog prototype ®lters can be determined. 3.6.2

An Nth-order Butterworth ®lter has a magnitudesquared frequency response given by 35

36

A typical magnitude frequency response for a lowpass Butterworth ®lter is shown in Fig. 9. It is characterized by a smooth transition from pass- to stopband. 3.6.3

Classic Butterworth Filter

1 jHsj2 1 "2 s2N

The order is estimated to be ! A2 1 1 N log 2 2 log1=k " d

Classical Chebyshev Filter

An Nth-order lowpass Chebyshev-I ®lter has a magnitude-squared frequency response given by jHsj2

1 1

2 s "2 C N

37

where CN s is a Chebyshev polynomial of order N. The order of a Chebyshev-I ®lter is estimated to be " p!# 1 2 log 1 2 N 38 s3 2 1 1 15 log4 kd kd A variation on the Chebyshev-I model is called the Chebyshev-II ®lter and is given by jHsj2

Figure 9 Typical Butterworth lowpass ®lter showing a magnitude frequency response.


1 2 j =s 1 "2 CN a

39

The order estimation formula is that for the Chebyshev-I model. A typical magnitude frequency

244

Taylor

response for a Chebyshev-I or -II ®lter is displayed in Fig. 10. The Chebyshev-I ®lter is seen to exhibit ripple in the passband and have a smooth transition into the stopband. The Chebyshev-II ®lter is seen to have ripple in the stopband and smooth transition into the passband. 3.6.4

Classical Elliptical Filters

The attenuation of an Nth-order elliptical ®lter is given by the solution to an elliptical integral equation. The order of an elliptical ®lter is estimated to be N

log16D log1=q

40

where

q 1 k2d p 1 k0 p q0 21 k 0 k0

41 42

q q0 2q50 15q90 1513 q

43

D d2

44

The typical magnitude frequency response of an elliptical lowpass ®lter is shown in Fig. 11. It can be seen that an elliptical ®lter has ripple in both the pass- and stopbands. 3.6.5

Figure 11 Magnitude frequency response of a typical elliptical IIR ®lter.

trary magnitude frequency response can be de®ned by the invention of an engineer or synthesized from measured data using spectral estimation tools such as autoregressive (AR) or autoregressive moving-average (ARMA) models. In all cases, the design objective is to create a model of an Nth-order transfer function Hz. If the ®lter design process begins with a legacy analog ®lter model, then the designer of a digital ®lter replacement of an analog system must convert Hs into a discrete-time ®lter model Hz. The basic domain conversion methods [i.e., Hs ! Hz] in common use are: 1. 2.

Impulse invariant method Bilinear z-transform method.

Other IIR Forms

Analog ®lter models, other than the classical Butterworth, Chebyshev, and elliptical ®lter models are also routinely encountered. Filters with an arbi-

3.6.5.1 Impulse-Invariant IIR Design The impulse-invariant ®lter design method produces a sampled-data system which is based on a continuous-

Figure 10 Typically Chebyshev-I and -II lowpass ®lter magnitude frequency response (linear on the left, logarithmic on the right).



245

time system model. The impulse response of a discretetime impulse-invariant system, denoted hd k, is related to the sampled values of continuous-time system's impulse response ha t through the de®ning relationship hd k Ts ha kTs

45

That is, if a system is impulse invariant, then the discrete- and continuous-time impulse responses agree, up to a scale factor Ts , at the sample instances. The standard z-transform possesses the impulse-invariant property. This can be of signi®cant importance in some application areas, such as control, where knowledge of the envelope of a signal in the time domain is of more importance than knowledge of its frequency response. Speci®cally, if a controller's speci®cations are de®ned in terms of risetime of overshoot, then an impulse-invariant solution is called for, since the frequency response of the controller is immaterial. Consider an analog ®lter having a known impulse response ha t with a known transfer function. For the sake of development, consider the Nth-order system described by the transfer function Hs having N distinct poles. Then, upon taking the impulse-invariant ztransform of Hs, the following results: N X ai ha t , Ha s s pi i1

N 1 X ai ! Ts i1 1 epi Ts z

1

1 1 Hz , hk Ts Ts

46 which mathematically restates the impulse-invariant property of the standard z-transform. As a direct con-


Equation (47) states that under the z-transform, the frequency response of the resulting system, namely Hej , is periodic on centers separated by 2=Ts fs radians (see Fig. 12) in the frequency domain. Observe that the spectral energy from any one frequency band, centered about ! k!s , can potentially overlap the neighboring spectral image of Ha j! centered about ! m!s , m 6 k. This overlap is called aliasing. Aliasing was noted to occur when a signal was sampled at too low a rate (see Chap. 3.4). Unfortunately, analog ®lters generally have a frequency response which can technically persist for all ®nite frequencies and therefore can naturally introduce aliasing errors for any ®nite sampling frequency. Example 1. First-Order Impulse-Invariant System: Consider the ®rst-order RC circuit having an input forcing function v(t) developing an output voltage vo t, de®ned by the solution to the ordinary differential equation v0 t RC

Z

Figure 12

sequence, the frequency response of a discrete-time having a transfer function Hz can be computed to be 1 1 X

2k j

H j 47 He Ts k 1 a Ts Ts

dv0 t vt dt

The transfer function associated with the RC circuit model is Hs

1

1 RCs

It then immediately follows that the impulse response is given by

Spectrum of a z-transformed ®lter.

246

Taylor

ht

1 e RC

t=RC

ut

For a given periodic sampling period of Ts , the resulting sampled impulse response is given by hd k , Ts hkTs or, for k 0 hd k

Ts e RC

where e Hz

kTs =RC

Ts =RC

Ts RC 1

Ts k RC

it follows that 1 T z s 1 z RC z

3.6.6

The frequency response of the impulse-invariant ®lter is given by j T e Hej s RC ej which is periodic with a normalized period . 3.6.5.2

Bilinear z-Transform

Lowpass ®lters have known advantages as a signal interpolator (see Chap. 3.4). In the continuous-time domain, an integrator is a standard lowpass ®lter model. A continuous-time integrator/interpolator is given by Hs

1 s

48

which has a common discrete-time Reimann model given by T yk 1 yk xk xk 1 2

49

which has a z-transform given by Yz z 1 Yz

T z 1 Xz Xz 2

50

which results in the relationship s

2 z 1 Ts z 1

51

or 2 s Ts z 2 s Ts

52

Equation (51) is called a bilinear z-transform. The advantage of the bilinear z-transform over the standard z-transform is that it eliminates aliasing errors


introduced when an analog ®lter model (with are arbitrarily long nonzero frequency response) was mapped into the z-plane. The disadvantage, in some applications, is that the bilinear z-transform is not impulse invariant. As a result, the bilinear z-transform is applied to designs which are speci®ed in terms of frequency-domain attributes and ignore time-domain quali®ers. If impulse invariance is required, the standard z-transform is used with an attendant loss of frequency-domain performance. Warping

The frequency response of a classic analog ®lter, denoted Ha j , 2 1; 1, eventually needs to be interpreted as a digital ®lter denoted Hej! , where ! 2 ; . The bilinear z-transform can map the analog frequency axis onto the digital frequency axis without introducing aliasing, or leakage as was found with a standard z-transform. To demonstrate this claim, consider evaluating Eq. (51) for a given analog frequency s j . Then j

2ej! 1 2 j sin!=2 2 j tan!=2 Ts ej! 1 Ts cos!=2 Ts 53

which, upon simpli®cation reduces to

2 tan!=2 Ts

54

or ! 2 tan 1 Ts =2

55

Equation (55) is graphically interpreted in Fig. 13. Equation (55) is called the warping equation and Eq. (54) is referred to as the prewarping equation. The nonlinear mapping that exists between the analog- and discrete-frequency axes will not, in general, directly map analog to identical frequencies. While the mapping is nonlinear, the bene®t is the elimination of aliasing. From Fig. 13 it can be seen that maps ! 1 to the continuous-frequency axis, ! ! f s (equivalently Nyquist frequency ! ! ) in the digital-frequency domain. Because of this, the bilinear z-transform is well suited to converting a classic analog ®lter into a discrete-time IIR model which preserves the shape of the magnitude frequency response of its analog parent. The design process that is invoked must however, account for these nonlinear effects and is presented


247

Figure 13 Relationship between the analog and digital frequency axes under the bilinear z-transform.

in Fig. 14. Such a process is outlined below as a stepby-step procedure. 1. 2. 3. 4. 5.

Specify the desired discrete-time ®lter requirements and attributes. Prewarp the discrete-time critical frequencies into corresponding analog frequencies and estimate analog ®lter order. Design an analog prototype ®lter from the given continuous-time parameters. Convert the analog prototype into an analog ®lter Hs using frequency-to-frequency transforms. Design a digital ®lter Hz using a bilinear ztransform of Hs which warps the frequency axis, which has previously been prewarped.

While this method may initially seem to be complicated, it is a simple procedure which can be reduced to a digital computer program. To exemplify the procedure, several simple examples are offered.

3.6.6.1

Classical IIR Design

Classical lowpass Butterworth, Chebyshev-I, Chebyshev-II, and elliptical IIR ®lters can be designed which meet or exceed the following speci®cations: Desired passband attenuation 1:0 dB Desired stopband attenuation 40:0 dB Sampling frequency 10,000.0 Hz Passband edge 1500:0 Hz Stopband edge 2500:0 Hz. The ®lters can be designed using MONARCHTM CAD tools (The Athena Group Inc.) which automatically implement the design steps shown in Fig. 13. The ®lter orders, required to meet or exceed the design speci®cations are: Order(Butterworth) N 8 Order(Chebyshev-I and -II) N 5 Order(Elliptical) N 4

Figure 14 Design of a discrete-time IIR from an analog model using a bilinear z-transform.


248

Taylor

Figure 15 Comparison of magnitude and log magnitude frequency response, phase, response, and group delay of four classical IIRs.

The magnitude frequency responses of the derived ®lters are shown in Fig. 15. It can be seen that the magnitude frequency of each classic IIR approximates the magnitude frequency response envelope of an ideal ®lter in an acceptable manner. The Cheybshev-I and elliptical introduce ripple in the passband, while the Chebyshev-II and elliptical exhibit ripple in the stopband. The Butterworth is ripple-free but requires a high-order implementation. The ®lters are seen to differ radically in terms of their phase and group-delay response. None of the IIR ®lters, however, is impulse invariant. 3.6.7

Finite Impulse Response (FIR) Filters

A ®nite impulse response (FIR) ®lter has an impulse response which consists only of a ®nite number of sample values. The impulse response of an Nth-order FIR is given by hk fh0 ; h1 ; . . . ; hN 1 g

56

The time-series response of an FIR to an arbitrary input xk, is given by the linear convolution sum yk

N X1 m0

hm xk

m

57

It is seen that the FIR consists of nothing more than a shift-register array of length N 1, N multipliers (called tap weight multipliers), and an accumulator. Formally, the z-transform of a ®lter having the impulse response described by Eq. (57) is given by Hz

N X1 m0

hm z

m


58

The normalized two-sided frequency response of an FIR having a transfer function Hz is Hej! , where z ej! and w 2 ; . The frequency response of an FIR can be expressed in magnitude±phase form as He! jHej! j !

59

A system is said to have a linear phase respfonse if the phase response has the general form ! ! . Linear phase behavior can be guaranteed by any FIR whose tap weight coef®cients are symmetrically distributed about the ®lter's midpoint, or center tap. The most popular FIR design found in practice today is called the equiripple method. The equiripple design rule satis®es the minimax error criteria "minimax minimizefmaximum"! j ! 2 0; !s =2g 60 where " is the error measured in the frequency domain measured as "! W!jHd ej!

Hej! j

61

where W! 0 is called the error weight. The error "! is seen to measure the weighted difference between the desired and realized ®lter's response at frequency !. For an Nth-order equiripple FIR, the maximum error occurs at discrete extremal frequencies !i . The location of the maximum errors are found using the alternation theorem from polynomial approximation theory since the signs of the maximal errors alternate [i.e., "!i "!i1 ]. This method was popularized by Parks and McClelland who solved the alternative theorem problem iteratively using the Remez exchange algorithm. Some of the interesting properties of an equiripple FIR is that all the maximal errors, called extremal errors, are equal. That is, "minimax j"!i j


249

for i 2 0; N 1 for !i an extremal frequency. Since all the errors have the same absolute value and alternate in sign, the FIR is generally referrd to by its popular name, equiripple. This method has been used for several decades and continues to provide reliable results. Example 2. Weighted Equiripple FIR: The 51st-order bandpass equiripple FIR is designed to have a 1 dB pass band and meet the following speci®cations. The weights W(f) are chosen to achieve the passband attenuation requirements for fs 100 kHz: Band 1: f 2 0:0; 10 kHz; desired W f 4, stopband. Band 2: f 2 12; 38 kHz; desired W f 1, passband. Band 3: f 2 40; 50 kHz; desired W f 4, stopband.

gain 0:0, gain 1:0, gain 0:0,

The FIR is to have a passband and stopband deviation from the ideal of p 1 dB and p 30 dB (see Fig. 16). While the passband deviation has been relaxed to an acceptable value, the stopband attenuation is approximately 23:5 dB to 30 dB. The advantage of an FIR is found in its implementation simplicity and ability to achieve linear phase performance, if desired. With the advent of highspeed DSP microprocessors, implementation of relatively high-order N 100 FIRs are feasible. As a result, FIRs are becoming increasingly popular as part of a DSP solution. 3.6.8

Multirate Systems

One of the important functions that a digital signal processing system can serve is that of sample rate conversion. A sample-rate converter changes a system's sample rate from a value of fin samples per second,

to a rate of fout samples per second. Systems which contain multiple sample rates are called multirate systems. If a time series xk is accepted at a sample rate fin and exported at a rate fout such that fin > fout , then the signal is said to be decimated by M where M is an integer satisfying M

fout fin

62

A decimated time series xd k xMk saves only every Mth sample of the original time series. Furthermore, the effective sample rate is reduced from fin to fdec fin =M samples per second, as shown in Fig. 17. Decimation is routinely found in audio signal processing applications where the various subsystems of differing sample rates (e.g., 40 kHz and 44.1 kHz) must be interconnected. At other times multirate systems are used to reduce the computational requirements of a system. Suppose an algorithm requires K operations be completed per algorithmic cycle. By reducing the sample rate of a signal or system by a factor M, the arithmetic bandwidth requirements are reduced from Kfs operations per second to Kfs =M (i.e., M-fold decrease in bandwidth requirements). Another class of applications involves resampling a signal at a lower rate to allow it to pass through a channel of limited bandwidth. In other cases, the performance of an algorithm or transform is based on multirate system theory (e.g., wavelet transforms). The spectral properties of a decimated signal can be examined in the transform domain. Consider the decimated time series modeled as xd k

1 X

xk m

kM

63

m 1

which has a z-transform given by

Figure 16 Magnitude frequency response for an equiripple FIR using the design weights W f4; 1; 4g. Also shown is the design for W f1; 1; 1g.


250

Taylor

Figure 17 Decimation-by-two example.

Xd z XzM

64

The frequency signature of the decimated signal, relative to the undecimated parent signal, is therefore given by Xd ej XejM

65

It can therefore be seen to be a frequency-scaled version of the original signal spectrum repeated on 2=M centers when plotted on a frequency axis de®ned with respect to the original sampling frequency. Example 3. Decimation: A signal given by xt cos 2fs t=16 is sampled at a 1 kHz rate to form a time series xk. The spectrum is given by Xem 0:5! 2 103 =16 0:5! 2 103 =16. The time series and spectrum are shown in Fig. 18. What is the spectrum of the decimated-by-four version of xk? From Shannon's sampling theorem, the highest frequency found in xk is B Hz. Aliasing can be avoided if the decimating sampling rate exceeds fd 2B Hz. This means that there is a practical upper bound to the decimation rate which is given by fs M

B>B

66

or f M< s 2B

67

Increasing the decimation rate beyond this maximal value will introduce aliasing errors into the decimated time series. The maximal decimation rate, however, is rarely used. Instead, a more conservative value is generally adopted which creates a guard band existing between the bandlimited spectra center on fs =M Hz centers. Example 4. Decimation Rate: The highest frequency found in the signal xt cos2 103 t is B 103 Hz. Suppose xt is highly oversampled at a rate fs 105 Hz The minimum lower bound on the sampling rate, namely the Nyquist frequency, is 2 103 Hz. Therefore the maximum decimation rate is 105 =2 103 50. The antithesis of decimation is called interpolation. In the context of multirate signal processing, interpolation simply refers to a mechanism of increasing the effective sample rate of a signal. Formally, suppose a signal xd k is interpolating by a factor N to form xi k, then xi k

xd k 0

if n 0 mod N otherwise

68

That is, the act of interpolation inserts N 1 zeros between the samples of the original time series. This action is sometimes referred to as zero-padding, being

Figure 18 (a) Parent time series xn and decimated-by-four time series xd k; (b) magnitude frequency responses Xn and Xd n.



sampled at a rate fin , which produces a new time series sampled at rate fout Nfin . Interpolation is often directly linked to decimation. Suppose xd k is a decimated-by-M version of a time series xk which was sampled at a rate fs . Then xd k contains only every Mth sample of xk and is de®ned with respect to a decimated sample rate fd fs =M. Interpolating xd k by N would result in a time series xi k, where xi Nk xd k and 0 otherwise. The sample rate of the interpolated signal would be increased from fd to fi Nfd Nfs =M. If N M, it can be seen that the output sample rate would be restored to fs . 3.7

DSP TECHNOLOGY AND HARDWARE

The semiconductor revolution of the mid-1970s produced the tools needed to effect many high-volume real-time DSP solutions. These include medium, large, and very large integrated circuit (MSI, LSI, VLSI) devices. The ubiquitous microprocessor, with its increasing capabilities and decreasing costs, now provides control and arithmetic support to virtually every technical discipline. Industry has also focused on developing application-speci®c single-chip dedicated DSP units called ASICs. The most prominent has been the DSP microprocessor. There is now an abundance of DSP chips on the market which provide a full range of services. Perhaps the most salient characteristic of a DSP chip is its multiplier. Since multipliers normally consume a large amount of chip real estate, their design has been constantly re®ned and rede®ned. The early AMI2811 had a slow 12 12 16 multiplier, while a later TMS320 had a 16 16 32-bits 200 nsec multiplier that occupied about 40% of the silicon area. These chips include some amount of onboard RAM for data storage and ROM for ®xed coef®cient storage. Since the cost of these chips is very low (tens of dollars), they have opened many new areas for DSP penetration. Many factors, such as speed, cost, performance, software support and programming language, debugging and emulation tools, and availability of peripheral support chips, go into the hardware design process. The Intel 2920 chip contained onboard ADC and DAC and de®ned what is now called the ®rst-generation DSP microprocessor. Since its introduction in the late 1970s, the Intel 2920 has given rise to three more generations of DSP microprocessors. The second removed the noise-sensitive ADC and DAC from the digital device and added a more powerful multiplier and


251

additional memory. Generation three introduced ¯oating-point. Generation four is generally considered to be multiprocessor DSP chips. DSP has traditionally focused on its primary mission of linear ®ltering (convolution) and spectral analysis (Fourier transforms). These operations have found a broad application in scienti®c instrumentation, commercial products, and defense systems. Because of the availability of low-cost high-performance DSP microprocessors and ASICs, DSP became a foundation technology during the 1980s and 90s. DSP processors are typi®ed by the following characteristics: Only one or two data types supported by the processor hardware No data cache memory No memory management hardware No support for hardware context management Exposed pipelines Predictable instruction execution timing Limited register ®les with special-purpose registers Nonorthogonal instruction sets Enhanced memory addressing modes Onboard fast RAM and/or ROM, and possibly DMA. Digital signal processors are designed around a different set of assumptions than those which drive the design of general-purpose processors. First, digital signal processors generally operate on arrays of data rather than scalars. Therefore the scalar load±store architectures found in general-purpose RISCs are absent in DSP microprocessors. The economics of software development for digital signal processors is different from that for general-purpose applications. Digital signal processing problems tend to be algorithmically smaller than, for example, a word processor. In many cases, the ability to use a slower and therefore less expensive digital signal processor by expending some additional software engineering effort is economically attractive. As a consequence, real-time programming of digital signal processors is often done in assembly language rather than high-level languages. Predicting the performance of a DSP processor in general and application-speci®c settings is the mission of a benchmark. A typical benchmark suite has been developed by Berkeley Design Technologies and consists of (1) real FIR, (2) complex FIR, (3) real single sample FIR, (4) LMS adaptive FIR, (5) real IIR, (6) vector dot product, (7) vector add, (8) vector maximum, (9) convolution encoder, (10) ®nite-state machine, and (11) radix-2 FFT.

252

Taylor

DSP theory is also making advances that are a logical extension of the early work in algorithms. DSP algorithm development efforts typically focus on linear ®ltering and transforms along with creating CAE environments for DSP development efforts. DSP algorithms have also become the core of image processing and compression, multimedia, and communications. Initiatives are also found in the areas of adaptive ®ltering, arti®cial neural nets, multidimensional signal processing, system and signal identi®cation, and time± frequency analysis.

3.8

SUMMARY

Even though the ®eld of digital signal processing is relatively young, it has had a profound impact on how we work and recreate. DSP has become the facilitating technology in industrial automation, as well as providing a host of services that would otherwise be impossible to offer or simply unaffordable. DSP is at the core of computer vision and speech systems. It is the driving force behind data communication networks whether optical, wired, or wireless. DSP has become an important element in the ®elds of instrumentation and manufacturing automation. The revolution is continuing and should continue to provide higher increased


levels of automation at lower costs from generation to generation. BIBLIOGRAPHY Antonious A. Digital Filters: Analysis and Design. New York, McGraw-Hill, 1979. Blahut R. Fast Algorithms for Digital Signal Processing. Reading, MA: Addison-Wesley, 1985. Bracewell R. Two Dimensional Imaging. New York: Prentice-Hall, 1995. Brigham EO. The Fast Fourier Transform and Its Application. New York: McGraw-Hill, 1988. Haykin S. Adaptive Filter Theory, 3rd ed. New York: Prentice-Hall, 1996. Oppenheim AV, ed. Application of Digital Signal Processing. Englewood Cliffs, NJ: Prentice-Hall, 1978. Proakis J, Manolakis DG. Digital Signal Processing: Principles, Algorithms, and Applications, 3rd ed. New York: Prentice-Hall, 1996. Rabiner LR, Gold B. Theory and Applications of Digital Signal Processing. Englewood Cliffs, NJ: Prentice-Hall, 1975. Taylor F. Digital Filter Design Handbook. New York: Marcel Dekker, 1983. Taylor, F. and Millott, J., ``Hands On Digital Signal Processing,'' McGraw-Hill, 1988. Zelniker G, Taylor F. Advanced Digital Signal Processing: Theory and Applications. New York: Marcel Dekker, 1994.

Chapter 3.4 Sampled-Data Systems Fred J. Taylor

University of Florida, Gainesville, Florida

4.1

ORIGINS OF SAMPLED-DATA SYSTEMS

period, and fs 1=Ts is the sample rate or sample frequency. The sampling theorem states that if a continuous-time (analog) signal xt, band limited to B Hz , is periodically at a rate fs > 2B, the signal xt can be exactly recovered (reconstructed) from its sample values xk using the interpolation rule

The study of signals in the physical world generally focuses on three signal classes called continuous-time (analog), discrete-time (sampled-data), and digital. Analog signals are continuously re®ned in both amplitude and time. Sampled-data signals are continuously re®ned in amplitude but discretely resolved in time. Digital signals are discretely resolved in both amplitude and time. These signals are compared in Fig. 1 and are generally produced by different mechanisms. Analog signals are naturally found in nature and can also be produced by electronic devices. Sampled-data signals begin as analog signals and are passed through an electronic sampler. Digital signals are produced by digital electronics located somewhere in the signal stream. All have an important role to play in signal processing history and contemporary applications. Of these cases, sampled data has the narrowest application-base at this time. However, sampled data is also known to be the gateway to the study of digital signal processing (DSP), a ®eld of great and growing importance (see Chap. 3.3). Sampled-data signal processing formally refers to the creation, modi®cation, manipulation, and presentation of signals which are de®ned in terms of a set of sample values called a time series and denoted fxkg. An individual sample has the value of an analog signal xt at the sample instance t kTs , namely, xt kTs xk, where Ts is the sample

xt

xkht

kTs

1

k 1

where ht has the sinx=x envelope and is de®ned to be ht

sint=Ts t=Ts

2

The interpolation process is graphically interpreted in Fig. 2. The lower bound on the sampling frequency fs is fL 2B, and is called the Nyquist sample rate. Satisfying the sampling theorem requires that the sampling frequency be strictly greater than the Nyquist sample rate or fs > fL . The frequency fN fs =2 > B called the Nyquist frequency, or folding frequency. This theory is both elegant and critically important to all sample data and DSP studies. Observe that the interpolation ®lter ht is both in®nitely long and exists before t 0 [i.e., t 2 1; 1]. Thus the interpolator is both impractical from a digital implementation standpoint and noncausal. As such, 253


1 X

254

Taylor

Figure 1 Signal hierarchy consisting of analog, discrete-time or sampled-data, and digital or quantized signal processes. Sampled-data and digital signals are quantized in time. Digital signals are also quantized in amplitude.

alternative interpolation schemes are generally used which approximate a Shannon interpolator. One of the most basic is called the zero-order hold. A zeroorder hold circuit simply ``holds'' the value of xk for a sample interval Ts beginning at t kTs . The zero-order interpolated signal is therefore a piecewise constant approximation of the true xt as shown in Fig. 3. The quality of the zero-order hold approxima-

tion of xt is in¯uenced by the choice of Ts . If xt rapidly changes in time, Ts must be extremely small in order for a piecewise constant zero-order hold signal to be in close agreement with the analog parent xt. Another important practical interpolation procedure is the ®rst-order hold. The ®rst-order hold linearly interpolates the values of xt between two adjacent sample values xk and xk 1 for t 2 kTs , kTs .

Figure 2 Shannon interpolator showing a sampler (left), Shannon interpolating ®lters (middle), and reconstruction after Eq. (1) (right).


Sampled-Data Systems

255

Figure 3 Zero- and ®rst-order hold and lowpass ®lter interpolators. Shown on the left is the interpolation process for a sowly sampled signal with the piecewise constant envelope of the zero-order hold clearly visible. The other interpolators are seen to provide reasonably good service. On the right is an oversampled case where all interpolators work reasonably well.

The ®rst-order hold interpolation scheme is graphically interpreted in Fig. 3. Again the quality of the interpolation is seen to be correlated to the value of Ts , but to a lesser degree than in the zero-order hold case. Another popular interpolation method uses a lowpass ®lter and is called a smoothing ®lter. It can be argued from the duality theorem of Fourier transforms that the inverse Fourier transform of Eq. (2) is itself an ideal lowpass ®lter. A practical lowpass ®lter will permit only small incremental changes to take place over a sample interval and does so in a smooth manner. The smoothing ®lter should be matched to the frequency dynamics of the signal. If the signal contains frequency components in the stopband of the smoothing ®lter, the interpolator will lose its ability to reconstruct sharp edges. If the smoothing ®lter's bandwidth is allowed to become too large, the interpolator will become too sensitive to amplitude changes and lose its ability to interpolate.

4.2

MATHEMATICAL REPRESENTATION OF SAMPLED-DATA SIGNALS

Sampled-data or discrete-time signals can be produced by presenting a continuous-time signal xt to an ideal sampler which is assumed to be operating above the Nyquist rate. The connection between continuous- and


sampled-data signals is well known in the context of a Laplace transform. Speci®cally, if xt $ Xs, then xt

kTs

L

!e

skTs

Xs

3

The time series fxkg fx0; x1; . . .g would therefore have a Laplace transform given by Xs x0 x1e 2sTs x2e 1 X xke ksTs

2sTs

4

k0

It can be seen that in the transform domain the representation of a sampled-data signal is punctuated with terms the form e skTs . For notational purposes, they have been given the shorthand representation z esTs

or

z

1

e

sTs

5

Equation (5) de®nes what is called the z-operator and provides the foundation for the z-transform. The complex mapping z ej' rej' , where r e and ' k2 '0 , results in a contour in the z-plane given by z re j2u0 re j'0 . If uniqueness is required, the imaginary part of s must be restricted to a range j'0 j which corresponds to bounding the normalized frequency range by plus or minus Nyquist frequency in the s-plane. For values of s outside this range, the mapping z esTs will ``wrap''

256

Taylor

around the unit circle modulo 2fs radians per second. The two-sided z-transform, for a double-ended time series fxkg, is formally given by Xz

1 X

xkz

k

6

xkz

k

7

k0

which again exists only if the sum converges. The range of values of z over which the z-transform will converge is called the region of convergence, or ROC. The ztransforms of elementary functions are generally cataloged, along with their ROCs, in Table 1. It is generally assumed that most of important signals can be represented as a mathematical combination of manipulated elementary functions. The most commonly used mapping techniques are summarized in Table 2. In addition to the properties listed in Table 2, there are several other z-transform relationships which are of

8

z!1

if xk is causal. The second property is called the ®nalvalue theorem which is given by z!1

if the sum converges. If the time series is de®ned for positive time instances only, called a right-sided time series, the one-sided z-transform applies and is given by 1 X

x0 lim Xz

x1 lim z

k 1

Xz

signi®cant importance. One is the initial-value theorem which states

1 Xz

9

provided Xz has no more than one pole on the unit circle and all other poles are interior to the unit circle.

4.3

INVERSE z-TRANSFORM

The inverse z-transform of a given Xz is de®ned by 1 xk Z 1 Xz Xzzn 1 dz 10 2j C

where C is a restricted closed path which resides in the ROC of Xz. Solving the integral equation can obviously be a very tedious process. Fortunately, algebraic methods can also be found to perform an inverse z-transform mapping. Partial fraction expansion is by far the most popular z-transform inversion method in contemporary use to map a given Xz into the original time series. A partial fraction expansion of Xz repre-

Table 1 z-Transform and ROCs

Time-domain k k m uk kuk k2 uk k3 uk expakTs ukTs kTs expakTs ukTs kTs 2 expakTs ukTs a uk ka uk k2 a uk sinbkTs ukTs cosbkTs ukTs expakTs sinbkTs ukTs expakTs cosbkTs ukTs ak sinbkTs ukTs ak cosbkTs ukTs ak ; k 2 0; N 1


z-Transform 1 z m z=z 1 z=z 12 zz 1=z 13 zz2 4z 1=z 14 z=z expaTs zTs expaTs =z expaTs 2 zTs 2 expaTs z expaTs =z expaTs 3 z=z a az=z a2 azz a=z a3 z sinbTs =z2 2z cosbTs 1 zz cosbTs =z2 2z cosbTs 1 z expaTs sinbTs =z2 2z expaTs cosbTs exp2aTs xz expaTs cosbTs =z2 2z expaTs cosbTs exp2aTs az sinbTs =z2 2az cosbTs a2 zz a cosbTs =z2 2az cosbTs a2 1 aN z N =1 az 1

Region of convergence: jzj > R Everywhere Everywhere 1 1 1 1 j expaTs j j expaTs j j expaTs j jaj jaj jaj 1 1 j expaTs j j expaTs j jaj jaj Everywhere


257 Table 2 Mapping Rules in the z-Domain Property

Time series

z-Transform

Linearity Real scaling Complex scaling

x1 k x2 k axk wk xk

X1 z X2 z aXz Xz=w

Delay

xk

z

L

L

Xz

1 X

z

Ln

xk

k L

Time reversal Modulation

x k e ak xk

Rampling

kxk k X

Summation

X1=z Xea z dXz z dz zXz z 1

xn

n 1

sents the transform as a linear combination of terms having a known correspondence to the primitive functions found in most standard tables of z-transforms (e.g., Table 1). The practical fraction expansion of the Xz having the rational polynomial representation Nz Dz

by formally dividing Nz by Dz. Once the Heaviside coef®cients i;j are computed, xk can be directly computed by weighting the inverse z-transform of z=z i j found in a standard table (see Table 1) by an amount i;j . A local expansion of Eq. (14) would produce terms of the form

11

Xz 0

is a mechanical process. The values of Nz which satisfy Nz 0 are called the zeros of Xz. The values of Dz which satisfy Dz 0 are called the poles of Xz. The denominator term Dz is assumed to be an Nth-order polynomial which can be expressed in product form as

Xz

Dz

L Y

z

i1

l ni

12

where N

L X

ni

13

zi;ni z z

i

ni

zj;k

j k

zj;n j z

j n j

15

The Heaviside coef®cients are given by ! z i n j Xz j;n j lim z!j z ( )1 0 i n j Xz 2 z B d C z B1 C B C j;n j 1 lim B C z!j @2 dz2 A

16

17

i1

That is, there are L distinct roots in Dz having values i respectively where the integer ni is called the multiplicity of the root i . If ni > 1, then i is said to be a repeated root and if ni 1, i is said to be distinct. If Xz is proper (i.e., M N, then the partial fraction or Heaviside expansion of Xz is given by L X X i;j z N 0 z 0 Dz i i i1 j1 z ni

and, in general, 0 j;k

d B B 1 lim B z!j B @n j k!

( n j k

)1 i n j Xz C z C C C n j k dz A z

14

18

where the coef®cients i;j are called the Heaviside coef®cients and N 0 z is the quotient polynomial obtained

The process of computing Heaviside coef®cients can therefore be seen to consist of a number of steps, namely

Xz 0


258

Taylor

Determine 0 in Eq. (14) along with N 0 z. Factor Dz to obtain the pole locations. Classify the poles as being distinct or repeated and if repeated, determine their multiplicity. Use Eq. (16) through (18) to determine the Heaviside coef®cients. Substitute the Heaviside coef®cients into Eq. (15). Use standard tables of z-transforms to invert Eq. (15). Example 1. Inverse z-transform: inverse z-transform of Xz

3

To compute the

3x 5z 3z z 12 z 0:5

z!0

z z z 21 22 0:5 z 1 z 12

zXz 0 z

1 lim

z

z!0:5

0:5Xz 3z3 5z2 3z lim z!0:5 z zz 1

!

5

22 a21

! 12 Xz 3z3 5z2 3z lim lim 2 z!1 z!1 z zz 0:5 ! d z 12 Xz 9z2 10z 3 lim lim z!1 dz z!1 z zz 0:5 ! 3z3 5z2 3z2z 0:5 2 zz 0:52 z

which states that the inverse z-transform of X(z) is given by xk 50:5k 2 2k uk.

4.4

LINEAR SHIFT-INVARIANT SYSTEMS

One of the most important concepts in the study of sampled-data systems is the superposition principle. A system S has the superposition property if the output of S to a given input xi k is yi k, denoted yi k Sxi k, then the output of S to xk is yk where


m1

ai Sxi k yk

19

A system is said to be a linear system if it exhibits the superposition property. If a system is not linear it is said to be nonlinear. A sampled-data system S is said to be shift invariant if a shift, or delay in the input time series, produces an identical shift or delay in the output. That is, if S

xk ! yk

20

S

In this case, the pole at z 1 has a multiplicity of 2. Using the production rules de®ned by Eq. (16) through (18), one obtains 0 lim

m1

L X

ai xi k )

xk m ! yk m

using Heaviside's method, it is required that X(z) be expanded in partial fraction form as z

L X

and S is shift invariant, then

2

Xz 0 1

xk

21

If a system is both linear and shift invariant, then it is said to be a linear shift-invariant (LSI) system. LSI systems are commonly encountered in studies of sampled-data and DSP which consider Nth-order system modeled as N X m0

am yk

m

M X m0

bm xk

m

22

If N M, the system is said to be proper and if a0 1, the system is classi®ed as being monic. What is of general interest is determining the forced, or inhomogeneous, solution yk of the LSI system de®ned in Eq. (22) to an arbitrary input xk. The input±output relationship of a causal at-rest (zero initial condition) LSI system to a forcing function xk is given by ! M N X 1 X b xk m am yk m 23 yk a0 m0 m m1 The solution to Eq. (23) is de®ned by a convolution sum which is speci®ed in terms the discrete-time system's impulse response hk, the response of an at-rest LSI to an input xk k. The convolution of an arbitrary time series xk by a system having an impulse response hk, denoted yk hk xk, is formally given by yk hk xk

1 X

1 X

hk

m0

hm xk

m xm 24

m

m0

Computing a convolution sum, however, often presents a challenging computational problem. An alternative technique, which is based on direct z-transform methods, can generally mitigate this problem. Suppose that the input xk and impulse response hk of an at-


259

rest discrete-time LSI system have z-transforms given by hk xk

Z

! Hz

25

Z

! Xz

respectively. Then, the z-transform of Eq. (24) would result in Yz Zyk

1 X

hm

m0

1 X m0

hmz

m

1 X

! xpz

p0

1 X

xpz

Hz Xz

26

p0

TRANSFER FUNCTION

M X

m0

Figure 4

bm Xzz

m

27

The ratio of Yz to Xz is formally called the transfer function, denoted Hz, and given by ! M X m bm z Yz m0 ! 28 N Hz X Xz m am z The transfer function describes how the z-transform of the input signal is transformed to the z-transformed of the output signal. An LSI system which has all its poles and zeros residing interior to the unit circle is called a minimum-phase system. Minimum phase systems are known to have strong transient responses and are important to the study of inverse systems [i.e., Gz 1=Hz]. Example 2. RLC Circuit: The RLC electrical circuit is assumed to satisfy the second-order ordinary differential equation d 2 yt dyt 2yt xt 3 2 dt dt which has a continuous-time system's impulse response given by ht e

t

e

2t

ut

For a sample period of Ts 1=fs seconds, the discretetime impulse response satis®es hk hkTs e

Applying the convolution theorem to the at-rest LSI model found in Eq. (22) produces


m

m0

Therefore the z-transform of the convolution sum yk hk xk is mathematically equivalent to multiplying the z-transforms of hk and xk in the zdomain, and then computing the inverse z-transform of the result. Equation (26) is also known by its popular name, the convolution theorem for z-transforms and provides a bridge between time-domain convolution and transform operations. If the regions of convergence for Xz and Hz are Rx and Rh respectively, then the region of convergence of Yz is Ry where Ry Rx \ Rh . This process is graphically interpreted in Fig. 4. The attraction of the convolution theorem is that it replaces a challenging convolution sum computation with a set of simple algebraic z- and inverse ztransform calls.

4.5

m0

am Yzz

pm

! p

N X

kTs

e

2kTs

ak

bk

where a and b are de®ned in the obvious manner. The z-transform of hk is given by

Convolution theorem.

260

Taylor

Hz

z z

z a

z

b

z

a bz az a

It is known that the input xk is a unit step, then Xz uz z=z 1. It immediately follows that Yz Xz Hz

z

a bz2 az az

hk r;1 pr k 1 r;2 kpr k

1

nr

Using previously established methods of inverting a ztransform, namely partial fraction expansion, the inverse of Yz is a time series: ! a b ak1 bk1 uk yk 1 a1 b 1 a 1 b which is also the step response of the LSI system.

4.6

STABILITY OF AN LSI SYSTEM

If, for all possible bounded initial conditions, the atrest solution of an LSI yk ! 0 as k ! 1, then the system is said to be asymptotically stable. If an LSI is asymptotically stable, then it is also bounded-input± bounded-output (BIBO) stable. BIBO stability simply states that the output will remain bounded provided the input is bounded. The stability of an LSI system can be determined in the transform domain. Suppose an LSI given by Hz contains N poles which are located at z pi , where pi may be real or complex, distinct or repeated. Then, in general, the partial fraction expansion of a strictly proper Hz is given by nr L X X r;i r;1 z Hz m z pr z pr 1 r1 m1 29 r;nr z r;2 z z pr 2 z pr nr where nr is the multiplicity of the pole located at pr , and L X

The coefr®cients 's are computed using Heaviside's method. The inverse z-transform of Hz is the system's impulse response hk which would have the general form

nr N

30

i1

nr 1 pr k 1 r;nr k

where the i 's are constants corresponding to the numerator weights of z-transforms of the form z=z am found in Table 1 scaled by the corresponding . Assume that pr r j!r , then hk converges asymptotically to zero if jr jk ! 0 as k ! 1. The system is conditionally stable if jr jk < V as k ! 1. Otherwise the system is unstable. Asymptotic stability can be insured if all the poles of Hz are interior to the unit circle. This gives rise to the so-called unit-circle criterion for stability. Since the poles of an LSI system can be easily computed with a modern digital computer, this test is generally considered to be adequate. It should be noted that if a pole is on the unit circle (i.e., jpr j 1), it must appear with a multiplicity of 1 if the system is to remain conditionally stable. If a conditionally stable system is presented with an input signal at the frequency occupied by the conditionally stable pole, instability will result. In this case the conditionally stable system is resonant and will diverge if driven at its resonate frequency. Finally, if any pole is unstable, the entire system is unstable. If all the poles are stable, but one or more is conditionally stable, the entire system is conditionally stable. In order for the system to be asymptotically stable, all the poles must be asymptotically stable. The establishment of the stability of a nonlinear system is a completely different story and generally requires considerable mathematical sophistication to establish stability. The stability cases are summarized in Table 3. The relationship between pole location and stability case is graphically motivated in Fig. 5. Example 3. Stability: Three strictly proper ®lters are considered having a transfer function Hz, where

Table 3 Pole Stability Conditions Stability classi®cation Asymptotic Conditional Unstable Unstable


31

Pole multiplicity

Pole magnitude jpr j

N 1 >1 N

1

BIBO stable Yes No No No


261

Figure 5 z-Domain relationship to the stability cases: stable (asymptotic), conditional, and unstable system behavior.

4 Y

z

Hz K m1 5 Y z m1

4.7

zm

If the LSI is asymptotically stable, then it can be assumed that the response to any nonzero initial condition will eventually decay to zero. This gives rise to the concept of steady-state analysis which states that any output present as t ! 1 must be due to an external input. If the input to an LSI system is a sinusoidal time-series of the form xk Ae j!k , then the output of an LSI has a structure given by yk Ve j!k , which corresponds to a possible amplitude and phase change relative to the input reference. Formally, the steadystate frequency response of an LSI system having a transfer function Hz to an assumed harmonic input xk Ae j!k is given by

pm

Three possible pole-zero distributions are shown below: H1 z H2 z H3 z

z5

0:002z4 z3 0:25z2 0:25z 3:3z4 5:04z3 4:272z2 2:002z

z5

0:002z4 z3 0:25z2 0:25z 3:314z4 5:086z3 4:329z2 2:036z 4

3

0:441 0:45

2

0:002z z 0:25z 0:25z 3:304z4 4:886z3 3:869z2 1:572z

z5

LSI SYSTEM FREQUENCY RESPONSE

0:308

jHe j! j jHzjze j! (magnitude frequency response)

and their pole locations summarized in Table 4 (determined using a general-purpose computer). The stability classi®cation of the systems immediately follows from the study of the pole locations and, in particular, results in

e j! argHe j! arctan

32

ImHe j! ReHe j!

33

(phase response)

H1 z asymptotically (BIBO) stable (all poles interior to the unit circle)

where ! 2 ; along the normalized frequency axis. The magnitude frequency response details the frequency selectivity of an LSI. The phase response establishes the amount of phase shift imparted by the discrete-time LSI. If e j! is positive, then the system is called a lead system. If negative, the system is called a

H1 z conditionally stable (two poles on the unit circle at z 0:707 j0:707 H1 z unstable (three poles exterior to the unit circle at z 0:767 j0:767 and 1.07) Table 4 Stability Summary Filter

K

z1

z2

z3

H1 z H2 z H3 z

0.002 0.002 0.002

0 0 0

1 1 1

j0:5 j0:5 j0:5


z4 j0:5 j0:5 j0:5

p1 5 j0:5 5 j0:5 5 j0:5

p2 5 5 5

j0:5 j0:5 j0:5

P3 0:7 j0:7 0:707 j0:707 0:767 j0:767

p4 0:7 j0:7 0:707 j0:707 0:767 j0:767

p5 0.9 0.9 1.07

262

Taylor

lag system. Regardless, a discrete-time LSI system has a steady-state response to a sinusoidal input of frequency ! given by N Y j!

He K

e j!

m1 N Y

N Y

zm K

e j!

pm

m1

m1 N Y m1

m j! 34 m j!

where m j! jm j!je jm

35

m j! j m j!je jm Equation (34) can be alternatively expressed as He j! jHe j! j argHe j!

36

where N Y j!

jHe j K

m1 N Y m1

jm j!j 37

Allowable passband deviation 1 dB, passband range f 2 0; 20 kHz. Minimum stopband attenuation 60 dB, stopband range f 2 22:5; 50 kHz. Using a commercial ®lter design package (Monarch), and eighth-order ®lter was designed which has a 1 dB maximum passband deviation and the minimum stopband attenuation is 69.97. The derived ®lter satis®ed z8 1:726z7 3:949z6 4:936z5 4 4:936z3 3:949z2 1:726z 1 5:923z Hz 0:00658 z8 3:658z2 7:495z6 11:432z5 11:906z4 8:996z3 4:845z2 1:711z 0:317

The frequency response of the eighth-order ®lter is reported in Fig. 6. The magnitude frequency response is seen to exhibit what is considered to have a classic pass- and stopband shape. Observe also that most of the phase variability is concentrated in the pass- and transition-, and early stopband. This is veri®ed by viewing the group delay which indicates that a delay of about 20 samples occurs at a transition band frequency.

j m j!j 4.8

and argHe j!

N X m1

m

N X m1

m 0 if K > 0

38

and if K < 0 Example 4. IIR: An eighth-order discrete-time ®lter is designed to meet or exceed the following speci®cations: Sampling frequency 100 kHz:

STATE-VARIABLE REPRESENTATION OF LSI SYSTEMS

Many important LSI systems are single-input±singleoutput (SISO) systems which can be modeled as a monic Nth-order difference equation yk a1 yk b1 uk

1 aN yk 1 bN uk

N b0 uk N

39

or as the transfer function Hz:

Figure 6 Response of an eight-order ®lter showing magnitude frequency response in linear and logarithmic (dB) units, phase response, and group delay (phase slope). (Courtesy of the Athena Group, Monarch 1 software.)



Hz

263

b0 b1 z 1 b N z N 1 a0 a 1 z 1 a N z

b0

b1

N

b0 a1 z 1 bN b0 aN z 1 a 0 a 1 z 1 aN z N

c1 z 1 cN z N 1 a 0 a 1 z 1 aN z 1 b0 Cz Dz b0

N

N

40 The transfer function is seen to consist of three distinct subsystems called 1. 2. 3.

A constant gain path b0 An all feedforward system denoted Cz An all feedback system Dz.

In general, a discrete-time system, consisting of pinputs, r-outputs, and N-states, has a state variable representation given by ~ 1 Akxk ~ Bk~ xk uk

~ x0 x0

(initial condition)

~ Dk~ uk y~k CT kxk

(state equation) 41 42 (output equation 43

where Ak is an N N matrix, Bk is an N P matrix, Ck is an N r matrix, and Dk is an R P ~ is matrix, u~k is an arbitrary P 1 input vector, xk an N 1 state vector, and y~k is an R 1 output vector. Such a system can also be represented by the four-tuple of matrices and vectors in the form

S fAk; Bk, Ck, Dkg. If the system is also an LSI system, then the state four-tuple is given by S fA; B; C; Dg. The state-determined system, described by Eqs. (41), (42), and (43), is graphically interpreted in Fig. 7. The states of an LSI system serve as information repositories and are saved in memory and/or shift registers. If an Nth-order system can be implemented with N shift registers, or N states, the system is said to be canonic. The states of the system reside at the shift-register locations and contain suf®cient information to completely characterize both the solution and the system architecture. Architecture corresponds to the method by which the fundamental building blocks of a sampled-data system are connected (wired) together. The coef®cient aij of A describes the gain of the path connecting the output of shift register j (state xj k) with the input to shift register i (state xi k 1). Two of the more popular architectures found in common use are the Direct II and cascade.

4.9

DIRECT II ARCHITECTURE

The system characterized by Eq. (40) can be placed into what is called a Direct II architectural model shown in Fig. 8. The canonic Direct II state model is de®ned in terms of an N-dimensional state vector given by 2 3 2 3 x1 k xk N 6 7 6 7 6 x2 k 7 6 xk N 1 7 6 7 6 7 7 6 7 ~ 6 xk 44 6 .. 7 6 7 .. 6 . 7 6 7 . 4 5 4 5 xN k xk and the following state assignments:

Figure 7 Discrete state-variable system model.


264

Taylor

Figure 8 2

x1 k 1

Direct II architecture.

3

c T bN

6 x k 1 7 6 2 7 7 ~ 1 6 xk .. 6 7 4 5 . 2

xN k 1

3

x2 k

6 6 6 6 4 aN x1 k

aN

x3 k .. . x k a2 xN 1 2

7 7 7 7 5 1 k

a1 xN k

uk

45

Here A is the N N coef®cient matrix 2 0 1 0 6 0 0 1 6 . .. .. .. .. A6 . . . 6 4 0 0 0 aN aN 1 aN 2

47

where, again aij de®nes the path gain existing between state xj k and xi k 1. Continuing, b is a N 1 vector satisfying 2 3 0 607 7 b6 48 4 ... 5 1

It can be immediately seen that Eq. (46) and (47) de®ne the feedback system found in the presence of the 1=Dz term in Eq. (40). The output, or output state equation, is given yk cT xk d0 uk

49

where c is a 1 N vector and d is a scalar satisfying


b0 aN

1

b1

b0 a 1 50 51

Hz 0:088 z8 4:43z7 10:76z6 17:46z5 20:48z4 17:46z3 10:76z2 4:43z 1 8 z 1:10z7 1:976 1:55z5 1:22z4 0:61z3 0:24z2 0:061z 0:008 A commercial CAD tool (Monarch) was used to convert the transfer function into the Direct II model shown on page 265. 4.10

a1

1

Example 5. Direct II Architecture: An eighth-order discrete-time ®lter has a transfer function given by

46 3 0 0 7 .. 7 . 7 7 1 5

bN

d 0 b0

which results in the state equation for a Direct II architecture which is given by ~ 1 Axk ~ buk xk

b0 aN

CASCADE ARCHITECTURE

A cascade architecture is shown in Fig. 9 and implements the transfer function factored as Hz K

Q Y i1

Hi z

52

where Hi z is a ®rst- or second-order subsystem de®ned with respect to real coef®cients. Each subsystem is represented by a state-determined model S i Ai ; bi ; ci ; d i and Q X i1

orderHi z N

53

A cascade architecture, as the name implies, links the output of one subsystem to the input of its succes-


265

DIRECT II STATE-VARIABLE FILTER DESCRIPTION Scale Factor=0.08883285197457290 A Matrix A1; i; i 2 0; 8 0.000000000000000

1.000000000000000

0.000000000000000

0.000000000000000

0.000000000000000

0.000000000000000

0.000000000000000

0.000000000000000

A2; i; i 2 0; 8 0.000000000000000

0.000000000000000

1.000000000000000

0.000000000000000

0.000000000000000

0.000000000000000

0.000000000000000

0.000000000000000

A3; i; i 2 0; 8 0.000000000000000

0.000000000000000

0.000000000000000

1.000000000000000

0.000000000000000

0.000000000000000

0.000000000000000

0.000000000000000

A4; i; i 2 0; 8 0.000000000000000

0.000000000000000

0.000000000000000

0.000000000000000

1.000000000000000

0.000000000000000

0.000000000000000

0.000000000000000

A5; i; i 2 0; 8 0.000000000000000

0.000000000000000

0.000000000000000

0.000000000000000

0.000000000000000

1.000000000000000

0.000000000000000

0.000000000000000

A6; i; i 2 0; 8 0.000000000000000

0.000000000000000

0.000000000000000

0.000000000000000

0.000000000000000

0.000000000000000

1.000000000000000

0.000000000000000

A7; i; i 2 0; 8 0.000000000000000

0.000000000000000

0.000000000000000

0.000000000000000

0.000000000000000

0.000000000000000

0.000000000000000

1.000000000000000

A8; 8; i 2 0; 8 0.007910400932499942

0.06099774584323624

0.2446494077658335

0.616051520514172

1.226408547493966

1.556364236494628

1.978668209561079

1.104614299236229

B Vector 0.000000000000000 0.000000000000000


C 0 Vector 0.9920989599067499 4.376921859721373

0.000000000000000

10.52456679079099

0.000000000000000

16.85365679994142

0.000000000000000

19.17645033204060

0.000000000000000

15.91334407549821

0.000000000000000

8.790547988995748

1.000000000000000

3.333305306328382

D Scalar 1.000000000000000

266

Taylor

Figure 9 Cascade architecture.

sor. Speci®cally, S i Ai ; bi ; ci ; di and S i1 Ai1 ; bi1 ; ci1 ; di1 can be chained together by mapping the yi k (output of S i ) to ui1 k (input of S i1 ). Following this procedure the state-variable model for a cascade system, given by S A; b; c; d where 0 B B B B B B A B B B B B @

A1

0

b2 cT1

A2

b3 d2 cT1

b3 cT1

.. .

.. .

bQ dQ 1 dQ

2

d2 cT1

0 0 A3 .. . bQ dQ 1 dQ

2

d4 cT3

bQ dQ 1 dQ 1 0 C 0 C C C C 0 C C C .. .. C . . C C A AQ

2

d3 cT2

54 0 B B bB @ dQ 0

b1 d1 b2 .. . 1

1 C C C A

55

d1 bQ 1

dq dQ 1 d2 c1 B dQ dQ 1 d3 c2 C B C cB C .. @ A . cQ


56

d dQ d Q

1

d 1 d1

57

The elements of A having indices aij , for i 2 j, correspond to the coupling of information from S i into S k where k > i. It can also be seen that the construction rules for a cascade design are also very straightforward. A cascade implementation of an Nth-order system can also be seen to require at most N multiplications from A (the terms aij , for i 2 j, are not physical multiplications), N from b and c, and one from d for a total complexity measure of Mmultiplier 3N 1, which is larger than computed for a Direct II ®lter. In practice, however, many Cascade coef®cients are of unit value which will often reduce the complexity of this architecture to a level similar to that of a Direct II. Example 6. Cascade Architecture Problem statement. Implement the eighth-order discrete-time studied in the Direct II example. Using a commercial CAD tool (Monarch) the following Cascade architecture was synthesized. The state-variable model presented over was produced using the Cascade architecture option (see page 267). The system is reported in terms of the state model for each secondorder sub®lter as well as the overall system. 4.11

SUMMARY

Sampled-data systems, per se, are of diminishing importance compared to the rapidly expanding ®eld of digital signal processing or DSP (see Chap. 3.3). The limiting factor which has impeded the development of sampled-data systems on a commercial scale has been technological. The basic building blocks of a


267

CASCADE STATE-VARIABLE FILTER DESCRIPTION Scale Factor = 0.08883285197457290 A Matrix A1; i; i 2 0; 8 0.000000000000000

1.000000000000000

0.000000000000000

0.000000000000000

0.000000000000000

0.000000000000000

0.000000000000000

0.000000000000000

A2; i; i 2 0; 8 0.09123912551991054

0.5174788167607780

0.000000000000000

0.000000000000000

0.000000000000000

0.000000000000000

0.000000000000000

0.000000000000000

A3; i; i 2 0:8 0.000000000000000

0.000000000000000

0.000000000000000

1.000000000000000

0.000000000000000

0.000000000000000

0.000000000000000

0.000000000000000

A4; i; i 2 0:8 0.9087608744800895

0.06330133197939697

0.2311930335002332

0.3741770017630547

0.000000000000000

0.000000000000000

0.000000000000000

0.000000000000000

A5; i : i 2 0:8 0.000000000000000

0.000000000000000

0.000000000000000

0.000000000000000

0.000000000000000

1.000000000000000

0.000000000000000

0.000000000000000

A6; i; i 2 0:8 0.9087608744800895

0.06330133197939697

0.7688069664997668

0.3793401006819637

0.4720529007738288

0.1778396572194128

0.000000000000000

0.000000000000000

A7; i; i 2 0; 8 0.000000000000000

0.000000000000000

0.000000000000000

0.000000000000000

0.000000000000000

0.000000000000000

0.000000000000000

1.000000000000000

A8; i; i 2 0; 8 0.9087608744800895

0.6330133197939697

0.7688069664997668

0.3793401006819637

0.5279470992261710

1.149648111678130

0.7944232896725211

0.03511882349298313

B Vector 0.000000000000000


C 0 Vector 0.9087608744800895

1.000000000000000

0.06330133197939697

0.000000000000000

0.7688069664997668

1.000000000000000

0.3793401006819637

0.000000000000000

0.5279470992261710

1.000000000000000

1.149648111678130

0.000000000000000

0.2055767103274789

1.000000000000000

1.867618425947684

D Scalar 1.000000000000000

268

sampled-data system would include samplers, multipliers, adders, and delays. Of this list, analog delays are by far the msot dif®cult to implement in hardware. Digital systems, however, are designed using ADCs, multipliers, adders, and delays. Delays in a digital technology are nothing more than clocked shift registers of digital memory. These devices are inexpensive and highly accurate. As a result, systems which are candidates for sampled-data implementation are, in a contemporary setting, implemented using DSP techniques and technology. BIBLIOGRAPHY Antonious A. Digital Filters: Analysis and Design. New York: McGraw-Hill, 1979.


Taylor Blahut R. Fast Algorithms for Digital Signal Processing. Reading, MA: Addison-Wesley, 1985. Brigham EO. The Fast Fourier Transform and Its Application. New York: McGraw-Hill, 1988. Oppenheim AV, ed. Application of Digital Signal Processing. Englewood Cliffs, NJ: Prentice-Hall, 1978. Oppenheim AV, Schafer R. Digital Signal Processing. Englewood Cliffs, NJ: Prentice-Hall, 1975. Proakis J, Manolakis DG. Introduction to Digital Signal Processing. New York: Macmillan, 1988. Rabiner LR, Gold B. Theory and Applications of Digital Signal Processing. Englewood Cliffs, NJ: Prentice-Hall, 1975. Taylor F. Digital Filter Design Handbook. New York: Marcel Dekker, 1983. Zelniker G, Taylor F. Advanced Digital Signal Processing: Theory and Applications. New York: Marcel Dekker, 1994.

Chapter 4.1 Regression Richard Brook

Off Campus Ltd., Palmerston North, New Zealand

Denny Meyer

Massey University±Albany, Palmerston North, New Zealand

1.1

be forecast exactly, the average value can be for a given value of the explanatory variable, X.

FITTING A MODEL TO DATA

1.1.1 1.1.1.1

What is Regression? Historical Note

1.1.1.2

Regression is, arguably, the most commonly used technique in applied statistics. It can be used with data that are collected in a very structured way, such as sample surveys or experiments, but it can also be applied to observational data. This ¯exibility is its strength but also its weakness, if used in an unthinking manner. The history of the method can be traced to Sir Francis Galton who published in 1885 a paper with the title, ``Regression toward mediocrity in hereditary stature.'' In essence, he measured the heights of parents and found the median height of each mother± father pair and compared these medians with the height of their adult offspring. He concluded that those with very tall parents were generally taller than average but were not as tall as the median height of their parents; those with short parents tended to be below average height but were not as short as the median height of their parents. Female offspring were combined with males by multiplying female heights by a factor of 1.08. Regression can be used to explain relationships or to predict outcomes. In Galton's data, the median height of parents is the explanatory or predictor variable, which we denote by X, while the response or predicted variable is the height of the offspring, denoted by Y. While the individual value of Y cannot

Uppermost in the minds of the authors of this chapter is the desire to relate some basic theory to the application and practice of regression. In Sec 1.1, we set out some terminology and basic theory. Section 1.2 examines statistics and graphs to explore how well the regression model ®ts the data. Section 1.3 concentrates on variables and how to select a small but effective model. Section 1.4 looks to individual data points and seeks out peculiar observations. We will attempt to relate the discussion to some data sets which are shown in Sec 1.5. Note that data may have many different forms and the questions asked of the data will vary considerably from one application to another. The variety of types of data is evident from the description of some of these data sets.

Example 1. Pairs (Triplets, etc.) of Variables (Sec. 1.5.1): The Y-variable in this example is the heat developed in mixing the components of certain cements which have varying amounts of four X-variables or chemicals in the mixture. There is no information about how the various amounts of the X-variables have been chosen. All variables are continuous variables. 269


Brief Overview

270

Brook and Meyer

Example 2. Grouping Variables (Sec. 1.5.2): Qualitative variables are introduced to indicate groups allocated to different safety programs. These qualitative variables differ from other variables in that they only take the values of 0 or 1. Example 3. A Designed Experiment (Sec. 1.5.3): In this example, the values of the X-variables have been set in advance as the design of the study is structured as a three-factor composite experimental design. The Xvariables form a pattern chosen to ensure that they are uncorrelated. 1.1.1.3

What Is a Statistical Model?

A statistical model is an abstraction from the actual data and refers to all possible values of Y in the population and the relationship between Y and the corresponding X in the model. In practice, we only have sample values, y and x, so that we can only check to ascertain whether the model is a reasonable ®t to these data values. In some area of science, there are laws such as the relationship e mc2 in which it is assumed that the model is an exact relationship. In other words, this law is a deterministic model in which there is no error. In statistical models, we assume that the model is stochastic, by which we mean that there is an error term, e, so that the model can be written as Y f X x e

In a regression model, f : indicates a linear function of the X-terms. The error term is assumed to be random with a mean of zero and a variance which is constant, that is, it does not depend on the value taken by the Xterm. It may re¯ect error in the measurement of the Yvariable or by variables or conditions not de®ned in the model. The X-variable, on the other hand, is assumed to be measured without error. In Galton's data on heights of parents and offspring, the error term may be due to measurement error in obtaining the heights or the natural variation that is likely to occur in the physical attributes of offspring compared with their parents. There is a saying that ``No model is correct but some are useful.'' In other words, no model will exactly capture all the peculiarities of a data set but some models will ®t better than others. 1.1.2

How to Fit a Model

1.1.2.1 Least-Squares Method We consider Example 1, but concentrate on the effect of the ®rst variable, x1 , which is tricalcium aluminate, on the response variable, which is the heat generated. The plot of heat on tricalcium aluminate, with the least-squares regression line, is shown in Fig. 1. The least-squares line is shown by the solid line and can be written as y^ f X x1 a bx1 81:5 1:87x1

where y^ is the predicted value of y for the given value x1 of the variable X1 .

Figure 1 Plot of heat, y, on tricalcium aluminate, x1 .


1

Regression

271

All the points represented by x1 ; y do not fall on the line but are scattered about it. The vertical distance between each observation, y, and its respective pre^ is called the residual, which we denote dicted value, y, by e. The residual is positive if the observed value of y falls above the line and negative if below it. Notice in Sec. 1.5.1 that for the fourth row in the table, the ®tted value is 102.04 and the residual (shown by e in Fig. 1) is 14:44, which corresponds to one of the four points below the regression line, namely the point x1 ; y 11; 87:6: At each of the x1 values in the data set we assume that the population values of Y can be written as a linear model, by which we mean that the model is linear in the parameters. For convenience, we drop the subscript in the following discussion. Y x "

2

More correctly, Y should be written as Y j x, which is read as ``Y given X x.'' Notice that a model, in this case a regression model, is a hypothetical device which explains relationships in the population for all possible values of Y for given values of X. The error (or deviation) term, ", is assumed to have for each point in the sample a population mean of zero and a constant variance of 2 so that for X a particular value x, Y has the following distribution: Y j x is distributed with mean x and variance 2 It is also assumed that for any two points in the sample, i and j, the deviations "i and "j are uncorrelated. The method of least squares uses the sample of n ( 13 here) values of x and y to ®nd the least-squares estimates, a and b, of the population parameters and by minimizing the deviations. More speci®cally, we seek to minimize the sum of squares of e, which we denote by S2 , which can be written as X 2 X X e y f x2 y a bx2 S2 P

3

The symbol indicates the summation over the n 13 points in the sample. 1.1.2.2

Normal Equations

The values of the coef®cients a and b which minimize S 2 can be found by solving the following, which are called normal equations. We do not prove this statement but the reader may refer to a textbook on regression, such as Brook and Arnold [1].


X

y a bx 0 or na b X xy a bx 0 or X X 2 X xy a xb x

X

x

X

y 4

By simple arithmetic, the solutions of these normal equations are a y bx hX b x

xy

iX y x

x2

5

Note:

P Likewise the mean 1. The mean of y is y=n, or y. of x is x. 2. b can be written as Sxy =Sxx , which can be called the sum of cross-products of x and y divided by the sum of squares of x. 3. From Sec. 1.5.1, we see that the mean of x is 7.5 and of y is 95.4.

The normal equations become 13a 97b 1240:5 97a 1139b 10,032

6

Simple arithmetic gives the solutions as a 81:5 and b 1:87. 1.1.3 1.1.3.1

Simple Transformations Scaling

The size of the coef®cients in a ®tted model will depend on the scales of the variables, predicted and predictor. In the cement example, the X variables are measured in grams. Clearly, if these variables were changed to kilograms, the values of the X would be divided by 1000 and, consequently, the sizes of the least squares coef®cients would be multiplied by 1000. In this example, the coef®cients would be large and it would be clumsy to use such a transformation. In some examples, it is not clear what scales should be used. To measure the consumption of petrol (gas), it is usual to quote the number of miles per gallon, but for those countries which use the metric system, it is the inverse which is often quoted, namely the number of liters per 100 km travelled. 1.1.3.2

Centering of Data

In some situations, it may be an advantage to change x The ®tted to its deviation from its mean, that is, x x. equation becomes

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y^ a bx

x

1.1.5

but these values of x and b may differ from Eq. (1). terms is zero as Notice that the sum of the x x X X X x x x x nx nx 0 The normal equations become, following Eq. (4), X na 0 y X X 7 2 x xy 0b x x Thus, a

X

y=n y

which differs somewhat from Eq. (5), but hX iX 2 x x b x xy which can be shown to be the same as in Eq. (5). The ®tted line is y^ 95:42 1:87x

x

If the y variable is also centered and the two centered variables are denoted by y and x, the ®tted line is y 1:87x The important point of this section is that the inclusion of a constant term in the model leads to the same coef®cient of the X term as transforming X to be centered about its mean. In practice, we do not need to perform this transformation of centering as the inclusion of a constant term in the model leads to the same estimated coef®cient for the X variable. 1.1.4

Correlations

Readers will be familiar with the correlation coef®cient between two variables. In particular the correlation between y and x is given by q 8 rxy Sxy = Sxx Syy There is a duality in this formula in that interchanging x and y would not change the value of r. The relationship between correlation and regression is that the coef®cient b in the simple regression line above can be written as q 9 b r Syy =Sxx In regression, the duality of x and y does not hold. A regression line of y on x will differ from a regression line of x and y.


Vectors

1.1.5.1 Vector Notation The data for the cement example (Sec. 1.5) appear as equal-length columns. This is typical of data sets in regression analysis. Each column could be considered as a column vector with 13 components. We focus on the three variables y (heat generated), y^ (FITS1 predicted values of y), and e (RESI1 residuals). Notice that we represent a vector by bold types: y, y^ , and e. The vectors simplify the columns of data to two aspects, the lengths and directions of the vectors and, hence, the angles between them. The length of a vector can be found by the inner, or scalar, product. The reader will recall that the inner product of y is represented as y y or yT y, which is simply the sum of the squares of the individual elements. Of more interest is the inner product of y^ with e, which can be shown to be zero. These two vectors are said to be orthogonal or `àt right angles'' as indicated in Fig. 2. We will not go into many details about the geometry of the vectors, but it is usual to talk of y^ being the projection of y in the direction of x. Similarly, e is the projection of y in a direction orthogonal to x, orthogonal being a generalization to many dimensions of `àt right angles to,'' which becomes clear when the angle is considered. Notice that e and y^ are `àt right angles'' or `òrthogonal.'' It can be shown that a necessary and suf®cient condition for this to be true is that eT y^ 0. In vector terms, the predicted value of y is y^ a1 bx and the ®tted model is y a1 bx e

10

Writing the constant term as a column vector of `1's pave the way for the introduction of matrices in Sec. 1.1.7.

Figure 2 Relationship between y; y^ and e.

1.1.5.2

VectorsÐCentering and Correlations

In this section, we write the vector terms in such a way that the components are deviations from the mean; we have y^ bx The sums of squares of y, y^ , and e are yT y Syy 78:5 109:4

95:422 74:3

95:422

95:422 2715:8

y^ T y^ Sy^y^ 1450:1

eT e See 1265:7

As we would expect from a right-angled triangle and Pythagoras' theorem, T

T

T

y y y^ y^ e e

1.1.7 1.1.7.1

We discuss this further in Sec. 1.2.1.5 on ANOVA, the analysis of variance. The length of the vector y, written as jyj, is the square root of yT y 52:11. Similarly the lengths of y^ and e are 38.08 and 35.57, respectively. The inner product of y with the vector of ®tted values, y^ , is X yi y^ i 1450:08 yT y^ The angle in Fig. 2 has a cosine given by p cos yT y^ =jyjj^yj 1450:1=2715:8 0:73 11 As y and x are centered, the correlation coef®cient of y on x can be shown to be cos . 1.1.6

sums are equal the means are equal and Section 1.5.1 shows that they are both 95.4. The second normal equation in Eq. (4) could be checked by multiplying the components of the two columns marked x1 and RESI1 and then adding the result. In Fig. 1.3, we would expect the residuals to approximately fall into a horizontal band on either side of the zero line. If the data satisfy the assumptions, we would expect that there would not be any systematic trend in the residuals. At times, our eyes may deceive us into thinking there is such a trend when in fact there is not one. We pick this topic up again later.

Residuals and Fits

Adding a Variable Two-Predictor Model

We consider the effect of adding the second term to the model: Y 0 x0 1 x1 2 x2 " The ®tted regression equation becomes y b0 x0 b1 x1 b2 x2 e To distinguish between the variables, subscripts have been reintroduced. The constant term has been written as b0 x0 and without loss of generality, x0 1. The normal equations follow a similar pattern to those indicated by Eq. (4), namely, X X y b0 b1 x1 b2 x2 X X x1 b0 b1 x1 b2 x2 x1 y 13 X X x2 b0 b1 x1 b2 x2 x2 y

We return to the actual values of the X and Y variables, not the centered values as above. Figure 2 provides more insight into the normal equations, as the least-squares solution to the normal equation occurs when the vector of residuals is orthogonal to the vector of predicted values. Notice that y^ T e 0 can be expanded to a1 bxT e a1T e bxT e 0

12

This condition will be true if each of the two parts are equal to zero, which leads to the normal equations, Eq. (4), above. Notice that the last column of Sec. 1.5.1 con®rms that the sum of the residuals is zero. It can be shown that the corollary of this is that the sum of the observed y is the same as the sum of the ®tted y values; if the


Figure 3 Plot of residuals against ®tted values for y on x1 .

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These yield 13b0 97b1 626b2 1240:5 97b0 1139b1 4922b2 10,032

14

626b0 4922b1 33,050b2 62,027:8 Note that the entries in bold type are the same as those in the normal equations of the model with one predictor variable. It is clear that the solutions for b0 and b1 will differ from those of a and b in the normal equations, Eq. (6). It can be shown that the solutions are: b0 52:6, b1 1:47, and b2 0:622: Note: 1.

2.

3.

By adding the second prediction variable x2 , the coef®cient for the constant term has changed from a 81:5 to b0 52:6. Likewise the coef®cient for x has changed from 1.87 to 1.47. The structure of the normal equations give some indication why this is so. The coef®cients would not change in value if the variables were orthogonal to each other. P For x0 x2 example, if x0 was orthogonal to x2 , would be zero. This would occur if x2 was in the form of deviation from itsP mean. Likewise, x1 x2 would be if x1 and x2 were orthogonal, zero. What is the meaning of the coef®cients, for example b1 ? From the ®tted regression equation, one is tempted to say that ``b1 is the increase in y when x1 increases by 1.'' From 2, we have to add to this, the words `ìn the presence of the other variables in the model.'' Hence, if you change the variables, the meaning of b1 also changes.

When other variables are added to the model, the formulas for the coef®cients become very clumsy and it is much easier to extend the notation of vectors to that of matrices. Matrices provide a clear, generic approach to the problem. 1.1.7.2

Vectors and Matrices

As an illustration, we use the cement data in which there are four predictor variables. The model is y 0 x0 1 x1 2 x2 3 x3 4 x4 " The ®tted regression equation can be written in vector notation, y b0 x0 b1 x1 b2 x2 b3 x3 b4 x4 e

15

The data are displayed in Sec. 1.5.1. Notice that each column vector has n 13 entries and there are k 5


vectors. As blocks of ®ve vectors, the predictors can be written as an n k 13 5 matrix, X. The ®tted regression equation is y Xb e

16

It can be shown that the normal equations are XT Xb XT y

17

Expanded in vector terms, xT0 x0 b0 xT0 x1 b1 xT0 x4 b4 xT0 y xT1 x0 b0 xT1 x1 b1 xT1 x4 b4 xT1 y xT4 x0 b0 xT4 x1 b1 xT4 x4 b4 xT4 y These yield the normal equations 13b0 97b1 626b2 153b3 39064b4 1240:5 97b0 1130b1 4922b2 769b3 2620b4 10,032 626b0 4922b1 33050b2 7201b3 15739b4 62,027.8 153b0 769b1 7201b2 2293b3 4628b4 13,981.5 39,064b0 2620b1 15;739b2 4628b3 15;062b4 34,733.3 Notice the symmetry in the coef®cients of the bi . The matrix solution is b XT X 1 XT Y bT 62:4; 1:55; 0:510; 0:102; 0:144

18

With the solution to the normal equations written as above, it is easy to see that the least-squares estimates of the parameters are weighted means of all the y values in the data. The estimates can be written as X wi y i bi where the weights wi are functions of the x values: The regression coef®cients re¯ect the strengths and weaknesses of means. The strengths are that each point in the data set contributes to each estimate but the weaknesses are that one or two unusual values in the data set can have a disproportionate effect on the resulting estimates. 1.1.7.3 The Projection Matrix, P From the matrix solution, the ®tted regression equation becomes

Regression

275

y^ xb xXT X 1 XT y

or

Py

19

P XXT X 1 XT is called the projection matrix and it has some nice properties, namely 1. 2. 3. 4.

T

P P that is, it is symmetrical. PT P P that is, it is idempotent. The residual vector e y y^ I Py. I is the identity matrix with diagonal elements being 1 and the off-diagonal elements being 0. From the triangle diagram, e is orthogonal to y^ , which is easy to see as eT y^ yT I

5. 6.

1.1.8 1.1.8.1

PT Py yT P

PT Py 0

P is the projection matrix onto X and y^ is the projection of y onto X. I P is the projection matrix orthogonal to X and the residual, 1, is the projection of y onto a direction orthogonal to X. The vector diagram of Fig. 2 becomes Fig. 4. Normality Assumptions about the Models

In the discussion so far, we have seen some of the relationships and estimates which result from the least-squares method which are dependent on assumptions about the error, or deviation, term in the model. We now add a further restriction to these assumptions, namely that the error term, e, is distributed normally. This allows us to ®nd the distribution of the residuals and ®nd con®dence intervals for certain estimates and carry out hypothesis tests on them. The addition of the assumption of normality adds to the concept of correlation as a zero correlation coef®cient between two variables will mean that they are statistically independent. 1.1.8.2

Var b0

2

1 x 2 n Sxx

!

and the variance of the coef®cient of the x variable is Var b1 2 =Sxx

We are usually more interested in the coef®cient of the x term. The con®dence interval (CI) for this coef®cient 1 is given by q 21 CI b1 tn 2 s2 =Sxx 1.1.8.3

Con®dence Interval for the Mean

^ The 95% con®dence interval for the predicted value, y, when x x0 is given by s 2 1 x0 x y^ 0 tn 2 s 22 Sxx n Note that the width of the con®dence interval is smal but the lest when the chosen x0 is close to the mean, x, width diverges the further the x0 is from the mean. A more important point is the danger of extrapolating outside of the range of values of X as the model may not be appropriate outside these limits. This con®dence interval is illustrated in Fig. 5 using the cement data. 1.1.8.4

Prediction Interval for a Future Value

At times one wants to forecast the value of y for a given single future value x0 of x. This prediction interval for a future single point is widier than the con®dence interval of the mean as the variance of single value of y around the mean is 2 . In fact, the ``1''

Distributions of Statistics

The variance of the constant term is

Figure 4 Projections of y in terms of P.


20

Figure 5 Con®dence and prediction intervals.

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Brook and Meyer

under the square root symbol may dominate the other terms. The formula is given by s 2 1 x x 23 y^ 0 tn 2 s 1 0 sxx n 1.1.9

Conclusions

Regression is a widely used and ¯exible tool, applicable to many situations. The method of least squares is the most commonly used in regression. The resulting estimates are weighted means of the response variable at each data point. Means may not be resistant to extreme values of either X or y. The normal, gaussian, distribution is closely linked to least squares, which facilitates the use of the standard statistical methods of con®dence intervals and hypothesis tests. In ®tting a model to data, an important result of the least-squares approach is that the vector of ®tted or predicted values is orthogonal to the vector of residuals. With the added assumptions of normality, the residuals are statistically independent of the ®tted values. The data appear as columns which can be considered as vectors. Groups of X vectors can be manipulated as a matrix. A projection matrix is a useful tool in understanding the relationships between the observed values of y, the predicted y and the residuals.

1.2

GOODNESS OF FIT OF THE MODEL

1.2.1 1.2.1.1

Regression Printout from MINITAB Regression with One or More Predictor Variables

In this section, comments are made on the printout from a MINITAB program on the cement data using the heat evolved as y and the number of grams of tricalcium aluminate as x. This is extended to two or more variables. 1.2.1.2

Regression Equation

The regression equation is y = 81.5 + 1.87 x 1


In keeping with the terminology we are using in this ^ Alternatively, if a chapter, the y above should be y. residual term e is added to the equation, we have termed this ``the ®tted regression equation.'' With one predictor variable, the ®tted equation will represent a line. We have noted in Sec. 1.1.7.1 that the estimated coef®cients will vary depending on the other variables in the model. With the ®rst two variables in the model, the ®tted regression equation represents a plane and the least-squares solution is y 52:6 1:47x1 0:662x2 In vector terms, it is clear that x1 is not orthogonal to x2 . 1.2.1.3 Distribution of the Coef®cients Predictor Constant x1

Coef 81.479 1.8687

StDev 4.927 0.5264

T 16.54 3.55

P 0.000 0.005

The formula for the standard deviation (also called the standard error by some authors) of the constant term and for the x1 term is given in Sec. 1.1.8.1. The T is the t-statistic (estimator hypothesized parameter)/standard deviation. The hypothesized parameter is its value under the null hypothesis, which is zero in this situation. The degrees of freedom are the same as those for the error or residual term. One measure of the goodness of ®t of the model is whether the values of the estimated coef®cients, and hence the values of the respective t-statistics, could have arisen by chance and these are indicated by the p-values. The p-value is the probability of obtaining a more extreme t-value by chance. As the p-values here are small, we conclude that small t-value is due to the presence of x1 in the model. In other words, as the probabilities are small (< 0:05 which is the common level used), both the constant and b1 are signi®cant at the 5% level. 1.2.1.4 R-Squared and Standard Error S = 10.73

R-Sq = 53.4%

R-Sq(adj) = 49.2%

S 10:73 is the standard error of the residual term. We would prefer to use lower case, s, as it is an estimate of the S in the S2 of Eq. (3). R Sq (short for R-squared) is the coef®cient of determination, R2 , which indicates the proportion of

Regression

277

the variation of Y explained by the regression equation: R2 Sy^y^ =Syy

and recall that

Syy

X

y

2 y

It is shown that R is the correlation coef®cient between y^ and y provided that the x and y terms have been centered. In terms of the projection matrices, P 2 y^ yT Py R P i2 T y y y 2

24

1.2.1.5

Analysis of Variance Source DF SS Regression 1 1450.1 Residual Error 11 1265.7 Total 12 2715.8

F P 12.60 0.005

115.1

Sums of squares of y Sums of squares of y^

R lies between 0, if the regression equation does not explain any of the variation of Y, and 1 if the regression equation explains all of the variation. Some authors and programs such as MINITAB write R2 as a percentage between 0 and 100%. In this case, R2 is only about 50%, which does not indicate a good ®t. After all, this means that 50% of the variation of y is unaccounted for. As more variables are added to the model, the value of R2 will increase as shown in the following table. The variables x1 ; x2 ; x3 , and x4 were sequentially added to the model. Some authors and computer programs consider the increase in R2 , denoted by R2 . In this example, x2 adds a considerable amount to R2 but the next two variables add very little. In fact, x4 appears not to add any prediction power to the model but this would suggest that the vector x4 is orthogonal to the others. It is more likely that some rounding error has occurred. 1

2

3

4

53.4 49.2

97.9 97.4 44.5

98.2 97.6 0.3

98.2 97.4 0.0

One peculiarity of R2 is that it will, by chance, give a value between 0 and 100% even if the X variable is a column of random numbers. To adjust for the random effect of the k variables in the model, the R2 , as a proportion, is reduced by k=n 1 and then adjusted to fall between 0 and 1 to give the adjusted R2 . It could be multiplied by 100 to become a percent: Adjusted R2 R2

MS 1450.1

The SS (sums of squares) can best be understood by referring to Fig. 4 (Sect. 1.7.3) which showed the relationship between the three vectors, y, y^ , and e provided that the Y- and X-variables are centered around their means. By Pythagoras' theorem,

2

Number of predictor variables R2 R2 (adjusted) Increase in R2 ; R2

Analysis of Variance

k=n


1n

1=n

k

1 25

Sums of squares of e That is, Sums of squares of total Sums of squares for regression

26

Sums of squares for residual The ANOVA table is set up to test the hypothesis that the parameter 0. If there are more than one predictor variable, the hypothesis would be, H: 1 2 3 0 If this is the case, it can be shown that the mean, or expected, value of y, y^ , and e will all be zero. An unbiased estimated of the variance of y, 2 , could be obtained from the mean squares of each of the three rows of the table by dividing the sums of squares by their degrees of freedom. From Fig. 4, we are now well aware that the vector of ®tted values is orthogonal to the vector of residuals and, hence, we use the ®rst two rows as their mean squares are independent and their ratio follows a distribution called the F-statistic. The degrees of freedom of the F-test will be 1 and 11 in this example. The p-value of 0.005 is the probability that by chance the F-statistic will be more extreme than the value of 12.6. This con®rms that the predictor variable, x1 tricalcium aluminate, predicts a signi®cant amount of the heat generated when the cement is mixed. What are the effects of adding variables to the model? These can be demonstrated by the cement data. The regression sum of squares monotonically increase as variables are added to the model; the residual sum of squares monotonically decrease; residual mean squares reduce to a minimum and then increase.

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One method of selecting a best-®t model is to select the one with the minimum residual mean squares. Number of predictor variables Regression sum of squares Residual sum of squares Residual mean squares s2

1.2.1.6

1 2 3 4 1450 2658 2668 2668 1266 58 48 48 115 5.8 5.4 6.0

Unusual Observations

Unusual Observations Obs

x1

y

Fit

10 21.0

115.90

120.72

StDev Fit 7.72

Residual -4.82

St Resid -0.65 X

Individual data points may be unusual because the yvalues are unusually large or small which would be measured according to whether they fall within a 95% con®dence interval. Alternatively, speci®c xvalues may differ from the others and have an unduly large effect on the regression equation and its coef®cients. More will be said on this in Section 1.4. 1.2.2

formation stretches larger values relatively more than smaller ones. Although the exponential does not ®t in very well, we have included it as it is the inverse of the logarithmic transformation. Other fractional powers could be used but they may be dif®cult to interpret. It would be feasible to transform either y or x, and, indeed, a transformation of y would be equivalent to the inverse transformation of x. For example, squaring y would have similar effects to taking the square root of x. If there are two or more predictor variables, it may be advisable to transform these in different ways rather than y, for if y is transformed to be linearly related to one predictor variable it may then not be linearly related to another. In general, hwoever, it is usual to transform the y, rather than the x, variable as this transformation may lead to a better-®tting model and also to a better distribution of the response variable and the residuals. Number of predictor variables R2 R2 (adjusted) Increase in R2 , R2

1 53.4 49.2 Ð

2 97.9 97.9 44.5

3 98.2 98.2 0.3

4 98.2 98.2 0.0

Power Transformations

Two variables, x and y, may be closely related but the relationship may not be linear. Ideally, theoretical clues would be present which point to a particular relationship such as an exponential growth model which is common in biology. Without such clues, we could ®rstly examine a scatter plot of y against x. Sometimes we may recognize a mathematical model, which ®ts the data well. Otherwise, we try to choose a simple transformation such as raising the variable to a power p as in Table 1. A power of 1 leaves the variable unchanged as raw data. As we proceed up or down the table from 1, the strength of the transformation increases; as we move up the table the transTable 1 Common Power Transformations p

Name

Ð 3 2

Exponential Cube Square

1

``Raw''

0:5 0 0:5 1

Square root Logarithmic Reciprocal/root Reciprocal


Effect Stretches Large Values Shrinks Large Values

1.2.3

Resistant Regression

The traditional approach to regression is via the leastsquares method, which has close relationships with means and the normal distribution. This is a powerful approach that is widely used. It does have problems in that the ®tted regression line can be greatly affected by a few unusually large or small y-values. Another approach, which is resistant to extreme values, is based on medians rather than means, as medians are not affected so much by strange values. The method is shown in Fig. 6 (data from Sec. 1.5.4). The xvalues are divided, as closely as possible, into three groups according to size. In this simple example, there are only nine points so that each group consists of three points. For the lower third, the median value of x is found and the median value of y giving the point 2; 12; this is repeated for the middle and upper third. The middle and upper median points are 5; 25 and 8; 95. The resistant line is found by joining the lower point, (2, 12), to the upper point, (8, 95) and is shown in Fig. 6 as a solid line. To check whether a curve would be more appropriate than a line, the three pairs of medians are linked by the dashed lines (- - -). If the slopes of the dashed lines differ from the slope of the resistant line, it would suggest that a curve should be used or the response variable, y, should be transformed. A rule of

Regression

279

Figure 6 Resistant line of value of stamp by year.

Figure 7 Plot of logarithm of stamp value by year.

thumb is that if the slope of the dashed line joining the middle and upper medians is more than two times or less than 0.5 times the slope of the dashed line joining the lower and the middle medians, a transformation is required. Here the upper slope is 70/3, whereas at the lower end the slope is only 13/3, suggesting a transformation is needed. Notice that the two dashed lines take on the appearance of an arrow head pointing down in this case which suggests that a transformation should be tried which shrinks the large y-values, namely a p-value less than 1. For example, a logarithm transformation may be appropriate, as shown in Fig. 7.

value? Some clues are provided by a comparison of the plots of the residuals from these models. The residuals could be plotted against predicted values or, as shown in Fig. 8, against the observation order. Figure 8 shows the strong pattern which remains in the residuals of the raw data and the curvature in the pattern indicates that a quadratic term could be added to the model. In Fig. 9, the transformed data, logarithm of the value, have removed the strong quadratic trend. In each residual plot, there remain certain trends in the residuals. If one considers the signs ( or ) of the residuals, the raw data gives a pattern of , whereas the logarithm of y yields the pattern . These patterns indicate a correlation between successive residuals which is termed autocorrelation. The strength of this autocorrelation seems to suggest that a basic assumption has

1.2.4

More on Residuals

Is the model using the logarithm of the value of the stamp data in Sect. 1.5.4, better than using the raw

Figure 8 Residuals versus the order of the data (response is value).


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Brook and Meyer

Figure 9

Residuals versus the order of the data (response is log value).

been violated, namely that successive deviations, ei and ei1 , are correlated. This autocorrelation is tested by the Durbin±Watson statistic, d, where X n n X 2 d et et 1 e2t t2

t1

If successive residuals are positively correlated with each other, the test statistic will be low. The hypothesis of uncorrelated errors is rejected for small values of this test statistic. If the test statistic d is below a lower critical value, dL , then the hypothesis of independence of errors is rejected. In other words, we conclude that the errors are autocorrelated. Values greater than the upper critical value, dU , allow us to accept the hypothesis of independence. Values of d between dL and dU are interpreted as `ìnconclusive.'' With this stamp data set, the length of the series is very short with only nine data points so that strong probability statements are not appropriate. Tables of the d statistic do not usually include information on dL and dU for n 9. However, for other sample sizes, n, the critical values for one predictor variable and a signi®cance level of 5%, are: n

dL

dU

15 20 25

1.08 1.20 1.29

1.36 1.41 1.45

With the raw stamp data, d 0:56 and for the transformed data, d 1:64. At least, we can conclude that


the logarithm transformation has improved the autocorrelation of the residuals. It has been mentioned before that the residuals should roughly fall in a horizontal band. An example where this is not so is shown in Fig. 10. The variance of the residuals seems to be increasing in absolute value as the ®tted value increases, which suggests that the assumption of constant variance may be violated. To reduce this effect, one should consider a power transformation, such as a logarithm. 1.2.5

Conclusions

For a model to be a good ®t to a data set, the F-test from the ANOVA should be signi®cant. Some, if not all, of the estimated coef®cients in the model will also be signi®cant.

Figure 10 Funnel plot of standardized residuals.

Regression

R2 indicates the proportion of the variation of the response variable which is explained by the model. This should be more than 50%, but one should take into account that R2 depends on the number of predictor variables, and this is corrected for to some extent by the adjusted R2 . The residual mean square is an estimate of the variance of the deviations in the model and a small value indicates a good ®t. Unfortunately, this statistic depends on the scale of the response variable. An examination of the residuals indicates if the model does not ®t well. The residuals can be plotted against variables in the model or yet to be entered but they should always be plotted against the ®tted, predicted variable. Residuals also should be examined to check for autocorrelations, constant variance by observation number, or other variables. To provide a better check on the goodness of ®t of a model, other variables to enter the model should be considered. In other words, one checks the goodness of ®t by looking for a model which provides a better ®t. A discussion on this follows in the next section. 1.3 1.3.1

WHAT VARIABLES SHOULD BE INCLUDED IN THE MODEL? Introduction

When a model can be formed by including some or all of the predictor variables, there is a problem in deciding how many variables to include. A small model with only a few predictor variables has the advantage that it is easy to understand the relationships between the variables. Furthermore, a small (parsimonious) model will usually yield predictions which are less in¯uenced by peculiarities in the sample and, hence, are more reliable. Another important decision which must be made is whether to use the original predictor variables or to transform them in some way. For example, the cost of laying rectangular concrete slabs largely depends on the length, breadth, and height of such slabs. Instead of using these three variables as predictors of the cost it would be much more sensible to use a single predictor which is the product of length, breadth, and height, that is, volume. This transformation has two advantages. It reduces the number of predictor variables and it introduces a predictor variable (volume) which has obvious physical implications for cost.


281

We shall start our discussion on variable selection by considering uncorrelated predictor variables. Such variables are often created in experimental design situations. 1.3.2

Uncorrelated Predictor Variables

In a regression with uncorrelated predictor variables the coef®cients for each predictor variable in the regression equation are not affected by the presence or absence of other predictor variables. In this case it is very easy to determine which predictor variables should be included in the model. This is done by ®tting a full regression model and then excluding any predictor variables which do not make a signi®cant contribution to the regression. We shall illustrate this idea using the following example. In Sec. 1.5.3, a three-factor central composite design is used to determine the effect of three predictor variables on the precipitation (y) of a chemical (stoichiometric dihydrate of calcium hydrogen orthophosphate). The three predictor variables were the mole ratio of ammonia to calcium chloride in the calcium chloride solution, time in minutes t, and the starting pH of the base solution. In order to simplify the design of the experiment the predictor variables were de®ned as scaled versions of the original variables as indicated in Sec. 1.5.3. In addition the experiment was designed in such a way as to ensure that the predictor variables were uncorrelated, as indicated below. Correlations (Pearson)

x2

x3

x1 0.000 1.000

x2

0.000 1.000

0.000 1.000

A full regression model has been ®tted to these data in Table 2. Only the coef®cients for the constant, x1 and x3 , are signi®cant. Because the predictor variables are uncorrelated this means that the coef®cients do not change when the nonsigni®cant predictor x2 is dropped from the model as shown in Table 3. (Note the marginal increase in the residual standard deviation s and the marginal reduction in R2 when the nonsigni®cant predictor is dropped from the regression equation.) If the predictor variables had not been uncorrelated this would not have been true and, in order to obtain an appropriate smaller, more parsimonious model,

282

Brook and Meyer

Table 2

Full Regression Model

Regression Analysis The regression equation is y = 71.9 + 5.49 x1 - 0.71 x2 + 10.2 x3 Predictor Constant x1 x2 x3 S = 7.646

Coef 71.895 5.488 -0.711 10.177

StDev 1.710 2.069 2.069 2.069

R-Sq = 66.2%

T 42.05 2.65 -0.34 4.92

P 0.000 0.017 0.736 0.000

R-Sq(adj) = 59.9%

Figure 11 Relationship between residuals and x3 .

special methods would have been required. Some of these methods are discussed in the next sections. Note that the ®t of the above model can be much improved by including the square of x3 as an additional predictor. This fact becomes obvious when the residuals for the model ®tted in Table 3 are plotted against x3 as shown in Fig. 11. 1.3.3

Testing Hypotheses

Suppose that we want to compare a full regression model with some reduced model. Assume that the reduced model estimates p coef®cients and the full model estimates q coef®cients. Consider the error sum of squares and the associated degrees of freedom for these two models. Error sum of squares

Model Reduced

Error degrees of freedom

SSE (reduced) SSE (full)

Full

n

p

n

q nE

Mean square error SSE (reduced)/ (n p) SSE (full)/ n q)

The following F-test can be used to determine whether the full model is signi®cantly better than the reduced model: Fq

p;n q

Regression Analysis The regression equation is y = 71.9 + 5.49 x1 + 10.2 x3

S = 7.445

Coef 71.895 5.488 10.177

p

1.3.4

Variable SelectionÐAll Possible Regressions

One method which is commonly used to obtain more parsimonious models is to run all possible regressions with k 1; 2; 3; . . . predictors and to choose the model which gives the most reliable ®t. De®ne p equal to the number of regression coef®cients including the constant (i.e., p k 1). Mallows [2] suggests using the following Cp statistic to compare the various models. SSE p s2

n

2p

The use of this statistic is illustrated in Example 1, which has been taken from Draper and Smith [3]. If the true model has been ®tted then

Smaller Model

Predictor Constant x1 x3

SSEReduced SSEFull=q MSEFull

If the p-value associated with this F-value is small < 0:05) it means that the full model is signi®cantly better than the reduced model.

Cp Table 3

StDev 1.665 2.015 2.015

R-Sq = 66.0%


ECp p k 1 T 43.19 2.72 5.05

P 0.000 0.014 0.000

R-Sq(adj) = 62.0%

The model with Cp closest to p therefore suggests the best model. This statistic penalizes models for which the number of coef®cients including the constant is large in relation to the sample size n, and it penalizes models for which the error sum of squares SSE p is

Regression

283

Table 4 Full Regression Model for the Cement Data

1.3.5

Regression Analysis The regression equation is y = 94.6 + 1.25 x1 + 0.172 x2 - 0.237 x3 0.460 x4 Predictor Constant x1 x2 x3 x4 S = 2.344

Coef 94.57 1.2508 0.1722 -0.2372 -0.4599

StDev 30.40 0.2634 0.3418 0.2773 0.3148

R-Sq = 98.4%

T 3.11 4.75 0.50 -0.86 -1.46

P 0.014 0.000 0.628 0.417 0.182

R-Sq(adj) = 97.6%

Variable SelectionÐSequential Methods

Another approach for the selection of predictor variables involves the sequential addition and/or removal of predictor variables when there is a signi®cant change in the regression sums of squares (SSR). When predictors are added sequentially this method is called forward selection. When the predictor variables are removed sequentially this method is called backward elimination. When both these methods are applied simultaneously this method is called sequential regression. 1.3.5.1

2

large in relation to the error variance s for the full model. For the example of Sec. 1.5.1, the amount of heat evolved in cement is to be modeled in terms of the amount of four ingredients in the mix. In this example the predictor variables are not uncorrelated. This means that we cannot simply drop the nonsigni®cant predictor variables from the full model ®tted in Table 4 in order to determine a more parsimonious model. In the output shown in Table 5 the two best onepredictor, two-predictor, and three-predictor models have been compared with the full model. The model with Cp closest to p is obtained for the three-predictor model involving x1 ; x2 , and x4 , suggesting that this is the best regression model for these data. This model has been ®tted in Table 8 producing a residual standard deviation and an R2 marginally smaller than for the full model. All the coef®cients are signi®cant at the 5% level in this three-predictor model, con®rming that, in this case, it would have been a mistake to simply drop all those predictor variables which were insigi®cant in the full model.

