Abstract
Introduction
With the growth of global competition, manufacturers now face a more complex marketing environment and must respond to a changing market more quickly, and their product must have better performance and lower costs. As the bridge that connects the customers, manufacturers, and suppliers, design is the key to ensuring the success of a product. Variant design is a type of design that adapts previous products in the local structure or the parameters of parts to satisfy new requirements. 1 Because variant design shows significant advantages in both time and cost, it is attracting increasing attention. 2
Many methods have been applied to increase the efficiency of variant design. Case-based reasoning (CBR) is one of the most widely applied techniques in this field. CBR, an artificial intelligence technique proposed by Schank, 3 infers the solution to a new problem based on previous experience. A typical CBR system consists of four sequential steps that are recalled to solve a problem: retrieve the most similar case, reuse the case to attempt to solve the new problem, revise (adapt) the suggested solution as necessary, and retain the new solution. 4 CBR has been applied in many domains, such as financial distress prediction, 5 chemistry, 6 medical diagnosis, 7 environmental protection, 8 and oceanography. 9
In general, case adaptation is usually required to complete a new design. However, case adaptation requires extensive adaptation knowledge and takes a long time. Therefore, the automation of case adaptation can significantly increase the efficiency of variant design. Case adaptation is essential for CBR implementation, and adaptation knowledge is very important for the application of the retrieved case to the solution. 10 However, since data play an important role in the process of new product development, 11 a large amount of design data has been collected. Therefore, mining knowledge from the design data is the key to increase the automation of case adaptation.
In this study, a data mining technique is introduced into CBR to acquire the adaptation knowledge, which is in the form of a production rule. Then, case retrieval and case adaptation are realized using the acquired adaptation knowledge.
Section “Literature review” presents a literature review. Section “Overview of the proposed method” describes the framework of the method in this study. Section “Adaptation rule acquisition” describes the method for the adaptation rule acquisition in detail. Section “Case retrieval and adaptation” describes the case retrieval and case adaptation methods in detail. Section “Case study” provides an example to illustrate the method. An experiment is shown in section “Experiments” to validate the effectiveness of the method. Section “Conclusion and future work” provides the conclusion.
Literature review
In general, a solution to a new design problem that has been retrieved cannot be used directly and must be adapted beforehand. However, case adaption is the bottleneck in CBR execution, and some studies have been performed to address the case adaptation bottleneck. Tong et al. 12 proposed an adaptation technique based on fuzzy regression for the process design of transfer molds for electronic packages. Qi et al. 13 addressed a new case adaptation method that uses a support vector machine, which incorporates the adaptability-related knowledge provided by the retrieved cases. Hu et al. 14 proposed a new case adaptation method for parametric machinery design using the weighted mean (WM). Jung et al. 10 proposed a new case adaptation method based on the artificial neural network and used the method to calculate the design values of a new shadow mask. These studies can increase the automation of case adaptation to some extent, but their methods apply only to the adaptation of numerical attributes. Because a product has both numerical attributes, such as the bore diameter, and categorical attributes, such as the material, an adaptation method that supports both types of attributes is required. Vong et al. 15 proposed a case-based adaptation method, which is a two-level CBR that contains a case library and an adaptation case library. However, the method applies only to a new adaptation that is completely consistent with an existing adaptation case in the library. Janthong et al. 16 proposed a case adaptation method based on rule inference, but the rule acquisition remains a bottleneck in his study. Li et al. 17 proposed a method of adaptation rule acquisition by manually comparing similar cases, but the method is applicable only when the case base is small and has relatively few attributes. For example, even if there are only 200 cases in the case base and each case has only 40 attributes, to extract all adaptation rules, comparisons should be performed 1,592,000 times, which cannot be handled manually. Because of the wide application of information systems, case bases usually contain many cases, and cases of mechanical design usually have many attributes, particularly for complex products.
Compared with the previous methods, our method has two main advantages that make it more applicable to variant design:
This method can handle the case adaptation with both numerical and categorical attributes.
This method can acquire adaptation rules automatically when the case base has many cases and when the cases have many attributes.
Overview of the proposed method
The method of case adaptation in this study can be divided into two main phases. In the first phase, the adaptation rules are acquired. In the second phase, the rules are used to retrieve the most similar case and adapt the retrieved case. The framework of the method is shown in Figure 1.

Framework of the proposed method.
In the rule acquisition phase, the cases are first pre-processed. Then, by comparing the case pairs, the changing events are extracted to represent the difference between cases. Then, the Apriori algorithm is applied to acquire the adaptation rules that are in the form where if
In the variant design phase, the most similar case is first retrieved by the similarity evaluation. Then, the adaptation rules are selected and used to obtain the inference result. Finally, the inference result is transformed into the uncoded form.
