Search Results (21)

With the advent of Industry 4.0, the manufacturing industry is facing unprecedented data challenges. Sensors, PLCs, and various types of automation equipment in smart factories continue to generate massive amounts of heterogeneous data, but existing systems generally have bottlenecks in data collection standardization, real-time processing capabilities, and system scalability, which make it difficult to meet the needs of efficient collaboration and dynamic decision making. This study proposes a multi-level industrial data processing framework based on edge computing that aims to improve the response speed and processing ability of manufacturing sites to data and to realize real-time decision making and lean management of intelligent manufacturing. At the edge layer, the OPC UA (OPC Unified Architecture) protocol is used to realize the standardized collection of heterogeneous equipment data, and a lightweight edge-computing algorithm is designed to complete the analysis and processing of data so as to realize a visualization of the manufacturing process and the inventory in a production workshop. In the storage layer, Apache Kafka is used to implement efficient data stream processing and improve the throughput and scalability of the system. The test results show that compared with the traditional workshop, the framework has excellent performance in improving the system throughput capacity and real-time response speed, can effectively support production process judgment and status analysis on the edge side, and can realize the real-time monitoring and management of the entire manufacturing workshop. This research provides a practical solution for the industrial data management system, not only helping enterprises improve the transparency level of manufacturing sites and the efficiency of resource scheduling but also providing a practical basis for further research on industrial data processing under the “edge-cloud collaboration” architecture in the academic community. Full article

In synthetic aperture radar (SAR) images, pixel-level Ground Truth (GT) is a scarce resource compared to Bounding Box (BBox) annotations. Therefore, exploring the use of unsupervised instance segmentation methods to convert BBox-level annotations into pixel-level GT holds great significance in the SAR field. However, previous unsupervised segmentation methods fail to perform well on SAR images due to the presence of speckle noise, low imaging accuracy, and gradual pixel transitions at the boundaries between targets and background, resulting in unclear edges. In this paper, we propose a Multi-threshold Adaptive Decision Network (MtAD-Net), which is capable of segmenting SAR ship images under unsupervised conditions and demonstrates good performance. Specifically, we design a Multiple CFAR Threshold-extraction Module (MCTM) to obtain a threshold vector by a false alarm rate vector. A Local U-shape Feature Extractor (LUFE) is designed to project each pixel of SAR images into a high-dimensional feature space, and a Global Vision Transformer Encoder (GVTE) is designed to obtain global features, and then, we use the global features to obtain a probability vector, which is the probability of each CFAR threshold. We further propose a PLC-Loss to adaptively reduce the feature distance of pixels of the same category and increase the feature distance of pixels of different categories. Moreover, we designed a label smoothing module to denoise the result of MtAD-Net. Experimental results on the dataset show that our MtAD-Net outperforms traditional and existing deep learning-based unsupervised segmentation methods in terms of pixel accuracy, kappa coefficient, mean intersection over union, frequency weighted intersection over union, and F1-Score. Full article

This study investigates the potential of deploying a neural network model on an advanced programmable logic controller (PLC), specifically the Finder Opta™, for real-time inference within the predictive maintenance framework. In the context of Industry 4.0, edge computing aims to process data directly on local devices rather than relying on a cloud infrastructure. This approach minimizes latency, enhances data security, and reduces the bandwidth required for data transmission, making it ideal for industrial applications that demand immediate response times. Despite the limited memory and processing power inherent to many edge devices, this proof-of-concept demonstrates the suitability of the Finder Opta™ for such applications. Using acoustic data, a convolutional neural network (CNN) is deployed to infer the rotational speed of a mechanical test bench. The findings underscore the potential of the Finder Opta™ to support scalable and efficient predictive maintenance solutions, laying the groundwork for future research in real-time anomaly detection. By enabling machine learning capabilities on compact, resource-constrained hardware, this approach promises a cost-effective, adaptable solution for diverse industrial environments. Full article