Forward Selection

The forward selection method starts with no predictor variables in the model and proceeds adding variables one at a time until a stopping criterion is reached. For each predictor variable an F-statistic is calculated in order to evaluate the signi®cance of a one-predictor model. This F-statistic is the ratio of the regression sums of squares (SSR) to the mean square error (MSE) for the one-predictor model. The MSE is obtained by dividing the SSE by the error degrees of freedom. In the following equation nR 1 represents the regression degrees of freedom and nE represents the error degrees of freedom: F

SSRone-predictor=nR SSRone-predictor SSE(one-predictor)=nE MSEone-predictor

The predictor variable with the highest F-value enters the regression, provided that this F-value is suf®ciently large. Next, F-statistics are calculated for all remaining predictors, in order to evaluate the signi®cance of an additional predictor in the regression. This F-statistic is the difference in the error sums of squares for a two-predictor and the best one-predictor model, divided by the mean square error for a two-predictor model. This means that the two-predictor model is the

Table 5 Best Subsets Regression Response is y

#Vars(k) 1 1 2 2 3 3 4


p 2 2 3 3 4 4 5

R-Sq 67.5 66.6 97.9 97.2 98.3 98.2 98.4

R-Sq (adj) 64.5 63.6 97.4 96.7 97.8 97.6 97.6

Cp 151.9 156.0 3.5 6.6 3.3 3.7 5.0

S 8.9639 9.0771 2.4063 2.7343 2.2447 2.3087 2.3440

x1x2x3x4 X X X X X X X X X X X X X X X X

284 Table 6

Brook and Meyer Best Regression

Regression Analysis The regression equation is y = 71.6 + 1.45 x1 + 0.416 x2 - 0.237 x4 Predictor Constant x1 x2 x4 S = 2.309

Coef 71.65 1.4519 0.4161 -0.2365

StDev 14.14 0.1170 0.1856 0.1733

R-Sq = 98.2%

T 5.07 12.41 2.24 -1.37

P 0.000 0.000 0.052 0.205

R-Sq(adj) = 97.6%

full model and the one-predictor model is the reduced model. Therefore q p 1 in the formula SSE(Reduced) SSE(Full)=q F MSE(Full)

p

The predictor with the highest F-value is added to the regression provided that its F-value is suf®ciently large. This process continues until all the predictors are included or until none of the remaining predictors would make a signi®cant contribution in explaining the variation in the response variable. Table 7 applies this method to the cement data of Sec. 1.5.1 (Example 1). In this example F-values in excess of 4 are required in order for the predictor to be added to the model. It is common to use t-values beyond t 2 to denote statistical signi®cance at a 5% level for n reasonable large, say 15. This transTable 7

Forward Selection for the Cement Data

Stepwise Regression F-to-Enter:

0.00

F-to-Remove:

x4 T-Value

1 117.57

2 103.10

3 109.78

4 94.57

-0.738 -4.77

-0.614 -12.62

-0.617 -15.44

-0.460 -1.46

1.44 10.40

1.15 6.97

1.25 4.75

-0.35 -2.42

-0.24 -0.86

x1 T-Value x3 T-Value x2 T-Value S R-Sq

0.17 0.50 8.96 67.45

2.73 97.25


2.24 98.33

y 109:8 1:15x1

2.34 98.38

0:35x3

0:617x4

Note that x4 entered the model ®rst, followed by x1 and then x3 . Note that this method produces the same regression model as the best subsets regression. This will not always be the case. Note that, as expected, R2 increases as successive variables are added to the model. The coef®cients for predictors included in the model (e.g., x4 ) change at each step because these predictor variables are not uncorrelated. 1.3.5.2 Backward Elimination The backward elimination method starts with all the k predictor variables in the model and proceeds to remove variables one at a time until a stopping criterion is reached. For each predictor variable an F-statistic is calculated in order to evaluate its contribution to the model. This F-statistic measures the effect of removing the predictor variable from the model. It is the difference in the error sums of squares for a k- and a k 1-predictor model divided by the mean square error for the k-predictor model

0.00

Response is y on 4 predictors, with N = 13 Step Constant

lates to F 4 because F1; n t2 n. The T-values in Table 7 are the square roots of the F-values de®ned above. The last column provides the recommended fourpredictor model. The coef®cients in this model are not all signi®cant. This means that a model with four predictors is not appropriate. If the F to enter had been set at 4 then the variable X2 would not have entered the regression and the analysis would have stopped at Step 3. Consider the three-predictor model under Step 3; all the coef®cients are signi®cant, indicating that this model is appropriate. That is,

F

SSEk

1 SSEk MSEk

The predictor variable with the lowest F-value makes the least contribution to the model. It leaves the regression provided that this F-value is suf®ciently small. Next, F-statistics are calculated for all predictors left in the regression, in order to determine if another predictor should be eliminated from the regression. This F-statistic is the difference in the error sums of squares for a k 1-predictor and a k 2-predictor model divided by the mean square error for a k 1-predictor model. F

SSEk

2 SSEk MSEk 1

1

Regression

285

The predictor with the lowest F-value is again eliminated from the regression provided that its F-value is suf®ciently small. This process continues until all the predictors are excluded or until all the predictors remaining in the regression make a signi®cant contribution in explaining the variation in the response variable. Table 8 applies this method to the cement data of Sec. 1.5.1. In this example predictors with F-values of less than 4 are dropped from the regression one by one. This method also produces the same regression model as the best subsets regression: y 109:8 1:15x1

0:35x3

0:617x4

The last column provides the recommended three-predictor model. Notice that, in step 2, x2 is dropped from the model because its T-value of 0.50 is the smallest Tvalue for step 1 and its F-value F t2 0:502 0:25 is less than 4. Backward elimination is recommended in preference to forward selection when dealing with pairs of predictor variables which together measure a gap. For example, if one predictor variable measures the inside diameter of a nut and another predictor variable is the diameter of the corresponding bolt, then it is the difference between these two measurements that may be of interest rather than their individual measurements. Forward selection may fail to enter either of these variables individually, hence failing to include their difference in the model. Backward elimination does not do this and is therefore recommended in this situation.

1.3.5.3

Hierarchical Regression

The above model uses a model consisting of only linear terms to ®t the data. In this case the ®t is so good R2 98:33% that there is no need to consider anything but linear terms. However, in other situations polynomial models are required in order to achieve a reasonable ®t. In polynomial models, powers (e.g., squares and cubes) of the existing variables are added to the model. In addition, interaction terms consisting of cross-products may be considered. In ®tting such polynomial models it is usual to add the higher-order terms one at a time in layersÐhence the name of hierarchical regression. Layers of higher order terms are added until there is no signi®cant increase in R2 as measured by the F-statistics de®ned in the last section. Note, however, that the stepwise methods should not be used to ®t these models because they might produce a model consisting of, say, only linear and cubic terms. To omit the quadratic terms in this way is not appropriate. Multicollinearity (i.e., high correlations between predictor variables) is a problem associated with hierarchical regression. As discussed in Sec. 1.4.4 multicollinearity causes computational and statistical dif®culties in regression. In hierarchical regression the higher-order variables (e.g., x3 ) are generally highly correlated with their low-order counterparts (e.g., x). This problem can often be overcome by subtracting the mean from each predictor variable. This results in regression terms of the form x

x x;

2 ; x x

3; . . . x

instead of Table 8 Backward Elimination for the Cement Data Stepwise Regression F-to-enter: 99999.00 F-to-Remove: 4.00 Response is y on 4 predictors, with N = 13 Step Constant

1 94.57

2 109.78

x1 T-Value

1.25 4.75

1.15 6.97

x2 T-Value

0.17 0.50

x3 T-Value

-0.24 -0.86

-0.35 -2.42

x4 T-Value

-0.460 -1.46

-0.617 -15.44

2.34 98.38

2.24 98.33

S R-Sq


x; x2 ; x3 ; . . . Hierarchical regression is illustrated below for the data of Sec. 1.5.3. For these data the means of the predictor variables have already been set to zero, so multicollinearity should not pose too much of a problem. The R2 for the linear model shown in Table 4 explained only 66.0% of the total variation in the response variable. Hopefully a model with higher-order terms will do better. Table 9 shows the second-order model including squares and an interaction term. Table 10 shows the third-order model. R2 for the second-order model is 94.9%, while R2 for the third-order model is 97.1%. In order to test whether there is a sign®icant improvement when going from a second- to a third-order model the following F-statistic is used. In this equation SSE denotes error sum of squares and MSE denotes mean square error.

286

Brook and Meyer Table 9 Second-Order Model for Experimental Design Data Regression Analysis The regression equation is y = 76.4 + 5.49 x1 + 10.2 x3 + 0.643 x12 - 7.22 x32 - 1.46 x1x3 Predictor Constant x1 x3 x12 x32 x1x3 S = 3.174

Coef 76.389 5.4880 10.1773 0.6429 -7.2236 -1.463 R-Sq = 94.9%

T 69.52 6.39 11.85 0.77 -8.68 -1.30

P 0.000 0.000 0.000 0.452 0.000 0.213

MS 525.42 10.07

F 52.16

St Dev 1.099 0.8588 0.8588 0.8319 0.8319 1.122

R-Sq(adj) = 93.1%

Analysis of Variance Source Regression Error Total

Model 2nd order 3rd order

DF 5 14 19

Error degrees of freedom

Error sums of squares

p 14 q 12

SSE(2nd order) SSE(3rd order)

SS 2627.09 141.02 2768.11

Mean square error

Fq

p;n q

MSE(3rd order)

Using the same F-test for comparing a reduced model with a full model,

P 0.000

SSE(2nd order) SSE(3rd order)=q MSE(3rd order) 141:02 81:2=14 12 6:77 4:418

The degrees of freedom associated with this F-value are 2 in the numerator and 12 in the denominator. An F-value of 3.89 is signi®cant at the 5% level, whereas an F-value of 6.93 is signi®cant at the 1% level. This means that the improvement produced by ®tting a third-order model as opposed to a second-

Table 10 Third-Order Model for Experimental Design Data Regression Analysis The regression equation is y = 76.4 + 3.22 x1 +6.78 x3 + 0.643 x12 - 7.22 x32 - 1.46 x1x3 + 1.29 x13 + 193 x33 Predictor Constant x1 x3 x12 x32 x1x3 x13 x33 S= 2.601

Coef 76.3886 3.224 6.778 0.6429 -7.2236 -1.4625 1.2881 1.9340 R-Sq = 97.1%

StDev 0.9006 1.543 1.543 0.6818 0.6818 0.9197 0.7185 0.7185

T 84.82 2.09 4.39 0.94 -10.59 -1.59 1.65 2.47

P 0.000 0.059 0.001 0.364 0.000 0.138 0.125 0.029

MS 83.84 6.77

F 56.73

R-Sq(adj) = 95.4%

Analysis of Variance Source Regression Error Total


DF 7 12 19

p

SS 2686.91 81.20 2768.11

P 0.000

Regression

287

order model is barely signi®cant. Indeed, it seems that all that is required is a linear model in terms of x1 and a quadratic model in terms of x3 . 1.3.6

Indicator (Grouping) Variables

In this section we show how qualitative variables can be introduced into a regression in order to test for differences between groups. This is done by de®ning the qualitative (group) variable in terms of dummy variables. Dummy variables are binary variables in that they can take only the values of 0 and 1. The number of dummy variables required in order to de®ne a single qualitative variable is always one less than the number of groups. As illustrated below, if there are only two groups then a single dummy variable is required to de®ne the groups, but if there are three groups then two dummy variables are required. For a three-group qualitative variable DUM1 1 for Group 1 only, DUM2 1 for Group 2 only and, for Group 3, DUM1 DUM2 0. Note that a third dummy variable, set equal to 1 for Group 3 and 0 otherwise, is therefore redundant. Two-groups Qualitative variable Group 1 Group 2

Dummy variable 0 1

Three-groups Qualitive variable Group 1 Group 2 Group 3

First dummy variable (DUM1) 1 0 0

Second dummy variable (DUM2) 0 1 0

Figure 12


By introducing such dummy variables into a regression, with additional terms de®ned as the product of the dummy variables and predictor variables, it is possible to ®t separate regressions for each group. In addition it is possible to test whether the coef®cients for the groups differ sign®ciantly. We shall illustrate this method using the following example. In a study of the effect of company size (measured using the number of employees) on the number of work hours lost due to work-related accidents, the presence or absence of a safety program is thought to be important. The data in Sec. 1.5.2 are illustrated in Fig. 12. The two groups have been coded using the dummy variable ``Dum.'' For companies with a safety program Dum 1 and for companies without a safety program Dum 0. The term DumEmp is de®ned as the product of Dum and the predictor variable `Èmployees.'' Three regressions have been ®tted to these data in Table 11. The ®rst regression suggests that the term Dum is redundant, so this term is eliminated in the second regression. The second regression suggests that the constant term is redundant, so this term is eliminated in the third regression. The ®nal equation contains only signi®cant terms, but note that R2 is not given for this model. This is due to the fact that the interpretation of the R2 for a regression model which does not have a constant term is problematic. In addition, the standard formulas given in previous sections are no longer valid. Because of these problems it may be easier to retain the constant in the regression model even when it is not signi®cant. Note, however, that the residual standard deviation, s, is smaller for the third regression, indicating an improvement in the model. Hours 0:0195454 Employees 0:0096209 DumEmp

Hours lost by the number of employees.

288

Brook and Meyer Table 11 Regressions for Safety Program Data First Regression Analysis The regression equation is Hours = -1.21 + 0.0197 Employees + 8.9 Dum - 0.0109 DumEmp Coef -1.213 0.019716 8.90 -0.010874

Predictor Constant Employees Dum DumEmp S = 13.28

R-Sq = 94.1%

StDev 7.593 0.001179 11.13 0.001721

T -0.16 16.72 0.80 -6.32

P 0.874 0.000 0.430 0.000

T 0.53 20.76 -13.53

P 0.599 0.000 0.000

R-Sq(adj) = 93.5%

Second Regression Analysis The regression equation is Hours = 2.93 + 0.0191 Employees - 0.00962 DumEmp Predictor Constant Employees DumEmp S = 13.30

Coef 2.934 0.0191327 -0.0096211 R-Sq = 94.0%

StDev 5.517 0.0009214 0.0007112

R-Sq(adj) = 93.6%

Third Regression Analysis The regression equation is Hours = 0.0195 Employees - 0.00962 DumEmp Predictor Noconstant Employees DumEmp

Coef

StDev

T

P

0.0195454 -0.0096209

0.0004914 0.0007030

39.78 -13.69

0.000 0.000

S = 13.05

Now, for companies without a safety program DumEmp equals zero, so Hours 0:0195454 Employees For companies with a safety program DumEmp, the product 1 Employees Employees, so that Hours 0:0195454 Employees 0:0096209 Employees 0:0291663 Employees There is a signi®cant difference between the slopes of these two lines because the DumEmp coef®cient is signi®cantly different from zero. Residual analysis con®rms that two lines with different slope but a common intercept of zero is a suitable model for these data. It is clear that the bene®t of a safety program in terms of reducing the number of hours lost due to accidents does depend on company size. There is a larger bene®t


Figure 13 Fitted model of safety program data.

Regression

289

for large companies than for smaller companies. Figure 13 shows the ®tted model for these data.

1.3.7

Conclusion

This section has dealt with the selection of predictor variables in regression. The main points are as follows: Small, parsimonious models are easier to understand and they predict more reliably. Predictor variables which are meaningful predictors of the response should be used. When predictor variables are uncorrelated the full model shows which predictors can be dropped. When predictor variables are correlated then other methods must be used. Best subsets regression de®nes the optimum model as the equation for which Cp p. Forward selection enters predictor variables one at a time in order of importance. Backward elimination removes predictor variables one at a time in order of least importance. Backward elimination is recommended when the difference between two predictors may be an important predictor, whereas the individual predictors are unimportant. k 1 dummy (zero±one) variables are required to de®ne k groups. Test for signi®cant differences between the relationship for the groups by testing the signi®cance of the dummy variable coef®cients and the coef®cients of the predictor±dummy-variable products.

Figure 14


1.4

PECULIARITIES OF OBSERVATIONS

1.4.1

Introduction

In Sec. 1.3 we considered the relationship between the response variable y and the k-predictor variables X x1 ; x2 ; . . . ; xk . This is a relationship between column vectors of data. In this section we turn our attention to rows or individual data points, x1i ; x2i ; . . . ; xki ; yi . Both predictor and response variable values must be considered when deciding whether a point is unusual. Points with peculiar x-values are termed sensitive or high leverage points. Points with unusual y-values are termed outliers. 1.4.2

Sensitive or High Leverage Points

The unusual x-values of high leverage points means that these points have much in¯uence on the regression equation. In addition the variance for y-predictions at these points are large. We shall illustrate these concepts using a simple example: x y

1 10

2 8

3 13

4 11

10 ?

Let us compare the regression lines when, for x 10, the y-value is 14 or 28. As shown in Fig. 14 the regression line is greatly in¯uenced by this y-value. This is because the x-value for this point is so unusual. The line ®tted to the point 10; 14 has a much smaller slope than the line ®tted to the point 10; 28. This means that for x 10 the value of y has a ``high leverage'' on the ®tted line.

Effect of a high leverage point at x 10.

290

Brook and Meyer

In algebraic terms y^ Py, where fpij g XX T X 1 X T . For this example, 2 3 1 6 7 6 1 7 6 7 1 7 P6 6 2 7130 1 2 3 4 10 6 7 4 4 5 10 2 3 1 2 3 4 10 6 7 4 6 8 20 7 6 2 6 7 130 1 6 6 9 12 30 7 6 3 7 6 7 8 12 14 40 5 4 4 10 20 30 40 100 and

2

3 y^1 6 y^2 7 6 7 7 y^ 6 6 y^3 7 130 4 y^4 5 y^5

2

1 6 2 6 16 6 3 4 4 10

2 4 6 8 20

3 4 6 8 9 12 12 16 30 40

P

32 3 10 y1 6 y2 7 20 7 76 7 6 7 30 7 76 y3 7 40 54 y4 5 y5 100

Clearly the in¯uence of y5 on all the predicted values is greater than all the other y-values due to its unusual x-value. The covariance matrix for these predictions equals P 2 . As a result, the variance for the predicted value of y5 is p55 2 100=130 2 , larger than that for the other y-values. Large values in the matrix P alert us to unusual x-values. In particular, points with the diagonal values of P, namely Pii , more than twice the average value of all the diagonal P values, can be regarded as high leverage points. that is, any point i with 2 pii >

n X j1

pjj

n

can be regarded as a high leverage point. In the above example any point with pii greater than 0.4 (that is 2130=130=5) can be regarded as a high leverage point. This means that only the ®fth point, with pii 100=130, is a high leverage point. 1.4.3

Outliers

Any point with a large difference between its observed and predicted y-values is probably an outlier. This means that it is the model as well as the observed yvalue which determine whether a point is an outlier. Therefore, if more or different predictors are included


in a model then it is likely that different points will show up as being potential outliers. Outliers are often dif®cult to detect because, in particular, they may be obscured by the presence of high leverage points. Generally speaking, an outlier has a high absolute value for its ``Studentized'' residual. Hoaglin and Welsch [4] suggest several alternative methods for detecting outliers. Many of these methods consider what happens to estimated coef®cients and residuals when a suspected outlier is deleted. Instead of discussing these methods we will use a principalcomponent method for detecting outliers in the next section. What should one do with outliers? If the sample size is large and it is suspected that the outlier is an error of measurement then an outlier can be deleted. However, it is important to consider such points very carefully because an outlier may suggest conditions under which the model is not valid. The most infamous outlier in recent times has been the ozone hole over the south pole. For several years this outlier was regarded as an error of measurement rather than a reality. 1.4.4

Eigenvalues and Principal Components

As mentioned above, principal-component analysis can be used to identify outliers. We shall illustrate this use of principal-component analysis using the cement data. In addition we shall show how principal-component analysis can be used to determine when there is collinearity or multicollinearity. This condition occurs when the correlations between the predictors are so large that the X T X matrix becomes nearly singular with a determinant close to zero. In this situation the variances associated with the estimated coef®cients are so large that their interpretation becomes meaningless. In principal-component analysis the predictor variables are transformed to principal components. The eigenvalues measure the variances of each of these principal components, with the ®rst component having the largest eigenvalue and the last eigenvector having the smallest eigenvalue. In Fig. 15, x1 and x2 represent the original predictors, while w1 and w2 represent the principal components. The variance associated with w1 is obviously maximized, while the variance associated with w2 is minimized. In Fig. 15 there is a strong correlation between x1 and x2 . As a result the eigenvalue (variance) associated with w2 is close to zero. Unusual values for w2 fall far from the w1 axis. Such values can be used to identify outliers. When there are more than two variables this

Regression

291

Figure 15 Original x-axis with w-principal-component axis.

rule can still be used to identify outliers. Any unusual principal-component value identi®es an outlier when it is associated with an unimportant (low-variance) eigenvalue. When there is a strong muilticollinearity, at least one of the eigenvalues is close to zero. In this situation the determinant of X T X (the product of the eigenvalues) is close to zero, causing the variance of the regression coef®cients 2 X T X 1 to be very big. According to Hoaglin and Welsch [4], if the ratio of the largest eigenvalue to the smallest eigenvalue exceeds 30 when a principal-component analysis is performed on a correlation matrix, then it means that multicollinearity is making the regression unreliable. In this situation, predictors should be combined or discarded. The principal-component analysis for the predictors of the heat evolved in cement appears in Table 12. The largest eigenvalue is 2.3246, while the smallest eigenvalue is 0.0077. This suggests a ratio

Table 12

2:3246=0:0077 302. This means that there is too much multicollinearity among these predictors for a full four-predictor model. Predictors must be combined or discarded in order to ensure that the estimated coef®cient variances are reasonably small, otherwise the regression will be unreliable. Table 13 shows the principal-component scores for these data. The last principal component identi®es no outliers, but the third component identi®es the fourth observation as an outlier. Observation 4 has a relatively high value for w3 . The loadings for w3 (high on x1 and x3 ) show in what sense this observation is an outlier. It has a relatively high score for x1 x3 . 1.4.5

Ridge Regression and Prior Information

We have seen that high correlations among the predictor variables tend to increase the variance of the estimated regression coef®cients, making these estimates and any predictions unreliable. We have suggested

Principal-Component Analysis: Predictors for Cement Data

Principal-Component Analysis Eigenanalysis of the Correlation Matrix Eigenvalue Proportion Cumulative

2.3246 0.581 0.581

1.3836 0.346 0.927

0.2841 0.071 0.998

0.0077 0.002 1.000

Variable x1 x2 x3 x4

PC1 0.437 0.569 -0.427 -0.550

PC2 0.551 -0.411 -0.568 0.453

PC3 0.693 -0.189 0.675 -0.169

PC4 0.158 0.687 0.200 0.681


292

Brook and Meyer Table 13 Principal-Component Scores y

x1 x3

78.5 74.3 104.3 87.6 95.9 109.2 102.7 72.5 93.1 115.9 83.8 113.3 109.4

13 16 19 29 13 20 20 23 20 25 24 20 18

w1 1:40199 2:06499 1:17609 1:28180 0:43662 1:00818 1:00079 2:18793 0:28684 1:65441 1:59558 1:73927 1:80377

w2 1:92387 0:28164 0:24906 0:76837 0:50652 0:24246 2:05957 0:59801 1:35846 1:93414 1:19351 0:31864 0:37788

that predictors should be combined or discarded in this situation. Another solution to the multicollinearity problem is to use a ridge regression estimator proposed by Hoerl and Kennard [5]. They suggest increasing the problematic determinant of the X T X matrix by adding a constant, k, to all diagonal terms. This obviously increases the determinant, producing smaller variances for the coef®cients. In general the value of k should be less than 0.2. Plots of the estimated coef®cients against k, known as ridge traces, are useful for deciding the optimum value for k. The best value of k is the lowest value of k for which the estimated coef®cients are reasonably stable. An optimum value for k of approximately 0.08 is suggested by the ridge trace shown in Fig. 16. A similar approach is used to incorporate prior information into a regression analysis. Say that the

w3 0:76496 0:49613 0:04723 1:01948 0:80836 0:04829 0:09935 0:28506 0:06863 0:76620 0:38017 0:01558 0:23013

w4

Observation

0:028472 0:049005 0:104609 0:196814 0:078454 0:036712 0:049964 0:070893 0:046095 0:112222 0:049449 0:042293 0:0729894

1 2 3 4 5 6 7 8 9 10 11 12 13

prior information about the coef®cients can be described by the model r R where is distributed N0; 2 I. Then the original model and this additional model can be combined into a single model y X " r R with the weighted least-squares estimator for given by b

X T y= 2 RT r=2 X T X= 2 RT R=2

If RT r 0 and RT R I and k =2 , then the ridge regression estimate is obviously obtained as a special case of this estimator. 1.4.6

Weighted Least Squares

One of the assumptions of least-squares regression is that the variance remains constant for all values of the predictor variables. If it is thought that this assumption is not valid, it is possible to modify the leastsquares method by giving different weights to different observations. Say that the response yi is the mean for a sample of ni individuals, then the variance for yi is 2 =ni . In order to force constant variances for each response value one p must multiply through by ni . That is, instead of ®tting the model Figure 16 A ridge trace.


yi 0 1 Xi "i

Regression

293

the following model should be ®tted in order to obtain constant variances: p p p p ni y i ni 0 n i 1 X 1 ni " i This model produces weighted coef®cient estimates of the form b X T WX 1 X T Wy where W is a diagonal matrix consisting of the sample sizes ni for each mean observation. When the variance for the ith mean is de®ned as s2i =ni , with different variances, then the weighted estimates are similarly de®ned, but W diagni =s2i . As an illustration, the relationship between book value and resale value is to be determined for a company's plant and equipment. The following data have been collected. A log transformation of book value is required in order to linearize these data. Book value ($) 0 and a < 0. In both cases, we divide the constraint by a. If a > 0 we get jXj 1=ay , , or c=a. Putting Y 1=ay and C c=a, the constraint becomes jXj Y ; ; or C If a < 0, the inequalities are reversed. Consequently, we have three possibilities to consider. The case is the easiest. The constraint jXj Y C is equivalent to the following two LP constraints uvY C

1

and Xu

v

2

To model the other two cases, jXj Y or C, in LP format, in addition to (2) and the appropriate modi®cation of (1) above, we use an INT variable Z and a ``big M'' in the following additional constraints: u MZ

3

and v M1

Z

4

These latter two constraints that at least one of u and v be zero, consequently jXj u v. General integer (GIN) variables are variables whose values are integers. INT and GIN variables will be used in some of the examples.

304

Example 4

Darst

A Primal-Dual Pair

Information Provided. The Volkswagen Company produces three products: the bug, the superbug, and the van. The pro®t from each bug, superbug, and van is $1000, $1500, and $2000, respectively. It takes 15, 18, and 20 labor-hours to produce an engine; 15, 19, and 30 labor-hours to produce a body; and 10, 20, and 25 minutes to assemble a bug, superbug, and van. The engine works has 10,000 labor-hours available, the body works has 15,000 labor-hours available, and the assembly line has 168 hours available each week. Plan weekly production to maximize pro®t. Solution Let B number of bugs produced per week. Let S number of superbugs produced per week. Let V number of vans produced per week. An LP model and solution for Example 4 follow. Maximize 1000 Subject to 2) 15 B + 3) 15 B + 4) 10 B +

B + 1500 S + 2000 V 18 S + 20 V = 2000

The constraints for this dual problem say that the number of dollars offered to pay to rent must be enough to make Volkswagen's rental income at least as much as the pro®t it would get by using its resources to manufacture vehicles instead of renting them to BMW. It turns out that the optimal objective function values for the primal and its dual are always equal. A solution follows. VARIABLE VALUE E 28.571430 W .000000 A 57.142860

Example 5

Percentage Constraints

Information Provided. A farmer requires that each of his cows receives between 16,000 and 18,000 calories, at least 2 kg of protein, and at least 3 g of vitamins per day. Three kinds of feed are available; the following table lists their relevant characteristics per kilogram.

Feed

Cost

Calories

Kg. of protein

Grams of vitamins

1 2 3

$0.8 $0.6 $0.2

3600 2000 1600

0.25 0.35 0.15

0.7 0.4 0.25

The farmer also requires that the mix of feeds contain at least 20% (by weight) feed 1 and at most 50% (by weight) feed 3. The farmer wishes to formulate a diet which meets his requirements at minimum cost. Solution Let A no. of kilograms of feed 1 to put in the diet. Let B no. of kilograms of feed 2 to put in the diet. Let C no. of kilograms of feed 3 to put in the diet. The ®rst four constraints correspsond to the calorie, protein and vitamin requirements of the diet. The last two correspond to the percentage requirements: A 0:2 A B C and C 0:5A B C. A model appears below, followed by a solution. The constraints have been adjusted to make the coef®cients integers.

Linear and Dynamic Programming Minimize 8 A + 6 B + 2 Subject to 2) 36 A + 20 B + 16 C 3) 36 A + 20 B + 16 C 4) 25 A + 35 B + 15 C 5) 70 A + 40 B + 25 C 6) 8 A - 2 B - 2 C >= 7) 5 A + 5 B - 5 C >=

305 4) P1 + P2 + P3 + P4 = 5 5) .3 G1 + .23 G2 + .16 G3 + .13 G4 + .46 A1 + .44 A2 + .34 A3 + .31 A4 + .53 P1 + .51 P2 + .47 P3 + .42 P4 10

C >= = >= 0 0

160 180 200 300

OBJECTIVE FUNCTION VALUE 82.4999900

OBJECTIVE FUNCTION VALUE 38.3132600 VARIABLE VALUE A 1.686747 B 2.831325 C 3.915662

Example 6

A Processing Problem

Information Provided. Fruit can be dried in a dryer according to the following table. The dryer can hold 1 m3 of fruit. Relative volume Drying hours 1 2 3 4

Grapes

Apricots

Plums

0.30 0.23 0.16 0.13

0.46 0.44 0.34 0.31

0.53 0.51 0.47 0.42

Formulate an LP to estimate the minimum time in which 20 m3 of grapes, 10 m3 of apricots, and 5 m3 of plums can be dried to a volume of no more than 10 m3 . Solution. We begin by making some simplifying assumptions. The dryer will be ®lled with one kind of fruit and operated for 1, 2, 3, or 4 hours, then the dried fruit will be removed from the dryer and the dryer will be re®lled. In accord with these assumptions, we have the following decision variables: Let GI no. of cubic meters of grapes to dry for I hours. Let AI no. of cubic meters of apricots to dry for I hours. Let PI no. of cubic meters of plums to dry for I hours. Time spent ®lling the dryer and removing dried fruit is assumed to be independent of the type of fruit being dried and the number of hours the fruit is dried. Then these factors do not need to be explicitly incorporated into the model. Minimize G1 + 2 G2 +3 G3 +3 A3 + 4 A4 + P1 + 2 P2 Subject to 2) G1 + G2 + G3 + G4 = 3) A1 + A2 + A3 + A4 =


+ 4 G4 + A1 + 2 A2 + 3 P3 + 4 P4 20 10

VARIABLE VALUE G1 .000000 G2 .000000 G3 20.000000 G4 .000000 A1 6.250004 A2 .000000 A3 3.749996 A4 .000000 P1 5.000000 P2 .000000 P3 .000000 P4 .000000

A1 and A3 are not integer valued. However, if we change A1 to 6 and A3 to 4, then we get an integervalued feasible solution with objective function value of 83. The objective function value of any integer valued solution will be an integer. Since 83 is the smallest integer which is 82:5, we know that changing A1 to 6 and A3 to 4 provides use with an optimal integer valued solution. Example 7

A Packaging Problem

Information Provided. The Brite-Lite Company receives an order for 78 ¯oor lamps, 198 dresser lamps, and 214 table lamps from Condoski Corp. Brite-Lite ships orders in two types of containers. The ®rst costs $15 and can hold two ¯oor lamps and two table lamps or two ¯oor lamps and two table lamps and four dresser lamps. The second type costs $25 and can hold three ¯oor lamps and eight table lamps or eight table lamps and 12 dresser lamps. Minimize the cost of a set of containers to hold the order. Solution Let CIJ = no. of containers of type I to pack with mix J; I 1; 2; J 1; 2 Minimize 15 C11 + 15 C12 + 25 C21 + 25 C22 Subject to 2) 2 C11+ 2 C12 + 3 C21 78 3) 4 C11 + 2 C12 + 8 C21 + 8 C22 214 4) 4 C12 + 12 C22 198 OBJECTIVE FUNCTION VALUE 852.500000 VARIABLE VALUE C11 .000000 C12 21.000000 C21 12.000000 C22 9.500000

306

Darst

This solution is not integer valued; however, it puts six dresser lamps in the half carton of type 2 packed with mix 2 and no other listed packing option will allow six dresser lamps in one carton. Consequently, I could put C22 10, increase the cost to 865, and claim that I now have the optimal solution. But claiming does not necessarily make it optimal. Is there a better solution? Using GIN variables, I found a better solution. The best integer-valued solution is C11 4, C12 20, C21 10 and C22 10, with objective function value 860; 5 may seem to be a trivial number of dollars, but if we are shipping different products and we are talking about hundreds of thousands of dollars, the difference might be signi®cant to you. Example 8

LP Can Model Diminishing Return Thresholds

Information Provided. The Model-Kit Company makes two types of kits. They have 215 engine assemblies, 525 axle assemblies, 440 balsa blocks, and 560 color packets in stock. Their earthmover kit contains two engine assemblies, three axle assemblies, four balsa blocks, and two color kits; its pro®t is $15. Their racing kit contains one engine assembly, two axle assemblies, two balsa blocks, and three color kits; its pro®t is $9.50. Sales have been slow and Sears offers to buy all that Model-Kit can supply using components in stock if Model-Kit will sell all earthmover kits over 60 at a $5 discount and all racing kits over 50 at a $3 discount. Determine which mix of model kits to sell to Sears to maximize pro®t using components in stock. Solution. The numbers 60 and 50 are thresholds for earthmover and racing kits. As production increases across the threshold, the return per unit diminishes. Let E and R denote the number of earthmover and racing kits to sell to Sears. Let E1 denote the number of earthmover kits to be sold at the regular price and let E2 denote the number to be sold for $5 less: E2 E E1. Let R1 and R2 play similar roles for racing kits. Maximize 15 E1 + 10 E2 + 9.5 R1 + 6.5 R2 Subject to 2) 2 E + R = 25 12) Y + H2 + Q4 + M11 >= 15 13) Y + H2 + Q4 + M12 >= 10 14) 10 Y + 7 H1 + 7 H2 + 5 Q1 + 5 Q2 5 Q3 + 5 Q4 + 3 M1 + 3 M2 + 3 M3 3 M4 + 3 M5 + 3 M6 + 3 M7 + 3 M8 3 M9 + 3 M10 + 3 M11 + 3 M12 - C

Q2 + M4 + M10 +

+ + + = 0

OBJECTIVE FUNCTION VALUE 510.00000 VARIABLE VALUE Y 43.000000 H1 .000000 H2 .000000 Q1 .000000 Q2 .000000 Q3 7.000000 Q4 .000000 M1 .000000 M2 .000000 M3 .000000 M4 .000000 M5 .000000 M6 9.000000 M7 .000000 M8 6.000000 M9 .000000 M10 .000000 M11 .000000 M12 .000000 C 510.000000

REDUCED COST .000000 .000000 4.000000 5.000000 .000000 .000000 5.000000 3.000000 3.000000 3.000000 3.000000 1.000000 3.000000 1.000000 .000000 3.000000 3.000000 3.000000 3.000000 .000000

Not only do we have a different solution, but now we have variables, H1 and Q2 with value equal to zero and reduced cost equal to zero. I changed the objective function to Maximize Q2 and added the constraint: 15) C 510. The following solution appeared. OBJECTIVE FUNCTION VALUE 18.000000 VARIABLE VALUE Q2 18.000000 Y 25.000000 Q1 .000000 M1 .000000 H1 .000000 M2 .000000 M3 .000000 M4 .000000 M5 .000000 M6 9.000000 Q3 25.000000 M7 .000000 H2 .000000

REDUCED COST .000000 .000000 2.500000 1.500000 1.000000 1.500000 1.500000 1.500000 1.500000 .000000 .000000 .500000 1.000000

308 M8 M9 Q4 M10 M11 M12 C

Darst 6.000000 .000000 .000000 .000000 .000000 .000000 510.000000

.000000 1.500000 1.500000 .500000 1.500000 1.500000 .000000

The point of this discussion is to make you aware of the possibility of multiple optimal solutions and indicate how you can begin to look for them. Example 10

There are four ways to load the truck.

Let L1 no. of trucks loaded with one type 1 pallet and three type 3 pallets. Let L2 no. of trucks loaded with four type 1 pallets and one type 3 pallet. Let L3 no. of trucks loaded with three type 1 pallets and two type 2 pallets. Let L4 no. of trucks loaded with two type 2 pallets and 2 type 3 pallets. Maximize L1 Subject to 2) L1 + 4 3) 2 L3 + 4) 3 L1 +

+ L2 + L3 + L4 L2 + 3 L3 = 7500 31 B4 >= 8000 + A3 + A4 - T = 7500 5) 10 A4 + 31 B4 >= 8000 6) A1 + A2 + A3 + A4 - T = >= >= >= >=

12 16 12 14 8

OBJECTIVE FUNCTION VALUE 36.000000 VARIABLE N N1 N2 N3 N4 N5 N6

VALUE 36 0 12 4 12 2 6

The LP solution turned out to have integer values, which was ®ne. There are many alternate solutions to the problem. Waitresses. To determine the number of regulartime waitresses needed, we will determine the number of waitresses that will begin their work week on each day of the week, and we will determine the number of waitresses to work overtime on each day of the week. Starting with Sunday corresponding to day 1, let WI denote the number of waitresses to begin their regular work week on day I, let DI denote the total number of regular time waitresses working on day I, and let OI denote the number of waitresses to work overtime on day I, I 7. Minimize 5 W + 1.5 O Subject to 2) W - W1 - W2 - W3 - W4 - W5 - W6 - W7 = 0 3) - W1 - W4 - W5 - W6 - W7 + D1 = 0 4) - W2 + W4 - D1 + D2 = 0 5) - W3 + W5 - D2 + D3 = 0 6) - W4 + W6 - D3 + D4 = 0 7) - W5 + W7 - D4 + D5 = 0 8) W1 - W6 - D5 + D6 = 0 9) W2 - W7 - D6 + D7 = 0 10) 6 D1 + 6 O1 >= 402 11) 6 D2 + 6 O2 >= 402 12) 6 D3 + 6 O3 >= 402 13) 6 D4 + 6 O4 >= 402 14) 6 D5 + 6 O5 >= 402 15) 6 D6 + 6 O6 >= 204 16) 6 D7 + 6 O7 >= 0 17) O - O1 - O2 - O3 - O4 - O5 -O6 - O7 = 0 18) W2 + W3 - 2 O1 >= 0 19) W3 + W4 - 2 O2 >= 0 20) W4 + W5 - 2 O3 >= 0 21) W5 + W6 - 2 O4 >= 0 22) W6 + W7 - 2 O5 >= 0 23) W1 + W7 - 2 O6 >= 0 24) W1 + W2 - 2 O7 >= 0


Constraints 4 to 9 are recursive formulations which relate the WI s to the DIs. The numbers on the right side of the inequalities in constraints 10 to 15 are the smallest multiples of 6 which are greater than or equal to the numbers listed in the table for the corresponding day. Because waitresses are available to work 6 hr per day, making these changes does not change the solution, but does encourage the solution to be interger valued, which we need. Before making these changes, the solution was a mess. After making them, it was still not integer valued, however the optimal value of the LP was 386.1, which implies that an integer solution with objective function value 386.5 is optimal. I added the constraint ``GIN W'' and got the following integer solution. NEW INTEGER SOLUTION OF 386.5 VARIABLE W O W1 W2 W3 W4 W5 W6 W7 D1 D2 D3 D4 D5 D6 D7 O1 O2 O3 O4 O5 O6 O7

Example 16

VALUE 68 31 64 2 0 1 0 1 0 66 67 67 67 67 4 2 1 0 0 0 0 30 0

Allocating Limited Resources in a Transportation Problem

Information Provided. A power authority operates four power plants, located near Denver, Fort Collins, Pueblo, and Salt Lake City. It can purchase coal from three suppliers, located in Colorado, Utah and Wyoming. It must have at least 400, 80, 120, and 560 boxcars of coal per month to keep the plants operating. It would like to have 1000, 230, 430, and 1400 boxcars per month at the power plants. The suppliers can provide 800, 600, and 1000 boxcars per month. The following table lists costs (including shipping) for a boxcar of coal delivered from a supplier to a power plant.

Linear and Dynamic Programming

Colorado Utah Wyoming

313

Denver

Fort Collins

Pueblo

Salt Lake

403 530 360

441 510 340

458 550 380

430 350 410

Solution. The total supply is 2400 boxcars and the total demand is 3030 boxcars, so total demand cannot be met. Consequently, we split the demand for each city into two demands, a minimal demand to keep the power plant running and an optional demand which represents the number of boxcars above minimal demand that the city would like to receive. The total minimal demand is 1160 boxcars. We will use available supply to meet the minimal demands. Consequently, there are 1240 boxcars available to meet some optimal demand. There are 630 boxcars of optimal demand that cannot be met. We will introduce a dummy supply of 630 boxcars to represent unmet demand, and we will introduce a big M cost of shipping from the dummy supply to the minimal demands to insure that minimal demands are met from real supplies. The costs from the dummy supply to the optimal demand will be put equal to zero, since we are not really shipping anything. A transportation tableau follows.

Den Den Fort Fort Peub Peub SL SL min opt min opt min opt min opt Supply Colorado Utah Wyoming Dummy Demand

403 530 360 M 400

Example 17

403 441 441 458 458 530 510 510 550 550 360 340 340 380 380 0 0 M 0 M 600 80 150 120 310

430 350 410 M 560

430 800 350 600 410 1000 0 660 840 3060

`Èveryone Wants More Money''

Information Provided. Four research centers are applying for grants from four government agencies. The centers need 20, 30, 40, and 50 million dollars next year to keep operating. They would each like an in®nite amount of money. The agencies have 40, 30, 30, and 80 million dollars available for research grants to the four centers next year. The government has decided to keep the centers operating and has prepared the following table of estimated bene®t per million dollars granted.


Center bene®t Agency

1

2

3

4

1 2 3 4

2 6 8 5

5 3 9 7

7 3 6 4

6 6 4 10

Solution. This situation can also be modeled as a transportation problem. It can be modeled as a ``maximize'' (bene®t) transportation problem, or as a ``minimize'' transportation problem after changing the bene®ts to costs by multiplying them by 1, and then adding 10 to each of these negative numbers to get nonnegative numbers. We present a transportation tableau for the minimize formulation below. The four research centers require a total of 140 million dollars to keep operating, this number is the sum of the minimal needs; enough money to meet minimal needs will be shipped from the agencies to the research centers. In addition to this 140 million, there are 40 million dollars available to meet optional demand (wants) by the research centers. Consequently, even though the research centers might prefer more, the most that any one can get is 40 million dollars; thus, the optional demands are set at 40 and a dummy supply of 120 is incorporated to balance total supply with total demand. We use 20 as a big M to keep from shipping arti®cial money to meet minimal demands. The minimal and optional demands of research center I are denoted by MI and OI. M1 O1 M2 O2 M3 O3 M4 O4 Supplies 1 8 2 4 3 2 4 5 Dummy 20 Demands 20

8 4 2 5 0 40

5 7 1 3 20 30

5 7 1 3 0 40

3 7 4 6 20 40

3 7 4 6 0 40

4 4 6 0 20 50

4 4 6 0 0 40

40 30 30 80 120 Ð

A solution in the form of an allocation table follows. M1 O1 M2 O2 M3 O3 M4 O4 Supplies 1 2 3 4 Dummy

Ð 20 Ð Ð Ð

Ð 10 Ð Ð 30

Ð Ð 30 Ð Ð

Ð Ð Ð Ð 40

40 Ð Ð Ð Ð

Ð Ð Ð Ð 40

Ð Ð Ð 50 Ð

Ð Ð Ð 30 10

40 30 30 80 120

314

Darst

Example 18

A Multiperiod Problem

Information Provided. A company produces two products, which we denote by P and Q. During the next four months the company wishes to produce the following numbers of products P and Q. No. of products Product

Month 1

Month 2

Month 3

Month 4

4000 6000

5000 6000

6000 7000

4000 6000

P Q

The company has decided to install new machines on which to produce product Q. These machines will become available at the end of month 2. The company wishes to plan production during a four-month changeover period. Maximum monthly production of product Q is 6000 during months 1 and 2, and 7000 during months 3 and 4; maximum total monthly production is 11,000 during months 1 and 2, and 12,000 during months 3 and 4. Manufacturing costs of product Q are $15 per unit less during months 3 and 4. Also, during the changeover period, units of product Q can be delivered late at a penalty of $10 per unit per month. Monthly inventory costs are $10 per unit per month for product P and $8 per unit per month for product Q. Formulate an LP to minimize production, penalty, and inventory costs during the four-month changeover period. Solution. Let PI and QI denote the numbers of units of products P and Q produced during month I, 1 I 4. Let XI denote the number of units of product Q in inventory at the end of month I, and let YI denote the number of units of product Q backlogged at the end of month I (i.e., not able to be delivered by the end of month I). Constraints: 1)

P1 >= 4

(Production for month 1)

2)

P1 + P2 >= 9

(Production for months 1 and 2)

3)

P1 + P2 + P3 >= 15

(Production for months 1-3)

4)

P1 + P2 + P3 + P4 = 19 (Production for months 1-4)

5)

Q1, Q2 Eb

a b , Ea Eb

2

where a b denotes `à is preferred to b,'' and a b denotes `à is indifferent to b.'' This rule is called the expected utility rule. A utility function which satis®es Eqs. (1) and (2) is uniquely obtained within the class of positive linear transformations. Figure 1 shows a decision tree and lotteries which explain the above-mentioned situation, where à ; `b ; . . . denote lotteries which the decision maker comes across when he chooses the alternative action a; b; . . . ; respectively, and described as à x1 ; x2 ; . . . ; p1 ; p2 ; . . . `b x1 ; x2 ; . . . ; q1 ; q2 ; . . . De®nition 1. A certainty equivalent of lottery à is an amouint x^ such that the decision maker is indifferent ^ between à and x. From the expected untility hypothesis we obtain X ^ uEa pi uxi 3 ux i

In a set X of all possible consequences, let x0 and x be the worst and the best consequences, respectively. Since the utility function is unique within the class of positive linear transformation, let us normalize the utility function as ux0 0

ux 1

Let hx ; p; x0 i be a lottery yielding consequences x and x0 with probabilities p and 1 p, respectively. In particular, when p 0:5 this lottery is called the 50±50 lottery and is denoted as hx ; x0 i. Let x be a certainty equivalent of lottery hx ; p; x0 i, that is, x hx ; p; x0 i Then ux pux 1

It is easy to identify a single-attribute utility function of a decision maker by asking the decision maker about the certainty equivalents of some 50±50 lotteries and by means of a curve-®tting technique. The attitude of a decision maker toward risk is described as follows. De®nition 2. A decision maker is risk P averse if he pre fers the expected consequence x i pi xi of any lotteries to the lottery itself. In this case X > ux pi uxi


4

i

If a decision maker is risk averse, his utility function is concave. The converse is also true. A decision maker is risk neutral (prone) if and only if his utility function is linear (convex). 5.2.2

Multiattribute Utility Function

The following results are the essential summary of Refs. 1 and 3. Let a speci®c consequence x 2 X be characterized by n attributes (performance indices) X1 ; X2 ; . . . ; Xn (e.g., price, design, performance, etc., of cars, productivity, ¯exibility, reliability, etc., of manufacturing systems, and so on). In this case a speci®c consequence x 2 X is represented by x x1 ; x2 ; . . . ; xn

Figure 1 A decision tree and lotteries.

p ux0 p

x1 2 X1 ; x2 2 X2 ; . . . ; xn 2 Xn

A set of all possible consequences X can be written as a subset of an n-dimensional Euclidean space as X X1 X2 Xn . This consequence space is called n-attribute space. An n-attribute utility function is de®ned on X X1 X2 Xn as u : X1 X2 Xn ! R. Let I be a subset of f1; 2; . . . ; ng with r 1 r < n elements, and J be a complementary subset of I with n r elements. Suppose a set of n attributes fX1 ; X2 ; . . . ; Xn g is divided into two subsets fXi ; i 2 Ig and fXi ; i 2 Jg. Let XI be an r-attribute space composed

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361

of fXi ; i 2 Ig, and XJ be an n r-attribute space composed of fXi ; i 2 Jg. Then X XI XJ . De®nition 3. Attribute XI is utility independent of attribute XJ , denoted XI UIXJ , if conditional preferences for lotteries on XI given xJ 2 XJ do not depend on the conditional level xJ 2 XJ . Let us assume that x0I and xI are the worst level and the best level of the attribute XI , respectively. De®nition 4. Given an arbitrary xJ 2 XJ , a normalized conditional utility function uI xI j xJ on XI is de®ned as uI xI j xJ :

uxI ; xJ uxI ; xJ

ux0I ; xJ ux0I ; xJ

5

where it is assumed that uxI ; xJ > ux0I ; xJ . From De®nition 4 it is obvious that uI xI j xJ 1

uI x0I j xJ 0

8xJ 2 XJ

From De®nitions 3 and 4 the following equation holds, if XI UIXJ : uI xI j xJ uI xI j

x0J

8xJ 2 XJ

In other words, utility independence implies that the normalized conditional utility functions do not depend on the different conditional levels. De®nition 5. Attributes X1 ; X2 ; . . . ; Xn are mutually utility independent, if XI UIXJ for any I f1; 2; . . . ; ng and its complementary subset J. Theorem 1. Attributes X1 ; X2 ; . . . ; Xn are mutually utility independent, if and only if ux ux1 ; x2 ; . . . ; xn

n X i1

ki ui xi

if

n X i1

ki 1 6

or kux 1

n Y i1

fkki ui xi 1g

if

n X i1

ki 6 1

7

holds, where ux01 ; x02 ; . . . ; x0n 0 ui xi : ui xi j x0ic

ux1 ; x2 ; . . . ; xn 1 ic f1; . . . ; i

ki uxi ; x0ic and k is a solution of


1; i 1; . . . ; ng

k1

n Y i1

kki 1

De®nition 6. Attributes X1 ; X2 ; . . . ; Xn are additive independent if preferences over lotteries on X1 ; X2 ; . . . ; Xn depend only on their marginal probability distributions, not on their joint probability distribution. Theorem 2. Attributes X1 ; X2 ; . . . ; Xn are additive independent if and only if Eq. (6) holds. From Theorems 1 and 2 the additive independence is a special case of mutual utility independence. For notational simplicity we deal only with the twoattribute case n 2 in the following discussion. The cases with more than two attributes are discussed in Tamura and Nakamura [3]. We deal with the case where u1 x1 j x2 6 u1 x1 u2 x2 j x1 6 u2 x2

for some x2 2 X2 for some x1 2 X1

that is, utility independence does not hold between the attributes X1 and X2 . De®nition 7. Attribute X1 is mth-order convex dependent on attribute X2 , denoted X1 CDm X2 , if there exist distinct xj2 2 X2 j 0; 1; . . . ; m and real functions j : X2 ! R j 0; 1; . . . ; m on X2 such that the normalized conditional utility function u1 x1 j x2 can be written as u1 x1 j x2

m X j0

j x2 u1 x1 j xj2

m X j1

j x2 1 8

for all x1 2 X1 ; x2 2 X2 , where m is the smallest nonnegative integer for which Eq. (8) holds. This de®nition says that, if X1 CDm X2 , then any normalized conditional utility function on X1 can be described as a convex combination of m 1 normalized conditional utility functions with different conditional levels where the coef®cients j x2 are not necessarily nonnegative. In De®nition 7, if m 0, then u1 x1 j x2 u1 x1 j x02 for all x2 2 X2 . This implies X1 CD0 X2 ) X1 UIX2 that is, zeroth-order convex dependence is nothing but the utility independence. This notion shows that the

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property of convex dependence is a natural extension of the property of utility independence. For m 0; 1; . . . ; if X1 CDm X2 , then X2 is at most m 1th-order convex dependent on X1 . If X1 UIX2 , then X2 UIX1 or X2 CD1 X1 . In general, if X1 CDm X2 , then X2 satis®es one of the three properties: X2 CDm 1 X1 , X2 CDm X1 or X2 CDm1 X1 . Theorem 3. if

For m 1; 2; . . . ; X1 CDm X2 if and only

ux1 ; x2 k1 u1 x1 j x02 k2 u2 x2 j x01

u1 x1 j x02 f x1 ; x2

m X m X

We have obtained two main convex decomposition theorems which can represent a wide range of utility functions. Moreover, when the utility on the arbitrary point has a particular value, that is, dij0 0 for all i; j in Eq. (10), we can obtain one more decomposition of utility functions which does not depend on that point. This decomposition still satis®es X1 CDm X2 and X2 CDm X1 , so we call this new property reduced mth-order convex dependence and denote it by X1 RCDm X2 . We note that when dij0 0 for all i; j and m 1, Eq. (10) reduces to Fishburn's bilateral decomposition [4]:

9

ux1 ; x2 k1 u1 x1 j x02 k2 u2 x2 j x01

i1 j1

f x1 ; x2 f x1 ; x2 = f x1 ; x2

cij Gx1 ; xi2 Gxj1 ; x2

When m 1 and dij0 6 0, that is, X1 MCD1 X, Eq. (10) reduces to

where f x1 ; x2 u1 x1 j x2 1

k1 u2 x2 j x1

ux1 ; x2 k1 u1 x1 j x02 k2 u2 x2 j x01

k1

k2 u2 x2 j x01

Gx1 ; x2 k1 1

k1 u2 x2 j x1

f x1 ; x2 f x1 ; x2 = f x1 ; x2

k1

k2 u2 x2 j x01

d 0 Gx1 ; x2 Hx1 ; x2

u1 x1 j x2 ux01 ; x2

ux1 ; x2

0;

k1 ux1 ; x02 ;

k1 u1 x1 j x02

u1 x1 j x02 1

k2 ux01 ; x2

cij is a constant, and summation i 1 to m means i 1; 2; . . . ; m 1, . Theorem 4. For m 1; 2; . . . X1 CDm X2 and X2 CDm X1 , that is, X1 and X2 are mutually mthorder convex dependent, denoted X1 MCDm X2 , if and only if ux1 ; x2 k1 u1 x1 j x02 k2 u2 x2 j x01

m X m X i1 j1

dij f x1 ; xi2 f xj1 ; x2 5.3

m X m X i1 j1

which is Bell's decomposition under the interpolation independence [5]. On two scalar attributes the difference between the conditional utility functions necessary to construct the previous decomposition models and the convex decomposition models is shown in Fig. 2. By assessing utilities on the lines and points shown bold, we can completely specify the utility function in the cases indicated in Fig. 2. As seen from Fig. 2. an advantage of the convex decomposition is that only single-attribute conditional utility functions need be assessed even for high-order convex dependent cases. Therefore, it is relatively easy to identify the utility functions.

dij0 Gx1 ; xi2 Hxj1 ; x2

where Hx1 ; x2 k2 1

k2 u1 x1 j x2

k2

k1 u1 x1 j x02

u2 x2 j x1 and dij and dij0 are constants.


u2 x2 j x01

10

MEASURABLE VALUE THEORY

Measurable value functions in this section are based on the concept of ``difference in the strength-of-preference'' [6] between alternatives. In this section we discuss such measurable value functions under certainty, under risk where the probability of each event occurring is known, and under uncertainty where the probability of each event occurring is unknown but the probability of a set of events occurring is known.

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363

Figure 2 Consequences (bold lines) for which we need to assign utilities to specify the utility function in each case indicated.

5.3.1

Measurable Value Function Under Certainty

Measurable value functions provide an interval scale of measurement for preferences. However, practically, it is too dif®cult to directly identify a multiattribute measurable value function. Therefore, it is necessary to develop conditions that reduce the dimensionality of the functions that are required to be identi®ed. These conditions restrict the form of a multiattribute measurable value function in a decomposition theorem. Dyer and Sarin [7] presented conditions for additive and multiplicative forms of the multiattribute measurable value function. These conditions are called difference independence and weak difference independence. They


correspond to additive independence and utility independence, respectively, described in Sec. 5.2. In this section, Dyer and Sarin's [7] difference independence and weak difference independence are brie¯y reviewed. Then, the condition of weak difference independence is extended to describe a new concept of ®nite-order independence of structural difference [8] for constructing multiattribute measurable value functions under certainty. This concept corresponds to convex dependence described in the previous section. Let X be the set of all consequences in a decision problem. In n-attribute problem X is described as X X1 X2 Xn where Xi denotes the set of possible consequences for the ith attribute. Let x1 ; x2 ; x3 ; x4 2 X where xk xk1 ; xk2 ; . . . ; xkn , k 1; 2; 3; 4. De®ne X

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Tamura

as a nonempty subset of X X and Q as a weak order on X . Describe x1 x2 Q x3 x4 to mean that the difference of the strength-of-preference for x1 over x2 is greater than or equal to the difference of the strength-of-preference for x3 over x4 . If it is assumed that X; X ; Q denotes a positive difference structure [9], there exists a real-valued function v on X such that, for all x1 ; x2 ; x3 ; x4 2 X, if x1 is preferred to x2 and x3 to x4 then 1 2

3 4

1

x x Q x x ; , vx

2

3

vx vx

4

vx

11

Furthermore, since v is unique up to positive linear transformation, it is a cardinal function, and v provides an interval scale of measurement. De®ne the binary relation Q on X by x1 x3 Q x2 x3 , x1 Qx2

12

then x1 Qx2 , vx1 vx2

13

Thus, v provides a measurable value function on X. For I f1; 2; . . . ; ng, partition X with n attributes into two sets XI with r attributes and XJ with n r attributes, that is, X XI XJ . For xI 2 XI , xJ 2 XJ , write x xI ; xJ . De®nition 8 [7]. The attribute set XI is difference independent of XJ , denoted XI DIXJ , if for all x1I ; x2I 2 X such that x1I ; xJ0 Qx2I ; xJ0 for some xJ0 2 XJ x1I ; xJ0 x2I ; xJ0

x1I ; xJ x2I ; xJ

8xJ 2 XJ

14

This de®nition says that if XI DIXJ the difference in the strength of preference between x1I ; xJ and x2I ; xJ is not affected by xJ 2 XJ . The property of this difference independence under certainty corresponds to the property of additive independence under uncertainty shown in De®nition 6, and the decomposition theorem is obtained as a theorem as follows. Theorem 5. Suppose there exists a multiattribute measurable value function v on X. Then a multiattribute measurable value function vx can be written as the same additive form shown in Eq. (6) if and only if Xi DIXic , i 1; 2; . . . ; n where ic f1; . . . ; i

1; i 1; . . . ; ng

X Xi Xi c

Dyer and Sarin [7] introduced a weaker condition than difference independence, which is called weak difference independence. This condition plays a similar


role to the utility independence condition in multiattribute utility functions. De®nition 9 [7]. XI is weak difference independent of XJ , denoted XI WDIXJ , if, for given x1I ; x2I ; x3I ; x4I 2 XI and some xJ0 2 XJ ; x1I ; xJ0 x2I ; xJ0 Q x3I ; xJ0 x4I ; xJ0 then x1I ; xJ x2I ; xJ Q x3I ; xJ x4I ; xJ

8xJ 2 XJ

15

This de®nition says that if XI WDIXJ the ordering of difference in the strength of preference depends only on the values of the attributes XI and not on the ®xed values of XJ . The property of the weak difference independence can be stated more clearly by using the normalized conditional value function, de®ned as follows. De®nition 10. Given an arbitrary xJ 2 XJ , de®ne a normalized conditional value function vI xI j xJ on XI as vI xI j xJ :

vxI ; xJ vxI ; xJ

vx0I ; xJ vx0I ; xJ

16

where vxI ; xJ > vx0I ; xJ and xI 2 X and x0I 2 XI denote the best and the worst consequences, respectively. Normalized conditional value function vI xI j xJ denotes the ordering of preference on XI , which is called preference structure here, under the given conditional level xJ 2 XJ . From De®nitions 9 and 10 we obtain a theorem as follows. Theorem 6. 8xJ 2 XJ .

XI WDIXJ , vI xI j xJ vI xI j x0J ,

This theorem shows that the property of weak difference independence is equivalent to the independence of normalized conditional value functions on the conditional level. Hence, this theorem is often used for assuring the property of weak difference independence. De®nition 11. The attributes X1 ; X2 ; . . . ; Xn are said to be mutually weak difference independent, if for every I f1; 2; . . . ; ng, XI WDIXJ .

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365

The basic decomposition theorem of the measurable additive/multiplicative value functions is now stated. Theorem 7. If there exists a measurable value function v on X and if X1 ; X2 ; . . . ; Xn are mutually weak difference independent, then a multiattribute measurable value function vx can be written as the same additive form as Eq. (6), or multiplicative form, as shown in Eq. (7). Dyer and Sarin [7] stated this theorem under the condition of mutual preferential independence plus one weak difference independence instead of using the condition of mutual weak difference independence. For practical applications it is easier to assess mutual preferential independence than to assess mutual weak difference independence. For notational simplicity we deal only with the twoattribute case n 2 in the following discussions. We deal with the cases where v1 x1 j x2 6 v1 x1 j

x02

for some x2 2 X2

that is, weak difference independence does not hold between X1 and X2 . De®nition 12. X1 is mth-order independent of structural difference with X2 , denoted X1 ISDm X2 , if for given x11 ; x21 ; x31 ; x41 2 X1 and some x2 2 X2 such that x11 ; x2 x21 ; x2 Q x31 ; x2 x41 ; x2

17

there exist xj2 2 X2 j 0; 1; . . . ; m and j : X2 ! R j 0; 1; . . . ; m such that m X j0 2

x

j x2 x11 ; xj2

x31 ; xj2

m X j0

m X j0

j x2 x21 ; xj2 Q

m X j0

j 18

j x2 x41 ; xj2

vx1 ; x2 x2

m X j0

j x2 vx1 ; xj2 x2

x2 > 0 holds. If we de®ne

j x2 vx1 ; xj2 vx01 ; xj2 j x2 : m X i x2 vx1 ; xi2 vx01 ; xi2 i0

we obtain m X j0

j x2 1

If we rewrite Eq. (16) using Eqs. (20) and (21), we obtain v1 x1 j x2

m X j0

j x2 v1 x1 j xj2

19

This notion shows that the property of independence of structural difference is a natural extension of the property of weak difference independence. De®nition 12 shows that there exists vx1 ; xj2 j 0; 1; . . . ; m such that


22

If m 0, we obtain Theorem 6 for n 2. From this notion we also ®nd that the property of independence of structural difference is a natural extension of the property of weak difference independence. Furthermore, Eq. (22) corresponds the de®nition of mth-order convex dependence in multiattribute utility theory shown in Eq. (8). If we de®ne d1 x1 j x2 : v1 x1 j x2

v1 x1 j x02

23

d1 x1 j x2 shows the difference of the preference structures for the conditional level of x2 2 X2 and x02 2 X2 , and it is called the structural difference function. Then we obtain

X1 ISDm X2 ) d1 x1 j x2

X1 ISD0 X2 ) X1 WDIX2

21

j 0; 1; . . . ; m

X1 ISD0 X2 ) d1 x1 j x2 0

This de®nition represents the ordering of difference in the strength of preference between the linear combinations of consequences on X1 with m 1 different conditional levels. If m 0 in Eq. (18), we obtain Eq. (15), and hence

20

m X j0

8x2 2 X2 j x2 d1 x1 j xj2

Since mth-order independence of structural difference in this measurable multiattribute value theory corresponds to mth-order convex dependence in multiattribute utility theory, the decomposition theorems described in Sec. 5.2 are valid if the expression `ùtility function'' is replaced by the expression ``measurable value function'' in Theorems 3 and 4. Multiattribute measurable value functions can be identi®ed if we know how to obtain: 1. Single-attribute value functions 2. The order of structural difference independence

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Tamura

3.

The scaling coef®cients appearing in the decomposition forms.

For identifying single-attribute measurable value functions, we use the equal-exchange method based on the concept of equal difference points [7]. De®nition 13. such that

For x0 ; x X, if there exists x1 2 X

x x1 x1 x0

24

0

1

for given x 2 X and x 2 X, then x is the equal difference point for x0 ; x X. From Eq. (24) we obtain vx

vx1 vx1 0

vx0

25 1

Since vx 0, vx 1, we obtain vx 0:5. Let x2 and x3 be the equal difference points for x0 ; x1 and x1 ; x , respectively. Then we obtain 2

vx 0:25

3

vx 0:75

It is easy to identify a single-attribute measurable value function of a decision maker from these ®ve points and a curve-®tting technique. How to ®nd the order of structural difference independence and the scaling coef®cients appearing in the decomposition forms is omitted here. Detailed discussion on this topic can be found in Tamura and Hikita [8]. 5.3.2

Measurable Value Function Under Risk

The expected utility model described in Sec. 5.2 has been widely used as a normative model of decision analysis under risk. But, as seen in Refs. 10±12, various paradoxes for the expected utility model have been reported, and it is argued that the expected utility model is not an adequate descriptive model. In this section a descriptive extension of the expected utility model to account for various paradoxes is discussed using the concept of strength of preference. Let X be a set of all consequences, x 2 X, and A a set of all risky alternatives; a risky alternative ` 2 A is written as ` x1 ; x2 ; . . . ; xn ; p1 ; p2 ; . . . ; pn

26

which yields consequence P xi 2 X with probability pi , i 1; 2; . . . ; n, where pi 1. Let A be a nonempty subset of A A, and Q and Q be binary relations on A and A , respectively.


Relation Q could also be a binary relation on X. We interpret `1 Q`2 `1 ; `2 2 A to mean that `1 is preferred or indifferent to `2 , and `1 `2 Q `3 `4 `1 ; `2 ; `3 ; `4 2 A to mean that the strength of preference for `1 over `2 is greater than or equal to the strength of preference for `3 over `4 . We postulate that A; A ; Q takes a positive difference structure which is based on the axioms described by Kranz et al. [9]. The axioms imply that there exists a real-valued function F on A such that for all `1 ; `2 ; `3 ; `4 2 A, if `1 Q`2 and `3 Q`4 , then `1 `2 Q `3 `4 , F`1

F`2 F`3

F`4

27

Since F is unique up to a positive linear transformation, it is a cardinal function. It is natural to hold for `1 ; `2 ; `3 2 A that `1 `3 Q `2 `3 , `1 Q`2 Then from Eq. (27) we obtain `1 Q`2 , F`1 F`2

28

Thus, F is a value function on A and, in view of Eq. (27), it is a measurable value function. We assume that the decision maker will try to maximize the value (or utility) of a risky alternative ` 2 A, which is given by the general form as follows: X f xi ; pi 29 max F` max `2A

`2A

i

where f x; p denotes the value (strength of preference) for a consequence x which comes out with probability p. This function is called the measurable value function under risk. The main objectives here are to give an appropriate decomposition and interpretation of f x; p and to explore its descriptive implications to account for the various paradoxes. The model Eq. (29) is reduced to the expected utility form by setting f x; p pux

30

when ux is regarded as a von Neumann±Morgenstern utility function, described in Sec. 5.2. The prospect theory of Kahneman and Tversky [11] is obtained by setting f x; p p vx

31

where p denotes a weighting function for probability and vx a value function for consequence. In this model the value of each consequence is multiplied by a decision weight for probability (not by probability itself). Extending this Kahneman±Tversky model we obtain a decomposition form [13]

Decision Analysis

367

f x; p wp j x vx

32

`1 ; `2 Q `3 `4 , f x1 ;

f x4 ; 38a , vx1 j vx2 j vx3 j

where w p j x :

f x; p f x; 1

33a

vx : vx j 1

33b

f x; p vx j p : f x ; p

33c

and x denotes the best consequence. In our model, Eq. (32), the expected utility model, Eq. (30), and Kahneman±Tversky model, Eq. (31) are included as special cases. Equation (33b) implies that vx denotes a measurable value function under certainty described in Sec. 5.3.1. Therefore, our model, Eq. (32), also includes Dyer and Sarin's model [7] as a special case. The model Eq. (32) could also be written as f x; p w p vx j p

34

where w p : w p j x

35

vx4 j

8x 2 X

f xR ; p 0

`10 x; xR ; 1 ; 1

1

`30 x; X R ; 3 ; 1

3 `40 x; xR ; 4 ; 1

36b

where xR 2 X denotes the reference point (e.g., status quo). The better region on X compared with xR is called the gain domain and the worse region the loss domain. We also assume that f x; p 0

on the gain domain

f x; p < 0

on the loss domain

It will be shown that the conditional weighting function w p j x describes the strength of preference for probability under the given conditional level of consequence, and vx j p describes the strength of preference for consequence under the given conditional level of probability. For interpreting the descriptive model f x; p we need to interpret F such that Eq. (27) holds. Dyer and Sarin [14] and Harzen [15] have discussed the strength of preference under risk where a certainty equivalent of a risky alternative is used to evaluate the strength of preference. For all x1 ; x2 ; x3 ; x4 2 X, 2 0; 1, and y 2 X such that x1 Qx2 Qx3 Qx4 , we consider four alternatives: `1 x1 ; y; ; 1 `3 x3 ; y; ; 1

In this case we obtain


`2 x2 ; y; ; 1 `4 x4 ; y; ; 1

37

`20 x; xR ; 2 ; 1

2 39a 4 39b

then we obtain `10 `20 Q `30 `40 , f x; 1 f x; 2 f x; 3 f x; 4

40a

, w1 j x w2 j x w3 j x 40b w4 j x

36a

8p 2 0; 1

38b

Therefore, the value function vx j p de®ned by Eq. (33c) represents the strength of preference for the four risky alternatives in Eq. (37). For all 1 ; 2 ; 3 ; 4 2 0; 1, x 2 X and xR 2 X, we consider four alternatives:

We assume that f x; 0 0

f x2 ; f x3 ;

Therefore, the weighting function de®ned by Eq. (33a) represents the strength of preference for the four risky alternatives in Eq. (39). The above discussions assert that the descriptive model f x; p represents the measurable value function under risk to evaluate the consequence x 2 X which comes out with probability p. In the expected utility model it assumes invariance of preference between certainty and risk when other things are equal. The Kahneman±Tversky model of Eq. (31) could explain a so-called certainty effect to resolve the Allais paradox [10]. Our descriptive model f x; p could also resolve the Allais paradox, as shown below. As an example, consider the following two situations in gain domain: 1. 2.

`1 `2 `3 `4

10M; 1, 50M; 10M; 0; 0:1; 0:89; 0:01. 50M; 0; 0:1; 0:9, 10M; 0; 0:11; 0:89.

where 1M $1000. Most people show the preference `1 10M; 1 `2 50M; 10M; 0; 0:1; 0:89; 0:01 41a `3 50M; 0; 0:1; 0:9 `4 10M; 0; 0:11; 0:89 41b

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Tamura

This preference violates the expected utility model as follows: Eq. (41a) implies u10M > 0:1u50M 0:89u10M 0:01u0 42a whereas Eq. (41b) implies 0:1u50M 0:9u0 > 0:11u10M 0:89u0 42b where u denotes a von Neumann±Morgenstern utility function. Equations (42a) and (42b) show the contradiction. This phenomenon is called the Allais paradox. The descriptive model f x; p could properly explain the preference of Eq. (41) as follows. Let v50M 1

v10M

v0 0 0 < < 1

Then, using our descriptive model f x; p, the preference of Eq. (41) can be written as v10M > f 50M; 0:1 f 10M; 0:89 v50M w0:1 j 50M v10M w0:89 j 10M and

of one at a given trial excludes the occurrence of the other. If A and B are mutually exclusive, then we obtain pA B pA pB in Bayes' theory of probability. This implies that if 1 pA 0:7 where A pA 0:3 then pA denotes the complement of A. In Dempster±Shafer theory of probability [16] let Ai be basic probability which could be assigned by any subset Ai of , where dentoes a set containing every possible element. The basic probability Ai can be regarded as a semimobile probability mass. Let 2 be a set containing every subset of . Then, the basic probability Ai is de®ned on and takes a value contained in 0; 1. When Ai > 0, Ai is called the focal element or the set element and the following conditions hold: ; 0 X Ai 1

Ai 2

f 50M; 0:1 > f 10M; 0:11 ) v50M w0:1 j 50M > v10M w0:11 j 10M Hence we obtain w0:1 j 50M w0:1 j 50M 2 > 3 routing. In these applications, the APB can not only handle the physical moves between cells, but can manage the storage of WIP that will develop between cells as a function of intercell variability. In most APBs the use of closed system replenishment rules provides an automatic kanban that throttles the system from having a runaway cell. As a free side eect, however, these systems can be tuned by the addition of ``free'' totes (extra totes in the system for use between cells). These free totes provide some internal slack to the strict kanban control, allowing cells to operate more smoothly in the presence of brief interruptions in the planned continuous ¯ow. For example, one cell may produce a product that is placed in an empty tote and delivered to the next cell for the next process operation. To perform the ®rst cell's function, it needs raw materials, and an empty tote in which to place the output to be transported to the next cell. The second cell may remove the product from the tote, process it, and place it in a ®nished product tote for delivery to a packaging station for shipment. The empty tote created is then sent back to the ®rst cell for replenishment. Between each operation, the loads may need to be stored to prevent work buildup at the workstation that may make the station inecient. Then, when it appears that the station will be able to accept the next load, the system needs to get it out to the cell before it is needed to prevent idleness. The ¯ow of product from cell 1 to cell 2 and so on, is balanced by the back ¯ow of empties to the sending cells. If a backup stalls one of the cells, the back¯ow stops, which in turn, stops the forward ¯ow of material. This provides for a self-metering system that needs little control logic to keep all cells operating in a balance with the total system's capacity. The ability of the system to keep running in lieu of single cell failures is then a function of the number of ``free'' totes held in the system between each cell. 2.10.2

653

actual data representing material arrivals and disbursements. In fact, the only way to analyze a side delivery system with multiple input and output stations is with a dynamic simulation. An alternative manual method is to compute the probable time to complete each class of move that might be scheduled at each station, and then sum the probability weighted average time for each move based on expected activity. While this method does not always expose system interferences due to contention for resources caused by scheduling, it is a good ®rst look at system capacity without the eort and expense of simulation. For end-of-aisle systems (input and output occurs at one end of the AS/R system aisle) there are two methods that produce comparable results. The purpose of approximating cycle time is, of course, to provide a ``®rst-pass'' analysis of the adequacy of a design, and to allow a comparison of alternative solutions. The ®rst solution is based on recommended methods developed and published by the Material Handling Institute, Inc. (MHI) [7]. It refers to the calculation procedures to compute the single cycle and dual cycle moves typical of end of aisle systems (see Fig. 13). The single cycle move is a complete cycle with the AS/R system machine in a home or P&D (pickup & deposit station) position, empty and idle. The single cycle time is measured by computing the time to move the crane to a rack location 75% of the length of the aisle away from the home position, and 75% of the height of the system above the ®rst level of storage. In a 100-bay long, 12-tier-tall system, the crane would

Computing Cycle Times

The throughput, or cycle time of AS/R systems has been de®ned in numerous ways. There are techniques such as activity zoning to attempt to improve the overall eciency of the device, but there are only a couple of industry benchmarks for computing cycle times. The best way of analyzing the capacity of a proposed system is with a simulation of the system using


Figure 13 Material handling institute AS/RS single cycle.

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leave the home position, travel to the 75th bay and ninth tier. This is often referred to as the 75/75 position. The total single cycle time is then computed as two times the time to make the 75/75 move, plus the time required to perform two complete shuttle moves. A shuttle move is the time required to extend the shuttle fork under the load, lift it o the rack, and then retract the shuttle with the load on board. A caution in applying this algorithm: modern AS/R systems have the ability to control acceleration and vehicle speed as a function of whether the retriever is traveling empty or with load. Therefore, true cycle times for single or dual cycles must be computed based on the speci®c performance parameters of the product being analyzed. The dual cycle, as de®ned by MHI is similar (see Fig. 14). The time is based on the crane starting empty at the home position. The cycle involves the crane picking up a load at the home (0, 0) position, taking it and storing it in the 75/75 position. The crane then moves to the 50/50 position (50% of the length of the aisle, and 50% of the height of the aisle) to pick up a load. After picking it up, the crane then moves back to the home position and deposits the load picked up from the 50/50 position. In summary, there are three crane moves and four shuttle moves making up the dual cycle. There are no speci®ed standards for the ratio of single to dual cycle commands performed by a given system. The use of input and output queuing conveyors can allow work to build up such that dual cycles are performed a majority of the time. Obviously, dual cycles are preferable to singles in that two loads are moved per three crane moves, but response require-

Parsley

ments often result in a series of single cycle moves to process a sudden demand for output. As a starting point, most planners will assume 30% of the moves will be single cycle moves, with the balance being duals. Additionally, AS/R system performance is usually enhanced through the use of velocity zoning of the storage aisle. This is the practice of storing the fastest moving inventory nearest the input/output station at the end of the aisle. In practice, it is unusual for a Pareto eect to not be present in the inventory activity pro®le. This eect will signi®cantly impact the overall requirements of the system design. Using this rule of thumb to weight the single and dual cycle move times, the expected loads moved per hour (M) can be simply approximated as follows: M 3600=0:30Cs 0:70Cd where Cs Seconds required to perform a single cycle move Cd Seconds required to perform a dual cycle move A second approach was more recently published that more directly approximates the cycle times for single and dual cycles of an end-of-aisle AS/R system. It takes into consideration the eects of randomized storage locations on cycle time and the probability of being commanded to store or retrieve to any location in the aisle [8]. It understates the overall capacity of a crane if the vehicle uses higher speeds and/or accelerations when moving in an unloaded condition. If used uniformly to analyze all options, however, it is useful for rough-cut analysis. These equations are TSC T1 Q2 =3 2Tp=d TDC T=3040 15Q2

Q3 4Tp=d

where T maxth ; tv Q minth =tv ; tv =th with TSC Single command cycle time TDC Dual command cycle time Tp=d Time to perform a pick up or drop o shuttle move Figure 14 Material handling institute AS/RS dual cycle.


th Time required to travel horizontally from the P/D station to the furthest location in the aisle

Automated Storage and Retrieval Systems

tv Time required to travel vertically from the P/D station to the furthest location in the aisle Again, this provides a single cycle and dual cycle estimate, but makes no attempt to state how many loads will be moved by the system per hour. The planner must determine the mix of single to dual cycles. The starting point, in lieu of other factors is 30% single, 70% duals. A ®nal rule of thumb for use in the feasibility stage of project design is to only apply equipment up to 80% of its theoretical capacity. The important thing to remember is that all cycle time estimates are just thatÐestimates. The technique should be used to analyze the perceived eciency of one concept or type of equipment over another. As long as the technique is used identically to compute throughput of all alternatives, it is an adequate tool to make a ®rst comparison of alternatives. In all cases, however, mission-critical systems should be simulated and tested against real or expected transaction data to ascertain actual system capacity to handle activities in the real system. 2.10.3

System Justi®cation Based on Flow Versus Static Costs

The rule of thumb is that if you put 15 engineers and accountants in a room, you will produce 347 dierent methods of computing the return on investment of a proposed project. The fact is: justi®cation is simple. It is a function of the computed payback period, the capital available to fund the project, and the commitment of management that the process the system will support is a process that will support the vision of the company into the foreseeable future. The only factor that the planner can deterministically project is the computed payback period. The balance of a payback analysis becomes subjective unless you realize that it is very dicult to justify any major material handling investment unless it is part of an overall process re-engineering eort. There is a strong temptation to jump directly to an analysis of alternatives by reducing the cost of a warehouse system to the cost per storage location. Even if the expected costs of labor, utilities, and facility space are factored into the equation, this method will almost always push the planner to the sutoptimal solution that overly depends on manual (human) resources. The inventory turns, and ¯exibility and responsiveness of the system, and the value adding capacity added by the system must be factored into the equation as well. Each of these factors must be approximated


655

for each alternative at varying degrees of activity. And do not assume that each alternative has a linear response to increases in activity rates. For example, it is common to see planners consider very narrow aisle (VNA) man-onboard order-picking systems technology over AS/R systems. At low rates, the cost per transaction is lower for VNA, primarily because the capacity of the AS/R system is available, but not being used. As the activity rates approach the design capacity of the AS/R system, however, the cost per transaction of the VNA will actually increase and responsiveness decrease because of the activity induced congestion. (Remember the earlier reference to the attributes; good, fast, and cheap). Add to the reality of these systems the variability of nonautomated or semiautomated man-to-load systems, and it becomes clear why so many of these warehouses are not functioning today as they were envisioned when built only a few years ago. The raw numbers (averages) may not clearly show the increased costs of VNA in this example. Only through complete system analysis can a correct decision be based, and this usually involves simulation. Simulation will not only help the planner understand the intrinsic behavior of the plan, but only through simulation will problems like gridlock be exposed that are not illustrated by the average throughput numbers often proposed in system concept summaries [9]. 2.11

THE ROLE OF THE SUPPLIER IN PLANNING AN AS/R SYSTEM

As much as the role of AS/R system has changed in the way it is applied, the role of the AS/R system supplier has changed to that of a consultative partner in the project of determining the optimal system for the application. The reason for this is related to the earlier discussion about the ineectiveness of trying to solve problems by breaking them apart into smaller subtasks and components. Asking a supplier to simply respond to concept speci®cations without having that supplier participate in the overall analysis of the logistics process will usually lead to a suboptimal concept proposal. 2.11.1

Objectivity of Solutions

There is still a belief that allowing the supplier in on the initial planning is a bit like letting the fox design the henhouse. In today's market, however, there is simply too much information being exchanged to ser-

656

Parsley

iously believe that a single supplier could substantially in¯uence a project team to only consider one oering. 2.11.2

Real-Time Cost Analysis

There are multiple bene®ts from involving the supplier in the planning and analysis process. To begin, if the budget is known by everyone, the supplier, who works with the technology every day, is in a good position to keep the team on track by pointing out the cost impact of ``features'' that may not be economically feasible. 2.11.3

Use of Standardized Products

More speci®cally, the supplier will be in a role to help the team understand the application of the technology, including the use of standardized componentry designed to reduce the custom engineering costs of a new design. Standardized products are often criticized as a supplier trying to hammer an old solution onto your problem. In fact, standardized products usually oer a wider set of standard functionality and variability than most custom engineered solutions. If the planner is able to use standardized solutions for the AS/R systems piece of the plan, substantial cost reductions can be realized in both engineering and total project cycle time. Reduction in project cycle time is often an overlooked opportunity. If you consider that many projects are approved only if they pay for themselves in 30 months or less, a reduction in project implementation time of 3 months (over other alternatives) nets you a 10% savings by giving you the system sooner. The sooner you start using it, the sooner the returns from the investment start to come in. 2.11.4

Performance Analysis and Optimization

Another role of the supplier as a member of the team is the ability to use supplier-based simulation and analysis tools for rough-cut analysis and decision making. For example, a common assumption is that the fastest crane will make a system faster and more responsive. There is a tradeo of cost for speed, but more speci®cally, there are system operational characteristics that will limit the ability to eectively use this speed. A person who does not work with the application of this technology on a regular basis will often miss the subtleties of these design limits. In a recent analysis, one supplier oered an 800 ft/ min crane for use in an asynchronous process buer. The crane could start from one end of the system,


attain the top speed, slow down and accurately position itself at the end of the 130 ft long system. However, the average move under the actual design of the process was less than 18 ft, with an estimated standard deviation of less than 10 ft. This means that 97.7% of the moves will be less than 38 ft. The acceleration and deceleration rates were the same across all speed ranges, but the cost of the 800-fpm drive was wasted since the crane would only attain speeds of less than 350 ft/min on 98% of its moves. The cost dierence between a 350 ft/min crane and an 800 ft/ min crane will approach 21%.

2.12

CONCLUSION

The technology of AS/R systems has been reinvented in the last 10 years. As part of a strategically planned process, it can eectively serve to free up human resources to other value-adding operations. The trend in application is towards smaller, more strategically focused systems that are located much closer to and integrated with the ¯ow plan of speci®c processes. While large systems are still being designed and justi®ed, these systems are less common that the small systems being installed within existing facilities without modi®cation to the buildings (see Fig. 15). The use of standardized system components has reduced the manufacturing and engineering costs of custom engineered, `òne-o '' designs, allowing planners a broader range of opportunity to use better, faster more reliable and productive equipment in the process of buering the material ¯ow. To fully exploit the opportunity for improvement, the planner must evaluate the entire process before simply specifying a storage buer. Use of the supplier

Figure 15

Automated Storage and Retrieval Systems

in the planning process will improve the quality of the recommendation for improvement, and will insure that solutions proposed are optimized, workable, and correct in terms of cost, schedule and overall system performance. REFERENCES 1. Considerations for Planning and Installing an Automated Storage/Retrieval System. Pittsburgh, PA: Automated Storage/Retrieval Systems Product Section, Material Handling Institute, 1977. 2. PM Senge. The Fifth Discipline. New York: Currency Doubleday, 1990. 3. DT Phillips, A Ravindran, JJ Solberg. Operations Research Principles and Practice. New York: Wiley, 1976.


657 4. JM Apple Jr, EF Frazelle. JTEC Panel Report on Material Handling Technologies in Japan. Baltimore, MD: Loyola College in Maryland, 1993, p 29. 5. RE Ward, HA Zollinger. JTEC Panel Report on Material Handling Technologies in Japan. Baltimore, MD: Loyola College in Maryland, 1993, p 81. 6. Applications Manual for the Revised NIOSH Lifting Equation. Pub no 94-110, U.S. Department of CommerceÐNational Technical Information Service (NTIS), Spring®eld, VA, 1994. 7. JM Apple. Lesson Guide Outline on Material Handling Education. Pittsburgh, PA: Material Handling Institute, 1975. 8. JA Tompkins, JA White. Facilities Planning. New York: Wiley, 1984. 9. N Knill. Just-in-time replenishment. Mater Handling Eng. February: pp 42±45, 1994.

Chapter 7.3 Containerization A. Kader Mazouz and C. P. Han

Florida Atlantic University, Boca Raton, Florida

This chapter reviews the design, transportation, and inventory of containers. Container design is a primary aspect of the handling and dispatching of containers. An ecient container design will keep adequately the quality of the product being carried. Two issues identi®ed at the design stage are quality and economic issues. An oine quality control program will enhance the design and usage of the container. Section 3.1 of the chapter will focus on the design. In this situation we will provide guidelines to performing a design experiment on a dunnage, a plastic container mainly used in the automobile industry to transport parts. Similar approaches could be used design corrugated boxes or any other type of container. Section 3.2 focuses on statistical modeling of container inventory control in a distribution network. Example practical problems are included for an automobile maker and a fresh fruit company. 3.1

under simulated conditions. A database is developed to help engineers to choose an optimal container design. The database includes the choice of structures, material process, wall thickness, shipping conditions, and any combinations of these. The method developed has been tested with dierent plastics using an illustrative example. 3.1.1

With the increasing competition in industry more and more factories are taking a closer look at material handling for ways of cutting expenses. Container design, because it is only an auxiliary part of the product, has not received enough attention. Often containers are designed according to experience. As a result, the container is either too strong so that its life is much longer than the life of the product contained and therefore adding unnecessary cost, or too weak, causing product damage.

EXPERIMENTAL APPROACH TO CONTAINER DESIGN

3.1.2

First the issue of design of containers is addressed. The approach is developed to determine an optimal container design, to eventually realize a durable container. An analysis and development of a design experiment is performed to identify the major controllable variables to perform a statistical signi®cance analysis on dierent containers. A container is modeled using ®nite-element techniques and tested to determine its durability

Procedure

Durability may be de®ned as a function of dierent variables. These variables may or may not have a great eect in the durability of the container. Once these variables are identi®ed, a design of experiments is performed. A design experiment is a test or series of tests in which purposeful changes are made to the input for changes in the output response. To use the statistical approach in designing and analyzing 659


Introduction

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Mazouz and Han

experiments, an outline of a recommended procedure is described in the sections that follow. 3.1.3

Choice of Factors and Levels

Close attention must be paid in selecting the independent variables or factors to be varied in the experiment, the ranges over which these factors will be varied, and the speci®c levels at which runs will be made. Thought must also be given to how these factors are to be controlled at the desired values and how they are to be measured. Variables which have a major eect on the durability of the dunnage are the material, the process used to produce the dunnage, the nominal wall thickness, the load applied, and the ambient temperature. The ®rst three are controllable variables and the other two are uncontrollable. The material may be limited to HDPE (high-density polyethylene), POM (acetal), or ABS (acrylonitrile butadiene styrene). Loads may be static to simulate the stacking of dunnages and impact loads or dynamic to simulate the transportation of parts via train, truck, or ship. Temperature conditions may be studied at 208F, 688F, and 1008F and the process reduced to four methods; vacuum, injection, rotational forming, and injection molding. 3.1.4

Choice of Experimental Design

The choice of design involves the consideration of sample size, the selection of a suitable run order for the experimental trials, and the determination of whether or not blocking or other randomization restrictions are involved. For this experiment it is known at the outset that some of the factors produce dierent responses. Consequently, it is of interest to identify which factors cause this dierence and the magnitude of the response. For example, two production conditions A and B may be compared, A being the standard and B a more cost-eective alternative. The experimenter will be interested in demonstrating that there is no dierence in strength between the two conditions. Factorial design can greatly reduce the number of experiments performed by looking at which combinations of factors have a greater eect in the durability of the dunnage. 3.1.5

Performing the Experiment

Using computer-aided design CAD and ANSYS (®nite-element software) a model of the dunnage is constructed. The name ®nite element summarizes the basic concept of the method: the transformation of an


engineering system with an in®nite number of unknowns (the response at every location in a system) to one that has a ®nite number of unknowns related to each other by elements of ®nite size. The element is the critical part of the ®nite-element method. The element interconnects the degrees of freedom, establishing how they act together and how they respond to applied actions. A plastic quadrilateral shell may be used as an element. This element has six degrees of freedom at each node (translation and rotation), plasticity, creep, stress stiening, and large defection capabilities. Because of the incompleteness of current data in service life prediction, some tests are necessary to set up an engineering plastics durability database. A nondestructive experiment is performed on the dunnage. This experiment measured the de¯ection of the dunnage under dierent loading. The de¯ection is measured at several sections, in order to make sure that the model constructed on ANSYS correlates to the actual one. Theoretical results obtained from the computer model are used to verify the experimental results. Once the model in ANSYS is veri®ed, the study under dierent loading conditions starts. Furthermore the ANSYS model can be brought to failure. Failure occurs when the stress level of the dunnage model is higher than the tensile yield stress. Stresses higher than this will cause permanent plastic deformation. 3.1.6

Data Analysis

Statistical methods provide guidelines as to the reliability and validity of results. Properly applied, statistical methods do not allow anything to be experimentally proven, but measure the likely error in a conclusion or attach a level of con®dence to a statement. There are presently several excellent software packages with the capability to analyze data for the design of experiments. With the help of statistical data on the durability of a speci®c dunnage and the results of the ANSYS model, an optimal decision can be made regarding the durability of the dunnage. 3.1.7

Database

A database is used to generate the decision support system. A ¯owchart of the dunnage durability database is shown in Fig. 1. The user-friendly program guides the user where data needs to be input. Help menus are available at any instant of the program. The output comes in the form of a report that shows the durability of the dunnage under the speci®ed con-

Containerization

661

Figure 1 Dunnage durability solution ¯owchart.

ditions selected. The database includes the choice of structure, material, shipping condition, wall thickness, and the process used to manufacture the container or any combination of these choices. Using this database, the life of the dunnage can be predicted.

3.1.8

Dunnage Experiment

As a test base, dunnage was provided by The Ford Motor Co. Figure 2 shows a simpli®ed CAD design of a typical dunnage. The dunnage geometry tends to be quite complicated, since the container has to hold


automobile parts in place while withstanding two test, for impact and vibration, as shown in Fig. 3: Vibration test: the container is placed in a motion table with a maximum displacement of 1 in. peak to peak, a frequency range of 1 to 4.5 Hz and an acceleration of 1:1 g. The motion of the table is circular for simulating train motion and angular for truck and transport. Impact test: the container is placed on top of a sled with a 108 incline and it is let go to reach a velocity of 15 mph at the time it hits a wall at the bottom of the sled. Deceleration is almost instantaneous.

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Mazouz and Han

Figure 2 CAD drawing of a dunnage.

Factors and levels of study are shown in Table 1. Levels were set to cover a wide range of possible scenarios of what the dunnage may undergo. The result is a factorial system of 32 by 43 . This means that two factors are at three levels and three factors area at four levels. A randomized factorial design was performed to obtain the set of experiments. Randomization is the corner stone underlying the use of statistical methods in experimental design. By randomization it is meant that both the allocation of the experimental material and the order in which the individual runs or trials of the experiment to the performed are randomly determined. By properly

randomizing the experiment, the eects of extraneous factors that may be present are `àveraged out.'' The randomized factorial design is shown in Table 2. A small section of the dunnage meshed in ANSYS is shown in Fig. 4. The ®nite-element method solves for the degree-of freedom values only at the nodes so it will be convenient to increase the number of elements in the critical areas of the container. ANSYS will provide at each node information regarding de¯ection, stresses, and forces. The ANSYS model was simpli®ed to make it fail sooner than the actual container. After performing the nondestructive experiment, results were compared

Figure 3 Vibration and impact test.


Containerization Table 1

663 32 43 Design

Factors

as shown in Fig. 5. The dotted line indicates the de¯ection obtained from the experiment, and the straight line was obtained from the ANSYS model.

Levels

Material Wall thickness Temperature Static loading Dynamic loading

3 4 3 4 4

3.1.9

Conclusion

A procedure to determine the durability of plastic containers has been shown. Using design experiments, an optimal container design can be obtained. The procedure is cost eective, and can be incorporated in the design of many dierent containers.

Table 2 Randomized Factorial Design Test

Mat.

Tem.

Thk.

Sta.

Dyn.

1st 2nd 3rd 4th 5th 6th 7th 8th 9th 10th 11th 12th 13th 14th 15th 16th

1 3 2 2 2 2 3 1 3 1 2 2 2 2 1 3

1 2 2 3 2 3 1 2 3 2 2 1 2 1 3 2

1 1 1 1 2 2 2 2 3 3 3 3 4 4 4 4

1 2 3 3 1 2 3 4 1 2 3 4 1 2 3 4

1 2 3 3 2 1 4 3 3 4 1 2 4 3 2 1

Figure 4 ANSYS ®nite-element model.


3.2

3.2.1

STATISTICAL MODELING OF CONTAINER INVENTORY CONTROL IN A DISTRIBUTION NETWORK Introduction

In most material transportation processes, containers are used to facilitate transportation, and protect the material being carried from possible damage. To complete transportation of material or goods, one requires the availability of enough containers at the supply sites. Shortages of containers at a supply site will delay the transportation of the material. Containers protect materials and facilitate handling. Containers are an integral part of the total transportation system. Less expensive materials such as paper, plastic bags, or carton boxes are used as containers to reduce cost. These containers are disposed of or recycled after transportation. With increasing freight volume and environmental concerns, the requirements for better quality and reusable containers are increasing rapidly. The cost of containers is becoming a signi®cant part of the total transportation cost.

Figure 5 FEM versus experimental results.

664

A distribution network identi®es a list of supply sites and destination sites connected by routes. When reusable containers are used in a distribution network, the containers are required to ¯ow through road networks carrying the materials in demand. After transportation, the containers are not necessarily returned to the supply site. The containers can be sent directly to container inventories of the destination sites for future use. A container inventory transportation network can be classi®ed as either a closed system or an open system. The closed system is a network in which the total number of containers in the system does not change. The open system is a network in which the total number containers changes. A transportation network can also be classi®ed as a balanced or unbalanced system. In a balanced system, the container inventory at each site is balanced, meaning that the number of containers shipped out by demand of a particular site is equal to the number of containers returned. The inventory level of containers remains unchanged at each site. In an unbalanced system the inventory at some sites will keep increasing or decreasing. There are two reasons why a system can be unbalanced. One is the number of containers broken during usage. We have to add new containers into the system to compensate for broken containers. The other reason is that the demand shipment and the return of containers are not equal for some sites. After a period of time, these sites will have extra containers or will have a container shortage. If the system is a closed system, the total containers in the system will still be kept the same. Therefore, we can ship containers to the sites with container shortages from the sites with extra containers. The redistribution of the containers within such an unbalanced system to make the containers available at every site is essential to the performance of the whole system. Closed unbalanced transportation systems are the subject of this section. When materials are transported between sites, the container inventory levels at each site will change. The container inventory control in a large transportation system is a type of network-location-allocation problem. The demand pattern of the containers is similar to the demand pattern of the materials. As with any of the other inventory items, container inventory also has its carrying cost, shortage cost, and replenishment cost. The container's carrying cost, shortage cost, and replenishment cost should be included into the total cost of the distribution network. Obviously, if there are not enough containers in the network, it will cause transportation delays. However,


Mazouz and Han

using more containers than necessary results in higher initial investment and carrying costs. One of the fundamental problems of distribution network optimization is to know how many containers should be maintained in a particular system to make it ecient and economic. On the other hand, although there are sucient containers in a system, if they are not located at proper sites, they are unavailable to the system at the moment when they are required. This will also cause transportation delays or give up optimal routes. An ecient way at reduce container inventory levels is to redistribute the empty containers to appropriate sites at appropriate times. The more frequently we redistribute empty containers, the lower the container inventory level that can be expected in the system. However, the cost for container transportation increases at the same time. An additional focus is when and how to redistribute empty containers in the system to reach the lowest total cost. How to satisfy the requirement of transportation and maintain a minimum amount of container inventory are common issues in analyzing such a transportation system. In this section we study the methods to minimize the total cost of a transportation distribution network. We use CIRBO as an acrony for Container Inventory contRol in a distriBution netwOrk. 3.2.2

Reusable Container Inventory Control in a Distribution Network

Reusable container inventory control in a distribution network presents the combination of the characteristics found in the transportation network system and the inventory control system. It deals with not only the inventory control but also the transportation systems management. In fact there are three major issues aecting the total cost considered here: 1. 2. 3.

Optimal supply site selection for the commodity in demand Control policy selection for the container inventory system Optimal empty container redistribution method.

In most cases, the demand and transportation time are probabilistic. Issue 1 and issue 3 are transportation problems with probabilistic demands. Issue 2 is a special inventory control problem. If the system has in®nite containers or if the containers are not used in the material transportation, this system becomes a pure transportation problem.

