Search Results (541)

This study aimed to monitor the operating state of an induction motor, a type of electromagnetic motor, using a highly sensitive magnetic sensor, which could be applied for anomaly detection in the future. Monitoring the health of electromagnetic motors is very important to minimize losses due to failures. Detecting anomalies using the changes compared with the initial state is a possible solution, but there are issues such as a lack of training data for machine learning and the need to install multiple sensors. Therefore, an attempt was made to acquire the various operating states of a motor from magnetic signals using a single magnetic sensor capable of non-contact measurement. The relationships between the magnetic flux density from the motor and the other motor conditions were investigated. As a result, the magnetic spectrum was found to contain information on the rotor rotation frequency, torque, and output power. Therefore, the magnetic sensor can be applied to monitor a motor’s operating conditions, making it a useful tool for advanced data analysis. Full article

Thermal control in rolling mills motors is gaining importance as more and more hard-to-deform steel grades are rolled. The capabilities of diagnostics monitoring also expand as digital IIoT-based technologies are adopted. Electrical drives in modern rolling mills are based on synchronous motors with frequency regulation. Such motors are expensive, while their reliability impacts the metallurgical plant output. Hence, developing the on-line temperature monitoring systems for such motors is extremely urgent. This paper presents a solution applying to synchronous motors of the upper and lower rolls in the horizontal roll stand of plate mill 5000. The installed capacity of each motor is 12 MW. According to the digitalization tendency, on-line monitoring systems should be based on digital shadows (coordinate observers) that are similar to digital twins, widely introduced at metallurgical plants. Modern reliability requirements set the continuous temperature monitoring for stator and rotor windings and iron core. This article is the first to describe a method for calculating thermal loads based on the data sets created during rolling. The authors have developed a thermal state observer based on four-mass model of motor heating built using the Simscape Thermal Models library domains that is part of the MATLAB Simulink. Virtual adjustment of the observer and of the thermal model was performed using hardware-in-the-loop (HIL) simulation. The authors have validated the results by comparing the observer’s values with the actual values measured at control points. The discrete masses heating was studied during the rolling cycle. The stator and rotor winding temperature was analysed at different periods. The authors have concluded that the motors of the upper and lower rolls are in a satisfactory condition. The results of the study conducted generally develop the idea of using object-oriented digital shadows for the industrial electrical equipment. The authors have introduced technologies that improve the reliability of the rolling mills electrical drives which accounts for the innovative development in metallurgy. The authors have also provided recommendations on expanded industrial applications of the research results. Full article

To address the challenges of weak fault features and strong non-stationarity in early-stage vibration signals, this study proposes a novel fault diagnosis method combining enhanced variational mode decomposition (VMD) with a structurally improved GoogLeNet. Specifically, an improved wild horse optimizer (IWHO) with tent chaotic mapping is employed to automatically optimize critical VMD parameters, including the number of modes K and the penalty factor α, enabling precise decomposition of non-stationary signals to extract weak fault features. The vibration signal is decomposed, and the top five intrinsic mode functions (IMFs) are selected based on the kurtosis criterion. Time–frequency features are then extracted from these IMFs and input into a modified GoogLeNet classifier. The GoogLeNet structure is improved by replacing standard n × n convolution kernels with cascaded 1 × n and n × 1 kernels, and by substituting the ReLU activation function with a parameterized TReLU function to enhance adaptability and convergence. Experimental results on two public rolling bearing datasets demonstrate that the proposed method effectively handles non-stationary signals, achieving 99.17% accuracy across four fault types and maintaining over 95.80% accuracy under noisy conditions. Full article

A cochlear implant (CI) system holds two spiral coils, one external and one implanted. These coils are used to transmit both data and power. A magnet at the center of the coils ensures proper alignment to assure the highest coupling. However, when the recipient needs a magnetic resonance imaging (MRI) scan, this magnet can cause problems due to the high magnetic field of such a scan. Therefore, a new type of implant without magnets would be beneficial and even supersede the current state of the art of hearing implants. To examine the feasibility of magnet-free cochlear implants, this research studies the impact of coil misalignment on the inductive coupling between the coils and thus the power and data transfer. Rather than using time-consuming finite element analysis (FEA), MATLAB is used to examine the impact of lateral, vertical and angular misalignment on the coupling coefficient using derivations of Neumann’s equation. The MATLAB model is verified with FEA software with a median 8% relative error on the coupling coefficient for various misalignments, ensuring that it can be used to study the feasibility of various magnet-free implants and wireless power and data transmission systems in general. In the case of cochlear implants, the results show that by taking patient and technology constraints like skinflap thickness and mechanical design dimensions into account, the mean error can even be reduced to below 5% and magnet-free cochlear implants can be feasible. Full article