Adaptation rule acquisition
In this section, the rule acquisition method based on data mining is described in detail. Data mining, a technique to discover knowledge in a database, has become a research area and has assumed increasing importance with the significant increase in the amount of data in recent years. 18 The data mining technique has been widely used in many fields, including biology, 19 agriculture, 20 medical science, 21 and finance. 22 The entire process of adaptation rule acquisition consists of two steps: data pre-processing and adaptation rule mining.
Data pre-processing
In this study, the cases are represented as attribute–value pairs, which include design requirement attribute–value pairs and design result attribute–value pairs. The requirements and results of variant design have both categorical attributes, such as the material used for the parts, and numerical attributes, such as the diameters of the holes. To realize rule mining, the raw data should be pre-processed. For the numerical attributes, equal-width binning is performed to discretize the attribute values. Equal-width binning is an unsupervised method for producing categorical values from numerical ones and involves dividing the range of observed values of a numerical attribute into
where
Each bin of an attribute is considered a value and given a uniform code. The categorical attributes can be directly coded. The values of the design requirements are expressed as
The adaptation rules are obtained by analyzing the co-occurrence between the changes in the design requirements and the design results. Each change in a design requirement or design result is called a “changing event” in this study. The changing events should be extracted by comparing two cases. A changing event of a design requirement is expressed as
Adaptation rule mining
The Apriori algorithm is used to acquire the adaptation rules in this study. The Apriori algorithm was proposed by Agrawal and colleagues24,25 and is one of the most widely used techniques for finding association rules. The algorithm operates in two phases. In the first phase, all itemsets with minimum support (frequent itemsets) are generated. This phase uses the downward closure property of support. In other words, if an itemset of size
A frequent itemset is an itemset with a larger support than the support threshold. The support of the itemset is obtained using equation (2)
where
Definition
The adaptation rules are stored in the rule base.
Case retrieval and adaptation
Variant design is realized by adapting previous design cases. Thus, the case that is most similar to the target case is retrieved first. Then, the retrieved case is adapted by the inference of the adaptation rules that were acquired in the previous section.
Case retrieval
The role of case retrieval is to find the most suitable case for the following adaptation. Case retrieval is realized by evaluating the similarity between the target case and the previous cases. The most important issue of similarity evaluation is weighting the design requirements. In this study, the weights of the design requirements are obtained by analyzing the adaptation rules. The adaptation rules express the changes in design requirements and the corresponding changes in design results. Therefore, if one change in a design requirement causes more changes in design results, the design requirement should be assigned a higher weight.
To weight the design requirements, the importance score of each design requirement is calculated first. The importance score of the
where
where
The similarity between two cases is obtained by calculating the weighted sum of the similarity between each corresponding design requirement of two cases. The most similar case is selected for the following adaptation.
Case adaptation
The role of case adaptation is adapting the retrieved case to satisfy the new design requirements. Case adaptation is realized by the inference of adaptation rules. During the course of inference, it is possible that no single rule can realize the inference. Thus, a group of rules should be used together to complete the inference. However, there may be more than one group of rules that can realize the inference, so it is necessary to select the suitable rule group. The rule group is selected by their applicability, which is obtained using equation (6)
where
Two rules may conflict with each other during the inference process. For example, the changes in
Extract the changing events by comparing the design requirements of the target case and the retrieved case.
Search for the single rule that exactly satisfies the changing events. If the single rule exists, the inference result is obtained directly.
If there is no single rule that satisfies the change events of the design requirements, select the rule group with the largest applicability and complete the inference.
The outputs of the rule inference are the changing events of the design result, as expressed in the coded form. To accomplish the variant design, the outputs should be translated into uncoded form. More importantly, the numerical attributes of the design result should be given exact values. The exact value of a numerical attribute is obtained in the following steps:
Select the cases that have the same encoded value with the attribute of the target case.
Calculate the similarity between the cases and the target case. The five cases with the largest similarity are selected as the valuation basis.
Calculate the weights of the cases using their similarity with the target case.
Obtain the exact value of the attribute of the target case by calculating the weighted average of the uncoded attribute values of the five cases.
Case study
An example of electromotor design is provided in this section to illustrate the proposed method of case adaptation. A model of an electromotor is shown in Figure 2. The main design requirements include rated power (RP), number of poles (NP), rated voltage (RV), rated frequency (RF), protection class (PC), cooling method (CM), mounting arrangement (MA), duty type (DT), and noise (N). The design results of variant design are the main attributes of the parts, such as the specification of the stator core (SC), specification of stator windings (SW), specification of the rotor core (RC), specification of bearings (B), specification of the fan (FA), specification of the frame (FR), and specification of the end covers (EC), as shown in Table 1.

A model of electromotor.
Example case.
RF: rated frequency; N: noise; MA: mounting arrangement; SW: stator windings; FA: fan; FR: frame; EC: end covers; B: bearings.