Containerization

On the other hand, if the optimal routes have been selected for commodity shipment, the system degenerates into a problem of multiple inventory control and container redistribution in a distribution network. In this case the system performance is totally dependent on the inventory policy or the container management. Analyzing such a system will clearly demonstrate how container management aects the performance of a transportation system. The framework of this section is to develop a simulation modeling procedure and address common problems of CIRBO systems. We ®rst de®ne the CIRBO problem and describe dierent inventory policies. Then, the simulation models for CIRBO are created using SIMAN# simulation language. A simulation code generator (SCG) system is then developed using SIMAN as a target program to systematically generate a CIRBO model based on a set of input conditions. The SCG itself is implemented by C language in an object-oriented window environment. The resultant framework is reusable, extendible and user friendly. 3.2.3

CIRBO Model Development

There are two steps in developing the CIRBO model. First, mathematical models are developed to describe the distribution network. Then a computer simulation code is generated. The mathematical models supply a theoretical foundation, while the simulation code creates a simulation model based on the user input speci®cations. 3.2.3.1

System Outline

Assume a typical transportation network with reusable containers which consists of m roads linking each site. Each site could be a commodity supply site and/or a commodity demand site. Each demand site can receive a commodity from multiple supply sites and each supply site can oer commodities to dierent demand sites. On each node, there can be a container inventory and commodity inventory, and it can also generate demand for commodities. Each supply site contains both a commodity inventory and a reusable container inventory. The commodity is contained in reusable containers and then transported by some method (airplane, ship, truck, or train) among these sites. When one site in the network requires materials, it looks for supply sites from all other sites in the transportation system. Some priorities for supply sites will be selected according to speci®c transportation rules.


665

Here the rules should concern many features, such as transportation cost, material availability, container availability, material inventories, and container inventories for possible future demands, etc. When the selected site has adequate commodity and containers available, the transportation takes place. However, if the commodity or container is not available at the selected site, the demand has to be sent to the secondary sites for supply. If, in some case, that demand cannot ®nd adequate supply in the whole system, it causes an unsatis®ed demand. A penalty will occur. From the above statements, we can see that there are two main issues in the transportation network. They are commodity transportation and container management. In container management, the issues that need to be concerned are container inventory policies (when and how much of a replenishment should be made) and empty container redistribution (how a replenishment should be made). Actually, we can decompose the whole problem into three subissues: 1. Optimal schedule and route plan to minimize the total cost for commodity transportation 2. Optimal container inventory control policy to minimize the holding cost, shortage cost, and redistribution cost 3. Optimal redistribution route selection to minimize unit redistribution cost. A network transportation problem can be studied in dierent ways. From the view of commodity demand and supply, it is basically a dynamic transportation problem. It mainly deals with the schedule and route problem of material transportation. The container availability and the container control policy can be handled as constraints for route and schedule optimization. On the other hand, from the view of containers, the problem can be described as a multiple inventory control problem. The problem deals with the holding cost, the shortage cost, and the redistribution cost for the reusable container inventory in the system. The commodity transportation aects the container demand pattern, the lead time and the shortage cost of the container inventory. The redistribution of containers in a multiple inventory is another dynamic transportation problem. The cost of this transportation can be calculated and added to the total cost as replenishment cost. In this section, we discuss this problem from the view of containers.

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Dynamic Transportation Models

If containers are not used, or there are in®nite containers in each site, we never need to worry about container availability. Distribution networks with reusable containers become a pure dynamic transportation system. The issue becomes that for each moment, the ¯ow of commodity from various sources to dierent destinations should be selected to minimize the total cost. The total cost consists of three parts: transportation cost, holding cost for commodity waiting in supply nodes, and penalty for unsatis®ed demand. 3.2.3.3

Container Inventory System Analysis

There are two major issues in a transportation system with reusable containers. The ®rst issue is to de®ne how many containers should be invested in the system to make it economic and ecient. Another issue is to ®nd the method to manage these containers to make them available when a supply site needs them. To highlight the eect of container and the eect of inventory policy, we assume that the optimal transportation route for commodity delivery has already been selected using some dynamic transportation solution method. If this optimal plan cannot be executed, the reason for that must be caused by the container shortages at some nodes. The dierence between the optimal plan and suboptimal transportation plan is the eect of container availability. 3.2.3.4

Redistribution Modeling

In CIRBO the unit cost for replenishment depends on how the redistribution route is selected. Also a cost matrix form can be constructed. The issue is that we want to ®nd the optimal transportation plan to satisfy the requirement of distribution and to minimize the redistribution cost. 3.2.3.5

Statistical Modeling and Optimization of the Container Inventory Control

Based on the mathematical models of the CIRBO system, the system performance measurement and various controllable variables can be identi®ed. However, it is still very dicult to ®nd the optimal solution using these models for such a complicated problem, especially when the system is a probabilistic system. A statistical systems modeling approach is therefore recommended as a tool to analyze such systems.


The ®rst consideration in building a simulation model is to specify the goals or the purpose of the model. In the CIRBO system analysis, we can optimize the number of containers in the system by: 1. 2. 3.

Minimizing the total cost, or Reaching a speci®ed service level, or Reducing the time of redistribution of empty containers, etc.

Here, item 2 (service level) or item 3 (time of redistribution) can be the focus of study. However, they do not indicate the overall performance of the system. Take the service level as an example, in order to improve the service level, one of two methods can be used. The ®rst one is to increase the number of containers in the system if the container carrying cost is small. The other method is to reduce the time period between the container redistribution if the redistribution cost is minimal. High service level is merely a measurement of the system performance. However, it makes no sense to seek high service levels without concerning the total cost of the system. A statistical systems modeling method is used in this section. The key issue to make the simulation technology more acceptable is to make the simulation process signi®cantly easier to learn and use. Here the simulation process includes not only the model building but also the experimental design and data analysis. 3.2.4

Case Studies

In this section, we present two case studies. One case study is performed for an automobile manufacturer and the another one is conducted for a fresh fruit company. 3.2.4.1 Modeling of a Transportation System for an Automobile Maker Problem Description. The transmission and chassis division of an automobile manufacturer manages the transportation of a large number of automobile components and subassemblies. Reusable containers are employed in the component subassembly transportation system. One of these systems is the Mexico± Canada route. This route includes a main plant in the United States, denoted US, two plants in Mexico (MF1 and MF2) and another plant in Canada (CN). Car parts are shipped from US to MF1. After some part assembles are performed at MF1, containers are needed to ship these assembled parts to MF2. The extra empty containers will be shipped back to US.

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More assembly work will take place at MF2. After that, they will be shipped to CN and then back to US using the amount of containers. The demand from each plant and the average time the containers spend in each plant, and delays on the board of customs and on the road are listed in Table 3. The time spent for each period is a random variable, and these follow a normal distribution with the variance of 6 0:1 to 0.2 days. This system has a ®xed schedule and transportation route. The plants usually work 5 days a week without holidays, and there are dierent holiday schedules in the United States, Canada and Mexico. During weekends and holidays, the plants only receive trucks but do not send any trucks out. The automobile manufacturer is very interested in a decision support system that can study the eects of the number of containers in the transportation system. The ideal decision support system should represent the current transportation system and be able to stimulate several proposed changes. It should also be able to trace the availability of containers at a given moment in each plant. Dierent container management and optimization methods should be tested with various numbers of containers in the system. This is a typical case of the CIRBO that has four sites with a ®xed route and a ®xed schedule. The demand size is also known. In this case, all the factors in the material transportation problem are ®xed and given. We can concentrate on the container inventory control problem. The system's variables are the numbers of containers in the system and the period of redistribution.

Simulation Modeling and Optimization. Using the SCG for CIRBO, we can create a SIMAN model for the car manufacturer. In this case, the number of sites is four. Each site has a unique supply. If there are not enough containers available at the location when needed, the truck has to wait until containers become available. We give a very high penalty to the container shortage because the manufacturer does not want this to happen at any situation. The user can input initial amount of containers for each location, then run the simulation. Using real demand data and assuring that there are 5000 containers in the system, the demand waiting time and container availability at each plant is collected. Figure 6 gives the average container availability for each plant over 5 years and Fig. 7 shows the average demand waiting time at each plant in the 5-year period. From Fig. 6 we see that most of the containers will be accumulated at MF1 while other plants have a container shortage. The demand waiting time in the United States and Canada will increase, while the time spent in the Mexico plant will decrease (see Fig. 7). There are two ways to avoid the accumulation of containers and elongated waiting time: one is to increase the container inventory and the other is to rearrange empty containers. For the purpose of comparing, we assume that there is the same number of containers in the system, and we redistribute empty containers annually to make the container inventory level back to its optimum. Running simulation for the same period, we have the results shown that average container level keeping at

Table 3 Data Prepared for Automobile Maker Transportation Systems Time in Plant

US US±MF1 MF1 MF1±MF2 MF2 MF2±CST CST CST±CN CN CN±US MF1±CST CST±US


Mean

Deviation

4.0

0.1

3.0

0.1

3.0

0.1

2.0

0.1

3.0

0.1

0.5 6.5

0.1 0.2

Time on Road Mean

Deviation

Demand (Cont./day)

4.5

0.2

101

2.0

0.1

80

0.5

0.1

80

4.5

0.1

80

2.0 0.5 4.5

0.1 0.1 0.2

80 21 21

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Figure 6 Average container availability for each plant during a 5-year period.

every plant is unchanged and the demand waiting time stays at zero. Now, we go a step further to optimize the number of containers in the system. The possibility to reduce the total number of containers in the system is studied. By arranging simulation runs with dierent amounts of initial containers at each location, the demand waiting time can be compared. The results can be used to optimize the number of containers in the system as follows. We arrange 10 simulation runs, with each run having a dierent number of containers in the systems from 4000 to 3000. Assume that if there are not enough containers available when needed, the truck waits until containers become available. The container availability at each site and the truck waiting times are used as the service level measurements. To make the results reliable, simulation conditions are replicated in order to establish a required con®dence level. The results of the simulation output are presented in Fig. 8. This is the plot of average demand waiting time versus the number of containers in the system. From the curve we can see that when the containers in the system is reduced, the waiting time stays at zero until the containers in the system dropped to 3500. After that a very short waiting time, 0.05 day (1.2 hr) occurred. If the containers in the system are reduced to be less than 3000, the waiting time increases rapidly. It was obvious that the containers should not be less than 3000. A better service level could be achieved with at least 3500 containers in the system. However, keeping more than 3500 containers in the system does not further improve the service level but will only increase the inventory. Summary. SCG for CIRBO has created a simulation model for an automobile maker successfully. This model can be used to analyze the performance of container inventory control in the transportation system. 1. 2.

An annual empty container redistribution is suggested to improve system performance. Using the simulation model generated by SCG, we optimize the number of containers in the system. The model reduced the total number of containers by 30% and still maintained a high service level.

3.2.4.2 Modeling for a Fresh Fruit Company

Figure 7

Average demand waiting time at each plant.


Problem Description. Bananas and other fresh fruit are imported into the United States from a port in Latin America. The fruit is shipped on boats in

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Figure 8 Optimize the number of containers in system.

marine-size shipping containers, and comes into a port in the Gulf of Mexico. Upon arrival the containers are distributed from the port to customer locations throughout the central part of the country. There is an inherent problem in this fruit distribution system; the trade is unidirectional. The trade imbalance between the United States and those locations from which the bananas come makes shipping in both directions impracticable. Full containers are imported from the source and empty containers must be exported to replenish the container inventory. For the system to be operated eciently, the boats returning to Latin America must return fully loaded with empty containers. An economical method is needed for keeping the number of containers in the Latin American port at a level high enough to ensure that the boats leaving for the United States will be fully loaded. This dependence on return shipment of containers means that a stable inventory of empty containers has to be kept at the U.S. port when the ship arrives. Unfortunately the U.S. side of the distribution system has a large amount of variability associated with it. Many factors eect the amount of time when a container leaves and returns to port as outlined below:


1. The distance from the port to the customer's location 2. The amount of time that the customer keeps the container before returning it 3. The speed variability of the trucks and the ships that deliver the containers 4. The day of the week that the container leaves and returns to the port. Currently, a high-level buer inventory is required to overcome this variability so that any shortages of empty containers can be made up with empty containers from the buer inventory. The size of buer inventory is approximately one-half the capacity of a ship used in the system. Objectives. The cost of owning and operating this fruit distribution system is tremendous. Each of the shipping containers costs approximately $20,000. Associated with each of the shipping containers is a refrigeration unit that costs approximately $7000± $10,000. In order for the refrigeration unit to operate there must be a generator to power it while it is in port. These cost approximately $5000 dollars per container. Lastly, for the containers to be moved there must be enough trailers. Trailers cost approximately $15,000 dollars each. The two container ships cost between

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20 and 40 million dollars each. This brings the total equipment cost required to run the small system to the neighborhood of 70 to 80 million dollars. The area targeted for cost reduction is the excess inventory of containers at the U.S. port. If the number of containers maintained in the buer inventory could be safely lowered by 10 containers, the company would save approximately $350,000. It also saves the cost of maintaining those containers and the associate equipment over the life of the container. On the other hand, with an investment of this size the system should look for maximum return on investment. To maximize the return in such a system, the system must be operated as eciently as possible. Consider that a sucient buer inventory of empty containers in the U.S. port will be used to ensure against any possible loss of ship capacity. Current practice is to keep an excessively large buer in container inventory at the U.S. port so the ships can be loaded eciently. This is a closed-loop system. If a company owns all the containers, there is no container replenishment in the system. The carrying cost and shortage cost are subject to control and are balanced. One of the policies is that container shortage is not allowed. The problem becomes that the company has to increase the number of containers and carrying cost. Another method is to use a leasing program to reduce the number of containers the company owns, and leased containers are used to meet peak demands. This is another typical inventory control problem. The total cost consists of the following: 1. 2. 3.

Carrying cost: the cost of investment in container inventories, of storage, of handling containers in storage, etc. Shortage cost: the cost of lost ship capacity Replenishment cost: the cost of leasing containers.

These three costs are subject to control. Thus the goal should be to optimize the total cost in such a way that the ships are ®lled to capacity. The shortage cost will always be less than the cost reduction of carrying cost and replenishment cost. Simulation Modeling. To ®nd the optimization solution, a simulation model has been constructed. The model uses two ships to simulate the transportation process and a network to simulate the distribution system in the United States. In order to approximate the actual system as closely as possible the original model had the following characteristics and capabilities:


1.

2.

3.

4. 5.

6.

Two ships, each with a capacity of 100 containers, were used to move containers between two ports. The ports were assumed to be 1500 miles apart and the ships operated at a variable speed. However, they work directly opposite each other so that the two ships never arrived at he same port at the same time. The U.S. port was open for trucking 5 days a week, but the ships operate 7 days a week. Thus if a customer ordered a container of fruit and requested that it be delivered by a speci®c time, the delivery time was estimated. If the optimal departure time for the truck was to be a Saturday or a Sunday, the truck was forced to leave on Friday. If a ship was to fully load on a weekend it would wait till the following Monday to allow trucks that had returned over the weekend to load their containers on the ship. The speed of the trucks used to deliver the containers varied slightly with a normal distribution around 55 mph. The amount of time that the trucker was allowed to hold on to the container before returning it was modeled with a normal distribution with mean based on the distance from the port. The model can accept any kind of demand pattern. The information used for demand was a hypothetical demand as a function of distance from the port. This model can also use history data for the future forecast.

Control Policy 1: Company Owns All Containers. When the company owns all the containers, no leasing containers are added to the system. The reusable containers will remain unchanged in the system while the container inventory at the U.S. port will ¯uctuate (see Fig. 9). In cargo shipping the shortage cost of not having enough containers is signi®cant compared with the container carrying cost. This requires that a ship be fully loaded when it leaves the port. The only way to ensure that is to increase the containers in the system (in the U.S. port as buer inventories). Control Policy 2: Leasing Program to Reduce Buer Inventory at the U.S. Port. When a leasing program is employed, the total containers in the system will change due to the leasing of containers. The inventory ¯uctuation is depicted in Fig. 10. Shortages are covered by leasing containers.

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The container carrying and leasing cost is subject to control. Reducing the buer inventory at the U.S. port means increasing the temporary leasing of containers. The amount of company owned containers and the leased containers are the decision variables. It depends on the ratio of carrying cost to leasing cost. Designing the simulation experiment in a way such that each simulation run will have dierent containers in the system and will lease containers when a shortage occurs, the ®nal solution is attained by balancing the level of containers owned by the company and the level of leased containers based on the carrying cost and container leasing cost. Summary. In this section the transportation problem of an inland±overseas fresh fruit operation is simulated. It is another example of the CIRBO. Simulation is successfully used to optimize the refrigerated container inventory at the U.S. port if the company owns all the containers. The leasing program is also introduced to make it possible to further reduce the buffer container level. It is suggested that the levels of container modeling can be reduced by 10±30% without impacting the delivery time (source level). Figure 9 The inventory ¯uctuations with company's own program.

3.2.5

Figure 10 The inventory ¯uctuations with leasing program.


Conclusion

The objective of this section was to ®nd methods to study reusable container inventory control in a distribution network. This system has many controllable variables and control policies. The container inventory control problem is a multivariable optimization problem. CIRBO is a special inventory control problem. To optimize a CIRBO system, mathematical models are presented to represent the CIRBO system in general. Various control policies are de®ned. Based on the mathematical description of the CIRBO system, simulation models can be constructed. Theoretically, simulation is not an optimization tool. The simulation modeling of a real CIRBO system is not able to optimize CIRBO directly. However, to optimize a CIRBO, design of experiment and optimization theory is utilized. Simulation experiments are arranged using a design of experiment approach. Running simulation in this way, we can compare simulation results to ®nd optimization solution. Simulation code generation is introduced to make the simulation modeling process simple for nonexpert simulation code generators. It also saves time for simulation program development.

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ACKNOWLEDGMENTS The authors would like to acknowledge the Material Handling Research Center at Florida Atlantic University, The National Science Foundation, and the Ford Motor Company for supporting this study. And also acknowledge the work and assistance done by the following students: P. P. Aguilera, Weiming Feng and Pankaj Kanwar.

BIBLIOGRAPHY KS Akbay. Using simulation optimization to ®nd the best solution. IIE Solut May: 24±27, 1996. ANSYS Manual Revision 4.3. Swanson Analysis Systems, Inc., Feb 15, 1994. CB Basnet, SC Karacal. Experiences in developing an objectoriented modeling environment for manufacturing system. Proceedings of the 1990 Winter Simulation Conference, 1990, pp 477±481. M Bogataj, L Bogataj. Inventory systems optimization for dynamic stochastic and periodical demand. Eng Costs Prod Econ 19(1±3): 295±299, 1990. Bonelli P, Parodi A. An ecient classi®er system and its experimental comparison with two representative learning methods on three medical domains. Proceedings of the Fourth International Conference on Genetic Algorithm. R Belew, LB Booker, eds. 1991, pp 288±296. MD Byrne. Multi-item production lot sizing using a search simulation approach. Eng Costs Prod Econ 19(1±3): 307± 311, 1990. M Chen, WP Chen, DC Gong, M. Goetschalckx, L McGinnis. An AGV simulation code generator. Proceedings of Material Handling Research Center at Georgia Tech, Nov 1991. C Das, SK Goyal. Economic ordering policy for deterministic two-echelon distribution systems. Eng Costs Prod Econ 21(3): 227±231, 1991.


Mazouz and Han N Erkip, WH Hausman, S Nahmias. Optimal centralized ordering policies in multiechelon inventory systems with correlated demands. Manag Sci 36(3): 381±392, 1990. M Goetschalckx. Local User's Manual. Material Handling Research Center, GIT, Atlanta, GA, 1991. JJ Gregenstette, C Ramsey, A Schultz. Learning sequential decision rules using simulation models and competition. Mach Learn J 5: 1990, 335±381. Hutchison, et al. Scheduling approaches for random job shop ¯exible manufacturing systems. Int J Prod Res 29(5): 1053±1067, 1991. RG Lavery. A simulation analysis of the eects of transportation system parameters on inventory levels. Proceedings of 90 Winter Simulation Conference, IEEE Service Center, Piscataway, NJ, 1990, pp 908±910. CJ Liao, CH Shyu. Stochastic inventory model with controllable lead time. Int J Syst Sci 22(11): 2347±2354, 1991. GE Liepins, AW Lori. Classi®er system learning of Boolean concepts. Proceedings of the Fourth International Conference on Genetic Algorithms, R Belew, LB Booker, eds, 1991. M Montazeri, LN Van Wassenhive. Analysis of scheduling rules for an FMS. Int J Prod Res 28(4): 785±802, 1990. DC Montgomery. Design and Analysis of Experiments. 4th ed. New York: John Wiley, 1996. CD Pegden, RE Shanon, RP Sadowski. Introduction to Simulation Using SIMAN. 2nd ed. McGraw-Hill, 1995. D Porcaro. Simulation Modeling and DOE. IIE Solut September: 23±25, 1996. R Riolo. Modeling simple human category learning with classi®er system. Proceedings of the Fourth International Conference on Genetic Algorithms, R Belew, LB Booker, eds, 1991. LW Robinson. Optimal and approximate policies in multiperiod, multiplication inventory models with transshipments. Operat Res 38(2): 278±295, 1990. SM Semenov. Determination of prior probabilities in entropy models of a transportation system. Autom Remote Control 50(10): 1408±1413, 1990. T Shimada, Yamasaki, Ichimori. Introduction of Packaging Design CAD System. Nippoh, 1990.

Chapter 7.4 Robotic Palletizing of Fixed- and Variable-Size/Content Parcels Hyder Nihal Agha and William H. DeCamp Motoman, Inc., West Carrollton, Ohio

Richard L. Shell and Ernest L. Hall


4.1

INTRODUCTION

the palletization of parcels of mixed size and shape have proven very successful.

Warehousing is an expensive activity in the United States, where it accounts for nearly 5% of the Gross Domestic Product [1]. It can best be described as the material handling functions of receiving, storing, and issuing of ®nished goods. It is often viewed in industry as a necessary evil, since it does not add value to a product. However, the warehousing and distribution functions are critical to a successful manufacturing enterprise. Warehousing functions include information processing, receiving, storage, order picking, palletization, and shipping. The typical process for material handling in a warehouse is as follows: 1. 2. 3. 4.

There are several disadvantages to human palletizing. One is related to cost. Even the most motivated and capable human can stack only about six parcels per minute, i.e., one parcel per 10 sec. Another disadvantage is related to safety and workers' compensation costs. A human who performs such a repetitive motion is at risk for cumulative trauma disorders, such as back and shoulder injuries. A typical human palletizer is shown in Fig. 1. The advantages of robotic palletizing include: the maximization of the usage of the pallet cube; the retention of knowledge about each parcel throughout the distribution system; increased pallet load stability, insurance of forming pallets in accordance with regulations (i.e., not stacking poisons on top of food items, and control of parcel fragility, which reduces waste. Distribution centers are a necessary component in the logistics system of most manufacturing industries from food items, to dry goods, to computer or aircraft engine components or machine tool parts. All distributors, including the defense industries, parcel industries, and even medical industries, are potential users of a robotic palletizing system. Palletizing may be de®ned as arranging products to form a unit load for convenient subsequent handling.

Items are received at a warehouse in multiple pallet loads of identical items. Loads are stored in the warehouse in some planned con®guration. When a customer's order arrives, an order picker goes through the warehouse to pick the desired items from separate pallets. Items are routed to a load forming, palletizing, or palletization, station where items of various sizes and shapes are placed together on pallets for shipment to the customer. Although this palletizing operation has traditionally depended upon human labor, recent eorts at automating 673


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(a)

(b)

Figure 1 A typical human palletizing food products for distribution: (a) removal of box from conveyors; (b) stacking of box on pallet.

Research in palletizing focuses on determining the optimal pallet size and on packing methodology to maximize space utilization. This chapter concentrates on the palletizing of pallets using prismatic boxes. This restriction is not signi®cant because the majority of stock-keeping units (SKUs) in distribution facilities are boxed. In addition, the methodologies developed for palletizing, with minimal changes, can apply to other palletizing approaches, such as container ®lling or pallet less stacking. The University of Cincinnati was recently awarded U.S. Patent 5,175,692 for palletizing randomly arriving parcels of mixed size and content. This patent has been licensed to Motoman, who has developed the robotic solution into a product that is now available and promises to eliminate back injuries, reduce costs, and improve the quality of loads. The purpose of this chapter is to describe robotic palletizing, including the algorithms for real-time pallet stacking of mixed-size/content parcels using an expertsystem approach. The chapter is organized as follows.


Previous research on robotic palletizing is reviewed in Sec. 4.2 The current palletizing methods are described in Sec 4.3. Future approaches to robotic palletizing are described in Sec. 4.4. Conclusions and recommendations are given in Sec. 4.5.

4.2

PALLETIZING

Palletization is a special case of a more general conformational problem called space ®lling. Space ®lling occurs in a variety of forms in industrial activities where the simplest one-dimensional case is called stock cutting. 4.2.1

Two-Dimensional Stock-Cutting Example

For this example, consider a continuous sheet of stock material of width, W, that is to be cut so as to satisfy the demands for lengths, Di , of strips with a width, wi ,

Robotic Palletizing of Parcels

where i 1; . . . ; m. In this case, the total demand or order is D D 1 D2 Dm The demand Di can be satis®ed by supplying any number of pieces, ni , of length, li , of the strips of width, wi , so long as the total lengths, Li sum to at least Di : D i 4 Li n i l i

for i 1; 2; . . . ; m

The demands are met by deciding on various slitting patterns for the sheet of width W. The jth slitting pattern is a way of dividing the width, W, into the smaller widths, wi , for i 1; . . . ; m. This pattern is applied to a length amount lj of the sheet: W 5 n 1 w 1 n 2 w 2 nm w m In the linear programming solution for this one-dimensional noninteger stock-cutting problem, the matrix A of the linear programming problem will have m rows and a large number of columns, k. One column will exist for each of the possible slitting patterns such that each vector. Ni n1 ; n2 ; . . . ; nm of nonnegative integers satisfying the following conditions. W 5 n 1 w 1 n 2 w 2 nm w m is a column of the matrix. If X is a column vector of variables, each corresponding to a slitting pattern, one for each column of A, and if O is a row vector of all 1's, then the linear-programming problem may be stated: Minimize OT X x1 x2 xk subject to AT X N where N is the column vector n1 ; n2 ; . . . ; nm T . Variations of this problem occur in both noninteger and integer forms. A linear-programming method may be used to solve the noninteger problem. However, a general diculty is encountered due to the very large number of columns of possible solutions. An integer problem is one in which the demands, Di , are in integers and the variables, xi are restricted to being integer. Rounded answers to the noninteger problem may be used to approximate the integer problem solution. 4.2.2

Three-Dimensional Space Filling

The general problem of ®lling a three-dimensional pallet with mixed-size parcels may be considered as


675

a mathematical problem of ®nding the space that is ®lling the pallet's volume. That is, N parcels must be placed at positions (xi ; yi ; zi and the total volume ®lled as completely as possible. Other problems of this nature include the traveling salesman problem and the game of chess. In general, these problems are called NP-complete, that is, the computation time required for an exact solution increases exponentially with N. There is no method for ®nding an exact solution except exhaustive search of all possible solutions. Fortunately, modern arti®cial intelligent techniques provide a means to obtain good solutions. An expert system has been invented which provides solutions which satisfy a set of rules and consequently provide ``good'' solutions. Furthermore, the approach can be applied not only to single-product, mixed-layer, column or prede®ned order of arrival palletizing, but also to real-time, randomly arriving, and mixed-size and content palletizing. 4.2.3

Factors Affecting Palletizing

From the above discussion, it is apparent that dierent factors can aect the palletizing. The most important are: Pallet size. Generally, the larger the pallet, the better are the chances of ®lling it eciently. Product proliferation. Contrary to initial intuition, a larger mix of sizes results in better load-forming eciency, but at the expense of higher computer run time. Stated dierently, if given an empty space, the chances of ®nding a box that closely ®lls that space are improved when a greater variety of box is available, but more time is needed to ®nd that box. Note that boxes in an actual order typically present some correlation; for example, it is likely that there will be multiple boxes of a certain type. Putting this information to use will result in faster heuristics in generating loadforming layouts. Standards. Establishing box/carton standards is essential because it greatly reduces the proliferation of boxes, thus allowing faster palletizing algorithms. Algorithm. Exact algorithms are time consuming to the computer and dicult to implement. Heuristics often result in ecient solutions in relatively little time. Arti®cial intelligent methods could result in a better performance, especially if based on ecient heuristics.

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Sequence of pick. Usually some pretreatment of the boxes can assist in the speed of reaching a solution. In many cases, the pretreatment may not even require additional work. For example, if boxes are stored and issued in a sequence that simpli®es the allocation of space to the boxes (e.g., heavier boxes ®rst, light ones later, boxes with identical sizes together, etc.), the solution could be reached more quickly and easily. Look ahead. The ability to look ahead can also be used to speed up the search for space. 4.2.4

Palletizing of Identical-Size Parcels

Steudel [2] formulated the problem of loading uniformsized boxes as a four-stage dynamic program that ®rst maximizes the utilization on the perimeter of the pallet and then projects the arrangement inward. Correction steps were given for the cases where the projection resulted in overlapping boxes or in a large central hole. Smith and DeCani [3] proposed a four-corner approach to ®lling a pallet with identical boxes. The procedure determined the minimum and maximum number of boxes that could be placed starting from each corner of the pallet, and then iteratively evaluated the possible combinations that maximized the total number of boxes on the pallet. Although no claim of optimality is made in the paper, the results compare favorably with exact methods. The results of these patterns are often summarized in a chart or table format. Apple [4] shows a set of patterns and a two-dimensional chart developed by the General Services Administration. The chart indicates which pattern is recommended for each box length±width combination. K. Dowsland [5] presented a three-dimensional pallet chart that works for dierent pallet sizes and indicates the sensitivity of the different patterns to variations in box sizes. Researchers have tried to include some physical constraints to the pallet-loading problem. Puls and Tanchoco [6] considered the case where boxes are handled by opposite sides, and they modi®ed the Smith and DeCani approach to start with three corners, resulting in layouts that are built with guillotine cuts. A guillotine cut is a straight line that cuts the pallet or rectangle across, resulting in two subrectangles. Carpenter and W. Dowsland [7] used a ®ve-area approach that started from each of the corners and from the middle to generate alternative layout patterns. They evaluated the results based on criteria for load stability and clampability, i.e., the ability to handle the load with a clamp truck. It was deduced that


layouts comprising two areas are the most suitable for clampability, but they also yield suboptimal utilization of the pallet volume. K. Dowsland [8] investigated the palletizing of boxes with a robot when it could handle one, two or four boxes at a time, and sought to determine the minimum number of transfers. Gupta [9] investigated the problem of determining the pallet size when dierent box types are present, but each pallet was to hold only a single type of box. The problem was formulated as a two-stage mixed-integer programming model. The ®rst stage seeks to optimize the placement of boxes along one side of the pallet and the second stage seeks to optimize the placement along the other. 4.2.5

Palletizing Boxes of Variable Sizes

In situations involving high volume and high complexity in terms of SKUs, the unit load to be formed is expected to contain items of dierent sizes. This problem has received much attention in operations research, especially under the closely related problems of bin packing, knapsack, stock cutting and plane tiling. The general form of the problem is far from being solved, and in fact can be shown to be NP-complete or ``hard.'' As an outline proof, consider the simpli®ed case where all the boxes have equal height and width, but dier in length. In this way, the problem is transformed into that of ®nding the combination of box lengths that best ®ll the pallet along its length. This problem is equivalent to the one-dimensional binpacking problem, which was shown to be NP-complete [10]. NP-complete refers to the class of problems for which the only known solution involves enumerating all the possible combinations, which is time prohibitive because the number of alternatives grows combinatorially with increasing items. Consequently, these problems are solved using heuristics or expert system approaches, which yield nonoptimal solutions. 4.2.5.1 Heuristic Methods Early eorts in the ®eld include the work of Gilmore and Gomory [11, 12]. Their work investigated the twodimensional stock cutting problem, which arises when a rectangular sheet of material is to be cut into smaller rectangles of dierent sizes. The problem is analogous to the palletizing of boxes of the same height. The authors formulated the problem as a linear program and suggested its solution by applying a knapsack function at every pivot step, recognizing that it would be computationally prohibitive.


Hertz [13] implemented a fast recursive tree search algorithm that optimized the solution obtained by using guillotine cuts. Note that this solution was not necessarily optimal for the general solution. Herz's algorithm assumed that the rectangles were positioned in one orientation only. When this assumption is applied to a box that can be rotated by 908, a duplicate box with the length and width interchanged must be created. Christo®des and Whitlock [14] also used a tree search routine to attempt to ®nd the optimal layout that can be obtained using guillotine cuts. They narrowed the search space by eliminating redundant nodes that arise due to symmetry, the ordering of the cuts, and the location of the unused space. Applying this procedure to a problem with 20 boxes, the solution required 130 sec CPU time on a CDC 7600 computer. Hodgson [15] combined heuristics and dynamic programming in the solution of a two-dimensional pallet layout. In this approach, the pallet is partitioned into a rectangular area, constituted by the boxes that were previously stacked starting from a corner, and into an L-shaped strip, the candidate to be ®lled. Dynamic programming was used to allocate boxes in the two rectangular sections forming the L. This approach restricted boxes to be placed in corridors around the starting corner, but because of the simple shape of the corridor, it resulted in signi®cantly fewer partitions to be evaluated. Using the system, the operator interactively selects the ®rst box (typically a large one) and the candidates for evaluation at each step. It was reported that the eciency of packing increases with increasing number of box types, but at the expense of higher computer run time. In an adaptation of Hodgson's work, designed to run on a microcomputer, Carlo et al. [16] used a simpler heuristic of ®tting boxes in order of decreasing size. The procedure was repeated by randomly varying the ®rst box to be place and the orientation of the boxes, and the best result was saved. When allowed to run 1 min on a microcomputer, the procedure resulted in area utilization of about 95%. Albano and Orsini [17] investigated the problem of cutting large sheets of material and proposed the approach of aggregating rectangles with an almost equal dimension into long strips. Then, a knapsack function was used to allocate strips across the width of the sheet. The procedure was fast and was found to result in very high area utilization (98%), especially when applied to larger problems. The problem of packing three-dimensional pallets has been less thoroughly investigated. George and Robinson [18] studied the problem of loading boxes


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into a container. They developed a layer-by-layer approach. Following the selection of an initial box, all boxes with the same height become candidates, and are ranked ®rst by decreasing width, second by quantity of boxes of the same type, and ®nally by decreasing length. The space in the layer is ®lled to preclude a face with pieces jutting by starting from one back corner and ®lling the area consistently to have a straight or steplike front. When evaluating their algorithm, George and Robinson found that it worked better with actual than with random or deterministic data, because actual shipments are likely to have correlated values. 4.2.5.2

Arti®cial Intelligence Approaches

Mazouz et al. [19±21] at the University of Cincinnati developed a rule-based expert system approach to palletize boxes arriving in a random sequence. The boxes are assigned locations on the pallet based on the criteria of size, toxicity and crushability. Toxicity is used to ensure that no toxic products are placed on top of edible goods, and crushability is used to ensure that no heavy loads are placed on top of soft or fragile boxes. The system was developed using the OPS5 expertsystem shell. The procedure ®rst divided the available space into smaller discrete volume elements called voxels. Second, a relation table was generated for the box types in the bill of lading. The relations specify how many of one box type need to be stacked in order to obtain the same height as a stack formed with dierent box types. These relations become important in a layer approach to palletizing, in which a ¯at surface is required to form the next layer. Third, the boxes in the bill of lading were ranked according to the criteria of toxicity and crushability. Finally, at run time, for each box arriving on the conveyor, the procedure performed a search of the available space to determine where to stack the boxes. Boxes that could not satisfy the threshold requirement on toxicity and crushability were placed on a queue pallet. The expert system then downloaded the co-ordinates of the box to the interfaced Cincinnati Milacron robot that performed the palletizing. Test runs were made, and required 40 min on a VAX 11/750 to generate a pattern of 17 boxes arriving in a random sequence. Due to the layered approach, the loads formed with the system tended to be somewhat pyramid shaped, with larger layers at the bottom and smaller on top. Another expert-system approach was developed at Georgia Tech University by Gilmore et al. [22] for use

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in palletizing boxes in a Kodak distribution center. The system was developed in Lisp-GEST and used a semantic frame representation. It considered the criteria of stability and crushability. The authors assumed that the order would be known in advance and that the boxes would arrive in a required sequence, and approached the building of pallets by columns rather than by layers. Using this approach, boxes of a similar type were stacked vertically in columns, which are then aggregated to form walls. A column approach is most applicable when there is some correlation between the boxes to be palletized. The column approach also requires simpler algorithms than a layer approach. The layer approach, on the other hand, provides stable pallets, even if they are moved before being wrapped. No report was provided on the speed or eectiveness of the Georgia Tech model. Other approaches, such as ``simulated annealing'' [23], could also be considered. The goal of building an intelligent system for palletizing is fundamentally a problem of designing a decision maker with acceptable performance over a wide range of complexity in parcel sizes and uncertainty in parcel arrival sequences. Three approaches that have potential for this intelligent system are: Expert system as a decision maker for palletizing. Fuzzy logic as the decision-producing element. Neural networks as decision-producing elements. The expert system uses a rule-based paradigm built around `Ìf-Then'' rules. When the procedure works forward from a sequence of `Ìf '' conditions to a sequence of ``Then'' actions, it is called forward chaining. Forward chaining requires a database and a set of rules. This approach may be satisfactory for palletizing; however, it may be too slow for high-speed systems and has limited learning capability. Backward chaining starts with a desired sequence of ``Then'' actions and works backward to determine whether the `Ìf '' conditions are met. The second approach deals with situations in which some of the de®ning relationships can be described by so-called fuzzy sets and fuzzy relational equations. In fuzzy set theory, the element membership decision function is continuous and lies between zero and unity. Fuzzy set theory is useful in situations in which data and relationships cannot be written in precise mathematical terms. For example, a ``good stacking arrangement'' may be dicult to quantify but provides signi®cant fuzzy information that may be integrated into the decision-making process. The third approach uses neural networks [24, 25]. With this approach, the input/output relationships


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can be modeled as a pattern recognition problem where the patterns to be recognized are ``change'' signals that map into `àction'' signals for speci®ed system performances. This type of intelligent system can recognize and isolate patterns of change in real time and ``learn'' from experience to recognize change more quickly, even from incomplete data.

4.3

CURRENT WORK IN AUTOMATED PALLETIZING

An expert system is an excellent approach for palletizing, since it determines a solution that satis®es a set of rules. In the current system, both parcels and pallet space are represented by discrete volume elements, or voxels, that are equal to zero if the space is empty or unity if the space is full. The pallet is represented by a ``blackboard'' database that is changed as the pallet is ®lled. A bill of lading is used to represent the set of parcels which are to be stacked. A database of content information, size, fragility, etc. is also available for each parcel type. In addition, a relational database is formed, indicating size relationships between dierent parcel types. For example, one relationship between two small parcels placed together is that they could form a base for a large parcel. The goal of the expert system is to determine where to place each randomly arriving parcel so that the overall center of mass coincides with the center of gravity or the pallet, and which satis®es all the other rules. Examples of rules include: Toxic substances should not be placed on top of nontoxic products. Boxes should not be crushed. Glass containers should not be stacked on the bottom. Fracture or fault lines should not be generated. Interlocking of parcels should be done, if possible. This expert system has been implemented in OPS5 and used to control a Cincinnati Milacron industrial robot, which was equipped with a vacuum gripper for palletizing food parcels. For all the tests conducted, a satisfactory stacking arrangement was obtained by the expert system. The major drawbacks at this time are computation time for the expert system. Speed of the robot was also a problem in the original implementation; however, a higher-speed Atlas robot was obtained. In the present research, we believe the computation time will be decreased by simplifying


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the algorithm, even though we expect to add additional rules throughout the study. A conceptual diagram of a robotic palletizing workcell is shown in Fig. 2. The top-center block, the visual pallet, is the parent graphical user interface [26], the nerve center of the software system. From it, all data is relayed to and from the other software modules, such as the interface module, the barcode dynamic linking library (DLL), and the visual dynamic control interface (DCI) [27] (a robot control interface). In the case of a palletizing job of mixed size, or of content boxes arriving in random order, the interface module would come into play. As a job begins, the ®rst box is scanned by the barcode reader. Then, the box SKU number is passed through a visual pallet to the interface, where its palletizing algorithm determines the box coordinates on the job pallet or a queue pallet. This data is passed through a visual pallet to a visual DCI which instructs the robot to palletize the box, return to the home position, and wait for the next instruction. After sending the co-ordinates to a visual DCI, the system

determines if the palletizing algorithm has space on the job pallet for a box in the queue pallet. If it determines that it has adequate space, then it sends the data to a visual pallet, which relays the coordinates to the robot through a visual DCI. If there are not further instructions from the palletizing algorithm, a visual DCI instructs, through the barcode DLL, the barcode reader to scan the next box. The whole process starts over and continues until the last box is palletized. In the past several years, a PC-based version of the expert system has been developed using the Windows development tool Visual C and integrated into the graphical interface described in this chapter [28,29]. The development of this PC-based palletizing algorithm was based on a revision of previously developed palletizing software, not a line-for-line conversion. Fortunately, all previously discovered rules can be included in this new software. Because of the recent improved processor capabilities in personal computers, the time required to process a solution for a pallet load has been greatly reduced. Processing time has been

Figure 2 A conceptual diagram of a robotic palletizing workcell.


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reduced from 2.35 min per box using the previous OPS5 expert system solution down to less than 5 sec per box using the presently developed PC-based palletizing solution. In light of these advancements, a robotic palletizing application becomes an even more attractive solution for every industry that utilizes this type of material handling. An expert-system or rule-based approach was utilized in the development of the palletizing algorithm. These rules have been implemented directly in C language. This permits the system to run on a standard PC, and the code is transportable and expandable. A ¯owchart of the palletizing process is shown in Fig. 3. The overall logic of the expert system is shown in Fig. 4. The palletizing software system begins with system setup. This includes the ®rst system setup in which pallet and box sizes are speci®ed and the bill of lading speci®cation and relationship determination. Then the real time loop is started in which a box is identi®ed, and a search for an acceptable space is initiated. If an appropriate space is found, the co-ordi-

Figure 3


nates are communicated to the robot and the space storage is updated. This loop continues until all the boxes from the bill of lading are placed. If space cannot be determined for any boxes, they are placed on a queue pallet. At the end of the loop, these boxes can be retrieved and placed on the pallet. Two types of inputs are required for the algorithms. The ®rst is a database of dimensional sizes and content information for the SKUs which are possible within the palletizing material handling stream. A separate eort is required to ®lter this data to ensure that all SKUs can be lifted by the particular robot gripper and placed by an industrial robot. Then, of the SKUs which can be handled, a relational database is prepared which examines spatial relationships, such as the number of boxes of one type that would form a stable base for a given number of boxes of another type. In addition, content-speci®c rules may be determined, such as those related to fragility, crushability, or contamination.

A ¯owchart of the palletizing process.


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Figure 4 The overall logic of the expert system.

The second type of input is a bill of lading for a particular pallet. Orders would be processed separately to determine the number of pallet loads required for the entire order. The main emphasis for this eort was single-pallet load stacking of randomly picked SKU parcels. However, certain picking orders may be preferable and lead to faster stacking or better quality pallets. A third type of input that could be used is a pallet database. The output of the software is the box locations for a pallet stacking arrangement. This arrangement satis®es all the rules built into the system and therefore gives an ecient pallet load. Measures of pallet quality, such as percentage utilization of the available cubic space, location of the three-dimensional centroid, etc., can be easily computed from the information available. The output ®le, with appropriate calibration and translation of co-ordinates, could give placement positions to a palletizing robot for each parcel on the pallet. The quality of the expert system pallet load is not `òptimum'' but rather `àcceptable'' quality, since it satis®es all the rules.


4.3.1

Establishing Set Relations

The set formation process, in which two boxes of type A are related to one box of type B in a length±width orientation, is shown in Fig. 5. Searching for box size combinations that form a stable base within the pallet size constraint forms relations. Note: in this section, C language code will be displayed in italics. In the algorithm; the sRelat function is called from Main by passing the variable numBoxTypes. This variable is used to determine the number of iterations to be used in the For loops which are used to compare dierent box types, scaled dimensions to form valid sets. A set relation is de®ned between two box types, in this case box1 and box2, which can be either of the same or dierent types. If one or more boxes of box1 forms the bottom layer of the set, then this bottom layer forms a stable base for the top layer comprising one or more boxes of box2. The type box1 always forms the bottom layer, and the type box2 always forms the top layer in a given set. The top layer can be either equal or one

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Figure 5 The set formation process in which two boxes of type A are related to one box of type B in a length±width orientation.

scaled-down unit smaller than the bottom layer along the length or width. A set is valid when sucient quantities of both box1 and box2 types are available, and the set dimensions, de®ned as setLength and setWidth, are such that the setLength does not exceed the scaled pallet length (SPL), and the setWidth does not exceed the scaled pallet width (SPW). Since the code requires many For loops and If statements, to avoid confusion, only the coded used to form these sets will be discussed. Each valid set is stored in the data structure sets_t. All the sets formed are stored in an array of structures, Sets[ ]. The size of this array is de®ned in the header ®le. struct sets_t{ char box1; char box2; char b1inLength; char b1inWidth; char b2inLength; char b2inWidth; char orient; char setLength; char setWidth; }; struct sets_tSets[MAX_SETS];


In the sets_t structure, the variable b1inLength is the number of boxes of type box1 arranged along the setLength and b1inwidth is the number of boxes of type box1 arranged along the setWidth. Similarly, the variables b2inLength and b2inWidth are for type box2. In a set, the length of box1 is always parallel to the setLength, and the length of box2 may be parallel or perpendicular to the setLength. If length of box2 is parallel to setLength, then the variable orient is de®ned as ORIENT_LL. Otherwise, if box2 is perpendicular to setLength, then orient is de®ned as ORIENT_LW.

4.3.2

Search for Space

When a box is identi®ed, a search for set relationships and quantities is made. If a set relationships is found with another box type and sucient boxes of that type are in the bill of lading; then the box is placed, and space is reserved for the new box type. Up to this point, a framework has been constructed which will allow for the necessary user input that will enable the palletizing software to perform.


4.3.3

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System Simulation and Performance

The results of this search are displayed as an output ®le showing box position, as shown in Fig. 6, or by an equivalent graphical output, as shown in Fig. 7. This type of output is very eective for displaying database information in a more visually pleasing and interactive form. Having both a box database and a pallet database linked to the interface also gives the user an inventory tool for the entire palletizing operation of a given distribution center/ warehouse. Several versions of the palletizing system have now been designed and constructed. A typical solution is shown in Fig. 8. The gripper is designed to lift the parcels that would be encountered in the application. The robot is selected to handle both the static load (weight) and the dynamic load of the parcels in motion. It must also have a sucient reach to accommodate the pallets in the workcell. The operator can view both the simulation and actual box placement. In normal operation no operator is required.

Figure 7 Equivalent graphical output of the search for space.

Figure 8

4.4 4.4.1

Figure 6 Results of the search for space displayed as an output ®le showing box position.


Motoman robotic palletizing system.

FUTURE RESEARCH ON ALGORITHMS FOR PALLETIZING Expert-System Improvement

The expert-system approach has led to a solution that is practical and robust. Further rules may always be included and improvements in computer technology easily added.

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4.4.2

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Fuzzy Logic Approach

Fuzzy logic has received considerable attention since its introduction by Zadeh in 1965 [30]. This fundamental concept involves generalizing the traditional membership function of an element from a set of binary values {0, 1} to continuous values on the interval [0, 1]. The fuzzy logic method seems appropriate for modeling several decisions encountered in palletizing. For example, in parcel placement, the amount of space used by each parcel may be modeled by a fuzzy membership function related to the volume ®lled by the parcel. In addition, the degree that a parcel is loaded also may be modeled by a continuous membership function. Finally, the degree of fragility of a parcel may be considered as a fuzzy set function. To apply fuzzy logic to palletizing, the heuristic rules could be formulated in terms of imprecise propositions as well as speci®cations of the domains and ranges. The rules for palletizing would then be implemented using fuzzy logic. Measuring the load quality would then be performed and used to evaluate the fuzzy rules. A promising combination of fuzzy logic and expert systems has been studied by Ralescu [31], and another interesting approach proposes the use of neural networks for computations of fuzzy logic inferences [32]. 4.4.3

Neural Networks

Several faculties of neural networks make them attractive as an approach to the palletizing problem. One attractive property is the ability of a neural network to derive solutions to problems that involve ``combinatorial explosion,'' and exponential increase in the number of possible answers. This ability was demonstrated by John Hop®eld and David Tank [33] for the classic traveling salesman problem. For the palletizing problem, a three-dimensional array of parcels on a pallet could be used as the input with the requirements of a ``good'' pallet as the output. Various pallet con®gurations could be simulated from the test data to obtain a training set. Several neural network programs such as the backpropagation algorithm are available, which could be trained on the test data and tested on independent data. Arti®cial neural networks (ANNs) are multilayered information processing structures consisting of large numbers of simple elements that process information in parallel [34]. These structures possess the ability to learn, associate, and generalize without rules. Arti®cial


neural networks have been used to classify sonar data, speech, and handwriting. They have also been used to predict ®nancial trends, to evaluate personnel data, to control robot arms, to model cognitive phenomena, and to superimpose geometrical regions. Several model ANNs have been proposed that have three things in common: 1. 2. 3.

Distributed processing elements, or neurons The connections between processing elements. The rules of learning.

Arti®cial neural networks learn by adapting to changes in input data as the network gains experience. This learning may be categorized as supervised or unsupervised. In unsupervised learning, such as in the Kohonen net that will be discussed later, the ANN constructs internal models that capture regularities in input data. The most well-known supervised learning rules are Hebb's rule and the delta rule. Hebb theorized that biological associative memory lies in the synaptic connections between nerve cells, and that the process of learning and memory storage involved changes in the strength with which nerve signals are transmitted across individual synapses. The delta rule is a modi®cation of Hebb's rule, stating that if there is a dierence between actual output and the desired output, then the weights are adjusted to reduce the dierence. Using the above discussion of ANN adaptive learning, we can consider several model ANNs that seem to relate to the palletizing problem. Some particularly useful models include the Hop®eld net, the single layer perceptron net, the multilayered perceptron net, and Kohonen's self-organizing feature-map forming net. Each of these will be brie¯y described. 4.4.3.1 Hop®eld The Hop®eld net is primarily used with binary input. These nets are more useful when exact binary representations are possible as with ASCII text, where input values represent bits in the 8-bit ASCII of each character. However, these nets are less appropriate when input values are continuous because a fundamental representation problem must be addressed to convert the analog quantities to binary values. The Hop®eld net may be used as an associative memory tool to solve optimization problems. It can also be used on problems where inputs are generated by selecting exemplar and reversing bit values randomly and independently with a given probability.


4.4.3.2

Single-Layer Perceptron

The single-layer perceptron can be used with both continuous and binary inputs. This simple net aroused much interest when it was initially developed because of its ability to learn to recognize simple patterns. The original perceptron convergence procedure was developed by Rosenblatt [35]. In this procedure, a perceptron decides whether input belongs to one of two classes by computing the weighted sum of the input elements and subtracting a threshold. The result is passed through a nonlinearity function so that the output is either A 1 or A 1. The decision rule is used to classify the output into one of the two classes. Connection weights and the threshold in a perceptron can be ®xed or adapted depending on the algorithm. First connection weights and the threshold values are initialized to small random nonzero values. Then the new input with N continuous valued elements is applied to the input and the output is computed. 4.4.3.3

Multilayer Perceptrons

Multilayer perceptrons are nets where there are one or more layers of nodes between the input and output nodes, where these additional hidden nodes are not directly connected to both the input and output nodes. The strengths of multilayer perceptrons stem from the nonlinearity within the nodes. If nodes were linear elements, then a single-layer perceptron with appropriate weights could exactly duplicate the calculations performed by any multilayer net. Although multilayer perceptrons overcome many of the limitations of the single layer perceptrons, they were generally not used in the past because eective training algorithms were not available. Recently, this has been changed with the development of a new algorithm. Although it cannot be proven that these algorithms converge as the single-layer perceptrons do, they have been showm to be successful in many problems. An interesting theorem that explains some of the capabilities of multilayer perceptrons was developed and proven by Kolmogorov. This theorem states that any continuous function of N variables can be computed using only linear summations and nonlinear, but continuously increasing, functions of only one variable. It also demonstrates that a threelayer perceptron with N 2N1 nodes with continuously increasing nonlinearity can compute any continuous function of N variables.


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4.4.3.4

Kohonen Self-Organizing Feature Maps

One important organizing principle of sensory pathways in the brain is that the placement of neurons is orderly and often re¯ects some physical characteristics of the external stimulus being sensed. For example, at each level of the auditory pathway, nerve cells are arranged in relation to the frequency that elicits the greatest response in each neuron, and this organization of the auditory pathway extends up to the auditory cortex. Some of the organization is created during learning by algorithms that promote self organization. Kohonen presents one such algorithm which produces what he calls self-organizing feature maps similar to those that occur in the brain. Kohonen's algorithm creates a vector quantizer by adjusting weights from common input nodes to M output nodes arranged in a two dimensional plane. Output nodes are highly linked by many local connections. Continuous input vectors are presented sequentially in time without specifying the desired output. These input vectors naturally form clusters with weights that specify the center of the vector clusters, de®ning the input space. After enough input vectors have been presented, the point density function of the vector center of the clusters tends to approximate the probability density function of the input vector. In addition, the weights will be organized such that close nodes are sensitive to inputs that are physically similar. Output nodes will thus be ordered in a natural manner. This type of ordering may be important in complex systems with many layers of processing, since it can reduce lengths of interlayer connections. Kohonen [36] presents examples and proofs related to this algorithm. He also demonstrates how the algorithm can be used as a vector quantizer in a speech recognizer. The algorithm does perform relatively well in noisy systems. Since the number of classes is ®xed, weights adapt slowly, and adaptation stops after training. Therefore, this algorithm is a viable sequential vector quantizer when the number of clusters desired can be speci®ed before use, and the amount of training data is large relative to the number of clusters desired. To apply neural network methods to the palletization problem, we start with the concept of a stable load. For a training set, parcels can be arranged in both stable and unstable stacking arrangements. Several algorithms such as the bidirectional associative memory [37], neocongnitron [38], adaptive resonant theory [39], Boltzmann and Cauchy [40], counterpropagation networks [41], and others have been studied by Hall and his students over the past several years. In

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many cases, both software and hardware implementations are available for this research. 4.4.4

New Architectures

Even though expert-system, fuzzy logic, and neural network approaches may be investigated and tested separately, it is possible that a new architecture or combination of these approaches will be discovered with further research. In fact, a neural network may be found to be superior for low-level decisions, while a fuzzy logic expert system may be superior for higherlevel decisions. 4.5

CONCLUSIONS AND RECOMMENDATIONS

An introduction to robotic palletizing for parcels handling has been considered. Human palletizing is still commonly used even though cumulative trauma injuries may result. Robotic palletizing is similar to stock cutting, chess, and other NP-complete problems for which only an exhaustive search leads to an optimal solution. The expert-system approach that implements many rules seems ideal for this problem. Rules based upon relationships between the items being placed on the pallet provide useful guidance for parcel placement. Other rules regarding toxicity, crushability, fragility, etc. can also be implemented. Other arti®cial approaches such as fuzzy logic and neural networks and new combinations are also brie¯y considered. Although the expert system solution is robust, other methods could lead to new solutions. REFERENCES 1. KF Bloemer. A conceptual design for order pick and palletizing with robot palletizing vehicles. PhD dissertation, University of Cincinnati, 1992, p. 19. 2. HJ Steudel. Generating pallet loading patterns: a special case of the two-dimensional cutting stock problem. Manag Sci 25(10): 997±1004, 1979. 3. AP Smith, P DeCani. An algorithm to optimize the layout of boxes in pallets. J Oper Res Soc 31(7): 573± 578, 1980. 4. JM Apple. Material Handling System Design. New York: Roland Press, 1972. 5. K. Dowsland. The three dimensional pallet chart: an analysis of the factors aecting the sett of feasible layouts for a class of two-dimensional packing problems. J Operat Res Soc 35(10): 895±905, 1984.


6. F Puls, J Tanchoco. Robotic implementation of pallet loading patterns. Int J Prod Res 24(3): 635±645, 1986. 7. H Carpenter, W Dowsland. Practical considerations of the pallet loading problem. J Operat Res Soc 36(6): 489±497, 1985. 8. K. Dowsland. Ecient automated pallet loading. Eur J Operat Res 44(2): 232±238, 1990. 9. A Gupta. Operations research models for design of palletization. J Inst Eng India) 57(ME 4): 183±185, 1977. 10. S Basse. Computer algorithms, introduction to design and analysis. Addison-Wesley Publishing, 1978, pp Reading, MA: pp. 268±271. 11. P Gilmore, R Gomory. A linear programming approach to the cutting stock problem. Operat Res 9(6): 849, 1961. 12. PC Gilmore, RE Gomory. Multistage cutting stock problems of two and more dimensions. Operat Res 113: 94±120, 1965. 13. JC Hertz. Recursive computational procedure for twodimensional stock cutting. IBM J Res Develop 16(5): 462±469, 1977. 14. N Christo®des, C Whitlock. An algorithm for twodimensional cutting problems. Operat Res 25(1): 30± 44, 1977. 15. T Hodgson, A combined approach to the pallet loading problem. IIE Trans 14(3): 175±182, 1982. 16. H Carlo, L. Hodgson, L Martin-Vega, E Stern. MicroIPLS: pallet loading on a microcomputer. Computers Indust Eng 9(1): 29±34, 1985. 17. A Albano, R Orsini. A heuristic solution of the rectangular cutting stock problem. Computer J 23(4): 1980. 18. J George, D Robinson. A heuristic for packing boxes into a container. Computers Operat Res 7: 147±156, 1980. 19. AK Mazouz. Expert system for control of ¯exible palletizing cell for mixed size and weight parcels. PhD dissertation, University of Cincinnati, Cincannati, OH, 1987. 20. EL Hall, GD Slutzky, AK Mazouz. A ®nal report, development and demonstration of robotic palletizing of mixed size and weight parcels for the Institute of Advanced Manufacturing Sciences, May 1987. 21. AK Mazouz, RL Shell, EL Hall. Expert system for ¯exible palletizing of mixed size and weight parcels. SPIE vol 848, Conference on Intelligent Robots and Computer Vision, Cambridge, MA, Nov 1±6, 1987, pp. 556±563. 22. J Gilmore, S Williams, E. Soniat du Fossat, R Bohlander, G Elling. An expert system approach to palletizing unequal sized containers. SPIE vol 1095, Applications of Arti®cial Intelligence VII, 1989, pp 933±942. 23. EE Witte, RD Chamberlain, MA Franklin. Task Assignment by Parallel Simulated Annealing. Procceedings of 1990 International Conference on Computer Design, Oct 1990.

Robotic Palletizing of Parcels 24. J Kinoshita, NG Palevsky, Computing with neural networks. High Technol May: 24±31, 1987. 25. B Bavarian, Introduction to neural networks. Course Notes IEEE International Conference on Robotics and Automation, May 13±18, 1990. 26. D Redmond-Pyle, A Moore. Graphical User Interface Design and Evaluation (Guide): A Practical Process. New York: Prentice-Hall, 1995, 2. 27. A Marcus, N Smilonich, L Thompson. The Cross-GUI Handbook For Multiplatform User Interface Design. Reading, MA: Addison-Wesley, 1995, p vii. 28. T Langley. A graphical user interface for a robotic palletizing application. MS thesis, University of Cincinnati, 1996. 29. H Agha. Robotic palletizing algorithms for mixed size parcels. MS thesis, University of Cincinnati, 2000. 30. L Zadeh. Fuzzy sets. Inform Control 8: 338±353, 1965. 31. AL Ralescu. Meta-level expert system design. ACM Fuzzy Logic Conference, OUCC, Oct 1989. 32. JM Keller, RR Yager, Fuzzy logic inference neural networks. Proceedings of SPIE, vol 1192, Intelligent Robots and Computer Vision VIII, 1989, pp 582±587.


687 33. DW Tank, JJ Hop®eld. Collective computation in neuronlike circuits. Scient Am July: 104±114, 1987. 34. JJ Hop®eld. Neural networks and physical systems with emergent collective computational abilities. Proc Nat Acad Sci USA, 79: 2554±2558, 1982. 35. F Rosenblatt. Principles of Neurodynamics. New York: Spartan, 1962. 36. T. Kohonen. Self-Organization and Associative Memory. Springer-Verlag, Berlin, 1984. 37. B Kosko. Bidirectional associative memories. IEEE Trans Syst Man Cybern 18(1): 49±60, 1988. 38. K Fukushima, S Miyake. Neocognitron: A New Algorithm for Pattern Recognition Tolerant of Deformation and Shifts in Position. Pattern Recognition 15(6): 455±469, 1982. 39. G Carpenter, S Grossberg, ART2: Self-organization of stable category recognition codes or analog input patterns. Appl Optics 26(23), 4919±4939, 1987. 40. GE Hinton, TJ Sejnowski. Learning and relearning in Boltzmann machines. In: Parallel Distributed Processing, vol 1 Cambridge, MA: MIT Press, 1986, pp. 282±317. 41. PP Wasserman, Neural Computing, Theory and Practice. New York: Van Nostrand Reinhold, 1989.

Chapter 8.1 Investigation Programs Ludwig Benner, Jr.

Events Analysis, Inc., Alexandria, Virginia

1.1

INTRODUCTION

1.2

This chapter describes what an investigation program is, what it should accomplish for an organization, how it should be created, and what investigators should do within that framework. It presents investigation fundamentals in a way that enables everyone in an organization to tailor the ideas so they satisfy their speci®c investigation needs. It includes models to help investigators during investigations, and references providing detailed guidance for program designers and investigators. Accidents involving automated systems occur infrequently. However, many kinds of investigations are conducted in organizations using automated systems. Supervisors, mechanics, engineers, labor representatives, claims adjusters, safety sta, and others investigate claims, operational disruptions, equipment breakdowns, accidents, ®res, injuries, outages, quality deviations, environmental insults, and other unexpected or undesired occurrences. Each type of investigation has many common tasks. These commonalties are masked by thinking about each kind of investigation as unique. In this fragmented environment nobody looks for the commonalties, or opportunities that co-ordinated thinking about all investigations might oer. Thus potential improvements in investigation programs are overlooked. This chapter addresses that oversight. It describes the overlooked opportunities and how to establish a program to take advantage of them.

An investigation program is an organization's ongoing structured activity to investigate unintended or unexpected and unwanted occurrences. This section describes the context in which such a program exists and functions, the role of the program in a dynamic organization, the nature of occurrences and investigations and the conceptual basis for an investigation program. The context provides the background that explains what an investigation program should accomplish, and what an organization should demand of an investigation program. The discussion of the role describes the relationship of an investigation program to other organizational activities. The discussion of the nature of occurrences and investigations describes useful ways to think about them within an organization. The discussion of the knowledge needed to do investigations describes essential investigation concepts and principles needed to produce the desired results

1.2.1

Investigation Program Context

Investigations take place within an organizational context and a regulatory context. The organizational context should dominate investigation programs, but must accommodate the regulatory environment. 689


WHAT IS AN INVESTIGATION PROGRAM?

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1.2.1.1

Benner

Organizational Context

Nobody likes unpleasant surprises. Progressive managers view an investigation program broadly as a set of continuing activities designed to understand, predict, and control or prevent unpleasant and unwanted ``surprises'' in operations. These surprises include many kinds of occurrences, such as injuries, accidents, ®res, breakdowns, outages or delays, environmental insults, operational disruptions, claims, or other kinds of undesired events. Surprises re¯ect deviations from expected or intended or hoped-for performance, interfering with desired outcomes. The fundamental mission of a comprehensive investigation program is to improve future performance by thoroughly understanding and acting on past occurrences of all kinds. Recurring unpleasant surprises are in indication, in part, of investigation program shortcomings or failures, or possibly the lack of a competent investigation program. 1.2.1.2

Regulatory Context

In addition to an organization's internal interests, certain regulatory requirements aect the investigation context in most organizations employing or supplying automated systems. Most employers are subject to occupational safety and health regulations, which include investigation program requirements [1]. Brie¯y summarized, regulations require that: 1. 2.

3.

4.

All accidents should be investigated. Accidents involving fatalities or hospitalization of ®ve or more employees be investigated to determine casual factors involved and that on scene evidence be left untouched until agency inspectors can examine it. Any information or evidence uncovered during accident investigations which would be of bene®t in developing a new regulatory standard or in modifying or revoking an existing standard be promptly transmitted to the agency. The investigative report of the accident shall include appropriate documentation on date, time, location, description of operations, description of accident, photographs, interviews of employees and witnesses, measurements, and other pertinent information, be distributed to certain people, and made available to an agency representative. The regulation does not specify explicitly the purpose of required investigations, but a standards development purpose is implied.


1.2.2

Investigation Roles

The basic functional role of investigations of all kinds is to develop a basis for and report on future action to improve future performance. The basis for action must always be a valid description and explanation of occurrences, developed promptly, eciently, objectively, and consistently. This requires investigators to document their description and explanation, reporting them in a way that enables managers and others to understand, accept, and want to act on this new information. Investigations should assure discovery and de®nition of problems or needs that require action, and of actions for addressing them. They should also provide a way to assess whether the changes introduced actually improved future performance. Investigations should also validate predictive analyses and design decisions. If these basic needs are satis®ed, opportunities for additional bene®ts can be realized. Investigators ®rst look backward in time to determine and explain what happened. When they understand that, they must look forward in time to identify changes that will improve future performance. To ful®ll their role, investigations must be perceived by all aected as desirable, valuable and helpful, rather than judgmental, threatening, punitive, vengeful, or accusatory. To achieve best long term results, the tone of the investigation program must encourage co-operation and support. 1.2.2.1 Desired Roles for Investigations Competently designed and implemented investigation programs should report new understanding of occurrences in ways that help: Reduce future surprises which interfere with desired outputs. Resolve claims and disputes. Satisfy regulatory requirements. They also have the potential to: Reduce resource needs by revealing potential process improvements. Enhance employee capability and morale with constructive work products. Reduce exposure to litigation. Provide a way to audit analyses of planned functions. Predict changes to in¯uence future risks. Identify shifting norms and parameters in operations.

Investigation Programs

Contribute to the organization's long term corporate memory. One other potential role requires an executive decision. The choice is whether or not to use investigations to assess installed safety and reliability systems and their performance. Audits require special criteria and audit methods, and additional data, so it is advisable to conduct program audits as stand-alone activities rather than an element of investigations. 1.2.2.2

Traditional Views of Investigation Role

That view diers from the regulatory view of the role of investigations. Traditional investigation perceptions and assumptions in industrial settings focus narrowly on accident investigations, failures, unsafe acts and conditions, basic, direct and indirect accident causes, and compliance. That focus does not address or satisfy many internal needs, and limits opportunities for broader achievements. The Federal agency regulating industrial robotics safety, for example, views investigations as an element of a safety program rather than a part of a broad organizational performance improvement program. In its view investigations have a narrow goal of preventing similar accidents and incidents in the future. It holds that ``thousands of accidents occur throughout the United States every day, and that the failure of people, equipment, supplies, or surroundings to behave or react as expected causes most of the accidents. Accident investigations determine how and why these failures occur'' [2]. Note the negative tone of this ``failure'' and cause-oriented perspective. The agency's demands of investigations are also narrow. ``By using the information gained through an investigation, a similar or perhaps more disastrous accident may be prevented. Conduct accident investigations with accident prevention in mind'' (emphasis added) [2]. The loss or harm threshold, rather than the surprise nature of the occurrence, narrows the ®eld of candidates for investigation. The authority to impose penalties also in¯uences the agency's perception of investigations, and the procedures it must follow. When it becomes involved in investigations, operating organizations must recognize and adapt to the regulatory agency's perspectives. In summary, the role of an investigation program should be constructive, designed to develop new knowledge to support a broad range of future actions in an organization, and produce timely, ecient, objective and consistent outputs.


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1.2.3

Nature of Investigation Processes

To investigate something is to examine it systematically. Any investigation should be a systematic examination process. The investigation process focuses on examining the people and objects involved in the occurrence, and everything they did that was necessary and sucient to produce the process outcome that prompted the investigation. Investigations involve many tasks. Most share many common investigation tasks and tools. For example, in every investigation the investigator must: Make observations of people and objects involved in the occurrence. Acquire, structure, document, and organize data about their interactions. Discover, de®ne, and describe what people and objects had to do to produce the outcomes. Apply logic to action data to de®ne cause-eect linkages. Recognize, de®ne, and act on unknowns, and frame questions to pose. Diagnose objectively what happened to de®ne needs for change and candidate changes. Evaluate needs and propose actions, with ways to monitor their success. Prepare valid and persuasive investigation work products. Mediate diering views. The speci®c nature of each task and level of eort required of the investigator dier in nature depending on the kind and level of investigation required. For example, the degree of eort required to prepare an incident report form is the least complex, and may be considered the lowest level of investigation (Level 1). The nature of that investigation is to gather data needed to complete a reporting form. That need is usually satis®ed by sequencing whatever data can be acquired in a relatively brief time. Note that the data collected on forms are analyzed later by accident or claims analysts. This may mean that several similar incidents must occur before sucient data for some analysis methods is available. A slightly greater eort and more tasks are required to complete a logically sequenced and tested narrative description of what happened, or Level 2 investigation. This level requires the investigator to do some logical analysis tasks as the data are gathered. For example, understanding equipment breakdowns requires this kind of eort.

692

Benner

When the description of what happened must be expanded to include carefully developed explanations, a greater level of investigation is required. Level 3 investigations may involve teams, and additional analytical and testing tasks to validate the explanation and assure adequate objectivity and quality. This level is required for matters that might be involved in litigation or compliance actions, or contractual disputes over equipment performance or warranty claims. If recommendations for actions to improve future performance are required of an investigator, the investigator must do additional forward-looking data gathering and dierent analytical tasks. Level 4 investigations are the most complex and demanding and usually involve an investigation team. They should be required for any major casualty, or facility or design changes driven by undesired occurrences. Thus the nature of an investigation and the knowledge and skills required to do them is dependent on the expected investigation level and outputs. The nature of an investigation is also partially dependent on the number of investigating organizations conducting investigations of the same occurrence. The tasks where interactions occur should be reviewed with organizations which might be involved in investigations. For example, whenever fatal injuries occur, an incident might involve investigators from organizations such as a local law enforcement agency or medical examiner, a state or federal regulatory authority, an insurance representative, and an organizational team. The authority and actions of those ocials should be identi®ed before an occurrence, and general agreement reached about who would do what in an investigation. When law enforcement or regulatory investigators are involved, their interests include access to witnesses and property, and preservation of evidence until an investigation has been completed [1]. Legal rights also may aect the nature of the investigation. These interactions are complex, but planning helps everyone work together when required.

Frequently those assumptions and ideas have contributed to the occurrence. Expert investigators avoid that trap by applying their investigation knowledge and skills. During the investigation process, investigators use investigation tools to determine, describe, and explain what happened. Sometimes they need expert help to acquire or interpret data they need from objects involved in the occurrence. These data can be acquired with the help of others by knowing how to identify the expertise needed, and how to frame the right questions for those experts. Typically, such experts have expert knowledge and experience in some specialized ®eld of the physical sciences, and can interpret what actions were required to produce the observed postoccurrence states. Their outputs must support the investigator's concrete needs. To discover and de®ne needs indicated by the occurrence, investigators require data about how a speci®c system was intended or expected to function in its daily environment. Expert investigators get such system data from people with system knowledge, either directly or from their work products. Those system experts have knowledge of a speci®c system's design, manufacture, testing, programming, operational behavior, safety or failure analyses, maintenance, or other system support activities.

1.2.4

1.2.5.1 Investigation Concepts

Investigation Knowledge Needs

Performance of investigation tasks requires knowledge about investigation concepts, principles and practices, and skills in applying that knowledge. Investigation knowledge is not the same as knowledge about automated or robotics systems. Every automated system expert is not intuitively an automated system investigation expert. Additionally, system experts tend to unconsciously accept assumptions and ideas on which their decisions about the system are structured.


1.2.5

Investigation Task Knowledge

Study of investigation processes has disclosed that, to be eective, investigation process tasks must be disciplined, objective, timely, ecient, and logical, and produce demonstrably valid, credible, and readily useful outputs. Special investigation knowledge investigators need to perform their investigation tasks adequately includes fundamental investigation concepts, principles, and procedures. They must incorporate this knowledge into investigation program plans for all kinds of investigations.

Concepts about occurrences and investigations guide how investigators think about what they are investigating, and what they do during an investigation [3]. Concepts needed by investigators to produce quality work products include: A multilinear conceptual framework. The role of change in occurrences. An investigation data language. Mental movies


Progressive analyses Break down events Energy tracing Event pairing Event linking Investigation quality assurance. Multilinear Conceptual Framework. What is the general nature of occurrences to be investigated? Research has identi®ed at least ®ve different perceptions of unintended and unexpected occurrences [4]. Each perception results in a different framework or model that drives what investigators think and do during investigations. The most helpful perception of occurrences or framework for investigators is the ``multilinear'' events sequences concept [5a]. This framework views occurrences as a process, during which people and objects act, concurrently and in sequence, to produce successive changes resulting in the outcomes of interest. Relative timing of events in this multilinear framework is often essential to understanding and explaining what happened. The framework leads investigators to focus on developing descriptions and explanations of process interactions that produced the outcomes of interest.

693

Other perceptions of the nature of occurrences are often encountered. A linear ``chain of events'' perception of occurrences such as accidents has long been the most popular in lay circles and the legal community. It relies on experts to identify a chain of unsafe acts and conditions and accident causes ``leading to the accident'' or incident. Typically, it results in subjectively developed, investigator-dependent, judgment-laden and frequently controversial investigation work products. The stochastic perception is similarly investigator or analyst dependent. The tree perception is more disciplined, and helps to organize data, but lacks criteria for selecting top events and a data language, does not accommodate relative event timing and duration considerations, or show interactions among concurrent events readily. The ®ve major perceptions are illustrated in Fig. 1. Role of Change in Occurrences. The role of change in surprise occurrences and their analysis was de®ned by Johnson during research leading to the MORT safety assurance system [6]. He pointed out the congruence between change control and accidents, and the importance of examining changes during investigations.

Figure 1 Perceptions of accidents: the ®ve ways investigators perceive the nature of the accident phenomenon. Each perception in¯uences what investigators think and do during investigations. (From Accident Investigation: Safety's Hidden Defect. Oakton, VA: Ludwig Benner & Associates, 1981.)


694

During the operation of a process, people or objects act on other people or objects to produce cascading changes, with resultant outputs or outcomes. When desired outputs result, change produces progress. When undesired or unintended outputs result, change produces trouble. The change concept facilitates investigations by providing a focus for investigators' data searches: look for the changes required to produce the outcome. When people act during a process, they act to produce an intended change, to adapt to an unanticipated change to sustain the process, or to arrest undesired cascading changes. For example, if a robotic device needs adjustment, a programmer acts to reprogram the device. If a robotics device suddenly activates during maintenance, the repairman might either adapt by trying to avoid the moving parts, or arrest the progression by activating the emergency `ò '' control. A useful aspect of change is the concept of change signals. The signal emitted by a change has consequences for investigators. For example, if the signal emitted is not detectable or detected too late, the opportunities for an adaptive response by either people or objects are foreclosed. If it is detectable, it must be detected before an adaptive response is mounted. This general adaptive subprocess has been modeled from observations during investigations (see Appendix A). Event Data Language. Investigation data language is the language structure and terms investigators use to document, analyze, describe, and explain an occurrence. To be consistent with the process framework for occurrences, the investigation data language must be able to describe and report what people and objects did to advance the undesired process toward its outcome. The data language structure used by investigators determines what they can do during an investigation. A structure that facilitates the veri®able reporting of what happened and why it happened is needed. A structure and terms that undermine veri®able reporting are not helpful. The structure should encourage investigators to focus their observations on ®nding and documenting data that de®ne and permit the value-free reporting of what the people and objects did during the occurrence. It should steer investigators to veri®able terms, and away from terms with built-in judgments or unsupported inferences which stop thought. The data language structure and terms that best satisfy these demands are the actor±action structure and event-related terms. The structure is simple:


Benner

one actor one action one event. That is the foundation for the ``think events'' guidance encouraging investigators to structure their investigation thought processes. It employs the de®nitive power of the grammatical active voice, facilitating the visualization of speci®c people or objects. This `àctor action''based structure, or `èvent'' structure, makes possible the most economical acquisition and ordering of data. It facilitates the most concrete descriptions of what happened, the most practical approach to systematic problem discovery and remedial action selection, the implementation of objective quality controls, and timely results. The actor action language structure helps guide other tasks, such as facilitating visualization of what happened, rather than impeding visualization of what happened. It should be used while interviewing witnesses, photographing ending states of objects, or designing damaged-equipment test protocols. Documenting data with abstract, ambiguous or equivocal terms does not oer such guidance. It is important to note that conditions are the result of actions by someone or something. Improving future performance requires a change in behavior of people or objects. A condition cannot be changed without changing the behavior of someone or something that created the condition. Thus, investigators should focus on the actor action data language during investigations, and use observed conditions as a basis to infer the actions that produced them. During investigations, investigators' major challenge is transforming their observations and all other information they acquire into a common format to give them building blocks for creating their description and explanation of what happened. This task is not intuitive. Further, it con¯icts with daily language experiences. The challenge is to recast all kinds of data from all kinds of sources into a basic common format suitable for documentation, analysis, testing, reporting, and dissemination. That challenge is depicted in Fig. 2. The exact attributes of event building blocks depend on the choice of investigation process adopted by an organization. The most basic form of event building blocks (Fig. 3) contains the following information: Actor is any person or any object that initiates a change of state during the process required to produce the outcome achieved by the occurrence. An actor has only one name. Ambiguous, compound, group, or plural names will corrupt the investigation and are unacceptable.


Figure 2 The investigator's data transformation challenge. The investigator must transform all kinds of data from all sources into the investigation data language format needed to describe what happened. (From 10 MES Investigation Guides. Guide 1, MES Event Building Blocks. Oakton, VA: Ludwig Benner & Associates, 1998, p. 6.)

Action is one speci®c act which aected another actor or action and helped initiate or sustain the process that produced the outcome of the occurrence. Descriptor is used to expand the description of what the actor did, to describe what the actor acted on, or otherwise to de®ne the act so it is uniquely described, can be visualized, and then can be related to other events. Source is the source of the data from which the event block was formulated, noted so it can be referenced as needed to verify the event. For more complex investigations or investigations requiring clear documentation of source data and veri-

695

Figure 3 Minimum event building block elements. This is the minimum information required to permit investigators to arrange events into their correct sequence as they develop their description of what happened. (Adapted from K Hendrick, L Benner. Investigating Accidents with STEP. New York: Marcel Dekker, 1986, p 128.)

®cation of the reasoning, it is helpful to use more comprehensive building blocks, as shown in Fig. 4. The numbers refer to the sequence in which the contents are typically added. Without a speci®ed data language structure to guide investigators, investigators are likely to use words that can corrupt the investigation or undermine the potential value of an investigation. Corrupting words include ambiguous names or action descriptions, implicit conclusions, and words with built-in judgments. For example, ambiguous names of actors like ``they'' or ``she'' or grouped actors like ``the crew'' or ``the second shift'' can confuse hearers or readers, because they can not visualize who did what without more data. Ambiguous actors re¯ecting inadvertent use of the passive voice grammatically, such as `ìt was decided,'' have the same eect. Investigators often use the passive voice to cover up their incomplete or shoddy investigation or unacknowledged unknowns. Implicit conclu-

Figure 4 Comprehensive event building block. This format is helpful for documenting actions during a complex occurrence, and for investigations which might be used in potentially controversial environments such as claims settlement, arbitration or litigation. (Adapted from K Hendrick, L Benner. Investigating Accidents with STEP. New York: Marcel Dekker, 1986, p 128.)


696

sions may be subtle, and are usually hidden in words like ``did not,'' or ``failed,'' or `ìnadequately.'' They should be avoided, unless the evidence and behavior standard on which the conclusion is based are also clearly de®ned and described. Most corrupting are words with built-in judgments. Descriptions of occurrences should be factual, not judgmental. Frequently the judgments can not be veri®ed, convey false certainty, rouse defensive feelings, mask dierences in understanding, sti¯e thought, and slant viewpoints. For example, once a judgment is made that someone ``failed'' to act, made a ``human error,'' or was `ìnadequately'' prepared, the tone of what follows is setÐto ®nd out what the person did wrong and lay blame on that person. Investigators should view such words as poison words, and avoid them. A review of language pitfalls described in Hayakawa's work [7] is highly recommended. The investigator should strive to report events at the lowest rung on Hayakawa's ladder of abstraction. Conformance to the actor action data structure helps investigators avoid these pitfalls, economize their investigation reporting eorts, and improve investigation eciencies. Mental Movies. A mental movie is a sequence of visualized images of what happened, arrayed in the sequential order and approximate times they happened. Making mental pictures or a ``mental movie'' of what people and objects did enables investigators to cope with new data as the data are acquired. They enable investigators to integrate data gathering and analysis functions. Mental movies serve four important investigation purposes. They force investigators to try to visualize what happened, demand concrete action data, help order the data as they are acquired, and pinpoint what they do not know about the occurrence. The mental movie construction requires investigators to visualize the speci®c actors and actions involved in the occurrence and the eects of their actions on others. As the data acquisition continues, the mental movie framework provides a place to order the actions relative to other data already in hand. When investigators cannot visualize what happened, each ``blank frame'' in the mental movie identi®es unknowns, and the need for speci®c data about the actor or action in the time period involved. Thus blank frames de®ne unknowns and narrow the search for additional data as the investigation progresses. The concept also applies to witness interviews. The investigators' challenge is to transfer the mental movie


Benner

from the witnesses' heads into their heads. This view helps investigators probe for concrete data from witnesses, and ask questions that generate concrete answers. Progressive Analysis. This is the concept of integrating new data into all existing data as each new data item is acquired during the investigation. The reason for using progressive analysis methods is to integrate the data gathering and analysis functions into an ef®cient, effective consolidated task as the investigation progresses. The progressive analysis concept provides a basis for establishing criteria for the selection of the investigation methods. The formulation of mental movies is an informal implementation of this concept. A more formal implementation is the multilinear events sequencing methodology and its ¯ow charting timeevents matrices, or worksheets. Using either method, investigators can achieve very ecient, real-time data gathering and analysis task integration during investigations. The historical approach to investigation has been to gather all the facts, analyze the facts, and then draw conclusions and report ®ndings. This approach results in separately gathering the ``facts'' and subsequently analyzing them to develop conclusions and ®ndings. The approach is widely used by traditional industrial accident investigators, by litigants, and by many public investigation organizations. This process is inecient, time consuming, and prone to overlooking relevant data. Additionally, it is more tolerant of ambiguous and irrelevant data, particularly in investigations with two or more investigators. The identi®cation of relevant data during data gathering tasks is ill de®ned, and objective quality management methods are not usually viable. Break Down Events. Breaking down or decomposing events is an old concept, but understanding how it is done is very important to investigators. When the ``think events'' concept is employed, unclear or grouped actors or actions can be ``broken down'' or decomposed into two or more actors or actions to help investigators understand what happened. One question every investigator faces in each investigation is how long to continue breaking down events. The technical answer is `ìt depends''Ðon the need to understand what happened in sucient detail to be able to reproduce the occurrence with a high degree of con®dence. Alternatively, it may depend on the resources available for the investigation: stop when the allotted time or money is exhausted. Still another


697

answer depends on the quality assurance task needs: stop when quality assurance tasks meet quality assurance criteria, including the degree to which uncertainties or unknowns are tolerated in work products. Event Pairs and Sets. An event pair or event set consists of two or more events, either next to each other in the sequence, or part of a cause±effect relationship. Event pairs or sets provide the foundation for sequencing events disclosed by the investigation data, using temporal and spatial sequencing logic. After the sequential logic is satis®ed, a second application of the concept is to apply cause±effect logic to determine if the events are causally related to each other. After causal relationships are established, application of necessary and suf®cient logic to each related pair or set can be used to determine the completeness of the investigation or description of the occurrence. The event pairing also enables investigators to de®ne gaps in the occurrence description, or any uncertainties associated with those events. That in turn enables investigators to integrate each new data item into the existing event patterns and gaps as data are acquired, as shown in Fig. 5. Event pairs are also used to compare what happened with what was expected to happen, as part of the problem discovery and de®nition investigative subprocess. Another use is for identifying and assessing performance improvement options, and preparing plans for monitoring implementation of new actions. By ``thinking events'' and using progressive analysis methods, investigators can accelerate the investigation and reduce data-gathering burdens. Event Linking. An event link is a representation of a cause±effect relationship between two events. The orderly sequencing of events found during the investigation generates the evolving description of what happened. To understand why events happened, the investigator needs identify and document rigorously and completely the cause±effect relationships among all the relevant the events. This task rests on the

Figure 5 Sequencing new events. As new data de®ning event A2 become available, the investigator can assure its proper sequencing by determining where it should be placed on the time±actor matrix relative to other known events. (From K Hendrick, L Benner. Investigating Accidents with STEP. New York: Marcel Dekker, 1986, p 135.)

event linking concept. In practice, links are arrows on documents showing the cause±effect relationships between the earlier and later events. By convention, links lead from the triggering event to the triggered event. To establish links, the investigator considers each potentially relevant event in pairs or sets, to decide whether or not they have a cause±eect relationship. If one had to occur to produce the other, the investigator links the events to document that relationship. If the causal relationship is not direct but through another event, that third event (or a ``?'') is added to the set. If the original events in the pair have no cause± eect relationship, no link is added, and one or both of the unlinked events may be irrelevant (Fig. 6). The linking concept provides a way to display logical cause±eect relationships for each event that is identi®ed. It also provides a way, with the question marks, to: Progressively incorporate relevant events into the description of the occurrence as each is acquired. Identify completed data acquisition tasks. Identify un®nished investigation tasks.

Figure 6 Linked events sets. Set 1 represents two events with a direct cause±effect relationship. Set 2 represents three events (A1, A2, A3) that will produce B1 every time they occur. Set 3 represents one event that will lead to three other events. Set 4 represents two events for which a causal relationship may exist. The ``?'' represents an un®nished investigation task. (From 10 MES Investigation Guides, Guide 2, Worksheets. Oakton, VA: Ludwig Benner & Associates, 1998, p 4.)


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De®ne speci®c remaining data needs and acquisition tasks or workload. Control expenditures of more time or money to get missing data. Filter irrelevant or unlinked data from work products. Show users uncertainties or unknowns at the end of an investigation. An ideal investigation will produce a description of the occurrence that consists of all interacting or linked events, and only those which were necessary and sucient to produce the outcomes. Anything less indicates an incomplete description of the occurrence. Anything more will almost certainly raise unnecessary questions. Energy Tracing. This concept is also based on Johnson's MORT safety research [6]. His point was that energy is directed by barriers to do desired work. When barriers do not successfully direct the energy to its work target, the energy can do harm to vulnerable targets. These events are part of the automated system or robotics accident or incident process. Energy produces the changes investigators see in objects or people. Tracing energy paths and ¯ows to ®nd what produced the observed changes helps investigators explain ``how did what you see come to be?'' Energy ¯ows leave tracks of varying duration. To trace energy ¯ows the investigator's challenge is to ®nd those tracks or changes that resulted from the energy ¯ow. This energy tracing can be done in a sequential way, from the time the energy enters the system until the energy has produced the work that can be observed. `Ènergy'' should be viewed broadly, ranging from the readily identi®ed electrical and mechanical categories to people inputs, for example [8]. It can also be a more obscure energy such as gas generated by bacterial action, temperature changes and oxygen that rusts iron. See Appendix B for a thought-starting list of energies observed by the author during investigations over a 20- year period [9,10]. Each energy form is an actor that is tracked through the system to identify any harm that it did, and any constructive work or control it brought to the system during the occurrence. The concept also has the eect of requiring an understanding of the system in which the energy ¯ows. Systems are designed to constructively direct energy ¯ows with barriers. Thus the investigator needs to ®nd out what energies might have aected


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the system, the barrier behaviors, and the harmful work that was done, and also to trace any amelioration work that aected the interactions or changed the potential outcome. The orderly tracing of energy ¯ow backward from the harm produced often helps de®ne the system, if it has not been de®ned before the occurrence. That is not unusual, and is why investigating minor occurrences is usually so valuable. Witness Plates. This concept was adapted from the explosives testing ®eld. During ®eld tests, metal plates positioned all around an outdoor explosion bore witness to work done on them by objects and energies released when the device was exploded. Experts then interpreted the changes to the witness plates to analyze what acted on them during the explosion. The concept de®nes the process for ``reading'' events on objects after an occurrence. It applies the energy-trace principle to investigation, in that energy which does work during occurrences leaves tracks on ``witness plates.'' Witness plates are the keepers of the tracks left by energy exchanges. This applies to both objects and people. By viewing both as witness plates or keepers of data about events that occurred, investigators respect the sources. They recognize that their ability to access the data depends on their own skills to acquire the data, more than the witness or object's ability to communicate their data to them. Thus the concept helps investigators maintain a constructive attitude about witnesses they interview, and objects they study in investigations. Objective Investigation Quality Assurance. Objective quality assurance is the use of nonjudgmental criteria to assess the quality of an investigation and its work products. This concept results in displaying events, and using rigorous logic tests to assess the order, relevance and completeness of the description and explanation of the occurrence. It uses time and spatial sequencing of events to assure the proper ordering of events. It then uses cause±effect logic to assure discovery of relevant interactions among events. It then uses necessary and suf®cient logic to assure the completeness of the ordered and linked events which describe and explain what happened. The display enables the investigator to invite constructive critiques of the logic ¯ow of the events constituting the occurrence. The demand to state the data and name the sources to justify any proposed additional events or changes to a ¯ow chart disciplines experience-based experts who want to challenge an investigator, promote their interests, redirect plans, or create uncertainty for other reasons.


1.2.5.2

Investigation Principles

Study of many investigation processes has disclosed key principles which can help investigators produce superior investigation results. These generally applicable principles should be incorporated into investigation program plans for all kinds of investigations. If You Can't Flowchart It, You Don't Understand It. This fundamental axiom is another contribution of Johnson's MORT safety research [6]. It is especially important when occurrences are perceived and treated as processes. Flowcharting the process interactions that produced an unexpected and unwanted outcome has many bene®ts. One of the most important is the discipline it imposes on investigators to produce complete, consistent, valid, and credible descriptions and explanations of what happened. They must understand the sequence, cause±eect relationships, and the necessity and suciency of all documented interactions during the occurrence to be able to prepare a valid ¯owchart. A second and equally important reason for ¯owcharting occurrences is the visibility the ¯owchart documentation provides for the events and the logic of their relationships. That visibility provides a convenient mechanism to organize and analyze data as they are acquired. It enables everyone associated with an occurrence or its investigation to pool their data into objective, logical, and disciplining patterns. It helps ®lter out questionable or extraneous data. Additionally, ¯owcharts provide an abbreviated record of the occurrence to share with aected personnel for training, retraining, process or equipment design, performance monitoring, or for monitoring the eectiveness of changes recommended by the investigator. Also, ¯owcharts of such processes can be archived and retrieved readily from corporate memory for future applications, which is a major consideration for building corporate memories. For investigation managers, ¯owcharts provide instant information about the current status of the investigation. If ¯ow charts are developed as the data are acquired, gaps help managers pinpoint what data are still needed, and what they might gain if they get the data. Investigators have a tendency to want to eliminate every possibility to arrive at the most likely possibility. With ¯ow charts, managers can make informed decisions about the value of expending more investigation resources. Track Change Makers. Process outcomes result from changes introduced by people and objects during the occurrence. Therefore, investigators have to focus on


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the change makers that produced the outcomes. Some people and objects are just along for the ride, while other people or objects shape the outcomes. Investigators must look for and identify the people and objects that shaped the outcome, and show those interactions. By starting with the outcomes, and working backwards, investigators pursue the change makers in a logical sequence. Focusing on change makers or ``doers'' leads to eciencies in investigations, by minimizing the amount of time spent on irrelevant people or objects. This mind set re¯ects the ``think events'' concept. This is one of the key secrets to achieving ecient investigations. ``Do No Harm'' Rule. Introducing changes to people and objects that survived the incident before you capture their data can corrupt an investigation. Thus the ``do no harm'' rule. Investigators must prevent any change in data sources until they have extracted the data needed from those sources. This rule poses dicult challenges for investigators. For example, rescue workers usually must disturb some witness plates to eect their rescue. Investigators can walk on debris and change it as they try to get closer to another object to observe its condition. Investigators may try to start something or turn it on to see if it works when they get there. They shut down power to immobilize a remote controller cabinet, and lose stored data in volatile memory chips. How can essential data be preserved in these circumstances? The answer is to make plans to prevent loss of data, and establish control over the site of the occurrence to prevent as much change as possible. Control of changes at the scene of an occurrence increases in dif®culty as the size of the scene or accessibility delay increases. This is particularly important when trying to control the people and objects at the site of a large occurrence, or when the investigator may arrive at the site later. A site involving large or dispersed equipment such as a gantry robot is more dicult to control that a small single station robot site, for example. The rule reminds investigators of the importance of an on-site mental assessment of the risks to data stored in people and objects before introducing new changes that can harm the data. Time Never Stands Still. Time is an independent variable during an occurrence. Every person and every object has to be someplace doing something during an incident. What they do is identi®able by when they did it, and how long it lasted. Each action during a process has a starting and an ending time. Time is

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used to order events data as they are acquired. Investigators should be concerned with establishing or at least roughly approximating the relative times when people and objects did something to advance the occurrence to its conclusion or outcome. Creation of a mental movie helps investigators do this. The principle is applicable directly during interviews of people. By trying to visualize what the witness was doing from the time the witness ®rst became aware of the occurrence, investigators can develop a ``time line'' of actions by the witness. Whenever a person or any object drops out of sight during the occurrence, the mental movie helps to pinpoint needed data and questions to ask. Meeker's Law. `Àlways expect everyone to act in what they perceive to be in their best interests, and you will never be disappointed'' [11]. Sometimes investigators have to deal with people who were actively engaged in the operation or process that went awry. For many reasons, they may perceive that it is their best interest to withhold some information from the investigator, or mislead an investigator, or perhaps even lie. Investigators should be aware of these perceptions of self interest, and be prepared to work around them. One way is to use the mental movie to assess the completeness and sequential logic of the actions described. Another is to document and display the events reported on a ¯owchart, and test their logic. Another way is to get corroborating or contradictory statements. Trust but remember the perceived interests and verify what is reported. The Silent Witness Rule. The witness has it, you need it, and the witness doesn't have to give it to you. Investigators are at the mercy of people who have in their memory the data they need. A companion to the self-interest principle, this principle helps investigators adopt a helpful frame of mind for talking to witnesses about an occurrence. It reminds investigators to look for, recognize, and adapt to the perceptions, interests, and motivation of each witness. They adapt by framing the purpose of the interview and all questions in a way that encourages each witness to share data the investigator needs. Ideally, successful investigators are able to transfer the witness' mental movies of the occurrence to their minds. An investigator's challenge is to get the witness to do 95% of the talking during an interview. Things Don't Lie. For many reasons data acquired from people are less reliable than data acquired from things. Things respond predictably to energy


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exchanges, according to laws of nature that enable prediction of changes in things. The value of this predictability is that investigators should rely on the most reliable dataÐderived from objectsÐto determine what happened. While they do not lie, objects are not ardent conversationalists. Thus it is up to the investigators to extract whatever data might be stored in things. To read data from an object, it is necessary to know the state of the object both before and after an occurrence, the changes that occurred during the incident, and the energies that changed it. This means capturing and documenting the ending state promptly and eciently is an investigation priority. Data from objects become critically important when nobody was around during the occurrence, or when those who saw what happened did not survive the occurrence. Experience Recycles Yesterday's Problems. Rationalizing experiences has the subtle but real capacity to normalize deviations or changes that increase risks or produce degrading performance or accidents [17]. The importance of this principle lies in the need to select investigation methods that prevent experience from leading to conclusions contrary to those demanded by the data. It also means that the selection of investigators must carefully balance their experience against their ability to subordinate it to logical thinking about the data they develop during their investigations. MORT training cautions investigators not to SLYP or solve last year's problems. Mental movies and ¯owcharts help prevent this. This is another reason why primary reliance on investigation knowledge and skills rather than system knowledge and skills is so important in good investigation programs. Investigations Are Remembered by Their Results. Investigations are meaningless and a waste of resources unless they contribute to timely and enduring change. Loss incidents have a way of bringing about temporary changes in behavior and views, even without any investigation. The challenge for any investigation program and every investigator is to produce work products leading to lasting improvements and retention of the understanding achieved. Retention is best achieved with brief, readily grasped descriptions of what happened, with obvious and broadly applicable principles that can be applied in many situations.


