Search Results (532)

This research presents a novel methodology for lightweighting and cost reduction of components with high structural demands by integrating advanced design and manufacturing techniques. Specifically, it combines topology optimization (TO) with additive manufacturing (AM), also known as 3D printing. Unlike conventional approaches, the proposed method first determines the optimal geometry using an artificially stiff material, and only then evaluates real materials for structural and manufacturing feasibility. This design-first, material-second strategy enables broader material screening and maximizes weight reduction without compromising performance. The proposed workflow is applied to the design of a turbofan air intake—an aeronautical component operating under supersonic conditions—addressing both structural integrity and manufacturing feasibility. Three materials from distinct classes are assessed: two metallic alloys (aluminum alloy 6061 and titanium alloy, Ti6Al4V) and a high-performance polymer (polyetheretherketone, PEEK). This last option is preliminarily discarded after being analyzed for this specific application. Finite element (FE) simulations are used to evaluate the mechanical behavior of the optimized geometries, including bird-strike conditions. Among the evaluated manufacturing techniques, Selective Laser Melting (SLM) is identified as the most suitable for the metallic materials selected, providing an effective balance between performance, manufacturability, and aerospace compliance. This study illustrates the potential of TO–AM synergy as a sustainable and efficient design approach for next-generation aerospace components. Simulation results demonstrate a weight reduction of up to 71% while preserving critical functional regions and maintaining structural integrity in Al 6061 and Ti6Al4V cases, under the diverse loading conditions typical of real flight scenarios, while PEEK remains an attractive option for uses where mechanical demands are less stringent. Full article

Most existing assembly accuracy analysis methods focus on rigid assemblies or assume assemblies to be rigid bodies, neglecting the influence of assembly deformation in weak rigid components (WRCs) such as thin-walled structures, cantilever structures, etc. As a result, the assembly accuracy analysis becomes inaccurate, and the accuracy of key components cannot be effectively controlled. This may lead to serious issues such as forced assembly, repair, and rework. To address these problems, this study proposes a rigid–flexible coupling-based assembly accuracy analysis method for WRCs. The stiffness matrix and assembly deformation of WRCs are calculated, and by coupling assembly deformation with other assembly deviations, a rigid–flexible coupling assembly accuracy data model is established. This model incorporates multiple deviation sources, including assembly process variations, design tolerances, and assembly deformations. Assembly deviation transfer modeling and accumulation calculation methods for WRCs are investigated, enabling assembly accuracy simulation and statistical analysis. A case study on WRC assembly accuracy analysis is conducted, and the results demonstrate that the proposed method improves the accuracy of assembly analysis for WRCs, verifying its reliability. Full article

This study presents the first investigation into the application of ultrasonic vibration-assisted electrical discharge machining (UV-EDM) using graphite electrodes for external cylindrical surface machining—an essential surface in the production of tablet punches and sheet metal-forming dies. A custom ultrasonic horn was designed and fabricated using 90CrSi material to operate effectively at a resonant frequency of 20 kHz, ensuring stable vibration transmission throughout the machining process. A Box–Behnken experimental design was employed to explore the effects of five process parameters—vibration amplitude (A), pulse-on time (Ton), pulse-off time (Toff), discharge current (Ip), and servo voltage (SV)—on two key performance indicators: material removal rate (MRR) and surface roughness (Ra). The optimization process was conducted in two stages: single-objective analysis to maximize MRR while ensuring Ra < 4 µm, followed by a hybrid multi-objective approach combining NSGA-II and the Analytic Hierarchy Process (AHP). The optimal solution achieved a high MRR of 9.28 g/h while maintaining Ra below the critical surface finish threshold, thus meeting the practical requirements for punch surface quality. The findings confirm the effectiveness of the proposed horn design and hybrid optimization strategy, offering a new direction for enhancing productivity and surface integrity in cylindrical EDM applications using graphite electrodes. Full article