For simplicity, 10 cases are selected for the example. The information in the table is only a sample of the complete case list, for brevity. The information for different cases, which is not listed in the table, is identical. The number of attributes that are not listed in the table is 65. In this example, because there are only 10 cases, the support threshold is set at 5% and the confidence threshold is set at 60%.Using the adaptation rule acquisition method in section “Adaptation rule acquisition,” the adaptation rules are acquired. The acquired rules and their support and confidence are shown in Table 2.
The acquired adaptation rules.
The weights of the design requirements are obtained using equation (4). The design requirements of the new design task are shown in Table 3.
New design requirements.
RF: rated frequency; N: noise; MA: mounting arrangement.
According to the similarity evaluation method, the case most similar to the target case is C5.
The difference between the design requirements of the target case and C5 is in RF. Rule R1 matches the changing event “The rate frequency changes from 50 Hz to 5 ∼ 50 Hz.” According to R1, the material of the stator windings of C5 should be changed from QP–1/200 to QP–2/200.
Experiments
Objective and data source
Two experiments were performed to investigate whether the proposed method can achieve higher adaptation performance compared with other methods. The proposed method is compared with two machine learning methods of adaptability-involving support vector machine (ASVM) 13 and radial basis function network (RBFN), 10 and a statistical method of WM. 14 A detailed description of ASVM, RBFN, and WM methods is given later. ASVM is implemented using the LIBSVM tool. 27 Apriori and RBFN are implemented using the WEKA library, which includes a set of machine learning algorithms. 28 A total of 300 electromotor cases from company N were collected as raw data. The main product of the company is an electromotor. The production mode of the company is multivariety and small batch. The support threshold was set at 2%. The confidence threshold was set at 40%.
Comparative methods
ASVM
The basic idea of using ASVM for adaptation is to perform a regression approximation that addresses the problem of estimating a function to model the associative relations between the input
According to previous work,
13
the kernel function,
RBFN
The method adopts RBFN to realize case adaptation 10
Equation (9) describes the RBFN-employing adaptation knowledge application process where
WM
The method obtains the design results by calculating the weighted average value of the same attribute of the
where
Validation technique
The 10-fold cross-validation technique 29 was adopted to compare the performance of different adaptation methods. The cases were randomly divided into 10 groups, with the same size, in every experiment. One group was used as a test fold, and the other nine groups were used to train the adaptation models. The mean absolute percentage error (MAPE) was used to measure the differences between the adapted values and the actual values of the test cases. MAPE was obtained using equation (11)
where
Experiment 1
In this experiment, the performance of the different methods was compared in case bases with sizes of 100, 150, 200, 250, and 300. The design requirements and design results included both numerical and categorical attributes. The design requirements included the RP, RV, NP, power factor, efficiency factor, PC, CM, and MA. The design results included the slot shape of the stator, the slot number, the frame diameter, the frame bore, the material of the stator core, the material of the stator coil, the rotor bars, the rotor major diameter, the rotor minor diameter, the material of the RC, the material of the rotor coil, and the axial length. For the ASVM, RBFN, and WM methods, the values of categorical attributes were mapped to numbers. The adapted values were rounded to the nearest integer.
As shown in Figure 3, our method outperformed other methods. The superiority became greater as the data scale became larger.

The performance of different methods with different data scales.
Experiment 2
In this experiment, the performance of the methods was compared with and without categorical attributes. The number of cases was set at 300. The MAPE of experiment 1, when the case number was 300, was used as the performance of the methods with categorical attributes. For the situation without categorical attributes, the design requirements included RP, RV, NP, power factor, efficiency factor, and the design result included slot number, frame diameter, frame bore, material of stator core, rotor bars, rotor major diameter, rotor minor diameter, and axial length.
As shown in Figure 4, ASVM and our method had the same performance when the design requirements and design results had only numerical attributes. However, our method outperformed other methods when the design requirements and design results had both numerical and categorical attributes.

The performance of different methods with and without categorical attributes.
Conclusion and future work
A method of case adaptation for variant design was proposed in this study. A technique of data mining was introduced to acquire the adaptation rules that reflect the relationship between the changes in design requirements and design results. First, the raw data are encoded. Then, the changing events are extracted by case comparison. Finally, the adaptation rules are acquired using the Apriori algorithm. In the case retrieval process, the design requirements are weighted by analyzing the adaptation rules. The most similar case is selected by similarity evaluation. In the case adaptation process, the suitable rules are selected by analyzing their support and confidence. Then, the adaptation inference is realized based on the selected rules. Finally, the inference result is decoded to accomplish the variant design. Two experiments are performed to validate the proposed method. The results show that our method outperforms other methods when the design requirements and design results have both numerical and categorical attributes.
In the discretization of numerical attributes of this study, the values of attributes are discretized by equal-width binning. A better discretization method may improve the accuracy of the adaptation rules. Thus, we will try other discretization methods in future work.