The integration of Artificial Intelligence (AI) into manufacturing is transforming the industry by advancing predictive maintenance, quality control, and supply chain optimisation, while also driving the shift from Industry 4.0 towards a more human-centric and sustainable vision. This emerging paradigm, known as Industry 5.0, emphasises resilience, ethical innovation, and the symbiosis between humans and intelligent systems, with AI playing a central enabling role. However, challenges such as the “black box” nature of AI models, data biases, ethical concerns, and the lack of robust frameworks for trustworthiness hinder its widespread adoption. This paper provides a comprehensive survey of AI trustworthiness in the manufacturing industry, examining the evolution of industrial paradigms, identifying key barriers to AI adoption, and examining principles such as transparency, fairness, robustness, and accountability. It offers a detailed summary of existing toolkits and methodologies for explainability, bias mitigation, and robustness, which are essential for fostering trust in AI systems. Additionally, this paper examines challenges throughout the AI pipeline, from data collection to model deployment, and concludes with recommendations and research questions aimed at addressing these issues. By offering actionable insights, this study aims to guide researchers, practitioners, and policymakers in developing ethical and reliable AI systems that align with the principles of Industry 5.0, ensuring both technological advancement and societal value. Full article

This study proposes MSFF-Net, a lightweight deep learning framework for bearing fault diagnosis based on frequency-domain multi-sensor fusion. The vibration and acoustic signals are initially converted into the frequency domain using the fast Fourier transform (FFT), enabling the extraction of temporally invariant spectral features. These features are processed by a compact one-dimensional convolutional neural network, where modality-specific representations are fused at the feature level to capture complementary fault-related information. The proposed method demonstrates robust and superior performance under both full and scarce data conditions, as verified through experiments on a publicly available dataset. Experimental results on a publicly available dataset indicate that the proposed model attains an average accuracy of 99.73%, outperforming state-of-the-art (SOTA) methods in both accuracy and stability. With only about 70.3% of the parameters of the SOTA model, it offers faster inference and reduced computational cost. Ablation studies confirm that multi-sensor fusion improves all classification metrics over single-sensor setups. Under few-shot conditions with 20 samples per class, the model retains 94.69% accuracy, highlighting its strong generalization in data-limited scenarios. The results validate the effectiveness, computational efficiency, and practical applicability of the model for deployment in data-constrained industrial environments. Full article

To promote the automation and intelligence of rail freight, the accurate identification and localization of bulk cargo unloading hoppers have become a key technical challenge. Under the technological wave driven by the deep integration of Industry 4.0 and artificial intelligence, the bulk cargo unloading process is undergoing a significant transformation from manual operation to intelligent control. In response to this demand, this paper proposes a vision-based 3D localization system for unloading hoppers, which adopts a single visual sensor architecture and integrates three core modules: object detection, corner extraction, and 3D localization. Firstly, a lightweight hybrid attention mechanism is incorporated into the YOLOv5 network to enable edge deployment and enhance the detection accuracy of unloading hoppers in complex industrial scenarios. Secondly, an image processing approach combining depth consistency constraint (DCC) and geometric structure constraints is designed to achieve sub-pixel level extraction of key corner points. Finally, a real-time 3D localization method is realized by integrating corner-based initialization with an RGB-D SLAM tracking mechanism. Experimental results demonstrate that the proposed system achieves an average localization accuracy of 97.07% under challenging working conditions. This system effectively meets the comprehensive requirements of automation, intelligence, and high precision in railway bulk cargo unloading processes, and exhibits strong engineering practicality and application potential. Full article