To enable safe and effective human–robot collaboration (HRC) in smart manufacturing, it is critical to seamlessly integrate sensing, cognition, and prediction into the robot controller for real-time awareness, response, and communication inside a heterogeneous environment (robots, humans, and equipment). The proposed approach takes advantage of the prediction capabilities of nonlinear model predictive control (NMPC) to execute safe path planning based on feedback from a vision system. To satisfy the requirements of real-time path planning, an embedded solver based on a penalty method is applied. However, due to tight sampling times, NMPC solutions are approximate; therefore, the safety of the system cannot be guaranteed. To address this, we formulate a novel safety-critical paradigm that uses an exponential control barrier function (ECBF) as a safety filter. Several common human–robot assembly subtasks have been integrated into a real-life HRC assembly task to validate the performance of the proposed controller and to investigate whether integrating human pose prediction can help with safe and efficient collaboration. The robot uses OptiTrack cameras for perception and dynamically generates collision-free trajectories to the predicted target interactive position. Results for a number of different configurations confirm the efficiency of the proposed motion planning and execution framework, with a 23.2% reduction in execution time achieved for the HRC task compared to an implementation without human motion prediction. Full article

The rising complexity of industrial systems following the Industry 4.0 era involves new challenges and the need for innovative solutions. In the context of arising digital technologies, Digital Twins represent a holistic solution to overcome heterogeneity and to achieve remote and dynamic control of cyber–physical systems. In common reference architectures, decision-making modules are usually integrated for system and process optimization. This work aims at introducing the adoption of a multi-purpose simulation module in a Digital Twin environment, with the objective of proving its versatility for different scopes. This is implemented in a relevant laboratory environment, strongly employed for the test and validation of mechatronic solutions. The paper starts from revising the common techniques adopted for decision-making modules in Digital Twin frameworks, proposing then a multi-purpose approach based on physics simulation. Performance profiling of the simulation environment demonstrates the potential of real-time-capable simulation while also revealing challenges related to computational load and communication latency. The outcome of this work is to provide the reader with an exemplary modular arrangement for the integration of such module in Digital Twin applications, highlighting challenges and limitations related to computational effort and communication. Full article

This study introduces a time-efficient rotating bending fatigue testing system featuring 11 dual-end spindles, enabling simultaneous testing of 22 specimens. Designed for high-throughput fatigue life (S–N curve) assessment, the system theoretically allows over 93% reduction in total test duration, with 87.5% savings demonstrated in validation experiments using AISI 304 stainless steel. The PLC-based architecture provides autonomous operation, real-time failure detection, and automatic cycle logging. ER16 collet holders are easily replaceable within one minute, and all the components are selected from widely available industrial-grade parts to ensure ease of maintenance. The modular design facilitates straightforward adaptation to different station counts. The validation results confirmed an endurance limit of 421 MPa, which is consistent with the established literature and within ±5% deviation. Fractographic analysis revealed distinct crack initiation and propagation zones, supporting the observed fatigue behavior. This high-throughput methodology significantly improves testing efficiency and statistical reliability, offering a practical solution for accelerated fatigue life evaluation in structural, automotive, and aerospace applications. Full article

Manual assembly remains essential in modern manufacturing, yet the increasing complexity of customised production imposes significant cognitive burdens and error rates on workers. Existing Spatial Augmented Reality (SAR) systems often operate passively, lacking adaptive interaction, real-time feedback and a control system with gesture. In response, we present Gest-SAR, a SAR framework that integrates a custom MediaPipe-based gesture classification model to deliver adaptive light-guided pick-to-place assembly instructions and real-time error feedback within a closed-loop interaction instance. In a within-subject study, ten participants completed standardised Duplo-based assembly tasks using Gest-SAR, paper-based manuals, and tablet-based instructions; performance was evaluated via assembly cycle time, selection and placement error rates, cognitive workload assessed by NASA-TLX, and usability test by post-experimental questionnaires. Quantitative results demonstrate that Gest-SAR significantly reduces cycle times with an average of 3.95 min compared to Paper (Mean = 7.89 min, p < 0.01) and Tablet (Mean = 6.99 min, p < 0.01). It also achieved 7 times less average error rates while lowering perceived cognitive workload (p < 0.05 for mental demand) compared to conventional modalities. In total, 90% of the users agreed to prefer SAR over paper and tablet modalities. These outcomes indicate that natural hand-gesture interaction coupled with real-time visual feedback enhances both the efficiency and accuracy of manual assembly. By embedding AI-driven gesture recognition and AR projection into a human-centric assistance system, Gest-SAR advances the collaborative interplay between humans and machines, aligning with Industry 5.0 objectives of resilient, sustainable, and intelligent manufacturing. Full article