Given these concepts and principles, what procedures will produce the desired investigation work products? 1.2.5.3

Investigation Processes

Investigation processes traditionally re¯ected the intuitive understanding of investigations by individuals performing the investigations. That is changing as alternative investigation methods have become available, starting with the MORT research around 1973 [6]. When considering alternative investigation processes, several precautions are advisable. These precautions include tailoring the investigation program to the needs and capabilities of the organization. In considering a selection, it is advisable to be aware of desirable capabilities and attributes to seek, as well as attributes that may impose constraints or create problems. Selection of an investigation program methodology should match the capabilities demanded by the favored choice(s) and the capabilities that can be made available within the organization. The following summary of criteria can assist in the task of selecting the investigation process. Preferred Capabilities and Attributes. A preferred investigation process [12] for implementation under the program plan can: Provide investigators with guidance about what to observe and how to frame questions. Help investigators organize and document data they acquire promptly and eciently. Give investigators real-time guidance for narrowing their data searches during the investigation (progressive analysis capability). Facilitate sequential, cause±eect and necessary and sucient logic testing of the data documented. Help investigators recognize and act on unknowns. De®ne problems, needs, and candidate remedial actions logically and objectively. Assist in the assessment of needs and candidate remedial actions, and prediction of their success. Point to ways to monitor actions to evaluate their success. Expedite preparation of valid and persuasive deliverable work products. Mediate diering viewpoints and guide their resolution. Adapt to the full range of occurrences likely to be encountered. Be learned and practiced at modest cost.


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Filter quickly any extraneous data during investigations, without alienating other investigators. Prevent investigators from drawing conclusions contrary to the data. Minimize dependence on experience and maximize dependence on logical reasoning. Facilitate the objective assessments of the investigation process and output quality. Attributes of Less Desirable Processes. Less attractive investigation processes also have some distinguishing attributes, including: Informal and very experience-dependent procedures A legally oriented facts±analysis±®ndings±conclusions framework A high tolerance level for ambiguous and abstract data usage, experiential assertions, built-in judgments, and subjective interpretations and conclusions Oversimpli®ed descriptions and explanations of what happened, with recurring jargon such as chain of events, unsafe acts, human error, failures, fault, and the like An emphasis on ®nding a single ``golden bullet'' to explain the occurrence such as ``the cause'' or the root cause or equivalent A lack of scienti®c rigor or disciplining procedures demanded of investigators, such as time-disciplined demonstration of relationships Lack of objective quality control criteria and procedures for the outputs or the process. An understanding of these concepts and principles provides a basis for developing an investigation program plan tailored for a speci®c organization. 1.3

INVESTIGATION PROGRAM PLANNING

This section describes the main investigation programplanning tasks. The operation of an eective investigation program depends on the design of the program and readiness of four primary program elements: executive commitment, a sound investigation plan, adequate investigator preparations and competent investigation support. The main investigation program planning decisions and actions are summarized in Fig. 7. Executives are responsible for an organization's overall performance, set policies, and allocate resources to achieve desired performance. The

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Figure 7 Organization-wide investigation program readiness tree displaying the preparatory steps needed to assure readiness of a comprehensive investigation program.



are the program's sponsors, and must be committed to and satis®ed by the program. Investigation program planners are responsible for the determining the investigation tasks investigators will perform. They are the program's creators. Their plans must be tailored for the organization, and capable of producing the desired results. Investigators and their supervisors are responsible for producing satisfactory deliverables within the program. They are the program implementers, and their work must satisfy their sponsor and their customers. Persons or groups who support investigators provide knowledge, advice, and support for the investigators. They are program auxiliaries. Investigation program readiness decisions and actions are shown for each group. Executive decisions and actions (blocks 1±9) de®ne what the program is expected to accomplish. Investigation program planning actions (blocks 11±19) de®ne how investigations are conducted, and what they deliver. Investigator selection training, and practice (blocks 21±29) lead to the investigation capability that will produce the desired work products. Preparation of support personnel (blocks 30±40) provides a needed ``resource pool'' to help investigators when they need it. 1.3.1

Executive Preparations

Executives set the direction and tone of an organization's activities. They also control the organization resources and their distribution. Investigations consume resourcesÐsometimes twice: once when they are conducted, and a second time if the investigation is ¯awed and undesired surprises continue. Success of an investigation program depends on engaging executives and getting their sponsorship of the program by showing them their stake in its success. The following actions by executives are required to get a successful investigation program underway, and to keep it going. The numbers in parentheses at the end of the task title refer to Fig. 7, the organization-wide investigation program readiness tree. 1.3.1.1

Acknowledge Opportunities (1)

This is the indispensable ®rst step. Executives must be able to recognize the narrowness and shortcomings of conventional approaches, and why those approaches do not satisfy their eorts to continually improve performance. Upon recognizing that need, they then need


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to recognize that new opportunities are available to them to achieve better results. If they understand these opportunities, they will want to take advantage of them, and will be more receptive to new approaches. 1.3.1.2

De®ne Mission, Purpose, and Demands (2)

The opportunities enable desires for continuing improvement to become the basis for revising the investigation program mission and purposes. Rather than a narrow accident prevention mission, everyone can endorse the broader mission of facilitating continuous performance improvement. This will establish the performance demands for the investigation program. After an executive decision has been made to acknowledge and seize opportunities to improve investigation programs, the investigation program planning begins. 1.3.1.3

Establish or Update Investigation Program Objectives (3)

Establish objectives for each kind and level of investigation, such as: Eciently and consistently produce timely, valid, and consistent descriptions and explanations of the occurrence being investigated. Report that new information in a form facilitating its use throughout the organization to discover and de®ne speci®c needs for change, and identify and assess candidate changes to improve future performance. Provide a basis for monitoring in real time the eectiveness of predictive analyses, and changes implemented as a result of investigations. Do all this in a constructive, harmonious manner. If the present investigation program has narrower objectives, establish new broader objectives for the program plan. 1.3.1.4

Adopt Investigation Policy Changes (4)

When executives are comfortable with the program objectives, they need to review the organization's investigation policy. If new investigation policies are needed, they should amend current policies. Changes should address the investigation program mission and goals, particularly regarding the tone of investigations. Determination of what happened and why it happened, and using that understanding to improve future performance should be common to all policies. Policy changes require executive acceptance and support.

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One element of this task is to ensure that the policy is compatible with regulatory requirements. Another element is to communicate the policy and need for co-operation with investigators to everyone in the organization who might become involved in investigations. 1.3.1.5

Adopt Updated Investigation Program Plan (5)

When the investigation program plan is ready it should be considered, accepted, and advocated at the executive level of an organization. By advocating the plan, the executives show their support for it. They also become the program's sponsor. The program operation must satisfy the sponsors, or they will abandon it. 1.3.1.6

Accept Executives' Roles (6)

The investigation plan should incorporate support roles at the executive level. Support roles include participating in periodic program performance reviews, in leading high-pro®le investigations that might aect the public's perception of the organization, and in the resolution of dierence aecting the levels of predicted residual risks accepted. These roles should be accepted by executives who will be involved in these tasks from time to time. 1.3.1.7

Ensure Investigation Budget (7)

If an initiative is worth undertaking, the organization should be prepared to pay a reasonable price to gain the bene®ts it expects to receive. By setting a budget for the investigation program, the value of the program is established, and one measure of its performance is put in place. The source or sources of the funds are less signi®cant that their allocation to investigations. This can have a positive eect on investigators, who will become conscious of the need to demonstrate the value of their work. It also encourages investigation eciencies. Caution should be exercised to avoid creating disincentives that penalize anyone via the budgeting process. 1.3.1.8

Establish Investigation Performance Feedback Process (8)

Periodic review of any function is an essential element of good management. If the broad mission for an investigation program is adopted, the suggested objectives provide a basis for assessing the program's achievements and value. A concomitant objective is


to change or terminate the program if it is not achieving its objectives. 1.3.1.9 Executives Ready (9) The importance of these executive-level tasks cannot be overstated. If the above actions are taken, the organization's executives will be ready to support the program and perform their role in achieving the desired bene®ts. 1.3.2

Investigation Process Plan

The best investigation plan for each speci®c organization should be identi®ed, prepare, and implemented. Planning tasks to achieve this include selecting, adapting, and implementing an eective investigation process. 1.3.2.1 Select Investigation Concepts (11) Selection of the conceptual framework for an investigation program is probably the second most important decision for ensuring an eective program. Criteria for program selection are applied during this task. What governing framework should be adopted? A review of references is strongly advised [2,3,5,6,13]. Should adoption of the change-driven process model and event data language concepts be the governing framework? Or should the concept of determining cause and unsafe acts or unsafe conditions in a chain of events be chosen? Or would the energy/barrier/ target MORT concept be most desirable for the organization? Use the criteria cited earlier during these deliberations, and document the reasons for the selection for later use. 1.3.2.2 De®ne Investigation Goals (12) Depending on the investigation policy and the framework selected, the speci®c goals of an investigation are de®ned next. Goals of any investigation should include development of a validated understanding and explanation of what happened. Other goals are suggested by the discussion above. Document the goals selected. 1.3.2.3 De®ne Investigation Process Deliverables (13) Plans should de®ne the work products to be delivered. Plans should also include criteria by which each work product will be evaluated during the investigations, and quality assurance procedures. Deliverable work products include the description and explanation of


the occurrence, source document ®les, visual aids and other materials required to support the description, presentations or brie®ngs, and any reporting forms or other documentation. If desired, deliverables may also include reported needs disclosed by the investigation, and proposed changes to improve operations. Planners must consider the regulatory requirements and their eects on criteria for the deliverables. It is advisable to review the potential adverse as well as bene®cial consequences of each with legal counsel before the plan is adopted. Another important deliverable, particularly when potential injury claims or litigation are foreseeable, is the source material used to de®ne the reported actions, consisting of documents, photos, selected debris, sketches, or other source materials. Plans should address their acquisition, handling, archiving, and disposal. Provide speci®cations for deliverables expected from investigations of incidents such as breakdowns, disruptions, or similar problems. If descriptions of the occurrences are not documented, the problems will probably return. When forms are required, provide examples of entries that satisfy the form's designers. 1.3.2.4

Select Preferred Investigation Process (14)

Alternative investigation processes are available for review [2,3,6,10,13±15]. Planners should document the criteria for the investigation process selection as part of the evaluation process. They will be used in subsequent evaluations of the process. The criteria should include those described above and any additional criteria needed to tailor the process to the organization's capabilities. Each candidate process should be evaluated against each criterion and the results compared, and documented for later review. 1.3.2.5

De®ne Case Selection Process (15)

What occurrences should be investigated? In a narrowly focused program, case selection is limited to those required by regulatory authorities, usually involving. a reportable or lost-time injury or fatality. In a broad program, the emphasis is on investigating any surprises, especially those during which a worse outcome was averted by successful intervention of people or object controls. Case selection can be made automatic. For example, when an automated system breaks down or functions erratically, the troubleshooting and repair are a form of investigation that is initiated automatically. When


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disruption of a production process occurs, investigations are also preuthorized. Preparations should include identi®cation of the kinds of occurrence that are investigated automatically and those for which a case selection decision will be required. Criteria for determining the scope of each kind of investigation should also be prepared to guide investigators in speci®c cases. These speci®cations should address at least the extent of the scenario to be developed, hours to be committed, and the investigation deliverables, among other speci®cations. 1.3.2.6

De®ne Investigation Operations (16)

This aspect of the investigation plan should address administrative matters. That includes guidance for the assignment of investigators, record keeping, and administrative requirements, including time and expense record keeping; also noti®cation of and coordination with others who have requested noti®cation, including regulatory agencies if applicable. Develop requirements for others in the organization to co-operate with investigators, and output reviews, distribution procedures, and any other speci®cations needed to tailor the plan for the organization. Do not overlook guidance for investigators when they suspect a crime rather than an unintended occurrence. 1.3.2.7

Document Investigation Process (17)

This section of the plan documents the selected investigation process. It outlines guidance for acquiring data from people and objects; for handling those data after they are acquired; for validating interactions or bridging gaps; for problem discovery and de®nition; for assessing support needs and capabilities; for quality assurance procedures; for distribution of work products; for media contacts; for consultations with counsel; for self or peer assessment of investigation performance; and any other tailored elements of the selected process. References provide detailed descriptions of investigation tasks [10,16]. 1.3.2.8

Adopt Investigation Plan (18)

This step is the ®nal co-ordination step. Each person aected by the plan reviews it, con®rms the intended operation and bene®ts, demonstrates any diculties it might present, helps modify it if so required, and commits to it with a sign-o indicating concurrence. This step typically involves selected executives, managers of activities that might be investigated, and the likely

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investigation program manager or senior or lead investigators who will implement the plan. 1.3.2.9

Investigation Plan Ready (20)

Plan future tasks needed to maintain plan readiness in the future. This may require periodic review and tuneup of the plan, by using performance indicators to identify the needed modi®cations or updates. 1.3.3 1.3.3.1

Investigator Preparation De®ne Investigator Tasks (21)

What are investigators expected to do during investigations? The investigation process selection decision determines investigators' tasks. If a formalized process is adopted, descriptions of various useful techniques can be identi®ed from the literature [2,3,6,9,10,13± 20]. Each reference oers dierent ideas about investigation processes and techniques. Review those ideas and techniques to determine if they should be incorporated into the plan. For example, tailoring might be needed because of special classes of robotics equipment. Tailoring might also be needed because of special regulatory considerations, or because of the nature of the organization or its policies. If so, descriptions of techniques in the literature should, of course, be modi®ed to accommodate those special needs. Task de®nitions need not be complex but should provide sucient detail to prevent inconsistent overall performance for dierent levels of investigation. Consider investigation task de®nitions to be dynamic, subject to change whenever circumstances change. For example, introduction of new products or new materials, expanded processes or any other changes aecting investigation performance might precipitate a review and modi®cation of the investigation procedures. 1.3.3.2

Document Investigator Procedures (22)

This planning task requires documentation of the orderly sequencing and execution of investigation tasks to provide guidance for investigators, and to accommodate the nature and levels of anticipated investigations. Investigation procedures might range from troubleshooting to major accidents. Planning for investigations of serious accidents should have priority. Include a ``walk through'' of each kind of investigation during planning, to determine personnel involved in the investigation, task interactions of these personnel, and the timing of the investigation tasks relative to each other. Project planning software can


be a useful aid to this documentation process. Be sure to designate a supervisory process to accommodate decision ¯ows during the investigations. Pay special technical attention to procedures for acquiring data after an incident from digital electronic devices and applications which control automated systems. In transport systems, recording devices are used to keep track of selected operating system parameters during operations, providing the ability to determine their behavior if an accident occurs. Without such recorders, operators should identify proposed means to examine such devices for whatever data they might hold. If this situation arises, information about available investigation techniques is available through sources such as the International Society of Air Safety investigators [21]. 1.3.3.3 De®ne Investigator Knowledge and Skill Needs (23) De®ne knowledge and skills required to perform investigation tasks next, to ensure that investigators are capable of performing their assigned tasks. The knowledge needs to include an understanding of tasks and outputs required, and methods that will equip investigators to perform those tasks. The knowledge needs are outlined above, but a few are worth repeating. Absolutely essential are knowledge of observation processes and how to transform data into investigation data language, practical knowledge of logical reasoning procedures, an understanding of problems that certain kinds of words and language can create, and awareness of investigation concepts and principles described earlier. These apply to all levels of investigation. 1.3.3.4 Establish Investigator Selection Criteria (24) Selection of personnel to qualify as investigators must be responsive to the needs dictated by the investigation process used. Generally, the more rigorously disciplined the investigation process, the more stringent the criteria for investigator selection. The level of investigations required also has a bearing on those criteria. Basic criteria for investigators must include the ability to make observations without distortion or bias; transform and document investigation data with minimal interjection of personal views, experiences or personal values; order and present data sequentially; visualize patterns and scenarios; reason logically; have a reasonable memory for detail; and be self-criti-


cal without personal constraints. Physical capabilities should be consistent with the tasks and environment in which the investigator will be working. If special knowledge or skills will be required because of the nature of the systems being investigated or the levels of investigation, include these criteria. 1.3.3.5

Complete Investigator Selection (25)

The interviewing and selection of investigators contribute to the subsequent tone of the activities and expectations of both the employee and supervisor. When describing the duties of the position, discuss the mission and policies governing investigations, particularly with respect to regulatory agencies. Also, resolve any questions about the levels of investigations, their authority and responsibilities, acceptability of their work products, and how their performance will be judged. Investigator selection might include selection of outside experts to assist in or direct Level 4 or 3 investigations under contract. The anticipated frequency of major investigation cases may be too low to justify development and maintenance of an investigation team within the organization. If so, the selection of an outside team to perform the investigations under contract might be desirable. Select all contractors based on their ability to perform the investigations as prescribed by the adopted investigation program plan criteria. 1.3.3.6

Train Investigators (26)

Typically, selected investigators will have systems expertise in some form. They will probably not have formal investigation training, so plans should include training in the selected investigation process and techniques before they are assigned a case. For level 1 investigations, an apprenticeship to trained investigators might oer sucient training. For other levels, consider providing classroom investigation training. Design the training to accommodate the mission, policies and plans, the tools provided for investigations, and tasks required to achieve the desired outputs. Ensure training in quality assurance tasks. 1.3.3.7

Complete Investigation Drills (27)

Include investigation drills for investigators in the program. During training, drills simulating hypothetical investigations or case studies can be developed for speci®c operations to strengthen the investigator thought processes. It is also good practice to have newly trained


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investigators do an independent quality assurance check of a recently completed case report. Have them use ¯owcharting tools and the quality assurance checks in Appendix C to build their skills in applying the desired thought processes. Use feedback about the results to reinforce any investigation process elements that need attention. A more sophisticated drill to give new investigators insights into and experience with the kinds of problems that arise during an actual investigation is desirable. Have them investigate the breakdown of an automated system to determine what happened and why it happened. This has the added advantage of introducing operational personnel to the thought processes used in investigations. A third kind of drill is to rotate the quality assurance of work products among investigators. This enables investigators to keep abreast of ®ndings by others, while continually improving their data gathering, analysis, and logic skills.

1.3.3.8

Put Quality Controls in Place (28)

Quality control procedures should be put in place to assure the adequacy of the deliverables, the quality of actions implemented as a result of the investigations, and the quality of the investigation process itself. The quality of the deliverables and ®ndings can be screened before they are distributed. Use the quality assurance check lists described in Appendix C. References provide detailed quality assurance instructions [9,22]. Tracking acceptance of the ®ndings provides another indicator of deliverable quality [4d]. The greater the controversy or reluctance to accept the ®ndings, the greater the likelihood that the quality of the investigation deliverables needs to be improved. The quality of the actions proposed as a result of the investigation is also assessed by the results they produce. Before they are released, any recommended actions should predict the intended eects in a way that can be veri®ed. Quality control plans should address the monitoring and veri®cation tasks. The quality of the investigation process is assessed by occasional spot auditing of the procedures at the conclusions of an investigation. It is also indicated by the performance against budgets, nature of any delays, handling of uncertainties and unknowns, complaints about the investigators or their actions, and the work products produced. Quality control plans should address this need.

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1.3.4

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Investigation Support Preparations

Investigators may need various kinds of help, particularly if the investigation involves casualties. 1.3.4.1

De®ne Support Needs for Organization (30)

Plans should identify the kind of help that may be needed during investigations, and assure that it will be available promptly when needed. The help required may include functional backup for collateral duty investigators, document handling, communications, go-kit maintenance, investigation equipment, readiness monitoring, technical expertise, legal expertise, and media expertise. Technical expertise may include electronics, mechanical, chemical, medical, or design experts. 1.3.4.2

Establish Data Source Handling Plan (31)

During investigations, sources from which investigators extract data increase in number as the investigation progresses. Address how data sources are to be documented, processed and preserved during and after investigations, including possible chain-of-custody implementation tasks in speci®ed cases. If willful harm is involved, consult counsel for planning guidance. 1.3.4.3

Communications Protocols and Equipment Ready (32)

Depending on the occurrence, voice or data communications links may be required at the site of an occurrence. Preparations should be responsive to any anticipated special requirements for such communications. For example, consider communications protocols, security concerns, interfacility electronic data transfers or exchanges, external data source access with suppliers, and incompatibility with facility communications or control equipment. 1.3.4.4

Complete Go Kit Preparations (33)

Go-kits are the investigators' transportable tool kits, containing the equipment an investigator will need on arrival at the site of an occurrence. At a minimum, preparations should specify the equipment to be provided, and its regular maintenance or updating. A camera and ®lm, sketch pad, voice recorder, personnel protective equipment, and note-taking equipment are absolute minimum equipment. A list of special instruments and special experts, with contact information, is


also a must. Planning should keep in mind that the investigator must be able to transport the go-kit, usually without help. 1.3.4.5 Con®rm Support Equipment Readiness (34) Surprises occur irregularly and hopefully infrequently. Thus preparations should address how support equipment will be maintained in a continuing state of operational readiness, including assignment of task responsibility and perhaps checklists and inspection schedules. 1.3.4.6 Arrange for Functional Backup (35) Investigations interrupt the normal duties assigned to investigators except in large organizations where investigation might be a full-time job. When investigations occur, preparations should provide for backup personnel to take over the investigator's normal duties when the investigator is at the occurrence site or elsewhere doing investigation tasks. 1.3.4.7 Prepare Technical Support Personnel (36) Technical support personnel are likely to be required when an investigator encounters a need to understand how something was designed to work, or how it actually worked. For example, if a tear down of an automated system or component is needed to examine internal parts after an occurrence, the investigator may need help in planning the tear down sequence and methods to minimize data loss. A tear down will probably require skilled mechanics or engineers. Expertise may be required to recover data or settings from electronic control components. Planners should identify and provide for access to in-house expertise, supplier expertise and contractor expertise. 1.3.4.8 Prepare Legal Support (37) When people are harmed in any way, and sometimes when warranties are involved, investigators may need help from a legal expert or counsel. Planners should work with counsel to identify when investigators should seek legal advice, and how to access and use it. 1.3.4.9 Prepare Media Support (38) Occasionally occurrences may precipitate media interest, particularly if fatalities occurred, or regulatory agencies become involved. Recognize that the media


tend to focus on controversy. Plans should establish procedures and contact points for responding to media inquiries, and for adequate guidance and compliance with those procedures. 1.3.4.10

Support Personnel Prepared (39)

The planning should include some scheduled feedback arrangement, to accommodate changes in personnel, personnel assignments, housekeeping, equipment obsolescence, expired supply dates, etc. Plans should assign feedback and review tasks to whoever manages or directs the investigation program. 1.3.5

Monitor Startup of Investigation Processes

Any change requires planning before implementation, and monitoring after implementation. If a new program is initiated, or changes in investigation practices are instituted, performance monitoring and feedback to the executive in charge of the investigation program should be provided frequently during startup, and periodically during subsequent operations. After a predetermined time, monitor the program for its achievements, and distribute periodic reports of its achievements. 1.4

CONDUCTING INVESTIGATIONS

This section outlines how to conduct investigations involving automated systems, and the basic tasks common to all kinds of investigations. Each occurrence is dierent, but this general guidance is applicable in all investigations. For detailed investigation task guidance, consult the references. Before beginning, remember a basic axiom of investigation: if you can't ¯owchart it, you don't understand it. Thus, as an investigation progresses it is good practice to work toward developing a ¯owchart of events constituting the occurrence. With automated systems, the relative timing of events involved with the system controls often become critical to understanding what happened [23]. 1.4.1

Initial Response to Noti®cation

The ®rst information about an occurrence is usually very sketchy, especially if any casualties are involved. However sketchy, it is necessarily the basis on which the decision is made to launch an investigation based on case selection guidance. Delaying a response often raises the risk of losing data or increasing the loss.


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Preauthorized automatic launches can begin immediately. If the responsible manager decides to launch an investigation, the manager assigns the investigator, with initial instructions about its speci®c goals, concerns, resources available, and deliverable schedule. The manager also implements the plans for backup and support services, including site preservation assignments pending arrival of the investigator. The manager then initiates the planned contacts, to provide them the information requested or required by regulation or local law. The investigator or team goes to the site of the occurrence. Early communications should also consider directions to retrieve data about the equipment or processes involved, or any earlier analyses of the operations, addressed to the custodians of those data. If deemed appropriate or necessary, those contacts can include directions to protect any data sources. 1.4.2

On-Site Tasks

On arrival at the site, the investigator has four priorities. They are to preserve the data at the site; to overview the occurrence setting and get a rough idea about what happened; to set priorities for data gathering; and, frequently, to restart the system. 1.4.2.1

Data Protection

Generally stated, the ®rst task is to prevent inadvertent or deliberate changes to the ending state of objects surviving the incident, or to the memories of people who acquired data during the occurrence. This can be done by roping o or otherwise isolating the area or the equipment or the people. Alternatively, post guards until the sources have been examined and the data they oer has been acquired by the investigator. 1.4.2.2

Data Acquisition and Processing

The next task is to begin to acquire data. The task challenge is to develop data in a format that supports ecient and timely development of a description and explanation of what happened. Further details are provided in the investigation plan discussion and references. Start with a ``walkaround'' at the site to get a general overview of what is there and what might have happened. During the walkaround task, the investigator begins to plan the order of the data acquisition tasks, setting priorities to examine or record the condition of any perishable data sources before they change. Priorities may also be required for examina-

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tion or documentation of equipment that is to be returned to service to restore operations. If potential witnesses to the occurrence are going to be leaving the site, arrangements for acquiring their data also require priority attention. A part of the walkaround task is to document the ending state of the objects found at the site. This can be accomplished with cameras, video camcorders, sketches, or drawings, or maps if debris is scattered. Notes describing what was photographed or sketched should be part of the documentation. Investigators should be prepared to delegate some of these tasks, such as the witness contacts and scheduling, or photographing damaged or changed equipment, for example. Use support personnel freely when needed. The acquisition of data from people and objects continues after the walkaround. The investigator's challenge is to identify the people and objects that contributed to the outcome, identify what they did, and document those actions. The order in which this is done varies with the occurrence, but generally it begins with asking the ®rst people found at the scene for their observations. They can help the investigator identify other data sources like witnesses and victims, or equipment that they observed doing something. They can also describe changes to debris or other objects which they introduced or saw occurring. When physical conditions of objects can be observed, investigators have to determine ``how what you see came to be''Ðor who or what did what to produce the condition(s) they see. Detailed guidance for extracting action data from physical objects can be found in some references [3,19,16,20]. Sometimes investigators want to conduct tests or simulations to determine what produced the condition or attributes of an object. Before any testing is initiated, the investigator should insist on a test plan, which incorporates criteria for creating actor±action formatted data as a test output. A test plan should specify who will do what and in what sequence, to ensure needed data are not lost inadvertently [24,25]. The acquisition of stored data from digital or analog electronic devices associated with automated or robotics systems poses dierent challenges. The plans for acquiring these data should be followed. Exercise caution to avoid changing such data before it has been retrieved. The next step is transforming observations of the data sources into descriptions of the actions that can be sequentially organized and analyzed. The best way to do this is to use the actor±action data structure. When listening to people describe what they observed,


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the investigator should be listening for and documenting data that describe who or what did what and when it happened, and documenting the data as events. 1.4.2.3 Restarts Sometimes the desire to restart equipment or processes involved in the occurrence with minimal delay in¯uences the investigation. When this desire exists, the need to identify what happened and identify the problems and new controls needed quickly in¯uences the priorities for the investigation, and the resources devoted to the investigation. The need to take shortcuts and the consequences of doing so should be discussed with the operational and investigation managers, who are responsible for accepting the risks. 1.4.3

Data Handling Tasks

As data about interactions are acquired, the investigator can add newly discovered actions to the developing scenario, as ``frames'' to the mental movie, or events to the events worksheets. The data handling goal is to narrow the focus of the investigation continuously. A concurrent goal may be to assure compliance with chain of custody requirements. When other organizations are involved, ensure that the investigation plan is observed. 1.4.3.1 Event Linking and Testing The technical goal of this task is to prepare a completed event ¯owchart that describes what happened and why it happened during the occurrence. Gaps in the mental movie or sequential layout of events point to speci®c questions that the investigator should pursue. Working the gaps narrows the focus of the data acquisition eort, and separates the relevant from the irrelevant events. As data are added to the mental movie or analysis worksheets, relevance is determined by examining events in pairs, and identifying cause± eect relationships between them. When they exist, the events should be linked to show the sequence and where important the relative timing of related interactions. The examination can begin with the process outcome, and proceeds backward in time toward the change event(s) that initiated the process. Alternatively, it can start wherever an event is displayed; work in both directions. Events that do not have a cause±eect relationship with other events should be considered irrelevant, and tentatively set aside; they can be recalled if additional information shows a need to do so.


When available data have been exhausted, the events with a cause±eect relationship should describe what happened in the proper sequence, from the ®rst deviant event to the last harmful event. In cases where adaptive actions prevented a loss outcome, the last event would be restoration of the original activity or a shutdown. The testing task checks the description of the events for completeness. The investigator looks at each ``causing'' event to determine if the ``causing'' event was sucient to produce the `èect'' event every time it occurred. If so, that part of the description is complete. If not, the investigator needs to determine what additional actions were needed to produce the `èect'' event each and every time the ``causing'' events occurred. When this task is ®nished the investigator has identi®ed all the events necessary to produce the outcome. Remaining gaps in the description identify remaining unknowns. Methods for hypothesizing events to ®ll gaps in the scenarios exposed by the testing task use bounded logic trees to display possible alternative scenarios. A bounded logic tree has both the top and bottom events de®ned. Alternative hypothesized scenarios are developed to link the bottom event to the top event. The most likely alternative supported by data recovered after the occurrence can be used to complete the description, provided their source is noted, and uncertainties acknowledged. 1.4.4

Work Product Development Tasks

These tasks depend on the deliverables speci®ed in the investigation plan. An investigation is remembered by the work products it produces. The description and explanation documentation are the main work product common to all investigations. An investigator's main task is to produce the documentation describing the ¯ow of interactions that produced the outcome. The mental movies or events ¯owcharts provide the basis for describing and explaining what happened. If acceptable in the organization, the ¯owchart satis®es the basic documentation needs. If not, a narrative description prepared from the ¯owchart may be needed to satisfy other needs. If another reporting structure is required, such as the facts/analysis/®ndings/conclusions reporting format, the events ¯owcharts with their supporting data enable investigators to produce that work product. Regardless of the format, the description must provide sucient information to enable the user to visualize what happened, and why it happened. If


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illustrations are needed to achieve this, they should be added to the description. An additional element of the investigation work product is the group of supporting source documents or objects. Each source of data used should be identi®ed and archived and retained according to the investigation plan. 1.4.4.1

Problem Identi®cation

One constructive use of the descriptions is problem discovery and de®nition. The problem discovery task requires a supplemental data-gathering eort. To de®ne a problem, an investigator must identify what a person or object was expected to do, or the norm for an action. Then the investigator must de®ne the dierence between what a person or object did and what they were expected to do, and examine why that occurred. This comparative approach is the basis for de®ning problems. Investigators sometimes fold this task into the description or explanation development tasks. That is not recommended unless restarting is urgent. Alternatively, if a ¯owchart is available, a problem can be de®ned as a subset of the events constituting the scenario. For example, if all expectations were satis®ed, but a person or object did not have adequate time to adapt to prior events, that subset of events identi®es a problem. See Appendix A for guidance about the kinds of events for which timing may be critical. However, then the investigator must pursue the reason the problem came into being. That pursuit can lead to design, administrative, supervisory, training, programming, or other less direct decisions, assumptions, or actions. 1.4.4.2

Recommendation Development

Another constructive use of the descriptions is in the development of recommendations for future actions [26]. If a ¯owchart of events is available, the events sets used to de®ne problems provide the basis for examining potential changes that might be introduced to change the future ¯ow of events. For each event in the set, every actor, action, or link can be examined as a candidate for change. Changes might include dierent sequencing or timing of events, changing the magnitude of events, or substitution of components, energies, or barriers, for example. Then, the consequences of each change can be estimated by studying what eect the change might have on the subsequent events involved in the occurrence. Comparing the predicted consequences of each candidate change provides a basis for evaluating and rank-

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ing the desirability of the alternative choices, in terms of their relative ecacy and eciency. This comparison and evaluation should include a discussion of the costs of implementation and value of predicted performance improvements [27]. 1.4.4.3

Success Monitoring

Another constructive use of the descriptions is to develop a monitoring plan with which the predicted success of proposed actions can be monitored if they are implemented. The approach is to look for the recurrence of problem events sets during future operations. Thus by identifying and monitoring those events sets the eectiveness can be identi®ed. If they recur, the change may be unsuccessful. If they do not recur, the change is probably successful. 1.4.4.4

Other Uses of Occurrence Descriptions

Action-based ¯owcharts of occurrences can be used for ecient personnel training or retraining, to identify operational improvements, for design reviews or new design guidance, or to support changes in standards, codes, or regulations. The information on the ¯owcharts is easy for individuals to assimilate because they can quickly relate actions shown on the ¯owchart to their own daily tasks. They can also see their relationship to others' tasks, and use that as a basis for doing their tasks more eciently. Other kinds of investigation outputs have more limited uses, usually take longer to absorb, and are more dicult for individuals to assimilate. 1.4.5

Quality Assurance Tasks

Quality assurance tasks involve examining the quality of the investigation work products, the investigation process, and the investigation program. 1.4.5.1

Investigation Work Product Quality

The quality assurance task varies with the investigation process chosen. If the actor±action-based process is used, the quality assurance task consists of having another investigator review the ¯owchart and supporting data for their logic and suciency. This helps identify and remove conjecture, speculation, and unsupported conclusions. Other indicators of quality problems are the number of questions raised by users, or the degree of controversy that follows release of a report.


If another process is chosen, the quickest way to assess the quality of the work products is to ¯owchart the reported actions and links showing relationships, and look for gaps or logic errors to identify problems with the work product or perhaps the investigation process [21]. 1.4.5.2 Investigation Process Quality Problems with the quality of the work products provide one indication of problems with the investigation process. If work products are found to have problems during the quality assurance tasks, the investigation process should be re-examined as one possible reason for the problems. The problem may also result from the process chosen, or its execution. Another indicator of problems with the investigation process is the level of complaints about investigator actions or behavior during the investigation. 1.4.5.3 Investigation Program Quality A third and broader indicator of problems is in the value of the results produced by investigations over time. A measure of performance is the comparison of the resources allocated to the investigation program and the cost of investigations with the value of the improvements produced. This quality assurance task is more subjective, but still requires attention. How that is done should re¯ect the assessment practices applied to other kinds of activities in the organization. 1.4.6

Deliverables

The speci®cations in the investigation plan de®ne the content of the deliverables produced by the investigation, and their distribution. The investigator's task is to produce the required deliverables. From time to time, the investigators are called upon to make oral presentations to explain or defend their deliverables. To do this well, investigators should ensure that the logic of their reasoning has been checked carefully. Another important deliverable, particularly when potential injury claims or litigation are foreseeable, is the source material. That consists of documents, photos, selected debris, sketches, or whatever source materials were used to de®ne and document the reported actions. Chain-of-custody documents may be an essential element of these deliverables. When regulatory agencies prepare a report, ensure that internal deliverables are compatible with those reports, or explain any inconsistencies. When accidents requiring investigation under regulations are investi-


gated, it is desirable to prepare reports containing the descriptive data required by regulations to meet their requirements. They require ``the date, time, description of operations, description of the accident, photographs, interviews of employees and witnesses, measurements, and other pertinent information.'' A separate report, with `ìnformation or evidence uncovered during the investigation'' that would be of bene®t in developing a new or changed standard is also required to be submitted to the agency [1]. It is good practice to review reports prepared for regulatory agencies to remove subjective opinions or built-in judgments from the reports. Cause statements can be contentious. To minimize arguments about causes, specify what action(s) caused what speci®c eects, using event terms. 1.4.7

Postinvestigation Tasks

Postinvestigation tasks involve distributing and using the investigation work products for additional purposes. These uses range from resolution of claims and disputes to long-term enhancement of corporate memory. Some uses are obvious, like resolution of claims, where the description of what happened provides a basis for negotiating settlements. Other uses include their incorporation into training or recurrent training of personnel as case studies. Charts can be used as guidance for operating personnel to help them to understand interactions among system components, and to do their jobs more eciently. Distribution to designers helps them identify design options or changes that could improve future performance. In multifacility organizations, the charts are convenient to exchange among facilities for the same purposes. When consistency among all investigation is achieved, it becomes possible to combine the outputs into a growing body of process ¯owcharts covering any aspect of operations that may have been investigated. Analogous to mapping DNA, use of investigation work products to build a map of operations increases understanding of the processes. That also provides new opportunities for developing improvement recommendations beyond those made in a single occurrence. This is a new frontier in industrial operations. Another important use of the work products is to update predictive job, hazard, or operational analyses of the systems. Investigations provide the main tool for assessing the quality of or verifying prior risk and hazard analyses of the system, and showing where changes might be needed [23].


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1.5

SUMMARY

For an investigation program to be of constructive value to an organization, a positive approach transcending conventional compliance and prevention perspectives needs to be in place. The program must rest on progressive policies, concepts, principles, plans, and preparations. The material presented helps organizations accomplish this, while enabling investigators to satisfy regulatory agency and other narrower demands of investigations. Investigation technology is expanding at an accelerating rate. Investigators are urged to use the Internet resources and newly published information to keep abreast of new developments. They present opportunities to learn more about the investigation process and emerging developments, and the investigation requirements imposed by regulations. The Internet is in ¯ux, but the web sites noted with the references are useful starting points as this is written.

1.6

APPENDICES: INVESTIGATION TOOLS

The models and checklists in the appendices oer guidance to help investigators during investigations. A.

General Human Decision Model for Investigators

This model was developed from observations of human behaviors in many transportation accident investigations (Fig. A1). It was developed by tracking what happened during the accident, and by using the event-based data language and event matrices to show the events ¯ows found. A.1

Application of the General Human Decision Model for Investigators

To apply this model during investigations or interviews, identify people who appear to have had a role in the incident process. For each relevant action: 1. Begin by ®nding the change or changes in the activity that created a need for action by that person to keep the activity progressing toward its undesired outcome. 2. When identifying that change, determine if the change emitted some kind of signal that a person could detect or observe. If it did not,

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Figure A1 This model represents decisions by people in response to changes. It helps investigators understand the roles of stimuli, sensory inputs, communications, diagnostics, decision making and implementation, training, design, procedural, supervisory, and many other ``human factors'' issues in occurrences. (Adapted from Four Accident Investigation Games, Simulations of the Accident Investigation Process. Appendix V-F, General Human Decision Model for Accident Investigation. Oakton, VA: Lufred Industries, Inc., 1982.)

3.

4.

5.

6.

explore why it did not and what eect that had on the outcome. If it did emit a signal, explore whether the person saw, heard, felt, or otherwise `òbserved'' the signal. If not, explore why not, and what eect that had on the outcome. If the person observed the signal, was the signal diagnosed correctly? Was the person able to predict the consequence(s) of the change from the signal, and knowledge of the system and its operation? If not, explore why not, and its eects. If the predicted consequences of the change were correctly identi®ed, did the person recognize that action was needed to counter those consequences? If not, explore why not, and its eects. If so, did the person identify the choices for action that were available for successful intervention? If not, explore why not, and its eects.


7.

8. 9.

Was this a new situation where the action had to be invented, or was this something that prior training anticipated and provided the responses to implement? In other words, was the person confronted by demand for an adaptive or habituated response? (Here, you start to get into the person's decision-making process, and potential personal judgment issues, so explore this area empathetically with the witness, particularly for adaptive responses.) If any response actions were identi®ed, did the person choose a successful response to implement? If a successful response was not chosen, explore why not. If a successful response was chosen, did the person successfully implement the desired action? If not, explore why not. If a suitable response was implemented, the system adapted to the change without an unintended loss or harm. If the response did not


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achieve a no-accident outcome, explore why it did not. Often this leads to discovery of invalid system design assumptions or other design problems.

5. 6. 7. 8. 9. 10. 11. 12. 13. 14.

After working with this model, you will be in a much better position to discover, de®ne, describe, and explain what happened when a so-called ``human error'' or ``failure'' is alleged. You will also be able to identify more than one possible action to improve future performance of that system. B.

Natural energy sources: 15. 16.

Energy Trace and Barrier Analysis

This model (Fig. B1) describes generally the steps to follow to examine events with the energy trace and barrier analysis (ETBA) method during investigations. It is a generalized model. Investigators can apply it to understand energy ¯ows that produced an observed changed condition or reaction, or when an action needs to be understood in greater detail. The kinds of energy that might be involved in a speci®c investigation are listed below. Look for possible energy sources when the energy source is not obvious. Man-made energy sources: 1. 2. 3. 4.

Electrical. Mass/gravity/height (MGH). Rotational kinetic. Pressure/volume/kinetic displacement (P/V/KD)

Linear kinetic. Noise/vibration. Dust. Chemical (acute or chronic sources). Thermal. Etiological agents. Radiation. Magnetic ®elds. Living creatures or things. Moisture humidity. Terrestrial. Atmospheric.

(Condensed from Ref. 9, Guide 5, p. 4. For an exhaustive listing of energy types see Ref. 14.) C.

Investigator Checklists

C.1

Quality Assurance Checklists

Description of Occurrence. After a quality check of the description of what happened, check it against the following checklist one last time. Event form and content in description okay? Event names consistent in description? Abstractions and ambiguities removed? Sources referenced okay? Scope of description adequate? Flowchart causal links complete and valid? Uncertainties clearly indicated.

Figure B1 Energy trace and barrier analysis process model for accident investigation. (Adapted from 10 MES Investigation Guides, Guide 5, ETBA. Oakton, VA: Ludwig Benner & Associates 1998, p 4.)


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Mental movie (visualization) supported? Editorial adjectives and adverbs removed? Unsupported opinions or judgments removed? QA checks completed okay? Referenced sources in archives? C.2

Recommendation Checklist

Recommendations. When including recommendations in a report, use the following checklist to review each recommendation [27]. Does the recommendation simply and concretely describe the problem? Does the recommendation clearly identify who will have to do what is proposed? Does the report state what speci®c improvement is expected to occur if the recommendation is implemented? Does that person have adequate authority and resources available to implement the proposed action? Is there enough uncertainty to indicate that a ®eld test of the action is needed before making the recommendation, or before it is widely implemented? If so, is the required testing, de®ned? Are appropriate implementation milestones needed? If so, are they included and reasonable? If more than one recommendation results from the investigation, are priorities for implementation necessary or provided? Do you know how the people who have to implement the recommendations will respond to them? Have you determined how both you and the recipient will know when your recommendation has produced successful results? Have you de®ned the follow-up process that is required to ensure implementation and verify that predicted performance was achieved? If you had to implement the recommendation, would you be willing to do so? Good rule: don't ask anyone to do something you wouldn't be willing to do yourself if you received the recommendation. C.3

Problem Words Checklist

Listed below are words which are known to create problems with descriptions and explanations of occurrences developed by investigators. Use the list to locate problem words, and replace them in ®nal reports if possible.


And Or He It She They Blame Not Nor Was Were Did not Failed to Fault Plural actor names (®re®ghters, crew) Compound actor names (third shift, crowd) Verbs with wrong tense (drive). Passive voice verbs (was struck) Built-in judgments (too, failed, erred, misjudged, violated, should have, ignored, etc.) Editorial ``ly'' adjectives and adverbs (badly, improperly, inadequately, poorly, etc.) Words conveying what did not, happen (e.g., did not replace). Say what did happen!

REFERENCES Developing Descriptions and Explanations of What Happened 1. U.S. Department of Labor, Occupational Safety and Health Administration. Title 29, Code of Federal Regulations, 1960.29 Accident Investigations (http:// www.osha-slc.gov/OshStd_data/1960_0029.html). 2. U.S. Department of Labor, Occupational Safety and Health Administration. OSHA's Small Business Outreach Training Program. Instructional Guide, Accident Investigation, May 1997 (http://www.oshaslc.gov/SLTC/smallbusiness/sec6.html). OSHA's view of investigation programs for small businesses. 3. K Hendrick, L Benner. Thinking about accidents and their investigation. In: Investigating Accidents with STEP. New York: Marcel Dekker, 1986. chap 2. 4. For a description of these perceptions and how they in¯uence investigations, see L Benner. 5 Accident Perceptions: Their Implications For Accident Investigators. ASSE Professional Safety, February 1982, or L Benner. Accident Perceptions: Their Implication For Investigators. International Society of Air Safety Investigators Forum, 14:1, 1981 (http:// www.iprr.org).

Investigation Programs 5. K Hendrick, L Benner. Investigation concepts. In: Investigating Accidents with STEP. New York: Marcel Dekker, 1986, pp 30, 235. 6. WG Johnson. The Management Oversight and Risk Tree-MORT. SAN 821-2 UC4l, prepared for the U.S. Atomic Energy Commission, Division of Operational Safety under contract AT(04-3)-821, submitted February 12, 1973, p 59. See also WG Johnson. MORT Safety Assurance Systems. New York: Marcel Dekker, 1980, Chapter 5. Many useful ideas about nature of mishaps and investigations. See also U.S. Department of Energy. Accident/Incident Investigation Manual, DOE/SSDC 76-45/27. 2nd ed. 1985. Built upon Johnson's research, and contains some additional useful investigation techniques; based on legal framework. 7. SI Hayakawa, AR Hayakawa. Language in Thought and Action. 5th ed. San Diego, CA: Harcourt Brace & Company, 1960, chap 3, pp 48, 85. Essential reading for investigators who want to use factual language to develop their work products. 8. N Leveson. Safeware: System Safety and Computers. Reading MA: Addison-Wesley 1995. Appendix A, Medical devices: The Therac-25 Story describes interactions between personnel input timing and software design, for example. 9. L Benner. 10 MES Investigation Guides. Oakton, VA: Ludwig Benner & Associates, 1998. Guides cover wide range of investigation procedures and practices. 10. D Vaughan. The Challenger Launch Decision, Chicago, II: University of Chicago Press, 1996, chap 5. Describes how deviations become normalized. 11. K Hendrick, L Benner. Meekers law and perceived interests, In: Investigating Accidents with STEP. New York: Marcel Dekker, NY, 1986, pp 149, 235. 12. Adapted from L Benner. Rating accident models and investigation methodologies. J Safety Res 16(3): 105126, 1985. This work can also be found in ref 3. 13. Handbook P88-I-1. Investigation of Mining Accidents and Other Occurrences Relating to Health and Safety. U.S. Department of Labor, Mine Safety and Health Administration, 6/21 /94 Release 3. (http:// www.msha.gov/READROOM/HANDBOOK/PH88I-l.pdf.) 14. Introduction to investigation. (Companion guide to a video ®lm with the same title), Stillwell OK: International Fire Service Training Association, Fire Protection Publications, 1997. Detailed investigation guidance is consistent with multilinear events sequencing concepts. 15. NFPA 921. Traditional guidance for ®re investigations. Quincy, MA: National Fire Protection Association, 1995, Traditional guidance for ®re investigations. 16. Accident Investigation. (Companion guide to a video ®lm with the same title), Stillwell OK: International


717

17.

18.

19.

20.

21.

Fire Service Training Association, Fire Protection Publications, 1997. Describes detailed investigation tasks, with checklist form of summary of tasks in chap 4. Guidelines for Investigating Chemical Process Incidents, New York: Center for Chemical Process Safety, American Institute of Chemical Engineers, 1992, p 50. Lists different kinds of investigation approaches, with subjective thoughts of their attributes. `Ù.S. Department of Labor, Occupational Safety and Health Administration, OSHA Field Inspection Reference Manual CPL 2.103, Section 6-Chapter II. Inspection Procedures; OSHA Instruction CPL 2.94 July 22, 1991 OSHA Response to Signi®cant Events of Potentially Catastrophic Consequences http:// www.osha.gov/(do site search)'' Fatality Inspection Procedures. OSHA Instruction CPL 2.113, U.S. Department of Labor, Directorate of Compliance Programs, Washington, DC April 1, 1996. Regulatory agency investigator guidance. (http://www.osha-slc.gov/OshDoc/Directive_data/ CPL 2_113.html.) RH Wood, W Sweginnis. Aircraft Accident Investigation. Casper, WY: Endeavor Books, 1995. Chapter 34 helpful for ``reading'' events from witness plates. Proceedings with technical papers from annual seminars and individual papers are available through the International Society of Air Safety Investigators, Sterling, VA 20164.

Assuring Quality 22. L Benner, I Rimson. Quality Management For Accident Investigations (in two parts). International Society of Air Safety Investigators Forum, 24(3), October 1991; 25(1): February 1992.(http://www.patriot.net/users/luben/5IRRQC.html.)

Developing Recommendations 23. I Rimson, L Benner. Mishap Investigations: Tools For Evaluating The Ouality Of System Safety Program Performance. Proceedings of 14th System Safety Conference, Albuquerque, NM. (www.iprr.org/LIB/ QMA_P1.html from http:/www.patriot.net/ 5IRRQC.html.) 24. K Hendrick, L Benner. Appendix E. In: Investigating Accidents with STEP. New York: Marcel Dekker, 1986. Presents instructions for preparing a test plan. 25. L Benner. 10 MES Investigation Guides. Oakton, VA: Ludwig Benner & Associates, 1998, Investigation Test Plan Guide.

718 26. L Benner, 10 MES Investigation Guides 2nd ed. Oakton, VA: Ludwig Benner & Associates, 1998, Guide 8. Helps investigators develop recommendations. 27. K Hendrick, L Benner. Investigating Accidents with STEP, New York: Marcel Dekker, 1986, pp 361±365. Describes recommendation quality control problems to avoid.

Internet Site References Several of the references provide Internet web addresses. Internet sites change frequently, and


Benner

more are coming on line daily. Sites of interest to investigators can be located by doing searches on accident investigation using one or more of the many internet search engines available. The searches will disclose the online sites when the search is conducted. References to additional investigation manuals, research reports, papers, books, videos, and links to investigation sites and investigation reports, publications, and other resources of interest can be found at www.iprr.org.

Chapter 8.2 Government Regulation and the Occupational Safety and Health Administration C. Ray Asfahl


2.1

INTRODUCTION

2.1.1

A comprehensive program of industrial automation must take into consideration the impact that government regulation and the Occupational Safety and Health Administration (OSHA) have had upon the workplace. Automated systems sometimes introduce hazards that are either not present in manual systems, or they do not pose a threat in manual setups. The introduction of these hazards may put the ®rm in violation of OSHA standards. Even more important to automation than the negative impact that automation can sometimes have upon hazards and violations of OSHA standards is the positive role automation can play in removing workers from hazardous workplaces or environments. In this respect, OSHA and federal safety and health standards can act as a driving force for the introduction of automated systems and robots to do jobs that are considered unsafe for humans or in violation of OSHA safety and health standards. Whether the impetus is to bring automated systems into compliance by removing hazards that they might introduce or to determine where automated systems can remove worker exposures to OSHA violations, the automated system designer needs to know what critical role the OSHA plays in today's workplace.

When the OSHA was brought forth by Congress in 1970 it had a stunning impact upon industry nationwide. Made a part of the U.S. Department of Labor, the new agency was given enforcement powers never before seen in the American workplace. For the ®rst time, federal inspectors were authorized to enter virtually any industry without advance notice at any ``reasonable time,'' including the night shift, and look around for violations of federal safety and health standards and then write citations with monetary penalties. As the law was originally written, the OSHA inspector had sweeping powers to enter the workplace without having to show cause or a court-issued search warrant, but later, in the landmark Barlow Decision, the U.S. Supreme Court ruled unconstitutional this broad power and required the federal OSHA inspector to seek and obtain a court order to enter a plant, if the proprietor demanded it [1]. Industry was caught by surprise by such sweeping powers. Congress speci®ed a mere four-month period between passage of the law and its effective date. This unusually short period for familiarization of the law was all the more remarkable for the fact that the force of the law was to be so generally applied. At the time of passage it was estimated that the law would affect

719


OSHA Enforcement Powers

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some 57 million workers in more than four million workplaces across the nation [2]. It would soon be found that the OSHA would affect virtually every U.S. citizen, nonworkers as well as workers. But before that was to happen, many industries had to become aware of the agency and what to do about it. Millions of ®rms and millions of workers were still uninformed of the OSHA's powers at the time that the law went into effect. When U.S. industry did ®nd out what the OSHA was all about, it reacted quickly and sometimes humorously. As one industry representative put it, `Ìf you think that ÒSHA' is a small town in Wisconsin, you are in big trouble!'' The new agency's powers were likened to Hitler's Gestapo. The OSHA quickly grew to become one of the most hated government agencies ever created. There is a suggestion that Congress had some premonition of the public indignation that the agency would generate, because in the wording of the law itself Congress speci®ed a penalty of up to life imprisonment for anyone convicted of killing an OSHA inspector. The vehemence with which industry attacked the new OSHA agency suggested that industry did not care about worker safety and health. The ostensible purpose of the lawÐto punish employers with monetary ®nes if they violated established and published standards for safety and healthÐseemed honorable and dif®cult to question. So why else would industry be so upset, unless they were indeed guilty of gross neglect of worker safety and health? The reason behind the public outcry becomes more apparent when the structure of standards promulgated by the OSHA is examined, in the section which follows. 2.1.2

Federal Standards

Congress set another quick deadline on the OSHA agency as soon as the agency went into effect. The agency was given two years in which the agency had the right to put into effect, without public comment, ``national consensus standards'' for occupational safety and health. The OSHA was faced with the task of quickly assembling appropriate existing standards for establishment as mandatory federal standards enforceable by law. To wait beyond the two-year deadline would require the OSHA to justify to the public the necessity for each standard using a lengthy, legal promulgation process. There were several problems associated with accomplishing the task of adopting a set of national consensus standards.


The ®rst problem was to decide which standards should be included. Congress speci®ed criteria for adoption under the classi®cation ``national consensus.'' However, many standards met the general criteria speci®ed by Congress, such as `àdopted and promulgated by a nationally recognized standards-producing organization'' or ``formulated in a manner which afforded an opportunity for diverse views to be considered.'' But the real problem was to determine whether the standards under consideration for adoption were ever intended to be mandatory, with inspections and penalties for failure to comply. In case of con¯icts between existing standards, Congress expressly took the more aggressive approach and speci®ed that OSHA shall ``promulgate the standard which assures the greatest protection of the safety or health of the affected employees.'' The OSHA could easily interpret the spirit of this mandate as ``when in doubt, go ahead and adopt a given standard.'' Another problem was to decide which standards applied to which industries. When standards were enforced by states, the state often published standards for each industry covered. While not all industries were covered, the states had the opportunity to focus upon industries that had poor safety records. But the OSHA law was so general in scope that it applied to virtually all industries. A very complex structure would be needed to determine exactly to which category each industry belonged and many decisions would have to be made to determine which ``national consensus standards'' should be applied to which industry. Since the OSHA law generalized upon a more speci®c structure for standards and enforcement, it became dif®cult for the agency to classify industries and make judgments to determine which industries would be required to abide by which standards. It is even questionable whether the new OSHA agency had been extended the authority by Congress to make such judgments. Therefore, OSHA departed from the standards-by-industry approach and adopted a strategy that became known as the ``horizontal standards approach.'' Therefore, early on, the OSHA published a ``national consensus standard'' consisting of standards to be applied in general, in all industries in which the speci®c circumstances described in the standard could be found. The new standard was designated ``General Industry Standards.'' The OSHA retained the traditional approach for certain industries, such as construction, sawmills, textile mills, and maritime industries and others for which it could identify speci®c industry standards. These standards became

Government Regulation and OSHA

known as ``vertical standards'' to contrast them with the horizontal types contained in the General Industry Standards. The General Industry Standards met the Congressional deadline for adoption within two years of the effective date of the OSHA law, but the agency was soon to regret that it had not used more discretion in selecting which standards to adopt. Many of the standards had been written in advisory language because, as was stated earlier, they had never been intended to be mandatory with inspections and penalties for failure to comply. To get around the problem of advisory language, the OSHA in some instances simply substituted the word ``shall'' for the word ``should'' when it adopted the language of the national consensus standards. The OSHA's right to do this was later challenged, as Congress had not given the OSHA the authority to change the wording of standards that met the de®nition of ``national consensus'' without going through the lengthy process of legal promulgation of the new standard, allowing the public to comment on whether the standard should be adopted. Another indiscretion on the part of the OSHA was its failure to screen standards to eliminate antiquated provisions that were no longer adhered to by anyone. For example, the OSHA was subjected to ridicule for adopting a standard that prohibited ice from coming into contact with drinking water. This ancient provision dated back to the days when ice was cut from ponds and was not considered safe for drinking. But the most critical problem generated by the new national consensus standards was their sheer volume. Since the OSHA had been unable to grapple with the problem of sorting out the standards into vertical standards for each industry, the ``horizontal standards'' strategy adopted by the OSHA left to the public the responsibility for reading the rules and determining which standards applied to their own operations. The standards were, and still are, so voluminous that industries large and small have had dif®culty ®nding which ones are suf®ciently relevant to their own operations to study in detail and formulate plans for coming into compliance. The volume of the standards has become a powerful weapon in the hands of the federal inspector, who has the latitude to dig deeply into the standards to ®nd violations, if he chooses to do so in a given inspection, or to take a more lenient posture overlooking minor violations. It is the inspector's option, because, as one industry representative put it, `ìf you are alive, you're wrong,'' in any careful, literal reading of the entire volume of the OSHA standards


721

applied ``wall-to-wall'' throughout an industrial plant of any reasonable size. 2.2

GENERAL REQUIREMENTS

Most OSHA standards have survived the public controversy over their volume, their origins, and their relevance to current industrial operations. While it may seem that nearly every topic is covered by standards, in fact OSHA inspection authorities are often unable to identify a particular standard to apply to a given hazardous situation. In these situations, one solution is to turn to the General Duty Clause of the OSHA law. 2.2.1

General Duty Clause

Congress anticipated that federal standards would not be in place to deal with every situation so they drafted a general requirement stated right in the text of the law, quoted here as follows [3]: Public Law 91-596 Section 5(a) Each employer . . . (1) shall furnish to each of his employees employment and a place of employment which are free from recognized hazards that are causing or are likely to cause death or serious physical harm to his employees . . . Particularly in the ®eld of automation, the OSHA applies the General Duty Clause because there are very few speci®c standards that apply to the speci®c areas covered by this book, i.e., programmable logic controllers, robots, etc. Another way that the OSHA applies the General Duty Clause is to ®nd a speci®c rule that applies to some other operation and then generalize the rule to other applications, using Section 5(a)(1). For example, types of point of operation guarding is well-speci®ed for certain machines, such as mechanical power presses. For some other machines, such as hydraulic presses or forging machines, the standards are less speci®c about how the machine should be guarded. Since it would be inappropriate for OSHA to cite a rule for a different machine than the type speci®ed in the standard, the OSHA can turn to the Section 5(a)(1) General Duty Clause and cite the dangerous situation anyway. Of course, to be upheld by the courts, the OSHA will have to provide justi®cation that the hazardous condition is ``likely to cause to death or serious physical harm'' to employees. In the example studied here, lack of point of operation guarding could lead to

722

Asfahl

an amputation, a condition that would meet the criterion of ``serious physical harm.'' There is also a General Duty Clause for employees, as follows: Public Law 91-596 Section 5(b) Each employee shall comply with occupational safety and health standards and all rules, regulations, and orders issued pursuant to this Act which are applicable to his own actions and conduct. The General Duty Clause for employees is rarely, if ever, cited by the OSHA. Indeed there are no penalties speci®ed in the law that are to be applied to employee conduct under Section 5(b). The General Duty Clause for employers, however, is very frequently cited and citations of this clause usually carry heavy penalties. 2.2.2

Enforcement Priorities

The OSHA agency, without doubt, must operate with limited resources, resources that have become even more limited in recent years. The OSHA must set priorities, and the result is that some categories of workplace are rarely visited. The OSHA law recognized the presence and importance of `ìmminent dangers'' that are of such a serious nature as to threaten immediate and serious harm to employees. Accordingly, the OSHA places the highest priority for inspection on `ìmminent dangers'' in the allocation of its inspection resources. Imminent dangers are rare, so rare that inspectors are not regularly scheduled to handle these situations. On the rare occasion that one does arise, usually at a construction site, the OSHA has been given authority to seek a court order to close down the worksite. Although this inspection priority is high, automation planners and designers should not expect to experience an imminent danger inspection. The second highest inspection priority is the investigation of reported fatalities or major incidents involving the hospitalization of ®ve or more employees. The OSHA law originally required the employer to notify the OSHA agency within 24 hr of occurrence of workplace fatalities or major incidents involving hospitalization of ®ve or more employees. The 24 hr deadline has since been shortened to 8 hr. Telephone, telegraph, or other suitable means are acceptable means of informing OSHA of these major incidents. Fortunately, tragedies of this magnitude are rare for applications of automation, but unlike the imminent danger category, fatalities or major accidents are de®nitely a possibility when working around automatic


machines, robots, or other automated systems. Accounts of human fatalities at the hands of industrial robots make big headlines in newspapers. Besides robots, other automated systems and automatic machines have caused fatalities, sometimes in surprising ways. Consider an automatic screw machine, for example. Although there are many moving parts in the highly mechanized operation of a multispindle automatic screw machine, most of these moving parts are enclosed or shielded in the operational head of the machine. For both safety and general containment of chips and cutting ¯uid, automatic screw machines usually have enclosed heads. It is dif®cult to see how a person could be injured seriously by an automatic screw machine, much less killed by one. But, as the following account reveals, fatalities around automatic screw machines are certainly a possibility. Case study. Worker FatalityÐMultispindle Automatic Screw Machine: A six-spindle automatic screw machine was operating with exposed rotating bar stock in a manufacturing facility for the production of socket wrenches. The bar stock had recently been changed and the bars were still very long, extending from the backside of the machine head as shown in Fig. 1. An awareness barrier, in the form of a stanchion and chain arrangement, warned personnel not to enter the area of the rotating bars. However, one of the bars was slightly bent when the machine was placed in operation. The situation was exacerbated when the machine was turned on and the bent bar began to rotate rapidly. The long length of the slightly bent bar also added to the problem. The combination of factors caused the bar to make contact with one of the other ®ve rotating bars, bending it also. Almost instantly, the entire bundle of rotating steel bars became a tangled mass, swinging wildly outside their usual work envelope. A female worker standing nearby was struck by the rotating tangle of steel bars and was fatally injured. This case study illustrates the need for awareness of the ways in which automated systems can become very dangerous in surprising ways. The OSHA was summoned in this incident in response to the high priority placed upon fatalities and major accidents. The next highest category for OSHA enforcement actions are complaints ®led by employees or others. The OSHA law provides for a procedure by which an employee can complain about a suspected violation of OSHA standards and request an inspection. To protect the employee from employer retaliation or from the fear of potential employer retaliation, the law


723

Figure 1 Multiple-spindle automatic screw machine. (From Ref. 4, copyright 1979 by John Wiley & Sons, Inc., New York, NY. Reprinted by permission.)

provides for concealing the identity of the employee making the complaint. Before undertaking any automation initiative, management needs to think about this provision of the OSHA law. Automation projects often generate hostility on the part of employees who fear that they may lose their jobs or otherwise be adversely affected by the new automated system. People experience anxiety when they are confronted with change beyond their control. Management would do well to consider carefully the impact of any automation project upon the attitudes of workers who will be affected. More speci®cally, management should expect workers to be intolerant toward any safety or health hazards that might be introduced by an automation project and should not be surprised if workers get the idea to call the OSHA and ®le a complaint. The OSHA can be expected to place a high priority on such complaints. Since the two higher priority categories (imminent danger and fatalities/major hospitalizations) are very rare, an inspection is almost a certainty if an employee ®les a complaint against the ®rm. The foregoing account seems to condemn automation as a generator of OSHA problems. The opposite is often closer to the truth, because on the other side of the complaint issue is the fact that a primary motivation for automation is to eliminate hazards to employees. Indeed, an employee complaint to the OSHA regarding a workplace hazard may ultimately


wind up as an automation project to eliminate the hazard. The OSHA itself places a high premium on `èngineering controls'' as a solution to workplace hazards, instead of relying on ``work practice controls'' or personal protective equipment.

2.2.3

Compliance Procedures

By whatever priority it is selected, once a ®rm is selected for inspection, the OSHA inspector has authority to search for violations of any standards contained in the general industry (29 CFR 1910) standards, provided the ®rm is not a special industry such as maritime, for which other volumes of standards apply. During the walkaround inspection of the facilities, the OSHA may request a representative of employees to accompany the inspector and a representative of management during the inspection. If violations are alleged, the ®rm is afforded the opportunity to request an informal conference in which the alleged violations and corrective actions are discussed by company management and the OSHA. If the OSHA believes that an observed violation ``has no direct or immediate relation to safety or health,'' it may choose to designate an alleged violation as ``de minimus'' and propose no penalty to be paid by the ®rm. Sometimes citation of an alleged violation is waived completely by

724

Asfahl

the OSHA, especially if the violation is corrected immediately. If a citation is issued, it will be received by the company within six months, the statutory limit for issuing a citation of alleged violations. After a citation is issued, time is of the essence, because from the date a citation is issued, the ®rm has 15 working days in which to decide whether to contest the citation. If left uncontested, the citation becomes a ®nal order and the employer is obliged to pay whatever monetary penalties have been proposed by the OSHA. If the citation is contested, the employer has an opportunity for the citation to be reviewed by the Occupational Safety and Health Review Commission (OSHRC), an independent reviewing body appointed by the President. Once the citation comes under review, the OSHRC is authorized to lower or to eliminate the penalty for the violation, but the ®rm should also be aware of the fact that the OSHRC also has the authority to increase the penalty to a level higher than was proposed by the OSHA. Congress extended to the OSHRC, not OSHA, the authority to set ®nal penalty levels, and although the OSHRC usually lowers penalty levels, it sometimes exercises its authority to set higher penalties. A more serious concern than the payment of ®nes for OSHA violations is the correction of the violation within whatever reasonable time for abatement is set by the OSHA. The OSHA usually discusses a proposed abatement period with the ®rm during the informal conference after the inspection. The abatement period is very important, and the ®rm should be sure that it is reasonable, and once the period is agreed upon, the ®rm should be diligent in taking whatever actions are necessary to correct the violation. If during the correction period if becomes evident that deadlines will not be met, the ®rm should get in touch with the OSHA and request an extension of the abatement period. If no extension is requested and the abatement period expires, the OSHA has authority to re-enter the plant and check to see whether violations have been corrected. If a violation is found to remain uncorrected, the ®rm becomes subject to severe penalties that are assessed for each day the violation remains uncorrected. 2.2.4

Recordkeeping

One of the ®rst things the OSHA inspector examines during an inspection is the company's records for injuries and illnesses. The Log/Summary of Occupational


Injuries/Illnesses (OSHA form 200) is now well recognized by industries as mandatory, except for small ®rms having fewer than 10 employees. At the end of each year the right side of the two-page form acts as a summary, to be posted by February 1 for employees to review the previous year's record. The required posting duration is 30 days. One might expect that recordkeeping violations are considered minor, even de minimus, but the OSHA takes seriously whether a ®rm is diligent in maintaining the log. Recordkeeping ®nes have exceeded $1000, and in the early 1990s, recordkeeping violations were among the most frequently cited violations on record. 2.2.5

Performance Measures

One reason recordkeeping is so important to the OSHA is that recordkeeping is the basis for computing injury/illness performance measures. Standard incidence performance measures are computed ratios of the number of injuries or illnesses per man-hours worked, the ratio being multiplied by a constant (200,000) to make the ratio more meaningful. The ®gure 200,000 is approximately the number of manhours worked per year by a 100-employee ®rm. The injury incidence rate is considered more meaningful than the illness rate, because it is dif®cult to de®ne a time of occurrence for illnesses. The most popular incidence rate is the ``Lost Workday Incidence Rate'' (LWDI) which includes injuries, but not fatalities. It should be recognized that the OSHA considers a workday ``lost'' if the worker is unable to do his or her regular job after the injury or illness. If the worker remains at work, but is transferred to another job after the injury or illness, the days spent in the other job are considered ``lost workdays'' by the OSHA. The LWDI is a measure of the number of incidents that result in one or more lost workdays, but it does not consider how many workdays are lost in each incident. The OSHA has used this popular index as a criterion for whether to continue an inspection of a given ®rm, and it has also used the LWDI as a criterion for targeting a given industry group using the Standard Industrial Classi®cation (SIC). The average LWDI for all manufacturing industries toward the end of the twentieth century was around 3 or 4. Some of the transportation industries have LWDIs of 10 or more. The next section examines ways in which automation can be used to keep incidence rates below the national averages and to avoid OSHA citation.


2.3

MACHINE GUARDING

It should not come as a surprise that the OSHA ®nds thousands of violations of machine guarding standards every year, as machine guarding seems to typify the subject of industrial safety. The automated-system designer should consider the safety aspects of manufacturing systems in the design phase, so that hazards of the human/machine interface can be guarded or engineered out before the system is built. It is particularly appropriate to consider machine guarding in this handbook, because the technology of automation can be quite successfully brought to bear upon the problem of guarding machines in general. Before examining the solutions this technology can bring forth, the various mechanical hazards introduced by machines should be explored. 2.3.1

Mechanical Hazards

The OSHA uses general requirements to cover all machines before proceeding to specialized requirements for such dangerous machines as punch presses, saws, and grinding machines. One of the most frequently cited general industry OSHA standards is as follows [5]: 29 CFR 1910. General Industry 212 General requirements for all machines. (a) Machine guarding. (1) Types of guarding. One or more methods of machine guarding shall be provided to protect the operator and other employees in the machine area from hazards such as those created by point of operation, ingoing nip points, rotating parts, ¯ying chips and sparks. Examples of guarding methods are: barrier guards, two-hand tripping devices, electronic safety devices, etc. Note that this standard leaves latitude for choice on the part of the process planner or machine designer with regard to the particular types of guards or guarding methods. Included are `èlectronic safety devices,'' which include a wide variety of automatic safeguarding mechanisms, such as photoelectric or infrared sensing barriers and other sophisticated control apparatus. In the context of this standard, the term `èlectronic'' should be construed to include `èlectromechanical'' devices. The general machine guarding standard is one of the most frequently cited of all OSHA standards. Even more frequently cited, though, is the general standard for point of operation guarding, detailed in the section which follows.


725

2.3.2

Point of Operation Safeguarding

The point of operation of a machine is de®ned as the `àrea on a machine where work is actually performed upon the material being processed.'' The frequently cited general OSHA standard for guarding the point of operation is quoted as follows [5]: 29 CFR 1910. General Industry 212. General requirements for all machines. (a) Machine guarding. (3) Point of operation guarding. (ii) The point of operation of machines whose operation exposes an employee to injury, shall be guarded. The guarding device shall be in conformity with any appropriate standards therefor, or, in the absence of applicable speci®c standards, shall be so designed and constructed as to prevent the operator from having any part of his body in the danger zone during the operating cycle. The point of operation is generally the most dangerous part of the machine and at the same time it is usually the most dif®cult to guard. Machines usually must have an opening to admit material to be processed, and the same opening that admits material also often exposes the operator to injury. Often the solution is to devise some means of alternating the opening and closure of the area around the danger zone so that the operator can have access to the point of operation during the loading and unloading portion of the cycle, and then the guarding system can close the danger zone during the processing portion of the machine cycle. If such a system can be made to be automatic, an increased level of safety is usually possible, because the system does not depend upon the judgment or discipline of the operator to be effective. The following sections describe some of the automated systems used to control access to the danger zone of machines. 2.3.2.1

Gates

The OSHA standards recognize a device (known as a ``gate'') for protecting the danger zone of punch presses (see Fig. 2). Gates are actually of two types. Type A closes and remains closed during the entire cycle of the ram as it closes the upper die upon the lower die and then reopens and rises until it comes to rest. The Type B gate closes for the downward portion of the cycle and then reopens as the ram returns to its up position. Type A is a little more conservative in that it provides more protection in the case of a ``repeat,'' in

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which the ram unexpectedly returns down and recloses the die after the cycle has ®nished. Although the Type B gate is not quite as safe, it affords higher production by shortening the closure of the danger zone to the more dangerous portion, the downward stroke. Control of gates of either Type A or Type B is possible using automated control systems such as are described in this book. The design and control of sophisticated gate devices for punch presses serve as an example of the ways that automated systems can be used to eliminate point of operation hazards on other types of machines as well. 2.3.2.2 Presence-Sensing Devices

Figure 2 Gate device for projection of the point of operation danger zone. (From Ref. 6.)

Figure 3 illustrates a system for sensing objects that penetrate an infrared screen and enter the danger zone. Such systems are recognized by the OSHA standards as a valid means of safeguarding the point of operation of some types of mechanical power presses. They can also be used very effectively for some machines other than presses. The principle behind the infrared ``light curtain,'' as these systems are sometimes called, is that the actua-

Figure 3 Photoelectric presence sensing screen. (From Ref. 6.)



tion of the machine is halted once the infrared beam is broken. For this principle to work the machine must be able to stop actuation mid-cycle. Some types of mechanical presses, especially the older types, are actuated by a heavy ¯ywheel that is engaged with the press ram in some positive way, such as with a mechanical dog, during each cycle. The inertia of the ¯ywheel is so great that once engaged the ram cannot be stopped. This seriously limits the effectiveness of the infrared sensing barrier, and indeed OSHA standards disqualify the presence-sensing barrier as a means of safeguarding the point of operation on such presses. Fortunately, many modern presses are equipped with clutches and brakes so that the ¯ywheel can be disengaged midstroke. Visible light can also be used instead of infrared, but infrared has several advantages. The main advantage is that ambient visible light does not trigger a sense condition in an infrared sensor. Besides using infrared radiation, the technology now permits these sensors to be LED-based and to be pulsed. A pulsed LED source of infrared radiation can be programmed in some unique way to produce a characteristic infrared radiation pattern that is not likely to be misinterpreted as ambient radiation. Another way that the pulsed LED infrared source can be programmed is to make a criss-cross pattern across the ®eld so that an object is unable to slip through the barrier without detection. Other types of presence sensing systems rely upon radio-frequency ®eld disturbances introduced by a person or object penetrating the danger zone. Radio-frequency detection systems can vary in their sensitivities from object to object, depending upon their size and physical composition. 2.3.2.3

Control Systems

Where presence sensing systems are used to protect operators from danger zones, there are ample opportunities to employ automation technology using digital logic to control what takes place whenever the barrier is violated. The same can be said of sophisticated two-hand control systems as shown in Fig. 4. The automated control system can detect when the operator has not depressed the palm buttons concurrently. In other words, the press should not operate if the operator depresses one palm button and then the other. 2.3.2.4

Automatic Brake Monitoring

Another consideration is the monitoring of the clutch and brake arrangement for presses designed to stop in


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Figure 4 Two-hand palm button control for keeping hands out of the danger zone. (From Ref. 6.)

midstroke. If the press is dependent upon the clutch release and brake engagement for safety, the automatic control system can be designed to monitor the condition of the brake and clutch to alert the operator or shut down the machine if stopping time deteriorates beyond established limits. The OSHA is very speci®c about brake monitoring and control systems as applied to mechanical power presses, as stated in the following provision of the OSHA standard [5]: 29 CFR 1910. General Industry 217. Mechanical power presses (c) Safeguarding the point of operation. (5) Additional requirements for safe-guarding. Where the operator feeds or removes parts by placing one or both hands in the point of operation, and a two hand control, presence sensing device of Type B gate or movable barrier (on a part revolution clutch) is used for safeguarding: (i) The employer shall use a control system and a brake monitor which comply . . .

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Asfahl

For machines other than mechanical power presses, the automated system designer can borrow from the technology required for mechanical power presses. 2.3.3

Interlock Mechanisms

Related to brake monitoring s and control systems are interlockmechanisms for preventing a machine from being operated if any part of the machine is in an unsafe mode. In a very simple example, an ordinary clothes dryer will not operate if the door is open. More complex machines may need to be interlocked dependent upon a complex logical relationship among several variables. The automated system designer is an ideal candidate to delineate the logic that such systems require on a case-by-case basis. A programmable logic controller is an effective device for housing and executing that logic. 2.3.4

Failsafe Systems

The OSHA standards re¯ect the principles of failsafe operation in a number of the detailed provisions. Automated system design should take into consideration the need to build failsafe logic into the system as it is being developed. For instance, if a fault is detected by the automated system that requires logical action, the control system can disable the ability of the machine to perform additional cycles, but the system can preserve the ability of the machine to keep itself in a safe mode. Example OSHA provisions or portions of provisions that recognize failsafe principles follows: 29 CFR 1910. General Industry 217. Mechanical power presses b. Mechanical power press guarding and construction, generalÐ 8. Electrical. (iii) All mechanical power press controls shall incorporate a type of drive motor starter that will disconnect the drive motor from the power source in event of control voltage or power source failure, and require operation of the motor start button to restart the motor when voltage conditions are restored to normal. (vi) Electrical clutch/brake control circuits shall incorporate features to minimize the possibility of an unintended stroke in the event of the failure of a control component to function properly, including relays, limit switches, and static output circuits. (13) Control reliability. . . . the control system shall be constructed so that a failure


within the system does not prevent the normal stopping action from being applied to the press when required, but does prevent initiation of a successive stroke until the failure is corrected. (i) Be so constructed as to automatically prevent the activation of a successive stroke if the stopping time or braking distance deteriorates to a point where . . . One can see from the foregoing that the OSHA standards specify the recognition of failsafe principles in the construction of the automatic control systems that are speci®ed to control presses. The principles apply to other machines as well. To an extent, then, it can be said that the OSHA requires automated systems to control the safety of certain machines. 2.4

REPETITIVE MOTION HAZARDS

Many jobs in the manufacturing environment require highly repetitious motion that can lead to trauma. The most publicized of these types of trauma is carpal tunnel syndrome (CTS), a disability of the wrist due to repetitive hand and ®nger motion. The OSHA has taken note of the high incidence of CTS in industrial exposures, especially in the last two decades of the twentieth century. Various designations have arisen to represent the general class of injuries typi®ed by CTS. One such designation is cumulative trauma disorders (CTD); another is repetitive strain injuries (RSI). The high rate of Workers Compensation claims for these types of injuries during the last two decades of the century led the OSHA to seek a general standard for ergonomics that addressed repetitive motion hazards in a systematic way. At the time of this writing, no general OSHA standard for ergonomics had been ®nalized. One dif®culty is the wide variety of workstation conditions that can lead to repetitive motion injuries. The OSHA attempted to specify a general review process whereby repetitive motion hazards could be identi®ed and removed through redesign of the workplace or by revision of the production process. Certain industries have proven to be more susceptible to repetitive motion hazards. Among these is the meatpacking industry, especially poultry processing. Any processing or manufacturing activity that is labor intensive is a potential candidate for repetitive motion hazards. In the absence of a speci®c OSHA standard for ergonomics or for repetitive motion injuries, the OSHA has turned to the General Duty Clause for citations of this hazard, with associated heavy


729

monetary penalties. An example is a snack food manufacturer, cited in the early 1990s for a total of $1,384,000 in penalties, of which more than half was for ``repetitive motion illnesses.'' Each instance of citation for repetitive motion illness resulted in a proposed penalty of $5000, for a total of $875,000 for repetitive motion illnesses alone [7]. Repetitive motion illnesses have been one of the biggest drivers of automation research in the meatpacking industry. By transferring jobs that are at risk from people to machines, the company often removes hazards, avoids OSHA penalties, and reduces production costs all at the same time. It is for this reason, more than any other, that this chapter has been included in this handbook.

centration of the PEL. The idea behind the action level is to provide a buffer to permit actions to be taken to control harmful air contaminants before they reach illegal levels. Without some sort of automated monitoring system it is dif®cult to respond to a change in concentration of toxic air contaminants. This suggests that automated systems can be employed to not only control the hazardous environment, but also to provide documentation of compliance with OSHA standards for air contaminants. Such systems can be controlled by a computer or a programmable logic controller. Figure 5 diagrams an environmental control system that suggests an automated logic control system to monitor ®lter conditions, control valves, and log compliance with air contamination limits.

2.5

2.5.2

HAZARDOUS ENVIRONMENTS

Another driver for automation in the workplace is the presence of hot, toxic, radioactive, ¯ammable, or simply unpleasant work environments. There are many ways automation can be brought to bear on this problem. Even when workers remain in the hazardous environment, automated systems can monitor exposures and control ventilation and other systems for keeping hazards in check. In other situations, too hazardous for human exposure, robotic solutions to production operations may be the answer. 2.5.1

Environmental Monitoring

The OSHA sets exposure limits for air contaminants in the workplace. These limits are designated permissible exposure levels (PELs). For most air contaminants these limits are expressed as 8 hr time-weighted averages (TWAs). This procedure recognizes that even very harmful toxic contaminants are tolerable for short durations. For most toxic substances, what is important is the overall average exposure for a full shift. The OSHA PELs are based upon ®ndings of the American Conference of Governmental Industrial Hygienists (ACGIH) Committee on Industrial Ventilation (CIV). ACGIH publishes a list of threshold limit values (TLVs) for each toxic air contaminant. The TLV is considered the level above which the contaminant can do signi®cant, permanent harm to the e individual exposed. The OSHA attempts to set PELs at the TLV levels, whenever possible, however it is dif®cult to promulgate a new standard every time the TLV is adjusted by ACGIH. The OSHA also recognizes an action level (AL) which is generally one-half the con-


Robotic Solutions

Some environments are too hazardous for employee exposure. Even some environments that in the past have been marginal are now considered intolerable in light of increased awareness of long-term effects of toxic air contaminants and the technological and economic price of bringing these environments into compliance with OSHA standards. The presence of federal regulation and the OSHA has also made management and worker sensitive to the safety hazards associated worker exposures to some hazardous environments. All of these factors are supporting increased research into robotic solutions to make possible the removal of the human worker from direct exposure to the hazards. On the other side of the robotics issue is the fact that robots themselves present new hazards. The intermittent, unpredictable nature of their very ¯exible operation, when programmed to perform a complex task, increases the hazard when personnel are exposed to the robot's work movement envelope. The OSHA has been sensitive to the new hazards the industrial robot brings to the workplace. However, the development of standards to deal with these hazards is a slow process. Most of the OSHA General Industry Standards were put into effect as national consensus standards in the OSHA's opening years. In the early 1970s industrial robots were scarcely in existence, much less were national consensus standards to address their safety. As of this writing there still exists no speci®c standard addressing the safety of industrial robots. Whenever a serious accident or fatality results from human exposure to industrial robots, the OSHA

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Asfahl

Figure 5 An automatic control system for exhaust ventilation for removing particulate air contaminants. (From Ref. 8, used with permission.)

generally cites Section 5.a.lÐGeneral Duty Clause of the OSHA law. Penalties are typically severe. Even without the presence of safety hazards, robots in the workplace generate animosity on the part of some employees. When an accident occurs, that animosity is ampli®ed, not only by workers, but by the press as well. If a ®rm is cited for an alleged hazardous condition caused by the motion of a robotic system, the Occupational Safety and Health Review Commission (OSHRC) may recognize the bene®t provided by an automatic interlock system that controls access to the danger zone, as the following excerpt from an OSHRC decision demonstrates [9]: It is undisputed that the machines had extensive precautions to protect servicing and maintenance employees. An electronically interlocked gate surrounded the machine area in each case. Once an employee opened that gate or pushed an emergency stop button, a time-consuming series of


eight to twelve steps were required before any hazardous movement of the machine could occur. The evidence indicated that the restart procedures would provide plenty of warning to the employees, in the form of alarms and visible motions, so that they could avoid any hazardous movement of the machinery. The advantage of an automated system to control access by means of an interlock is obvious in the foregoing description of an alleged hazardous condition at General Motors Corporation that was vacated by the reviewing body.

2.6

SUMMARY

This chapter began with an introduction to OSHA and the origin of federal standards that have an impact upon the ®eld of industrial automation. The OSHA has been granted powers by Congress to make inspec-


tions and write citations for alleged violations of detailed standards from a large volume of general industry standards. The OSHA has changed the way companies have dealt with safety and health standards. One of these changes is that issues that were formerly advisory in nature have become mandatory with penalties for violation. Another way that standards have changed is that a more horizontal structure predominates the OSHA approach, which has replaced a more vertical, or industry-by-industry approach used by the various states prior to the OSHA. Despite the detail of the OSHA standards, many situations believed to be hazardous do not seem to ®t any of the described conditions spelled out in existing national consensus standards. This is especially true of industrial automation systems, such as robots, material handling systems, and process control systems. Many modern industrial automation systems, such as those described in this book, were not invented at the time of the writing of the general body of national consensus standards that represent the bulk of what the OSHA enforces. Therefore, the OSHA has turned to a general provision of the OSHA law itself, the so-called ``General Duty Clause'' of the OSHA Act. Many citations of industrial automation systems are citations of this general duty clause, and it is a provision that the automated system designer should understand and heed. The OSHA does have a priority structure for inspections, placing imminent danger highest, followed by fatalities and major accidents, and employee complaints, respectively. Because of the resentment that industrial automation systems sometimes engender on the part of employees, system designers should prepare for possible OSHA inspection as a result of employee complaints. If an employer does receive a citation of alleged violations of OSHA standards, there is an appeals process available, but timely action is essential. Recordkeeping is another aspect of the safety system that OSHA takes very seriously, as is evidenced by signi®cant ®nes for recordkeeping violations. One reason for the importance placed upon recordkeeping is that it forms the database for the computation of performance measures that are used to evaluate both companies and entire industries and to be used as decision criteria for OSHA inspection frequency. Machine guarding is one of the most relevant areas of federal standards as they apply to industrial automation systems. Within the machine guarding standards, the most signi®cant application area for automated systems is guarding the point of operation. The OSHA has some very speci®c rules for guarding


731

the point of operation on certain machines, such as mechanical power presses. The principle behind these speci®c rules can be used in the design of industrial automation systems to be used on a wide variety of machines in general. Typical point-of-operation safeguarding strategies that employ automated control systems are gates, presence sensing devices, and two-hand controls. To facilitate the operation of these systems, overall machine control systems and automatic brake monitoring systems are also appropriate in many cases. The concepts of interlock mechanisms and failsafe principles also apply to many of the OSHA standards and are relevant to the application of the principles contained in this book. An industrial hazard category of increasing signi®cance is the collection of disorders known as ``repetitive motion hazards.'' The OSHA has responded to this increasing signi®cance by vigorous enforcement in industries reporting a high incidence of this type of hazard. Since there is no speci®c standard for this class of hazard, OSHA is citing the General Duty Clause and is proposing severe penalties, especially in the meatpacking industry. The presence of repetitive motion hazards and OSHA penalties is a strong motivation to implement a program of industrial automation using the concepts and principles contained in this book. Another strong motivation for automation is the presence of hazardous environments, such as atmospheres contaminated with toxic substances. The OSHA has had an impact in this area, too, by setting standard ``permissible exposure levels'' (PELs). For the most part these PELs are time-weighted averages over an 8 hr shift. Such standards form a rational basis for implementing automatic monitoring and control systems for protecting employees and documenting compliance with OSHA standards. Finally, some environments are so hazardous that they support development and investment in industrial robots to replace humans in these undesirable workstations. The presence of federal standards and the OSHA enforcement agency have a signi®cant impact upon the present and future development of robots and industrial automation systems. At the same time, industrial automation systems designers should remain aware of the fact that public sentiment is not very tolerant of machines that hurt people. The sentiment is particularly compelling if that machine is an industrial robot, which is often perceived as a replacement for human workers. The profession of the industrial automation system designer, then, is challenged with the task of providing robots and automated systems

732

that eliminate hazards and heed OSHA standards, while at the same time taking care not to introduce new hazards that run afoul of other OSHA standards. REFERENCES 1. CR Asfahl. Industrial Safety and Health Management. 3rd ed. Upper Saddle River, NJ: Prentice-Hall, 1995. 2. CR Asfahl. Robots and Manufacturing Automation. Rev ed. New York: John Wiley, 1992. 3. Job Safety and Health Act of 1970. Washington, DC: The Bureau of National Affairs, 1971. 4. Williams-Steiger Occupational Safety and Health Act of 1970 (Public Law 91-596). December 29, 1970. 5. BH Amstead, F Ostwald, ML Begeman. Manufacturing Processes. 7th ed. New York: John Wiley, 1979.


Asfahl 6. General Industry OSHA Safety and Health Standards (29CFR1910, OSHA 2206 (rev). Washington DC: U.S. Department of Labor, Occupational Safety and Health Administration, 1989. 7. Concepts and Techniques of Machine Safeguarding (OSHA 3067). Washington, DC: U.S. Department of Labor, Occupational Safety and Health Administration, 1980. 8. OSHA proposes ®nes for ergonomics-related injuries. Mater Handling Eng 44(2): 42, 1989. 9. Industrial Ventilation. 15th ed. Lansing, MI. American Conference of Governmental Industrial Hygienists, Committee on Industrial Ventilation, 1978. 10. OSHRC Docket Nos. 91-2973, 91-3116, and 91-3117. Secretary of Labor, Complainant, vs. General Motors Corporation, Delco Chassis Division, Respondent, April 26, 1995.

Chapter 8.3 Standards Verna Fitzsimmons and Ron Collier


3.1

INTRODUCTION

regulations, design practices, and guidelines and to be able to apply them in his or her work. There are literally hundreds of standards, codes, design practices, and guidelines that come into play within the engineering professions. Regulations are equally voluminous. Unfortunately, being able to determine or understand exactly what standards, codes, or regulations may apply to any given engineering design or project can be daunting to say the least, especially for the engineer just starting his or her career. The labyrinth of standards, codes, regulations, recommended practices, and guidelines that could apply, and in many cases are required, can best be described as a bowl of spaghetti. These crucial documents are published by an array of organizations (government and private) and, as often as not, are intertwined and interrelated. Just where does one start? This chapter is intended to help the engineer answer this question, and ®nd some path through the spaghetti bowl called standards, codes, regulations, design practices, and guidelines.

Standards and codes are part of our everyday life. We are raised with a set of standards taught to us by our parents. We abide by a set of standard rules and codes at school and in sports. We are considered ``law-abiding citizens'' if we follow the social rules and regulations established in our communities. It should not be a surprise, then, that we also have standards, codes, regulations, and guidelines in our work. All professionals have a ``Code of Ethics'' usually developed by the professional organization. A standard or code is simply a rule, test or, requirement that is deemed necessary by someone in authority. There are domestic or national standards and codes (de®nes as applicable in originating country). There are international rules. Some of these rules are required by law (mandatory) in the form of regulations, while others are recommended practices or guidelines which can be interpreted as voluntary. There are rules for product design, compatibility, safety, and reliability. There are rules for construction, manufacturing, and processes. There are rules of management, operations, and for selling goods and services. This is just the beginning! A word of caution: do not underestimate the importance of standards, codes, regulations, recommended practices, and guidelines. Every person, every process, and every product is, in some way, aected by these. It is the duty of the engineer to understand the applicable standards, codes,

3.2

First, there is much confusion derived from terminology. Many organizations that develop and publish standards, codes, regulations, recommended practices, and guidelines toss these terms around lavishly and in many cases use them interchangeably. This can add to 733


TERMINOLOGY

734

the confusion and the complexity of when and where to apply a standard, code, regulation, practice, or guideline. In order to reduce this confusion a review of the de®nition of each of these terms is recommended. Webster's New Collegiate Dictionary de®nes each of these terms as follows: Standard: ``Something established by authority, custom, or general consent as a model or example: CRITERION: something set-up and established by authority as a rule for measure of quantity, weight, extent, value, or quality.'' Code: `À systematic statement of a body of law; one given statutory force. A system of principles or rule.'' Practice: ``To do or perform often, customarily, or habitually: to do something customarily: a repeated or customary action: the usual way of doing something: systematic exercise for pro®ciency.'' Regulation: `Àn authoritative rule dealing with details or procedure: a rule or order having the force of law issued by an executive authority of a government.'' Guideline: `À line by which one is guided: an indication or outline (as by a government) of policy or conduct.'' As can be seen from these de®nitions, there are some distinct dierences between standards, codes, regulations, practices, and guidelines. For example, in the de®nition of a standard, notice the phrase `èstablished by authority.'' This authority is usually an appointed body, association or committee of interested experts from a particular ®eld of interest. This convened body of experts does not have legislative authority. The committee develops a ``consensus'' standard, so named because a majority of the committee members must agree. Unanimity is not necessary, and in theory, not preferred, since unanimity generally results in a standard of lower quality. Their primary objective is to formulate a standard set of rules that meets the due process requirements of their industry and the intent of the standard they are to develop. The committee is also considered a duly constituted review authority for the standard and subsequent revisions to it. Therefore, the standards that are developed, although established by an authoritative group of recognized experts, do not have the force of law. Standards are documents that require some degree of consent [1] by the users; standards generally


Fitzsimmons and Collier

have no criminal penalty attached to them for noncompliance. They are strictly voluntary. Again, there are exceptions to the ``voluntary'' standard de®nition. If a consensus standard is referenced in a federal, state, or local law, then that consensus standard can become a part of that law and made mandatory by de facto. An example of this is the listing of certain National Fire Prevention Association (NFPA) standards and guidelines in many state building codes. The NFPA standards and guidelines are documents that establish a reasonable level of ®re safety for life and property. The NFPA standards and codes themselves do not carry the force of law. They are recommended practices based on the ®re prevention experience that builders of industrial, commercial, and residential properties, and their insurance underwriters have gained over many years of study. They are purely advisory documents as far as the National Fire Protection Associate is concerned [2]. When listed in a local building code, which does have the force of law, these referenced standards and guidelines become a part of the building code and, therefore, state law. Another example of where NFPA standards and guidelines have been adopted into law is the inclusion of many of them in the Occupational Safety and Health Act (OSHA) of 1970. The OSHA uses the NFPA standards and codes either by citing them as references in the OSHA regulation, or by actually extracting the written text from the NFPA standard and guideline and including it directly within the body of the OSHA rule or regulation. In either case, the NFPA standard or guideline cited becomes part of the federal law. International standards, such as those developed by the International Standards Organization (ISO) and the International Electrotechnical Committee (IEC), are consensus standards. In these cases, interested experts from dierent countries come together. The process involves the standard being approved and accepted by the member countries. There is also a blurring of de®nitions between governmental and nongovernmental organizations. The federal government promulgates standards that have the force of law. These standards are usually consensus standards that are ®rst developed by a committee of nongovernmental, voluntary experts and reviewed by the interested industries as well as government agencies before being incorporated into the law as a regulation published in the Code of Federal Register. All of this simply means that a document called a ``standard'' may or may not be required by law, carry-

Standards

ing noncompliance and, possibly, criminal penalties. The engineer must determine the origin and authority of any standard that may apply to the project. Ignoring the history and legal authority of a standard can prove to be detrimental and costly to the engineer and the company. As a rule of thumb, it is best to comply with any standard related to the project work, in particular, if the standard deals with public or worker safety. Codes, on the other hand, do have the force of law. Paraphrasing Webster's de®nition will help to understand the dierence between a standard and a code. A code is a system of principles or rules that have statutory force by their inclusion or reference in a systematic statement of a body of law [i.e., Code of Federal Register (CFR), or State Administrative Code (SAC)]. This body of law is generally established by a group of individuals who has legislative authority (i.e., congress, state legislators, etc.). Noncompliance with a code can carry criminal penalties and can be punishable by ®nes, and in some cases prosecution and imprisonment. In the United States, codes and regulations are generally recognized as requirements that have the force of law. An example of this is the three-model Building Code: the Uniform Building Code (UBC), the National Building Code (NBC), and the Southern Building Code (SBC). These documents detail the design and occupancy requirements for all buildings in the United States. They become law by adoption and reference in the state and local statutes and regulations. The individual states and localities can pass tighter codes, but the model Building Codes are the minimum requirement in the jurisdictions adopting them. Another example of a standard that became law through codi®cation is the American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code. This code is recognized throughout the world as the primary document for the design and construction of boilers and pressure vessels used in industry today. It not only establishes design and construction parameters for all boilers and pressure vessels used in the United States, Canada, and other parts of the world, but also details maintenance, and inspection criteria for this equipment. The Boiler and Pressure Vessels Code was originally developed as a recommended consensus standard after industry had experienced a signi®cant number of boiler explosions that resulted in loss of life and property during the early 1900s. Since then, the original standard has been legally adopted (codi®ed), in whole or in part, by most countries using boilers and pressure vessels.


735

The standard has also become an American National Standards Institute (ANSI) standard. Many of the state building codes and the federal Environment Protection Agency (EPA) and OSHA regulations reference ASME Boiler and Pressure Vessel Code in the body of their text, thus making the Boiler and Pressure Vessel Code part of the law by inclusion. The ASME Boiler and Pressure Vessel Code is a living document that is constantly undergoing reviews and revision as the state of the art in technology changes. In addition to standards, codes, and regulations there are recommended design practices and guidelines. These are usually written methods or procedures for development of a product or process. Generally, they are developed within a particular industry and are accepted as the ``best'' method for conducting business. These documents are often referred to as ``Good Engineering Practices'' or ``Good Manufacturing Practices (GMP).'' In all cases the development of design practices or guidelines is based on experience of the particular industry to which the practice or guideline applies, and has developed over time. Usually, this experience factor is documented and the guidelines are continuously updated by the industry as further experience is gained. The key point to remember about recommended practices and guidelines is that they are not ®xed, ®rm methods that must be followed without question. They are rarely, if ever, considered mandatory. Instead, they are procedures or principles that are based on experience factors and should be considered, built upon, and improved. They do not depict the only way of doing something. They are but one possible solution. Recommended practices and guidelines allow the engineer to include independent thoughts on how something can be designed or built. Recommended practices and guidelines are established much in the same way as standards. These generally tend to be more corporate speci®c, as opposed to industry-wide acceptance. They are generally used for standardization of procedures and methods for performing a particular function. Penalty for noncompliance is internal to the company and is left to the discretion of management. However, there is another exception. The Federal Drug Administration (FDA) requires GMP to be followed in drug and medical device manufacturing. Normally, one would consider GMP as an administrative management decision, not a requirement imposed by a government agency. From the above discussion one hopefully begins to appreciate why the term ``bowl of spaghetti'' is used

736


when considering the subject of standards, codes, regulations, practices, and guidelines. Since many organizations use the terms standard, code, regulation, practice, and guideline interchangeably in their documents, how does one determine a particular document's legal or mandatory requirement, In particular, if the document has applicability to the project's work? An easy way for the engineer to do this is to look for key words internal to the standard, code, and regulation, practice, or guideline. The NFPA's de®nition for each of the above terms demonstrates this ``word association'' technique. The NFPA explains: A standard is a document containing both mandatory provisions (using the word ``shall'' to indicate requirements) and advisory provisions (using the word ``should'' in indicate recommendations [3]. A code or regulation is a document containing only mandatory provisions using the word ``shall'' in indicate requirements. Explanatory material may be included only in the form of ``®ne print notes,'' in footnotes, or in an appendix [3]. A recommended practice is a document containing only advisory provisions (using the word ``should'' to indicate recommendations) in the body of the text [3]. A guideline is a document which is informative in nature and does not contain requirements or recommendations [3]. This word association technique is not 100% foolproof, and should not be substituted for a thorough veri®cation of the document's mandatory or statutory requirements. It is, however, a consistent method to use to get started in determining what standards, codes, regulations, and guidelines apply to a given project. It should also be noted that this word association technique works equally as well with international standards. In this chapter, the terms standard, code, regulation, recommended practice, and guideline will be used as the parent or originating organization has called it. This is done so that as the engineer looks for the needed document, the published term can be used. 3.3

WHY DO WE HAVE STANDARDS?