With the advent of the Internet of Things (IoT), large volumes of sensitive data are produced from IoT devices, driving the adoption of Machine Learning as a Service (MLaaS) to overcome their limited computational resources. However, as privacy concerns in MLaaS grow, the demand for Privacy-Preserving Machine Learning (PPML) has increased. Fully Homomorphic Encryption (FHE) offers a promising solution by enabling computations on encrypted data without exposing the raw data. However, FHE-based neural network inference suffers from substantial overhead due to expensive primitive operations, such as ciphertext rotation and bootstrapping. While previous research has primarily focused on optimizing the efficiency of these computations, our work takes a different approach by concentrating on the rotation keyset design, a pre-generated data structure prepared before execution. We systematically explore three key design spaces (KDS) that influence rotation keyset design and propose an optimized keyset that reduces both computational overhead and memory consumption. To demonstrate the effectiveness of our new KDS design, we present two case studies that achieve up to 11.29× memory reduction and 1.67–2.55× speedup, highlighting the benefits of our optimized keyset. Full article

Industrial production often involves complex time-varying operating conditions that result in continuous time-series production data. The traditional soft sensor approach has difficulty adjusting to such dynamic changes, which makes model performance less optimal. Furthermore, online analytical systems have significant operational and maintenance costs and entail a substantial delay in measurement output, limiting their ability to provide real-time control. In order to deal with these challenges, this paper introduces a multivariate multi-step predictive multilayer perceptron regression soft-sensing model, referred to as incremental MVMS-MLP. This model incorporates incremental learning strategies to enhance its adaptability and accuracy in multivariate predictions. As part of the method, a pre-trained MVMS-MLP model is developed, which integrates multivariate multi-step prediction with MLP regression to handle temporal data. Through the use of incremental learning, an incremental MVMS-MLP model is constructed from this pre-trained model. The effectiveness of the proposed method is demonstrated by benchmark problems and real-world industrial case studies. Full article

This article presents a method that uses a spark plug as a sensor to monitor an internal combustion engine. In addition, the voltage sensors measured the high voltage at the spark plugs using a non-contact method. Monitoring can now be performed in a simple way in real time, along with data processing. This method can be effectively used for the monitoring of all cylinders in an internal combustion engine as well as supplementing other measurement methods to optimize engine maintenance and enable correct diagnostic decisions to be made. Experimental analysis focused on the effect of the spark plug gap on the arc duration, flashover voltage, and high-voltage waveforms. It was found that with an increasing gap, the arc duration is shortened, and the breakdown voltage increases linearly, indicating wear of the spark gap. With increasing temperature, the breakdown voltage value decreased. Non-contact measurements at different frequencies showed a relationship between the magnitude of the electric field and the spark plug gap. Full article

Traditional PMUT ultrasonic ranging systems usually possess a large measurement blind area under the integrated transmit–receive mode, dramatically limiting its distance measurement in confined spaces, such as when determining the clearance of large bearing components. Here, a broadband PMUT rangefinder was designed by integrating six types of different cells with adjacent resonant frequencies into an array. Through overlapping and coupling of the bandwidths from the different cells, the proposed PMUTs showed a wide –6 dB fractional bandwidth of 108% in silicon oil. Due to the broadening of bandwidth, the device could obtain the maximum steady state with less excitation (5 cycles versus 14 cycles) and reduce its residual ring-down (ca. 6 μs versus 15 μs) compared with the traditional PMUT array with the same cells, resulting in a small blind area. The pulse–echo ranging experiments demonstrated that the blind area was effectively reduced to 4.4 mm in air or 12.8 mm in silicon oil, and the error was controlled within ±0.3 mm for distance measurements up to 250 mm. In addition, a specific ultrasound signal processing circuit with functions of transmitting, receiving, and processing ultrasonic waves was developed. Combining the processing circuit and PMUT device, the system was applied to determine the axial clearance of the main bearing in a tunneling machine. This work develops broadband PMUTs with a small blind area and high resolution for distance measurement in narrow and confined spaces, opening up a new path for ultrasonic ranging technology. Full article