The Online Droplet Inspection system plays a vital role in closed-loop control for OLED inkjet printing. However, generating realistic synthetic droplet images for reliable restoration and precise measurement of droplet parameters remains challenging due to the complex, multi-factor degradation inherent to microscale droplet imaging. To address this, we propose a physics-informed degradation model, Diffraction–Gaussian–Motion–Noise (DGMN), that integrates Fraunhofer diffraction, defocus blur, motion blur, and adaptive noise to replicate real-world degradation in droplet images. To optimize the multi-parameter configuration of DGMN, we introduce the MISABO (Multi-strategy Improved Subtraction-Average-Based Optimizer), which incorporates Sobol sequence initialization for search diversity, lens opposition-based learning (LensOBL) for enhanced accuracy, and dimension learning-based hunting (DLH) for balanced global–local optimization. Benchmark function evaluations demonstrate that MISABO achieves superior convergence speed and accuracy. When applied to generate synthetic droplet images based on real droplet images captured from a self-developed OLED inkjet printer, the proposed MISABO-optimized DGMN framework significantly improves realism, enhancing synthesis quality by 37.7% over traditional manually configured models. This work lays a solid foundation for generating high-quality synthetic data to support droplet image restoration and downstream inkjet printing processes. Full article

This study investigates the dynamic relationship between bearing gearbox condition indicators (BGCIs) and the lubrication oil temperature within the framework of health and usage monitoring system (HUMS) applications. Using the dynamic autoregressive distributed lag (DARDL) simulation model, we quantified both the short- and long-term responses of condition indicators to shocks in oil temperature, offering a robust framework for a counterfactual analysis. To complement the time-domain perspective, we applied a wavelet coherence analysis (WCA) to explore time–frequency co-movements and phase relationships between the condition indicators under varying operational regimes. The DARDL results revealed that the ball energy, cage energy, and inner and outer race indicators significantly increased in response to the oil temperature in the long run. The WCA results further confirmed the positive association between oil temperature and the condition indicators under examination, aligning with the DARDL estimations. The DARDL model revealed that the ball energy and the inner race energy have statistically significant long-term effects on the oil temperature, with p-values < 0.01. The adjusted R² of 0.785 and the root mean square error (MSE) of 0.008 confirm the model’s robustness. The wavelet coherence analysis showed strong time–frequency correlations, especially in the 8–16 scale range, while the frequency-domain causality (FDC) tests confirmed a bidirectional influence between the oil temperature and several condition indicators. The FDC analysis showed that the oil temperature significantly affected the BGCIs, with evidence of feedback effects, suggesting a mutual dependency. These findings contribute to the advancement of predictive maintenance frameworks in HUMSs by providing practical insights for enhancing system reliability and optimizing maintenance schedules. The integration of dynamic econometric approaches demonstrates a robust methodology for monitoring critical mechanical components and encourages further research in broader aerospace and industrial contexts. Full article

Liquid rocket engines occasionally experience abnormal phenomena with unclear mechanisms, causing difficulty in design improvements. To address the above issue, a data mining method that combines ante hoc explainability, post hoc explainability, and prediction accuracy is proposed. For ante hoc explainability, a feature selection method driven by data, models, and domain knowledge is established. Global sensitivity analysis of a physical model combined with expert knowledge and data correlation is utilized to establish the correlations between different types of parameters. Then a two-stage optimization approach is proposed to obtain the best feature subset and train the prediction model. For the post hoc explainability, the partial dependence plot (PDP) and SHapley Additive exPlanations (SHAP) analysis are used to discover complex patterns between input features and the dependent variable. The effectiveness of the hybrid feature selection method and its applicability under different noise combinations are validated using synthesized data from a high-fidelity simulation model of a pressurization system. Then the analysis of the causes of a large vibration phenomenon in an active engine shows that the prediction model has good accuracy, and the feature selection results have a clear mechanism and align with domain knowledge, providing both accuracy and interpretability. The proposed method shows significant potential for data mining in complex aerospace products. Full article

This paper aims to develop a model for calculating the ball load of the thin-walled flexible bearing (FB) in a harmonic drive under various external torque conditions. The effect of the flexspline (FS) on the FB ball load is considered, and the equivalent ring is improved to calculate the ball load of the FB. Then, the accuracy of the proposed model in calculating the ball load is verified using a finite element analysis model. Finally, a fitting formula is obtained to rapidly evaluate the FB ball load via the geometrical parameters of the FB and the FS under various external torques. The results show that the FB ball load is mainly affected by the FB maximum radial deformation under low external torque. When subjected to heavy external torque, the maximum ball load is mainly affected by the FS’s geometric parameters. Full article