Standards have been developed because of some perceived need. There are a variety of driving forces


behind standards. Governments and consumers demand safety, quality, and performance. Marketing departments demand products that can be sold to the targeted market and the ability to compete in speci®c markets. The military and aerospace industries require high reliability and operation in adverse environmental conditions. Some newly emerging markets are fragile and need protection. Some markets are very sensitive and need protection for national interest reasons. There is an increase in imports and exports requiring standards to protect the environment, agriculture, and consumers. By having rules, governments and consumers can have some degree of con®dence that what they are allowing into the country and buying is not going to be harmful to the people or environment. In some industries, there has been a converging of product designs and materials that have proven to be the best practice. For example, videocassettes have converged to the VHS format in the United States, leaving people with beta machines out in the cold. The same has happened with computer ¯oppy disks. A person would be hard pressed to ®nd a 5.25 in. disk drive as standard equipment in today's PC. Standardization helps to advance society. The Romans standardized the width of roads. Without standardization railways could not share tracks. Transportation standards incorporating seat belts backed by the force of law in their use has reduced deaths as a result of car accidents. 3.4

WHY DO WE NEED STANDARDS?

The only reason for standards is protection! To protect public safety, the federal government passed regulations such as the Clean Air Act (CAA), Resource Conservation and Recovery Act (RCRA), Clean Water Act (CWA), and the Occupational Safety and Health Act of 1970. The government has created agencies such as the OSHA and the EPA to oversee compliance with these rules. The air and water quality is regulated by the EPA. To protect the health and safety of workers, the OSHA has regulatory authority. Depending on what part of the United States you are in, building construction and occupancy safety is governed by one of three model building codes; the Uniform Building Code, the National Building Code, or the Southern Building Code. These building codes have the force of law through their adoption by either state or, in some cases, local administrative codes. By the year 2000 all three of these codes will be combined

Standards

into what will be known as the International Building Code and will be used by the United States and Canada for all building construction. The International Mechanical Code and the International Plumbing Code are already in use by both countries. The United States protects consumers by federal agencies such as the FDA, and the Consumer Product and Safety Commission (CPSC). Governments protect fragile markets with such rules as those developed by the Securities and Exchange Commission } and the various banking laws. In order to ensure product usability and compatibility, professional organizations such as the Institute of Electrical and Electronic Engineers (IEEE) have issued standards for electrical and electronic devices. Many of the IEEE standards have been accepted worldwide. As consumers, we want to feel con®dent that when we purchase a product it will work or perform and that it continues in operation for a reasonable length of time. The standards world is present in this arena. Underwriters Laboratory has been active in developing standards and testing methods for electrical and electronic equipment for decades. The ISO has developed a set of standards known as ISO 9000, which is a quality management standard. This particular set of documents has been accepted worldwide and many customers are demanding compliance to it. The ISO has continued in its standard writing eorts for the general protection of the environment; ISO 14000 is the ®rst international environmental management standard. 3.5

ROLE OF STANDARDS ORGANIZATIONS

Standard writing organizations give consideration to safety, product usefulness and service life, as well as advancements in technology, and past experiences. They assist interested parties in identifying the common basis for behavior for a product, whether the product is a toy or a chemical re®nery or an airplane. The interested parties include suppliers (manufacturers, sellers, designers, etc.), consumers (end users, purchasers, etc.), experts (technicians, researchers, lawyers, etc.), advocates (politicians, moralists, etc.), government agencies, and professional associations. The common base of behavior has several components. The minimum acceptable level of design or performance is studied. An established method of testing is needed to ensure compliance. This leads to the need for measurements and a way of grading the variations.


737

Processes are also a piece of the common base of behavior. Standardize design criteria is also considered. This includes possible interchangeability and the actual use of anything. 3.6

WHEN DO WE APPLY STANDARDS, CODES, RECOMMENDED PRACTICES, AND GUIDELINES?

In general, we would like to say that standards, codes, and guidelines are used everyday to protect property and life. However, in reality, standards, codes, and guidelines are used when it is in the best interest of the business to do so. This means that if a business can sell its goods and services only if the goods and services are in compliance with some set of standards, codes, or guidelines, then businesses will conform. The threat of criminal or civil penalties for noncompliance also provides motivation for businesses to comply. 3.7

PROVING COMPLIANCE

Now that we know the standards, codes, and guidelines associated with the project, determination of compliance is needed. In the standards and codes that are dictated by law, a means for verifying compliance is also dictated. The means of verifying compliance can vary from self-certi®cation to a third-party audit by a noti®ed body. Self-certi®cation is the process whereby the company with the legal responsibility for the project performs the required testing for the project and signs a document detailing compliance. Self-certi®cation can be economically attractive, but may not be available in all situations. When self-certi®cation is not an option, independent testing houses are available. There are many organizations around the world that will test a product, process or operations for compliance with standards. These groups are generally known as ``third party'' because they are not directly involved with the design, manufacturing or sale of the items that they test. In more and more situations consumers and governments are requiring this type of third party testing or auditing as proof of compliance. In the United States, the OSHA maintains a list of what are called the National Recognized Testing Laboratories (NRTL). Third-party testing is evident all around us. Just look at the back of any computer monitor or power tool tags. There are labels stating compliance with various standards and codes.

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3.8


WHERE TO GO TO FIND STANDARDS

When starting a new project the question of what standards, codes, design practices, and guidelines apply, and where to go to ®nd them can be a nagging concern, and impact schedule. It would be nice to have a convenient list or ``road map'' to get started, but unfortunately standards are not that simple. The ®rst place for any engineer to start is right inside the company. Most medium- to large-sized companies and many small companies have developed their own set of standards called policies and procedures. These rules can dictate as well as guide the engineer through product design, manufacturing, operations, sales and marketing, maintenance, and decommission. Company standards are usually reviewed by the company legal representative or an attorney in that industry. The complex product liability and malpractice law suits have made this review advisable and, in some cases, a business necessity. Within the company, there may be another resource. The very lucky engineer might ®nd an `ìnhouse guru,'' that is, someone who has signi®cant experience with standards and their application. This resident expert may be another engineer or legal counsel. These resources may be able to provide a historical look at the product, process or operation evolution, including standards, codes, regulations, practices, and guidelines. If the company is a consulting ®rm, the client will usually specify the appropriate standards in the contract. However, it may be up to the consultant to discover standards, codes, regulations, and guidelines that apply that the client is not aware of. The NRTLs can also provide assistance in determining what standards may be required. Some of the NRTLs in the United States have developed agreements with testing houses in other countries. This provides additional assistance in requirements for sale of a product anywhere in the world. Another resource that the engineer should use is industry-related societies and associations. These organizations frequently have libraries with standards, codes, regulations, practices, and guidelines available for member use. They often support lobbying eorts on behalf of the industry as well. Also available to the engineer are outside information service organizations that can be accessed through the internet. Most of these organizations have a wide range of technical databases, which include US and International Industrial Standards,


Military and Federal speci®cations, Electronic Component Databases, Medical Device Standards, Regulatory Data, vendor equipment catalog information, and more. These service organizations usually have the most complete sets of data available under one source library, and they regularly update this information to keep it current. Their databases can be delivered right to the engineer's desktop computer in what ever format is needed. Such access to critical engineering data, standards, codes, and regulatory data is very cost eective, and in most cases reduces the time spent researching for the required project information. Most of these information services organizations can provide their information on CD-ROM, or through online databases and internet websites. When project deadlines or product-to-market schedules are critical, ecient and eective access to key standards, codes, and regulations can be of the utmost importance if a successful project is to be achieved.

3.9

WHAT IF NO STANDARD EXISTS?

From time to time engineers are presented with the opportunity to work on a project that uses ``cuttingedge technology'' to produce a new, never-before-seen product or process. The engineer assigned to such a job often discovers that existing standards do not adequately cover the new design. They may in some cases ®nd that adequate standards simply do not exist. The latter case is rare. Because of the vast arena of standards, codes, regulations, practices, and guidelines existing in industry and the military today, it is hard to develop any new product or process not yet addressed to some degree. For those cases where existing standards are not adequate, what does the engineer do? Where does one start? The ®rst reaction the engineer may have when ®nding themselves in this situation may be: ``Great! I don't have any standards, codes, or regulations that need considering, so I have a wide-open ®eld of design opportunities.'' To some degree this is true. However, the engineer should not forget why there are standards, codes, regulations, recommended practices, and guidelines in the ®rst place. For protection! The engineer has a direct and vital impact on the quality of life of many people and their ``Code of Ethics'' requires them to be dedicated to the protection of the public health, safety, and welfare [4]. Thus, the real opportunity comes with

Standards

being the ®rst to set the pace for technology yet to come. Being the ®rst one to develop and establish an industry standard provides the opportunity for the engineer to become the expert, the technical guru of this new ®eld of interest. When developing a new standard, practice or guideline, two key points to remember are to use common sense and simplify the language of the document. Eliminating ``technospeak'' in the body of text will add clarity and simplicity to the document. This in turn improves the understanding of the subject matter and usability of the document. The ®rst step in developing a standard for the new work is to organize a committee of interested experts from within the company. This team may include key members of the product or process design team, manufacturing, health and safety representative, etc. Once assembled, determine the scope of the eort. A review committee that includes corporate counsel should also be established. The next step is to ask the questions, `Ìs a standard necessary or would a recommended practice or guideline be more appropriate?'' A recommended practice or guideline provides more latitude in the product, process, or operation development. If the team of experts determine a standard is necessary, then a development subcommittee should be appointed to prepare a draft text of the proposed standard. The ®rst thing the development subcommittee should consider is using a technical data or information service organization to assemble any related standards, codes, regulations, practices, and guidelines for there assignment. These documents although not directly applicable, often as not can be used as resources and possible templates for the drafting of the proposed standard. After the development subcommittee has prepare a draft of the proposed standard, then the entire team of experts should review the draft text, resolve dierences, provide clari®cation where needed, and develop the document details for a ®nal presentation to the review committee. The next step, and usually a very wise one, is to get a legal review of the new proposed standard by the company's legal department or through an independent attorney who specializes in corporate liability aairs. After the draft of the proposed standard is reviewed and all legal questions answered, a ®nal draft can be prepared and circulated among all team members along with the review committee's comments and recommended changes.


739

A deadline for receipt of all advice and comments from team members on the ®nal draft of the proposed standard should be established and rigidly held to. A consensus vote of all team members should then be called on the ®nal draft of the proposed standard, with the understanding that a majority vote of team members determines acceptance of the ®nal draft as written. A test of the proposed standard's validity by benchmarking it against an existing standard for a comparable product or process, even if a competitor's, should be performed. Under certain cases where public safety may be impacted by the new process or product, it may be wise to solicit public comment as well. After performing a benchmark test of the proposed standard, further meetings should be held so that the team of experts can reconsider the standard in regards to the comments or data received from the test, or public comment if that be the case. The review team should also provide their input on these results and comments. The standard should be amended accordingly if necessary, and a reballoting of all team members with two-thirds approval required to proceed with publication. The ocial standard should be published and submitted to the corporate board of directors or the industrial association within which the standard is to be applied, for adoption and signature. Following its ocial adoption the new standard should be issued by its parenting organizations for implementation. Where appropriate the standard should be presented to the American National Standards Institute (ANSI) for approval as an ANSI standard in accordance with the institute's by-laws and regulations. Although the above steps are not inclusive of the total process to develop and implement a new standard, they do cover the basics and are indicative of the same process used by many of the larger standards writing organization. The key point that the engineer must remember when developing any new standard, practice, or guideline, is that the document must address any process or product parameter that could presently or in the future have an impact upon the health, safety, and welfare of the workers, consumer, and general public. If the engineer can achieve this, then the standard will be a credit to the profession and the process of developing it will be a rewarding experience. It is not an easy task, but it can be a rewarding one.

740

3.10


SUMMARY

The engineer has a professional obligation to protect the general health and welfare of the public. This encompasses any, and all, work done while working for a corporation, or as an independent consultant. The engineer is assisted in this endeavor by using the appropriate standards, codes, regulations, practices, and guidelines as required. This may sound relatively simple, but it is not. Just locating the appropriate documents can be an awesome and time-consuming experience. The ®rst place the engineer should start in the quest for the applicable rules and guides is within the company's policies and procedures. Another starting point for the engineer would be to contract a technical data or information service organization to do the search, or provide the databases by which the research can be expedited, especially if the engineer's project schedule is critical. Such database services can assist the engineer in reducing the time required to locate project pertinent standards, codes, regulations, practices and guidelines. The less time the engineer spends searching for critical documents the more time he or she will have to apply to the design, which in most cases, is schedule driven. Maneuvering through the maze of standards, codes, regulations, design practices, and guidelines that are required for projects in today's global economy can be an engineer's nightmare. The eciency and eectiveness of how quick this documentation can be assessed and absorbed often dictates the difference between a successful project and one that fails. A solid understanding of standards, codes, regulations, practices, and guidelines by the engineer cannot be emphasized more strongly when considering the litigious society in which we live and work. ``Remember, always design per codes and standards. Just because you meet the codes and standards established by your profession, does not mean you or your company is o the liability hook. However, if you don't meet the codes and standards, you can rest assured you will be held negligent should someone suer personal harm or property damage'' (from a personal conversation with Dr Rodney Simmons, University of Cincinnati, May 1996). A word of encouragement: the engineer cannot hope to be a marvel at determining what standards, codes, regulations, practices, or guidelines apply or where to ®nd the documents when ®rst entering this strange world. This skill is learned and developed through practice and time spent in the maze. It does become easier. Good luck!


3.11

ORGANIZATION LISTINGS

This section lists the names, addresses, phone numbers, and websites of parenting organizations for many of the standards, codes, regulations, practices, and guidelines used throughout the engineering community. It is a generalized list and is not speci®c to any one engineering discipline. Many corporate engineering departments and consulting ®rms have similar listings to aid their sta in reaching the required documents. Also, it is not a comprehensive list of all organizations who establish and maintain such documents. It is an attempt at providing the engineer with a list of the more commonly known organizations as a starting point to build upon and develop their own. One point of caution must be noted: as with any list of addresses, phone numbers, and even names of organizations, this information is subject to change! Organizations tend to move, merge, change their name, and in some cases cease to exist. The following list of organizations, and the information provided for each one, is current at the time of writing this chapter. The engineer is encouraged to add organizations to this list as experience demands, and to review and update the information on a regular basis. 3.11.1

Regulatory Organizations

CA Congressional Acts Superintendent of Documents U.S. Government Printing Oce 809 Channing Place, NE Washington, DC 20018 Phone: 202/576-6693 Website: www.explore.gpo.gov CFR Code of Federal Regulations Superintendent of Documents U.S. Government Printing Oce 809 Channing Place, NE Washington, DC 20018 Phone: 202/576-6693 Website: www.explore.gpo.gov DOE U.S. Department of Energy 1000 Independence Avenue, SW Washington, DC 20585 Phone: 202/586-9642 Website: www.explore.doe.gov EO Executive Orders National Archives and Records Administration 8th Street and Pennsylvania Avenue, NW Washington, DC 20408

Standards

Phone: 202/523-5230 Website: www.nara.gov/fedreg ERDA (Energy Research and Development Administration, see U.S. Department of Energy, DOE) FR Federal Register Superintendent of Documents U.S. Government Printing Oce 809 Channing Place, NE Washington, DC 20018 Phone: 202/576-6693 Website: www.explore.gpo.gov GSA General Services Administration Public Buildings Service Oce of Government-wide Real Property Policy and Oversight 19th and F Streets, NW Washington, DC 20405 Phone: 202/501-0398 Website: www.explore.gsa.gov OMB Oce of Management and Budget Executive Oce of the President Washington, DC 20503 Phone: 202/395-3000 Website: www.whitehouse.gov/wh/eop/omb 3.11.2

Reference Standards and Guides Organizations

AA Aluminum Association 900 19th Street, NW, Suite 300 Washington, DC 20006 Phone: 202/862-5100 Website: www.aluminum.org AABC Associated Air Balance Council 1518 K Street, NW Washington, DC 20005 Phone: 202/737-0202 Website: www.aabchq.com AAMA American Architectural Manufacturers Association 1827 Walden Oce Square, Suite 104 Schaumberg, IL 60173 Phone: 847/303-5664 Website: www.aamanet.org AAMI Association for the Advancement of Medical Instrumentation 3330 Washington Blvd. Arlington, VA 22201-4598 Phone: 703-525-4890 Website: www.aami.org


741

AASHTO American Association of State Highway and Transportation Ocials 444 N. Capitol St. NW, Suite 249 Washington, DC 20001 Phone: 202/624-5800 Website: www.aashto.org AATCC American Association of Textile Chemists and Colorists 1 Davis Drive P.O. Box 12215 Research Triangle Park, NC 27709 Phone: 919/549-8141 Website: www.aatcc.org ABMA American Boiler Manufacturers Association 950 North Glebe Road Suite 160 Arlington, VA 22203 Phone: 703/522-7350 Website: www.abma.com ABMA (DC) American Bearing Manufacturers Association 12001 19th Street, NW Washington, DC 20036 Phone: 202/429-5155 Website: www.abma-dc.org ACGIH American Conference of Governmental Industrial Hygienist 1330 Kemper Meadow Drive Cincinnati, OH 45240 Phone: 513/742-2040 Website: www.acgih.org ACI American Concrete Institute International 38800 Country Club Drive Farmington Hills, MI 48331 Phone: 248/848-3700 Website: www.aci-int.org ACTS (See Congressional Acts, CA, Regulatory Organizations) AGA (American Gas Association, see International Approval Services, Inc., IAS) AGMA American Gear Manufacturers Association 1500 King Street, Suite 201 Alexandria, VA 22314 Phone: 703/684-0211 Website: www.agma.org AI Asphalt Institute Research Park Drive P.O. Box 14052 Lexington, KY 40512 Website: www.asphaltinstitute.org

742

AIA/NAS Aerospace Industries Association of America, Inc. 1250 Eye Street, NW Washington, DC 20005 Phone: 202/371-8400 Website: www.aia-aerospace.org AIA American Institute of Architects 1735 New York, NW Washington, DC 20006 Phone: 202/626-7300 Website: www.aiaonline.com AICHE American Institute of Chemical Engineers 345 East 47th Street New York, NY 10017 Phone: 212/705-7335 Website: www.aiche.org AIIM Association for Information and Image Management 1100 Wayne Avenue, Suite 1100 Silver Springs, MD 20910 Phone: 301/587-8202 Website: www.aiim.org AISC American Institute of Steel Construction 1 East Wacker Drive, Suite 3100 Chicago, IL 60601-2001 Phone: 312/670-2400 Website: www.aisc.org AISI American Iron and Steel Institute 1101 17th Street, NW, Suite 1300 Washington, DC 20036 Phone: 202/452-7100 Website: www.steel.org AMCA Air Movement and Control Association 30 West University Drive Arlington Heights, IL 60004 Phone: 847/394-0150 Website: www.amca.org ANL Argonne National Laboratory 9800 South Cass Avenue Argonne, IL 60439 Phone: 630/252-2000 Website: www.anl.gov ANS American Nuclear Society 555 North Kensington Avenue LaGrange Park, IL 60526 Phone: 708/352-6611 Website: www.ans.org ANSI American National Standards Institute 11 West 42nd Street, 13th Floor New York, NY 10036 Phone: 212/642-4900 Website: www.ansi.org



API American Petroleum Institute 1220 L Street, NW Washington, DC 20037 Phone: 202/682-8000 Website: www.api.org AREA American Railway Engineering Association 8201 Corporate Drive, Suite 1125 Landover, Md. 20785 Phone: 301/459-3200 Website: None ARI Air Conditioning and Refrigeration Institute 4301 North Fairfax Drive, Suite 425 Arlington, VA 22203 Phone: 703/524-8800 Website: www.ari.org ARMA Asphalt Roo®ng Manufacturers Association 4041 Powder Mill Road Centerpark Suite 404 Calverton Md. 20705 Phone: 301/231-9050 Website: www.asphaltroo®ng.org ARMY U.S. Department of the Army National Technical Information Services 5285 Port Royal Road Spring®eld, VA 22161 Phone: 703/605-6000 Website: www.ntis.gov ASA Acoustical Society of America 120 Wall Street 32nd Floor New York, NY 10005-3993 Phone: 212/248-0373 Website: [email protected] ASCE American Society of Civil Engineers 1801 Alexander Bell Drive Reston VA. 20191-4400 Phone: 703/295-6000 Website: www.asce.org ASHRAE American Society of Heating, Refrigerating, and Air-Conditioning Engineers 1791 Tullie Circle, NE Atlanta, GA 30329 Phone: 404/636-8400 Website: www.ashrae.org ASME American Society of Mechanical Engineers 22 Law Drive P.O. Box 2900 Fair®eld, NJ 07007 Phone: 973/882-1167 Website: www.asme.org

Standards

ASNT The American Society For Nondestructive Testing 1711 Arlingate Lane P.O. Box 28518 Columbus, OH 43228-0518 Phone: 614/274-6003 Website: www.asnt.org ASQ American Society for Quality 3611 East Wisconsin Avenue Milwaukee, WI 53203-4606 Phone: 414/272-8575 Website: www.asq.org ASTM American Society for Testing and Materials 100 Harbor Drive W. Conshohocken, PA 19428-2959 Phone: 610/832-9500 Website: www.astm.org AWS American Welding Society 550 NW LeJune Road Miami, FL 33126 Phone: 305/443-9353 Website: www.aws.org AWWA American Water Works Association 6666 West Quincy Avenue Denver, CO 80235 Phone: 303/794-7711 Website: www.awwa.org BIA Brick Industry Association 11490 Commerce Park Drive, Suite 300 Reston, VA 20191 Phone: 703/620-0010 Website: www.bia.org BOCA Building Ocials and Code Administrators International, Inc. 4051 West Flossmoor Road Country Club Hills, IL 60487 Phone: 708/799-2300 Website: www.bocai.org CAA (Clean Air Act, see Congressional Acts, Regulatory Organizations) CABO (Council of American Building Ocials, See International Conference of Building Ocials, ICBO) CERC Coastal Engineering Research Center & Hydraulics Laboratory U.S. Army Corps of Engineers 3909 Halls Ferry Rd. Vicksburg, MO; 39180-6199 Phone: 601/634-3339 Website: www.chl.wes.army.mil CERCLA (Comprehensive Environmental Response, Compensation and Liability Act, see Congressional Acts, Regulatory Organizations)


743

CFR (Code of Federal Regulations, see Regulatory Organizations) CGA Compressed Gas Association 1725 Jeerson Davis Highway, Suite 1004 Arlington, VA 22202-4102 Phone: 703/412-0900 Website: www.cganet.com CMAA Crane Manufacturers Association of America 8720 Red Oak Blvd. Suite 201 Charlotte, NC 28217 Phone: 704/676-1190 Website: www.mhia.org CRI Carpet and Rug Institute 310 Holiday Avenue Box 2048 Dafton, GA 30720 Phone: 706/278-3176 Website: www.carpet-rug.com CSA Canadian Standards Association 178 Rexdale Blvd. Etobicoke (Toronto), Ontario, Canada M9W1R3 Phone: 416/747-4000 Website: www.csa.ca CTI Cooling Tower Institute 530 Wells Fargo, Suite 218 Houston, TX 77090 Phone: 281/583-4087 Website: www.cti.org CWA (Clean Water Act, see Congressional Acts, Regulatory Organizations) DOD U.S. Department of Defense Defense Technical Information Center, Suite 0944 Fort Belvoir, VA 22060-6218 Phone: 703/767-8274 Website: www.dtic.mil DOE (U.S. Department of Energy, see Regulatory Organizations) DOE/OSTI DOE/Oce of Scienti®c and Technical Information P.O. Box 62 Oak Ridge, TN 37831 Phone: 423/574-1000 Website: www.explore.doe.gov DSWA Defense Special Weapons Agency 6801 Telegraph Road Alexandria, VA 22310 Phone: 703/325-8775 Website: www.dswa.mil EIA Electronics Industries Alliance 2500 Wilson Blvd.

744

Arlington, VA 22201-3834 Phone: 703/907-7500 Website: www.eia.org EO (Executive Orders, see Regulatory Organizations) EPA (Environmental Protection Agency, see U.S. Environmental Protection Agency) EPRI Electric Power Research Institute P.O. Box 10412 Palto Alto, CA 94303 Phone: 650/855-2000 Website: www.epri.com ERDA (Energy Research and Development Administration, see U.S. Department of Energy, DOE) FAA Federal Aviation Administration U.S. Department of Transportation 800 Independence SW Washington, DC 20591 Phone: 202/267-3111 Website: www.faa.gov FAI Fauske & Associates, Inc. 16W070 West 83rd Street Burr Ridge, IL 60521 Phone: 630/323-8750 Website: www.fauske.com FEMA Federal Emergency Management Agency Federal Center Plaza 500 C Street, SW Washington, DC 20472 Phone: 202/646-4600 Website: www.fema.gov FGMA Glass Association of North America White Lakes Professional Building 3310 SW Harrison Street Topeka, KS 66611 Phone: 913/266-7013 Website: www.gana.org FIPS Federal Information Processing Standards National Bureau of Standards Bldg. 820, Room 562 Gaithersburg, MD 20899 Phone: 301/975-2816 Website: none FM Factory Mutual Engineering and Research 1151 Boston Providence Turnpike Norwood, MA 02062 Phone: 781/762-4300 Website: www.factorymutual.com FR (Federal Register, see Regulatory Organizations)



FS Federal Speci®cations Naval Inventory Control Point 700 Robbins Avenue Philadelphia, PA 19111 Phone: 215/697-4374 Website: None GA Gypsum Association 810 First Street, NE, Suite 510 Washington, DC 20002 Phone: 202/289-5440 Website: www.gypsum.org HES Health Education Services P.O. Box 7126 Albany, NY 12224 Phone: 518/439-7286 Website: www.hes.org IAPMO International Association of Plumbing and Mechanical Ocials 20001 Walnut Drive Walnut, CA 91789-2825 Phone: 909/595-8449 Website: www.iapmo.org IAS International Approval Services, Inc. (formerly American Gas Association) 8501 East Pleasant Valley Road Cleveland, OH 44131 Phone: 216/524-4990 Website: www.iasapproval.org ICBO International Conference of Building Ocials 5360 South Workman Mill Road Whittier, CA 90601 Phone: 562/699-0541 Website: www.icbo.org ICC (International Code Council, see International Conference of Building Ocials, ICBO) IEC (International Electrotechnical Committee, see American National Standards Institute, ANSI) IEEE Institute of Electrical and Electronics Engineers United Engineering Center 345 East 47th Street New York, NY 10017 Phone: 212/705-7000 Website: www.ieee.org IESNA Illuminating Engineering Society of North America 120 Wall Street 17th Floor

Standards

New York, NY 10005 Phone: 212/248-5000 Website: www.iesna.org IMC (International Mechanical Code, see International Conference of Building Ocials, ICBO) IPC The Institute for Interconnecting and Packaging Electronic Circuits 2215 Sanders Road Northbrook, IL 60062 Phone: 847/509-9700 Website: www.ipc.org IPC (International Plumbing Code, see International Conference of Building Ocials, ICBO) IPSDC (International Private Sewage Disposal Code, see International Conference of Building Ocials, ICBO) ISA Instrument Society of America P.O. Box 12277 Research Triangle Park, NC 27709 Phone: 919/549-8411 Website: www.isa.org ISDSI Insulated Steel Door Systems Institute 30200 Detroit Road Cleveland, OH 44145 Phone: 440/899-0010 Website: www.isdi.org ISHM International Society for Hybrid Microelectronics 1861 Wiehle Reston, VA 22090 ISIAQ International Society of Indoor Air Quality and Climate P.O. Box 22038 Ottawa, ON, Canada K1V 0W2 Phone: 613/731-2559 Website: www.isiaq.org ISO (International Standards Organization, see American National Standards Institute, ANSI) LANL Los Alamos National Laboratory P.O. Box 1663 Los Alamos, NM 87545 Phone: 505/667-7000 Website: www.lanl.gov LBL Lawrence Berkeley Laboratory 1 Cyclotron Road Berkeley, CA 94720 Phone: 510/486-4000 Website: www.lbl.gov LLNL Lawrence Livermore National Laboratory 7000 East Avenue


745

Livermore, CA 94550 Phone: 925/422-1100 Website: www.llnl.gov MBMA Metal Building Manufacturing Association 1300 Summer Avenue Cleveland, OH 44115-2180 Phone: 216/241-7333 Website: www.taol.com/mbma MHMS Material Handling and Management Society 8720 Red Oak Blvd. Charlotte, NC 28217 Phone: 704/676-1183 Website: www.mhia.org/mhms MIL (Millitary Speci®cations, see Department of Defense, DOD) NACE National Association of Corrosion Engineers 1440 South Creek Drive Houston, TX 77084 Phone: 281/492-0535 Website: www.nace.org NADCA North American Die Casting Association 9701 W. Higgins Road, Suite 880 Rosemont, IL 60018-4721 Phone: 847/292-3600 Website: www.diecasting.org NAPHCC National Association of PlumbingHeating-Cooling Contractors 180 South Washington Street Falls Church, VA 22046 Phone: 703/237-8100 Website: www.naphcc.org NASA National Aeronautics and Space Administration NASA Headquarters 300 East Street, SW Washington, DC 20546 Phone: 202/453-2928 Website: www.nasa.gov NAVFAC (U.S. Naval Facilities Engineering Command; see U.S. Department of the Navy, US NAVY) NBC (National Building Code, see BOCA) NBS National Bureau of Standards (currently National Institute of Standards and Technology) Clopper & Quints Orchard Gaithersburg, MD 20899 Phone: 301/975-2000 Website: www.nist.gov

746

NCMA National Concrete Masonry Association 2302 Horse Pen Road Herndon, VA 20171 Phone: 703/713-1900 Website: www.ncma.org NEC (National Electric Code, see National Fire Protection Association STD-70) NEMA National Electrical Manufacturers Association 1300 North 17th Street, Suite 1847 Rosslyn, VA 22209 Phone: 703/841-3200 Website: www.nema.org NEPA (National Environmental Policy Act, see Congressional Acts, Regulatory Organizations) NFPA National Fire Protection Association 11 Tracy Drive Avon, MA 02322 Phone: 800/344-3555 Website: www.nfpa.org NIJ National Institute of Justice 810 7th Street, NW Washington, DC 20531 Phone: 202/307-2942 Website: www.usdoj.gov/nij NOAA National Oceanic and Atmospheric Administration 1315 East West Highway Silver Springs, MD 20910 Phone: 301/713-4000 Website: www.noaa.gov NPDES (National Pollution Discharge Elimination System, see 40 CFR 125, Regulatory Organizations) NRC U.S. Nuclear Regulatory Commission 1155 Rockville Pike Rockville, MD 20852 Phone: 301/415-7000 Website: www.nrc.gov NRCA National Roo®ng Contractors Association 10255 West Higgins Road Suite 600 Rosemont, IL 60018 Phone: 847/299-9070 Website: www.roofonline.org NSA National Security Agency/Central Security Service 9800 Savage Road Fort Meade, MD 20755 Phone: 301/688-7111 Website: www.nsa.gov



NTIS National Technical Information Services 5285 Port Royal Road Spring®eld, VA 22161 Phone: 703/605-6000 Website: www.ntis.gov NWWDA National Wood Window and Door Association 1400 East Touchy Avenue, Suite 470 Des Plaines, IL 60018 Phone: 847/299-5200 Website: www.nwwda.org OMB (Oce of Management and Budget, see Regulatory Organizations) OSHA (Occupational Safety and Health Act, see Congressional Acts, Regulatory Organizations) OSHA Occupational Safety and Health Administration 200 Constitution Avenue NW Washington, DC 20210 Phone: 202/219-8151 Website: www.osha.gov PCA Portland Cement Association 5420 Old Orchard Road Skokie, IL 60077-1083 Phone: 847/966-6200 Website: www.portcement.org PCI Prestressed Concrete Institute 175 West Jackson Boulevard Chicago, IL 60604 Phone: 312/786-0300 Website: www.pci.org PCMI Photo-Chemical Machining Institute 810 Knott Place Phone: 215/825-2506 Website: www.pcmi.org PDCA Painting and Decorating Contractors of America 3913 Old Lee Highway, Suite 33B Fairtax, VA 22030 Phone: 703/359-0826 Website: www.pdca.com PMA Precision Metalforming Association 27027 Chardon Road Richmond Heights, OH 44143 Phone: 440/585-8800 Website: www.metalforming.com PTI Post-Tensioning Institute 1717 West Northern Avenue Phoenix, AZ 85021 Phone: 602/870-7540 Website: www.pti-usa.org

Standards

RCRA (Resource conservation and Recovery Act, see Congressional Acts, Regulatory Organizations) RFCI Resilient Floor Covering Institute 966 Hungerford Drive Suite 12-B Rockville, MD 20850 Phone: 301/340-8580 Website: www.rfci.org SACMA Suppliers of Advanced Composite Materials Association 1600 Wilson Blvd. Arlington, VA 22209 Phone: 703/841-1556 Website: www.sacma.org SAE Society of Automotive Engineers, Inc. 400 Commonwealth Drive Warrendale, PA 15096 Phone: 724/776-4841 Website: www.sae.org SBC (Standard Building Code, see Southern Building Code Congress International, Inc., SBCCI) SBCCI Southern Building Code Congress International, Inc. 900 Montclair Road Birmingham, ALA 35213-1206 Phone: 205/591-1853 Website: www.sbcci.org SCS Soil Conservation Service, U.S. Department of Agriculture 14th and Independence Avenue, SW Washington, DC 20250 Phone: 202/205-0026 Website: www.doa.gov SDI Steel Door Institute 30200 Detroit Road Cleveland, OH 44145 Phone: 440/899-0010 Website: www.steeldoor.org SDWA (Safe Drinking Water Act, see Congressional Acts, Regulatory Organizations) SEMI Semiconductor Equipment and Materials International 805 East Middle®eld Road Mountain View, CA 94043 Phone: 650/964-5111 Website: www.semi.org SJI Steel Joist Institute 3127 10th Avenue North Myrtle Beach, SC 29577 Phone: 843/626-1995 Website: www.steeljoist.org


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SMA Screen Manufacturers Association 2850 South Ocean Blvd., No. 114 Palm Beach, FLA 33480-5535 Phone: 561/533-0991 Website: none SMACNA Sheet Metal and Air Conditioning Contractors National Association 4201 Lafayette Center Drive Chantilly, VA 20151 Phone: 703/803-2980 Website: www.smacna.org SNL Sandia National Laboratories P.O. Box 5800 Albuquerque, NM 87185 Phone: 505/284-3958 Website: www.irnsandia.gov SPI Society of the Plastics Industry 1801 K Street N.W., Suite 600K Washington, DC 20006 Phone: 202/974-5251 Website: www.socplas.org SPICI (SPI Composites Institute, see Society of the Plastics Industry, SPI) SSFI Scaolding, Shoring, and Framing Institute 1300 Sumner Avenue Cleveland, OH 44115 Phone: 216/241-7333 Website: www.taol.com/ss® SWI Steel Window Institute 1300 Sumner Avenue Cleveland, OH 44115-2851 Phone: 216/241-7333 Website: www.taol.com/swi TFA The Ferroalloys Association 900 2nd Street N.E., Suite 201 Washington, DC 20002 Phone: 202/842-0292 Website: www.tfa.org TSCA (Toxic Substance Control Act, see Congressional Acts, Regulatory Organizations) UBC (Uniform Building Code, see International Conference of Building Ocials, ICBO) UL Underwriters Laboratories 333 P®ngsten Road Northbroook, IL 60062 Phone: 847/272-8800 Website: www.ul.com UPC (Uniform Plumbing Code, see IAPMO) USAF U.S. Department of the Air Force National Technical Information Services 5285 Port Royal Road Spring®eld, VA 22161

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Phone: 703/605-6000 Website: www.ntis.gov USARMY U.S. Department of the Army National Technical Information Services 5285 Port Royal Road Spring®eld, VA 22161 Phone: 703/605-6000 Website: www.ntis.gov USEPA U.S. Environmental Protection Agency 401 M. Street, SW Washington, DC 20460 Phone: 202/260-2090 Website: www.epa.gov USNAVY U.S. Department of the Navy National Technical Information Services 5285 Port Royal Road Spring®eld, VA 22161 Phone: 703/605-6000 Website: www.ntis.gov USNRC (U.S. Nuclear Regulatory Commission, see NRC) WEF Water Environment Federation (formerly Water Pollution Control Federation) 601 Wythe Street Alexandria, VA 22308 Phone: 703/684-2400 Website: www.wef.org



WQA (Water Quality Act, see Congressional Acts, Regulatory Organizations) WRC Water Resources Council, Hydrology Committee U.S. Department of the Interior 1849 C Street, NW Washington, DC 20240 Phone: 202/208-3100 Website: www.doi.gov REFERENCES 1. JF Thorpe, WH Middendorf. What Every Engineer Should Know About Product Liability. New York: Marcel Dekker, 1979, p 42. 2. National Fire Protection Association. Guide to OSHA Fire Protection Regulations. Boston, MA: National Fire Protection Association, 1971. 3. National Fire Protection Association. Guide to OSHA Fire Protection Regulations. Boston, MA: National Fire Protection Association, 1971, p 7. 4. National Society of Professional Engineers. Code of Ethics. Preamble, p 1.

ADDITIONAL READING AL Batik. The Engineering Standard, A Most Useful Tool. Ashland, OH: Book Master/EI Rancho, 1992.

Chapter 9.1 Perspectives on Designing Human Interfaces for Automated Systems Anil Mital


Arunkumar Pennathur

University of Texas at El Paso, El Paso, Texas

1.1 1.1.1

INTRODUCTION

will continue to play, important roles in manufacturing operations [2]. Another important factor that prompts due consideration of human factors in a manufacturing system, during its design, is the recent and continuous upward trend in nonfatal occupational injuries that has been observed in the manufacturing industry in the United States [3]. While these injuries may not be as severe and grave as the ones due to accidents such as the Chernobyl Nuclear Reactor accident (the Three Mile Island nuclear accident prompted an upswing in human factors research, especially in nuclear power plants and in process industry settings), the increasing trend in injuries leaves the claim that `àutomation'' of manufacturing has resulted in softer jobs for manufacturing workers questionable. In fact, many manufacturing researchers and practitioners believe that an increase in severe injuries in manufacturing is primarily due to the automation of simpler tasks, leaving the dicult ones for the humans to perform. This belief is logical as the technology to automate dicult tasks is either unavailable or expensive. The factors discussed suggest that manufacturing systems (our de®nition of a system is broad; a system may thus be a combination of a number of equipment/ machines and/or humans) be designed with human limitations and capabilities in mind, if the system is to be productive, error-free, and safe, and result in

Importance and Relevance of Human Factors Considerations in Manufacturing Systems Design

The design and operation of manufacturing systems continue to have great signi®cance in countries with large and moderate manufacturing base, such as the United States, Germany, Japan, South Korea, Taiwan, and Singapore. It was widely believed in the 1980s that complete automation of manufacturing activities through design concepts such as ``lights-out factories,'' would completely eliminate human in¯uence from manufacturing, and make manufacturing more productive [1]. However, we now see that complete automation of manufacturing activities has not happened, except in a few isolated cases. We see three basic types of manufacturing systems present and emergingÐthe still somewhat prevalent traditional manual manufacturing mode with heavy human involvement in physical tasks, the predominant hybrid manufacturing scenario (also referred to traditionally as the mechanical or the semiautomatic systems) with powered machinery sharing tasks with humans, and the few isolated cases of what are called computerintegrated manufacturing (CIM) systems with very little human involvement, primarily in supervisory capacities. Indeed, human operators are playing, and 749


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quality goods and services, all vital goals for manufacturing organizations. 1.1.2

The Human±Machine System Framework for Interface Design

Traditionally, system designers have accounted for human limitations and capabilities by considering the human operator as an information processor having sensory and motor capabilities and limitations (Fig. 1). It can be readily seen from Fig. 1 that the key elements to the ecient and error-free functioning of a human±machine system are the provision of information to human operators in the system, and the provision for control of the system by humans. Displays provide information about the machine or the system to human operators, and controls enable

human operators to take actions and change machine or system states (conditions). Operator feedback is obtained through interaction with the controls (tactile sensing, for instance). Thus, in the classical view, human interaction with automation is mediated through displays and controls for a two-way exchange of information. The recent view of the human±machine system, resulting out of advances in computerized information systems, sees the human operator as a supervisory controller [4] responsible for supervisory functions such as planning, teaching, monitoring, intervening, learning, etc. (Fig. 2). Even though, in such a view, the human operator has a changed role, displays and controls still provide the fundamental medium for human interaction with the system. Indeed, properly designed displays and controls are fundamental to the ecient and error-free functioning

Figure 1 Traditional representation of human interaction with machine.


Human Interfaces for Automated Systems

Figure 2 The latest notion of human as a supervisory controller.

of manufacturing systems. Ergonomics, which we de®ne as the study of issues involved in the application of technology to an appropriate degree to assist the human element in work and in the workplace, provides recommendations for interface design based on research in human sensory and motor capabilities and limitations. 1.1.3

Scope of This Chapter

Even though displays and controls, and their eective design, are fundamental to the ecient and error-free operation of the system, a number of important activities need to be carried out before one can think of displays and controls. These activities stem from the central need to build systems to suit human limitations and capabilities. Some of these activities, such


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as `ùser needs analysis,'' are relatively new concepts and form the core of what is called the `ùsability engineering approach'' to design. Techniques associated with other activities, such as task analysis and function allocation between humans and automated equipment, are an integral part of designing ``good'' jobs, and have been in existence for some time. We present some of these techniques and methods. Inherent throughout our presentation is the essence of the ``human-centered interface design approach.'' We ®rst present elements of this approach and contrast it with the ``system-centered interface design approach.'' It is recommended that this concept of human-centered design guide the designer at both the system, as well as at the nuts-and-bolts, design levels. Displays and controls, the selection, design, and evaluation of which will be the theme for the remainder of the chapter, form a part of aids, equipment, tools, devices, etc., that are necessary for a system to operate satisfactorily. Due to the wide variety of available technologies, and due to the fact that most ergonomics recommendations for the design of displays and controls remain the same regardless of the technology used (e.g., recommendations on the design of lettering remain the same whether the recommendation is for a conventional hand-held meter, a visual display unit, or printed material), we provide only general recommendations for dierent types of displays and controls, without reference to commercial products and equipment. A few other notes about the scope of this chapter: due to the vast literature available in the area of design of human±machine systems, our emphasis in this chapter is on the breadth of coverage rather than depth in any area. This emphasis is deliberate, and is motivated, in addition, by our intention to provide the reader a taste of the process of design and evaluation of a modern human±machine system. Readers interested in more detail in any one area or technique should refer to our recommended reading list. Also, even though the recommendations and guidelines summarized in this chapter come from research in human±machine settings other than hardcore manufacturing settings, they are equally applicable to manufacturing systemsÐthe general framework and the speci®c recommendations we have collected and provided in this chapter for design of human±machine systems are applicable across systems.

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1.2

1.2.1

Mital and Pennathur

APPROACHES TO DESIGNING SYSTEMS FOR HUMAN±MACHINE INTERFACE The System-Centered Design Approach

The system-centered design approach, as the name suggests, analyzes the system currently in use, designs and speci®es the new system based on this analysis, builds and tests the new system, and delivers the system and makes minor changes to the system (Fig. 3). The focus is on the goals of the system and the goals of the organization within which the system is to perform. Designers following this approach fail to consider the users before designing the system. As a result, users of such systems are required to remember too much information. Also, typically, these systems are intolerant of minor user errors, and are confusing to new users. More often than not, such systems do not provide the functions users want, and force the users to perform tasks in undesirable ways. New systems designed the system-centered way have also been shown to cause unacceptable changes to the structure and practices in entire organizations [5].

1.2.2

The Human-Centered Design Approach

The human-centered design approach to human± machine interaction, unlike the system-centered approach, puts the human attributes in the system ahead of system goals. In other words, the entire

Figure 3 System-centered approach to design.


system is built around the user of the systemÐthe human in the system. This approach has been variously called the `ùsability engineering approach,'' the `ùser-centered approach'' or the `ànthropocentric approach to production systems,'' etc. Figure 4 provides our conception of the human-centered approach to interface design. The ®rst step in this design approach is information collection. Information about user needs, information about user cognitive and mental models, information on task demands, information on the environment in which the users have to perform, information on the existing interface between the human operator (the user of the system) and the machine(s), requirements of the design, etc., are some of the more important variables about which information is collected. This information is then used in the detailed design of the new interface. The design is then evaluated. Prototype development and testing of the prototype are then performed just as in any other design process. User testing and evaluation of the prototype, the other important characteristic of this design process which calls for input from the end user, is then carried out. This results in new input to the design of the interface, making the entire design process iterative in nature. Even though the human-centered design approach is intended to take human capabilities and limitations into account in system design and make the system usable, there are a number of diculties with this approach. The usability of the system is only as good as its usability goals. Thus, if the input from the users about the usability goals of the system are inappropriate, the system will be unusable. One approach to overcome this problem is to include users when setting usability goals; not just when measuring the usability goals. Another common diculty with this approach is the lack of provision to take into account qualitative data for designing and re®ning the design. This is due to the de®ciency inherent in the de®nition of usability which calls for quantitative data to accurately assess the usability of a system. There is also the drawback that this approach is best suited for designing new systems, and that it is not as eective for redesign of existing systems. Despite these limitations, the human-centered design approach merits consideration from designers because it proactively takes the user of the product (displays and controls with which we are concerned, and which make up the interfaces for human±machine interaction, are products) into the system design process, and as a result, engineers usability, into the product.


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Figure 4 Human-centered approach.

1.3

THE PROCESS OF SOLVING HUMAN± MACHINE INTERFACE PROBLEMS

Even though displays and controls are the ®nal means of information exchange between humans and machines in a system, the actual design of the hardware and software for displays and controls comes only last in order, in the process of solving human± machine interface problems. The other key steps in this process include user-needs analysis, task analysis, situation analysis, and function allocation decisions, after which the modes of information presentation


and control can be decided. In the following sections, we discuss each of these steps. 1.3.1

User-Needs Analysis

The goal of user-needs analysis is to collect information about users and incorporate it into the design process for better design of the human±machine interface. User-needs analysis typically involves the following activities: characterization of the user, characterization of the task the user performs, and characterization of the situation under which the user

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has to perform the task. What follows are guidelines and methods for performing each of these three activities prior to designing the system. 1.3.1.1

Characterization of the User

Table 1 provides a user characterization checklist. Included in this checklist are questions to elicit information about the users, information about users' jobs, information about users' backgrounds, information about usage constraints, and information about the personal preferences and traits of the users. As is obvious from the nature of the questions in the checklist, the goal of collecting such information is to use the information in designing a usable system. 1.3.1.2

Characterization of the Task

Characterization of the tasks users have to perform to attain system goals is done through task analysis. Task analysis is defned as the formal study of what a human operator (or a team of operators) is required to do to achieve a system goal [6]. This study is conducted in terms of the actions and/or the cognitive processes

involved in achieving the system goal. Task analysis is a methodology supported by a number of techniques to help the analyst collect information about a system, organize this information, and use this information to make system design decisions. Task analysis is an essential part of system design to ensure ecient and eective integration of the human element into the system by taking into account the limitations and capabilities in human performance and behavior. This integration is key to the safe and productive operation of the system. The key questions to ask when performing task analysis activities are shown in Table 2. The task analysis methodology ®nds use at all stages in the life cycle of a systemÐfrom initial conception through the preliminary and detailed design phases, to the prototype and actual product development, to the storage and demolition stage. Task analysis is also useful for system evaluation, especially in situations involving system safety issues, and in solving speci®c problems that may arise during the daily operations of a system. Task analysis can be carried out by system designers or by the operations managers who run the system on a day-to-day basis.

Table 1 User Characteristics Checklist Data about users

What What What What

is the target user group? proportion of users are male and what proportion are female? is average age/age range of users? are the cultural characteristics of users?

Data about job

What What What What What What What What

is the role of the user (job description)? are the main activities in the job? are the main responsibilities of the user? is the reporting structure for the user? is the reward structure for the user? are the user schedules? is the quality of output from the user? is the turnover rate of the user?

Data about user background

What is the education/knowledge/experience of the user relevant to the job? What are the relevant skills possessed by the user? What relevant training have the users undergone?

Data about usage constrains

Is the current equipment use by users voluntary or mandatory? What are the motivators and demotivators for use?

Data about user personal preferences and traits

What What What What What

Adapted from Ref. 5.


is the learning style of the user? is the interaction style of the user? is the aesthetic preference of the user? are the personality traits of the user? are the physical traits of the user?


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Table 2 Checklist for Task Analysis Activities Goals

What are the important goals and supporting tasks?

For every important task: Intrinsics of the task What What What What What What What What What What

is the task? are the inputs and outputs for the task? is the transformation process (inputs to outputs)? are the operational procedures? are the operational patterns? are the decision points? problems need solving? planning is needed? is the terminology used for task speci®cation? is the equipment used?

Task dependency and criticality

What are the dependency relationships between the current task and the other tasks and systems? What are the concurrently occurring eects? What is the criticality of the task?

Current user problems

What are the current user problems in performing this task?

Performance criteria

What is the speed? What is the accuracy? What is the quality

Task criteria

What What What What What What

User discretion

Can the user control or determine pace? Can the user control or determine priority? Can the user control or determine procedure?

Task demands

What What What What What

is the sequence of actions? is the frequency of actions? is the importance of actions? are the functional relationships between actions? is the availability of functions? is the ¯exibility of operations?

are are are are are

the the the the the

physical demands? perceptual demands? cognitive demands? envirornmental demands? health and safety requirements?


While many dierent task analysis techniques exist to suit the dierent design requirements in systems, our primary focus here is on techniques that help in designing the interface. The key issues involved in designing a human interface with automated equipment are assessing what will be needed to do a job (the types of information that human operators will need to understand the current system status and requirements; the types of output that human operators will have to make to control the system), and deciding how this will be provided. Table 3 provides a summary of the important activities involved in the process of interface design and the corresponding task analysis technique


to use in designing this activity. We present brief summaries of each of these techniques in the following sections. The reader should refer to Kirwan and Ainsworth [6], or other articles on task analysis, for a detailed discussion of the dierent task analysis techniques. Hierarchical Task Analysis. This enables the analyst to describe tasks in terms of operations performed by the human operator to attain speci®c goals, and ``plans'' or ``statements of conditions'' when each of a set of operations has to be carried out to attain an operating goal. Goals are de®ned as ``desired states of

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Mital and Pennathur Table 3 Summary of Task Analysis Activities and Methods Involved in Interface Design Activity

Task analysis method

Gathering task information representing the activities within the task

Hierarchical task analysis Activity sampling

Stating required information, actions, and feedback

Work study Task decomposition Decision/action diagrams

Checking adequacy of provisions for information ¯ows for successful completion of the task

Table-top analysis Simulation Walk-through/talk-through Operator modi®cations surveys Coding consistency surveys

Identifying links between attributes (total system check) to ensure system success

Link analysis Petri nets Mock-ups Simulator trials

Provide detailed design recommendations

Person speci®cation Ergonomics checklists

Modi®ed from Ref. 6.

systems under control or supervision'' (e.g., maximum system productivity). Tasks are the elements in the method to obtain the goals in the presence of constraints (e.g., material availability). Operations are what humans actually do to attain the goals. Thus, hierarchical task analysis is ``the process of critically examining the task factors, i.e., the human operator's resources, constraints and preferencesÐin order to establish how these in¯uence human operations in the attainment of system goals.'' System goals can be described at various levels of detail (or subgoals), and hence the term ``hierarchical.'' The hierarchical task analysis process begins with the statement of overall goal, followed by statements of the subordinate operations, and the plans to achieve the goal. The subordinate operations and the plans are then checked for adequacy of redescription (of the goal into suboperations and plans). The level of detail necessary to adequately describe a goal in terms of its task elements determines the ``stopping rule'' to use when redescribing. A possible stopping rule could be when the probability of inadequate performance multiplied by the costs involved if further redescription is not carried out, is acceptable to the analyst. Activity Sampling. This is another commonly used task analysis method for collecting information about the type and the frequency of activities making up


a task. Figure 5 shows the steps involved in activity sampling. Samples of the human operator's behavior at speci®ed intervals are collected to determine the proportion of time the operator spends performing the identi®ed activities. Two key factors for the activity sampling method to work include the requirements that the task elements be observable and distinct from one another, and that the sampling keep pace with the performance of the task. Typically, the analyst performing activity sampling, classi®es the activities involved, develops a sampling schedule (these two aspects form the core of the design of activity sampling), collects and records information about activities, and analyzes the collected activity samples. Activity sampling has its advantages and disadvantages. Objectivity in data recording and collection, ease of administering the technique, and the ability of the technique to reveal task-unrelated activities that need analysis, are some of the advantages of the method. Requirements of a skilled analyst (for proper identi®cation and description of the task elements), and the inability of the technique to provide for analysis of cognitive activities are the main disadvantages of the technique. Task Decomposition. This is a method used to exactly state the tasks involved in terms of information con-


757

Figure 5 Activities involved in activity sampling.

tent, and actions and feedback required of the operator. Once a broad list of activities and the tasks involved have been generated using either hierarchical task analysis or activity sampling, task decomposition can be used to systematically expand on the task descriptions. The various steps involved in task decomposition are presented in Fig. 6. Decision±Action Diagram. This is one of the most commonly used tools for decision making. Figure 7 is an example of a decision±action diagram [7]. The decision±action diagram sequentially proceeds through a series of questions (representing decisions) and possible yes/no answers (representing actions that can be taken). The questions are represented as diamonds, and the possible alternatives are labeled on the exit lines from the diamond. A thorough knowledge of the system components, and the possible outcomes of making decisions about system components is essential for constructing complete and representative decision± action diagrams. Table-Top Analysis. As the name implies, this is a technique through which experts knowledgeable about a system discuss speci®c system characteristics. In the context of interface design, this task analysis methodology is used for checking if the information


¯ows identi®ed during the initial task analysis and task description, is adequate for successful task completion. Table-top analysis, hence, typically follows the initial hierarchical or other forms of task analysis which yield task descriptions, and provides information input for the decomposition of the tasks. A number of group discussion techniques exist in practice, including the Delphi method, the group consensus approach, the nominal group technique, etc., for conducting table-top analysis, each with its own merits and demerits. Walk-Through/Talk-Through Analysis. These analyses involve operators and other individuals having operational experience with the system, walking and talking the analyst through observable task components of a system in real time. Walk-through is normally achieved in a completely operational system or in a simulated setting or even in a mock-up setting. Talk-through can be performed even without a simulation of the systemÐthe only requirements are drawing and other system speci®c documentation to enable the analysts to set system and task boundaries while performing the talk-through analysis. For more information on walk-through and talk-through analyses, refer to Meister [8].

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Figure 6 The task decomposition process.

Operator Modi®cation Surveys. These surveys are performed to gather input from the actual users, (i.e., the operators) of the system, to check if there will be diculties in using the system, and of what types. This checking of the adequacy of the interface design of the system from the users' perspective is done through surveys conducted on similar already operational systems. In general, operators and other users of systems maintain and provide information on design inadequacies through memory aids, such as their own labels on displays to mark safe limits, perceptual cues, such as makeshift pointers, and organizational cues, such as grouping instruments through the use of lines. These makeshift modi®cations done


by the operators indicate design de®ciencies in the system, and can be planned for and included in the redesign of the existing system or in the design of a new system. Coding Consistency Surveys. These surveys are used to determine if the coding schemes in use in the system are consistent with the associated meanings, and if and where additional coding is needed. The recommendation when performing coding consistency surveys is to record the description of the location of the item, a description of the coding used for that item (intermittent siren sound), a description of any other coding schemes used for that item (inter-


759

Link analysis has been found to be particularly useful in applications where the physical layout of equipment, instruments, etc., is important to optimize the interaction of the human operator with the system. Link analysis does not require extensive resources to perform (in fact, paper and pencil are the only resources required to perform a link analysis). Link analysis proceeds by ®rst collecting information about the system components used during task performance. This information is then used to develop a complete list of links between individual system elements. The links thus established are then diagramed and ranked for importance. The order of importance may be determined based on the frequency of activity between two links, or based on other appropriate measures decided by the system expert. The nature of the links to be studied (is it a movement of attention or position between parts of the system?), and the level of detail to include in de®ning each link are important factors that determine the overall structure and usefulness of the links established. Link analysis does not need observational data collection; a mere description of the procedures in the form of a technical manual is sucient for identifying and establishing the links. The extensive graphical and tabular representations involved in link analysis, however, limits the use of this technique for large systems with involved linkages in the system.

Figure 7 Generic function allocation analysis ¯owchart.

mittent siren sound accompanied by a yellow ¯ashing light), and a complete description of the function being coded. Link Analysis. This is a technique used to identify and represent the nature, frequency, and/or the importance of relationships or links existing between individual operators and some portion of the system [9].


Simulator Analysis. The goal of simulation studies is to replicate, and observe, system (including operator and operating environment) performance while making the performance environment as representative and close to the real-time environment as possible. Dierent forms of simulations exist depending on the platform or the simulator used for the simulation: a simple paper-and-pencil simulation, to a mock-up of a system that may or may not be dynamic, to a dynamic simulation which will respond in real time. Whatever the method of simulation used, the key consideration in simulation studies is the trade-o between the ®delity of simulation (deciding the features of the system that need ®delity is an issue too), and the cost of involved in building high-®delity simulations. Despite this limitation, simulation analysis can be useful when designing task situations that are dangerous for humans to perform, or dicult to observe. Person Speci®cation. The goal of person speci®cation is to detail the key physical and mental capabilities, the key qualifcations and personality traits, and experience, required of the operator to perform specif ed tasks. Person speci®cation is similar to the user char-

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Figure 7


(continued)


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Figure 7 (continued)


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acterization exercise described in Sec. 1.3.1.1; the checklist used for user characterization can be used for person speci®cation also. One of the widely used techniques for person speci®cation is the position analysis questionnaire. Broadly, position analysis questionnaires require the operator to identify for their speci®ed tasks andjobs, the information input, the mental processes, the work output, the context of the job, the relationship with other personnel in the system, and any other relevant job characteristics. Using the responses from the operators, the skill content of tasks and jobs can be determined, and can help in designing personnel selection and training programs to ensure optimal human±machine interaction. Ergonomics Checklists. These checklists are generally used to ascertain if a particular system meets ergonomic principles and criteria. Ergonomics checklists can check for subjective or objective information and can cover issues ranging from overall system design to the design of individual equipment. Checklists can also range in detail from the broad ergonomic aspects to the minute detail. Table 4 provides an example of a checklist for equipment operation. A number of other standard checklists have also been developed by the ergonomics community. Important among these are the widely used and comprehensive set of checklists for dierent ergonomics issues by Woodson [10,11], MIL-STD 1472C [12] which covers equipment design (written primarily for military equipment, but can be used as a guide to develop checklists), EPRI NP-2360 [13] which is a checklist for maintenance activities in any large-scale system, NUREG0700 [14] which is a comprehensive checklist for control room design, the HSE checklist [15] which deals with industrial safety and human error, and the numerous checklists for CRT displays and VDUs [16,17]. 1.3.1.3

Characterization of the Situation

Apart from the user and the task variables that could aect system performance, the external environment in which the system functions can also in¯uence the human±system interaction performance. Table 5 provides a representative checklist for the most commonly encountered situations for which the system analyst must obtain answers, and attempt to provide for these situations in design. 1.3.2

Allocation of Functions

In designing the human±machine interface, once comprehensive information about the users and the activ-


ities/tasks these users will perform is known (through the use of tools presented in the earlier sections), the speci®c activities and tasks need to be assigned either to the humans or to the machines. The allocation of functions is a necessary ®rst step before any further design of the interface in the human±machine system can be carried out. The need for solving the function allocation problem directly stems from the need to decide the extent of automation of manufacturing activities. This is so because, in the present day manufacturing scenario, the decision to make is no longer whether or not to automate functions in manufacturing, but to what extent and how. The function allocation problem is perhaps as old as the industrial revolution itself. Fitts' list, conceived in 1951 (Table 6), was the ®rst major eort to resolve the function allocation problem. However, while Fitts' list provided fundamental and generic principles that researchers still follow for studying function allocation problems, its failure to provide quantitative criteria for function allocation resulted in its having little impact on engineering design practices. The development of practical and quantitative criteria for allocating functions is compounded by an important issue: unless one can describe functions in engineering terms, it is impossible to ascertain if a machine can perform the function; and, if one can describe human behavior in engineering terms, it may be possible to design a machine to do the job better (than the human). But many functions cannot be completely speci®ed in engineering (numerical) terms. This implies that those functions that cannot be speci®ed in engineering terms should be allocated to humans, with the rest allocated to the machines. In addition, for the practitioner, function allocation considerations have been limited due to the lack of [19]: 1. 2.

3. 4. 5.

Systematic and step-by-step approaches to decision making during function allocation Systematic and concise data for addressing issues such as the capability and limitations of humans and automated equipment, and under what circumstances one option is preferable over the other Methodology for symbiotic agents such as manufacturing engineers and ergonomists, to integrate human and machine behaviors Uni®ed theory addressing domain issues such as roles, authorities, etc Integration of other decision-making criteria (such as the economics of the situation) so


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Table 4 Example of an Ergonomics Checklist for Equipment Operation Characteristic

Satisfactory

Console shape/size Desk height, area Control reach Display view Body, limb clearance Panel location Frequency of use Sequence of use Emergency response Multioperator use Panel layout Functional grouping Sequential organization Identi®cation Clearance spacing Displays Functional compatibility for intended purposes Intelligibility of information content Control interaction Legibility; ®gures, pointers, scales Visibility; illumination, parallax Location Identi®cation Controls Functional compatibility for intended purposes Location, motion excursion, and force Display interaction Spacing, clearance, size Identi®cation Adapted from Ref. 10.


Compromise but acceptable

Unsatisfactory

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Table 5

Checklist for Situation Analysis What are the likely situations that could arise during system use and how will these aect use of the system?

2.

Equipment

Falls short of target performance Falls short of speci®cation Fails

Availability

Data is missing Materials are missing Personnel are missing Support is missing

Overloads

Of people/machines Of data, information, materials, etc.

4.

Interruptions

The process breaks down Complete restart of process required

5.

Environment

Changes: in physical or social environment

6.

Policy changes

Changes in laws, rules, standards and guidelines

7.


3.

8.

that the function allocation decision is not made in isolation Easily usable tools to simulate dierent con®gurations of humans and machines.

10.

In spite of these shortcomings, research on function allocation has permitted the following general inferences for the practitioner:

11.

6.

1.

Table 6

Function allocation cannot be accomplished by a formulaÐor example, rules which may

9.

apply in one situation may be irrelevant in another. Function allocation is not a one-shot decisionÐthe ®nal assignment depends on activities at the levels of the tasks, the con¯ation of tasks into jobs, the relationships of jobs within a larger workgroup, and the likely changes in the higher level manufacturing processes themselves. Function allocation can be systematizedÐit is clear that there are a number of sequential steps that can be taken to best allocate functions. Both humans and machines can be good or bad at certain tasks. Using analogies can facilitate the function allocation process. Function allocation can be targeted to a speci®c time frame. Function allocation depends on the nature of the taskÐit varies based on whether the task is perceptual, cognitive, or psychomotor. Function allocation decisions must be based on sound economic analyses of options as well as the capabilities and limitations of humans and machines. Human and machine performances are not always antithetical. Function allocation decisions must consider technology advances within a given time frame. In cases where both humans and machines can perform a function, the system should be designed in such a way so that humans can delegate the function to machines, or can

Fitts' List

Humans appear to surpass present-day machines with respect to the following: Ability to detect small amounts of visual or acoustic energy Ability to perceive patterns of light or sound Ability to improvise and use ¯exible procedures Ability to store very large amounts of information for long periods and to recall relevant facts at the appropriate time Ability to reason inductively Ability to exercise judgment Present-day machines appear to surpass humans with respect to the following: Ability to respond quickly to control signals, and to apply great force smoothly and precisely Ability to perform repetitive, routine tasks Ability to store information brie¯y and then to erase it completely Ability to reason inductively, including computational ability Ability to handle complex operations, i.e., to do many dierent things at once Adapted from Ref. 18.



take over the function when circumstances demand it. A number of approaches have been suggested in the literature for solving the function allocation problem. Some of the promising approaches include function allocation criteria based on speci®c performance measures (time required to complete tasks, for example) [20±24], criteria based on comparison of capabilities and limitations of humans with particular attention given to knowledge, skills, and information sources and channels [25±34] criteria based on economics (allocate the function to the less expensive option), [21,35,36], and criteria based on safety (to the human operator in the system) [37±39]. Experiments with these approaches suggest that functions that are well-proceduralized permitting algorithmic analysis, and requiring little creative input, are prime candidates for automation. On the other hand, functions requiring cognitive skills of a higher order, such as design, planning, monitoring, exception handling, etc., are functions that are better performed by humans. The prime requirements for automating any function are the availability of a model of the activities necessary for that function, the ability to quantify that model, and a clear understanding of the associated control and information requirements. Clearly, there are some functions that should be performed by machines because of: 1. 2. 3. 4. 5.

Design accuracy and tolerance requirements. The nature of the activity is such that it cannot be performed by humans. Speed and high production volume requirements. Size, force, weight, and volume requirement. Hazardous nature of the activity.

Equally clearly, there are some activities that should be performed by humans because of: 1. 2. 3. 4. 5. 6.

Information-acquisition and decision-making needs Higher level skill needs such as programming Specialized manipulation, dexterity, and sensing needs Space limitations (e.g., work that must be done in narrow and con®ned spaces) Situations involving poor equipment reliability or where equipment failure could prove catastrophic Activities for which technology is lacking.


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Mital et al. [7] provide a generic methodology in the form of decision-making ¯owcharts for the systematic allocation of functions between humans and machines. Figure 7, presented earlier is a part of these ¯owcharts. These ¯owcharts are based on the requirements of complex decision making, on a detailed safety analysis, and on a comprehensive economic analysis of the alternatives. These function allocation ¯owcharts are available for dierent manufacturing functions such as assembly, inspection, packaging, shipping, etc., and should be consulted for a detailed analysis of the question of manufacturing function allocation. 1.3.3 1.3.3.1

Information Presentation and Control The Scienti®c Basis for Information Input and Processing

Reduced to a fundamental level, human interaction with automation can be said to be dependent upon the information processing ability of the human, and upon the exchange of information among the dierent elements in a system. Over the years, behavioral scientists have attempted to explain human information processing through various conceptual models and theories. One such theory is the information theory [40] Information, according to information theory, is de®ned as the reduction of uncertainty. Implicit in this de®nition is the tenet that events that are highly certain to occur provide little information; events that are highly unlikely to occur, on the other hand, provide more information. Rather than emphasize the importance of a message in de®ning information, information theory considers the probability of occurrence of a certain event in determining if there is information worth considering. For instance, the ``nosmoking'' sign that appears in airplanes before takeo, while being an important message, does not convey much information due to the high likelihood of its appearance every time an aircraft takes o. On the other hand, according to information theory, messages from the crew about emergency landing procedures when the plane is about to perform an emergency landing convey more information due to the small likelihood of such an event. Information is measured in bits (denoted by H). One bit is de®ned as the amount of information required to decide between two equally likely alternatives. When the dierent alternatives all have the same probability, the amount of information (H) is given by H log2 N

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where N is the number of alternatives. For example, when an event only has two alternatives associated with it, and when the two alternatives are equally likely, by the above equation, the amount of information, in bits, is 1.0. When the alternatives are not equally likely (i.e., the alternatives have dierent probabilities of occurrence), the information conveyed by an event is given by hi log2 1=pi where hi is the information associated with event i, and pi is the probability of occurrence of event i. The average information (Hav conveyed by a series of events having dierent probabilities is given by X Hav pi log2 1=pi where pi is the probability of the event i. Just as a bit is the amount of information, redundancy is the amount of reduction in information from the maximum due to the unequal probabilities of occurrence of events. Redundancy is expressed as a percentage, and is given by % Redundancy 1

Hav =Hmax 100

Information theory, while providing insight into measuring information, has major limitations when applied to human beings. It is valid only for simple situations which can split into units of information and coded signals [41]. It does not fully explain the stimulus-carrying information in situations where there are more than two alternatives, with dierent probabilities. The channel capacity theory, another theory explaining information uptake by humans, is based on the premise that human sense organs deliver a certain quantity of information to the input end of a channel, and that the output from the channel depends upon the capacity of the channel. It has been determined that if the input is small, there is very little absorption of it by the channel, but that if the input rises, it reaches the threshold channel capacity, beyond which the output from the channel is no longer a linear function of the input [41]. Experimental investigations have shown that humans have a large channel capacity for information conveyed to them through the spoken word than through any other medium. A vocabulary of 2500 words requires a channel capacity of 34 to 42 bits per second [42]. Designers must keep in mind that in this day and age of information technology, the central nervous system of humans is subjected to more information than the information channel can


handle, and that a considerable reduction in the amount of information must be carried out before humans process the information. In addition to theories such as the information theory and the channel capacity theory that explain information uptake, many conceptual models of human information processing have been proposed by researchers over the last four decades. Figure 8 shows one such fundamental model (most other models contain elements of this basic model) depicting the stages involved in information processing [43]. The key elements of the model are perception, memory, decision making, attention, response execution, and feedback. The following is a brief discussion of each of these elements. Perception may involve detection (determining whether or not a signal is present), or identi®cation and detection (involving detection and classi®cation). The theory of signal detection [43±45] through the concept of noise in signals, attempts to explain the process of perception and response to the perceived signals. Four possible outcomes are recognized in signal detection theory: (1) hit (correctly concluding that there is a signal when there is one), (2) false alarm (concluding that there is a signal when, in actuality, there is none), (3) miss (concluding that there is no signal when, in actuality, there is one and (4) correction rejection (correctly concluding that there is no signal when there is none). The fundamental postulate of signal detection theory is that humans tend to make decisions based on criteria whose probabilities depend upon the probabilities of the outcomes above. The probability of observing a signal, and the costs and bene®ts associated with the four possible outcomes above, determine the responses of the human to the signal. The resolution of the human sensory activities (ability to separate the noise distribution from the distribution of the signal) has also been found to aect the signal detection capability of the human. Memory, in humans, has been conceptualized as consisting of three processes, namely, sensory storage, working memory, and long-term memory [43]. According to this conception, information from sensory storage must pass through working memory before it can be stored in long-term memory. Sensory storage refers to the short-term memory of the stimulus. Two types of short-term memory storage are well knownÐiconic storage associated with visual senses, and echoic storage associated with the auditory senses [46]. Sensory storage or short-term memory has been shown to be nearly automatic requiring no sustained attention on the part of the human to retain it.


Figure 8

Fundamental model of human information processing.

Information transfer from sensory storage to working memory is brought about through attention (to the process). Information from stimuli is believed to be stored in the working memory primarily in the form of either visual, phonetic, or semantic codes. It is also believed that the capacity of working memory is ®ve to nine chunks of information (similar units regardless of the size) [47]. Researchers recommend presenting ®ve to nine meaningful and distinct chunks of information for improved recall. It has also been determined that there is a linear relationship between the number of items in a memorized list and the time required to search the list of items in the working memory [48]. Also, all items in the working memory are searched one at a time, even if a match is found early in the search process. The transfer of information from working memory to the long-term memory is believed to take place through semantic coding, i.e., by analyzing, comparing, and relating information in the working memory to past stores of knowledge in the long-term memory [46]. The extent to which information can be retrieved from long-term memory depends on the extent of organization of the information in the longterm memory. Rational decision making is de®ned as the process that involves seeking information relevant to the decision at hand, estimating the probabilities of


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various alternatives, and attaching values to the anticipated alternatives. A number of biases, however, have been identi®ed to exist among humans that often makes decision making irrational. Table 7 lists some of these biases. Attention is another key factor in¯uencing human information input and processing. Research has identi®ed four types of tasks or situations requiring attention. These are selective attention, focused attention, divided attention, and sustained attention. When several information sources are to be monitored to perform a single task, attention is said to be selective (e.g., a process control operator scanning several instrument panels before detecting a deviant value). Table 8 provides guidelines for improving performances in tasks requiring selective attention. When a human has to focus attention on one source of information and exclude all other sources of information for task performance, attention is said to be focused. Task performance under focused attention is aected by the physical proximity of the sources of information. While physical proximity enhances performance in tasks requiring selective attention, it impedes performance in tasks requiring focused attention. Table 9 provides guidelines for improving performances in tasks requiring focused attention. When humans do more than one task at a time, their atten-

768 Table 7

Mital and Pennathur Common Human Biases

Humans attach more importance to early information than subsequent information. Humans generally do not optimally extract information from sources. Humans do not optimally assess subjective odds of alternative scenarios. Humans have a tendency to become more con®dent in their decisions with more information, but do not necessarily become more accurate. Humans tend to seek more information than they can absorb. Humans generally treat all information as equally reliable. Humans seem to have a limited ability to evaluate a maximum of more than three or four hypotheses at a time. Humans tend to focus only on a few critical factors at a time and consider only a few possible choices related to these critical factors. Humans tend to seek information that con®rms their choice of action than information that contradicts or discon®rms their action. Human view a potential loss more seriously than a potential gain. Humans tend to believe that mildly positive outcomes are more likely than mildly negative or highly positive outcomes. Humans tend to believe that highly negative outcomes are less likely than mildly negative outcomes. Adapted from Ref. 43.

tion is said to be divided (among the tasks). While much of the theoretical base for explaining performance of tasks requiring divided attention is still evolving [43,49], some guidelines for designing tasks that require divided attention are available, and are provided in Table 10. When humans maintain attention and remain vigilant to external stimuli over prolonged periods of time, attention is said to be sustained. Nearly four decades of research in vigilance and vigilance decrement [50±53] has provided guidelines for improving performance in tasks requiring sustained attention (Table 11). In addition to the factors discussed above, considerable attention is being paid to the concept of mental workload (which is but an extension of divided attention). Reviews of mental workload measurement techniques are available [54±56], and should be consulted for discussions of the methodologies involved in mental workload assessment.

Table 8

1.3.3.2 The Scienti®c Basis for Human Control of Systems Humans respond to information and take controlling actions. The controlling actions of the human are mediated through the motor system in the human body. The human skeletal system, the muscles, and the nervous system help bring into play motor skills that enable the human to respond to stimuli. Motor skill is defned as `àbility to use the correct muscles with the exact force necessary to perform the desired response with proper sequence and timing'' [57]. In addition, skilled performance requires adjusting to changing environmental conditions, and acting consistently from situation to situation [58]. A number of dierent types of human movements have been recognized in the literature [46]. These include discrete movements (involving a single reaching movement to a target that is stationary), repetitive movements (a single movement is repeated), sequential movements

Recommendations for Designing Tasks Requiring Selective Attention

Use as few signal channels as possible, even if it means increasing the signal rate per channel. Inform the human the relative importance of various channels for eective direction of attention. Reduce stress levels on human so more channels can be monitored. Inform the human beforehand where signals will occur in future. Train the human to develop optimal scan patterns. Reduce scanning requirements on the human by putting multiple visual information sources close to each other, and by making sure that multiple sources of auditory information do not mask each other. Provide signal for a sucient length of time for individual to respond; where possible, provide for human control of signal rate. Adapted from Ref. 46.



769

Table 9 Recommendations for Designing Tasks Requiring Focused Attention

Table 11 Recommendations for Designing Tasks Requiring Sustained Attention

Make the dierent channels of information as distinct as possible from the channel to which the human must attend. Physically separate the channel of interest from the other channels. Reduce the number of competing channels. Make the channel of interest prominent by making it larger in size, or brighter, or louder, or by locating it centrally.

Provide appropriate work±rest schedules. Provide task variation by interpolating dierent activities. Make the signal larger, and/or more intense, and/or longer in duration, and/or distinct. Reduce uncertainty in time and place of occurrence of signal. Use arti®cial signals and provide feedback to humans on their performance. Reduce the rate of presentation of stimuli if it is high. Provide optimal environmental conditions such as lighting, noise level, etc. Provide adequate training to humans to clarify the nature of signals to be identi®ed.


(a number of discrete movements to stationary targets), continuous movements (involving muscular control adjustments during movement), and static positioning (maintaining a speci®c position of a body member for a speci®ed period of time). In addition, certain theoretical models of human motor responses explain the control aspects of human responses based on only two fundamental types of movementsÐfast and slow. Closed-loop theories [59,60], whether the movement be fast or slow, use the concept of sensory feedback (sensory information available during or after the motor response) to explain motor responses (to correct/reduce errors obtained through feedback). The sensory receptors for feedback and feedforward (sensory information available prior to the action that regulates and triggers responses), are believed to be located in the muscle spindles (for sensing the muscle length and the rate of change of length) [58,61], tendons (the Golgi tendons inhibit muscle contraction and regulate muscle action), joints (the tension in the joints in¯uences the generation of nerve impulses), cutaneous tissue (skin is believed to have receptors that aect joint movement), and the eyes (important for timing of responses) [62]. Openloop theories, on the other hand, are based on the belief that there are higher-level structured motor programs containing information necessary for

Table 10 Recommendations for Designing Tasks Requiring Divided Attention Minimize the potential sources of information. Provide human with a relative priority of tasks to optimize the strategy of divided attention. Keep the level of diculty of tasks low. Make tasks as dissimilar as possible in terms of task demands on the human. Adapted from Ref. 46.


patterning the dierent movements [63,64]. Dierent de®ciencies, such as the error of selection (where a person calls the wrong motor program for a controlling action) and the error of execution (where the correct motor program fails during execution of controlling actions) have been identi®ed with motor programs [65]. Much of the development in understanding human controlling actions in response to stimuli is still in its infancy, but has important practical consequences (how to improve skilled performance, for example). The time it takes for the human to respond to stimuli is another critical factor that has been studied extensively in the literature [46]. An understanding of response time of the human is essential for good design of the tasks involved in human interaction with automated systems. Response time is, in general, composed of reaction time, and movement time. Reaction time is de®ned as the time from the signal onset calling for a response, to the beginning of the response. Simple reaction time (reaction time in the presence of a single source of stimulus) has been shown to be between 0.15 sec and 0.20 sec. The mode through which the single stimulus occurs (visual, auditory etc.,) the detectability of the stimulus (intensity, duration, and size), the frequency, the preparedness (of the human for the stimulus), the age, and the location of the stimulus (location in the peripheral ®eld of view, for instance) are among the factors that have been shown to aect simple reaction time. Choice reaction time (reaction time in the presence of one of several possible stimuli each with dierent possible responses), is a function of the probability of a stimulus occurring, i.e., the reaction time is faster for events with greater probability. It has been shown to increase by about 0.15 sec for each doubling of the number of possible

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alternative stimuli [66]. Choice reaction time has been shown to be in¯uenced by a numerous factors, including the degree of compatibility between stimuli and responses, practice, presence or absence of a warning signal, the type and complexity of the movement involved in the responses, and whether or not more than one stimulus is present in the signal. Movement time is defned as the time from the beginning of the response to its completion. It is the time required to physically make the response to the stimulus. Movements based on pivoting about the elbow have been shown to take less time, and have more accuracy, than movements based on upper-arm and shoulder action. Also, it has been determined that movement time is a logarithmic function of distance of movement, when target size is a constant, and further that movement time is a logarithmic function of target size, when the distance of movement is constant. This ®nding is popularly known as Fitts' law [67], and is represented as MT a b log2 2D=W where MT is the movement time, a and b are empirical constants dependent upon the type of movement, D is the distance of movement from start to the center of the target, and W is the width of the target. Human response to stimuli is not only dependent upon the speed of the response, but also on the accuracy of the response. The accuracy of the human response assumes special importance when the response has to be made in situations where there is no visual feedback (a situation referred to as ``blind positioning''). Movements that take place in a blind positioning situation have been determined to be more accurate when the target is located dead-ahead than when located on the sides. Also, targets below the shoulder height and the waist level are more readily reachable than targets located above the shoulder or the head [68]. The distance and speed of movement have also been found to in¯uence the accuracy of the response [69,70]. 1.3.3.3

Displays

Types of Displays. A display is de®ned as any indirect means of presenting information. Displays are generally one of the following four types: visual, auditory, tactual, and olfactory. The visual and the auditory modes of displaying information are the most common. Displays based on tactile and olfactory senses are mostly used for special task or user situations (e.g., for the hearing impaired).


Selecting the mode of display whether it should be visual or auditory in nature) is an important factor due to the relative advantages and disadvantages certain modes of display may have over other modes, for speci®c types of task situations (auditory mode is better than visual displays in vigilance), environment (lighting conditions), or user characteristics (person's information handling capacity). Table 12 provides general guidelines for deciding between two common modes of information presentation, namely, auditory and visual. The types of displays to use to present information also depend on the type of information to present. Dierent types of information can be presented using displays when the sensing mode is indirect. Information can either be dynamic or static. Dynamic information is categorized by changes occurnng in time (e.g., fuel gage). Static information,

Table 12 Guidelines for Deciding When to Use Visual Displays and When to Use Auditory Displays Characteristics Message characteristics Simple message Complex message Short message Long message Potential reference value of message High Low Immediacy of action requirement of message High Low Message deals with events in time Message deals with locations in space Human capability Auditory system overburdened Visual system overburdened Environmental factors Location too bright or too dark requiring signi®cant adaptation Location too noisy Adapted for Ref. 71.

Visual displays p p p

p

Auditory displays p p

p p p

p

p p

p p


on the other hand, does not change with time (e.g., printed safety signs). A number of other types of information are also recognized in the literature. Table 13 provides a list of these types along with a brief description of the characteristics of these types of information. In the following sections, we discuss recommendations for the design of dierent types of visual and auditory displays (we restrict our attention in this chapter only to these two common modes). We ®rst provide a brief discussion of the dierent factors aecting human visual and auditory capabilities. We then present speci®c display design issues and recommendations for these two broad types of displays. Visual displays: factors affecting design. Accommodation refers to the ability of the lens in the eye to focus the light rays on the retina. The distance (of the target object from the eye) at which the image of the object becomes blurred, and the eye is not able to focus the image any further, is called the near point. There is also a far point (in®nity, in normal vision) beyond which the eye cannot clearly focus. Focal distances are measured in diopters. One diopter is 1/(distance of the target in meters). Inadequate accommodation capacity of the eyes result either in nearsightedness (the far point is too close) or in farsightedness (the near point is too close). Literature recommends an average focusing distance of 800 mm at the resting position of the eye (also known as the resting accommodation) [72]. Due to changes in the iris (which controls the shape of the lens), aging results in substantial receding of the near point, the far point remaining unchanged or becoming shorter. Figure 9 shows how the mean near point recedes with age. It is recom-

771

mended that the designer use this information when designing visual displays. Visual acuity is de®ned as the ability of the eye to separate ®ne detail. The minimum separable acuity refers to the smallest feature that the eye can detect. Visual acuity is measured by the reciprocal of the visual angle subtended at the eye by the smallest detail that the eye can distinguish. Visual angle (for angles less than 108) is given by Visual angle in minutes 3438H=D where H is the height of the stimulus detail, and D is the distance from the eye, both H and D measured in the same units of distance. Besides minimum separable visual acuity, there are other types of visual acuity measure, such as vernier acuity (ability to dierentiate lateral displacements), minimum perceptible acuity (ability to detect a spot from its background), and stereoscopic acuity (ability to dierentiate depth in a single object). In general, an individual is considered to have normal visual acuity if he or she is able to resolve a separation between two signs 1 0 of arc wide. Visual acuity has been found to increase with increasing levels of illumination. Luckiesh and Moss [73] showed that increasing the illumination level from approximately 10 l to 100 l increased the visual acuity from 100 to 130%, and increasing the illumination level from approximately 10 l to 1000 l increased the visual acuity from 100 to 170%. For provision of maximum visual acuity, it is recommended that the illumination level in the work area be 1000 l. Providing adequate contrast between the object being viewed and the immediate background, and making the signs and

Table 13 Commonly Found Types of Information and Their Characteristics Type of information Quantitative information Qualitative information Status information Warning and signal information Representational information Identi®cation information Alphanumeric and Symbolic information Time-phased information Adapted from Ref. 46.


Characteristics Information on the quantitative value of a variable Information on the approximate value, trend, rate of change, direction of change, or other similar aspects of a changeable variable Information on the status of a system, information on a one of a limited number of conditions, and information on independent conditions of some class Information on emergency or unsafe conditions, information on presence or absence of some conditions Pictorial or graphic representations of objects, areas, or other con®gurations Information in coded form to identify static condition, situation, or object Information of verbal, numerical, and related coded information in other forms such as signs, labels, placards, instructions, etc. Information about pulsed or time-phased signals

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Figure 9 Effect of age on near point for visual accomodation.

characters (in the object being viewed) sharp, will also increase visual acuity. The general recommendation is to use dark symbols and characters on a bright background than vice versa, as the former increases the visual acuity. Visual acuity has also been shown to decrease with age [74]. Figure 10 illustrates how visual acuity decreases with age. Contrast sensitivity is another factor that has implications for design of the interface. It is the ability of the eye to dierentiate lightness between black and white. Contrast sensitivity is generally expressed as the reciprocal of the threshold contrast, where the threshold contrast is the level of contrast that just stops short of making the colors appear homogeneous. Other measures for contrast sensitivity include modulation contrast computed as C Lmax

sensitivity. Since contrast sensitivity is greater for larger areas, it is recommended that the viewing area be made as large as possible. Also, making the object boundaries sharper will increase contrast sensitivity. The surrounding luminance, and the intensity of light (or the level of illumination), have been shown to have an eect on contrast sensitivity. Contrast sensitivity

Lmin =Lmax Lmin

where Lmax and Lmin are the maximum and the minimum luminances in the pattern. The literature provides certain general rules to follow when designing displays in order to provide the best possible contrast


Figure 10

Effect of age on visual acuity.


has been determined to be the largest when the surrounding luminance is within the range of 70 cd/m2 , and more than 1000 cd/m2 [75]. Also, Luckiesh and Moss [73] showed that increasing the illumination level from approximately 10 l to 100 1 increased the contrast sensitivity from 100 to 280%, and increasing the illumination level from approximately 10 l to 1000 l increased the contrast sensitivity from 100 to 450%. The literature [41] also recommends that the background be at least 2% brighter or darker than the target for optimal contrast sensitivity. As brie¯y described above, visual acuity and contrast sensitivity are aected by a number of factor, such as luminance level (in general, the higher the luminance, the more the visual acuity and contrast sensitivity), contrast, exposure time, motion of the target, age (there is a decline in both visual acuity and contrast sensitivity with age), and training (through surgery of the eye or through corrective lenses, etc.). Adaptation is another factor that aects the visual capability of the human eye. It is de®ned as the changes in the sensitivity of the eye to light. A measure of adaptation is the time it takes for the eye to adapt to light or dark. It has been found that, in general, adaptation to light occurs more quickly than adaptation to the dark. Darkness adaptation has been found to be quick in the ®rst 5 min of exposure; nearly 80% of the adaptation to darkness has been shown to take about 25 min with full adaptation taking as much as one full hour [41]. Adaptation can also be partial (depending on whether the visual ®eld contains a dark or a bright area), and can aect the sensitivity of the retina and the vision. For optimal adaptation, the overall recommendation is to provide the same order of brightness on all important surfaces, and provide a stable and non¯uctuating levels of illumination. It is also important to avoid the eects of glare (which is a process of overloading the adaptation processes of the eye). This can be achieved by avoiding excessive brightness contrasts, avoiding excessive brightness in the light source, and providing for transient adaptation. The ability of the eye to discriminate between different colors is called color discrimination. Color discrimination de®ciency is due to the reduced sensitivity of the particular (to a color) cone receptors. While it is dicult to measure precisely the type and degree of a person's color de®ciency, it is important from the perspective of designing tasks which require perception of colored targets for task performance.


773

The ability to read, and the ability to perceive meaning, are the other key factors that have to be accounted for when designing visual displays. Design recommendations for visual displays. As already mentioned, visual displays are classi®ed on the basis of the type of information they present to the user. Information presented to the user can be static or dynamic in nature. Display of dynamic information will require capture of the changing nature of the information (for example, continuous changes in speed indicated by the tachometer in the car). Static displays do not display, in real time, the changes in the information content in time. (Note that, in static displays, the displays themselves do not change with time. However, static displays can be used to present, in the form of graphs, for example, changes in information content over time, after the event has occurred; static displays do not provide information in real time.) Almost all dynamic visual displays contain elements of one of the more fundamental forms of static information displays, namely, textual information, information in the form of graphical displays, information in some coded form, or symbolic information. In the following sections, we ®rst brie¯y present recommendations on design of these four forms of static visual displays. We then provide guidelines on designing dynamic information displays. Static visual displays. The literature distinguishes between two forms of textual displaysÐtextual displays in hardcopy format, and textual displays in visual display terminals or computer screens [46]. While there are differences in performance based on whether the display is in hardcopy form or in a visual display unit, there are three essential characteristics of any display in the form of text; the textual display should be visible, legible, and readable. Visibility of the text refers to the characteristic that makes a character or a symbol distinguishable and separate from its surroundings. Legibility of the text refers to the characteristic of alphanumeric characters that makes it possible to identify one character from the other. The stroke width, the character format, contrast, illumination etc., in¯uence the legibility of the text. Readability of the text refers to the characteristic of alphanumeric characters that enables organization of the content into meaningful groups (of information) such as words and sentences. Various factors in¯uence the visibility, the legibility, and the readability of textual information presented in hardcopy form. They are typography, size, case, layout, and reading ease.

774

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The typography has been found to be especially important when the viewing conditions are unfavorable, or when the information is critical (such as a sign warning of danger). Typography depends on factors such as the stroke width of the alphanumeric character (ratio of thickness of the stroke to height of the character), the width-to-height ratio of the character, and the type style. Table 14 also provides accepted guidelines, based on research, for size of characters, case, layout of characters, and for reading ease of alphanumeric characters. Some examples of type style and other aspects in typography of text are given in Fig. 11.

Table 14

Numerical text can also be represented in graphical forms. Graphs can be in dierent forms such as line graphs, bar and column graphs, pie charts, etc. Pictorial information such as in the form of graphs improves the speed of reading, but the general recommendation in the literature is to combine pictorial information with information in the form of plain text, improve the accuracy of the information presented [76,77]. The visibility, readability, and legibility of visualdisplay-terminal-based text has been found to depend upon the typography, the reading distance, the size of characters, and hardware considerations, such as the

Recommendations for Design of Hardcopy Text

Characteristic

Recommendations

Typography Stroke width

When the illumination is reasonable, use 1 : 6 to 1 : 8 for black on white and 1 : 8 to 1 : 10 for white on black When the illumination is reduced, use thick letters than thin letters for greater readability When illumination is low or with low background contrast, use boldface characters with a low stroke width±height ratio When letters are highly luminous, use 1 : 12 to 1 : 20 ratio When letters are black on a highly luminous background, use thick strokes Use a 3 : 5 ratio for most practical applications; for transluminated or engraved legends, use 1:1

Width±height ratio Size of character For close reading

For distant reading

When the reading distance is 12 to 16 in.: Use 0.09±0.11 in. or 22 to 27 0 of visual angle for normal use of alphanumeric characters When the viewing distance is 28 in.: For critical use under 0.03 fL luminance, and variable position of character, use 020±0.30 in. height For critical use over 1.0 fL luminance, and variable position of character, use 0.12±0.20 in. height For critical use under 0.03 fL luminance, and ®xed position of character, use 0.15 to 0.30 in. height For critical use over 1.0 fL luminance, and ®xed position of character, use 0.10±0.20 in. height For noncritical use 0.05±0.20 in. height Use Ws 1:45 10 5 S d, and HL Ws =R, where Ws is the stroke width, S is the denominator of the Snellen acuity score (20/20, 20/40 etc.), d is the reading distance, HL is the height of the letter, and R is the stroke width-to-height ratio of the font

Case

In general, use lowercase letters than uppercase letters for better readability Use initial uppercase for search tasks

Layout Interletter spacing Interline spacing

Provide close-set type than regular-set type where possible for easier readability Increase spacing between lines for better clarity

Reading ease Type of sentence Order of words

Use simple, armative, active sentences where possible Match order of words in sentence to the order of actions to be taken




Figure 11

775

Examples of different type styles and type size.

polarity of the screen, and screen color. It is generally recommended that the size of the dot matrix for alphanumeric characters used in visual display terminals be at least 7 9 for continuous reading of the text. The ANSI recommendation for reading distance is 18± 20 in. This distance denotes the distance from the eye to the screen, and is based on the assumption that the user is seated in an upright position. The ANSI speci®cation for the minimum character height for capital letters is 16 0 of visual angle for reading tasks where legibility is important. The maximum character height according to ANSI should be 24 0 of visual angle, with the preferred character height set at 20±22 0 of visual angle. As regards polarity of the screen, since the sensitivity to ¯icker is greater when the screen background is brighter, the literature recommends that display units with light backgrounds have a higher refresh rate than display units with dark backgrounds.


Information, in the form of stimuli, can be sensed either through direct observation of the object, or through the use of a indirect mediating device. During indirect sensing, the stimuli themselves mostly come in a coded form (such as a visual or an auditory display), and sometimes in the form of exact or modi®ed (in size) reproductions of the original stimulus (such as a picture on a television screen). Coding of information can be along dierent stimulus dimensions; for example, coding can be done based on color, shape, size, etc. Research has shown that the success of coding in conveying the necessary information depends on people's ability to distinguish between two or more stimuli which vary along a dimension (e.g., which of the two stimuli is smaller in size), and on the ability to identify a single stimulus based on the measure of that stimulus on the dimension scale (e.g., whether the target is bright or dim) [46]. These abilities,

776

respectively, are said to be dependent on the relative (comparing more than one stimulus) and the absolute judgments (identi®cation of stimulus without the opportunity to compare) of people. It has also been shown that humans, in general, have the ability to make better relative judgments than absolute judgments [47,78]. This being the case, the orthogonality or independence of the coding schemes determines how unique the information provided by a code is, and results in an increase in the number of stimuli that can be identifed on an absolute basis [46]; for example, if size (large and small) and color (black and white) were orthogonal dimensions of coding, then each of the possible codes namely, large-black, large-white, small-black, and small-white, would provide unique information. A number of dierent guidelines also exist in the literature that can help good coding practices. Table 15 summarizes general guidelines for designing a good visual coding system. In addition, dierent visual coding methods have their own speci®c design features that can be exploited by the designer for speci®c tasks and work situations. Using alphanumeric characters (which are 0, 1, 2, 3; . . . ; 9 and a; b; c; . . . ; z in the English language), singly and in combination, for instance, has been found to be useful for identi®cation purposes, and for situations with space constraints. Color coding of surfaces (24 or more combinations of hues, saturation, and brightness are possible, though research recommends use of no more than nine combinations) are useful for industrial tasks requiring searching and counting. Color-coding surfaces can, however, be ineective if the worker population is color de®cient [79,80]. Color coding any lights used in the workplace has been shown to be eective for qualitative reading [81]. The recommendation is to limit the number of lights coded to three. Coding using geomerical shapes

Mital and Pennathur

(there are a total of 15 or more geometrical shapes), has been found to be useful in situations using symbolic representation of an action or an event. The literature recommends the use of no more than ®ve geometrical shapes, as using more than ®ve will lead to diculty in discrimination of the dierent shapes [81]. While a total of 24 dierent angles of inclination (of characters) are available if coding is to be done by using angles of inclination, the recommended limit is 12 [82]. Using this form of coding has been found to be useful for indicating direction, angle, or position on round instruments. Other commonly used forms of visual coding include diering brightness of lights (recommended limit is two levels) [81], and diering ¯ash rates of lights (recommended limit is two levels). Using symbols for coding information is another important means of representing visual information. The eectiveness of symbolic coding depends on how strongly the symbol is associated with the concept or objects it is intended to represent. The strength of this association has been shown to depend on any existing and established association [83], and on the ease of leaming any new associations. The normal procedure in setting up symbolic coding systems in the workplace should involve considerable experimentation with existing and any new proposed symbolic codes. The experimentation should involve the worker population for which the symbolic coding system is intended, and coding system should be evaluated on the basis of the ease of recognition, on matching symbols with what they represent (based on reaction time of participants), and based on the preferences and opinions of the users. Figure 12 provides examples of good and bad symbol designs. The symbol labeled ``bad design'' in the ®gure has too much detail and is not simple in design. The symbol labeled ``good design'' in the ®gure has all the

Table 15 General Recommendations for Designing a Good Coding System Make codes detectable by the human sensory mechanisms under the given environmental conditions, Make codes discriminable from each other by providing for a dierence threshold or a just-noticeable dierence. Make codes meaningful to the user by providing for conceptual compatibility. Where possible, standardize codes from situation to situation. Use multidimensional codes to increase the number and discriminability of coding stimuli used. Adapted from Ref. 46.