Ensuring that electrical workers use personal protective equipment (PPE) correctly is critical to electrical safety, but existing detection methods face significant limitations when applied in the electrical industry. This paper introduces MRC-DETR (Multi-Scale Re-calibration Detection Transformer), a novel framework for detecting Power Engineering Personal Protective Equipment (PEPPE) in complex electrical operating environments. Our method introduces two technical innovations: a Multi-Scale Enhanced Boundary Attention (MEBA) module, which significantly improves the detection of small and occluded targets through optimized feature representation, and a knowledge distillation strategy that enables efficient deployment on edge devices. We further contribute a dedicated PEPPE dataset to address the lack of domain-specific training data. Experimental results demonstrate superior performance compared to existing methods, particularly in challenging power industry scenarios. Full article

The progressive proliferation of sensor deployment in distribution networks (DNs), propelled by the dual drivers of power automation and ubiquitous IoT infrastructure development, has precipitated exponential growth in real-time data generated by multisource heterogeneous (MSH) sensors within multilayer grid architectures. This phenomenon presents dual implications: large-scale datasets offer an enhanced foundation for reliability assessment and dispatch planning in DNs; the dramatic escalation in data volume imposes demands on the computational precision and response speed of traditional evaluation approaches. The identification of critical influencing factors under extreme operating conditions, coupled with dynamic assessment and prediction of DN reliability through MSH data approaches, has emerged as a pressing challenge to address. Through a brief analysis of existing technologies and algorithms, this article reviews the technological development of MSH data analysis in DNs. By integrating the stability advantages of conventional approaches in practice with the computational adaptability of artificial intelligence, this article focuses on discussing key approaches for MSH data processing and assessment. Based on the characteristics of DN data, e.g., diverse sources, heterogeneous structures, and complex correlations, this article proposes several practical future directions. It is expected to provide insights for practitioners in power systems and sensor data processing that offer technical inspirations for intelligent, reliable, and stable next-generation DN construction. Full article

Anomaly detection in multivariate time series is a critical task across a range of real-world domains, such as industrial automation and the internet of things. These environments are generally monitored by various types of sensors that produce complex, high-dimensional time-series data with intricate cross-sensor dependencies. While existing methods often utilize sequence modeling or graph neural networks to capture global sensor relationships, they typically treat all sensors uniformly—potentially overlooking the benefit of grouping sensors with similar temporal patterns. To this end, we propose a novel framework called Multi-task Learning Anomaly Detection (MLAD), which leverages clustering techniques to group sensors based on their temporal characteristics, and employs a multi-task learning paradigm to jointly capture both shared patterns across all sensors and specialized patterns within each cluster. MLAD consists of four key modules: (1) sensor clustering based on sensors’ time series, (2) representation learning with a cluster-constrained graph neural network, (3) multi-task forecasting with shared and cluster-specific learning layers, and (4) anomaly scoring. Extensive experiments on three public datasets demonstrate that MLAD achieves superior detection performance over state-of-the-art baselines. Ablation studies further validate the effectiveness of the modules of our MLAD. This study highlights the value of incorporating sensor heterogeneity into model design, which contributes to more accurate and robust anomaly detection in sensor-based monitoring systems. Full article

Effective monitoring of fish passage through river barriers is essential for evaluating fishway performance and supporting adaptive river management. Traditional methods are often invasive, labor-intensive, or too costly to enable widespread implementation across most fishways. Infrared (IR) beam-break counters offer a promising alternative, but their adoption has been limited by high costs and a lack of flexibility. We developed and tested a novel, low-cost infrared beam-break counter—FishTracker—based on open-source Raspberry Pi and Arduino platforms. The system detects fish passages by analyzing interruptions in an IR curtain and reconstructing fish silhouettes to estimate movement, direction, speed, and morphometrics under a wide range of turbidity conditions. It also offers remote access capabilities for easy management. Field validation involved controlled tests with dummy fish, experiments with small-bodied live specimens (bleak) under varying turbidity conditions, and verification against synchronized video of free-swimming fish (koi carp). This first version of FishTracker achieved detection rates of 95–100% under controlled conditions and approximately 70% in semi-natural conditions, comparable to commercial counters. Most errors were due to surface distortion caused by partial submersion during the experimental setup, which could be avoided by fully submerging the device. Body length estimation based on passage speed and beam-interruption duration proved consistent, aligning with published allometric models for carps. FishTracker offers a promising and affordable solution for non-invasive fish monitoring in multispecies contexts. Its design, based primarily on open technology, allows for flexible adaptation and broad deployment, particularly in locations where commercial technologies are economically unfeasible. Full article