This article explores the issue of surface modification through tumbling and vaporisation of 3D-printed materials, and its impact on the electrolytic deposition of metal coatings on previously non-conductive materials. Plastic materials represent an affordable alternative, but their surface treatment, in the form of post-coating, achieves properties comparable to those of metal parts while saving expensive metal material. Samples prepared by selective laser sintering (SLS) with different surface treatments were used. Polyamide 12 (PA12) was chosen as the base material and copper (Cu) as the metallic coating. Graphite was sprayed on the samples to ensure conductivity. The Cu coating was electrodeposited from an acidic copper electrolyte. The quantitative analysis of the surface was carried out using standard ISO parameters. The thickness of the deposited copper layer was determined using destructive measurements on a digital microscope. The results show that surface modification has a significant effect on the functional properties of the surface quality and the thickness of the deposited copper layer. Full article

In the era of rapid industrial automation advancements, the complexity of intelligent manufacturing equipment has been steadily escalated. Stringent demands for high-efficiency and high-precision diagnosis are increasingly being unmet by conventional fault diagnosis methods. To address these challenges, a novel fault diagnosis approach grounded in quantum Q-learning is presented in this paper. The distinct advantages of quantum computing are innovatively integrated with the decision-making framework of Q-learning through this method. By harnessing the multi-information-carrying capacities of qubits, vast amounts of multi-source heterogeneous data generated during equipment operation can be efficiently processed. Latent fault features are thereby rapidly uncovered, significantly reducing the time required for fault-feature extraction. Furthermore, optimal decisions can be dynamically formulated by Q-learning within evolving production environments, leveraging precise analysis outcomes from quantum computing. Real-time equipment status is continuously monitored to accurately identify fault types, pinpoint locations, and promptly generate targeted maintenance strategies. Fault-diagnosis tests conducted on typical industrial intelligent manufacturing equipment demonstrate that the quantum Q-learning method outperforms traditional approaches in terms of diagnosis accuracy, efficiency, and adaptability to complex fault patterns. This breakthrough opens up new frontiers for fault diagnosis in intelligent manufacturing systems. Full article

This paper presents a digital twin-driven multi-objective optimization approach for enhancing the performance and productivity of a multi-product manufacturing system under complex operational challenges. More specifically, the concept of digital twin is applied to virtually replicate a physical system that leverages real-time data fusion from Internet of Things devices or sensors. JaamSim serves as the platform for modeling the digital twin, simulating the dynamics of the manufacturing system. The implemented digital twin is a manufacturing system that incorporates a three-stage production line to complete and stockpile two gear types. The production line is subject to unpredictable events, including equipment breakdowns, maintenance, and product returns. The stochasticity of these real-world-like events is modeled using a normal distribution. Manufacturing control strategies, such as CONWIP and Kanban, are implemented to evaluate the impact on the performance of the manufacturing system in a simulation environment. The evaluation is performed based on three key indicators: service level, the amount of work-in-progress items, and overall system profitability. Multiple objective functions are formulated to optimize the behavior of the system by reducing the work-in-progress items and improving both cost-effectiveness and service level. To this end, the proposed approach couples the JaamSim-based digital twins with evolutionary and swarm-based algorithms to carry out the multi-objective optimization under varying conditions. In this sense, the present work offers an early demonstration of an industrial digital twin, implementing an offline simulation-based manufacturing environment that utilizes optimization algorithms. Results demonstrate the trade-offs between the employed strategies and offer insights on the implementation of hybrid production control systems in dynamic environments. Full article

Predicting workload for tasks in manufacturing is a complex challenge due to the numerous variables involved. In small- and medium-sized enterprises (SMEs), this process is often experience-based, leading to inaccurate predictions that significantly impact production planning, order management, and consequently the ability to meet customer deadlines. This paper presents an approach that leverages machine learning to enhance workload prediction with minimal data collection, making it particularly suitable for SMEs. A case study application using supervised machine learning models for regression, trained in an open-source data analytics, reporting, and integration platform (KNIME Analytics Platform), has been carried out. An Automated Machine Learning (AutoML) regression approach was employed to identify the most suitable model for task workload prediction based on minimising the Mean Absolute Error (MAE) scores. Specifically, the Regression Tree (RT) model demonstrated superior accuracy compared to more traditional simple averaging and manual predictions when modelling data for a single product type. When incorporating all available product data, despite a slight performance decrease, the XGBoost Tree Ensemble still outperformed the traditional approaches. These findings highlight the potential of machine learning to improve workload forecasting in manufacturing, offering a practical and easily implementable solution for SMEs. Full article