Figure 12 Examples of good and bad symbol design.


details identifying the symbol within the boundary of the symbol, and not outside the symbol. Dynamic information displays. These displays are used to present information about variables that are subject to change in time. Depending on the type of information presented by the display, dynamic displays can provide quantitative information, qualitative information, check readings, and information on situation awareness measures.

777

Quantitative visual displays provide information about the quantitative value of a variable of interest. The conventional types of displays used to convey quantitative information include analog displays (®xed scale and moving pointer, moving scale and ®xed pointer) and digital displays (mechanical type counters). Figure 13 provides some examples of the three conventional types of displays. Research in analog displays has provided certain general guidelines for

Figure 13 Commonly used quantitative displays.


778

designing such displays [84]. Fixed scale and moving pointer displays are preferable to moving scale and ®xed pointer displays in most cases. This is more so especially when manual control is used to control the moving element in the display (since it is better to control the pointer rather than the scale). Also, any small variations are better apparent when using a moving pointer, ®xed scale device. However, when the range of numerical values is too large to be accommodated within the scale, the recommendation is to use a ®xed pointer, moving scale display with rectangular open windows in the scale for easier reference. In general, it has been determined that digital displays perform better than analog displays where precise numerical values are needed, and when the presented numerical values are not continuously changing. In addition to these guidelines for the design of quantitative displays, research has identi®ed numerous characteristics that contribute towards making design of quantitative displays eective and ecient. Some of these characteristics include the design of the scale range (dierence between the largest and the smallest scale values), the design of the numbered interval in the scale (numerical dierence between adj acent scale numbers), the design of the graduation interval (the dierence between the smallest scale points), the design of the scale unit (smallest unit to which the scale can be read), the numerical progressions used in scales, the design of scale markers, and the design of scale pointers [46]. The numerical progression by 1's (0; 1; 2; 3; . . . has been found to be the easiest to use. Decimals in scales, and scales with unusual numerical progressions such as by 6's and 7's are discouraged. The most common recommendation for the length of the scale unit is to use values ranging from 0.05 to 0.07 in. The key factor in deciding the length of the scale unit is that the values should be as distinct as possible to permit easy human reading. Recommendations [81] are also available for design of scale markers (see Fig. 14 for a summary of these recommendations). Some common recommendations for design of pointers include having a pointed (about 208 tip angle) pointers, and having the tip of the pointer meet the smallest of the scale markers in the scale. Also, to avoid parallax between the scale and the pointer, it is recommended to have the pointer as close as possible to the surface of the scale [46]. Qualitative visual displays are used to present information on a changing variable based on quantitative information about a variable. The information presented could be indicative of a trend in the variable, or a rate of change of the variable. Also, qualitative


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displays can be used to determine the status of a variable in terms of predetermined ranges (whether the fuel tank is empty, full, or half-full), or for maintaining a desirable range of values of a variable (such as speed). The most common forms of presenting qualitative information through displays is by color coding or by using shapes (or areas to represent variables of speci®c interest, such as ``danger'') to code the information. Figure 15 provides an example of a color- and area-coded qualitative display. Research [85] on check-reading displays (used to determine if a particular reading is normal or not) has provided the following conclusions about the design of such displays: 1. 2.

3.

4.

5. 6.

In general, males make fewer errors in checkreading tasks than females. The accuracy of check reading is a function of viewing time; fewer errors will be made if the exposure time is relatively long (greater than 0.5 sec); also, check-reading performance dierences between males and females become insigni®cant when exposure time is increased to 0.75 sec. The selection of background color is important for check-reading tasks; for exposure time less than 0.75 sec, black dials and pointers with a white background lead to fewer errors in check reading than with white dials and pointers on a black background; however, for exposure times greater than 0.75 sec, fewer errors result with a black dial background; the ®nal selection of the background color should be based on the time routinely available for check reading (Fig. 16). Both the 9 o'clock and the 12 o'clock pointer positions in the dial yield acceptable performances; the actual design has then to be based on user preferences. Check-reading performance is not aected by the presence of between 1% and 3% deviant dials. The normal reading must be coded clearly; if many instruments are used in concert, the displays must be con®gured clearly so that the deviant reading stands out. Figure 16 provides examples of good and bad check reading displays.

One other type of qualitative display is status indicator displays. These indicators are usually representative of discrete pieces of information such as whether the condition is normal or dangerous, or


779

Figure 14 Recommendations on scale marker design for normal and low illumination viewing conditions.

if the working surface is hot or cold. Colored lights are the most commonly used form of status indicators. Signal and warning lights are the types of dynamic information displays that have relevance in the context of industrial settings. Detectability (of such lights) is

Figure 15

Example of area coded display.


the most important design issue related to signal and warning lights. The detectability of signal and warning lights is in¯uenced by factors such as the size of the light, the luminance, the exposure time, the color of lights, and the ¯ash rate of lights. Table 16 provides widely accepted guidelines for the design of signal and warning lights. Auditory displays: factors affecting design. Literature identi®es four different types of tasks involved in detection of auditory signals [46]: detection (determining whether or not a signal is present), relative discrimination (differentiating between two or more close signals), absolute identi®cation (identifying a particular signal when only one signal is present),

780

Mital and Pennathur

Figure 16

Check reading displays.

and localization (determining the direction of the signal source). These functions are based upon fundamental attributes in sound energy propagation, namely, the frequency of sound, and the intensity of sound. The number of cycles of sound waves produced in one second is called frequency. Frequency of sound is expressed in hertz (Hz). It is generally true that the human ear can detect frequencies ranging from 20 to 20,000 Hz. A related concept is the pitch of the sound (pitch denotes the highness or lowness of a sound; high frequencies result in high pitched tones, and low frequencies result in low-pitched tones). The intensity of sound is de®ned as the sound power in one square meter of area (W/m2 ). Since it is dif®cult to measure sound power level directly, the intensity of sound is measured in terms of the sound pressure level. Sound pressure level, in decibels, is given by 20 logP1 =P0 ;


where P1 is the sound power level corresponding to the sound to be measured, and P0 is the sound power level corresponding to 0 dB. The sound pressure levels can be directly measured using commercially available sound level meters. The detectability of auditory signals depends upon the environmental in¯uences (noise) present in the signal. In the presence of noise in the surroundings, the threshold of detectability of the signal is increased, i.e., the signal intensity must exceed this threshold if it is to be detected. A rule of thumb pertaining to auditory signal detection in the presence of noise or masking states that the signal intensity (at the outer ear) should be midway between the masked threshold of the signal in the presence of noise and 110 dB. In quiet surroundings, the detectability of the signal depends upon the frequency and the duration of the

Human Interfaces for Automated Systems Table 16 Recommendations for Design of Signal and Warning Lights Use signal and warning lights to warn of an actual or potential danger. Use only one light in normal circumstances; if several lights are used, have a master warning light to indicate speci®c danger. For commonly encountered danger or warning situations, do not use a ¯ashing light; use only a steady light. For situations that are new or occasional, use ¯ashing warning lights. Use four ¯ashes per second when using ¯ashing warning lights. When using dierent ¯ashing rates to indicate dierent levels of some variable, do not use more than three such rates with one light. Have the signal or warning light at least twice as bright as the background. Use red color for these lights and dierentiate danger lights from other signal lights in the immediate environment. Ensure that the warning lights subtend at least a visual angle of 18. Adapted from Ref. 84.

signal. The standard recommendation is that these signals should be at least 500 ms in duration; if they are shorter than this, the recommendation is to increase the intensity of the signal. Dierent recommendations have been made by researchers to improve the detectability of auditory signals. A summary of these recommendations is provided in Table 17. The relative discriminability of auditory signals also depends upon the intensity and the frequency of sound, and the interaction between these two factors. Relative discriminability is usually measured in terms of the just-noticeable dierence, which is the smallest change in the intensity or frequency that can be noticed

Table 17 Recommendations for Increasing the Detectability of Auditory Signals Reduce the intensity of noise near the frequency of the signal of interest. Increase the intensity of the signal. Present the signal for at least 0.5±1 sec. Determine the frequency where noise is low, and change the signal frequency to correspond this frequency. Present noise to both ears and the signal to one ear only. Introduce a phase shift in the signal and present the unshifted signal to one ear and the shifted signal to the other. Adapted from Ref. 86.


781

by humans 50% of the time. The smaller the justnoticeable dierence, the easier it is to detect the dierences in either intensity or frequency of sound. Research has shown that it is easier to detect the smallest dierences when the intensity of sound is higher (at least 60 dB above the threshold level). Also, with respect to frequency, it is recommended that signals use lower frequencies for higher discriminability. However, since ambient noise is also a lowfrequency sound, it is advisable to use signals in the 500±1000 Hz range. Also, it is good to keep signals 30 dB or more above the threshold level for ecient frequency discrimination. It has also been determined that, on an absolute basis (identi®cation of an individual stimulus presented by itself), it is possible for the human ear to identify four to ®ve levels of intensity, four to seven levels of frequency, two to three levels of duration, and about nine levels of intensity and frequency combined. Sound localization is the ability to determine and localize the direction of the sound. The dierences in the intensity of sounds, and the dierences in the phase of sounds are the primary measures by which the human auditory system determines the direction of the sound source. It has been shown that for frequencies below 1500 Hz, if the source of the auditory signal is directly to one side of the head, the signal reaches the nearer ear approximately 0.8 msec before it reaches the other ear. Also, localization is dicult at low frequencies, since there is very little dierence in the time it takes for the signal to reach both ears simultaneously. However, at high frequencies (generally above 3000 Hz), the presence of the head between the ears makes intensity dierences more pronounced resulting in eective localization of the sound source. Design recommendations for auditory displays. A summary of recommendations for the design of auditory displays is provided in Table 18. This is in addition to the recommendations in the table on when to use auditory displays, as opposed to visual displays. 1.3.3.4

Controls

General Considerations in Control Design. Controls are the primary means of transmitting the controlling action to devices and systems. Numerous factors affect the design of control devices. These factors include the ease of identi®cation, the size of the control, control± response ratio, resistance of the control, lag, backlash, deadspace, and location. In the following paragraphs,

782 Table 18

Mital and Pennathur Checklist for Designing Auditory Displays

Design elements Compatibility Approximation Dissociability Parsimony Invariance Presentation

Installation

Questions to ask Are the signal dimensions and the coded displays compatible with user excectations? If the information presented is complex, are the signals attention-getting, and providing precise information as well? Are the auditory signals of interest clearly discernible from other signals? Do the signals provide the correct amount of information? Is a particular signal used for providing the same information every time? Are the signals moderate and not extreme? Is the signal intensity level such that it is not masked by noise? Has care been taken not to overload the auditory system of operator by presenting too many signals at the same time? Has the signal been tested with the target user group? Are the new signals really new (are they noncontradictory to the existing signals? If auditory displays are entirely new to the setting, have the operators been given enough time to adjust to the new type of display?

Note: Answering ``Yes'' to all the above questions in the checklist is the desirable scenario. Adapted from Refs. 46, 87, and 88.

we will summarize and present recommendations from research for each of these factors. The ease of identi®cation of controls depends upon how well the controls have been coded. The ecacy of the coding used can be determined using measures mentioned in an earlier section, namely, using detectability, discriminability, compatibility, meaningfulness, and the extent of standardization. Controls can be coded using shape, texture, size, location, operational methods, color, and labels. Shape coding uses tactual sensitivity of the human for discriminating between the dierent shapes of the controls. Figure 17 provides examples of dierent shapes that are commonly used in controls. Three dierent types of textures have been identi®ed as being suitable for coding control devices: smooth surface, ¯uted surface, and knurled surface. The most important consideration when coding by size is to provide adequate discriminability between the dierent sizes used. For coding based on location of controls, the recommendation is to use at least 2.5 in. between adjacent vertical controls, and at least 4 in. between adjacent horizontal controls. In addition, it is recommended that the general guidelines provided in table be followed when coding controls based on location. There are instances when coding is based on the method of operation of the control (pushbutton controls, for example). Table 19 provides the recommended minimum separation distances when this is the case. Such operational coding, is undesirable, however, when operation time or potential operator errors are considerations. Another way to code


controls is by color. Meaningful colors (such as red for a danger button), combined with other coding dimensions such as shape and size, have been shown to be eective in enhancing the discriminability of the controls. Color coding, however, cannot eective in situations with poor illumination or in dirty environments. One of the most commonly used methods of coding controls is by labels. In fact, labels are considered a minimum requirement in many situations as they do not place extensive learning demands on the operators. Labels, however, have the disadvantage in that they take time to read and are not useful as a coding method in situations that have a high operation speed. Also, the placement of the label on the control has been shown to pose accessibility problems to the reader. Control devices can have unique combinations of codes, or even redundant codes. Considerations such as the illumination and the potential visual handicaps of the operator, maintenance of mechanical controls, and the speed and the accuracy with which the controls have to be operated, are other factors to consider in designing controls for ease of identi®cation. Control±response ratio (denoted by C/R) is the ratio of the movement of the control device to the movement of the system response. By this de®nition, a sensitive control will have a low C/R ratio (i.e., the response will be large even for a slight change in the control). It is believed that human motor actions take place at two levelsÐat a gross-adjustment level, and at a ®ne-adjustment level. Hence the optimal level of C/R ratio to use in a control device, is generally decided as a


Figure 17

783

Different shapes that have been commonly used and demonstrated to be effective for coding controls.

tradeo between the time it takes to accomplish the gross movement and the time it takes for the ®ne adjustment involved in a controlling action. It has been shown that an optimum C/R ratio is dependent upon factors including the type of control (lever, crank, wheel, etc.), the size of the display, and the tolerance permitted in setting the control. Resistance in a control is responsible for providing feedback about the controlling action to the operator. In essence, the resistance oered by the control is made up of two fundamental elements: the force applied to the control, and the distance to which this force is applied (or the distance to which the control moves). Free-position or isotonic controls oer no resistance to movement, and feedback to the operator is based on the displacement that occurs. Isometric controls, on


the other hand, provide feedback, based only on the force or the pressure applied to the control. Most controls use a combination of both pure displacement and pure force mechanisms for providing operator feedback. Control resistance can signi®cantly aect operator performance by aecting the speed and precision of control operations, by changing the feel in the control, by changing the smoothness of the control movement, and by subjecting the control to the eect of shock and vibration. It is therefore vital to consider control resistance when designing or selecting controls for a speci®c task. Some design guidelines regarding control resistance are provided in Table 20. Deadspace is de®ned as the amount of movement near the null position of the control. The amount of deadspace in a control device has been shown to aect

784 Table 19

Mital and Pennathur Recommended Minimum and Maximum Separation for Dierent Control Devices Recommended separation (in inches)

Control

Use

Minimum

Desired

Push button

Randomly with one ®nger Sequentially with one ®nger Randomly or Sequentially with dierent ®ngers

0.5 0.25 0.5

2 1 0.5

Toggle switch

Randomly with one ®nger Sequentially with one ®nger Randomly or Sequentially with dierent ®ngers

0.75 0.5 0.625

2 1 0.75

Crank and lever

Randomly with one hand Simultaneously with two hands

2 3

4 5

Knob

Randomly with one hand Simultaneously with two hands

1 3

2 5

Pedal

Randomly with one foot

4 (between the inner sides of the pedal) 8 (between the outer sides of the pedal) 2 (between the inner sides of the pedal) 6 (between the outer sides of the pedal)

6 (between the inner sides of the pedal) 10 (between the outer sides of the pedal) 4 (between the inner sides of the pedal) 8 (between the outer sides of the pedal)

Randomly with one foot Sequentially with one foot Sequentially with one foot Adapted from Ref. 89.

Table 20 Recommendations on Control Resistance and Control Operation Control movements should be as short as possible Positive indication of control activation must be provided to the operator. Feedback on system response to control activation must be provided to the operator. Control surfaces should be designed to prevent slippage when activating. Arm or foot support should be provided to the operator if precise, sustained positioning of the controls is required. Controls must be provided with enough resistance to avoid accidental activation due to the weight of hands or feet. If a seated operator has to push a force more than 5 lbf on a one-hand control, a backrest must be provided to the operator. The operator has to be able to move the trunk and entire body if both hands are required to exert more than 30 lbf through more than 15 in. in the fore-and-aft plan. The speed, force, and accuracy of controls should ®t most people, not just the most capable. Adapted from Ref. 90.


the sensitivity, and hence the performance, of the control system. It has been shown by researchers that deadspace in a control device can be compensated to a certain extent by making the control-ratio relationships less sensitive. Backlash in a control device is de®ned as the deadspace at any control position. Research on backlash shows that systems with high control gain need to have minimum backlash to reduce system errors. If the control system design makes it impossible to reduce the backlash, the recommendation is to make the control gain as low as possible, since humans have been shown to cope badly with backlash errors. Types of Control Devices. Controls can be classi®ed as being discrete or continuous controls based on whether they transmit discrete (on and o) or continuous (machine speed increase from 0 to 100 km/hr) information. Controls are also classi®ed based on the amount of force required to operate them (small or large). The most common types of control devices used to transmit discrete information and requiring a small force to operate include push buttons, keyboards, toggle switches, rotary selector


785

switches, and detent thumb wheels. Common control devices used to transmit discrete information and requiring a large amount of force include detent levers, large hand push buttons, and foot push buttons. For transmitting continuous information, the traditional control devices such as rotary knobs, multirotational knobs, thumb wheels, levers or joysticks, and small cranks, require only a small amount force to operate them. On the other hand, other traditional control devices used to impart continuous information, such as handwheels, foot pedals, large levers, and large cranks, need large amounts of force to manipulate and operate. In general, control selection for common controls, such as toggle switches, rocker switches, knobs, cranks, handwheels, etc., is based on operational factors such as speed, accuracy, space requirements, and ease of operation. With the advent of information technology, control devices such as joysticks, trackballs, mice, touch tablets, light pens, touch screens, etc., are becoming popular devices for transmitting continuous information to the system. Technology has advanced to such an extent that these modern devices demand only a small amount of physical force from the human operator. Given the variety of both traditional and modern control devices in use in industry (see Fig. 18 for examples of some of these control devices), it is beyond the scope of

Figure 18


this chapter to explain the design of each of these devices in detail. Besides, many excellent design tables and recommendations already exist in the literature for design and selection of control devices, and are widely available. The interested reader is referred to these design guidelines. Such guidelines can be found in Sanders and McCormick [46], Woodson et al. [11], Chapanis and Kinkade [91] Salvendy [92], Eastman Kodak [90], etc. 1.3.3.5

Other Design Considerations in Information Presentation and Control

Besides the individual design factors aecting the design and operation of displays and controls, there are other general considerations in display and control design that aect the overall eectiveness of the information presentation and control system as a whole. We have chosen to present two such important factors. They are compatibility, and grouping and location of controls. Compatibility. This the relationship between the expectations of the human and the input stimuli and responses of the system with which the human is interacting. Any system with human users should be compatible with the human expectations. In general, good compatibility will result in fewer user errors, and better

Examples of common control devices.

786

human and overall system performance. Literature identi®es four types of compatibility [47] conceptual, movement, spatial and modality compatibilities. Conceptual compatibility refers to the matching that should exist between certain forms of stimuli such as symbols, and the conceptual associations humans make with such stimuli. Movement compatibility (also commonly referred to as population stereotypes) denotes the relationship between the movement of the displays and controls and the output response of the system being controlled. Numerous types of movement compatibilities have been studied by researchers. The most important types of movement compatibilities include the movement of a control to follow the movement of a display, the movement of a control to control the movement of a display, the movement of a control to produce a speci®c system response, and the movement of a display without any related response. The common principles of movement compatibility for various types of displays and control devices are presented in Table 21. Spatial compatibility refers to the relationship that should exist between, the physical features, and arrangement, of the controls and their associated displays. A good example of compatibility in physical features between the displays and the controls is the design of the function keys on a keyboard, and the corresponding labels for these function keys. In a number of experiments with household stove tops, human factors researchers have demonstrated conclusively the need for physically arranging displays and the associated controls in a corresponding and compatible way. Modality compatibility is a fairly new addition to the list, and refers to certain stimulus-response combinations being more compatible with some tasks than with others. Principles of Control-Display Arrangement in a Workspace. The physical location and arrangement of the displays and controls in a given workspace also has to be based on the human sensory capabilities, and the anthropometric, biomechanical, and other characteristics of the human user. Table 22 provides general guidelines for locating controls in a workspace. The ideal goal of placing each and every display and control at an optimal location and in an optimal arrangement with respect to the human user, is dicult, if not impossible, to achieve in practice. A few general principles of control-display location and arrangement are useful in setting priorities and in determining tradeos for good design, if not the optimal.


Mital and Pennathur

According to the importance principle, components that are vital to system goals should be placed in convenient locations. System experts determine what these vital goals are. According to the frequency-ofuse principle, components that are frequently used should be placed in convenient locations. According to the functional principle, components that are functionally related in the operation of the overall system should be grouped and placed together. Figures 19a (before redesign) and 19b (after redesign) illustrate the use of the principle of functional grouping in the redesign of the machining controller of a Dynamite DM2400 bench-top programmable machining center. According to the sequence-of-use principle, components should be arranged in the sequence in which they ®nd frequent use in the operation of the system or in the performance of a task. Use of one or a combination of these principles requires that the system designer collect information about the human users involved (the user characterization step described in Sec. 1.3.1 as the ®rst step in the process of solving human± machine interaction problems), the tasks involved (the task characterization step using task analysis techniques also described in Sec. 1.3.1 as the second step in the process), and the environment in which the user has to perform the task (characterization of the situation, again mentioned in Sec. 1.3.1 as the third step in the process). Based on extensive research, the recommendations that have been suggested for designing workspaces with various forms of displays and controls are presented in Table 23.

1.4

SUMMARY

This chapter presented the overall ``process'' of designing and evaluating systems involving humans and automated devices. The key elements involved in this process were brie¯y described, and the essentials of these elements were presented in the form of guidelines and recommendations for practice.

ACKNOWLEDGMENTS We thank Mr. Sampath Damodarasamy, doctoral student in industrial engineering at the University of Cincinnati, for help with the evaluation of the DYNAMYTE 2400 machine controller example, and the two ®gures he generated for this example.


787

Table 21 Common Principles and Recommendations for Movement Compatibility for Dierent Displays and Controls Type of display±control relationship

Principles of movement compatibility

Rotary displays and rotary controls in same plane

For ®xed scale/rotary pointers, ensure that clockwise turn of the pointer is associated with clockwise tum of the control. For ®xed scale/rotary pointers, clockwise rotation of pointer/ display should indicate increase in value and vice versa. For moving scale/®xed pointer, ensure scale rotates in the same direction as control knob. Ensure scale numbers increase from left to right. Ensure clockwise turn of control increases value.

Linear displays and rotary controls in same plane

When the control is located to the side of the display, the common expectation is the display pointer will move in the same direction of that side of the control which is nearest to it. The common expectation is pointer will move in the same direction as the side of the control knob on the same side as the scale markings on the display. The common expectation is a clockwise turn of a rotary control will increase the value on the display no matter where the control is located relative to the display.

Movement of displays and controls in diernt planes

For rotary controls, the common expectation is a clockwise rotation results in an increase in value. For rotary controls, the common expectation is a clockwise rotation results in movement away from individual and vice versa. For stick-type controls (both horizontally mounted on vertical plane and vertically mounted on horizontal plane), the common expectation is an upward movement of control results in an increase in value and an upward movement of display.

Movement of power switches

U.S. system is switch-up is for on, and switch-down is for o. British system is switch-up is for o switch-down is for on.

Directional compatibility of operator movement (when operator is not directly facing the control)

The common expectation is that a control movement in a certain direction produces a parallel movement of the indicator on the display, irrespective of the position of the operator. The direction of movement of the display indicator when the indicator is in the visual ®eld of the subject, is the same as the direction of movement of the controlling limb. The direction of movement of the display indicator when the indicator is in the visual ®eld of the subject, is the same as the direction of movement of the control relative to the subject's trunk.

Adapted from Refs. 41, 89, 91, and 93±97


788

Mital and Pennathur

(a)

(b)

Figure 19 (a) The machining controller before redesign. (b) Functional grouping in a machining controllerÐAfter redesign.


Human Interfaces for Automated Systems Table 22 Guidelines for Location of Controls Keep the number of controls minimum. Ensure easy and simple activation of controls except when designing to avoid accidental activation. Arrange controls to allow for operator posture adjustments. For one-hand or one-foot operation of several controls in sequence, arrange controls to allow continuous movement through an arc. Controls requiring high-speed or high-precision operations should be assigned to the hands. If there is only one major control device, place it in front of the operator midway between hands. If a control requires a precise movement, place it on the right as a majority of the population are right handed. Controls requiring high forces for operation should be assigned to the feet. Emergency controls and displays must be distinguished from controls and displays used in normal working situations. Emergency controls should be placed within 30 degrees of the operator's normal line of sight. Keep the same relative groupings for major controls and displays; if not make the exception conspicuous. To prevent accidental activation of a control, place it away from frequently used controls, or make it conspicuous. Adapted from Ref. 90.

REFERENCES 1. HJ Bullinger, HJ Warnecke, Factory of the Future. Heidelberg, Germany: Springer-Verlag, 1985. 2. A Mital, What role for humans in computer integrated manufacturing? Int J Computer Integ Manuf 10: 190± 198, 1997. 3. A Mital, A Pennathur, Musculoskeletal overexertion injuries in the United State: an industrial pro®le. Int J Ind Ergon: 25: 109±129, 1999. 4. TB Sheridan, Supervisory control. In: G Salvendy, ed. Handbook of Human Factors, New York: John Wiley & Sons, 1987. 5. PA Booth, An Introduction to Human±Computer Interaction. Hove and London: Lawrence Erlbaum Associates, 1989. 6. B Kirwan, LK Ainsworth, eds. A Guide to task Analysis. London: Taylor & Francis, 1992. 7. A Mital, A Morotwala, M Kulkarni, M Sinclair, C Siemieniuch, Allocation of functions to humans and machines in a manufacturing environment: Part IIÐ The scienti®c basis (knowledge base) for the guide. Int J Ind Ergon 14: 33±49, 1994. 8. D Meister, Human Factors Testing and Evaluation. New York: Elsevier Science Publishers, 1986. 9. A Chapanis, Research Techniques in Human Engineering. Baltimore: John Hopkins, 1976.


789 Table 23 List of Priorities When Making Tradeos for Optimum Design of Workspace with Displays and Controls Priority First Second Third Fourth Fifth Sixth

Elements in design Primary visual tasks Primary controls that interact with primary visual tasks Control±display relationships Arrangement of elements to be used in sequence Convenient location of elements to be used in sequence Consistency with other layouts within the system or in other systems


10. WE Woodson, Human Factors Design Handbook. New York: McGraw-Hill, 1981. 11. WE Woodson, B Tillman, P Tillman, Human Factors Design Handbook: Information and Guidelines for the Design of Sciences, Facilities, Equipment, and Products for Human Use. New York: McGraw-Hill, 1991. 12. Department of Defense, Human Engineering Criteria for Military Systems, Equipments and Facilities. MILSTD 1472C, Washington, DC: U.S. Department of Labor, 1981. 13. J Seminara, Human Factors Methods for Assessing and Enhancing Power Plant Maintainability. Report EPRINP-2360. Electric Power Research Institute, Palo Alto, CA. 1949. 14. Nuclear Regulatory Commission, Guidelines for Control Room Design Reviews. Report no. NUREG0700, U.S. Nuclear Regulatory Commission, Washington, DC. 1981. 15. HSE, Human Factors in Industrial Safety. HS(G). London: HMSO, 1989. 16. A Cakir, DJ Hart, TFM Stewart, Visual Units. Chichester: John Wiley, 1980. 17. HS Blackman, DI Gertman, WE Gilmore. CRT Display Evaluation: The Checklist Evaluation of CRT-Generated Displays, Report No. NUREG/CR3557, Washington DC: Nuclear Regulatory Commission, 1983. 18. P Fitts, Huyman Engineering for An Eective AirNavigation and Trac-Control System. Washington, DC: National Research Council, 1951. 19. A Mital, A Motorwala, M Kulkarni, M Singlair, C Siemieniuch, Allocation of functions to humans and machines in a manufacturing environment: Part I±Guidelines for the practitioner. Int J Ind Ergon 14: 3±31, 1994. 20. RP Paul, S Nof, Work methods measurementsÐa comparison between robot and human task performance. Int J Prod Res, 17: 277±303, 1979.

790 21. A Mital, A Mahajan, ML Brown, A Comparison of manual and automated assembly methods, In: Proceedings of the IIE Integrated Systems Conference. Norcross, GA: Institute of Industrial Engineers, 1988, pp 206±211. 22. A Mital, A Mahahjan, Impact of production volume, wage, and interest rates on economic decision making: the case of automated assembly. Proceedings of the Conference of the Society for Integrated manufacturing Conference. Norcross, GA: 1989, pp 558±563. 23. A Mital, Manual versus ¯exible assembly: a crosscomparison of performance and cost in four dierent countries. In: M Pridham, C O'Brien, eds. Production Research: Approaching the 21st Century. London: Taylor & Francis, 1991. 24. A. Mital, Economics of ¯exible assembly automation: in¯uence of production and market factors. In: HR Parsaei, A Mital eds. Economics of Advanced Manufacturing Systems. London: Chapman & Hall, pp 45±72, 1992. 25. H Andersson, P Back, J Wirstad, Job Analysis for Training Design and EvaluationÐDescription of a Job Analysis Method for Process Industries. Report no. 6, Ergonomrad, Karlstad, Sweden, 1979. 26. J Badaracco, The Knowledge Link. Cambridge, MA: Harvard Business School Press, 1990. 27. P Ehn, The Work Oriented Design of Computer Artifacts. Stockholm: Arbetsmiljo, Arbelistratum, 1988. 28. T Engstrom, Future assembly workÐnatural grouping. In: Designing for EveryoneÐProceedings of the XIth Congress of the International Ergonomics Association, vol 2, London: Taylor & Francis, 1991, pp 1317±1319. 29. AM Genaidy, T Gupta, Robot and human performance evaluation. In: M Rahimi, W Karwowski, eds. Human±Robot Interaction. London: Taylor & Francis, 1992, pp 4±15. 30. LS Bainbridge, SAR Quintanilla. Developing Skills with Information Technology. Chichester: John Wiley, 1989. 31. CK Prahalad, G Hamel, The core competence of the corporation. Harv Bus Rev 68: 79±91. 32. J Rasmussen, Some Trends in Man±Machine Interface Design for Industrial Process Plants. Report number Riso-M-2228. Riso National Laboratory, Roskilde, Denmark. 1980. 33. P Shipley. The analysis of organizations as an aid for ergonomics practice. In: JR Wilson, EN Corlett, eds. Evaluation of Human Work: A Practical Ergonomics Methodology. London: Taylor & Francis, 1995. 34. J Wirstad, On knowledge structures for process operators. In: LP Goodstein, HB Ansderson, SE Olsen, eds. Tasks, Errors and Mental Models. London: Taylor & Francis, 1988. 35. A Mital, R Vinayagamoorthy, Case study: economic feasibility of a robot installation. Eng Economist 32: 173±196, 1987.


Mital and Pennathur 36. A Mital, LJ George, Economic feasibility of a product line assembly: a case study. Eng Economist 35: 25±38, 1989. 37. BC Jiang OSH Cheng, Six severity level design for robotic cell safety. In: M Rahimi, W Karwowski eds. Human-Robot Interaction, 1992. 38. J. Hartley, Robots at Work: A Practical Guide for Engineers and Managers. Bedford: IFS; Amsterdam: North-Holland, 1983. 39. A Mital, LJ George, Human issues in automated (hybrid) factories. In: F Aghazadeh, ed. Trends in Ergonomics/Human Factors V. Amsterdam: NorthHolland, 1988, pp 373±378. 40. CE Shannon, W Weaver. The Mathematical Theory of Communication. Urbana, IL: University of Illinois Press, 1949. 41. E Grandjean, Fitting the Task to the Man. 4th ed. London: Taylor & Francis, 1988. 42. JR Pierce, JE Karlin, Reading rates and the information rate of a human channel. Bell Teleph J 36: 497±516. 43. C Wickens, Engineering Psychology and Human Performance, Merrill, Columbus, Ohio, 1984. 44. J Swets ed. Signal detection and recognition by human observers: contemporary readings. Los Altos, CA: Peninsula Publishing, 1988. 45. D Green, J Swets, Signal Detection Theory and Psychophysics. Los Altos, CA: Peninsula Publishing, 1988. 46. MS Sanders, EJ McCormick, Human Factors in Engineering and Design. New York: McGraw-Hill, 1993. 47. G. Miller, The magical number seven, plus or minus two: some limits on our capacity for processing information. Psychol Rev 63: 81±97, 1956. 48. S Sternberg, High-speed scanning in human memory. Science 153: 652±654, 1966. 49. D Lane, Limited capacity, attention allocation, and productivity. In: W Howell, E Fleishman, eds. Human Performance and Productivity: Information Processing and Decision Making. Hillsdale, NJ: Lawrence Erlbaum Associates, 1982. 50. A Graig, Vigilance: theories and laboratory studies. In: S Folkard, T Monk, eds. Chichester: Wiley, 1985. 51. R Parasuraman, Vigilance, monitoring, and search. In: K Bo, L Kaufmann, J Thomas eds. Handbook of Perception and Human Performance: Cognitive Process and Performance. New York: Wiley 1986. 52. D Davies R Parasuraman, The Psychology of Vigilance. London: Academic Press, 1982. 53. J Warm, ed. Sustaining attention in human performance. Chichester: Wiley, 1984. 54. FT Eggemeier, Properties of workload assessment techniques. In: P hancock, N Meshkati, eds. Human Mental Workload. Amsterdam: North-Holland, 1988. 55. N Moray, Mental workload since 1979. Int Rev Ergon 2: 123±150, 1988.

Human Interfaces for Automated Systems 56. R O'Donnell, FT Eggemeier, Workload assessment methodology. In: K Bo, L Kaufman, J Thomas, eds. Handbook of Perception and Human Performance, New York: Wiley, 1986. 57. C Jensen, G Schultz, B Bangerter, Applied Kinesiology and Biomechanics. New York: McGraw-Hill. 1983. 58. J Kelso, Human Motor Behavior: An Introduction. Hillsdale, NJ: Lawrence Erlbaum Associates, 1982. 59. J Adams, A closed-loop theory of motor learning. J Motor Behav 3: 111±150, 1981. 60. J Adams, Issues for a closed-loop theory of motor learning. In: G Stelmach Motor Control: Issues and Trends. New York: Academic Press, 1976. 61. C Winstein, R Schmidt, Sensorimotor feedback. In: H Holding ed. Human Skills, 2nd ed. Chichester: Wiley, 1989. 62. B Bridgeman, M Kirch, A Sperling, Segregation of cognitive and motor aspects of visual information using induced motion. Percept Psychophys 29: 336±342, 1981. 63. S Grillner, Neurobiological bases of rhythmic motor acts in vertebrates. Science 228: 143±149, 1985. 64. S Klapp, W Anderson, R Berrian, Implicit speech in reading, reconsidered. J Exper Psychol 100: 368±374, 1973. 65. R Schmidt, Motor Control and Learning: A Behavioral Emphasis, Champaign, IL: Human Kinetics. 1982. 66. R Woodworth, Experimental Psychology. New York: Henry Holt, 1938. 67. P Fitts, The information capacity of the human motor system in controlling the amplitude of movement. J Exper Psychol 47: 381±391, 1954. 68. P Fitts, A study of location discrimination ability. In: P Fitts, ed. Psychological Research on Equipment Design. Research Report 19, Army, Air Force, Aviation Psychology Program, Ohio State University, Columbus, OH, 1947. 69. J Brown, E Knauft, G Rosenbaum, The accuracy of positioning reactions as a function of their direction and extent. Am J Psychol 61: 167±182, 1947. 70. R Schmidt, H Zelaznik, B Hawkins, J Frank, J Quinn, Jr. Motor output variability: a theory for the accuracy of rapid motor acts. Psychol Rev 86: 415±451, 1979. 71. BH Deatherage, Auditory and other sensory forms of iformation presentation. In: HP Van Cott, R Kinkade, eds. Human Engineering Guide to Equipment Design, Washington, DC: Government Printing Oce, 1972. 72. H Krueger, J Hessen, Obkective kontinuierliche Messung der Refraktion des Auges. Biomed Tech 27: 142±147, 1982. 73. H Luckiesh, FK Moss, The Science of Seeing. New York: Van Nostrand, 1937. 74. H Krueger, W Muller-Limmroth, Arbeiten mit dem Bildschirm-aber richtig! Bayerisches Staatsministerium fuÈr Arbeit und Sozialordnung, Winzererstr 9, 8000 Munuch 40, 1979.


791 75. IBM, Human Factors of Workstations with Visual Displays. IBM Human factors Center, Dept. P15, Bldg. 078, 5600 Cottle Road, San Jose, CA. 1984. 76. H Booher, Relative comprehensibility of pictorial information and printed words in proceduralized instructions. Hum Factor 17: 266±277, 1975. 77. A Fisk, M Scerbo, R Kobylak, Relative value of pictures and text in conveying information: performance and memory evaluations. Proceedings of the Human Factors Society 30th Anual Meeting, Santa Monica, CA, 1986, pp 1269±1271. 78. G Mowbray, J Gebhard, Man's senses vs. information channels. In: W Sinaiko ed. Selected Papers on Human Factors in Design and Use of Control Systems, New York: Dover, 1961. 79. J Feallock, J Southard, M Kobayashi, W Howell, Absolute judgements of colors in the gederal standards system. J Appl Psychol 50: 266±272, 1966. 80. M Jones, Color Coding. Hum Factors: 4: 355±365, 1962. 81. W Grether, C Baker, Visual presentation of information. In: HP Van Cott, R Kinkade, eds. Human Engineering Guide to Equipment Design. Washington, DC: Government Printing Oce, 1972. 82. P. Muller, R Sidorsky, A. Slivinske, E. Alluisi, P Fitts, The Symbolic Coding of Informationa on Cathode Ray Tubes and Similar Displays. TR-55-375. WrightPatterson Air Force base, OH. 1955. 83. P Cairney, D Seiss, Communication eectiveness of symbolic safety signs with dierent user groups. App Ergon 13: 91±97, 1982. 84. H. Heglin, NAVSHIPS Display Illumination Design Guide, vol. 2. NELC-TD223. Naval Electronics Laboratory Center, San Diego, CA: 1972. 85. A Mital, S Ramanan, Results of the simulation of a qualitative information display. Hum Factors, 28: 341±346, 1986. 86. B Mulligan, D McBride, L Goodman, A Design Guide for Non-Speech Auditory Displays. SR-84-1. Naval Aerospace Medical Research Laboratory, Pensacola, FL. 1984. 87. SA Mudd, The scaling and experimental investigation of four dimensions of pure tone and their use in an audiovisual monitoring problem. Unpublished doctoral dissertation, Purdue University, Lafayatte, IN. 1961. 88. JCR Licklider, Audio Warning Signals for Air Force Weapon Systems. TR-60-814, USAF, Wright Air Development Division, Wright-Patterson Air Force Base, OH, 1961. 89. JV Bradley, Desirable Control-Display Relationship For Moving-Scale Instruments. TR-54-423, USAF, Wright Air Development Center, Wright-Patterson Air Force base, OH, 1954. 90. Eastman Kodak Company, 1983, Ergonomic Design for People at Work. Belmont, CA: Lifetime Learning Publications, 1983.

792 91. A Chapanis, R Kinkade, Design of controls. In: HP Van Cott, R Kinkade eds. Human Engineering Guide to Equipment Design. Washington, DC: Government Printing Oce 1972. 92. G Salvendy, Handbook of Human Factors and Ergonomics. New York: John Wiley & Sons. 1997. 93. MJ Warrick, Direction of movement in the use of control knobs to position visual indicators. In: PM Fitts, ed. Psychological Research on Equipment Design. 94. J Brebner, B Sandow, The eect of scale side on popuation stereotype. Ergonomics 19: 471±580, 1976. 95. H Petropoulos, J Brebner, Stereotypes for direction-ofmovement of rotary controls associated with linear displays: the eect of scale presence and position, of poiter direction, and distances between the controls and the display. Ergonomics, 24: 143±151, 1981. 96. DH Holding, Direction of motion relationships between controls and displays in dierent planes, J Appl Psychol 41: 93±97, 1957. 97. C Worringham, D Beringer, Operator orientation and compatibility in visual-motor task performance. Ergonomics, 32: 387±400, 1989. 98. HP Van Cott, R Kinkade, Human Engineering Guide to Equipment Design. Washington, DC: Government Printing Oce, 1972.

RECOMMENDED READING LIST A Guide to Task Analysis (B Kirwan, LK Ainsworth, eds.). London: Taylor & Francis, 1992. Applied Ergonomics Handbook (B Shakel, ed.) London: Butterworth Scienti®c, 1982.


Mital and Pennathur Barnes RM. Motion and Time Study: Design and Measurement of Work. New York: John Wiley & Sons, 1980. Booth PA. An Introduction to Human±Computer Interaction. Hove and London: Lawrence Erlbaum Associates, 1989. Eastman Kodal Company. Ergonomic Design for People at Work, London: Lifetime Learning Publications, 1983. Evaluation of Human Work: A Practical Ergonomics Methodology (JR Wilson, EN Corlett, eds.) London: Taylor & Francis, 1995. Grandjean E. Fitting the Task to the Man. 4th ed. London: Taylor & Francis, 1988. Handbook of Human Factors and Ergonomics (G Salvendy, ed.). New York: John Wiley & Sons, 1997. Helander M. Handbook of Human±Computer Interaction. Amsterdam: North-Holland, 1988. Human Engineering Guide to Equipment Design (HP Van Cott, R Kinkade, eds.), Washington, DC: Government Pringtin Of®ce, 1972. Nielsen J. Coordinating User Interfaces for Consistency. New York: Academic Press, NY, 1989. Ravden S, Johnson G. Evaluating Usability of Human±Computer Interfaces. New York: Ellis Horwood, 1989. Sanders MS, McCormick EJ. Human Factors in Engineering and Design. New York: McGraw-Hill, 1993. Woodson, WE, Tillman B, Tillman P. Human Factors Design Handbook: Information and Guidelines for the Design Systems, Facilities, Equipment, and Products for Human Use. New York: McGraw-Hill, 1991.

Chapter 9.2 Workstation Design Christin Shoaf and Ashraf M. Genaidy University of Cincinnati, Cincinnati, Ohio

2.1

INTRODUCTION

repetitive jobs. While this chapter is intended to provide general principles and guidelines for ergonomic workstation design, detailed speci®cations are available from several sources [4±6].

Workstation design, including consideration of work methods, can be used to address several problems facing the contemporary workplace. With the spread of video display terminal (VDT) use in the workplace, cumulative trauma disorders are being reported with increasing frequency [1]. This new technology has increased the incidence of health disorders due to its physical requirements manifested in terms of repetitive motion and static constrained posture demands [2]. Workstation design principles can be used to lessen the stress demands imposed by these postures and motions and therefore reduce the risk of injury. Secondly, as companies continue to cut costs and strive to achieve more with fewer people, workstation design can also be used as an eective tool to optimize human eectiveness, thus resulting in increased eciency and productivity. In a competitive industrial environment with health treatment, litigation and disability costs all rising, workstation design has become a signi®cant factor not only in determining the health of the employee but the success of the business as well. When considering the design of workstations, work methods, tools and handles, three factors account for the majority of ergonomic problems across a variety of industries. Therefore, the design principles guiding the biomechanical solution of these problems is based on the control of these factors. The three general methods [3] of reducing stress requirements are the reduction of extreme joint movement, excessive forces, and highly

2.2

Safe work results when the job ®ts the worker. The contemporary workplace is composed of an increasing number of women, elderly, and minorities. Although recommended workstation dimensions based on anthropometric data are available [5], this data may adequately describe the varied population in today's work environment. Therefore, it is very important that workstations be designed to allow the maximum degree of ¯exibility in order to accommodate the contemporary worker population. The ideal work situation is to alternate between sitting and standing at regular intervals [7]. Frequently changing body postures serves to minimize the discomfort and fatigue associated with maintaining the same posture for a long period of time. However, if a job cannot be designed to include tasks which include both sitting and standing postures, the seated position is preferable as it provides: Stability required for tasks with high visual and motor control requirements Less energy consumption than standing Less stress on the leg joints 793


PHYSICAL LAYOUT CONSIDERATIONS

794

Shoaf and Genaidy

Lower hydrostatic pressure on leg circulation [5, 7]. 2.2.1

Chair Design Guidelines

Prolonged work in the seated position can result in pain, fatigue, or injury in the lower back, shoulders, legs, arms, and neck. However, careful consideration to chair design can reduce the likelihood of these problems. Table 1 provides a list of chair parameters. 2.2.2

Height of Work Table/Activity

The work table should be adjustable to allow for work to be performed in the seated or standing position or to accommodate various seated tasks. Easy adjustability ensures that a large population of workers can be accommodated and awkward postures can be avoided. For most jobs, the work area should be designed around elbow height when standing or sitting in an erect posture. For precise work, the working height should be 2±4 in. above the elbow; for heavy manual work, the working height should be about 4±5 in. below the elbow [3,6]. 2.2.3

Materials, Controls, Tools, and Equipment

All materials, tools, and equipment should be easily accessible to the worker to prevent awkward postures. All reaching should be below and in front of the shoulder and frequent work should be kept in the area that can be conveniently reached by the sweep of the arm with the upper arm hanging in a natural position at the side of the trunk [3]. Table 1 Chair Design Parameters Parameter Backrests

Height Footrests Seat pan Arm rests Casters

Requirements Should be adjustable for height and angle of tilt, and provide continuous lumbar region support; should be independent from the seat pan Should be adjustable Should be provided and adjustable Front edge should roll forward to prevent compression of the leg Should be provided when feasible Provide ``safety'' caster chairs (these do not roll easily with no weight in the chair) when lateral movements are required within the work area


2.2.4

Lighting

Adequate overhead lighting should be provided for all work areas. Task-speci®c localized lighting should also be provided if detailed work is required. Where documents are read, illumination levels of 500±700 l are recommended. Inadequate lighting may cause employees to work in awkward postures. 2.3

WORK METHOD CONSIDERATIONS

Although physical workstation design is the primary mechanism contributing to a healthful workplace, work method considerations can be employed as a temporary solution when workstation design changes are not immediately possible, or can be used as a complement to the design changes. Training in how to perform the work task as well as how to use all tools and equipment is mandatory for new employees and should be available as needed to experienced employees. Self pacing of work, especially for new employees, is recommended to alleviate mental and physical stresses. Also, frequent rest breaks should be allowed. In addition to these measures, the design of the work situation can be altered to lessen stress eects. Highly repetitive jobs may be automated or a job consisting of few repeated tasks can be enlarged by combining varying tasks. Job enrichment is another job redesign technique which may be employed to increase job satisfaction. Job enrichment increases the amount of control and meaningfulness the employee experiences. When job enlargement or job enrichment is not feasible, rotating job tasks among employees is an alternative method of relieving stress due to repetition. 2.4

VIDEO DISPLAY TERMINAL GUIDELINES

The VDT work environment has become commonplace in recent years and has provoked a signi®cant amount of discomfort and health complaints. Visual problems as well as musculoskeletal injuries are two frequently reported concerns which can be lessened by workstation design and work methods changes. Visual fatigue can result from viewing objects on the VDT screen at a close range for an extended period of time as well as from excessive re¯ected glare. A brightly lit oce environment, often found in the conventional oce setting, can create a risk in VDT work as screen re¯ections occur. Several measures, including

Workstation Design

reorienting the VDT screen, selective removal of light sources or use of partitions or blinds, can aid in controlling light in VDT work areas [8]. If these solutions are not feasible, a micro®lament mesh ®lter can be ®tted over the screen or a parabolic lighting ®xture (louver) can be installed below a conventional ¯uorescent ®xture to reduce screen glare. Rest breaks can also be used to combat visual fatigue. The National Institute of Occupational Safety and Health (NIOSH) [9] recommends, as a minimum, a break should be taken after 2 hr of continuous VDT work. In order to ensure adequate employee visual capacity to perform VDT work, NIOSH [9] advocates visual testing before beginning VDT work and periodically thereafter. The second frequent complaint among VDT workers is musculoskeletal discomfort. Early NIOSH studies report a prevalence rate exceeding 75% for the `òccasional'' experience of back, neck, and shoulder discomfort among VDT users [10,11]. As VDT work is stationary and sedentary, operators most often remain seated in ®xed, sometimes awkward, postures for extended periods of time. Consequently, joint forces and static loads can be increased to levels causing discomfort. For example, elevation of the arms to reach the keyboard may aggravate neck and shoulder pain. Proper workstation design is the ®rst step necessary to improve the VDT work environment. As previously stated, adjustability is paramount in good workstation design. This is also true for the VDT workstation. Some of the most important VDT workstation features are [12,13]: Movable keyboards with adjustable height that allow the operator's arms to be approximately parallel to the ¯oor Adjustable backrest to support the lower back Adjustable height and depth of the chair seat Swivel chair with ®ve-point base and casters Screen between 1 and 2 ft away; middle of screen slightly below eye level; characters large and sharp enough to read easily; brightness and contrast controls; adjustable terminal height and tilt; glareproof surface; no visible ¯icker of characters Indirect general lighting 200-500 l, moderate brightness Direct, adjustable task lighting Feet resting ®rmly on the ¯oor, footrest for shorter operators; thighs approximately parallel to the ¯oor Adequate work-table space for a document holder approximately the same distance as the screen


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Additional ventilation or air-conditioning where required to compensate for the heat generated by many VDTs operating in a work space VDT cables positioned and secured to prevent tripping. In addition to proper workstation design, consideration to work methods is also required to discourage the health risks associated with VDT operation. First, operators should be aware of ergonomic principles and then trained to adjust their own workstations. Secondly, even with good workstation design, physical stress can result due to the prolonged postures demanded by many VDT tasks. Frequent rest breaks can alleviate some of this stress. Therefore, VDT operators should periodically change positions or stretch during long assignments. Walking around during breaks or performing simple stretching exercises can also be bene®cial. Lee et al. [14] provide an excellent review of physical exercise programs recommended for VDT operators. 2.5

SUMMARY

Careful consideration of workstation design, including work methods, should be given whenever the physical work setting changes and should continually be reevaluated to ensure proper person±environment ®t. Attention to workstation design can serve as an eective tool in the prevention of work-related health disorders as well as for increasing employee productivity. Consequently, both of these outcomes will result in higher company pro®t. By consulting current design guidelines, training employees in equipment use as well as in basic ergonomic principles and encouraging employee feedback, an eective workstation environment can be realized.

REFERENCES 1. EL Greene. Cumulative trauma disorders on the rise. Med Trib July 26: 1990. 2. EB Chapnik, CM Gross. Evaluation, oce improvements can reduce VDT operator. Occupat Health Safety 56:7, 1987. 3. V Putz-Anderson. Cumulative Trauma Disorders. A Manual for Musculoskeletal Diseases of the Upper Limbs. London: Taylor & Francis, 1988, pp 85±103. 4. American National Standard for Human Factors Engineering of Visual Display Terminal Workstations,

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5. 6. 7. 8.

9.

Shoaf and Genaidy ANSI/HFS 100-1988. Santa Monica, CA: Human Factors Society, 1988. DB Chan, GB Andersson. Occupational Biomechanics. New York: John Wiley Sons, 1991. E Grandjean. Fitting the task to the man. Philadelphia, PA, Taylor & Francis, 1988. R Carson. Ergonomically Designed Chairs Adjust to Individual Demands. Occupat Health Safety. June: 71±75, 1993. SL Sauter, TM Schnorr. Occupational health aspects of work with video display terminals. In: WN Rom, ed. Environmental and Occupational Medicine. Boston, Toronto, London: Little Brown and Company, 1992. BL Johnson, JM Melius. A review of NIOSH's VDT studies and recommendations. Presented at Work with


10.

11. 12. 13. 14.

Display Units International Conference, Stockholm, Sweden, May, 1996. SL Sauter, MS Gottlieb, KC Jones, VN Dodson. Job and health implications of VDT use: initial results of the Wisconsin-NIOSH study. Commun Assoc Comput Machinery 26: 1982, pp 284±294. MJ Smith, BGF Cohen, LW Stammerjohn. An investigation of health complaints and stress in video display operations. Hum Factors 23: 1981. M Sullivan. Video display health concerns. AAOHN J 37:7, 1989, pp 254±257. JP Shield. Video display terminals and occupational health. Prof Safety Dec: 1990, pp 17±19. K Lee, N Swanson, S Sauter, R Wickstrom, A Waikar, M Magnum. A review of physical exercises recommended for VDT operators. Appl Ergon 23:6, 1992, pp 387±408.

Chapter 9.3 Physical Strength Assessment in Ergonomics Sean Gallagher

National Institute for Occupational Safety and Health, Pittsburgh, Pennsylvania

J. Steven Moore

The University of Texas Health Center, Tyler, Texas

Terrence J. Stobbe

West Virginia University, Morgantown, West Virginia

James D. McGlothlin

Purdue University, West Lafayette, Indiana

Amit Bhattacharya


3.1

INTRODUCTION

applied to job design so that ``hard'' jobs are changed into jobs the are within the physical strength capability of most people. Thus, since human physical strength is important, it is necessary to ®nd ways to quantify it through testing. This chapter is about human physical strength testing. Its purpose is not to recommend any particular type of testing, but rather to describe the types of testing that are available, and the uses to which strength testing has been put. It is up to individual users of the strength testing to decide which testing technique is the most appropriate for his or her particular application. This chapter discusses four types of strength testing: isometric, isoinertial, psychophysical, and isokinetic.

Humankind's interest in the measurement of human physical strength probably dates to the ®rst humans. At that time, life was truly a struggle in which the ®ttest survived. To a great extent, ®ttest meant strongest. It is perhaps ironic that in a modern civilized world, children still emphasize the relative importance of physical size and strength in determining the status hierarchy within a group. It is equally ironic that current interest in human physical strength comes from 1970s±1980s vintage research which demonstrated that persons with adequate physical strength were less likely to be injured on physically demanding jobs. Survival in many modern workplaces may still be a case of survival of the strongest. There is, however, a ¯ip side to this issue. If persons with limited strength are likely to be injured on ``hard'' jobs, what we know about physical strength can be

3.1.1

Before describing the dierent types of strength measurement, the term strength must be de®ned and the 797


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concept of strength measurement must be explained. Strength is de®ned as the capacity to produce force or torque with a voluntary muscle contraction. Maximum strength is de®ned as the capacity to produce force or torque with a maximum voluntary muscle contraction [1,2]. These de®nitions have some key words which must be explained. A voluntary muscle contraction is ``voluntary.'' When a person's physical strength is measured, only the voluntary eort the person is willing to put forth at the time is measured. Thus, when we test a person's maximum strength, we do not measure their maximum; we measure some smaller number that represents what they are comfortable expressing at the time with the existing equipment and environmental conditions. It is interesting to note that researchers have experimented with startling persons being tested (for example by setting o a starter's pistol behind them during a test) and have found signi®cant increases in measured strength [3]. It has been hypothesized that the lower strength displayed by persons during normal testing provides a margin of safety against overloading and damaging muscle tissue. It is also true that the test equipment and the tested person's familiarity with the process will in¯uence their ``voluntary'' strength output. This is particularly true of the interface between the tested person and the test equipment. A poorly designed interface will induce localized tissue pressures which vary from uncomfortable to painful. In this situation, you are measuring voluntary discomfort toleranceÐnot strength. It is important for strength researchers to keep the ``voluntary'' nature of their data in mind when they are designing their equipment and protocols. The de®nition of strength also speaks of force or torque. Strength researchers and users of strength data must also understand this distinction. We commonly use the terms ``muscle force'' and ``muscle strength'' to describe the strength phenomenon. Technically, this is incorrect. For most human movements and force exertions, there is actually a group of individual muscles (a functional muscle group) which work together to produce the observable output. In complicated exertions, there are a number of functional muscle groups working together to produce the measured output. Elbow ¯exion strength, for example, is the result of the combined eorts of the biceps brachii, brachialis, and the brachioradialis, and a squat lift is the result of the combined eorts of the legs, back, and arms. In elbow ¯exion, each individual muscle's contribution to the functional muscle group's output depends on the posture of the arm


Gallagher et al.

being measured. Thus, when we measure elbow ¯exion strength, we are measuring the strength of the elbow ¯exor muscle group, not the strength of any individual muscle. Furthermore, we are measuring (recording) the force created by the functional muscle group(s) against the interface between the person and the equipment (a set of handles for example). Consider the elbow ¯exion measurement depicted in Fig. 1. The force generated by the elbow ¯exor muscle group is shown by Fm . This force acts through lever arm a. In so doing, it creates a torque about the elbow joint equal to Fm a. The measured force (Q, R, or S) will depend upon how far (b, c, or d) the interface (force cu) is from the elbow. Assuming that the exertion is static (nothing moves) in this example, the measured force (on the gage) will equal the elbow ¯exor torque divided by the distance that the gage's associated force cu is from the elbowjoint. That is, Q Fm a=b

1

R Fm a=c

2

S Fm a=d

3

or or As we move the interface (force cu) from the elbow to the hand, the measured force will decrease. This example highlights four points. First, ``muscular strength is what is measured by an instrument'' [4]. Second, people publishing/using strength data must report/understand in detail how the measurements were done. Third, the dierences in published strengths of the various body parts may be due to dierences in the measurement methods and locations. Fourth, interface locations selected using anthropometric criteria will result in more consistent results across the population measured [5]. In summary, a record of a person's strength describes what the instrumentation measured when the person voluntarily produced a muscle contraction in a speci®c set of circumstances with a speci®c interface and instrumentation. 3.1.2

Purposes of Strength Measurement in Ergonomics

There are a number of reasons people may want to collect human strength data. One of the most common is collecting population strength data which can be used to build an anthropometric database; create

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Figure 1 Given a constant muscle force (Fm ), forces measured at various distances from the elbow will result in different force readings (FQ , FR , or FS ).

design data for products, tasks, equipment, etc.; and for basic research into the strength phenomenon. This chapter will focus on two common uses of physical strength assessment in ergonomics: worker selection and placement and job design. 3.1.2.1

Worker Selection and Placement

The purpose of worker selection and placement programs is to ensure that jobs which involve heavy physical demands are not performed by those lacking the necessary strength capabilities [6]. It should be noted that this method is not the preferred strategy of the ergonomist, but is a provisional measure for the control of work-related musculoskeletal disorders (WMSDs) where job design cannot be used to alleviate task demands. Nonetheless, this method can be eective in reducing the harmful physical eects caused by the mismatch of worker and job, given adherence to two fundamental principles. These principles are: (1) ensuring that the strength measures are a close simulation of


the actual high-strength elements in a job, and (2) that strength assessment is performed only under circumstances where they can predict who may be at risk of WMSD. The following paragraphs describe these issues in more detail. It has become quite clear over the past several years that strength, in and of itself, is a poor predictor of the risk of future injury to a worker [7±9]. Evaluation of worker strength capacity is only predictive o of those at risk of injury when it is carefully equated with job demands [10]. All too often, emphasis is placed on collecting data on the former attribute, while the latter receives little or no attention. Recent evidence has illustrated that the analysis of job demands cannot be a generalized description of ``light'' versus ``heavy'' jobs [11], there needs to be a careful biomechanical evaluation of strenuous tasks as performed by the worker. The need to analyze strength in relation to speci®c job demands can be illustrated using the following scenario. An employer has an opening for a physically

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demanding job and wishes to hire an individual with strength sucient for the task. This employer decides to base his employment decision on a strength test given to a group of applicants. Naturally, he selects the applicant with the highest strength score to perform the job. The employer may have hired the strongest job applicant; however, what this employer must understand is that he may not have decreased the risk of injury to his employee if the demands of his job still exceed this individual's maximum voluntary strength capacity. This example should make it clear that only through knowing both about the person's capabilities and the job demands might worker selection protect workers from WMSDs. The second issue that must be considered when worker selection is to be implemented is that of the test's predictive value. The predictive value of a test is a measure of its ability to determine who is at risk of future WMSD [6]. In the case of job-related strengthtesting, the predictive value appears to hold only when testing individuals for jobs where high risk is known (that is, for jobs known to possess high strength demands). Strength testing does not appear to predict the risk of injury or disease to an individual when job demands are low or moderate. It should be clear from the preceding arguments that worker selection procedures are not the preferred method of reducing the risk of WMSDs, and are not to be applied indiscriminately in the workplace. Instead, care must be exercised to ensure that these strength testing procedures are applied only in select circumstances. This procedure appears only to be eective when jobs are known to entail high strength demands, and only when the worker's strength is evaluated in the context of the high strength elements of a job. However, if attention is paid to these limitations, worker selection can be an eective tool to decrease the risk of WMSDs.

3.1.2.2

Job Design

The use of physical strength assessment in ergonomics is not limited to its role in worker selection, it can also be used for the purpose of job design. Job design has been a primary focus of the psychophysical method of determining acceptable weights and forces. Rather than determining individual worker strength capabilities and comparing these to job demands, the psychophysical method attempts to determine workloads that are `àcceptable'' (a submaximal strength assessment) for populations of workers. Once the acceptable work-


loads for a population are determined, the job or task is designed to accommodate the vast majority of the population. For example, a lifting task might be designed by selecting a weight that is acceptable to 75% of females and 90% of males. The use of strength assessment for job design has been shown to be an eective method of controlling WMSDs. It has been estimated that proper design of manual tasks using psychophysical strength assessment might reduce the risk of back injuries by up to 33% [12]. 3.1.3

Purpose of This Chapter

Muscular strength is a complicated function which can vary greatly depending on the methods of assessment. As a result, there is often a great deal of confusion and misunderstanding of the appropriate uses of strength testing in ergonomics. It is not uncommon to see these techniques misapplied by persons who are not thoroughly familiar with the caveats and limitations inherent with various strength assessment procedures. The purposes of this chapter are: (1) to familiarize the reader with the four most common techniques of strength assessment used in ergonomics (isometric, isoinertial, psychophysical, and isokinetic); and (2) to describe the proper applications of these techniques in the attempt to control WMSDs in the workplace. This chapter contains four parts, one for each of the four strength measurement techniques listed above. Each part describes the strength measurement technique and reviews the relevant published data. Equipment considerations and testing protocols are described, and the utility of the tests in the context of ergonomics are also evaluated. Finally, each part concludes with a discussion of the measurement technique with regard to the Criteria for Physical Assessment in Worker Selection [6]. In this discussion, each measurement technique is subjected to the following set of questions: 1. 2. 3. 4. 5.

Is it safe to administer? Does it give reliable, quantitative values? Is it related to speci®c job requirements? Is it practical? Does it predict risk of future injury or illness?

It is hoped that this part of the chapter will provide a resource that can be used to better understand and properly apply these strength assessment techniques in the eort to reduce the risk of WMSDs.


3.2 3.2.1

PART I: ISOMETRIC STRENGTH Introduction and De®nition

Isometric strength is de®ned as the capacity to produce force or torque with a voluntary isometric [muscle(s) maintain(s) a constant length] contraction. The key thing to understand about this type of contraction and strength measurement is that there is no body movement during the measurement period. The tested person's body angles and posture remain the same throughout the test. Isometric strength has historically been the one most studied and measured. It is probably the easiest to measure and the easiest to understand. Some strength researchers feel that isometric strength data may be dicult to apply to some ``real life'' situations because in most real circumstances people are movingÐthey are not static. Other researchers counter that it is equally dicult to determine the speed of movement of a person group of persons doing a job (each moves in their own unique manner and at their own speed across the links and joints of the body). Thus, dynamic strength test data collected on persons moving at a dierent speed and/or in a dierent posture from the ``real world'' condition will be just as hard to apply. In truth, neither is betterÐthey are different measurements and both researchers and users should collect/use data which they understand and which ®ts their application. 3.2.2

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The following procedures are generally used in this biomechanical analysis technique. First, workers are observed (and usually photographed or videotaped) during the performance of physically demanding tasks. For each task, the posture of the torso and the extremities are documented at the time of peak exertion. The postures are then recreated using a computerized software package, which calculates the load moments produced at various joints of the body during the performance of the task. The values obtained during this analysis are then compared to population norms for isometric strength obtained from a population of industrial workers. In this manner, the model can estimate the proportion of the population capable of performing the exertion, as well as the predicted compression forces acting on the lumbar disks resulting from the task. Figure 2 shows an example of the workplace analysis necessary for this type of approach. Direct observations of the worker performing the task provide the necessary data. For example, the load magnitude and direction must be known (in this case a 200 N load acting downward), the size of the worker, the postural angles of the body (obtained from photographs or videotape), and whether the task requires one or two hands. Furthermore, the analysis requires accurate measurement of the load center relative to the ankles and the low back. A computer analysis program

Workplace Assessment

When a worker is called upon to perform a physically demanding lifting task moments (or torques) are produced about various joints of the body by the external load [13]. Often these moments are augmented by the force of gravity acting on the mass of various body segments. For example, in a biceps curl exercise, the moment produced by the forearm ¯exors must counteract the moment of the weight held in the hands, as well as the moment caused by gravity acting on the center of mass of the forearm. In order to successfully perform the task, the muscles responsible for moving the joint must develop a greater moment than that imposed by the combined moment of the external load and body segment. It should be clear that for each joint of the body, there exists a limit to the strength that can be produced by the muscle to move ever increasing external loads. This concept has formed the basis of isometric muscle strength prediction modelling [13].


Figure 2 Postural data required for analysis of joint moment strengths using the isometric technique.

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can be used to calculate the strength requirements for the task, and the percentage of workers who would be likely to have sucient strength capabilities to perform it. Results of this particular analysis indicate that the muscles at the hip are most stressed, with 83% of men having the necessary capabilities but on slightly more than half of women would have the necessary strength in this region. These results can then be used as the basis for determining those workers who have adequate strength for the job. However, such results can also the used as ammunition for recommending changes in job design [13]. 3.2.3

Isometric Testing Protocol

The basic testing protocol for isometric strength testing was developed by Caldwell et al. [1] and published in an AIHA ergonomics guide by Chan [2]. The protocol outlined herein includes additional information determined by researchers since that time. When conducting isometric testing, there are a number of factors that must be considered and controlled (if possible) to avoid biased results. These factors include the equipment used to make the measurements, the instructions given to the person tested, the duration of the measurement period, the person's posture during the test, the length of the rest period between trials, the number of trials a person is given for each test, the tested person's physical state at the time of testing, the type of postural control used during the tests, and the environmental conditions during the test. 3.2.4

Test Duration

The length of an isometric strength test can impact the result in two ways. If it is too long, the subject will fatigue and their strength score will decline. If it is too short, the subject will not reach their maximum force level before the test is terminated. The existing AIHA Guide suggests a 4 sec test with the score being the average strength displayed during seconds 2±4. The appropriate 3 sec period can be determined as follows. If the measuring equipment has the capability, collect strength data by having the person begin their contraction with the equipment monitoring the force until some preselected threshold is reached (usually 20± 30% below the expected maximum force for the person and posture), have the equipment wait 1 sec, and then have the equipment average the displayed force for the next 3 sec. This is easily done with computerized systems.


If the equipment does not have the above capability, then have the person tested begin the test and gradually increase their force over a 1 sec period. The force should be measured and averaged over the next 3 sec. In complex whole body tests where multiple functional muscle groups are involved, it may take persons a few seconds to reach their maximum. Under these conditions, the data collector must adjust the premeasurement time interval accordingly, and they must carefully monitor the progress of the testing to insure that they are fact measuring the maximal force during the 3 sec period. 3.2.5

Instructions

The instructions to the person tested should be factual, include no emotional appeals, and be the same for all persons in a given test group. This is most reliably accomplished with standardized written instruction, since the test administrator's feelings about the testee or the desired outcome may become evident during verbal instruction. The following additional factors should also be considered. The purpose of the test, the use of the test results, the test procedures, and the test equipment should be thoroughly explained to the persons tested. Generally, the anonymity of the persons tested is maintained, but if names may be released, the tested person's written permission must be obtained. Any risks inherent to the testing procedure should be explained to the persons tested, and an informed consent document should be provided to, and signed by, all participating persons. All test participants should be volunteers. Rewards, performance goals, encouragement during the test (for example, ``pull, pull, pull, you can do it,'' etc.), spectators, between person competition, and unusual noises will all aect the outcome of the tests and must be avoided. Feedback to the tested person should be positive and qualitative. Feedback should not be provided during the test exertion, but may be provided after a trial or test is complete. No quantitative results should be provided during the testing period because they may change the person's incentive and thus their test result. To the tested person, a 4 sec maximal exertion seems to take a long time. During the test, feedback in the form of a slow four count or some other tester±testee agreed-upon manner should be provided so the tested person knows how much longer a test will last.


3.2.6

Rest Period Length

Persons undergoing isometric strength testing will generally be performing a series of tests, with a number of trials for each test. Under these conditions, a person could develop localized muscle fatigue, and this must be avoided, since it will result in underestimating strength. Studies by Schanne [14] and Stobbe [5] have shown that a minimum rest period of 2 min between trials of a given test or between tests is adequate to prevent localized muscle fatigue. The data collector must be alert for signs of fatigue, such as a drop in strength scores as a test progresses. The person tested must be encouraged to report any symptoms of fatigue and the rest periods should be adjusted accordingly. Whenever possible, successive tests should not stress the same muscle groups. 3.2.7

Number of Trials for Each Test

The test±retest variability for this type of testing is about 10%. It is higher for people with limited experience with either isometric testing or with forceful physical exertion in general. In addition, these people will often require a series of trials of a test to reach their maximum. The use of a single trial of a test will generally underestimate a person's maximum strength, and may underestimate it by more than 50%. A twotrial protocol results in less of an underestimate, but it may still exceed 30% [15]. For this reason, the preferred approach to determining the number of trials for each test is to make the choice on the basis of performance. Begin by having the subject perform two trials of the test. The two scores are then compared and if they are within 10% of each other the highest of the two values is used as the estimate of the person's maximal strength, and you proceed to the next test. If the two values dier by more than 10%, additional trials of the same test are performed until the two largest values are within 10% of each other. Using this approach, Stobbe and Plummer averaged 2.43 trials per test across 67 subjects performing an average of 30 dierent strength tests [15]. In any case, a minimum of two trials is needed for each test. 3.2.8

When to Give Tests

A person's measured strength is, for a variety of reasons, somewhat variable. It will not be constant over time, nor over a workday. However, in the absence of speci®c muscle strength training, it should remain


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within a relatively narrow range. It is generally higher at the beginning of a workday than at the end. The fatigue-induced strength decrement will vary from person to person and will depend on the nature of the work done during the day. A person who performs repetitive lifting tasks all day can be expected to have a large lifting strength decrement over a workday, whereas a sedentary worker should have little or no decrement. Based on these results, the fairest evaluation of a person's maximum strength can be done at the beginning of, or at least early in, a workday. 3.2.9

Test Posture

Measured strength is highly posture dependent. Even small changes in the body angles of persons being tested and/or changes in the direction of force application can result in large changes in measured strength. When collecting strength data, a researcher should ®rst determine what type of data is sought, and then one or more strength tests which will provide that speci®c type of data should be designed. If, for example, the test is being done to determine whether people are physically ®t for a job, the test posture should emulate, to the extent possible, the posture required on the job. Once the test posture has been determined, the researcher must ensure that the same posture is used on each trial of the test. The researcher must monitor the test to ensure that the person's posture does not change during the test. If these things are not done, the test results will be erratic, and may seriously overestimate or underestimate the person's actual maximal strength. 3.2.10

Restraint Systems

Restraint systems are generally used either to con®ne a person to the desired test posture, or to isolate some part of the tested person's body so that a speci®c muscle group (or groups) can be tested (see Fig. 3). In addition, restraint systems help to assure that all persons participating in a given study will be performing the same test. The type and location of restraint system used can have a major impact on test results. Similarly, the lack of a restraint system can allow the posture to vary or allow the use of the wrong or additional muscle groups, both of which will impact test results. Any restraint system used should be comfortable, it should be padded in a manner that prevents local tissue stress concentrations during the test; it should be positioned so that the correct muscle group(s) and

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Figure 3 Example of a test ®xture designed to restrain various body segments during isometric strength testing.

posture(s) are used and maintained. This latter item often requires some experimentation to correctly achieve. For many strength tests, the use of a restraint system will be necessary if consistent and meaningful results are to be achieved. Researchers reporting strength testing results should describe the restraints used and their location in detail so that other researchers and persons applying their data will be able to interpret it correctly. The nonuse of restraints should also be reported. 3.2.11

Environmental Conditions

The environmental conditions selected for the testing periods should be appropriate to the purpose of the test. For most testing, the environmental conditions found in a typical oce building or medical department will be acceptable. In some cases, the eects of the environment on measured strength or physical performance must be determined, and then appropriate conditions can be established (e.g., worksites requiring exposure to hot or cold temperature extremes). 3.2.12

Equipment

Isometric strength-testing equipment has not been standardized. Any equipment which has the capability


to perform the necessary timing and averaging described above under ``test duration'' is probably acceptable. Today, this varies from dedicated force measurement devices such as the force monitor developed in the 1970s at University of Michigan, to a force transducer coupled to a PC via an analog-to-digital converter and managed by appropriate software, to complex multiple-mode strength-measuring devices manufactured by companies like Cybex, Chattex, Loredan, and Isotechnologies. The associated prices vary from $1000 or so to as high as $50,000±$100,000. However, equipment price is not the issue; rather, it is equipment function. Researchers should select or build equipment suited to their needs. Researchers must also understand what is happening inside the device (and its associated software) they are using so that the data they collect can be properly interpreted. The human±equipment interface is another matter which can impact the test results. The interface must be appropriate to the task measured, it should be comfortable (unless discomfort eects are being studied), and it should give the person tested a sense of security about the test. Persons will generally be providing a maximal exertion in a situation where there is no movement. If they fear that the testing system may fail or move unexpectedly, they will not give a maximal performance. Similarly, the equipment must be strong enough to remain intact under the maximum load placed on it. If it fails unexpectedly, someone is going to be injuredÐperhaps severely. 3.2.13

Subjects

The subjects selected for strength testing will determine the results obtained. This means that when strength data are collected, the selection of subjects must appropriately represent the population it claims to describe (for example, design data for retired persons should be collected on retired persons, and design data for entrylevel construction workers should be collected on young healthy adults). For general research purposes, persons participating in a strength testing project should not have a history of musculoskeletal injuries. There are other medical conditions, including hypertension, which may pose a threat of harm to a participant. Whenever possible, prospective participants should be medically evaluated and approved before participating in a strength-testing project. The following data should be provided about the subject population when reporting strength-testing results:


1. 2. 3. 4. 5. 6. 7.

Gender Age distribution Relevant anthropometry (height, weight, etc.) Sample size Method by which sample was selected and who it is intended to represent Extent of strength training done by participants, and their experience with isometric testing Health status of participants (medical exam and/or health questionnaire recommended.

3.2.14

Strength Data Reporting

The minimum data which should be reported for strength-testing projects are: 1. 2. 3.

Mean, median, and mode of data set Standard deviation of data set Skewness of data set (or histogram describing data set) Minimum and maximum values.

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program, individual isometric strength remains relatively stable over time. When the number of trials is based on the 10% criterion discussed earlier, the recorded strength is near or at the tested person's maximum voluntary strength. Assuming the above factors, and that test postures are properly controlled, isometric strength testing is highly reliable and quantitative. 3.2.15.3

Is Method Practical?

Isometric strength testing has already been used successfully in industry for employee placement, in laboratories for the collection of design data, and in rehabilitation facilities for patient progress assessment. 3.2.15.4

Is the Method Related to Speci®c Job Requirements (Content Validity)?

A set of ®ve criteria have been purposed to evaluate the utility of all forms of strength testing. Isometric strength testing is evaluated with respect to these criteria in the following sections.

Isometric strength testing can be performed in any posture. When it is conducted for employee placement purposes, the test postures should be as similar as possible to the postures that will be used on the job. The force vector applied by the tested person should also be similar to the force vector that will be applied on the job. When these two criteria are met, isometric strength testing is closely related to job requirements. However, it should be noted that results obtained using isometric strength testing loses both content and criterion-related validity as job demands become more dynamic.

3.2.15.1

3.2.15.5

4. 3.2.15

Evaluation According to Physical Assessment Criteria

Is It Safe to Administer?

Any form of physical exertion carries with it some risk. The directions for the person undergoing an isometric test speci®cally state that the person is to slowly increase the force until they reach what they feel is a maximum, and to stop if at any time during the exertion they feel discomfort or pain. The directions also expressly forbid jerking on the equipment. When isometric testing is performed in this manner it is quite safe to administer because the tested person is deciding how much force to apply, over what time interval, and how long to apply it. The only known complaints relating to participation in isometric testing are some residual soreness in the muscles which were active in the test(s), and this is rarely reported. 3.2.15.2

Does the Method Provide Reliable Quantitative Values?

The test-retest variability for isometric testing is 5± 10%. In the absence of a speci®c strength training


Does the Method Predict the Risk of Future Injury or Illness?

A number of researchers have demonstrated that isometric strength testing does predict risk of future injury or illness for people on physically stressful job [16,17]. The accuracy of this prediction is dependent on the quality of the job evaluation on which the strength tests are based, and the care with which the tests are administered. 3.3 3.3.1

PART II: MAXIMAL ISOINERTIAL STRENGTH TESTING De®nition of Isoinertial Strength

Kroemer [18±20] and Kroemer et al. [4] de®ne the isoinertial technique of strength assessment as one in which mass properties of an object are held constant, as in lifting a given weight over a predetermined distance. Several strength assessment procedures possess

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the attribute in this de®nition. Most commonly associated with the term is a speci®c test developed to provide a relatively quick assessment of a subject's maximal lifting capacity using a modi®ed weight-lifting device [18,21]. The classic psychophysical methodology of assessing maximum acceptable weights of lift is also as an isoinertial technique under this de®nition [12]. While the de®nition provided by Kroemer [18] and Kroemer et al. [4] has been most widely accepted in the literature, some have applied the term `ìsoinertial'' to techniques that dier somewhat from the de®nition given above, such as in a description of the Isotechnologies B-200 strength-testing device [22]. Rather than lifting a constant mass, the B-200 applies a constant force against which the subject performs an exertion. The isoinertial tests described in this chapter apply to situations in which the mass to be moved by a musculoskeletal eort is set to a constant. 3.3.2

Is Isoinertial Testing Psychophysical or Is Psychophysical Testing Isoinertial?

As various types of strength tests have evolved over the pasts few decades, there have been some unfortunate developments in the terminology that have arisen to describe and/or classify dierent strength assessment procedures. This is particularly evident when one tries to sort out the various tests that have been labelled `ìsoinertial.'' One example was cited above. Another problem that has evolved is that the term `ìsoinertial strength'' has developed two dierent connotations. The ®rst connotation is the conceptual de®nitionÐisoinertial strength tests describe any strength test where a constant mass is handled. However, in practice, the term is often used to denote a speci®c strength test where subjects' maximal lifting capacity is determined using a machine where a constant mass is lifted [18,21]. Partially as a result of this dual connotation, the literature contains both references to `ìsoinertial strength test'' as a psychophysical variant [23], and to the psychophysical method as an `ìsoinertial strength test'' [4,24]. In order to lay the framework for the next two parts, the authors would like to brie¯y discuss some operational de®nitions of tests of isoinertial and psychophysical strength. When Ayoub and Mital [23] state that the isoinertial strength test is a variant of the psychophysical method, they refer to the speci®c strength test developed by Kroemer [18] and McDaniel et al. [21]. Clearly, this isoinertial protocol has many similarities to the psychophysical method: both are dynamic; weight is adjusted in both; both measure the load a subject is


willing to endure under speci®ed circumstances, etc. However, while both deal with lifting and adjusting loads, there are signi®cant dierences between the psychophysical (isoinertial) technique and the Kroemer± McDaniel (isoinertial) protocol, both procedurally and in use of the data collected in these tests. For purposes of this chapter we will designate the Kroemer± McDaniel protocol maximal isoinertial strength tests (MIST). This part deals with the latter isoinertial technique, which diers from the psychophysical technique on the following counts: 1.

2.

3.

3.3.3

In maximal isoinertial strength tests, the amount of weight lifted by the subject is systematically adjusted by the experimenter, primarily through increasing the load to the subject's maximum. In contrast, in psychophysical tests, weight adjustment is freely controlled by the subject, and may be upwards or downwards. The maximal isoinertial strength tests discussed in this part are designed to quickly establish an individual's maximal strength using a limited number of lifting repetitions, whereas psychophysical strength assessments are typically performed over a longer duration of time (usually at least 20 min), and instructions are that the subject select an acceptable (submaximal) weight of lift, not a maximal one. Due to the typically longer duration of psychophysical assessments, greater aerobic and cardiovascular components are usually involved in the acceptable workload chosen. Isoinertial strength tests have traditionally been used as a worker selection tool (a method of matching physically capable individuals to demanding tasks). A primary focus of psychophysical methods has been to establish data that can be used for the purpose of ergonomic job design [12]. Published Data

There are two primary maximal isoinertial strength test procedures that will be described in this section. One involves the use of a modi®ed weight-lifting machine where the subject lifts a rack of hidden weights to prescribed heights, as depicted in Fig. 4 [21]. Kroemer [18] refers to his technique as LIFTEST, while the Air Force protocol has been named the strength aptitude test (SAT). The other test uses a lifting box, into which weights are placed incrementally at speci®ed times until the lifting limit is reached [25]. The greatest


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Figure 4 The incremental weight lift machine developed by the Air Force for the strength aptitude test.

bulk of the isoinertial testing literature deals with the former procedure. 3.3.4

The LIFTEST/Strength Aptitude Test Techniques

The LIFTEST and SAT procedures are isoinertial techniques of strength testing that attempt to establish the maximal amount of weight that a person can safely lift [18]. In this technique, a preselected mass, constant in each test, is lifted by the subject (typically from knee height to knuckle height, elbow height, or to overhead reach height). The amount of weight to be lifted is at ®rst relatively light, but the amount of mass is continually increased in succeeding tests until it reaches the maximal amount that the subject voluntarily indicates he or she can handle. This technique has been used extensively by the U.S. Air Force [21], and is applicable to dynamic lifting tasks in industry as well [18,26]. Since a constant mass is lifted in LIFTEST, the acceleration of the load during a test is dependent on


the force applied to the load during the test (in accordance with Newton's second law: F ma). The dynamic nature of this procedure, the fact that a constant mass is being lifted, and the subject's freedom to choose the preferred lifting technique, all give the LIFTEST a general similarity to certain types of industrial lifting tasks. A unique aspect of the LIFTEST technique is that it is the only strength measurement procedure discussed in this chapter where results are based on the success or failure to perform a prescribed criterion task. The criterion tasks studied have typically included lifting to shoulder height [20,21,26,27], elbow height [21,26], or knuckle height [20,26]. The USAF also developed a muscular endurance test using an incremental lift machine (ILM) [21]. The LIFTEST shoulder height maximal strength test has demonstrated the highest correlation with manual materials handling activities [26], and has been subjected to a biomechanical analysis by Stevenson et al. [28]. They demonstrated that this criterion task could be separated into three distinct

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phases: (1) a powerful upward pulling phase, where maximal acceleration, velocity, and power values are observed; (2) a wrist changeover manoeuvre (at approximately elbow height), where momentum is required to compensate for low force and acceleration; and (3) a pushing phase (at or above chest height), characterized by a secondary (lower) maximal force and acceleration pro®le. The analysis by Stevenson et al. [28] suggested that successful performance of the criterion shoulder height lift requires a technique quite dierent from the concept of slow, smooth lifting usually recommended for submaximal lifting tasks. On the contrary, lifting of a maximal load requires a rapid and powerful lifting motion. This is due in large part to the need to develop sucient momentum to allow successful completion of the wrist changeover portion of the lift. Most lift failures occur during the wrist changeover procedure, probably the result of poor mechanical advantage of the upper limb to apply force to the load at this point in the lift [28]. Stevenson et al. [28] found that certain anatomical landmarks were associated with maximal force, velocity, and power readings (see Fig. 5). Maximal force readings were found to occur at midthigh, maximal velocity at chest height, minimum force was recorded at head height, and the second maximal acceleration (pushing phase) was observed at 113% of the subject's stature. 3.3.5

The Strength Aptitude Test

The strength aptitude test (SAT) [21] is a classi®cation tool for matching the physical strength abilities of individuals with the physical strength requirements of jobs in the Air Force (McDaniel, personal communication, 1994). The SAT is given to all Air Force recruits as part of their preinduction examinations. Results of the SAT are used to determine whether the individual tested possesses the minimum strength criterion which is a prerequisite for admission to various Air Force specialties (AFSs). The physical demands of each AFS are objectively computed from an average physical demand weighted by the frequency of performance and the percent of the AFS members performing the task. Objects weighing less than 10 lb are not considered physically demanding and are not considered in the job analysis. Prior to averaging the physical demands of the AFS, the actual weights of objects handled are converted into equivalent performance on the incremental weight lift test using regression equations developed over years of testing. These relationships consider the type of


Figure 5 Analysis of the shoulder height strength test indicates three distinct lift phases: (1) a powerful upward pulling phase (where maximal forces are developed), (2) a wrist changeover maneuver (where most failures occur), and (3) a pushing phase (where a secondary, lower, maximal force is observed).

task (lifting, carrying, pushing, etc.), the size and weight of the object handled, as well as the type and height of the lift. Thus, the physical job demands are related to, but are not identical to, the ability to lift an object to a certain height. Job demands for various AFSs are reanalyzed periodically for purposes of updating the SAT. The ®rst major report describing this classi®cation tool was a study of 1671 basic trainees (1066 males and 605 females) [21]. The incremental weight lift tests started with a 18.1 kg weight which was to be raised to 1.83 m or more above the ¯oor. This initial weight was increased in 4.5 kg increments until subjects were unable to raise the weight to 1.83 m. Maximal weight


lift to elbow height was then tested as a continuation of the incremental weight lift test. In the test of lifting the weight to 1.83 m, males averaged 51.8 kg (10.5), while females averaged 25.8 kg (5.3). The respective weights lifted to elbow height were 58.6 kg (11.2) and 30.7 kg ( 6.3). The distributions of weight lifting capabilities for both male and female basic trainees in lifts to 6 ft are provided in Fig. 6. Results of the elbow height lift are presented in Table 1. McDaniel et al. [21] also performed a test of isoinertial endurance. This involved holding a 31.8 kg weight at elbow height for the duration the subject could perform the task. Male basic trainees were able to hold the weight for an average of 53.3 sec (22.11), while female basic trainees managed to hold the weight an average of 10.3 sec (10.5 SD). When developing the SAT, the Air Force examined more than 60 candidate tests in an extensive, four-year research program and found the incremental weight lift to 1.83 m to be the single test of overall dynamic strength capability, which was both safe and reliable (McDaniel, personal communication 1994). This ®nding was con®rmed by an independent study funded by the U.S. Army [29]. This study compared the SAT to a battery of tests developed by the Army (including isometric and dynamic tests) and compared these with representative heavy demand tasks performed within the Army. Results showed the SAT to be superior to all others in predicting performance on the criterion tasks.

809 Table 1 Weight-Lifting Capabilities of Basic Trainees for Lifts to Elbow Height Males Percentile

Pounds

1 5 10 20 30 40 50 60 70 80 90 95 99

80 93 100 109 116 122 127 133 140 150 160 171 197

Females

Kilograms 36.3 42.2 45.4 49.5 52.6 55.4 57.6 60.3 63.5 68.1 47.6 77.6 89.4

Mean 129.07 58.56 SD 24.60 11.16 Minimum 50 22.7 Maximum >200 >90.7 Number 1066

Pounds

Kilograms

40 48 52 58 61 65 68 71 75 78 85 90 100 67.66 13.91 75%; < 5% and 75%; and 5%. They observed that the incidence of back injuries, incidence of disabling injuries, days lost per injury, and total cost increased as the percent of population `òverstressed'' increased. The authors did not report any statistical analyses. Both Sets of Data. Another study that examined the predictive validity of the psychophysical methodology was published by Herrin et al. [46]. These investigators performed detailed biomechanical and psychophysical evaluations on 55 industrial jobs from ®ve major industries. The psychophysical analyses involved determining the minimum percent of capable population from the Liberty Mutual tables for each individual task (PSY.MIN) as well as an average percent of capable population when the job involved multiple tasks (PSY.AVG). Additional comparison variables


included the JSI and lifting strength ratio (LSR). These investigators modi®ed the de®nition of JSI to represent a frequency- and time-weighted ratio of weights lifted compared to the average task-speci®c lifting strength of males and females, averaged across all tasks. By contrast, the lifting strength ratio represented the worst case scenario in that the LSR was the largest single ratio identi®ed among all the tasks. After the jobs were characterized as described above, injury and illness data for 6912 incumbent workers were monitored for two years retrospectively and one year prospectively (> 12:6 million man-hours). Morbidity was categorized as contact incidents, musculoskeletal disorders (excluding the back), and back incidents, and expressed as incidence rates (number of incidents per 100 workers per year). Severity data was also examined (lost time versus no lost time). The results revealed a signi®cant negative correlation between the minimum percent capable population (PSY.MIN) and all three incidence rates, i.e., the incidence rates increased as the percent capable population decreased. A similar correlation was noted between PSY.MIN and severity. There was no correlation between the average percent capable population (PSY.AVG) with any incidence rate or severity. The incidence rates for musculoskeletal disorders and back disorders were positively and signi®cantly correlated with the LSR. The LSR was also correlated with severity. The only correlated with severity, not incidence. The authors oered the following conclusions: 1. 2.

3.

3.4.9

Overexertion injuries can be related to physical job stresses. Indices representing the extremes of the job requirements (PSY.MIN and LSR) are generally more predictive of risk than indices representing averages (PSY.AVG and JSI). The percent capable population for the most stressful aspect of the job, either isometric or psychophysical, is the most simple index of this type.

Evaluation According to Criteria for Physical Assessment

3.4.9.1 Is It Safe to Administer? According to Snook, there has been one compensable injury among the 119 industrial worker test subjects [47]. This single episode involved a chest wall strain associated with a high lift. It was also associated


with four days restricted activity, but no permanent disability. 3.4.9.2

Does the Protocol Give Reliable Quantitative Values?

The Liberty Mutual protocol incorporates a criterion for test±retest reliability (maximum dierence of 15%). Legg and Myles reported that 34% of their data did not meet this criterion [48]. In contrast, Gallagher reported that only 3% of tests in their study had to be repeated because of violating the 15% test±retest criterion [49]. Clearly, the maximum acceptable weights and forces are quantitative. 3.4.9.3

Is It Practical?

There are two major sources of impracticality associated with this type of strength assessment: (1) it is conducted in a laboratory, and (2) the duration of testing is somewhat prolonged compared to other strength assessment methods. It is possible, however, to have the subjects use objects that are actually handled in the workplace. Equipment is not very costly. 3.4.9.4

Is It Related to Speci®c Job Requirements (Content Validity)?

The content validity of this method of strength assessment is one of its greatest assets. One potential weakness, however, is its insensitivity to bending and twisting. 3.4.9.5

Does It Predict Risk of Future Injury or Illness (Predictive Validity)?

The results of two epidemiological studies suggest that selected indices derived from the psychophysical data are predictive of risk for contact injury, musculoskeletal disorders (excluding the back), and back disorders [44,45]. These indices are correlated to the severity of these injuries. A third study demonstrated predictive value [46]. It should be noted, however, that at high frequencies, test subjects selected weights and forces that often exceeded consensus criteria for acceptable levels of energy expenditure. In addition, test subjects may also select weights and forces that exceed consensus levels of acceptable disk compression.


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3.5 3.5.1

PART IV: ISOKINETIC STRENGTH Theory and Description of Isokinetic Strength Measurement

The concept of isokinetic measurement of strength was originally related by Hislop and Perrine [71]. Characteristics of an isokinetic exertionare constant velocity throughout a predetermined range of motion. Strictly speaking, a means of speed control, and not a load in the usual sense, is applied in isokinetic exertion [71]. However, load and resistance are de®nitely present in this technique. In this case, the load is a result of the energy absorption process performed by the device to keep the exertion speed constant. Energy cannot be dissipated through acceleration in isokinetic exercise, because this is prevented by the device. Because the energy is not dissipated in the process, it is converted into a resistive force, which varies in relation to the eciency of the skeletal muscle. Since the speed of motion is held constant in isokinetic exercise, the resistance experienced during a contraction is equivalent to the force applied throughout the range of motion. For this reason, the technique of isokinetic exercise has sometimes been referred to as accommodating resistance exercise. This type of exercise allows the muscle to contract at its maximum capability at all points throughout the range of motion. At the extremes of the range of motion of a joint, the muscle has the least mechanical advantage, and the resistance oered by the machine is correspondingly lower. Similarly, as the muscle reaches its optimal mechanical advantage, the resistance of the machine increases proportionally. It must be understood, however, that while isokinetic devices control the speed of the exertion, this does not assure a constant speed of muscle contraction. It should be noted that while the speed of isokinetic contractions is constant during individual exertions, it is also possible to compare muscular performance over a wide range of isokinetic velocities. Increasing the isokinetic speed of contraction will place increasing demands on Type II muscle ®bers (fast twitch and fast oxidative glycolytic). 3.5.2

Workplace Assessment

It is clear that isometric strength testing cannot substitute for dynamic strength assessment when examining highly dynamic occupational job demands. As most industrial work tasks contain a signi®cant dynamic component, analysis of isokinetic strength

820

capabilities would appear to oer some advantage to isometric testing in this regard. However, it must be recognized that isokinetic devices are not entirely realistic in comparison with free dynamic lifting, where subjects may use rapid acceleration to gain a weight lifting advantage. The majority of isokinetic devices available on.the market focus on quantifying strength about isolated joints or body segments, for example, trunk extension and ¯exion (see Fig. 7). This may be useful for rehabilitation or clinical use, but isolated joint testing is generally not appropriate for evaluating an individual's ability to perform occupational lifting tasks. One should not make the mistake of assuming, for instance, that isolated trunk extension strength is representative of an individual's ability to perform a lift. In fact, lifting strength may be almost entirely unrelated to trunk muscle strength. Strength of the arms or legs (and not the trunk) may be the limiting factor in an individual's lifting strength. For this reason, machines that measure isokinetic strengths of isolated joints or body segments should not be used as a method of evaluating worker capabilities related to job demands in most instances. Many investigators have used dynamic isokinetic lifting devices speci®cally designed to measure wholebody lifting strength [72,73] (see Fig. 8). These devices typically have a handle connected by a rope to a winch, which rotates at a speci®ed isokinetic velocity when the

Gallagher et al.

handle is pulled. Studies using this type of device have demonstrated good correlations between isokinetic dynamic lift strength (i.e., a lift from ¯oor to chest height) and the maximum weights individuals were willing to lift for infrequent tasks [72]. Thus, under certain circumstances, this device appears to possess some validity for assessment of job related dynamic lifting strength capabilities of individuals. However, many of these isokinetic lifting devices are limited to analysis of relatively simple lifting tasks (i.e., a simple sagittal plane lift). Unfortunately, such rudimentary lifting tasks are rare in industry. Some investigators have attempted to modify this type of instrument by providing means to mount it so that isokinetic strength can be measured in vertical, horizontal, and transverse planes [74]. In spite of eorts to improve the versatility of these devices, however, it remains clear that complex lifting tasks are not well simulated by current isokinetic apparatus. 3.5.3

Evaluation According to Criteria for Physical Assessment

3.5.3.1 Is It Safe to Administer? Given proper procedures and supervision, isokinetic musculoskeletal testing appears to be a reasonably safe method of evaluating muscular strength and endurance. Certain risks associated with use of free weights, weight machines, and other isotonic methods

Figure 7 Many isokinetic devices are designed to evaluate isolated joint muscle strengths. Such devices can be of great bene®t in a clinical setting, but may not be as conducive to workplace assessment procedures.



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developed by the Testing Task Force:

AAOS

Human

Performance

1. The equipment must be determined safe for both the subject and the tester. 2. The reliability and validity of the equipment should be documented. 3. The equipment should be designed to ensure freedom of movement with subject comfort, and isolation of the motion should be achieved via proper stabilization techniques. 4. Training and education in correct use of the equipment should be available. 3.5.3.2

Figure 8 An isokinetic whole-body strength measurement system. This device allows the experimenter to assess various muscular strengths (such as those shown) at a constant velocity.

of assessing strength are not present in isokinetic testing. In addition, since the resistance or load experienced by the subject is directly related to the force the subject voluntarily applies, theoretically there would be decreased risk of injury due to overloading of the or musculature, because the subject can control his or her own eort. However, it should be noted that some investigators have reported that lower velocity isokinetic exertions may be painful [75,76]. Certain precautions have been suggested to reduce injury risk in performance of isokinetic musculoskeletal evaluations: 1. 2.

3. 4.

Warm-up and stretching of the involved muscle groups Performance of 5±10 submaximal trial repetitions to assess proper alignment, subject comfort, and subject familiarization with the test requirements Postexercise stretching Ice/compression/elevation any time postexercise eusion or swelling occurs.

In addition, subjects should wear tennis or running shoes during isokinetic muscle testing when performing standing exertions. Guidelines have been established by the American Academy of Orthopaedic Surgeons (AAOS) that should be met when testing dynamic muscle performance [77]. The following summarize the guidelines


Does It Give Reliable, Quantitative Values?

Several studies have reported on the reliability of values obtained using isokinetic devices. Results have generally indicated high reliability for isokinetic equipment. In a study examining the isokinetic movement of the knee extensors using a CYBEX II dynamometer, Johnson and Siegel [78] found reliability coecients ranged from 0.93 to 0.99. Furthermore, these authors reported that reliability appeared to be aected more by testing over days than when comparing dierent trials performed on the same day. Pipes and Wilmore [79] reported test reliability in isokinetic exertions of a similar magnitude (r 0:92 0:99 when testing bench press strength and leg press strength. Moroid et al. [80] performed a test of reliability for torque measurements at various velocities with a CYBEX device and found that peak torque was reliably measured (r 0:999) at velocities ranging from 4 to 12 rpm. Intratest, intertest, and intertester reliability of isokinetic strength measurements was examined in a study quantifying strength in children using a CYBEX dynamometer [81]. The authors concluded that none of these sources of measurement error constituted a signi®cant source of inaccuracy. While good reliability for the CYBEX dynamometer has been reported, some authors have expressed concern about a torque `òvershoot'' artifact that may appear in CYBEX torque measurements [82]. This artifact is evidenced as an initial prominent spike in the torque output curve, which is then followed by a series of progressively diminishing secondary oscillations. The cause of this phenomenon appears to be a result of `òverspeeding'' of the dynamometer's input lever during a free acceleration period prior to engagement of its resistance mechanism. The authors concluded that the prominent initial spikes represent inertial forces and should not be confused with actual

822

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muscle tension development. Proper signal damping procedures may suppress this `òvershoot''; however, damping should not be used when absolute torque values are required. Many other isokinetic devices have been developed since the introduction of the CYBEX in 1980. Most of these devices have demonstrated reliability similar to the CYBEX. Klopfer and Greij [75] analyzed the liability of torque production on the Biodex B-200 at high isokinetic velocities (3008 4508 sec) and found that coecients of ta correlation ranged from 0.95 to 0.97, re¯ecting a high degree of reliability of the test equipment. Other authors reported reliability of between 0.94 and 0.99 with the same equipment [83]. A study analyzing the reliability of the Kinetic Communicator (KINCOM) device reported intraclass correlation coecients of 0.94±0.99 [84]. Reliability of the Lido isokinetic system appears somewhat lower than the others reported above, ranging from 0.83± 0.94 [85]. The reliability of the Mini-Gym (the isokinetic device best suited to analysis of occupational tasks) does not appear to have been reported in the literature. The foregoing data suggests that isokinetic strength testing equipment generally exhibits a high degree of reliability. However, it should be noted that results obtained using one system may not be comparable to results collected on other systems. Several studies have attempted to compare results between systems, and all have found signi®cant dierences. Torque values may vary as much as 10±15% when comparing dierent systems [86,87]. These discrepancies indicate that data collected on dierent devices cannot be compared, and that normative data generated on one system cannot be used on other systems. 3.5.3.3

Is It Practical?

Several issues may impact the practicality of using isokinetic devices to examine an individual's muscular capabilities. Not the least of these is the signi®cant cost of purchasing an isokinetic measurement system. Many of the systems discussed in this section cost tens of thousands of dollars, which may render such systems impractical for many applications. Another important issue related to practicality in terms of job speci®c strength assessment is the ability of these devices to easily simulate a variety of occupational tasks. While certain isokinetic devices have been speci®cally designed to mimic lifting tasks [72], many are designed simply for quanti®cation of strength of iso-


lated muscle groups in a clinical setting without regard to accurate simulation of work tasks. 3.5.3.4 Is it related to speci®c job requirements? The answer to this question depends upon the type of isokinetic device and how it is used. As discussed previously, isokinetic machines that test isolated muscle groups do not meet this criterion if the job requires use of many muscle groups or body segments. On the other hand, the Mini-Gym can be used to evaluate the dynamic strength necessary to perform many types of occupational tasks, and results of strength tests using this device appear to be related to lifting capacity, at least under certain conditions [72]. However, many industrial tasks are clearly too complicated to be evaluated using current isokinetic technologies. Great care must be taken to ensure that isokinetic strength measurements are appropriate for analysis of strength requirements associated with speci®c occupational tasks. 3.5.3.5 Does It Predict Risk of Future Injury or Illness? A recent prospective epidemiological investigation analyzed whether isokinetic lifting strength was able to predict those at risk of occupational low-back pain (LBP) [82]. Subjects were required to perform maximal whole-body lifting exertions using an isokinetic linear lift task device, and were then followed for two years to evaluate whether this measure of strength was predictive of those who would experience LBP. Results of this study indicated that isokinetic lifting strength was a poor predictor of subsequent LBP or injury. However, it should be noted that no attempt was made in this study to compare job strength requirements to individual strength capabilities. Whether isokinetic strength tests can be used to predict future LBP when a careful comparison of job demands and individual strength capacity is made has yet to be determined. 3.6

SUMMARY

In spite of advances in measurement techniques and an explosive increase in the volume of research, our understanding of human strength remains in its introductory stages. It is clear that muscle strength is a highly complex and variable function dependent on a large number of factors. It is not surprising, therefore, that there are not only large dierences in strength


between individuals, but even within the same individual tested repeatedly on a given piece of equipment. The issue is compounded by the fact that correlations of strength among dierent muscle groups in the same individual are generally low, and that tests of isometric strength do not necessarily re¯ect the strength an individual might exhibit in a dynamic test. As a result of these and other in¯uences, it is evident that great care needs to be exercised in the design, evaluation, reporting, and interpretation of muscular strength assessments. Traditionally, tests of muscular strength were in the domain of the orthopedist, physical therapist, and exercise physiologist. However, such tests are also an important tool for the ergonomist due to the high strength demands required of workers in manual materials handling tasks. In some cases, it has been shown that task demands may approach or even exceed the strength that an individual is voluntarily willing to exert in a test of strength. In such cases, there is evidence to suggest that the likelihood of injury is signi®cantly greater than when the task demands lie well within an individual's strength capacity. Because the relationship between strength capabilities, job demands, and musculoskeletal injury has been established, it becomes apparent that tests of muscular strength may be of bene®t to the ergonomist both in the design of jobs, and in ensuring that individuals have sucient strength to safely perform physically demanding jobs. Several dierent strength assessment techniques have been employed for these purposes, each possessing unique characteristics and applicability to job design and/or worker selection procedures. The main purpose of this chapter has been to elucidate these strengths and weaknesses of the various procedures, so that tests of strength may be properly applied in the design of jobs and the selection of workers. One of the crucial points emphasized in this chapter is that any test of strength used in job design or worker selection must be directly related to the demands of the job [89]. For example, if an occupational lifting task has a high dynamic component, a test of isometric strength is not likely to provide the data necessary for proper design of the job. Of course, use of dynamic strength tests to assess a job requiring isometric exertions would also be a misapplication. Another potential pitfall is the use of tests of strength on isolated muscle groups, and assuming that these tests are indicative of whole-body strength. For example, one might mistakenly assume that dynamic trunk extension strength is representative of a person's capability to


823

perform a lifting task. However, an individual's lifting capacity may be entirely unrelated to trunk extension strength. Instead, lifting capacity may be limited by an individual's arm or leg strength, depending upon the task being performed. It should be clear from the parts discussed in this chapter that tests of muscular strength are a tool that can be used in the prevention of occupational musculoskeletal disease. However, it is imperative that the use of these techniques be applied with a clear understanding of the advantages and limitations associated with each technique. The paragraphs that follow summarize the tests of muscular strength covered in this chapter. Isometric strength is de®ned as the capacity to produce force or torque with a voluntary isometric (muscles maintain a constant length) contraction. A characteristic of this type of strength measurement is the absence of body movement during the measurement period. Isometric strength testing has a long history, and it may be the easiest to measure and understand. The basic procedures for testing isometric strength are well established. Risk of injury appears to be small, and of relatively minor nature. Residual soreness of muscle groups tested is occasionally reported. Tests of isometric strength appear reliable, with test± retest variability on the order of 5±10%. The approach appears quite practical and has been applied in many industrial situations. The major limitation of isometric strength testing is in its inability to accurately model materials handling tasks that have a signi®cant dynamic component. It is therefore recommended that tests of isometric strength be applied when there is little or no dynamic movement involved. In spite of this limitation, it should be duly noted that of all the procedures reviewed in this chapter, tests of isometric strength are the only strength tests that have shown the ability to predict individuals with a high risk of future injury or illness on physically stressful jobs [89]. The accuracy of this prediction appears to be dependent on the quality of the job evaluation on which the strength tests are based, and on the care with which the tests are administered. Tests of isoinertial strength are de®ned as those in which the mass properties of an object are held constant, as in lifting a given weight (mass) over a predetermined distance. Several strength tests reviewed in this chapter possess the attribute in this de®nition. However, there are signi®cant philosophical and procedural dierences among the dierent isoinertial procedures in use, and the authors have subdivided isoinertial strength tests into maximal isoinertia strength tests [19,21,25], and psychophysical strength

824

Gallagher et al.

tests [12]. The following distinctions are made between these techniques: 1.

2.

3.

In maximal isoinertial strength tests, the amount of weight lifted by the subject is systematically adjusted by the experimenter. In contrast, in psychophysical tests, weight adjustment is freely controlled by the subject. Maximal isoinertial strength tests are designed to quickly establish an individual's maximal strength using a limited number of lifting repetitions, whereas psychophysical strength assessments are typically performed over a longer duration of time (usually at least 20 min), and instructions are that the subject select an acceptable (submaximal) weight of lift, not a maximal one. Maximal isoinertial strength tests have traditionally been used as a worker selection tool (a method of matching physically capable individuals to demanding tasks). A primary focus of psychophysical methods has been to establish data that can be used for the purpose of ergonomic job design [12].

Two primary maximum isoinertial strength tests have been described. One involves the use of a modi®ed weightlifting machine where a subject lifts a rack of unseen weights to various prescribed heights (often termed the LIFTEST). The other, the progressive isoinertial lifting evaluation (PILE), uses a standard lifting box, into which weights are placed incrementally until the lifting limit is reached. Both procedures appear to be safe to administer and remarkably free of injury. These techniques also appear to compare favorably to other strength tests in terms of test±retest reliability. Both tests are practical in that they require relatively inexpensive hardware, and can be administered quickly with minimal time needed for subject instruction and learning. The dynamic nature of the LIFTEST gives the procedure a similarity to certain industrial lifting tasks, and has correlated well with psychophysical test results [41]. A vast and expanding base of literature is devoted to psychophysical strength assessment. The psychophysical method, as applied to strength, has been used to determine maximum acceptable weights and forces associated with manual materials handling tasks for healthy adult male and female industrial workers [33,35]. The focus of this approach is to establish data that can be used to improve the design of manual materials handling activities. Psychophysical strength tests appear very safe, with isolated reports


of muscle strain. Psychophysical results are very reproducible and seem to be related to low back pain [34]. The cost of the procedure is extremely low, except in the time that it takes to administer the tests. Of all the strength techniques reviewed in this chapter, the psychophysical approach is the one best suited to simulating speci®c industrial work tasks. However, it should be noted that at high lifting frequencies, test subjects may select weights and forces that exceed manual materials handling limits based on metabolic or disk compression criteria. Furthermore, there is some question as to whether psychophysical lifting tests are sensitive to bending and twisting motions, which are often associated with the onset of low-back pain. At this time, the use of psychophysical methods of strength assessment for the prediction of future risk of injury, illness, impairment, or disability for an individual has not been validated. The characteristics of isokinetic strength tests are variable displacement and constant velocity of motion [71]. The majority of isokinetic devices focus on quantifying torques about isolated joints or body segments. Isolated joint testing may be most useful in rehabilitation or in clinical use, but is more limited in terms of evaluating occupational job demands. However, devices that measure isokinetic whole-body lifting strength, consisting of a handle connected by rope to a winch (which rotates at a speci®ed isokinetic velocity) have also been developed. Studies using this type of device have shown good correlations between an isokinetic lift from ¯oor to chest height and psychophysically acceptable weights for infrequent lifting tasks [72,74]. Given proper procedures and supervision, isokinetic strength tests appear to be a reasonably safe method of evaluating muscular strength and endurance. However, some investigators have indicated that low velocity isokinetic exertions may be painful [75]. There are numerous isokinetic devices on the market, and all appear to possess high reliability. The practicality of isokinetic strength testing may well hinge on the considerable cost associated with purchase of the equipment. Another issue in terms of practicality is the ability of isokinetic devices to easily simulate a variety of occupational tasks. Many industrial tasks are clearly too complicated to be evaluated using current isokinetic technologies. Thus far, prospective studies have shown that generic isokinetic lifting tests are poor predictors of future low back disorders [88]. Whether isokinetic tests can be used to predict injury or illness when careful comparisons of job demands and individual strength capabilities are performed has not yet been investigated.


A ®nal point on strength assessment should be made. An individual's strength capability cannot be considered a ®xed human attribute. Strength training regimens can increase an individual's strength capability by 30±40%. Whether such changes have a preventive eect when a person performs heavy physical work has yet to be established in epidemiologic studies; however, some anecdotal evidence supports the possibility [89]. REFERENCES 1. LS Caldwel, DB Chan, FN Dukes-Dobos, KHE Kroemer, LL Laubach, SH Snook, et al. A proposed standard procedure for static muscle strength testing. Am Ind Hyg Assoc J 35:201±206, 1974. 2. DB Chan. Ergonomics guide for the assessment of human static strength. Am Ind Hyg Assoc J 36:505± 511, 1975. 3. M Ikai, AH Steinhaus. Some factors modifying the expression of strength. J Appl Physiol 16:157±163, 1991. 4. KHE Kroemer, WS Marras, JD McGlothlin, DR McIntyre, M Nordin. On the measurement of human strength. Int J Indust Ergon, 6:199±210, 1990. 5. TJ Stobbe. The development of a practical strength testing program in industry. Unpublished PhD dissertation, University of Michigan, Ann Arbor, MI, 1982. 6. DB Chan, GBJ Andersson. Occupational Biomechanics. 2nd ed. New York: John Wiley and Sons, 464±466, 1991. 7. Troup, JDG, JW Martin, DCEF Lloyd, Back pain in industry. A prospective study. Spine 6:61±69, 1981. 8. MC Battie, SJ Bigos, LD Fisher, TH Hansson, ME Jones, MD Wortley. Isometric lifting strength as a predictor of industrial back pain. Spine 14:851±856, 1989. 9. RA Mostardi, DA Noe, MW Kovacik, JA Porter®eld. Isokinetic lifting strength and occupational injury: A prospective study. Spine 17(2):189±193, 1992. 10. DB Chan. Ergonomic basis for job-related strength testing. In: Disability Evaluation. SL Demeter, GBJ Anderson, GM Smith, eds. Louis, MO: Mosby, 1996, 159±167. 11. V Mooney, K Kenney, S Leggett, B Holmes. Relationship of Lumbar Strength in Shipyard Workers to Workplace Injury Claims. Spine 21:2001± 2005, 1996. 12. SH Snook. The design of manual handling tasks. Ergonomics 21 (12):963±985, 1978. 13. DB Chan, GBJ Andersson. Occupational Biomechanics. 2nd ed. New York: John Wiley and Sons, pp. 105±106, 1991. 14. FT Schanne. Three dimensional hand force capability model for a seated person. Unpublished PhD dissertation, University of Michigan, Ann Arbor, MI, 1992.


825 15. TJ Stobbe, RW Plummer. A test±retest criterion for isometric strength testing. Proceedings of the Human Factors Society 28th Annual Meeting, Oct 22±26, 1984, San Antonio, TX, pp. 455±459, 1984. 16. DB Chan, GD Herrin, WM Keyserline. Pre-employment strength testing: an updated position. J Occupat Med 20(6): 403±408, 1978. 17. WM Keyserling, GD Herrin, DB Chan. Isometric strength testing as a means of controlling medical incidents on strenuous jobs. J Occupat Med 22(5):332±366, 1980. 18. KHE Kroemer. Development of LIFTEST: A dynamic technique to assess the individual capability to lift material. Final Report, NIOSH Contract 210-79-0041. Blacksburg, VA: Ergonomics Laboratory, IEOR Department, Virginia Polytechnic Institute and State University, 1982. 19. KHE Kroemer. An isoinertial technique to assess individual lifting capability. Hum Factors 25(5):493±506, 1983. 20. KHE Kroemer. Testing individual capability to lift material: repeatability of a dynamic test compared with static testing. J Safety Res 16(1):1±7, 1985. 21. JW McDaniel, RJ Shandis, SW Madole. Weight lifting capabilities of Air Force basic trainees. AFAMRL-TR83-0001. Wright-Patterson AFBDH, Air Force Aerospace Medical Research Laboratory, 1983. 22. M Parnianpour, M Nordin, N Kahanovitz, V Frankel. The triaxial coupling of torque generation of trunk muscles during isometric exertions and the eect of fatiguing isoinertial movements on the motor output and movement patterns. Spine 13(9):982±992, 1988. 23. MM Ayoub, A Mital. Manual Materials Handling. London: Taylor and Francis, 1989, pp 241±242. 24. DB Chan, GBJ Andersson. Occupational Biomechanics. New York: John Wiley and Sons, 1991, pp 152±153. 25. TG Mayer, D Barnes, ND Kishino, G Nichols, RJ Gatchell, H Mayer, V Mooney. Progressive isoinertial lifting evaluationÐI. A standardized protocol and normative database. Spine 13(9):993±997, 1988. 26. BC Jiang, JL Smith, MM Ayoub. Psychophysical modelling of manual materials-handling capacities using isoinertial strength variables. Hum Factors 28(6):691±702, 1986. 27. LT Ostrom, JL Smith, MM Ayoub. The eects of training on the results of the isoinertial 6-foot incremental lift strength test. Int J Indust Ergon 6:225±229, 1990. 28. JM Stevenson, JT Bryant, SL French, DR Greenhorn, GM Andrew, JM Thomson. Dynamic analysis of isoinertial lifting technique. Ergonomics 33(2): 161±172, 1990. 29. DO Myers, DL Gebhardt, CE Crump, EA Fleishman. Validation of the Military Entrance Physical Strength Capacity Test (MEPSCAT). U.S. Army Research

826

30.

31. 32. 33.

34. 35. 36.

37. 38.

39. 40.

41. 42. 43. 44. 45. 46.

Gallagher et al. Institute Technical Report 610, NTIS No. AD-A142 169, 1984. TG Mayer, D Barnes, G Nichols, ND Kishino, K Coval, B Piel, D Hoshino, RJ Gatchell. Progressive isoinertial lifting evaluationÐII. A comparison with isokinetic lifting in a chronic low-back pain industrial population. Spine 13(8):998±1002, 1988. SS Stevens. On the psychophysical law. Psychol Rev 64:153±181, 1957. LA Jones. Perception of force and weight: Theory and research. Psychol Bull 100(1):29±42, 1986. SH Snook. Psychophysical acceptability as a constraint in manual workbility of the psychophysical approach to manual materials handling activities. Ergonomics 29:237±248, 1986. SH Snook. Psychophysical considerations in permissible loads. Ergonomics 28(1):327±330, 1985. SH Snook, VM Ciriello. The design of manual handling tasks: revised tables of maximum acceptable weights and forces. Ergonomics 34(9):1197±1213, 1991. MM Ayoub, NJ Bethea, S. Devanayagam, SS Asfour, GM Bakken, D Liles, A Mital, M Sherif. Determination and modeling of lifting capacity, ®nal report. HEW (NIOSH) Grant No. 5-RO1-OH-0054502. A Mital. Comprehensive maximum acceptable weight of lift database for regular 8 h shifts. Ergonomics 27:1127±1138, 1978. DD Thompson, DB Chan. Can biomechanically determined stress be perceived? Human Factors and Ergonomics Society, Proceedings of the 37th Annual Meeting, Seattle WA. 1993, pp 789±792. SH Snook. Approaches to the control of back pain in industry: Job design, job placement, and education/ training. Spine: State Art Rev 2:45±59, 1987. VM Ciriello, SH Snook, AC Blick, PL Wilkinson. The eects of task duration on psychophysically determined maximum acceptable weights and forces. Ergonomics 33:187±200, 1990. BC Jiang, JL Smith, MM Ayoub. Psychophysical modelling for combined manual materials-handling activities. Ergonomics 29(10):1173±1190, 1986. W Karwowski, JW Yates. Reliability of the psychophysical approach to manual materials handling activities. Ergonomics 29:237±248, 1986. A Mital. The psychophysical approach-in-manual liftingÐa veri®cation study. Hum Factors 25(5):485±491, 1983. SH Snook, RA Campanelli, JW Hart. A study of three preventive approaches to low back injury. J Occup Med 20(7):478±481, 1978. MM Ayoub, JL Selan, DH Liles. An ergonomics approach for the design of manual materials-handling tasks. Hum Factors 25(5):507±515, 1983. GD Herrin, M Jaraiedi, CK Anderson. Prediction of overexertion injuries using biomechanical and psycho-


47.

48.

49. 50. 51. 52. 53. 54.

55. 56. 57.

58. 59.

60.

61. 62. 63.

physical models. Am Ind Hyg Assoc J 47(6):322±330, 1986. SH Snook. Assessment of human strength: Psychophysical methods. Roundtable presentation at the American Industrial Hygiene Conference and Exposition, Boston, 1992. SJ Legg, WS Myles. Metabolic and cardiovascular cost, and perceived eort over an 8 hour day when lifting loads selected by the psychophysical method. Ergonomics 28(1):337±343, 1985. S Gallagher. Acceptable weights and psychophysical costs of performing combined manual handling tasks in restricted postures. Ergonomics 34(7):939±952, 1991. VM Ciriello, SH Snook. A study of size, distance, height, and frequency eects on manual handling tasks. Hum Factors 25(5):473±483, 1983. A Mital, MM Ayoub. Eect of task variables and their interactions in lifting and lowering loads. Am Ind Hyg Assoc J 42:134±142, 1981. SS Asfour, MM Ayoub, AM Genaidy. A psychophysical study of the eect of task variables on lifting and lowering tasks. J Hum Ergol 13:3±14, 1984. A Garg, A Mital, SS Asfour. A comparison of isometric and dynamic lifting capability. Ergonomics 23(1):13±27, 1980. A Mital, I Manivasagan. Maximum acceptable weight of lift as a function of material density, center of gravity location, hand preference, and frequency. Hum Factors 25(1):33±42, 1983. SJ Legg, DR Haslam. Eect of sleep deprivation on self selected workload. Ergonomics 27(4):389±396, 1984. JL Smith, BC Jiang. A manual materials handling study of bag lifting. Am Ind Hyg Assoc J 45(8):505±508, 1984. A Mital, HF Fard. Psychophysical and physiological responses to lifting symmetrical and asymmetrical loads symmetrically and asymmetrically. Ergonomics 29(10):1263±1272, 1986. A Mital. Maximum weights of asymmetrical loads acceptable to industrial workers for symmetrical lifting. Am Ind Hyg Assoc J 48(6):539±544, 1987. A Mital. Psychophysical capacity of industrial workers for lifting symmetrical loads and asymmetrical loads symmetrically and asymmetrically for 8 hour work shifts. Ergonomics 35(718):745±754, 1992. CG Drury, JM Deeb, B Hartman, S Wooley, CE Drury, S Gallagher. Symmetric and asymmetric manual materials handling. Part 1. Physiology and psychophysics. Ergonomics 32(5):467±489, 1989. SL Legg, CM Pateman. Human capabilities in repetitive lifting. Ergonomics 28(1):309±321, 1985. CG Drury, JM Deeb. Handle positions and angles in a dynamic lifting task. Part 2. Psychophysical measures and heart rate. Ergonomics 29(6):769±777, 1986. A Mital. Maximum acceptable weights of lift acceptable to male and female industrial workers for extended work shifts. Ergonomics 27(11):1115±1126, 1984.

Physical Strength Assessment in Ergonomics 64. JE Fernandez, MM Ayoub, JL Smith. Psychophysical lifting capacity over extended periods. Ergonomics 34(1):23±32, 1991. 65. A Mital, F Aghazadeh. Psychophysical lifting capabilities for overreach heights. Ergonomics 30(6):901±909, 1987. 66. A Mital, L-W Wang. Eects on load handling of restricted and unrestricted shelf opening clearances. Ergonomics 32(1):39±49, 1989. 67. A Mital. Patterns of dierences between the maximum weights of lift acceptable to experienced and inexperienced materials handlers. Ergonomics 30(8):1137± 1147, 1987. 68. JL Smith, MM Ayoub, JW McDaniel. Manual materials handling capabilities in non-standard postures. Ergonomics 35(7/8):807±831, 1992. 69. S Gallagher, WS Marras, TG Bobick. Lifting in stooped and kneeling postures: Eects on lifting capacity, metabolic costs, and electromyography of eight trunk muscles. Int J Ind Ergon 3:65±76, 1988. 70. S Gallagher, CA Hamrick. Acceptable workloads for three common mining materials. Ergonomics 35(9):1013±1031, 1992. 71. H Hislop, JJ Perrine. The isokinetic concept of exercise. Phys Therapy 47:114±117, 1967. 72. JL Pytel, E Kamon. Dynamic strength test as a predictor for maximal and acceptable lift. Ergonomics 24(9):663±672, 1981. 73. ND Kishino, TG Mayer, RJ Gatchel, MM Parish, C Anderson, L Gustin, V Mooney. Quanti®cation of lumbar function: Part 4: isometric and isokinetic lifting simulation in normal subjects and low-back dysfunction patients, Spine 10(10):921±927, 1985. 74. A Mital, R Vinayagormoothy. Three-dimensional dynamic strength measuring device: a prototype. Am Ind Hyg Assoc J 45:B9±B12, 1984. 75. DA Klopfer, SD Greij. Examining quadriceps/hamstrings performance at high velocity isokinetics in untrained subjects. J Orthop Sports Phys Therapy 10:18±22, 1988.


827 76. RC Elsner, LR Pedegana, J Lang. Protocol for strength testing and rehabilitation of the upper extremity. J Orthop Sports Phys Therapy 4:229, 1983. 77. American Academy of Orthopaedic Surgeons (AAOS). Human Performance Testing Task Force, October 1988. 78. J Johnson, D Siegel. Reliability of an isokinetic movement of the knee extensors. Res Q 49:88±90. 79. TV Pipes, JH Wilmore. Isokinetic vs. Isotonic strength training in adult men. Med Sci Sports Exercise 7:262± 271, 1975. 80. M Moroid, R Whipple, J Hofkosh, et al. A study of isokinetic exercise. Phys Therapy 49:735, 1969. 81. GE Molnar, J Alexander, N Gut®eld. Reliability of quantitative strength measurements in children. Arch Phys Med Rehab 60:218, 1979. 82. AA Sapega, JA Nicholas, D Sokolow, D., A Saraniti. The nature of torque `òvershoot'' in CYBEX isokinetic dynamometry. Med Sci Sports Exercise 14(5):368±375, 1982. 83. KE Wilk, RE Johnson. The reliability of the Biodex B200 (abstract). Phys Therapy 68:792, 1988. 84. M Farrell, JG Richards. Analysis of the reliability and validity of the , kinetic communicator exercise device. Med Sci Sports Exercise 18:44±49. 85. J Lord, S Aitkins, M McCrory, M., et al. Reliability of the Lido Digital Isokinetic system for the measurement of muscular strength (abstract). Phys Therapy 67:757, 1987. 86. KE Wilk, RE Johnson, et al. A comparison of peak torque values of knee extensor and ¯exor muscle groups using Biodex, Cybex, and Kin-Com isokinetic dynamometers. Phys Therapy 67:789, 1987. 87. KE Timm. Comparison of knee extensor and ¯exor group performance using the Cybex 340 and the Merac isokinetic dynamometers. Phys Therapy 69:389, 1989. 88. RA Mostardi, DA Noe, MW Kovacik, JA Porter®eld. Isokinetic Lifting Strength and Occupational Injury: A prospective study. Spine 17(2): 189±193.

Chapter 10.1 Engineering Economy Thomas R. Huston


1.1

INTRODUCTION

disbursements associated with an alternative. Such an assessment will consider the magnitude and timing of the receipts and disbursements. In¯ation and taxes may also be factors that enter into the economic evaluation of an alternative. The basic principles of engineering economics also provide methods for the comparison of alternatives and the subsequent selection of an optimal alternative. For example, an engineer may be confronted with the selection of machinery from a variety of sources. As another example, the engineer may face the economic decision of manufacturing a part versus purchasing a part. It should also be recognized that there are limitations to engineering economics. Certain problems may not have the potential to be evaluated properly in economic terms. Some problems may be highly complex wherein economics is a minor consideration. Still other problems may not be of sucient importance to warrant engineering economic analysis.

Engineering is the profession that is devoted to the application of scienti®c knowledge for practical purposes. Through the application of scienti®c knowledge, engineers are continually developing products, processes, and services for the bene®t of society. Engineers have been instrumental in many of the advances of society. For example, the state of modern transportation can be linked to the eorts of engineers. While undertaking such pursuits, the engineer is typically faced with a variety of alternatives. These alternatives may include material selections, the degree of computer automation, the selection of an applicable safety system, and the means of manufacturing. Each alternative will have inherent technical advantages and disadvantages that the engineer must evaluate. The evaluation of any alternative will also have to consider the constraints of the particular problem or project. The engineer will typically be well informed about the technical aspects of various alternatives. However, the engineer must also have a sound understanding of the economic feasibility of the various alternatives. Indeed, money is a scarce resource that must be allocated in a prudent fashion. This chapter provides a foundation in the basic principles of engineering economics. Through the application of these basic principles, the engineer will be able to address economic issues. One such issue is the economic feasibility of alternatives. Engineering economics oers a means to assess any receipts and

1.2

There are several fundamental concepts that form a foundation for the application of the methods of engineering economics. One fundamental concept is the recognition that money has a time value. The value of a given amount of money will depend upon when it is received or disbursed. Money possessed in the 829


ELEMENTARY CONCEPTS OF ENGINEERING ECONOMICS

830

present will have a greater value than the same amount of money at some point in the future. It would be preferable to receive $1000 in the present rather than receiving $1000 ®ve years hence. Due to the earning power of money, the economic value of $1000 received at the present will exceed the value of $1000 received ®ve years in the future. The $1000 received today could be deposited into an interest bearing savings account. During the intervening period of ®ve years, the $1000 would earn additional money from the interest payments and its accumulated amount would exceed $1000. The time value of money is also related to the purchasing power of money. The amount of goods and services that a quantity of money will purchase is usually not static. In¯ation corresponds to a loss in the purchasing power of money over time. Under the pressures of in¯ation, the cost of a good or service will increase. As an example, during the period of 1967 to 1997 the cost of a U.S. ®rst-class postage stamp rose to 32 cents from 5 cents. De¯ation is the opposite condition of in¯ation. Historically, in¯ationary periods have been far more common than periods of de¯ation. A fundamental concept that is related to the time value of money is interest. Money is a valuable commodity, so businesses and individuals will pay a fee for the use of money over a period of time. Interest is de®ned as the rental fee paid for the use of such a sum of money. Interest is usually quanti®ed by the interest rate where the interest rate represents a percentage of the original sum of money that is periodically applied. For instance, a ®nancial institution may charge 1% per month for a borrowed sum of money. This means that at the end of a month, a fee of 1% of the amount borrowed would have to be paid to the ®nancial institution. The periodic payment of interest on a loan represents a cash transaction. During such a transaction, a borrower would view the associated interest as a disbursement while the interest would be a receipt for the lender. In engineering economics analysis, a point of view must be selected for reference. All analysis should proceed from a sole viewpoint. Engineering economic analysis should also only consider and assess feasible alternatives. Alternatives that ordinarily would be feasible may be infeasible due to the particular constraints of a problem or project. A frequently overlooked alternative is the do-nothing alternative. Under the do-nothing alternative, the option of doing nothing is preferable to any of the other feasible alternatives.


Huston

It is the inherent dierences between alternatives that must be evaluated. Indeed it is the dierences in alternatives that will lead to the selection of an optimal alternative. Such an evaluation will utilize money as a common unit of measurement to discern the dierences between alternatives. The evaluation of alternatives should also utilize a uniform time horizon to reveal the dierences in alternatives. It is essential to recognize that any decisions about alternatives will only aect the present and the future. Therefore, past decisions and any associated costs should be ignored in engineering economic analysis. The associated costs from past decisions are known as sunk costs. Sunk costs are irrelevant in engineering economic analysis. 1.3 1.3.1

ECONOMIC EQUIVALENCE AND CASH FLOW FORMULAS Economic Equivalence

In engineering, two conditions are said to be equivalent when each condition produces the same eect or impact. The concept of equivalence also pertains to engineering economics. Two separate alternatives will have economic equivalence whenever each alternative possesses the same economic value. Any prospective economic equivalence between two alternatives will be dependent upon several factors. One factor is the respective magnitudes of the cash ¯ow for each alternative. Another factor is the timing of the receipts and disbursements for each alternative. A third factor is the interest rate that accounts for the time value of money. Through a combination of these factors, two cash ¯ows that dier in magnitude may possess the same inherent economic value. The concept of economic equivalence is revealed through the cash ¯ows associated with a routine loan. Suppose an individual borrowed $10,000 at 6% compounded annually to be repaid in annual instalments of $2374 over ®ve years. One cash ¯ow would be the sum of $10,000 at the present. The other cash ¯ow would entail ®ve annual payments of $2374 that totaled $11,870. Although each cash ¯ow occurs at distinct points in time and has a dierent magnitude, both cash ¯ows would be equivalent at the interest rate of 6% compounded annually. 1.3.2

Simple and Compound Interest

There are dierent ways in determining the amount of interest that a sum of money will produce. One way is simple interest. Under simple interest, the amount of

Engineering Economy

831

interest accrued, I, on a given sum of money, P, is calculated by I Pni

1

where P is the principal amount, n the number of interest periods, and i the interest rate. Hence with simple interest, a sum of money would increase to F P I P Pni

2

With simple interest, any interest earned during an interest period does not earn additional interest in forthcoming interest periods. In contrast, with compound interest, the interest is. determined by the principal sum of money and on any interest that has accumulated to date. So any previous interest will earn interest in the future. For example, if a sum of money, P, is deposited into an interest-bearing account at an interest rate, i, after one period the amount of money available, F, would be determined by F P1 i

3

If the sum of money were deposited for two periods, the amount of money available, F, would be determined by F P1 i1 i P1 i2

4

In general, the amount of money, F, that would accumulate with n additional periods would be F P1 in

5

Compound interest is more prevalent in ®nancial transactions than simple interest, although simple interest is often encountered in bonds. 1.3.3

Cash Flow Diagrams and End-of-Period Convention

In engineering, diagrams are frequently drawn to help the individual understand a particular engineering issue. A cash ¯ow diagram is often used to depict the magnitude and the timing of cash ¯ows in an engineering economics issue. A cash ¯ow diagram presumes a particular point of view. A horizontal line is used to represent the time horizon, while vertical lines from the horizontal line depict cash ¯ows. An upward arrow indicates a receipt of money, while a downward arrow is a disbursement (see Fig. 1). In this chapter, there is an assumption that cash ¯ows will be discrete and will occur at the end of a period. Continuous ¯ows of cash over a period will


Figure 1 Cash ¯ow diagram.

not be considered. An extensive discussion of continuous cash ¯ows is oered in the references. 1.3.4

Cash Flow Patterns

In ®nancial transactions, a cash ¯ow may undertake a variety of patterns. The simplest pattern is the single cash ¯ow. Under this cash ¯ow pattern, a single present amount is transformed into a single future amount (see Fig. 2). The uniform series is another cash ¯ow pattern. With this pattern, all of the cash ¯ows are of the same magnitude and the cash ¯ows occur at equally spaced time intervals (see Fig. 3). A cash ¯ow that increases or decreases by the same amount in each succeeding period would be a uniform gradient cash ¯ow pattern (see Fig. 4). Whereas, a cash ¯ow that increases or decreases by the same percentage in each succeeding period would be a geometrical gradient cash ¯ow pattern. (see Fig. 5).

Figure 2

Present amount and future amount.

832

Huston

Figure 3 Uniform series.

An irregular cash ¯ow pattern would occur whenever the cash ¯ow did not maintain one of the aforementioned regular patterns. Occasionally, a portion of an irregular cash ¯ow pattern may exhibit a regular pattern (see Fig. 6). In Fig. 6, the overall cash ¯ow pattern would be classi®ed as irregular but in the ®nal three years there is a uniform series pattern. Equivalent relationships between the various cash ¯ow patterns may be developed mathematically. Due to the time value of money, such relationships will be dependent upon the prevailing interest rates and the duration of the associated cash ¯ows. 1.3.5

Single-Payment Compound Amount Factor

Due to the time value of money, a single cash ¯ow, P, will increase over time to an equivalent future value, F. The future value, F, will depend upon the length of time, the prevailing interest rate, and the type of interest. If the single cash ¯ow, P, is invested at a constant compound interest rate, i, for a given number of interest periods, n, then the future value, F, will be determined by Eq. (5). Eq. (5) may be rewritten to introduce the following notation: F P1 in PFjP; i; n

Figure 4 Uniform gradient.

Figure 5 Geometrical gradient series.


6

The conversion factor, FjP; i; n, is referred to as the single-payment compound amount factor. It is interpreted as ``to ®nd the equivalent future amount, F, given the present amount, P, at the interest rate, i, for n periods.'' The single-payment compound amount factor, FjP; i; n, is simply the quantity (1 in . The evaluation of the single-payment compound amount factor is an easy calculation. Tabulated values of the single-payment compound amount factor for interest rates of 1%, 8%, and 10% may be found in Tables 1 to

Figure 6 Irregular cash ¯ow.

Engineering Economy

833

3. Note, other economic equivalence factors can also be found in Tables 1 to 3. Example 1. A sum of $5000 is deposited into an account that pays 10% interest compounded annually. To determine the future value of the sum of money 20 years hence, utilize Eq. (6): F $50001 0:1020 $33,637

1.3.6

Through simple algebra, Eq. (6) can be solved for P, wherein the resulting factor, PjF; i; n, is designated as the single-payment present worth factor: n

FPjF; i; n

7

Example 2. In the settlement of a litigation action, a boy is to receive a lump sum of $250,000 10 years in the future. What is the present worth of such a payment presuming an annual compound interest rate of 8%? P $250,0001 0:08

10

$115,798

Example 3. What annual rate of interest was earned if an investment of $11,000 produced a value of $21,000 after 10 years? F P1 i

$79,685 Sinking Fund Factor

Similarly, an equivalent uniform series cash ¯ow pattern, A, can be obtained from a single future cash ¯ow pattern, F: i AF 1 in 1 FAjF; i; n 1.3.9

9

Present-Worth Factor

It is often desirable to be able to relate a present amount, P, to a uniform series cash ¯ow pattern, A. The present worth factor converts a uniform series cash ¯ow pattern, A, to a single present amount, P. The formula for the present-worth factor is 1 in 1 PA i1 in A APjA; i; n 1.3.10

10

1 0:066 6:6%

Compound Amount Factor

Formulas can be derived that relate a single future cash ¯ow pattern, F, to a uniform series of cash ¯ow patterns, A. The equivalent future amount, F, that a uniform cash ¯ow pattern, A, will produce is 1 in 1 F A i AFjA; i; n

8

Example 4. A design engineer expects to collect $5000 per year on patent royalties. The patent remains in eect for the next 10 years. What is the future value of this


Capital Recovery Factor

The capital recovery factor is the reciprocal of the present-worth factor. This conversion factor transforms a single present amount, P, to a uniform series of cash ¯ows: i1 in AP 1 in 1

1:909 1 i10

1.3.7

$500015:937

n

$21,000 $11,0001 i10 i 1:9091=10

F AFjA; i; n $5,000FjA; 10%; 10

1.3.8

Single Payment Present-Worth Amount Factor

P F1 i

series of patent royalties if it is deposited into a fund that earns 10% compounded annually?

PAjP; i; n

11

Example 5. To purchase a new machine, a manufacturer secures a $50,000 loan to be paid o in annual payments over the next ®ve years. If the interest rate of the loan is 8% compounded annually, what is the periodic payment that the manufacturer must pay? A PAjP; I; n $50,000AjP; 8%; 5 $50,0000:2505 $12,525

Table 1 One Percent: Compound Interest Factors N 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 55 60 65 70 75 80 85 90 95

FjP

PjF

FjA

AjF

PjA

AjP

AjG

1.0100 1.0201 1.0303 1.0406 1.0510 1.0615 1.0721 1.0829 1.0937 1.1046 1.1157 1.1268 1.1381 1.1495 1.1610 1.1726 1.1843 1.1961 1.2081 1.2202 1.2324 1.2447 1.2572 1.2697 1.2824 1.2953 1.3082 1.3213 1.3345 1.3478 1.3613 1.3749 1.3887 1.4026 1.4166 1.4308 1.4451 1.4595 1.4741 1.4889 1.5038 1.5188 1.5340 1.5493 1.5648 1.5805 1.5963 1.6122 1.6283 1.6446 1.7285 1.8167 1.9094 2.0068 2.1091 2.2167 2.3298 2.4486 2.5735

0.99010 0.98030 0.97059 0.96098 0.95147 0.94205 0.93272 0.92348 0.91434 0.90529 0.89632 0.88745 0.87866 0.86996 0.86135 0.85282 0.84438 0.83602 0.82774 0.81954 0.81143 0.80340 0.79544 0.78757 0.77977 0.77205 0.76440 0.75684 0.74934 0.74192 0.73458 0.72730 0.72010 0.71297 0.70591 0.69892 0.69200 0.68515 0.67837 0.67165 0.66500 0.65842 0.65190 0.64545 0.63905 0.63273 0.62646 0.62026 0.61412 0.60804 0.57853 0.55045 0.52373 0.49831 0.47413 0.45112 0.42922 0.40839 0.38857

1.0000 2.0100 3.0301 4.0604 5.1010 6.1520 7.2135 8.2857 9.3685 10.4622 11.5668 12.6825 13.8093 14.9474 16.0969 17.2579 18.4304 19.6147 20.8109 22.0190 23.2392 24.4716 25.7163 26.9735 28.2432 29.5256 30.8209 32.1291 33.4504 34.7849 36.1327 37.4941 38.8690 40.2577 41.6603 43.0769 44.5076 45.9527 47.4123 48.8864 50.3752 51.8790 53.3978 54.9318 56.4811 58.0459 59.6263 61.2226 62.8348 64.4632 72.8525 81.6697 90.9366 100.6763 110.9128 121.6715 132.9790 144.8633 157.3538

1.00000 1.49751 0.33002 0.24628 0.19604 0.16255 0.13863 0.12069 0.10674 0.09558 0.08645 0.07885 0.07241 0.06690 0.06212 0.05794 0.05426 0.05098 0.04805 0.04542 0.04303 0.04086 0.03889 0.03707 0.03541 0.03387 0.03245 0.03112 0.02990 0.02875 0.02768 0.02667 0.02573 0.02484 0.02400 0.02321 0.02247 0.02176 0.02109 0.02046 0.01985 0.01928 0.01873 0.01820 0.01771 0.01723 0.01677 0.01633 0.01591 0.01551 0.01373 0.01224 0.01100 0.00993 0.00902 0.00822 0.00752 0.00690 0.00636

0.99010 1.97040 2.94099 3.90197 4.85343 5.79548 6.72819 7.65168 8.56602 9.47130 10.36763 11.25508 12.13374 13.00370 13.86505 14.71787 15.56225 16.39827 17.22601 18.04555 18.85698 19.66038 20.45582 21.24339 22.02316 22.79520 23.55961 24.31644 25.06579 25.80771 26.54229 27.26959 27.98969 28.70267 29.40858 30.10751 30.79951 31.48466 32.16303 32.83469 33.49969 34.15811 34.81001 35.45545 36.09451 36.72724 37.35370 37.97396 38.58808 39.19612 42.14719 44.95504 47.62661 50.16851 52.58705 54.88821 57.07768 59.16088 61.14298

1.01000 0.50751 0.34002 0.25628 0.20604 0.17255 0.14863 0.13069 0.11674 0.10558 0.09645 0.08885 0.08241 0.07690 0.07212 0.06794 0.06426 0.06098 0.05805 0.05542 0.05303 0.05086 0.04889 0.04707 0.04541 0.04387 0.04245 0.04112 0.03990 0.03875 0.03768 0.03667 0.03537 0.03484 0.03400 0.03321 0.03247 0.03176 0.03109 0.03046 0.02985 0.02928 0.02873 0.02820 0.02771 0.02723 0.02677 0.02633 0.02591 0.02551 0.02373 0.02224 0.02100 0.01993 0.01902 0.01822 0.01752 0.01690 0.01638

0.00000 0.49751 0.99337 1.48756 1.98010 2.47098 2.96020 3.44777 3.93367 4.41792 4.90052 5.38145 5.86073 6.33836 6.81433 7.28865 7.76131 8.23231 8.70167 9.16937 9.63542 10.09982 10.56257 11.02367 11.48312 11.94092 12.39707 12.85158 13.30444 13.75566 14.20523 14.65317 15.09946 15.54410 15.98711 16.42848 16.86822 17.30632 17.74278 18.17761 18.61080 19.04237 19.47231 19.90061 12.32730 20.75235 21.17578 21.59759 22.10778 22.43635 24.50495 26.53331 28.52167 30.47026 32.37934 34.24920 36.08013 37.87245 39.62648

834


Table 2 Eight Percent: Compound Interest Factors N 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 55 60 65 70 75 80 85 90

FjP

PjF

FjA

AjF

PjA

AjP

AjG

1.0800 1.1664 1.2597 1.3605 1.4693 1.5869 1.7138 1.8509 1.9990 2.1589 2.3316 2.5182 2.7196 2.9372 3.1722 3.4259 3.7000 3.9960 4.3157 4.6610 5.0338 5.4365 5.8715 6.3412 6.8485 7.3964 7.9881 8.6271 9.3173 10.0627 10.8677 11.7371 12.6760 13.6901 14.7583 15.9682 17.2456 18.6253 20.1153 21.7245 23.4625 25.3395 27.3666 29.5560 31.9204 34.4741 37.2320 40.2106 43.4274 46.9016 68.9139 101.2571 148.7798 218.6064 321.2045 471.9548 693.4565 1,018.9151

0.92593 0.85734 0.79383 0.73503 0.68058 0.63017 0.58349 0.54027 0.50025 0.46319 0.42888 0.39711 0.36770 0.34046 0.31524 0.29189 0.27027 0.25025 0.23171 0.21455 0.19866 0.18394 0.17032 0.15770 0.14602 0.13520 0.12519 0.11591 0.10733 0.09938 0.09202 0.08520 0.07889 0.07305 0.06763 0.06262 0.05799 0.05369 0.04971 0.04603 0.04262 0.03946 0.03654 0.03383 0.03133 0.02901 0.02686 0.02487 0.02303 0.02132 0.01451 0.00988 0.00672 0.00457 0.00311 0.00212 0.00144 0.00098

1.0000 2.0800 3.2464 4.5061 5.8666 7.3359 8.9228 10.6366 12.4876 14.4866 16.6455 18.9771 21.4953 24.2149 27.1521 30.3243 33.7502 37.4502 41.4463 45.7620 50.4229 55.4568 60.8933 66.7648 73.1059 79.9544 87.3508 95.3388 103.9659 113.2832 123.3459 134.2135 145.9506 158.6267 172.3168 187.1021 203.0703 220.3159 238.9412 259.0565 280.7810 304.2453 329.5830 356.9496 386.5056 418.4261 452.9002 490.1322 530.3427 573.7702 848.9232 1,253.2133 1,847.2481 2,720.0801 4,002.5566 5,886.9354 8,655.7061 12,723.9386

1.00000 0.48077 0.30803 0.22192 0.17046 0.13632 0.11207 0.09401 0.08008 0.06903 0.06008 0.05270 0.04652 0.04130 0.03683 0.03289 0.02963 0.02670 0.02413 0.02185 0.01983 0.01803 0.01624 0.01498 0.01368 0.01251 0.01145 0.01049 0.00962 0.00883 0.00811 0.00745 0.00685 0.00630 0.00580 0.00534 0.00492 0.00454 0.00419 0.00386 0.00356 0.00329 0.00303 0.00280 0.00259 0.00239 0.l00221 0.00204 0.00189 0.00174 0.00118 0.00080 0.00054 0.00037 0.00025 0.00017 0.00012 0.00008

0.92593 1.78326 2.57710 3.31213 3.99271 4.62288 5.20637 5.74664 6.24689 6.71008 7.13896 7.53608 7.90378 8.24424 8.55948 8.85137 9.12164 9.37189 9.60360 9.81815 10.01680 10.20074 10.37106 10.52876 10.67478 10.80998 10.93516 11.05108 11.15841 11.25778 11.34980 11.43500 11.51389 11.58693 11.65457 11.71719 11.77518 11.82887 11.87858 11.92461 11.96723 12.00760 12.04324 12.07707 12.10840 12.13741 12.16427 12.18914 12.21216 12.23348 12.31861 12.37655 12.41598 12.44282 12.46108 12.47351 12.48197 12.48773

1.08000 0.56077 0.38803 0.30192 0.25046 0.21632 0.19207 0.17401 0.16008 0.14903 0.14008 0.13270 0.12652 0.12130 0.11683 0.11298 0.10963 0.10670 0.10413 0.10185 0.09983 0.09803 0.09642 0.09498 0.09368 0.09251 0.09145 0.09049 0.08962 0.08883 0.08811 0.08745 0.08685 0.08630 0.08580 0.08534 0.08492 0.08454 0.08419 0.08386 0.08356 0.08329 0.08303 0.08280 0.08259 0.10823 0.08221 0.08204 0.08189 0.08174 0.08118 0.08080 0.08054 0.08037 0.08025 0.08017 0.08012 0.08008

0.00000 0.48077 0.94874 1.40396 1.84647 2.27635 2.69366 3.09852 3.49103 3.87131 4.23950 4.59575 4.94021 5.27305 5.59446 5.90463 6.20375 6.49203 6.76969 7.03695 7.29403 7.54118 7.77863 8.00661 8.22538 8.43518 8.63627 8.82888 9.01328 9.18971 9.35843 9.51967 9.67370 9.82075 9.96107 10.09490 10.22246 10.34401 10.45975 10.56992 10.67473 10.77441 10.86915 10.95917 11.04465 11.12580 11.20280 11.27584 11.34509 11.41071 11.69015 11.90154 12.06016 12.17832 12.26577 12.33013 12.37725 12.41158

835


Table 3 Ten Percent: Compound Interest Factors N 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 55 60 65 70 75 80 85 90 95 100

FjP

PjF

FjA

1.1000 1.2100 1.1300 1.4641 1.6105 1.7716 1.9487 2.1436 2.3579 2.5937 2.8531 3.1384 3.4523 3.7975 4.1772 4.5960 5.0545 5.5599 6.1159 6.7275 7.4002 8.1403 8.9543 9.8497 10.8347 11.9182 13.1100 14.4210 15.8631 17.4494 19.1943 21.1138 23.2252 25.5477 28.1024 30.9127 34.0039 37.4043 41.1448 45.2593 49.7852 54.7637 60.2401 66.2641 72.8905 80.1795 88.1975 96.0172 106.7190 117.3909 189.0591 304.4816 490.3707 789.7470 1,271.8954 2,048.4002 3,298.9690 5,313.0226 8,556.6760 13,780.6123

0.90909 0.82645 0.75131 0.68301 0.62092 0.56447 0.51316 0.46651 0.42410 0.38554 0.35049 0.31863 0.28966 0.26333 0.23939 0.21763 0.19784 0.17986 0.16351 0.14864 0.13513 0.12285 0.11168 0.10153 0.09230 0.08391 0.06728 0.06934 0.06304 0.05731 0.05210 0.04736 0.04306 0.03914 0.03558 0.03235 0.02941 0.02673 0.02430 0.02209 0.02009 0.01826 0.01660 0.01509 0.01372 0.01247 0.01134 0.01031 0.00937 0.00852 0.00529 0.00328 0.00204 0.00127 0.00079 0.00049 0.00030 0.00019 0.00012 0.00007

1.0000 2.1000 3.3100 4.6410 6.1051 7.7156 9.4872 11.4359 13.5796 15.9374 18.5312 21.3843 24.5227 27.9750 31.7725 35.9497 40.5447 45.5992 51.1591 57.2750 64.0025 71.4027 79.5430 88.4973 98.3471 109.1818 121.0999 134.2099 148.6309 164.4940 181.9434 201.1378 222.2515 245.4767 271.0244 299.1268 330.0395 364.0434 401.4478 442.5926 487.8518 537.6370 592.4007 652.6408 718.9048 791.7953 871.8749 960.1723 1,057.1896 1,163.9085 1,880.5914 3,034.8164 4,893.7073 7,887.4696 12,708.9537 20,474.0021 32,979.6903 53,120.2261 85,556.7605 137,796.1234


AjF 1.00000 0.47619 0.30211 0.21547 0.16380 0.12961 0.10541 0.08744 0.07364 0.06275 0.05396 0.04676 0.04078 0.03575 0.03147 0.02782 0.02466 0.02193 0.01955 0.01746 0.01562 0.01401 0.01257 0.01130 0.01017 0.00916 0.00826 0.00745 0.00673 0.00608 0.00550 0.00497 0.00450 0.00407 0.00369 0.00334 0.00303 0.00275 0.00249 0.00226 0.00205 0.00186 0.00169 0.00153 0.00139 0.00126 0.00115 0.00104 0.00095 0.00086 0.00053 0.00033 0.00020 0.00013 0.00008 0.00005 0.00003 0.00002 0.00001 0.00001

PjA

AjP

0.90909 1.73554 2.48685 3.16987 3.79079 4.35528 4.86842 5.33493 5.75902 6.14457 6.49508 6.81369 7.10336 7.36669 7.60608 7.82371 8.02155 8.20141 8.36492 8.51356 8.64869 8.77154 8.88322 8.98474 9.07704 9.16095 9.23722 9.30657 9.36961 9.42691 9.47901 9.52638 9.56943 9.60857 9.64416 9.67651 9.70592 9.72265 9.75696 9.77905 9.79914 9.81740 9.83400 9.84909 9.86281 9.87528 9.88662 9.89693 9.90630 9.91481 9.94711 9.96716 9.97961 9.98734 9.99214 9.99512 9.99697 9.99812 9.99883 9.99927

1.10000 0.57619 0.40211 0.31547 0.26380 0.22961 0.20541 0.18744 0.17364 0.16276 0.15396 0.14676 0.14078 0.13575 0.13147 0.12782 0.12466 0.12193 0.11955 0.11746 0.11562 0.11401 0.11257 0.11130 0.11017 0.10916 0.10826 0.10745 0.10673 0.10608 0.10550 0.10497 0.10450 0.10407 0.10369 0.10334 0.10303 0.10275 0.10249 0.10226 0.10205 0.10186 0.10169 0.10153 0.10139 0.10126 0.10115 0.10104 0.10095 0.10086 0.10053 0.10033 0.10020 0.10013 0.10008 0.10005 0.10003 0.10002 0.10001 0.10001

AjG 0.00000 0.47619 0.93656 1.38117 1.81013 2.22356 2.62162 3.00448 3.37235 3.72546 4.06405 4.38840 4.69879 4.99553 5.27893 5.54934 5.80710 6.05256 6.28610 6.50808 6.71888 6.91889 7.10848 7.28805 7.45798 7.61865 7.77044 7.91372 8.04886 8.17623 8.29617 8.40905 8.51520 8.61494 8.70860 8.79650 8.87892 8.95617 9.02852 9.09623 9.15958 9.21880 9.27414 9.32582 9.37405 9.41904 9.46099 9.50009 9.53651 9.57041 9.70754 9.80229 9.86718 9.91125 9.94099 9.96093 9.97423 9.98306 9.98890 9.99274

Engineering Economy

1.3.11

837

Uniform Gradient Series Factor

1.3.13

As previously discussed, a cash ¯ow series is not always uniform. Gradient series are frequently encountered in engineering economics. Formulas for conversion factors of gradient series have likewise been developed. Speci®cally, a uniform gradient series can be expressed as a uniform series of cash ¯ows by 1 in in 1 AG i1 in i AAjG; i; n 1.3.12

12

Geometrical Gradient Present-Worth Factor

Cash ¯ow series that increase or decrease by a constant percentage, g, with each succeeding period can be converted to a present amount by the geometric gradient present worth factor. A1 1 g*n 1 P 1 g g*1 g)n where

A1 PjA; g*; n 1g

1 i g* 1 g

13

1

Example 6. A manufacturer has established a new production line at an existing facility. It has been estimated that the additional energy costs for the new production line are $5,000 for the ®rst year and will increase 3% for each subsequent year. The production line is expected to have a life span of 10 years. Given an annual compound interest rate of 5% what is the present worth of the energy costs for the new production line? First calculate the value of g* given that g 3% and i 5%: 1 i 1:05 1 1 0:0194175 g* 1 g 1:03 then

A1 1 g*n 1 P 1 g g*1 g*n " # $5000 1:1019417510 1 1:03 0:01941751:019417510

P $43,738


Frequency of Compounding and Its Impact on Equivalence

Compounding periods may assume a variety of durations. Interest can be compounded annually, semiannually, quarterly, monthly, daily, or continuously. Perhaps, the most common compounding period is annual. Similarly, the ¯ow of funds also can occur over a variety of periods. For example, the periodic payments on a loan may be monthly. Hence, there are three conditions that can occur, concerning the frequency of the compounding periods and the frequency of the periods for the cash ¯ow. First, the frequency of the compounding periods and that of the cash ¯ow are synchronized. Secondly, the compounding periods are shorter than the periods for the cash ¯ow. Third, the compounding periods are longer than the corresponding periods of the cash ¯ow. If the periods of the compounding and the ¯ow of funds are synchronized, the aforementioned conversion factors can be utilized to determine any equivalent cash ¯ow. When the compounding periods and the periods of the cash lows are not synchronized, then intermediate steps to synchronize the periods must be undertaken prior to utilizing the aforementioned conversion factors. Example 7. What is the present value of a series of annual payments of $90,000 over 10 years at the rate of 12% compounded monthly? Convert i 1%/month to an eective annual interest rate: ie 1 0:0112

1 0:126825

P APjA; 0:126825; 10 1:12682510 1 $90,000 0:1268251:12682510

!

$494,622 For the condition where the compounding periods are less frequent than the cash ¯ows, it should be noted that interest is not earned on funds that are not on deposit for the entire interest period. To synchronize the timing of the ¯ows of funds with the compounding periods, any cash receipt or disbursement is moved to the end of its respective time period. With the movement of cash receipts and disbursements to the end of the time periods, economic equivalence can be determined with the use of the aforementioned conversion factors.

838

Huston

1.3.14

A $10,000AjP; 1%; 12 $10,0000:08885

Amortized Loans

The capital needed to ®nance engineering projects will not always be available through retained earnings. Indeed, money will often have to be borrowed. There are many types of loans that exist, but this chapter will focus upon the standard amortized loan. With an amortized loan, the loan is repaid through installments over time. The most prevalent amortized loan has monthly installments with interest that is compounded monthly. Also, the monthly installments are ®xed. Each installment consists of a portion that pays the interest on the loan and a portion that repays the outstanding balance. With each succeeding installment, the interest portion will diminish, while the portion devoted to the repayment of the outstanding balance will increase. The magnitude of an installment payment is determined through the use of the capital recovery conversion factor. In short, the payment, A, is found by A PAjP; i; n

14

Noting that each installment payment consists of an interest portion and a remaining balance portion, the following notation is introduced: Ij interest payment in period j Prj principal payment in period j Bj outstanding balance at end of period j The interest portion of any installment payment is simply the product of the outstanding balance times the prevailing interest rate: Ij Bj 1 i

15

The portion of the installment that may be applied to the outstanding balance: Prj A

Ij

16

Example 8. A consulting ®rm obtains a $10,000 loan to purchase a computer workstation. The terms of the loan are 12 months at a nominal rate of 12% compounded monthly. What is the monthly installment payment? How does the interest portion of the installment payment vary monthly? The installment payment is calculated by merely applying the capital recovery conversion factor, (AjP; i; n:


from Eq: 14 $888:50 The interest portion of the ®rst installment would be I1 B1 1 i $10,0000:01

from Eq: 15

$100:00 Hence, the portion of the ®rst installment applied to the principle would be the dierence between A and I1 : Pr1 A

I1 $888:50

100:00

from 16

$788:50 The new outstanding balance would be B1 $10; 000

788:50

$9211:50 Through an iterative process, the values for Ij and Bj can be found for the remaining 11 months. Obviously, the iterative nature of this problem is ideal for a computer application.

Installment no. 1 2 3 4 5 6 7 8 9 10 11 12

Payment ($)

Principal ($)

Interest ($)

Balance ($)

888.50 888.50 888.50 888.50 888.50 888.50 888.50 888.50 888.50 888.50 888.50 888.50

788.50 796.39 804.35 812.40 820.52 828.73 837.02 845.39 853.84 862.38 871.01 870.19

100.00 92.11 84.15 76.10 67.98 59.77 51.48 43.11 34.66 26.12 17.49 8.78

9211.50 8415.11 7610.76 6798.36 5977.34 5148.61 4311.59 3466.20 2612.36 1749.98 878.97 0.00

There are also formulas that enable one to determine the interest portion of any installment payment without having to engage an iterative solution: Ij Bj 1 i APjA; i; n

j 1i

17

The corresponding remaining balance after n j payments may also be found via the following formula: Bj APjA; i; n

j

18

Likewise, the principal payment for a particular installment would be obtained by subtracting the interest

Engineering Economy

839

paid for a particular installment from the periodic payment: Prj A

Ij

19

Returning to Example 8, the interest portion of the sixth payment may be found as follows: I6 APjA; i; n

j 1i

$888:50PjA; 1%; 12

6 10:01

$888:50PjA; 1%; 70:01

from Eq: 17

$888:506:72820:01 $59:77 1.4

ECONOMIC EVALUATION OF ALTERNATIVES

Often an engineer will be faced with the responsibility of determining the economic feasibility of various projects and propositions known as alternatives. In short, the engineer will have to make a decision on whether to proceed with an alternative. With a thorough understanding of cash ¯ow patterns and the compounding of interest, one may apply a variety of techniques to evaluate various alternatives. The application of these techniques requires that one be able to classify alternatives. Alternatives are classi®ed as independent whenever the decision to proceed with the alternative or to reject the alternative has no bearing on other prospective alternatives. For example, the decision for a consulting ®rm to purchase a new computer system would ordinarily be unrelated to the ®rm's decision as to whether the ®rm should utilize a particular long-distance carrier for its telecommunication system. Alternatives may also be classi®ed as mutually exclusive. Such a condition exists when there are a series of alternatives from which only one alternative may be selected. If an engineer had to select a machine for a workstation from three distinct machines each having unique ®rst costs, maintenance costs, and salvages, then this would be a condition where the alternatives were mutually exclusive. With mutually exclusive alternatives, the selection of an alternative prevents the selection of another alternative. Often when identifying alternatives, an individual must include the do-nothing alternative. The do-nothing alternative simply represents the opportunity to maintain the existing conditions. In many instances, after the careful evaluation of a series of alternatives,


the optimal decision will be to do-nothing or to maintain the existing conditions. The selection of the donothing alternative will preserve the scarce resource of capital. The comparison of various alternatives involves the estimation of cash ¯ows for each alternative. These estimated cash ¯ows also extend over several time periods. A decision will have to made as to the duration of the planning horizon. The planning horizon represents the time period over which the alternatives will be evaluated. The selection of the planning horizon is important. If the planning horizon is too short, one runs the risk of rejecting alternatives that are initially expensive but generate large returns in the future. Conversely, a planning horizon that is too long can result in an entity collapsing before it reaps any bene®ts from accepted alternatives. Further, the basic concept of time value of money must be incorporated into the evaluation of alternatives. This is accomplished through the selection of an interest rate that will be used to adjust the various cash ¯ows in the panning horizon. This interest rate has been identi®ed with a variety of names: minimum attractive rate of return (MARR), discount rate, return on capital, and cost of money. In this chapter, the term MARR will be used. The determination of the value of the MARR is important. The value of the MARR should not be arbitrarily assigned. The MARR should recognize the cost of capital and should compensate for the risk associated in adopting an alternative. If the MARR is set unnecessarily high, an entity may needlessly reject worthwhile projects. Similarly, if the MARR is set too low, an entity can be exposed to the potential of investing in projects that are expensive and wasteful. 1.4.1

Present-Worth Method

This technique for evaluating economic alternatives entails the conversion of any pertinent estimated cash ¯ows to the present. The cash ¯ows are converted by the methods previously discussed in this chapter. In short, all cash ¯ows are converted to an equivalent P pattern that is referred to as the present worth (PW). The conversions utilize a chosen MARR and a speci®ed planning horizon. Each alternative must be evaluated over the same planning horizon. If the economic alternative is an independent alternative, then the alternative is accepted by entity whenever the present worth has a value greater than zero.

840

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Example 9. A consulting company is considering undertaking a project. The initial cash outlay for the 10 year project would be $50,000. The project is estimated to yield $8000 per year for 10 years. If the MARR is 10%, should the project be undertaken? PW

$50,000 $8000PjA; 10%; 10

$50,000 $80006:1446

$843:20

Due to the negative present worth, this project should be rejected. When faced with mutually exclusive alternatives, the optimal alternative is the alternative with the highest present worth. Indeed, the present worth of each alternative can be used to rank the alternatives. It should also be noted that on occasion each of the mutually exclusive alternatives may have a negative present worth. In such a situation, one would select the alternative that was the least costly by choosing the alternative that had the highest present worth. Example 10. Two different machines are being considered by a manufacturing company. Due to constraints, the manufacturing company must select one of the two machines. Machine A has an initial cost of $75,000 and an estimated salvage of $25,000 after ®ve years. The annual operating costs for Machine A are assessed at $7500. Machine B has an initial cost of $50,000 and its salvage is negligible after ®ve years. Its operating costs are $9000 per year. Given a MARR of 10%, which machine should the company select?

1.4.2

Annual-Worth Method

This technique is similar to the present-worth technique. However, this technique involves the conversion of the estimated cash ¯ows into a uniform annual cash ¯ow that is known as the annual worth (AW). The conversion of the cash ¯ows is based on an identi®ed MARR and a speci®ed time horizon. Each alternative must be evaluated over the same planning horizon. An independent alternative will be accepted, if its annual worth exceeds zero. For mutually exclusive alternatives, the annual worth of each alternative provides a ranking. The alternative with the greatest annual worth is the optimal alternative. It is also possible, that each of the alternatives may have a negative annual worth. The best alternative still would be the alternative that had the greatest annual worth. This would be the least costly alternative. Example 11. Two different machines are being considered by a manufacturing company. Due to constraints, the manufacturing company must select one of the two machines. Machine A has an initial cost of $75,000 and an estimated salvage of $25,000 after ®ve years. The annual operating costs for Machine A are assessed at $7500. Machine B has an initial cost of $50,000 and its salvage is negligible after ®ve years. Its operating costs are $9000 per year. Given a MARR of 10%, which machine should the company select? Utilize the annual worth approach. Machine A: AW

$25,000AjF; 10%; 5

Machine A: PW

$75,000AjP; 10%; 5

$75,000 $25,000PjF; 10%; 5 $7500PjA; 10%; 5

PW

$75,000 $25,0000:6209

PW

$87,909

$75003:7908

AW

$7500

$75,0000:2638 $25,0000:1638 $7500

AW

$23,190

Machine B:

Machine B: PW

$50,000

$9000PjA; 10%; 5

PW

$50,000

$90003:7908

PW

$84,117

Therefore, Machine B is preferred over Machine A.


AW

$50,000AjP; 10%; 5

AW

$50,0000:2638

AW

$22,190

$9000

$9000

Hence, Machine B is preferred to Machine A. Also note the consistency between the annual worth and presentworth methods. See Example 10.

Engineering Economy

1.4.3

841

Rate of Return Method

For independent alternatives, this technique relies on the concept of determining the interest rate where an alternative's receipts will be equivalent to its disbursements. The interest rate is known as the rate of return (ROR). The rate of return is then compared to the MARR. If the rate of return exceeds the MARR, then the alternative is viewed favorably and funds are expended for it. Example 12. A consulting company is considering undertaking a project. The initial cash outlay for the project would be $50,000. The project is estimated to yield $8000 per year for 10 years. If the MARR is 10%, should the project be undertaken? Solve using the rate-of-return approach. The ROR is the interest rate where PW 0

$50,000 $8000PjA; i; 10

PWi 10%

$50,000 $80006:4177 $1341 $50,000 $80006:1446

$843

Thus ROR is between 9 and 10%. Using interpolation the ROR is found to be 9.6%. The project is rejected because the ROR (9.6%) is less than the MARR (10%). Note the consistency between methods of evaluating alternatives. See Example 9. For mutually exclusive alternatives, the optimal alternative is not decided from the individual rates of return of each alternative. Rather, an incremental analysis is employed. The incremental analysis compares pairs of alternatives. First, the alternatives are ranked according to the initial investments. Then for the alternative that has the smallest initial investment, its rate of return is calculated. Provided that its rate of return is greater than the MARR, then it is accepted as viable alternative. The viable alternative is then compared to next most expensive alternative. The comparison is based on the incremental additional investment and the incremental additional cash ¯ows. If the incremental investment yields a rate of return greater than the MARR, then the more expensive alternative is selected. Conversely, if the incremental investment does not have a rate of return greater than the MARR, then the more expensive alternative is rejected. This pairwise comparison continues until all of the alternatives have been examined.


First cost ($)

Annual income ($)

Salvage value ($)

500 400 300 250

61 60 50 61

375 250 250 0

A B C D

If the MARR is 8%, and utilizing the incremental rate of return approach, which alternative if any should be selected? Alternative D vs. Do-nothing: PW

Via trial and error: PWi 9%

Example 13. Consider four mutually exclusive alternatives, each of which has an eight-year useful life:

$250 $61PjA; 8%; 8 $250 $6155:7466 $100:54

Conclude that the incremental ROR > MARR; hence accept Alternative D and reject do-nothing. Alternative C vs. Alternative D: PW $300

$250 $50

$61PjA; 8%; 8

$50 $115:7466 $21:86

Conclude that the incremental ROR > MARR; hence accept Alternative C and reject Alternative D. Alternative B vs. Alternative C: PW $400 $60

$300 $50PjA; 8%; 8

$100 $105:7466

$42:53

Conclude that the incremental ROR < MARR; hence reject Alternative B and keep Alternative C. Alternative A vs. Alternative C: PW $500

$300 $61

$50PjA; 8%; 8

$200 $115:7466 $136:78 Conclude that the incremental ROR < MARR; hence reject Alternative A and keep Alternative C. Through the pairwise comparison of the incremental ROR, Alternative C is accepted as the optimal alternative.

842

1.4.4

Huston

Bene®t±Cost Ratio

This technique operates on the simple concept that in order for an alternative to be deemed worthwhile it bene®ts must outweigh its costs. To make such a comparison requires that the bene®ts and costs be presented in equivalent economic terms. Ordinarily, the bene®ts and costs are expressed as either equivalent P patterns or equivalent A patterns. These equivalent P patterns or A patterns are determined using a given MARR and a stated planning horizon. For independent alternatives, the bene®ts are then compared to the costs by means of a ratio. If the ratio of bene®ts to costs exceeds unity, then the alternative should be accepted. Example 14. A local government is evaluating a construction proposal for a roadway. The initial cost of the roadway is $1,650,000. It is estimated that the annual maintenance costs on the roadway will be $75,000. The estimated annual bene®ts to be derived from the roadway are $310,000. The useful life of the roadway is 20 years without a salvage. Using the bene®t±cost approach, should the road be constructed with a 10% MARR? Annual projected bene®ts: $310,000 Annual project costs:

This incremental pairwise comparison continues until all alternatives have been examined. 1.4.5

Payback Method

This is a technique that is often used due to its simplicity and its ease of application. In short, the payback method determines the length of time for an alternative to pay for itself. Under the most common form of the payback method, any relevant cash ¯ows are not adjusted for their inherent time value. For mutually exclusive alternatives, the optimal alternative would be the one with the shortest payback. There are inherent disadvantages to this common form of the payback method. It ignores the time value of money. Also, the common form of the payback method ignores the duration of the alternatives. Example 15. Examine the following four alternatives. Note that each alternative has a payback period of two years. However, the alternatives are obviously not equivalent.

Year end 0 1 2 3 4 5

$1,650,000AjP; 10%; 20 $75,000 $1,650,0000:1175 $75,000 $269,075 Bene®t±cost ratio:

Alt. I ($) 1500 750 750 750 750 750

Alt. II ($) 1500 500 1000 1500 2000 2500

Alt. III ($)

Alt. IV ($)

1500 1000 500 0 0 0

1500 0 1500 1500 1500 1500

B $310,000 1:15 C $269,075 Based on the bene®t±cost ratio being greater than 1, the roadway should be constructed. Mutually exclusive alternatives require an incremental analysis. One cannot select the optimal alternative by merely examining individual bene®t±cost ratios. Initially, the alternatives are ranked in ascending order of equivalent ®rst costs. The ®rst viable alternative is then found by selecting the alternative with the smallest initial costs that has an individual bene®t±cost ratio greater than 1. Once a viable alternative is found, then any remaining alternatives are evaluated on a pairwise basis to analyze whether additional costs are justi®ed by the additional bene®ts. Throughout this procedure, once a viable alternative is found, it remains the alternative of choice unless the incremental pairwise analysis yields a superior alternative. Then the superior alternative becomes the alternative of choice.


Another form of the payback method is known as the discounted payback method. Here, the cash ¯ows are converted by means of a MARR. The alternatives are then evaluated by the length of time that it takes for the alternative to pay for itself. However, the discounted payback method still fails to account for the duration of the alternatives. Both payback methods provide estimates that may be useful in explaining economic alternatives. However, due to the inherent ¯aws with these methods, it is recommended that the payback methods only be used as an ancillary technique. 1.5

AFTER-TAX ANALYSIS

The consideration of taxes must often be included in the evaluation of economic alternatives. In such an

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843

evaluation, taxes are simply another expenditure. Indeed, an alternative that may initially appear to be viable may lose its viability with the inclusion of taxes. The magnitude of this taxation depends upon the prevailing federal, state, and local tax laws. These tax laws have been passed by legislatures so that these governments can operate. Taxation occurs in many dierent forms. A partial listing of various forms of taxation includes federal income tax, state income tax, local income tax, local property tax, state and local sales tax, federal excise tax, and federal and state gasoline tax. The topic of taxes is complex. Tax laws are continually changing due to political forces and underlying economic conditions. In this chapter, the concentration will be upon federal income taxes. The techniques introduced will be applicable notwithstanding the inconstant nature of taxes. 1.5.1

Depreciation

The term depreciation has several meanings. In one sense, depreciation refers to the deterioration of an asset. For example, as a machine ages, its downtime will often increase and its overall productivity will diminish. Similarly, depreciation can be equated with obsolescence. A desktop computer from the mid-1980s is obsolete in the late 1990s. However, in engineering economics, the concept of depreciation that is utilized by accountants is adopted. Depreciation is simply the accounting procedure that amortizes the cost of an asset over the estimated life of the asset. In short, the cost of an asset is not expensed at the time of purchase but rather is rationally spread throughout the useful life of the asset. Such a concept is adopted because this concept of depreciation is utilized in the calculation of federal income taxes. It should be noted that depreciation does not represent a cash ¯ow. Rather it is an accounting procedure. Heretofore, all of the economic analysis has concentrated upon cash ¯ows. Depreciation must be included in any after-tax economic analysis because depreciation will aect the amount of taxes owed. There are some basic terms associated with depreciation. Book value, BVj , denotes the undepreciated value of an asset. The cost basis of an asset is usually the acquisition cost. Hence, the book value is the difference between the cost basis and the accumulated depreciation costs. The book value is given in the following formula: BVj CB

D1 D2 Dt


20

where BVj is the book value, CB is the cost basis, and Dt is the depreciation charge for year t. The salvage value of an asset is the estimated value of an asset at the end of its estimated life. Over the years, a variety of methods have been used to calculate depreciation charges. These methods are prescribed by the Internal Revenue Service (IRS). Prior to 1981, the permissible depreciation methods were straight-line, declining balance, and sum-of years digits. The Economic Recovery Tax Act of 1981 introduced the accelerated cost recovery system (ACRS). In 1986, the Tax Reform Act again modi®ed allowable depreciation methods with the introduction of the modi®ed accelerated cost recovery system (MACRS). This chapter will examine the MACRS method of depreciation. The MACRS applies to assets placed in service after December 31, 1986. The references oer rigorous examinations of the other depreciation methods for assets placed in service prior to December 31, 1986. The MACRS categorizes assets into eight classi®cations known as the recovery period: 3-year, 5-year, 7year, 10-year, 15-year, 20-year, 27.5-year, and 39-year. The IRS has guidelines that determine into which classi®cation an asset should be placed. These guidelines are found in the IRS Publication 946 How to Depreciate Property [1]. Table 4 gives examples of some common assets and their pertinent recovery periods. For each MACRS classi®cation, the IRS has speci®c depreciation rates. The depreciation rates are the recovery allowance percentages. The MACRS method also uses a half year convention so that all property is treated as if it were placed into service at the midyear. Hence, depreciation charges exist for an additional tax year beyond the class designation. For instance, 3-year property will be allocated over four tax years. Table 5 sets forth the recovery allowance percentages for the various classi®cations. The depreciation charges then for any given year depend upon the acquisition cost and the appropriate recovery allowance percentage. The depreciation charge is then simply the product of the acquisition cost and the appropriate recovery allowance percentage. Example 16. A computer system with an initial cost of $20,000 is purchased in 1997 by an engineering consulting company. Compute the allowable annual depreciation charges and the corresponding book values. Computers are classi®ed as having a 5-year recovery period.

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Table 4 MACRS Classi®cations of Depreciable Property Classi®cation

Property

3-year

Fabricated metal products; special handling devices for food and beverage manufacture; tractor units for over-the-road use; certain livestock Automobiles; light and heavy trucks; computers and copiers; equipment used in research and experimentation; equipment used in oil wells All other property not assigned to another classi®cation; of®ce furniture and equipment; single-purpose agricultural structures; railroad track; telephone station equipment Assets used in petroleum re®ning; assets used in manufacture of castings, forgings, tobacco, and certain food products; vessels and water transportation equipment Waste-water plants; telephone distribution equipment; industrial steam and electrical generation equipment; railroad wharves and docks; storage tanks Municipal sewers; barges and tugs; electrical power plant Residential rental property Nonresidential rental property

5-year 7-year 10-year 15-year 20-year 27.5-year 39-year

Table 5 MACRS Recovery Allowance Percentages Recovery year

3-year class

5-year class

7-year class

10-year class

15-year class

20-year class

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21

33.33% 44.45 14.81 7.41

20.00% 32.00 19.20 11.52 11.52 5.76

14.29% 24.49 7.49 12.49 8.93 8.92 8.93 4.46

10.00% 18.00 14.40 11.52 9.22 7.37 6.55 6.55 6.56 6.55 3.28

5.00% 9.50 8.55 7.70 6.93 6.23 5.90 5.90 5.91 5.90 5.91 5.90 5.91 5.90 5.91 2.95

3.750% 7.219 6.677 6.177 5.713 5.285 4.888 4.522 4.462 4.461 4.462 4.461 4.462 4.461 4.462 4.461 4.462 4.461 4.462 4.461 2.231


Engineering Economy

845

D1 $20,0000:20 $4000 BV1 $20,000

4000 $16,000

D2 $20,0000:32 $6400 BV2 $16,000

6400 $9600

D3 $20,0000:192 $3840 BV3 $9600

3840 $5760

D4 $20,0000:1152 $2304 BV4 $5760

2304 $3456

D5 $20,0000:1152 $2304 BV5 $3456

2304 $1152

D6 $20,0000:0576 $1152 BV6 $1152

1.5.2

1152 $0

Income Tax Rates

Federal income tax rates for both corporations and individuals have varied over the years. Note, the top federal income tax rate for an individual in 1970 was 70%, while in 1995 it was 39.6%. The income tax rates are also graduated so that the rate depends upon the taxable income. In 1997, a corporation with a taxable income of $40,000 was taxed at the rate of 15%, whereas the corporation with a taxable income of $1,000,000 would be taxed at the 34% level for all taxable income over $335,000. In engineering economic analysis an eective income tax rate is usually used. The eective incometax rate is simply a percentage. The product of the eective income tax rate and the taxable income then yields the tax owed. The concept of an eective income tax rate often combines the federal, state, and local income tax rates. 1.5.3

Factors Affecting Taxable Income

The taxable income re¯ects the quantity from which income taxes are determined. Therefore, the taxable income includes before-tax cash ¯ows such as income and expenses. Also, included in the taxable income are any applicable depreciation charges. Recall, these depreciation charges are not cash ¯ows. Depreciation charges will further reduce the taxable income and in turn reduce the tax liability.


Loans are commonly used to ®nance business operations. The interest paid on such loans is ordinarily viewed as an expense by the federal government. Hence, any interest paid on a loan by a corporation would be deductible from the taxable income. Note, only the interest payments on a loan and not the principal portion is deductible. In essence, this reduces the eective cost of borrowing through the alleviation of tax liability. 1.5.4

After-Tax Analysis

In order to proceed with an after-tax analysis on an alternative there are several preliminary considerations. The MARR must be established. The MARR used for after-tax analysis should not be the same MARR used for before-tax analysis. The eective income tax rate must be identi®ed. Remember that the eective income tax rate is often based upon the prevailing federal, state, and local income tax rates. If necessary, the appropriate depreciation method and associated depreciation charges must be calculated. Similarly, any relevant interest on loans must be determined. Also, the length of the time horizon needs to be set. The underlying concept is to try to calculate an after-tax cash ¯ow for each period within the time horizon. After securing these after-tax cash ¯ows, then one can proceed to utilize any of the previously mentioned means of evaluating alternatives. For example, an after-tax present-worth analysis is simply where the present-worth technique is applied to the after-tax cash ¯ows. Similarly, an after-tax rate of return utilizes the rate-of return technique on after-tax cash ¯ows. The following example illustrates the procedures for completing an after-tax cash ¯ow analysis. Example 17. With the purchase of a $100,000 computer system, a consulting ®rm estimated that it could receive an additional $40,000 in before-tax income. The ®rm is in the 30% income tax bracket and expects an after-tax MARR of 10%. If the funds for the computer are borrowed on a 4-year direct 8% reduction loan with equal annual payments, what is the present worth of the after-tax cash ¯ow? First ®nd the annual loan payment: A PAjP; 8%; 4 $100,0000:3019 $30,190 Then determine the interest paid each year on the loan:

846

Huston

Ij APjA; j; n

j 1i

from Eq: 17

The taxable income is calculated by summing the beforetax amount, the interest paid, and the depreciation expense [add columns (2), (4), and (5)]. The taxes paid are simply the product of the taxable income and the tax rate. The after-tax cash ¯ow is then the sum of the before-tax, the principal paid, the interest paid, and taxes paid [add columns (2), (3), (4), and (7)]. The after-tax column then is analyzed for its present worth:

I1 $30,190PjA; 8%; 40:08 $30,1903:31210:08 $7999 I2 $30,190PjA; 8%; 30:08 $30,1902:57710:08 $6224

PW $6210PjF; 10%; 1 $9277PjF; 10%; 2

I3 $30,190PjA; 8%; 20:08

$28,000PjF; 10%; 10

$30,1901:78330:08 $4307

PW $6,2100:9091 $9,2770:8265 $28,0000:3856

I4 $30,190PjA; 8%; 10:08

PW $104; 700

$30,1900:92590:08 $2236 Note that computers are classi®ed as having a 5-year recovery period. Hence, the annual depreciation expenses are:

1.6

D1 $100,0000:20 $20,000 D2 $100,0000:32 $32; 000 D3 $100,0000:192 $19,200 D4 $100,0000:1152 $11,520 D5 $100,0000:1152 $11,520 D6 $100,0000:0576 $5760 Construct a table to calculate the after-tax cash ¯ow (amounts in dollars):

Year (1)

Before tax (2)

Prin. paid (3)

Int. paid (4)

1 2 3 4 5 6 7 8 9 10

40,000 40,000 40,000 40,000 40,000 40,000 40,000 40,000 40,000 40,000

22,191 23,966 25,883 27,954 0 0 0 0 0 0

7,999 6,224 4,307 2,236 0 0 0 0 0 0


Therefore the project is sound.

INFLATION

The purchasing power of money is not static over time. Prices for goods and services are rarely constant from one year to the next. With in¯ationary pressures, the cost of goods and services increases with time. Whereas, decreasing prices would signify the condition of de¯ation. Recall that the time value of money is based upon the earning power of money and also the purchasing power of the money. When evaluating alternatives or computing economic equivalence, it is often desirable to separate the earning power of money from its purchasing power. In short, an `ìn¯ation-free'' analysis is frequently preferred.

Deprec. expense (5) 20,000 32,000 19,200 11,520 11,520 5,760 0 0 0 0

Taxable income (6) 12,001 1,776 16,493 26,244 28,480 34,240 40,000 40,000 40,000 40,000

Taxes paid (7)

After tax (8)

3,600 533 4,948 7,873 8,544 10,272 12,000 12,000 12,000 12,000

6,210 9,277 4,862 1,937 31,456 29,728 28,000 28,000 28,000 28,000

Engineering Economy

1.6.1

847

Measures of In¯ation

Indexes of in¯ation are frequently used to monitor changes in prices. The Consumer Price Index (CPI) is perhaps the most widely referenced index of in¯ation. Indexes of in¯ation are merely weighted averages of a series of goods and services. The index then tracks how the prices of the goods and services vary from period to period. Care should be undertaken in the selection of an in¯ation index. One should verify that a particular in¯ation index is tracking the factors that are needed for a particular analysis. For example, rises in the cost of groceries may not be a signi®cant factor to an equipment manufacturer. An in¯ation index will have a base year or time period. Subsequent changes in price are measured against the base year or period. For example, the CPI has a base year of 1967 with a value of 100.00. In 1990, the CPI index had a value of 391.4. This indicates that comparable goods and services that cost $100 in 1967 would have cost $391.40 in 1990. With the selection of an appropriate in¯ation index, it is possible to analyze economic alternatives on an in¯ation-free basis. Such an approach requires that one convert all of the cash ¯ows to a particular year or time period based on the in¯ation index. Once the conversion has been made, then an alternative can be evaluated using any of the previously mentioned techniques for the evaluation of alternatives. However, one must still include a means to account for the time value of money based upon the earning power of money. This interest rate is generally called the in¯ation-free interest rate and is denoted as i 0 . Example 18. In 1985, a manufacturing company invested in a new process that cost $4,500,000. In the subsequent four years, the net pro®t after taxes made by the facility, along with the price index was: Year

Net pro®t (actual $)

Price index (1967 100)

1985 1986 1987 1988 1989

Ð 2,200,000 1,700,000 1,900,000 1,500,000

322.2 328.3 340.4 354.4 371.4

If the in¯ation-free rate of return, i 0 , was 3%, determine the present worth of the investment in 1985 dollars. Was the investment a sound one?


First express net pro®t in terms of 1985 dollars: 322:2 2,159,122 1986 : $2,200,000 328:3 3:22 1987 : $1,700,000 1,609,107 340:4 322:2 1988 : $1,900,000 1,727,370 354:4 322:2 1989 : $1,500,000 1,301,292 371:4 Then ®nd present worth: PW

$4,500,000 $2,159,122PjF 0 ; 3%; 1 $1,609,107PjF 0 ; 3%; 2 $1,727,370PjF 0 ; 3%; 3 $1,301,292PjF 0 ; 3%; 4

$4,500,000 $2,159,1220:9709 $1,609,1070:9426 $1,727,3700:9152 $1,301,2920:8885 $1,850,123 Thus, the investment was sound. 1.6.2

Average In¯ation Rate

A diculty associated with an in¯ation index is that the index tracks past in¯ationary patterns. It will not necessarily give reliable estimates of future in¯ationary trends. Also, from the examination of an in¯ation index, it is obvious that in¯ation is rarely constant. Hence, an average in¯ation rate is often used to account for the variation in the in¯ation rates over a number of years. An average in¯ation rate can be calculated from an in¯ation index by the following equation: Indext 1 f n Indextn 1.6.3

21

Actual and Constant Dollars

In any analysis where in¯ation is taken into account, there are a few fundamental terms and relationships that must be understood. Constant dollars represent money where the money has been adjusted for in¯ationary eects. Cash ¯ow patterns may be expressed in constant dollars. A notation with a prime superscript often denotes a constant dollar cash ¯ow pattern. For

848

Huston

instance, an F 0 would denote a constant dollar future cash ¯ow. Actual or current dollars represent a monetary value that incorporates both in¯ation and the earning power of money. Estimates in actual dollars represent the true sums of money that one could anticipate to receive or disburse. The in¯ation-free interest rate, i 0 , is an estimate of the earning power of money without in¯ation, whereas the market interest rate, i, combines the earning power of money and the eects of in¯ation. The market interest rate is what one will encounter in common everyday experiences. The interest rate on a standard mortgage is an example of a market interest rate. The in¯ation-free interest rate, the market interest rate, and the average in¯ation rate are related by the following equation: 0

0

i i f i f

22

Therefore, a series of cash ¯ows can then be expressed either in constant dollars or in actual dollars. The conversion from actual dollars to constant dollars in any given period would be accomplished by multiplying by the following factor: Constant dollarn Actual dollarn 1 f

n

23 Similarly, the conversion from constant dollars to actual dollar utilizes this factor: Actual dollarn Constant dollarn 1 f n

24

For after-tax analysis where the average in¯ation rate is estimated, it is recommended that the subject cash ¯ows be converted to actual dollars. Such a conversion will enable one to readily assess the pertinent tax liabilities. There are two approaches for a before-tax analysis with in¯ation. One approach calls for all of the cash ¯ows to be expressed in terms of actual dollars with the subsequent analysis to use the market interest rate, i. Under the second approach, all of the cash ¯ows are expressed in terms of constant dollars with the subsequent analysis utilizing the in¯ation-free interest rate, i 0 . Example 19. A manufacturing corporation is constructing a new production line. The associated production costs for the new line are estimated at $2.5 million.


Over the ensuing years, the production costs are expected to increase $100,000 per year in actual dollars. The yearly in¯ation rate is presumed to be 4% and the market interest rate is 8%. Given a life span of 10 years, ®nd the annual worth of the production costs in terms of constant dollars. Recall, i i 0 f i 0f 0

from Eq: 22 0

0:08 i 0:04 i i 0 0:04 Via algebra, i 0 0:03846 Next ®nd the annual worth of production costs in actual dollars: A A1 GAjG; 8%; 10 A $2,500,000 100,0003:8713 A $2,887,130 Convert to present worth: P $2,887,130PjA; 8%; 10 P $2,887,1306:7101 P $19,372,931 Convert to constant annual worth using i 0 3:846%: A 0 $19,372,931A 0 jP; 3:846%; 10 A 0 $19,372,9310:12234

from Eq: 11

0

A $2,370,250=year

REFERENCES EL Grant, WG Ireson, RS Leavenworth. Principles of Engineering Economy. New York: John Wiley & Sons, 1990. IRS Publication 946. How to Depreciate Property. Washington DC: United States Government Printing Of®ce, 1997. DG Newnan, B Johnson. Engineering Economic Analysis. San Jose, CA: Engineering Press, 1995. GJ Thuesen, WJ Fabrycky. Engineering Economy. Englewood Cliffs, NJ: Prentice Hall. CS Park. Contemporary Engineering Economics. Menlo Park, CA: Addison-Wesley, 1997.

Chapter 10.2 Manufacturing-Cost Recovery and Estimating Systems Eric M. Malstromy and Terry R. Collins


2.1

INTRODUCTION

The chapter concludes by discussing how high levels of manufacturing automation impact the processes of manufacturing cost estimating and recovery.

This chapter overviews cost recovery and estimating systems typically used by manufacturing organizations. The chapter begins by overviewing conventional manufacturing-cost estimating systems. Cost centers are described, as are types of costs and use of performance standards in making cost estimates. Process design and its eect on manufacturing costs is addressed, as is the integration of learning curves into estimating procedures. Contingency allowances are addressed, as is the concept of making cost reviews or re-estimates based on the progress of a manufacturing project. Conventional cost recovery systems are next described. In these systems direct labor is used as a recovery basis variable. Concepts of capital budgeting are introduced as are subsequent adjustments of obtained labor/overhead rates. Quick-response estimating is next described with an emphasis on cost variable identi®cation and construction of estimating relationships. The relationship to group technology and production mix/volume scenarios is addressed as well. Cost estimating software development concepts are introduced. The merits of purchasing commercially available software versus inhouse software development are described. Activity based costing is described in some detail. Topics include mechanics of the recovery procedure, and the identi®cation and selection of cost drivers.

2.2

Manufacturing-cost estimating is a topic that has not enjoyed high visibility in university curricula. In 1981, only three books existed that addressed this subject in sucient depth to permit them to be used is textbooks for university courses on this subject [1±3]. In 1981, almost no university faculty specialized in the ®eld of cost estimating. This continues to be true at present. The result has been limited availability of suitable texts on this subject. To be an eective cost estimator requires prior industrial experience. Comparatively few university faculty members have signi®cant work experience outside academia. Consequently, scant academic research on this subject has, or is being accomplished. 2.2.1

Cost Estimating De®ned

Cost estimating may be described as the process by which a forecast of costs required to manufacture a product or complete a speci®ed task can be made. The estimate consists of the costs of people, materials, methods, and management. The accuracy of a cost

y Deceased. 849


CONVENTIONAL COST ESTIMATING PROCEDURES

850

Malstrom and Collins

estimate is a function of the degree of design or project de®nition available at the time the estimate is made. The more ®nalized and ®rm the design and de®nition, the more accurate the estimate is likely to be. Estimate accuracy is also a function of the time and resources that the estimator has available to compile a bid. Accuracy may also be aected by the quantity of units that are to be fabricated or produced. 2.2.2

Role of Engineers in Cost Estimating

Engineers have had historically a limited role in the cost estimating process. Few engineering curricula have formal courses on this subject. Good estimating skills require detailed knowledge of an organization's product line, production facilities, and manufacturing processes. In many cases nondegreed personnel who have formal shop ¯oor experience have better backgrounds with which to perform cost estimating tasks. Engineers have a professional need to be knowledgeable about estimating procedures [11]. They need this knowledge to specify cost-eective designs. Often engineers assume managerial positions which encompass or oversee the estimating function. 2.2.3

Basic Steps in the Estimating Process

The steps in compiling a cost estimating include determining whether each part in the bill of materials of an end item should be made in-house or purchased. This is followed by preliminary process sequence planning and the subsequent tallying of labor and material costs. Dependent costs must also be determined and tallied. These include the costs of indirect labor and overhead, manufacturing engineering, and inspection/ quality control. Finally, an appropriate contingency allowance must be determined and included. 2.2.4

Types of Manufacturing Costs

Two of the most basic types of manufacturing costs are direct labor and direct material [1, 4]. Direct labor is the cost of all ``hands-on'' eort to manufacture a product. Typical direct labor activities include machining, assembly, inspection, testing, and troubleshooting. Direct material is the cost of all components and raw materials included in the end product that is be produced. The sum of direct labor and direct material is often referred to as prime cost. Factory expenses may be de®ned as the total costs for rent, heat, electricity, water, expendable factory supplies, and indirect labor. Factory cost is often


de®ned as the sum of prime cost plus factory expenses. General expenses are the costs of design engineering, purchasing, oce sta salaries, and depreciation. Manufacturing cost is the sum of general expenses plus factory cost. Sales expenses are all costs incurred in selling and delivering the end product. These include the cost of advertising, sales commission, and shipping costs. Total costs may be de®ned as the sum of sales expense plus manufacturing cost. Finally, the selling price of the end product is the sum of the total costs plus the organization's desired pro®t margin. 2.2.5

Performance Standards

Performance standards are the best prior estimate of the length of time a labor task is likely to require. Such standards can therefore be applied to determine the labor content of a manufacturing cost estimate. Principal data sources for work standards are from time study analyses and predetermined time systems. The role of and use of performance standards in making cost estimates is described in more detail in Refs. 1 and 4. 2.2.6

Cost Centers and Shop Orders

Cost estimating requires the use of both cost centers and shop orders. Often organizational divisions and departments are de®ned by numerical codes. For example, if a three-digit code is used, the hundreds digit might be used to indicate a department. The tens digit can be used to designate a division within an department. Finally, the units digit may denote a branch within a division within a department. Some sample organization codes indicating both departments and divisions are illustrated in Table 1. Cost estimating requires establishing an audit trail for charge tracability. An account number is used to determine where in the organization a labor charge has occurred. The cost center is often a numerical subset of the account number and re¯ects all or part of the organization code of the department, division, or branch in which the labor charge has occurred. A job order is basically a project number re¯ecting which manufacturing project has been or should be ``billed'' for labor or material charges. A shop order is an authorization to perform work on a given cost center. A shop order code is usually alphanumeric in format. The alpha pre®x of the shop order code re¯ects the type of manufacturing eort on a given cost center

Manufacturing-Cost Recovery and Estimating Systems Table 1 Sample Organization Codes Organizational name

Assigned code

Manufacturing Department Manufacturing Engineering Division Assembly Division Assembly Division Comptroller Department Quality Control Department Quality Engineering Division Inspection Division Standards and Calibration Division Industrial Relations Department Marketing Department Engineering Department Product Design Engineering Division Research and Development Engineering Division

200 210 220 230 300 400 410 420 430 500 600 700 710 720

that is being performed. A labor charge on a manufacturing project is thus made in conjunction with a cost center, a job order, and a shop order. The cost center speci®es where in the organization the work was performed. The job order speci®es which manufacturing project was or should be billed for the charge. Finally, the shop order indicates what type of manufacturing eort is being performed on the project.

Table 2

851

Example cost centers and shop orders are illustrated in Table 2. Readers desiring more detailed information on cost centers, job orders, and shop orders should consult Refs. 1 and 4.

2.2.7

Making the Initial Cost Estimate

Initial cost estimates are those made prior to the start of production. They are important as their accuracy sets the pro®t/loss position of the ®rm. The process begins by reviewing the bill of materials or part explosion structure of the end item to be manufactured. A determination must initially be made on an item-byitem basis as to whether each individual component should be purchased or fabricated in-house. Usually these determinations are made on the basis of which alternative is less expensive. The cost estimator must anticipate the process sequence for each part in the bill of materials which is to be fabricated. Prior shop experience of the estimator is vital in accurately anticipating the process sequence that will be used to actually make each part. The preliminary sequence is speci®ed by generating a sketch process routing for each ``make'' part. This routing contains:

Example Cost Centers and Shop Orders

Cost center 21 Manufacturing Engineering

22 Machining

23 Assembly

42 Inspection 43 Standards and Calibration 70 Engineering


Activity

Shop order code

Process Tool design Generation of NC tapes Packaging Chip turning Sheet metal Tool fabrication and maintenance Painting Plating Heat treating Rework Assembly Testing Wire cutting Troubleshooting Rework Encapsulation Inspection of purchased parts Inspection of fabricated parts Mechanical and electronic calibration Engineering support to manufacturing

M-XXXXX D-XXXXX N-XXXXX K-XXXXX C-XXXXX S-XXXXX V-XXXXX P-XXXXX L-XXXXX H-XXXXX R-XXXXX A-XXXXX T-XXXXX W-XXXXX G-XXXXX R-XXXXX J-XXXXX B-XXXXX F-XXXXX O-XXXXX E-XXXXX

852


The anticipated sequence of manufacturing operations The departmental location for each operation The required machines and equipment for each routing operation A brief description of each production operation The applicable shop order and cost center Estimated setup and ``per piece'' run times for each operation. The estimated times are obtained from performance standards or time study analyses. Alternately, some machine cycle times are often estimated from formulae. 2.2.8

The Contingency Allowance

The contingency allowance is an estimate supplement used to account for work content and materials that are expected to occur, but cannot be accurately anticipated or accounted for at the time the initial cost estimate is made. The contingency allowance varies with both the degree of initial design de®nition and the time available to make the estimate. Vernon [3] has de®ned seven separate estimate classes as a function of the type and quantity of information available at the time the estimate is made. These classes are illustrated in Table 3. Malstrom [1, 4] has described typical contingency allowance percentages as a function of estimate con®dence and design de®nition. These percentages are summarized in Table 4.

2.2.9

Aggregating Labor and Material Costs

Malstrom [1, 4] has discussed how labor and material costs are aggregated for compilation of initial estimate totals. Labor hours are tallied by shop order within cost centers. Each cost center has a separate and often dierent labor overhead rate determined by the capital budgeting process (described later). The labor/ overhead (LOH) rate for each cost center converts labor hours into labor dollars and overhead dollars. Material costs are aggregated and totaled by individual cost centers as well. The labor, overhead, and material cost dollars are totaled for each cost center. The sum of these cost totals over all cost centers is the estimated production cost (EPC). The contingency allowance is expressed as a ®xed percentage of the EPC. The EPC plus the dollar magnitude of the contingency allowance is the estimated total cost (ETC). Adding pro®t to the ETC results in the total bid cost that can be submitted to a prospective customer. Malstrom has illustrated how to summarize these costs on an estimate grid. This grid is illustrated in Fig. 1. 2.3

COST REVIEWS

A cost review is a follow-on cost estimate of a manufacturing task that has already begun and is in process at the time the cost review is made. The time required to complete a cost review is signi®cant and approxi-

Table 3 Information De®ning Numerical Estimate Classes Estimate class Description of data

1

2

3

4

5

6

7

General design speci®cation, quantity, and production rate Assembly drawings Proposed subassemblies Detailed drawings and bill of materials Test and inspection procedures/equipment Machine tool and equipment requirements Packaging/transportation requirements Manufacturing routings Detailed tool, machine, gage and equipment lists Operation analysis and workplace studies Standard time data Material release data Subcontractor cost and delivery date Area and building requirements

X X X X X X X X X X X X X X

X X X X X X X X X X X X X

X X X X X X X X

X X X X X X X

X X X

X X

X

Source: Ref. 3.


Manufacturing-Cost Recovery and Estimating Systems Table 4 Estimate Classes Class A B C D F

X

De®nition Excellent con®denceÐrepeat job, excellent de®nition, no major changes anticipated. Good con®denceÐnew design, ®rst build, good de®nition, some design changes anticipated. Contingency 10±20%. Average con®denceÐpreliminary or partial design, verbal information, changes anticipated. Contingency 20±30%. ``Ball park'' estimatesÐde®nition very sketchy and preliminary, many unknowns several design changes anticipated. Contingency 30±40%. BudgetingÐan estimate prepared only for the purpose of budgeting funds. Contingency allowance levels vary depending on design de®nition. Directed estimateÐa modi®cation of any previous cost estimate to conform to budget cuts and restrictions which are not based on scope decisions. Adjustments may be increases or reductions in the allowance or in any cost element as directed by top management decisions.

mates the level of eort required to compile an initial cost estimate. Consequently, cost reviews are generally performed only on those jobs where ®scal de®cits or surplus are expected to occur. The procedure begins by selecting a review date. This date is a ``snapshot'' of the project's ®scal status at a given point in time. Prior to the review date are actual expenditures on the project which have occurred. After the review date are those expenditures expected to occur up until the project being reviewed is expected to be completed. The mechanics of the cost review procedure are illustrated in the cost review grid illustrated in Fig. 2. This grid lists all cost centers on which direct labor expenditures are expected to occur. The procedure begins by recording all labor hour charges that have occurred, by shop order, prior to the review date. Each cost center has four distinct rows. The Estimated row contains estimated labor hours and costs from the most recent prior cost estimate or review for each of the cost centers. The Expended row contains dollar expenditures for labor and material by cost centers. The labor dollar expenditures correspond to the labor hours expended by shop order for each cost center. These hourly entries are entered, by shop order in the Used column for each cost center.


853

The cost analyst next estimates the required hours to complete the project for each cost center by shop order. These hour entries are placed in the To Comp. column for each cost center and shop order. Material dollar expenditures required for project completion are estimated for each cost center as well. The material dollar expenditures are entered in the To Complete row for each cost center in the Material column of the grid. Next, labor and overhead rates are entered in the To Complete row for each cost center. These rates may be higher than those used in the most recent prior cost estimate or review. The To Comp. hours are then totaled by shop order and entered in the Hrs. column of the To Complete row for each cost center. The totals in the Hrs. column of the To Complete row are multiplied by the labor and overhead rates for each cost center. These dollar totals are entered Labor and Overhead columns of the To Complete row for each cost center. The next step is to add the entries of the Expended and To Complete rows. The resultant sums are placed in the Total row of each cost center as illustrated in Fig. 2. The information is next transferred to the cost estimate grid illustrated in Fig. 3. The hour entries from the Used column of Fig. 2 are transcribed to the Hrs. Exp. to Date column of Fig. 3 by both shop order and cost center. The hour entries from the To Comp. column of Fig. 2 are transferred to the Hrs. to Compl. column of Fig. 3 by shop order and cost center. Hour and dollar entries from the Total row of Fig. 2 are next transcribed to the Direct Labor Hours, Labor, Overhead, Material, and Total Cost columns of Fig. 3 by cost center. The entries in the Total Cost column of Fig. 3 are summed. The contingency allowance and pro®t margin are adjusted as necessary depending on whether a cost de®cit or surplus is projected to occur. Readers desiring a more detailed description of the cost review process are urged to consult Refs. 1 and 4. 2.4

LEARNING CURVES

Learning or product improvement curves re¯ect decreasing labor costs as the production quantity completed increases. These decreases re¯ect the eects of both human learning and process improvements associated with the startup of production. 2.4.1

Learning Curves De®ned

Learning curves may be described by

854


Figure 1 Cost estimate grid.

Y KX n

1

where K Time in hours required to produce the first unit: X Total units manufactured n A negative exponent which determines the percent by which Y decreases each time X is doubled Y The cumulative average time per unit to build a quantity of X units The de®nitions above are for cumulative average learning curves. Unit learning curves also exist and may be used for cost analysis purposes. With unit curves, Y is de®ned as the time in hours required to build the Xth unit. The remaining variables described above are the


same for both types of curves. Readers desiring more detailed descriptions of learning curves are urged to consult Refs. 1, 4, 5, 6, and 13. 2.4.2

Learning-Curve Considerations in Estimating Procedures

Cost estimates are dependent on labor hours derived from work or labor standards. Without exception, work or time standards are derived from constant ``time per unit'' values. The eects of process improvement and human learning are usually not directly considered in labor standard development. To eectively integrate the eects of learning into estimating procedures, it is necessary to determine at what quantity level on the learning curve the standard time is reached. Construction of actual learning curves requires the determination of both K and n in Eq.

Manufacturing-Cost Recovery and Estimating Systems

855

Figure 2 Cost review grid.

(1). The nature of labor standard development makes this determination dicult in practice. An alternate approach is to compile historical ratios of actual to standard hours after manufacturing tasks are complete. These ratios can be compiled and aggregated by both shop order type, production quantity, and product type or family. Multivariate linear regression can be used to determine mathematical functions which specify predicted ratios of actual to standard hours by shop order as functions of both production quantity and product type or family. These ratios may be used as multipliers for hourly totals by shop order compiled by the estimating methods previously described. The eects of learning curves will be embedded in these multipliers. 2.5

CAPITAL BUDGETING

Capital budgeting may be de®ned as the way in which individual labor/overhead rates are determined for each cost center. Most capital budgeting procedures utilize direct labor as a recovery basis variable. The procedure


is to estimate the required overhead that must be charged in addition to the direct labor for each cost center, to recover the cost of both indirect labor and burden associated with the operation of a manufacturing facility. The capital budgeting procedure has been described in some detail by Malstrom [5] and is reproduced in some detail in the sections that follow. 2.5.1

Components of LOH Rates

The labor/overhead rate for any cost center has four distinct components [12]. The ®rst of these is the direct labor rate. The direct labor rate is the composite average of all direct labor wages (including bene®ts) on the cost center being analyzed. The second component is the expense rate. The expense rate is the sum of all indirect labor dollars estimated to be expended in a budgetary quarter divided by the total number of direct labor hours estimated to be expended during that same quarter. Burden is the cost, in dollars, of rent, utilities, building/equipment depreciation, and expendable supplies

856


Figure 3

Revised cost estimate grid.

for any budgetary quarter. Finally, general and administrative costs are the cost of top executives' salaries and centralized plant computing facilities. The labor/ overhead rate for any cost center may be described by LOHCC LD ER B G&A

The mechanics of the capital budgeting process are best illustrated with an example. This example is the subject of the following section and has been adapted from Ref. 5.

2 2.5.2

where LOHCC The labor=overhead rate for a specific cost center in dollars=hr LD The direct labor rate; dollars=hr ER The expense rate; dollars=hr B Burden in dollars=hr G&A General and administrative cost rate in dollars=hr The dollar amounts for burden and general administrative costs expected to be expended during any quarter are divided by the total number of direct labor hours to be expended to determine the burden and G&A cost rates in Eq. (2).


A Capital Budgeting Example

Consider a manufacturing plant with a total of 1000 employees. Suppose it is desired to determine the labor/overhead rate for the machining cost center 22. For example purposes we will assume that cost center 22 has a total of 200 employees. Of this total we will further assume that 150 are involved with direct labor activities. To begin our analysis, we need to know the rest of the cost centers that exist and the respective number of employees in the plant that are associated with them. These stang levels are illustrated in Table 5. In Table 5, there are a total of four cost centers on which direct labor is performed. These include cost centers 21, 22, 23, and 42 which are Manufacturing Engineering, Machining, Assembly, and Inspection respectively.

Manufacturing-Cost Recovery and Estimating Systems Table 5 Employee Staf®ng Levels by Cost Center Description

Number of employees

Manufacturing Engineering Machining Assembly Comptroller Quality Engineering Inspection Standards and Calibration Personnel Marketing Design Engineering Research and Development

100 200 200 50 50 50 50 50 100 100 50

Cost center 21 22 23 30 41 42 43 50 60 71 72

Total 1000

Each of these four cost centers contain some indirect labor employees as well. Some examples of this indirect labor would be supervisory and secretarial personnel. The remaining cost centers in Table 5 support directly labor activities and contain only indirect labor employees. We wish to determine the labor/overhead rate associated with cost center 22. Let us assume that 40 hours exist in each work week. Assume further that there are exactly four weeks in each month and that a budgetary quarter consists of three months. Then the number of direct labor hours worked each quarter on cost center 22 is 40 hr=week 4 weeks=month 3 months 4780 hr Total number of work hours per quarter

857

costs that need to be recovered. The ®rst is the cost of indirect labor on cost center 22 itself. The second is the cost of indirect labor on pure indirect labor costs centers that support the manufacturing activities of cost center 22. The average salary levels of indirect labor employees, by cost center, are summarized in Table 6. The average indirect salary on cost center 22 is $28,000 per year. We need to recover one-fourth of this amount for the next quarter for the 50 indirect employees who work in cost center 22. This amount is $7000=employee 50 employees $350,000 The indirect labor cost centers in Table 5 are cost centers 30, 41, 43, 50, 60, 71, and 72. Direct labor cost centers 21, 23, and 42 also have indirect costs. However, these costs are recovered through the labor/overhead rates that will be determined and associated with these cost centers. The indirect labor cost centers support all four of the direct labor cost centers. A common way to amortize these costs over the direct labor cost centers is on the basis of the total number of employees (direct and indirect) on each of the direct labor cost centers. From Table 5, cost centers 21, 22, 23, and 42 have employee totals of 100, 200, 200, and 50, respectively. According to the proration logic, pure indirect labor cost centers support the direct labor cost centers proportionately on the basis of people. Therefore, the percentage for cost center 22 would be determined as 200=100 200 200 50 200=550 The total number of employees on each of the four cost centers are used since the other pure indirect labor cost centers support all of cost center 22, not just the direct

488 hr=employee 150 direct labor employees 72,000 hr 2.5.3

Direct Labor Determination

Our ®rst step is to determine the direct labor rate, LD , in Eq. (2). This term is merely a composite average of all of the direct labor hourly wage rates, including bene®ts, on this cost center. For example purposes we will assume that this average is $10.00 per hour. 2.5.4

Expense Rate Determination

The expense rate in Eq. (2) recovers the cost of indirect labor employees. There are two types of indirect labor


Table 6 Average Salary Levels of Indirect Employees Cost center 21 22 23 30 41 42 43 50 60 71 72

Description Manufacturing Engineering Machining Assembly Controller Quality Engineering Inspection Standards and Calibration Personnel Marketing Design Engineering Research and development

Average salary level ($) 32,000 28,000 28,000 32,000 36,000 28,000 32,000 36,000 40,000 44,000 48,000

858


labor activities. The total indirect costs to be recovered are summarized in Table 7. Column 6 in Table 7 includes no entries for cost centers 21, 23, and 42 because these indirect costs will be captured in their entirety when the budgeting process is repeated for these cost centers. There is no entry in the same column for cost center 22 because the procedure assumes that cost center 22 must pay for all of its own indirect costs. This is applicable for all cost centers that include direct labor activities. The expense rate, ER , for the cost center may now be determined. The total of the entries in column 6 of Table 7 is $1,599,916. The indirect costs on cost center 22 ($350,000) are added to this total. This sum is divided by the total number of direct labor hours expected to be worked in cost center 22 during the quarter (72,000 hr. The result is ER

2.5.5

$350,000 $1,599,916 $27:08=hr 72,000 hr

center 22 on the basis of the total number of employees on each of the direct labor cost centers. We assume that the burden on cost center 22 is $500,000 and that the total burden for the quarter on all of the indirect labor cost centers is $1,000,000. The burden rate then is calculated as Total Burden $500,000 $1,000,000 200=550 $863; 636 Burden Rate B $863,636=72,000 hr $11:99=hr 2.5.6

G&A Determination

We assume that the total dollar value of G&A to be recovered for the budgetary any quarter is $400,000. This amount is prorated on the basis of total direct employees and is charged to cost center 22 as $400,000 200=550 $145,440 Therefore, the G&A rate per hour is

Burden Determination

There are two types of burden rates to be considered. The ®rst is the burden for cost center 22 itself. The second portion is for all of the pure indirect labor cost centers. As with the expense rate, the burden on cost center 22 must be recovered in its entirety during the quarter. The burden for the rest of the indirect labor cost centers is charged proportionally to cost

G&A $145,440=72,000 hr $2:02 hr 2.5.7

Hourly Rate Determination and Adjustment

The four components of the labor/overhead rate for cost center 22 have now been determined. These components may now be summed as speci®ed by Eq. (2)

Table 7 Proration of Indirect Costs for Cost Center 22 1 Cost center 21 22 23 30 41 42 43 50 60 71 72

2 Average indirect salary ($)

3 Column 2 1=4 ($)

4 Number of indirect employees

5 Column 3 column 4 ($)

32,000 28,000 28,000 32,000 36,000 28,000 32,000 36,000 40,000 44,000 48,000

8,000 7,000 7,000 8,000 9,000 7,000 8,000 9,000 10,000 11,000 12,000

50a 50a 50a 50 50 20a 50 50 100 100 50

400,000 350,000b 350,000 400,000 450,000 140,000 400,000 450,000 1,000,000 1,100,000 600,000

6 Column 5 200/500 ($)

145,440 163,620 145,440 163,620 363,636 400,000 218,160 Total 1,599,916

a b

Number of indirect employees out of total on cost center. Total must be recovered in its entirety by cost center 22.



to determine the labor/overhead (LOH) rate for cost center 22: LOH22 $10:00=hr 27:08=hr 11:99=hr $2:02=hr 51:09=hr This procedure is repeated for the remaining direct labor cost centers, 21, 23, and 42. Each LOH rate obtained is an estimate or forecast. This is because the dollar values of indirect labor, burden, and G&A, are estimated values. Likewise, it was estimated that 72,000 hr would be worked during the quarter on cost center 22. As the budgetary quarter is completed, actual values of indirect labor, burden, G&A, and the number of direct labor hours worked will dier from the estimated values used in the LOH rate computation. This is also true of the average direct labor wage rate used in Eq. (2). Cost engineering personnel will collect actual values for each of these parameters at the end of the quarter. This will permit an actual LOH rate to be determined. This actual rate will be either greater or less than the budgeted rate prior to the quarter that was calculated above. If the budgeted rate is greater than the actual rate, excess costs will be recovered. If the budgeted rate is less than the actual rate, insucient costs will be recovered. A common practice is to compare these budgeted and actual rates for all direct labor cost centers over several quarters. Subsequent estimates for the parameters in Eq. (2) may be adjusted upward or downward, as appropriate, in subsequent budgetary periods to make the actual and budgeted LOH values more closely approximate one another.

2.6

ACTIVITY BASED COSTING

Activity-based costing (ABC) has gained increased popularity in recent years as a more accurate alternative to conventional careful budgeting methods for some manufacturing activities [14]. Some cost analysts have questioned the accuracy and validity of the use of direct labor hours as a proration basis variable in cost recovery. Some organizations have found that conventional capital budgeting cost recovery methods are not vernier enough to accurately estimate overhead costs and indirect labor amortization. Implementers of ABC ®nd that their organizations have often been grossly undercharging their customers for small-volume production end items. High-volume items often have in¯ated pro-


859

duction cost values with conventional cost recovery methods. 2.6.1

Cost Center De®nition

With ABC, the number of cost centers is usually expanded to encompass small work cells, or even individual machines. Consider a work cell that contains one new and highly automated ®ve-axis machining center. Suppose this cell contains ®ve other manual, conventional machine tools. With this work cell de®nition, parts processed by the work cell might not be accurately charged for the manufacturing procedures they require during the fabrication process. The overhead rate for the cell will seek to recover the costs of all of its machines. Parts entering the cell that require processing only by the cheaper, conventional machines, might be unfairly charged overhead for the automated machining center, even though they did not require processing by this piece of equipment. A better cell de®nition might be to de®ne the automated machining center as its own work cell. The older conventional machines might be grouped together in a second work cell. This philosophy can result in more than one hundred separate cost centers, many of which may consist of only one machine. This type of cost center de®nition enables the cost of manufactured end items to be determined as a function of those manufacturing procedures arid services they consume or require during their manufacturing process sequence. This is true for both direct and indirect labor and materials. The cost recovery methodology for ABC is the subject of the subsection that follows. 2.6.2

ABC Cost Recovery Methodology

Activity-based costing de®nes a cost rate per unit time that is associated with each de®ned work center or center. This rate has been described by Ramachandran et al. [7, 8] and is illustrated by RD;i

CDL CD CU CFS CT CI CIL CO HB 3

where RD;I Hourly operation cost of direct labor work center i in dollars per hour CDL Cost of direct labor in the work center over the budgetary period in dollars CD Cost of depreciation for equipment in the

860


CU CFS CT CI CIL CO

HB

work center during the budgetary period in dollars Cost of utilities attributable to the work center during the budgetary period in dollars Cost of building ¯oor space attributable to the work center during the budgetary period in dollars Cost of taxes attributable to the work center during the budgetary i period in dollars Cost of insuring the work center's equipment and ¯oor space during the budgetary period in dollars Cost of indirect labor required to support the work center during the budgetary period in dollars Cost of fringe bene®ts, other overhead, and any supplementary indirect labor wages required by the work center during the budgetary period in dollars Estimated or capable number of hours during the budgetary period that the work center is expected to operate

Some of the parameters that make up Eq. (3) require interpretation. Suppose a total of m direct labor employees work in a given work center, i, during a budgetary period. The direct labor cost can then be described by CDL

m X j1

Lj Nj;i

4

where: Lj Hourly pay rate including beneEts for direct labor employee j in dollars per hour Nj;i Number of hours worked by employee j in work center i during the budgetary period 2.6.3

ABC Operation on a Quarterly Basis

The process of assessing the accuracy of work center rates using Eq. (3) is similar to the capital budgeting process previously described. Prior to a given budgetary quarter, estimates of all parameters is Eq. (3) must be compiled to,determine a budgetary or forecast cost rate for all direct labor work centers. At the end of each quarter, estimated parameters in Eq. (3) are compared with actual values at the end of the quarterly budgeting period. This enables an actual work center cost rate to be determined.


If the actual rate is less than the estimated or budgeted rate, the plant has overcharged for the services of the work center. If the reverse is true, the plant has undercharged products for the work center's use. Comparing actual and projected work center rates on a quarter by quarter basis gives the cost analysis some basis for adjusting follow-on estimates for each of the parameters in Eq. (3). This facilitates the compilation of more accurate budgeted work center rates in future budgetary quarters. 2.7

QUICK-RESPONSE ESTIMATING AND ESTIMATING SOFTWARE

Manufacturers often ®nd it necessary to supply cost estimates with extremely short lead times. Quickresponse estimating systems rely on parametric estimating techniques. Parametric estimating entails the development of mathematical relationships that relate the product's manufacturing cost to salient, identi®able features of the product being manufactured. Other factors considered in the estimating equation are production quantity and the number of times the end product has been previously manufactured. 2.7.1

Development of Estimating Equations

Multivariate regression analysis is a tool that can be used to develop parametric estimating relationships. Both linear and nonlinear equations can be ®tted to historical cost data using this approach. Many spreadsheet packages currently permit multivariate regression analysis to readily be completed on a personal computer. It is important to assess the quality of obtained curve ®ts that relate product cost to features of a the end item being produced. A coecient of determination (r2 ) of at least 80% is recommended. It is also important that developed estimating relationships be validated before being used. This may be accomplished by dividing historical cost data bases into two parts. The parametric equations can be developed using the ®rst half of the historical data. The developed relationships can then be ``tested'' on the second half, comparing projected cost from the obtained equations, with actual historical costs that were incurred in practice. 2.7.2

De®nition of Part Families

Estimating relationships should be developed by part family. For example, cost data used to make an FM


radio should obviously not be used to estimate the cost of an automobile drive shaft. Group technology (GT) de®nes manufacturing production cells that are dedicated to producing parts with geometrically similar attributes. Coding and classi®cation methods are used to de®ne families of parts that are manufactured by GT cells. Often, parts within de®ned GT families are candidates for the use of the same parametric cost relationship. Group technology lends itself most readily to metalworking operations. For electronics manufacturing, part family de®nition must be more intuitive. Example part families for electronics manufacturing might be as de®ned below. Point-to-point wired cables Printed circuit board assemblies Wired chassis assemblies to interface printed circuit boards Interface wiring between separate chassis assemblies Metalworking operations to punch and machine the chassis prior to interfacing wiring. 2.7.3

Production Mix

Parametric estimating systems are much easier to implement in high volume, low mix types of production environments. Organizations should expect to make an investment on the order of person-months to person-years in terms of statistician and cost engineering time to develop and validate such relationships prior to their being used. 2.7.4

Development and Use of Estimating Software

In many cases, software is developed to assist in expediting the completion of cost estimates and order quotations to customers. In most cases, it is more expeditious to generate such software `ìn-house'' as opposed to procuring commercially available software packages. Such software must have the organization's product line `èmbedded'' within its architecture. This requirement often makes it necessary to modify commercial software packages. Required modi®cation costs can be extensive enough to justify ``company-generated'' software. This justi®cation is enhanced by the fact that many commercially available estimating software packages are extremely expensive. Commercially available software is also usually di cult to interface with the user organization's historical cost records.


861

Parametric estimating relationships, if previously developed by the organization, are easily incorporated into estimating software that is written `ìn-house.'' Inhouse software is not necessarily less expensive, but is almost always more useful to the organization in the long run. 2.8

IMPACT OF AUTOMATION ON ESTIMATING PROCEDURES

Manufacturing automation has, and continues to have a dramatic eect on conventional estimating procedures. High levels of automation reduce the amount of human direct labor associated with the manufacture of parts. Overhead costs are increased, usually due to the procurement of expensive automated machining centers, industrial robots, and assembly equipment. Indirect labor costs tend to increase due to programming and maintenance costs. Product quality is generally enhanced as a result of automation. This has a positive eect in reducing warranty and return costs. Cost variation between parts and groups of parts is greatly reduced. Machine cycle times are more constant, and except for unscheduled maintenance, are functions of programs for the machines and transfer mechanisms. This makes the incorporation of learning curves (previously described), of less importance than for manufacturing procedures that incorporate low automation levels. Production, inspection, and part transfer times that are machine dependent need to be incorporated in cost estimates that will use these manufacturing facilities and machines. The large capital investments tied up in automated manufacturing facilities increasingly mandate the use of activity based costing. The individual work center de®nition and cost rates provided by ABC more accurately associate automation costs with end products that use or consume automated facilities and resources during the manufacturing process. Automated equipment is almost always more expensive than its conventional counterpart. Manufacturing automation results in recurring costs associated with more expensive maintenance, programming costs (generation, debugging, and storage). When a plant invests heavily in automation, there is extreme pressure to have high equipment utilization levels. This may prompt the use of such equipment for some parts that might have otherwise been manufactured by cheaper, more conventional methods. The cost increases and savings associated with manufacturing automation have been described in detail by

862


Butler et al. [7, 9, 10]. These authors have developed software that enables prospective users to assess the net cost increase or savings associated with manufacturing automation alternatives. Readers desiring more information on this subject are urged to consult these references.

2.9

SUMMARY

This chapter has overviewed manufacturing cost estimating and recovery techniques and methods. There have been many books that have been devoted exclusively to the extensive coverage of these topics. Readers desiring more information on any of the subjects of this chapter are urged to consult the list of references that follows.

REFERENCES 1. M Malstrom. What Every Engineer Should Know About Manufacturing Cost Estimating. New York: Marcel Dekker, 1981, pp 1±48. 2. PF Oswald. Cost Estimating for Engineering and Management. Englewood Clis, NJ: Prentice-Hall, p 1±4. 3. R Vernon, ed. Realistic Cost Estimating for Manufacturing. Dearborn, MI: Society of Manufacturing Engineers, 1968, p 1.


4. EM Malstrom, ed. Manufacturing Cost Engineering Handbook. New York: Marcel Dekker, 1984. 5. EM Malstrom. Cost estimating and control. In: R Veilleux, ed. Tool and Manufacturing Engineers Handbook, vol. 5. Dearborn, MI: Society of Manufacturing Engineers, 1988, pp 4.1±12. 6. EM Malstrom, RL Shell. A review of product improvement curves. Manuf Eng 82(5): 1979, pp 70±76. 7. DP Butler, EM Malstrom, K Ramachandran. A computerized ABC model for a job shop environment. AACE Trans, June: 1995, p 9.1±3. 8. K Ramachandran, DP Butler, EM Malstrom. A computer assisted model for activity based costing. Proceedings of the 22nd International Conference on Computers and Industrial Engineering. Cairo, Egypt, December 1997. 9. DP Butler, EM Malstrom, SC Parker. A tutorial model for the economic evaluation of automated manufacturing systems. Cost Eng 38(6): 1996, pp 25±32. 10. DP Butler, EM Malstrom, SC Parker. Assessing the true cost savings associated with the procurement of automated systems. Technical paper MM93-384. Dearborn, MI: Society of Manufacturing Engineers, 1993. 11. CM Creese, M Adithan, BS Pabla. Estimating and Costing for the Metal Manufacturing Industries. New York: Marcel Dekker, 1992, p 12. 12. EM Malstrom, W Beatty. A cost recovery methodology for automated manufacturing workcells. Cost Eng 34(5): 1992, pp 15±20. 13. PE Ostwald, ed. Manufacturing Cost Estimating. Society of Manufacturing Engineers, 1980, p 9. 14. ER Sims, Jr. Precision Manufacturing Costing. New York: Marcel Dekker, 1995.

x

[Addition table] P*,117 AdeptOne robots, 502 Adiabatic shear bands, 541 Adoption of standards, 738-739 After tax analysis, 845-846 Age vs. visual acuity, 772 Age of Alloys, 530 Age of Materials, 529 Agility, 482 AIHA ergonomics guide, 802 Air contaminant removal, 730 Aircraft, 629 Alarm values, 201 Alcohol aqueous solutions density, 494-496 concentration and temperature fit, 496-498 Algebra, 129-135 groups, 129-133 rings and fields, 133-135 Allen-Bradley’s programmable controller configuration system (PCCS), 195 Alligatoring defect, 569 Allocation of functions, 762-765 Allocation analysis flowchart, 759 Alloys, 545-549 corrosion, 561-564 precipitation, 546-549 wear, 561-564

Abelian groups, 129-1 30 Absolute stability, 220 criteria, 221-227 Absolute value function, 65 Absolute values linear programming, 303 Accidents causes industrial settings, 691 investigations ETBA, 715 industrial settings, 69 l perceptions, 693 Accol 11, 195 Action, 694 Action levels (AL), 729 Active stereo imaging, 420-421 Activities (see a h Function) performed by humans, 765 Activity based costing manufacturing-cost recovery and estimating systems, 859-860 Activity sampling, 756, 757 Actor, 694 Actual dollars, 847-848 Ada, 203 ADALINE (ADAptive LINear Element), 508 Adaptation visual capability, 773 Adaptative critical methods, 195 Adaptive control, 202 Adaptive critic method, 524 Adding variables, 273-275 Addition table 863

86 Alternation theorem, 248 Aluminum extrusion, 570 Aluminum alloy precipitates, 546 American Conference of Governmental Industrial Hygienists (ACGIH), 729 American National Standards Institute (ANSI), 735 American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code, 735 Amortized loans, 838-839 Amplifier error budgets instrumentation error-modeled performance, 137-140, 141 Analog filters, 241 Analog frequency, 236 Analog prototypes, 241 Analog signals and systems, 235 Analog systems, 233 vs. digital system, 234 Analog-to-digital converter (ADC), 147-150, 194, 234 Analysis flowchart, 759 Annealing twins, 541 Annual worth method, 840 Anthropocentric appwach to production system, 752 Antialiasing filter, 234, 238 Antiderivatives calculus, 75-76 Application layer, 21 1 Application-specific integrated circuits (ASICs), 234, 237, 25 l Arccosecant function, 66 Arccotangent function, 66 Arcs Petri nets, 355 Arcsecant function, 66 Arcsine function, 66 Arctangent function, 66 Area between two curves, 81, 82 A~ature-controlleddigital control motor, 168 Artifacts, 239, 240 Artificial intelligence (AI), 499 Artificial neural networks (ANNs), 407-409 robots, 506-508, 518 Artificial neuron model, 407-408 ASEA MASTER system, 213 Assemble-totorder, 458 Assembly robotics, 502 Associated Petri net, 353 Asymptomatically stable, 236 Asynchronous process buffers (ASPS) vs. storage system buffers, 652-653 Attention, 767 Attribute measurement system, 41 1 Auditory displays, 770, 779-782

Index Auditory senses, 766-767 Automated guided vehicle (AGV), 171 Automated systems designing human interfaces, 749-789 Automatic brake monitoring, 727 Automatic guided vehicle systems (AGVS), 633-635 Automatic storage and retrieval systems (ASRS), 635, 639640, 643-657 computing cycle times, 653-655 design, 648-649 design philosophies, 646 dynamic buffers, 652-655 flow vs. static costs, 655 historical development, 643-644 inventory, 645-646 microltote-load systems, 652 rack-supported vs. freestanding buildings, 65 1 state of mind, 644 supplier, 655-656 technology classes, 649-652 technology shift, 646-648 Automation, 338, 485 impact manufacturing-cost recovery and estimating systems, 861-862 OSHA, 731 robotics, 500-503 Autoregressive (AR) model, 244 Autoregressive moving-average (ARMA) models, 244 Axiom of Dominance I, 368-369 B-spline, 426 Back-propagation of utility, 195 Backlash, 784 Backlighting, 439 Backpropagation method (BP), 508 Backpropagation of utility, 524 Backward DP model dynamic programming, 318 Backward-inhibitor model, 394395 Basic control algorithms, 205 Batch machines, 593 Batch process control, 202 Bayes’ Theorem, 4 Behavioral analytical hierarchy process, 370-375 algorithm, 371-372 numerical examples, 372-375 preference characteristics, 370-371 status characteristics, 371 Behavioral properties Petri net, 341-342 Belt conveyors, 633 Bending, 572 Benefit cost ratio, 842 Bernoulli distribution, 9, 10 Bernoulli random variable

865

Index [Bernoulli random variable] moment-generating function, 20, 21 Bessel lowpass filters, 141-143 Beta distribution, 13-14 Bezier curve, 426 Bias errors, 178 Bilinear z-Transform, 246, 247 Billowing, 597 Binary phase diagrams, 546, 547 Binary state indicators, 202 Binomial distribution, 10 Biological neurons diagram, 407 Biomechanical analysis technique, 801 Black-and-white image function, 397-398 Blank, 596 Blanking, 571 Blind positioning, 770 Block Petri net, 353 Blow molding, 589-592 modeling, 592 technology, 589-591 Body-centered cubic (BCC) lattice, 535 Boiler and Pressure Vessel Code, 735 Boolean algebra, 113-1 27 Boolean function, l15-1 17 Boolean matrices, 120-1 25 generalization, 125-1 27 switching functions, 117-1 20 Boolean function, 115-1 17 Boolean function f truth table, 116 Boolean matrices, 120-125 inequality, 121 Bounded-input-bounded-output (BIBO) domain criteria, 221-222 stability, 260 Boundedness, 344 Petri net, 342 Brake monitoring, 727 Bravais lattices, 534 Break down events, 696-697 Bright-field illumination, 439 Brittle fracture, 560 Bronze historical perspective, 530 Bronze Age, 530 Budgeting capital manufacturing-cost recovery and estimating systems, 855-859 Building codes, 735, 736-737 Bulk, 61 1, 626 Burgers vector, 537 Bus-oriented hierarchical system, 197 Bus-oriented systems, 2 12

Butterworth filter, 243 Butterworth lowpass filters, 141-144 Calculus, 65-86 antiderivatives, 75-76 chain rule, 69-75 continuity, 68-69 differentiability, 69-75 differential equations, 83-86 functions, 65-66 integral applications, 8 1-83 integration, 77-8 1 limits, 67-68 Cameras, 396 Canny edges detector images, 406 Capacitive-based sensors, 380-381 Capital budgeting manufacturing-cost recovery and estimating systems, 855-859 Capital recovery factor, 833 Carpal tunnel syndrome (CTS), 728 Cartesian product, 38 Cascade architecture, 264267 Cash flow diagrams, 831 Cash flow patterns, 831 Cast iron, 530 CAT scanners, 406 Cathodic protection, 564 Cause-effect relationship, 697 Cavity filling, 578 Cell wall, 543 Cellular manufacturing system, 460-462 Cement data regression, 293-294 Cementation, 564 Censored data, 5-6 Centering of data, 271-272 Centers mass, 83 Central computer system, 204 Central control room, 188, 209 Central limit theorem, 14 Central monitoring interfaces, 192 CENTUM, 213 Ceramic crystal structures, 556 Ceramic materials, 553-558 structure and properties, 553-558 structure-property-performance, 557 Ceramic superconductor, 555 Ceramics brittle fracture, 560 Chain conveyors, 633 Chain rule, 69-75 Chairs workstations, 794 1

Index

Chalcolithic Age, 529-530 Change signals, 694 Change-of-basis matrices vector spaces, 53-54 Channel capacity theory, 766 Characteristic function random variables, 21-22 Charge-coupled device (CCD), 443 Chebyshev filter, 243-244 Chi-squared distribution, 12, 14 Choice Petri net, 351, 352 Choice reaction time, 769 CIBRO model development container inventory control, 665-666 Circular flow, 623 Classical digital filters, 241 Classification detection, 766 Clean Air Act (CAA), 736 Clean Water Act (CWA), 736 Closed interval, 65 Closed loop theories, 769 Closed-die forging, 570 Closed-loop control, 187, 188-1 89 Cloudy day illumination, 438 Co-ordinate measuring machine (CMM), 415, 502 Coaxial illumination, 439 Code of Ethics, 733, 738 Codes, 735 (see also Standards) definitions, 733, 734 NFPA definition, 736 organizations names, addresses, websites and phone numbers, 740-748 Coding consistency surveys, 758-759 Coding information symbols, 776 Coding system recommendation, 776 Cognition problems, 195 Coinjection molding, 581-583 modeling, 583 technology, 581-582 Cold standby, 214 Cold working, 568 Collision avoidance, 413 Color three-dimensional, 398, 400 Color coding surfaces, 776 Color discrimination, 773 Colored Petri nets, 355-356 Committee on Industrial Ventilation (CIV), 729 Communication links, 209-21 3 Commutative rings, 134 Compactors, 202 Compatibility, 785-786 Compilers, 202

Complement sets, 34 Complete controllable Petri net, 343 Compliance industrial settings, 691 Composition, 65 Compound amount factor, 833 Compound interest, 830-83 1 Compound interest factors eight percent, 835 one percent, 834 ten percent, 836 Compounding frequency, 837 Compression molding, 573-577 car fender, 577 in-molding curve, 574 modeling, 575-577 plunger force, 574 presses, 574 stages, 574 technology, 573-575 Compression molds components, 575 ejection systems, 575 Computed-torque control, 505 Computer analysis linear first-order differential equations, 111-1 12 Computer integrated manufacturing (CIN), 451452 Computer-aided design (CAD), 424425 Computer-controlled servo system functional elements, 173 Conceptual compatibility, 786 Conditional probability, 3 Conditional probability distribution, 17 Cones, 393-394 Conservation Petri net, 342 Constant dollars, 847-848 Consumer Product and Safety Commission (CPSC), 737 Contained, 626 Container inventory control, 663-672 CIBRO model development, 665-666 fresh fruit modeling, 668471 reusable, 664665 transportation system, 666-668 Containerization, 659-671 experimental design, 659-663 choice, 660 data analysis, 660 database, 660-66 1 dunnage, 66 1-662 factors and levels, 660 performance, 660 procedure, 659-660 inventory control, 663-672 Containers~supports,629

867

Index Contaminant removal, 730 Contangent hyperbolic, 72 Continuity, 68-49 Continuous machines, 593 Continuous random variables, 5 transformations, 23-24 Continuous uniform, 6-7 Continuous uniform distribution, 11 Continuous uniform random variable characteristic function, 21-22 Continuous-time Fourier series (CTFS), 236 Continuous-time Fourier transform (CTFT), 236 Continuous-time signals, 253 Continuous-time systems, 222, 227-228, 233 Contrast sensitivity, 772-773 Controllability Petri net, 346 Controller DC, 172 robots, 503 Controller mode backup, 190 Controls algorithm, 194 and display flow charts, 204 arrangement principles, 786 compensator, 158 databases, 203 design, 781-785, 789 devices types, 784-785 location guidelines, 789 movement compatibility, 787 resistance, 783 response ratio, 782 systems, 727 tasks, 203 theory, 157 Conveyors, 629, 633 Convolution algorithm, 401 Convolution theorem, 235, 259, 402 ~ONvirIP(CONstant Work In Process), 469-470 Cooley-Turkey fast Fourier transform (FTT) algorithm, 233 Cooling, 578, 596 Coordinate maps vector spaces, 53-54 Copper fatigue, 563 historical perspective, 529-530 metallurgy, 531-545 atomic unit cells, 534 crystal unit cells, 532 metalworking, 540-545 periodic system, 533 structure-property, 535-540 smelting, 530

[Copper] stress and strain, 543 Copper Age, 529-530 Correlations, 272 Corruption investigation, 695-696 word list, 695 Cosecant hyperbolic, 72 Cost analysis ASRS, 656 Cost estimating systems (see ~anufacturing-costrecovery and estimating systems) Cost reviews manufacturing-cost recovery and estimating systems, 852-853 costs ASRS, 655 Counterbalanced industrial forklift trucks (FLTs), 630, 633 Covalent bonding polymeric materials, 559 Coverability tree, 345 Petri net, 344-345, 346 Cramer’s rule, 58 Creep, 540, 558-564 Creep curve, 560 Critical frequencies, 24 1 Crystal defects, 536, 538 Crystal systems, 534 Cumulative distribution function (cdf), 7-8 Cumulative trauma disorders (CTD), 728 Current loop DC, 171 Current vector, 349 Curve sketching, 73-74 Curves area between two, 81, 82 length, 82 Customer focus, 48 1-482 Cutting edge technology, 738 Dark-field illumination, 438 Data acquisition functions, 200 Data entries, 203 Data file organization, 205-209 Data files, 203 Data handling tasks for investigation, 710-7 11 Data language structure, 694 Data link layer, 210 Data sets regression, 293-295 Database units, 206 DC1 5000, 213 De minimus, 723 Dead zone, 570

68

Deadspace, 783 Decimation, 250 Decimation rate, 250-25 1 Decision action diagram, 757 Decision analysis, 359-375 behavioral analytical hierarchy process, 370-375 measurable value theory, 362-370 utility theory, 359-362 Decision making definitions, 767 Decision tables, 202 Decision tree, 360 Decomposing events, 696-697 Dedicated computers, 189 Deep drawing, 571-572 Deliverables investigator’s task, 712-713 Denavit-Hartenberg representation robot arm kinematics, 512-514 Dependence, 3-4 Dependent variable, 66 Depreciation, 843-845 Derivative, 69 Descriptor, 695 Design for manufacturability, 502 Designing human interfaces automated systems, 749-789 Detection vs. perception, 766 Determinants, 56-58 Deterministic timed Petri nets, 349-350 DFT parameters, 238 Die cavities, 570-571 Die material, 569 Difference equations, 2 17-2 19 Differentiability, 69-75 Differential entropy, 487 Differential equations, 83-86, 217-2 19 first-order, 83-84 integrating factors, 84-85 partial derivatives, 84-85 Differentiation implicit, 74-75 Diffuse illumination, 438 Diffusion, 546 Digital control loop, 154, 155 Digital control system error instrumentation error-modeled performance, 154-1 56 Digital controller, 169-170 Digital filters, 241-25 1 Digital motion control, 157-1 75 digital controller, 169-170 digital-controlled servo system, 170, 171 flexible-link pendulum, 158-162 motion control architectures, 157-1 58

Index [Digital motion control] motorized robot arm, 166-169 rigid-link pendulum, 162-1 66 system analysis, 172 system analysis with compensator, 174-175 system compensation objective, 173-1 74 system modeling, 171-1 72 Digital signal processing (DSP), 233-252 algorithm, 234 analog signals and systems, 235 digital filters, 241-251 digital systems, 235-236 Fourier analysis, 236-239 systems, 233 signal train, 234 technology and hardware, 251-252 ’ windowing, 239-240 Digital signals, 253 Digital systems, 235-236 Digital-controlled servo system, 170, 171 Digital-to-analog converter (DAC), 146-147, 234 DC, 172 Dihedral groups, 130 Direct digital control (DDC), 193 Direct extrusion, 570-571 Direct I1 architecture, 263-265 Direct inverse control, 524 Direct inverse controllers, 195 Direct process control level, 196-198 Direct-driven arms (DDArm), 504 Directed path, 343 Directional illumination, 438 Discontinuous function, 69 Discrete Fourier transform (DFT), 236, 237 analysis equation, 237 Discrete random variables, 5 Discrete uniform distribution, 9-10 Discrete uniform random variable characteristic function, 21 Discrete-event systems, 337 Discrete-time signals, 253 Discrete-time systems, 225-227, 233 Disjoint sets, 34 Dislocation cells, 543 Dislocation line defect, 537 Dislocation loop, 537 Dislocations, 537, 544 Displays arrangements, 786 auditory, 770, 779-782 design, 789 dynamic information, 777 guidelines, 770 legibility, 773 modes, 770 movement compatibilty, 787

69

Index [Displays] qualitative visual, 778 quantitative visual, 777 readability, 773 shaded surface, 407 static visual, 773 status indicator, 778-779 stereoscopic, 407 terminal guidelines, 794-795 textual, 773 types, 770 visibilty, 773 visual, 770, 771, 773 Distance, 619 Distance measure poles, 228-229 Distance-intensity (D-I) plots, 619, 621, 628 Distributed control systems, 185-214 c o ~ u n i c a t i o nlinks, 209-2 13 computer technology, 191-192 computer-based plant automation, 189-191 control technology, 192-196 data file organization, 205-209 hierarchical distributed system structure, 196-198 hierarchical levels, 198-205 plant automation classical approach, 187-1 89 reliability, 213-214 safety, 2 l 3-2 14 Divided attention, 768, 769 Do no harm rule, 699 Domain, 65 Double-deep racks, 638 DP model formulation dynamic programming, 318 Drape forming, 597 Drawing, 571 Drive-in racks, 638-639 Duality linear programming, 302-303 Ductile fracture, 560 stainless steel, 562 Dunnage, 66 1-662 Duplicate node, 344 Dynamic buffers, 652-655 asynchronous process vs. storage system, 652-653 Dynamic compensation functions, 20 1 Dynarnic information displays, 777 Dynamic programming, 318-322 DP model backward, 3 18 formulation, 318 Dynamic recrystallization, 541 Dynamic transportation models, 666

*

Echoic storage, 766-767

Economy engineering (see Engineering economy) Edge, 537 Edge cracks, 569 Edge detection images, 404-405 Edge-based systems, 41 1 Eigenvalues, 58-59, 290-291 Elastomers, 379-380, 388, 558 injection molding, 577 Electrode potentials, 563 Electronic safety devices, 725 Electrostatic discharge (ESD), 61 1 Elementary circuit, 343 Elementary matrices inverses, 48-50 Empirical cumulative distribution function (ecdf) probability plots, 28 Empowerment, 454, 48 1 Empty set, 33 Encoder DC, 172, 173 End of period convention, 831 Energy management software, 202 Energy trace and barrier analysis (ETBA) method, 715 Energy tracing, 698 Engineer-to-order, 458 Engineering economy, 829-848 after tax analysis, 842-846 alternative evaluation, 839-842 cash flow formulas, 830-839 concepts, 829-830 inflation, 846-848 Environment Protection Agency (EPA), 735 Environmental monitoring, 729 Equipment handling cost comparisons, 630 Equipment operation ergonomics checklist, 763 Equiripple method, 248-249 Equivalence concepts, 830 Equivalence relations, 40 Equivalent connection graph, 123 Equivalent flow unit (EFU), 61 1-614 Ergonomics checklist, 762 equipment operation, 763 definitions, 75 1 physical strength assessment, 797-825 Erosion corrosion, 564 Error budgets, 178-179 Error correction, 2 14 Error detection, 214 Error location, 214 Error of execution, 769 Error of selection, 769

870 Estimating systems manufacturing-cost,849-862 ETHERNET, 21 l Euler exponential function, 68 Event building block, 695 elements, 695 Event data language, 694-696 Event linking, 697-698 Event pairs and sets, 697 Events sequencing, 697 Exact differential equations, 89-91 Executive preparations investigation planning, 703-704 Exfoliation corrosion, 564 Exhaust ventilation air contaminant removal, 730 Expected utility model, 359-350 Experience recycles yesterday’s problems, 700 Experimental design data regression, 294 Expert controller, 195 Explosion proof, 187 Explosive forming, 572 Exponential distribution, 11-1 3 Exponential random variable moment-generating function, 20, 21 Extrinsic sensors, 200 Extrusion, 570-57 l aluminum, 570 ferrous metals, 570-571 friction, 570 Extrusion blow molding, 589

F distribution, 12, 15 Face-centered cubic (FCC) unit cell, 535 Failsafe system, 728 Failures industrial settings, 69 1 FAIS (Factory Automation InterconnectionSystem) Project, 198-1 99 Far point, 771 Far sightedness, 771 Fast Fourier transform (FFT) algorithm, 237 Fatality worker case study, 722 Fatigue, 540 copper, 563 stainless steel, 563 Fatigue fracture, 561 Feature extraction, 195 Federal Drug Administration (FDA), 735 Federal standards OSHA, 720-72 l Feedback devices robots, 503

Index Feedback neural network, 408 Feedforward, 509 Feedforward neural network, 408 Ferroelectric materials, 557 Ferrous metals extrusion, 570-571 Fiber devices, 199-200 Fiber optics, 440 Field level communication links, 209, 21 1 Field multiplexers, 209 FIELDBUS, 198-199 Fields algebra, 133-1 35 Filter passband errors, 141-142, 144 Fingering effect, 585 Finite impulse response (FIR) filters, 248-249 Finite limits, 67 Finite-state machine, 123 Finite-state nondeterministic machine, 123 Firmware module, 205 First-order equations, 83-84 First-order hold, 254, 255 Fits, 273 Fitts’ list, 762, 764 Fixed automation, 500 Fixed field digital control motor, 167 Flash molding, 574 Flat-rolling process, 568 Flexible automation, 500 Flexible machining systems (FMS), 461 Flexible-link pendulum, 158-1 62 linear-approach modeling, 160-161 nonlinear-approach modeling, 161-1 62 Floor stacking, 638, 642 Flow line, 461,462, 463 Flow manufacturing, 476-477 flow line design, 478-479 inventory control, 480 market data analysis, 477 multibin Kanban system, 479-480 safety stocks, 480 sequence of events sheets, 478 Takt time, 477-478 time study analysis, 478 vendors, 480 Flow-through racks, 638 Flowcharting investigation principle, 699 Fluorescence, 440 Focused attention, 767, 769 Folding frequency, 253 Food containers, 595 Force-sensing resistor, 380 Forging, 569-570 Form block, 572

Index FORTRAN, 203 Four-axis S C A M robot, 516 inverse kinematics, 516-518 kinematic parameters, 515 Four-beam wrist sensor, 389 Four-element multiplication table, 115 Four-way trucks, 633 Fourier analysis, 236-239 Fourier transform, 400-401 Fovea, 393-394 Fracture toughness, 556, 561 Fragility, 612 Framework multilinear conceptual, 693 Free blowing, 597 Frequency of compounding, 837 Frequency response functions, 2 18 Frequency transition ratio, 241 Frequency-to-frequencytransform, 241, 242, 243 Fresh fruit modeling container inventory control, 668-67 1 Friction extrusion, 570 rolling, 569 Frobenius matrix, 50 Function allocation problems, 762, 764 Function analysis, 764 Functions, 65 (see a h Activities) allocations of, 762-765 performed by machines, 765 Fundamental Homomo~hismTheorem for Rings, 135 Fundamental Theorem of Algebra, 135 Fundamental Theorem of Calculus, 75-76 Fundamental Theorem of Homomorphism, 131-1 32 Fuzzy logic controller, 195 Gain and phase margin, 229-230 Gain frequency, 243 Gallium arsenide, 553 Gamma distribution, 12-1 3 Gamma random variable characteristic function, 2 1, 22 Gantry configuration robots, 504 Gantt chart, 466 Gas-assisted molding, 583-585 modeling, 585 process parameters, 584 technology, 583-585 Gates, 578, 725-726 Gating, 239 Gaussian distribution, 14 Gaussian elimination matrices, 47-48 General duty clause

[General duty clause] OSHA, 721-722 General Industry Standards, 720-721 Generalized stochastic Petri nets (GSPN), 350-351 Generic diet problem linear programming, 300-301 Geometric distribution, 10 Geometrical gradient present worth factor, 837 Geometrical gradient series, 832 GIN variables, 303, 31 1-3 12 Glass blowing, 589 Go-kit preparations, 708 Gold heat of sublimation, 490, 491 second-law data analysis, 493 third-law data analysis, 493 Good Engineering Practices, 735 Good Manufacturing Practices (GMP), 735 Government regulations, 7 19-732 Grain boundaries, 535, 551 Grain growth, 542 Gram-Schmidt process, 6 1 Graph of the inverse function, 66 Graphical function charts, 204 Graphics Interchange Format (GIF), 396 Greatest common divisor multiplication table, 114 Green-Lagrange strain tensor, 598 Group delay, 236 Group of Rigid Motions, 133 Group stations, 204 Groups actions, 133 algebra, 129-1 33 Guidelines (see aZso Standards) definitions, 734 NFPA definition, 736 organizations names, addresses, websites and phone numbers, 740-748 Gumbel probability plot, 29-31 4 V>%

Hadamard transform, 400 Halogen, 440 Hammers, 569 Handling, 635 Hard automation, 500 Hard copy design recommendations, 774 Hazardous environments OSHA, 729-730 Heaviside function, 67 Hele-Shaw flow approximation, 585, 587 Hesitation marks, 585 Heterogenous nucleation, 547-548 Hexagonal close-packed (HCP) carbon, 548 Hierarchical distributed system structure distributed control systems, 196-1 98

Index: [Industrial machine vision] generic applications, 434-435 image formation, 436-444 illumination, 438-440 optics, 440-442 video array, 442-444 image processing, 444-448 correlation, 445-446 decision making, 444 edges, 446-447 feature vector, 444 feature vector processing, 447-448 objective, 444 segmentation, 444 interfacing, 448 rules, 435-436 speed, 448-449 structure, 432-434 Industrial Revolution, 45 1 Industrial robot defined, 499 Industrial robot control, 413 Industrial vehicles, 629 Infared screen, 726 Infinite impulse response filters (IIR), 241-243 Infinite limits, 67-68 Inflation engineering economy, 846-848 measures, 847 Inflation rate average, 847 Information definitions, 765 types and characteristics, 771 Information input and processing scientific basis, 765 Information processing, 767 Information technology, 482 Information theory vs. information measuring, 766 Initial response for investigation, 709 Injection molding, 558, 577-580 machine, 578 modeling, 579-580 pressure-time curve, 579 stages, 578 technology, 577-579 Injection-compression molding, 580-58 1 Inner-product spaces, 59-63 defined, 59-60 least-squares problems, 61-62 normal matrices, 62-63 orthogonality, 60-61 Input device drivers, 200, 205 Input signal conditioning, 205 Input signal-conditioningalgorithms, 201

873

Inspection, 4 10-412 robotics, 502-503 Institute of Electronic Engineers (IEEE), 737 Instrumentation amplifiers, 137-140 amplifier error budgets, 141 amplifier parameters, 139-140 Instrumentation databases, 203 Instrumentation error-modeled performance, 137-1 54 analog-to-digital converters, 147-1 50 digital control system error, 154156 digital-to-analog converters, 146-147 instrumentation amplifiers and error budgets, 137-140 inst~mentationfilters, 140-142 measurement signal conditioning, 142-146 signal sampling and reconstruction, 150-154 Instrumentation filters, 140-142 INT variables, 303, 310-311 Integer variables linear programming, 303-3 18 Integral applications, 8 1-83 Integrated automation concept, 185 Integrated circuit (IC), 200, 61 l Integrated computer-aided m~nufacturing,2 10 Integrated optics, 200 Integrating factors, 84-85 Integration calculus, 75-8 1 improper integrals, 8 1 integral, 76-77 numerical, 80-8 1 partial fraction, 79-80 parts, 78 substitution, 75 trigonometric integrals, 78-79 trigonometric substitutions, 79 Intelligent automation workstation, 487 Intelligent control, 286, 485-487 co-ordination level, 486-487 execution level, 487 organization level, 486 Intelligent industrial robots, 499-525 automation, 500-503 Intelligent machines structure, 486 Intelligent manufacturing, 485-498 Intelligent sensors, 199 Intelligent systems, 454 Intensity, 6 19 Interest, 830 Interfaces, 535 Interferometry, 416 Intergranular fracture iron, 562 Interlock mechanisms, 728 International Electrotechnical Commission (IEC), 209, 734

Index Hierarchical task analysis, 755-756 High leverage points, 289-290 High-performance instrumentation amplifier, 138 Histogram, 401-404 Historical databases, 208 Holding, 635 Hollow articles, 592 Holonic systems, 454 Homogeneous nucleation, 547-548 Homogenous first-order equation, 91 Homogenous system linear first-order differential equations, 101-107 Homogenous transformation matrix robot arm kinematics, 5 11-512 Hooke’s law, 536 Horizontal edges images, 405-406 Horizontal line test, 66 Horizontal standards OSHA, 721 Hot forging, 569 Hot isostatic pressing (HIP), 558 Hot standby, 214 Hot working, 568 Hotelling transform, 400 Hough transform, 400 Human machine interaction, 750 supervisory control, 751 Human decision model for investigators, 7 13-7 15 illustration, 714 Human i n f o ~ a processing, ~ ~ n 767 Human resources, 48 1 Human strength ergonomics assessment, 797-798 Human visual system, 393-395 Human-centered interface design approach, 751 limitations, 752 Human-machine interface designing systems, 752 problem solving process, 753-786 Hy~ro-Abrasive~ a c ~ n i n502-503 g, Hydrogen bonding, 553 Hyperbolic contangent, 72 Hyperbolic cosecant, 72 Hyperbolic functions, 7 l Hypergeometric distribution, 10-1 1 Iconic storage, 766-767 Identity function, 65 IEEE 802 Project, 210 Illumination, 395-396 industrial machine vision, 438-440 optics, 440 sources, 440

Image array, 437 Image depth of focus, 416 Image formation industrial machine vision, 436-444 Image thresholding, 403-404 Images, 396 analysis and segmentation, 404-407 digitized, 398, 400 enhancement, 401-404 formats, 397 frequency space analysis, 399-401 functions and characte~stics,396-398 geometry effects, 398, 400 gray-scale quantization, 398, 400 processing applications, 409 recognition and decisions, 407-409 spatial resolutions, 398, 399 three dimensional, 406-407 Imminent dangers OSHA, 722 Impact test, 661, 662 Implicants, 118-1 19 prime computation, 119-1 20 Implicit differentiation, 74-75 Implicit relationship, 66 Improper integrals, 8 1 Impulse responses, 2 18-2 19 Impulse-invariant filter, 244-246 In-process measurement, 177-184 process control, 180-183 process qualification, 183-1 84 process variation, 178-1 80 Incandescent light, 440 Income tax returns, 845 Increasing precision with decreasing intelligence (IPIDI), 485-486 Independence, 3-4 Independent variable, 66 Indeterminate form, 7l Indirect driven arm, 504 Industrial forklift trucks (FLTs), 630, 633 Industrial intelligent robots A N N , 506-508 arm geometries, 503-504 characteristics, 503-504 configurations, 503-504 control strategies, 504-506 market, 501 robot arm dynamics, 519-524 robot arm kinematics, 509-519 robot neural controller, 524-525 Industrial machine vision, 43 1-455 block diagram, 437 calibration, 449 cost, 448-449

Index International Standards Organization (ISO), 734 Internet site references investigation programs, 718 Interrupt controlled, 20 1 Intersection defined, 2 sets, 34 Interstitial atoms, 537 Intrinsic sensors, 200 Inventory, 637 Inverse function, 65-46 Inverse of a trigonometric function, 66 Inverse z-transform, 256-258 Inverse-dynamics control, 505 Inverses elementary matrices, 48-50 Investigation assuring quality, 717-7 18 concepts, 692-698 conducting, 709-7 13 corruption or undermining, 695-696 developing descriptions and explanations, 716-7 17 r~ommendations,7 17 knowledge, 692 principles, 699-701 flowcharting, 699 process plan, 704-706 processes, 70 1 quality program and process, 7 12 support preparation, 708-709 tasks, 691 after, 713 performance, 692 tools, 713-7 16 Investigation manuals web site addresses, 718 Investigation processes, 691-492 Investigation programs conducting investigation, 709-7 13 context, 689-4590 definitions, 689 for organizations, 689-7 18 internet site references, 718 investigation guides, 7 17 knowledge needs, 692 planning, 70 1-709 processes, 691-692 quality assurance, 7 17-7 18 reference tools, 716-7 17 roles, 690-69 1 task knowledge, 692-698 tools, 713-7 16 Investigations are remembered by their results, 700 Investigator’s data transformation challenge, 695

Investigators checklists, 715-716 helps, 7 13-7 16 preparation, 706-707 task deliverables, 7 12-7 13 Iron allotropic, 548 intergranular fracture, 562 Iron-carbon alloys microstructural variations, 550 Irregular cash flow, 832 ISO/OSI Model, 210 Isoinertial strength testing physical strength assessment ergonomics, 805-8 13 Isokinetic strength physical strength assessment ergonomics, 8 19-822 Isolation instrumentation amplifier, 138-1 39 Isometric strength physical strength assessment ergonomics, 801-805 Jacketed machines, 593 Jaynes’ principle of maximum entropy, 487 Job design ergonomics assessment, 800 Job shop, 458-459 characteristics, 459 Johnson’s MORT safety research energy tracing, 698 investigation principles, 699 Jury test, 225-226 Just in time, 472-473 Kanban, 466-469 Kanban cards conveyance and production, 469 Kharatonov polynomials, 227 L’Hospital’s rule, 71-72 L-shape flow, 623 Laboratory services typical, 185-1 86 Ladder diagrams, 204 Lagrange’s Theorem, 131 Lagrange-Euler method, 520-523 Lamellar injection molding (LIM), 582 Laplace expansion, 57-58 Large optics diamond turning machine LLNL, 179 Laser scanner, 421-422, 424 Lawrence Livermore National Laboratory (LLNL) large optics diamond turning machine, 179 Leadership, 480-48 1 Leakage, 238-240 Learning supervised, 408-409

Index

[Learning] unsupervised, 408-409 Learning curves manufacturing-cost recovery and estimating systems, 853-855 Least-squares error, 202 Least-squares method, 270-271 LED-based sensors, 727 Left censoring, 5-6 Legal support investigation preparation, 708 Legibility textual displays, 773 Lens optics and imaging, 441 Liberty Mutual Tables weight lifting, 816, 817 LIFTEST, 806, 807-808 Lifting equipment, 629 Light, 393 Light curtian, 726-727 Light direction, 438 Light-emitting diodes, 440 Lighting, 439 workstations, 794 Limit cycle, 194 Limit values, 201 Limits, 67-68 finite, 67 infinite, 67-68 Line defect, 537 Linear algebra, 43-63 determinants, 56-58 Eigenvalues, 58-59 inner-product spaces, 59-63 matrices, 43-5 1 vector spaces, 51-56 Linear differential equation, 89 Linear equations nonconstant coefficients, 95-96 Linear first-order differential equations, 96-108 computer analysis, 111-112 homogenous system, 101-107 matrices theory, 96-1 0 1 nonhomogenous system, 107 nonlinear equations, 108-1 12 numerical analysis, l l 1-1 12 Linear flow, 622 Linear programming, 297-3 18 absolute values, 303 canonical form, 299-300 duality, 302-303 formulation, 297 generic diet problem, 300-301 integer variables, 303-3 18 GIN variables, 303, 311-312

875

[Linear programming] INT variables, 303, 310-31 1 multiperiod problem, 3 14-3 15 production problem, 297-300 standard form, 299 transportation problem, 301-302, 312-3 13 Linear shift-invariant (LSI) system, 235, 258-259 frequency response, 26 1-262 stability, 260-261 state-variable representation, 262-263 Linear time-invariant system models stability, 2 17-220 Linear transformation vector spaces, 54-56 Link analysis, 759 Linked events sets, 697 Linking concepts, 697-698 Links, 759 Liquid crystalline polymers (LCP)/theroplastic (TP), 575 Liveness, 344 Petri net, 342 Locational diagrams, 621, 622 Log-normal distribution, 12, 14 Log-normal probabi~typlot, 29, 30 LOGISTAT CP 80 system, 212-21 3 Long term memory, 766-767 Lost Workday Incidence Rate (LWIR), 724 Lowest common multiple multiplication table, 114 LSI system (see Linear shift-invariant (LSI) system) LU-factorizations matrices, 50-5 1 Lyapunov stability nonlinear systems, 23 1-232 Machine human interaction, 750 temperature excursions, 183 temperature measurements, 182 Machine guarding OSHA, 725-728 Machine monitoring, 413 Machine vision attribute measurement system, 41 1 defect location, 41 1-412 defined, 43 1 dimensional measurements, 4 11 future development, 409-410 hole location, 41 1 image functions and characteristics, 396-398 industrial robot control, 413 inspection, 410-412 limitations, 397 part identification and sorting, 4 12-413 bin picking, 413 character recognition, 4 12 conveyor picking-overlap, 4 12

876 [Machine vision] inventory monitoring, 412 no overlap, 412-413 recommendations, 413 surface contour accuracy, 4 12 Machine vision hardware, 395-396 MACRS depreciation, 844 MADALINE (Multilayer ADAptive LINear Element), 508 Magnetic-based sensors, 381 Mainstream architecture, 192 Make-to-order, 458 Make-to-stock, 458 Management databases, 203, 207, 208 Management level communication links, 209 Manipulator, 503 Manipulator motion kinematic equations robot arm kinematics, 518-5 19 Manufacturing engineering new approach, 453-454 future, 451-455 Manufacturing resource planning (MRPII), 462 Manufacturing systems, 457-483 components, 458 contemporary manufacturing philosophies, 472-480 design definition, 749-750 product processing strategies, 458-461 product-positioning strategies, 457-458 push versus pull techniques, 461-472 simulation analysis documentation, 334-335 measures of variability, 333-334 output analysis, 332-333 recommendations, 334 sensitivity analysis, 334 simulation modeling, 330-332 simulation project, 324-328 verification and validation, 331-332 situation analysis, 323-335 VVCM, 480-483 Manufacturing-cost recovery and estimating systems, 849-862 activity based costing, 859-860 automation impact, 861-862 capital budgeting, 855-4359 conventional procedures, 849-852 cost reviews, 852-853 learning curves, 853-855 software, 860-86 1 Marginal probability distribution, 17 Marginal stability, 220-221 criteria and tests, 227-228 Marine carriers, 629

Marked graph, 343 MARR, 840, 841 Marshal-Olkin distribution, 19-20 Mask, 398 Mass centers, 83 moments, 83 Master production schedule (MPS), 463 Matched die molding, 597 Material classification summary, 612 Material flow analysis (MFA), 609-624 data, 616-617 data source determination, 6 14-6 16 flow calibration, 617-618 flow units identification, 6 11-6 14 graphical representation, 619-624 flow complexity, 623-624 macrolevel flow patterns, 622-623 material classification, 609-611 objectives, 609 Material flow diagrams equipment selection, 628 Material flow patterns, 608 Material flow report, 618 Material handling channel systems, 627 direct systems, 627 equipment, 628-631 robotics, 501-502 selection guide, 632 system design and documentation, 635 terminal systems, 627-628 Material requirements planning (MRP), 461-466 Material warehousing and storage, 635-640 Material-handling-systemdesign, 624-628 containers, 626 route structure, 627-628 Materials fracture, 560-561 strengthening mechanisms, 549-553 tensile stress-strain curves, 560 Matlab, 164 Matrices, 43-5 1 adding variables, 274 arithmetic, 44-46 block multiplication, 47 canonical forms, 99-100 determinants, 97-98 elementary, 48-50 exponent, 98-99 Gaussian elimination, 47-48 linear first-order differential equations, 96-101 linear programming, 300 LU-factorizations, 50-5 l products, 97-98 shapes and sizes, 4 3 4

Index

[Matrices] sums, 97-98 Matrix groups, 130 Matrix impulse responses, 2 19-220 Matrix transfer functions, 219 McCulloch-Pitts neuron, 507-508 Mean cell size, 543 Mean value theorem, 76 Measurable value function under certainty, 362-366 Measurable value function under risk, 366-368 Measurable value function under uncertainty, 368-370 Measurable value theory, 362-370 certainty, 362-366 risk, 366-368 uncertainty, 368-370 Measurement, 489-498 alcohol concentration and temperature, 496-498 gold data, 493 graphical representation, 491-492 one-way classifications, 490 one-way data iterative analysis, 492-493 parameters, 137 robotics, 502-503 second- and third-law data analyses, 492 signal conditioning, 142-146 statistics, 489-490 two-way tables, 493-495 Measures of location manufacturing analysis simulation analysis, 332-333 Measures of variability manufacturing analysis simulation analysis, 333-334 Mechanical hazzards, 725 Mechanically based sensors, 379 Mechatronics, 157 Media support investigation preparation, 708-709 Meeker’s Law, 700 Melt temperature gas-assisted molding, 584 Memory in humans, 766-767 Memory aids, 758 Mental movies, 696 Metal alloys historical perspective, 530 Metal crystals slip systems, 540 Metals atomic structure, 530-53 1 corrosion, 561-564 creep, 558-564 historical perspective, 529-530 wear, 561-564 . , Microprocessor, 251 Microstructure evolution, 544

877

Miller index notation, 535 Miller-Bravais index notation, 535 Miniload cranes, 650-65 1 MINITAB regression printout, 276-278 Miniterms, 118 MIST, 810-811 Mixed random variables, 5-6 Mobile robots applications, 413 Modality compatibility, 786 Modular software, 204-205 Moire systems, 420-421 Mold temperature gas-assisted molding, 584 Moment-generating function (mgf) random variables, 20, 21 Moments mass, 83 multidimensional random variables, 17-1 8, 19 random variables, 8 Motion control, 157 architectures, 157-1 58 Motion hazards OSHA, 728-729 Motion trajectory problem, 504-505 Motor vehicles, 629 Motorized robot a m , 166-169 Movement compatibilty, 786 displays and controls, 787 Multi-step themoforming, 597 Multiattribute utility function, 360-362 Multibus system, 213 7 Multidimensional continuous random variables, 16-1 Multidimensional discrete random variables, 15-16 Multidimensional random variables, 15-20 moments, 17-18, 19 Multidisciplinary teams, 454 Multilinear conceptual framework, 693 Multiloop controller, 195 Multinomial distribution, 16 ~ u l t i n o ~distribution, al 19 M u l t i n o ~ arandom l variable characteristic function, 21,23 Multiperiod problem linear programming, 314-3 15 Multiple places Petri nets, 355 Multiple tokens Petri nets, 355 Multiplication table Po, 117 Multirate systems, 249-25 1 Multispindle automatic screw machine, 722-723 Multistimuli touch sensors, 385 Multivariate case

878 [Multivariate case] random variables simulation, 24 Multivariate moment-generating education, 18-1 9 Mutual exclusion Petri net, 351, 352 National Building Code (NBC), 735, 736-737 National consenus OSHA, 721 National Fire Prevention Association (NFPA), 734 National Recognized Testing Laboratories (NTRL), 737 Natural logarithm, 68 Near point, 771 Near sightedness, 77 1 Near-net-shape, 567 Negative binomial distribution, 10, 11 Net-shape, 567 Network layer, 210 Neural adaptive control, 195, 524 Neural computers, 499 Neural networks, 407-409 Neuron, 506, 507 Neurosoftware, 195 Newton's method finding roots, 73 Newton-Euler (N-E) formulation, 520-521 Nickel stress and strain, 543 Node dominance, 345 Noncentral chi-squared random variable, 14 Noncentral Snedecor F random variable, 15 Noncommutative rings, 134 Nonhomogenous system linear first-order differential equations, 107 Nonlinear equations, 108-1 12 classical techniques, 108-1 11 pertubation theory, 108-109 Poincare-Bendixson theory, 109-1 10 stability theory, 110-1 l1 modern techniques, 1l1 Nonzero binomial, 10 Normal distribution, 14 Normality, 275-276 Nucleation, 546 Null set, 33 Numerical analysis linear first-order differential equations, 111-1 12 Numerical integration, 80-8 1 Nyquist frequency, 253 Nyquist stability criterion, 224 Objective investigation quality assurance, 698 Occupational Safety and Health Administration (OSHA), 7 19-732 enforcement powers, 719-720 Federal standards, 720-72 1 general requirements, 721-724

Index

[Occupational Safety and Health Ad~inistration(OSHA)] hazardous environments, 729-730 machine guarding, 725-728 repetitive motion hazards, 728-729 worker fatality case study, 722 Occupational Safety and Health Review Commission (OSHRC), 724 Occurrences role of change, 693-694 One-step ~ e r m o f o ~ i n597 g, One-way classifications, 490 Open interval, 65 Open loop theories, 769 Open-die forging, 570 Operating system, 200 Operator feedback, 750 Operator modification surveys, 758 Optical integrated circuits, 200 Optical sensors, 381-383 Optical slip sensors, 387 Optical-fiber based sensors, 383 Optics industrial machine vision, 440-442 Optoelectronics, 200 Orbit-Stabilizer Theorem, 133 Order relations, 40-41 Order statistics distributions, 24-27, 28 Order-Disorder phenomena, 546 Ordered pairs, 37 Orders, 637 Ordinary differential equation (ODE), 87-1 12, 235 classical techniques, 88-93 exact differential equations, 89-91 linear equation of first order, 89 separable equations, 88-89 substitution methods, 91-93 geometric approach, 93 linear equations nonconstant coefficients, 95-96 linear first-order differential equations, 96-1 08 Organization-wide investigation program readiness tree, 702 Organizational context investigation programs, 690 Organizational cues, 758 Organizations standards names, addresses, websites and phone numbers, 740-748 Original equipment manufacturer (OEM), 463 Orthogonality inner-product spaces, 60-61 Outliers, 290 Output analysis manufacturing analysis simulation analysis, 332-333 Output data, 203 Output device drivers, 205

hdex Output functions, 20 1 Output signal condition algorithms, 201 Output signal conditioning, 205 Overhead conveyors, 633 P-invariants Petri net, 346 Packing, 578 Pallet racks, 638 Pallet storage, 638-639 Pallet trucks, 633 Parallel mutual exclusion (PME), 353, 354 Parallel Petri net, 351 Parallel robot confi~ration,504 Parison, 59 1 Parison mesh, 593 Partial consistent Petri net, 343 Partial derivatives, 84-85 Partial differential equations, 87 Partial fraction, 79-80 Partial fraction expansion, 256 Partitioning strengthening, 554 Partitions equivalence relations, 40 Pascal distribution, 10 Passive stereo imaging, 419-420 Pattern recognition, 195 Payback method, 842 PEARL (Process and Experiment Automation Real-Time Language), 203 Perception vs. detection, 766 Perceptual cues, 758 Performance analysis ASRS, 656 Performance index, 202 Permissible exposure levels (PELS),729, 731 Permutation groups, 130, 132-1 33 Person specification, 759-760 Pertubation theory, 108-109 Petri nets, 337-356 behavioral properties, 341-342 colored, 355-356 coverability tree, 344-345, 346 dedicated resource modeling, 352 DES, 337 features, 344 invariants, 346-347 modeling coupled process shared resources, 353-354 models, 348 choice, 352 initial, 351 mutual exclusion, 35 1, 352 operation places, 351-352.

I

[Petri nets] parallel, 352 sequence, 351, 352 notation and definitions, 339-340 original extensions, 355-356 reachability tree, 344-345 state automata, 338 state equation, 340-341 state machine, 344 state transition function, 340 stochastic, 350-351 structural analysis state equation, 346-349 structural properties, 342-343 subclasses, 343-344 synthesis technique procedure, 354-355 timed models, 349-351 transition refinement, 353 Phase diagrams, 546 Phase equilibria, 545-546 Physical layer, 210 Physical strength assessment ergonomics, 797-825 isoinertial strength testing, 805-8 13 isokinetic strength, 8 19-822 isometric strength, 801-805 psychophysical strength, 813-8 18 PICON, 195 Piezoelectric drive system, 557 Piezoelectric effect, 557 Piezoelectric sensors, 383-384 Pig iron, 530 Pinhole camera, 418 Piola-Kirchho~stress tensor, 598 Pixel, 398 Planar defect, 537 Plant analysis, 199 Plant automation classical approach, 187-1 89 computer-based, 189-1 9l Plant databases, 203, 206, 207 Plant instrumentation level, 198 Plant management level, 196-198, 200, 203 Plant operator interfaces, 192 Plant supervisory control level, 196-198 Plant supervisory level, 200, 201 Plastic deformation, 567-568 Plastics, 558 creep, 558-564 Plug-assisted pressure forming, 597 Plug-assisted vacuum forming, 597 Plunger, 570-571 Plunger transfer molding, 586 Poincare-Bendixson theory, 109-1 10 Point defect, 537 Point of operation

80

[Point of operation] safeguarding, 725 Poisson distribution, 11 Poisson random variable moment-generating function, 20, 22 Poles distance measure, 228-229 Po~yamideimide(PAT), 575 Polyetheretherketone (PEEK), 575 Polyetherimide (PEI), 575 Polyethersulfone (PES), 575 Polymers covalent bonding, 559 structure and properties, 558 Polymethyl methacrylate (PMMA), 558 Polynomial coefficient test, 222 Polynomial rings, 135 Polynomial test, 227-228 Polyphenylene sulfide (PPS), 575 Polyvinylidene fluoride (PVDF), 383-384 Position-contro~ledserver system block diagram, 174 Positioning/weig~ng/controlling, 629 Positive molding, 574 Postage stamp value regression, 295 Postinvestigation tasks, 713 Pot transfer molding, 586 Power transformation, 278 Practices definitions, 734 NFPA definition, 736 organizations names, addresses, websites and phone numbers, 740-748 Prefiltering, 194 Preformance measures OSHA, 724 Preforms, 575 Presence sensing devices, 726-727 Present worth factor, 833 Present worth method, 839-840 Presentation layer, 21 1 Press brake, 572 Pressure forming, 597 Prewarping requation, 246-247 Prime implicants computation, 119-120 Primitive connection matrix, 122-123 Principal component analysis regression, 290-29 1 Principle of Duality, 113-1 15 Probabilities graphical representation, 6-7 Probability concepts, 1-31 basic, 1-4 multidimens~onalrandom variables, 15-20

Index [Probability concepts] order statistics and extremes, 24-27 probability plots, 27-3 1 random variables characteristics, 20-23 random variables simulation, 24 random variables transformations, 23-24 unidimensional random variables, 4-8 univariate continuous models, 11-1 5 univariate discrete models, 8-1 1 Probability density curve, 6 Probability density function (pdf), 7 Probability distribution tables, 6 Probability mass function (pmf), 7 Probability mass-density function (pmdf), 7 Probability measure, 2-3 Probability plots, 27-3 1 empirical cumulative distribution function, 28 fundamentals, 28 Cumbel, 29-3 l log-normal probability, 29, 30 normal, 28-29 plotting positions formulas, 28 Weibull, 31 Process bias, 178 Process closed-loop bandwidth, 155 Process control in-process measurement, 180-183 Process control level, 200 communication link, 2 11 communication links, 209 Process data transfer standard, 198 Process database, 206 Process design, 609 Process efficiency, 609 Process errors, 177 Process interface standardization, 198 Process qualification in-process measurement, 183-1 84 Process variation, 178-180 Process-controlled-variabledefined error, 155, 156 Process-oriented programming languages, 203 Product volume (PV)/mode curve, 608-609 Product volume plot, 608 Production control level communication link, 2 11-2 12 com~unicationlinks, 209 Production databases, 203, 207, 208 Production dispatch interfaces, 192 Production management level communication link, 2 11-2 12 Production monitoring interfaces, 192 Production problem linear programming, 297-300 Production scheduling and control level, 196-198 database, 208 Production system

c

Index [Production system] controls, 472 Products, 637 Program controlled, 20 1 Programmable controllers, 190 Programmable timers, 202 Progressive analysis, 696 Progressive isoinertial lifting evaluation (PILE), 8 10-811 Project shop, 460 Projection matrix adding variables, 274-275 PROWAY (Process Data Highway), 209 Psychophysical strength physical strength assessment ergonomics, 8 13-8 18 Pull systems, 466-470 vs. push systems, 470-472 Punching, 571 Push systems, 463-466 vs. pull systems, 470-472 Push versus pull techniques, 4'61-472 Qualitative visual displays, 778 Quality assurance checklists, 715-7 16 for investigation, 7 12 Quantitative visual displays, 777 Quantization error, 194 Railroad cars, 629 Random experiment, 2 Random variables, 4-6 characteristic function, 21-22 characteristics, 20-23 linear transformations, 18 moment-generating function, 20, 21 moments, 8 one-to-one transformations, 23-24 probability distributions, 6 simulation, 24 sums and products, 18 transformations, 23-24 Randomized factorial design, 663 Rate of return method, 841 Rational decision making definitions, 767 Rayleigh random variable, 12, 14 Reach trucks, 633 Reachability Petri net, 341-342 Reachability tree Petri net, 344345 Reaction injection molding, 577-578 Reaction time, 769 Readability textual displays, 773 Real FFTs, 237

Real-time programming languages, 203 Reccommeded practice NFPA definition, 736 Recipe managers, 202 Recommended practices (see Standards) Record keeping OSHA, 724 Recovery systems manufacturing-cost, 849-862 Recrystallization, 542 Recurrent network, 508-509 Recursive filter, 241-243 Redistribution modeling, 666 Redundancy, 766 Redundant robot confi~ration,504 Region of convergence (ROC), 256 Regression, 269-295 adding variables, 273-275 correlations, 272 data sets, 293-295 eigenvalues, 290-29 1 high leverage "points,289-290 historical development, 269 model fitting, 270-27 1 model goodness of fit, 276-281 nomality, 275-276 outliers, 290 residuals fits, 273 transformations, 27 1-272 variables, 281-289 vectors, 272-273 weighted least squares, 292-293 Regulations, 735 (see also Standards) definitions, 734 organizations names, addresses, websites and phone numbers, 740-748 Regulatory context investigat~onprograms, 690 Regulatory organizational listing addresses, websites and phone numbers, 740-748 Relational blocks, 202 Relations, 37-41 Cartesian product, 38 equivalence, 40 order, 40-41 ordered pairs, 37 Relative stability, 221 criteria and tests, 228-230 Remote terminal units (RTUs), 209 Repetitive motion hazards OSHA, 728-729 Repetitive motion illness, 729 Repetitive Petri net, 343 Repetitive strain injuries (RSI), 728 Residuals, 273, 279-280

882

Resin transfer molding (RTM), 587-589 modeling, 589 technology, 587-588 Resistant regression, 278-279 Resistive-based sensors, 379-380 Resource Conservation and Recovery Act (RCRA), 736 Response time, 769 Retina, 393-394 Ridge regression, 29 1-292 Right censoring, 5-6 Rigid-link pendulum, 162-166 Rigorous proofs set operations, 36 Ring rolling process, 568 Rings algebra, 133-135 RISC processor chips, 192 River diagrams, 621, 622 RLC circuit, 259-260 Robot arm dynamics, 5 19-524 Robot arm kinematics ~enavit- art en berg representation, 5 12-5 14 homogenous transformation matrix, 5 11-5 12 industrial intelligent robots, 509-5 19 inverse kinematic solution, 5 16-518 manipulator arm kinematic equations, 5 14-516 manipulator motion kinematic equations, 5 18-5 19 Robotic solutions, 729-730 Robotics automation, 500-503 Robots, 499-525 Adeptone, 502 arm dynamics, 5 19-524 arm kinematics, 509-524 artificial neural networks (ANNs), 506-508, 518 automation, 500-503 controller, 503 feedback devices, 503 gantry configuration, 504 industrial intelligent, 503-508 mobile applications, 413 neural controller, 524-525 Rods, 393-394 Role of change in occurrences, 693-694 Roll defects, 569 Rollback databases, 208 Roller conveyors, 633 Rolling friction, 569 Rolling process, 568-569 Ronchi grid stripes, 421 Root node, 344 Roots Newton’s method, 73 Rotational molding, 592-595 machines, 59

Index [Rotational molding] modeling, 595 technology, 592-594 Routh Test, 222-223, 228 Rubbers, 558, 585 Runner systems, 579 Safeguarding, 725 Safety program data regression, 293-294 Sample path, 337, 338 Sample space, 2 Sample-data systems, 233, 253-268 cascade architecture, 264-267 direct I1 architecture, 263-265 inverse z-transform, 256-258 linear shift-invariant systems, 258-259 LSI system frequency response, 261-262 LSI system stability, 260-261 LSI system state-variable representation, 262-263 mathematical representation, 255-256 origins, 253-255 transfer function, 259-260 Sampling, 398 Sandwich injection molding, 58 1-582 Scaling, 27 1 SCARA (Selective Compliant Articulated Robot for Assembly), 163 dynamic model, 523-524 Schur-Cohn Test, 225 Screw, 537 Seam welding, 413 Selective attention, 767, 768 Self-certification, 737 Self-tuning control, 202 Semiconductors, 553 Semiopen interval, 65 Semipositive molding, 574 Semirings inclines, 127 properties, 127 Sensitive leverage points, 289-290 Sensors, 726-727 characteristics, 388 force and torque measurement, 386-390 Sensory storage, 766-767 Separable equations, 88-89 Sequence, 6 19 Sequence Petri net, 351, 352 Sequencing new events, 697 Sequential mutual exclusion (SME), 354 Servo motor, 170 Session layer, 21 1 Set operations, 34-37 indexed family, 37 rigorous proofs, 36

Index [Set operations] Venn diagrams, 35-36 Set-point values, 188 Sets, 33-37 Shaded surface display, 407 Shannon interpolator, 254 Shape, 61 1-612 Shape-rolling process, 568 Shearing, 571 Sheet molding compounds (SMCs), 575 Sheet-metal operations, 571-572 Shift invariant, 258 Shop boxes, 626 Shuttle machines, 593 Side-loader trucks, 633 Signal lights, 779, 781 Signal quantization, 194 Signal sampling and reconstruction inst~mentationerror-modeled performance, 150-154 Signal-conditioningalgorithms input, 201 Signal-conditioningchannel, 143, 145 Silent witness rule, 700 Silicon, 553 Silicon-based sensors, 384-385 Simple interest, 830-83 1 Simple reaction time, 769 Simulation advantages, 324 appropriateness, 323-324 defined, 323 disadvantages, 324 Simulation analysis manufacturing systems (see ~anufacturingsystems simulation analysis) Simulation modeling, 330-332 assumptions, 330-331 data collection, 330 inputs, 331 structure, 330 terminology, 331 Simulation project analytical objectives, 325 development, 324, 325 experiment design, 328-330 factorial design, 329-330 run length and replication, 328-329 warm-up period, 328 problem definition, 324-326 simulation software selection, 326-327 solution method selection, 326 system definition, 325-326 system performance measures definition, 327-328 Simulation tool classes, 326-327 Simulator analysis, 759 Simulink, 162-163

3

Single payment compound amount factor, 832-833 Single payment present worth amount factor, 833 Singles, 626 Sinking fund factor, 833 Situation analysis, 764 Skate-wheel conveyors, 633 Slip, 377, 568 Slip sensors, 385-386 Slip systems metal crystals, 540 Small parts storage, 639 Smart sensors, 385 Smoothing images, 405 Snapshot databases, 208 Soft automation, 500 Software, 202-203 manufacturing-cost recovery and estimating systems, 860-861 Solid of revolution volume and surface area, 81-82 Solid solution, 545 Source, 695 Southern Building Code (SBC), 735, 736-737 Spatial compatibility, 786 Spatially three-dimensional image, 406 Spectrum, 236 Spray coating robotics, 502 Stability, 217-232 criteria and tests, 221-227 defined, 220-221 linear time-invariant system models, 2 17-220 nonlinear systems, 230-232 Stability theory, 110-1 11 Stackers, 633 Stacking fault, 544 stainless steel, 545 Stainless steel ductile fracture, 562 fatigue, 563 precipitation, 551 stacking fault, 545 Standards, 733-748 (see also Occupational Safety and Health Administration (OSHA)) compliance determination, 737 creating new ones, 738 definitions, 733, 734 importance of, 736 NFPA definition, 736 nonexistant, 738-739 organizations names, addresses, websites and phone numbers, 740-748 reason for, 736-737 resource location, 738

4

[Standards] terminology, 733-736 writing organizations, 737 State automata, 338 State equation Petri net, 340-341 structural analysis Petri net, 346-349 State machine Petri net, 344 State space models, 219 State transition diagram, 338 State transition function Petri net, 340 Static recrystallization, 541 Static visual displays, 773 Statistical model, 270 Statistics measurements, 489-490 Status characteristics behavioral analytical hierarchy process, 371 Status indicator display, 778-779 Status places Petri nets, 355 Steady-state sinusoidal response, 236 Steel tempering, 549 Stepwise control, 202 Stereo vision system, 423-424 Stereometry, 407 Stereoscopic display, 407 Steward platform, 504 Stochastic Petri nets (SPN), 350-351 Storage systems analysis and design, 635-636 ASRS, 639-640 implementation, 636-637 macrolayout, 635 orientation, 635 pallet, 638-639 planning, 637-638 populated layouts, 636 small part, 639 Straight-through flow, 622 Strain, 541 Strain gages, 384 Strategic planning, 48 1 Strength aptitude test (SAT), 806, 807, 808-809 Strengthening partitioning, 554 Stress, 541 Stress amplitude, 563 Stress corrosion cracking (SCC), 564 Stretch blow molding, 589 Stretching, 572, 596 String diagrams, 621, 623

Index Strongly connected Petri net, 344 Structural analysis state equation Petri net, 346-349 Structural bounded Petri net, 342 Structural conservative Petri net, 342-343 Structural consistent Petri net, 343 Structural live Petri net, 342 Structural properties Petri net, 342-343 Substitution integration, 75 Substitutional impurities, 537 Substitutional solid solutions, 545 Superconductors, 553 Superposition property, 258 Supervised control, 524 Supervised controllers, 195 Supervised learning, 408-409 Supervisory control human, 751 Supervisory databases, 203 Supervisory stations, 204 Supplier management, 483 Sustained attention, 769 Switching circuits general, 122 values, 117 Switching functions Boolean algebra, 117-120 Sylow’s Theorem, 13l Symbols coding information, 776 Synchronous manufacturing, 475476 System-centered interface design approach, 751 T distribution, 12, 14-15 T-invariants Petri net, 346 Table fan workstation, 468 Table top analysis, 757 Tables workstations, 794 Tactile sensing, 377-378 TAKT time, 608 Talk through analysis, 757 Tandem rolling, 569 Task analysis, 755-756 characteristics, 754-755 Task decomposition, 756-757 Taxable income affecting factors, 845 Telecentric optics, 442 Temporal databases, 209 Tensile stress-strain diagrams, 540

Index Terminal guidelines, 794-795 Terminal node, 344 Test and check algorithms, 201 Test and check functions, 201 Test and check operations, 205 Textual displays, 773 Theory of constraints (TOG), 473-475 Thermal camber, 569 Thermoforming, 595-598 methods, 597 molding, 598 technology, 595-597 Thermoplastics, 558 injection molding, 577-580 Thermosets, 585 compression molding, 573 injection molding, 577 Thermosetting plastics, 558 Thermosetting polyimides (TPI), 575 Things don’t lie, 700 Think events guidance, 694, 696-697 Third party testing, 737 Thread rolling process, 568 Three-dimensional vision, 415-429 comparison, 4 16 competing technologies, 415-416 data processing, 424-429 cubic splines review, 425-427 data to splines, 427-428 goals, 424-425 system types, 419-422 triangulation-missing data, 424 triangulation-reso~ution,422-425 Threshold limit values (TLVs), 729 Time delay modules, 202 Time never stands still, 699-700 Time of flight, 415-416 Time weighted averages ( W A S ) , 729 Time-critical responses, 2 14 Time-related data, 207-208 Timed Petri nets, 349-351 Timed place Petri net (TPPN), 349-350 Timed transition Petri net (TTPN), 349-350 Timers, 202 Tin Token capacity, 354 Token ring, 21 1 Tool co-ordinate system, 5 15 Tool set cycle, 181 Tool shape errors, 182 Topology, 506, 507 Torsion, 540 Total Probability Theorem, 4 Tote pans, 626 Touch, 377-378

Touch sensing, 377 technology, 378-386 Towveyors, 635 Track change makers, 699 Transfer functions, 218, 235, 259-260 Transfer molding, 585-587 Transition gain ratio, 241 Transport layer, 2 10 Transport work material flow evaluation, 625 Transportation problem linear programming, 301-302, 312-3 13 Transportation system container inventory control, 666-668 Trian~lation-missingdata, 424 Triangulation-resolution, 422-425 Trigonometric integrals, 78-79 Trigonometric substitutions, 79 Truck unloading, 642 Truth table Boolean function f, 116 Tube bending, 572 Tungsten particles, 548 Turning machine, 180 Turret rucks, 633 Twinning, 568 Two-dimensional vision, 416-419 Two-predictor model adding variables, 273-274 Type size and styles, 775 U-shape flow, 623 Ultimate tensile stress (UTS), 536 Uncorrelated predictor variables regression, 28 1-282 Unidimensional random variables, 4-8 Uniform Building Code (UBC), 735, 736-737 Uniform gradient, 832 Uniform gradient series factor, 837 Uniform series, 832 Union defined, 2 sets, 34 Unit-load cranes, 649-650 Unity-gain filter network capacitor values, 141, 143 Univariate case random variables simulation, 24 Univariate continuous models, 11-15 Univariate discrete models, 8-1 1 Unsafe acts and conditions industrial settings, 69 l Unsupervised learning, 408-409 Usability definition, 752

Index Yield stress, 536 Yttrium barium copper oxide, 553 Zero-inputstability criteria, 221

Zero-order hold (ZOH), 172, 254, 255 Ziegler-Nicholes test, 188-189 Zipper cracks, 569

Index

886

Usability engineering approach, 751,752 User characteristics, 754 User need analysis, 751, 753-754 User-centered interface design approach, 75 1 752 Utility programs, 202 Utility theory, 359-362 Vacuum forming, 597 Validation manufacturing analysis simulation analysis, 332 Value, 612 Value-free reporting, 694 Van der Weals, 553 Variables backward elimination, 284-285 best regression, 283, 284 forward selection regression, 283-284 hierarchical regression, 285-286 indicator, 287-289 regression, 28 1-289 Variation-of-constants formula, 107 Variation-of-parameters formula, 107 Vector spaces, 51-56 bases, 52-53 change-of-basis matrices, 53-54 coordinate maps, 53-54 defined, 5 1-52 linear transformation, 54-56 Vectors, 272-273 adding variables, 274 linear programming, 300 Velocity loop DC, 171-172 Venn diagrams, 35-36 Verifiable reporting, 694 Verification manufacturing analysis simulation analysis, 33 1-332 Vertical edges images, 405, 406 Vertical standards OSHA, 721 Vibration test, 661, 662 Vibratory machines, 633 Video array industrial machine vision, 442-444 Video display terminal guidelines workstation design, 794-795 Virtual reality, 454 Visibilty textual displays, 773 Visible light, 727 Visual acuity vs. age, 772 Visual angle, 775

Visual cortex, 393-394 Visual displays, 770, 771 design recommedations, 773 Visual senses, 766-767 Visual system neural processing, 394-395 Void set, 33 Voltage loop DC, 171 Volume defect, 537 Volumes, 637

I

W-Plane Transformation/Routh test, 226-227 Walk through analysis, 757 Walsh transform, 400 Warehouse information system computerized, 641 Warning lights, 779, 781 Warping, 246-247 Wavelengths, 438, 441 Websites investigation manuals, 7 18 regulatory organizational listing, 740-748 Weibull probability plot, 31 Weight, 61 1 Weight lifting Liberty Mutual Tables, 816, 817 Weighted least squares regression, 292-293 Welding robotics, 500-501 Windowing, 239-240 Witness plates, 698 Work product development tasks, 7 11-712 Work product quality for investigation, 7 12 Worker fatality case study OSHA, 722 Working memory, 766-767 Workstation design, 793-795 physical layout, 793-794 video display terminal guidelines, 794-795 World-class manufacturing (WCM), 480-483 agility, 482 customer focus, 48 1-482 information technology, 482 organizational culture, 480-48 1 product development, 483 quality, 482-483 supplier management, 483 Wrought iron, 530 Xenon strobes, 440 YEWCOM, 213 YEWPAC, 213

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