In this paper, an improved 100 CMM regenerative thermal oxidizer (RTO) is implemented for low-emission combustion. The existing RTO system is a cylindrical drum structure that cyclically introduces and discharges VOC gas into and from the rotating disk, and which achieves excellent energy efficiency with a heat recovery rate of more than 95%. However, the drive shaft designed under the RTO combustion chamber increases wear around the rotating shaft due to the load of the combustion chamber and there is a problem that the untreated gas is simultaneously released through the outlet due to the channeling phenomenon of the combustion chamber and the drive shaft. In addition, the combustion chamber, used at a high temperature of 800 °C, may cause serious problems such as rotation stop or explosion due to pollutants, dust accumulation, and thermal expansion in the chamber. Particularly when treating VOCs harmful gasses, RTO performance may be degraded due to the burner’s non-uniform temperature control and unstable combustion function. To solve this problem, first, the design of the combustion chamber rotating plate driving device is improved. Second, when treating high concentration VOC gas, the design of combustion chamber considers a temperature increase of up to 920 °C or more. For this, the diameter of the gas burner is 125 mm and the outlet dimension is set to 650 mm × 650 mm to effectively discharge high-temperature waste heat. Third, the heat storage material in the combustion chamber is composed of a ceramic block with a thickness of 250 mm, and the outer diameter and height of the combustion chamber are set to, 2530 mm and 1875 mm, respectively, to optimize gas residence time and heat insulation thickness. Fourth, we supplement safe operation by applying the trip control algorithm of the programmable logic controller (PLC) panel for failure prediction of RTO and the Edge-IoT-based intelligent algorithm for this. Finally, we evaluate the economic performance of 100 CMM RTO by conducting empirical experiments to analyze changes in VOCs removal efficiency, nitrogen oxide emission concentration, and total hydrocarbon (THC) concentration through 10 CMM design and implementation. Full article

An online inspection method based on machine vision was proposed and validated to address the issues of high work intensity, low efficiency, low accuracy, and risk of missed inspection in traditional sampling methods for screw threads of rebar head. Firstly, an industrial camera was used to capture real-time images of the processed rebar thread heads, preprocess the images, and locate the target positions in the images to reduce the complexity and running time of subsequent algorithms. Then, the Canny operator was used to roughly extract the edge feature information of the rebar head, and the Shi–Tomasi algorithm was used for corner inspection to achieve precise optimization of sub-pixel level corners. Based on robust linear regression, the diagonal points were fitted with lines to detect the corresponding size parameters. Finally, an inspection system on screw threads of rebar head parameter was designed and developed, which consisted of an image-acquisition device, Siemens PLC controller, and inspection software. Test results show that this method can achieve online inspection without contact, with inspection accuracy reaching the micrometer level, and 8–10 rebar heads can be inspected per second. Full article

Obtaining mathematical models of nonlinear cyber–physical systems for use in controller design is both difficult and time consuming. In this paper, an ANN-based method is proposed to design a controller for a nonlinear system that does not require a mathematical model. The developed ANN-based control algorithm is implemented directly on a real-time field controller, and its performance is evaluated without the use of auxiliary devices, such as PCs or workstations. By executing machine learning algorithms on local devices or embedded systems, edge artificial intelligence (Edge AI) with transfer learning gives priority to processing data at the source, minimizing the necessity for continuous connectivity to remote servers. The control algorithm was developed using the Matlab Simulink environment. The first and second ANNs were cascaded, wherein the first ANN computes the appropriate pressure signal for the given displacement, while the second predicts the force based on the pressure value from the first ANN. Subsequently, the ANN-based control algorithm was converted to SCL code using the Simulink PLC Coder and deployed on the PLC for operation. The algorithm was tested using two different scenarios. The conducted tests demonstrated the successful prediction of pressure signals corresponding to the targeted displacement values and accurate estimation of force values. Experimental work was carried out on PAM manipulators as a nonlinear model application, and the obtained results were discussed. Full article

Designs of timer function blocks (FBs) are presented in the article. The developed modules are IEC 61131-3. An analysis of IEC 61131-3 in terms of timer functionality and implementation options is presented. Three types are presented, timer-on, timer-off, and timer-pulse, with each type designed to be fully hardware or software-like. Both designs, hardware or software-like, can operate as multi-channel timers. Particularly noteworthy is the software-like design, for which a solution without edge detectors was achieved. Such a feature was obtained by reversing the method of time determination by counting the difference between the start and end times and by using specific features of the D flip-flops, that is, clock-enable inputs. The presented timers were written in Verilog language and implemented in an FPGA chip. Thanks to the universal design of the interface, the proposed FBs can be used for the hardware support of existing programmable logic controllers (PLCs) or as an integral part of newly built PLC CPUs. The idea of a CPU architecture with hardware support is proposed. The paper presents the results of the implementation in an FPGA of the Kintex UltraScale+ family from AMD-Xilinx. Full article

An IoT-based wireless centralized monitoring system has been proposed which is an effective way to monitor and control building systems. The system will serve the purpose of replacing an old and expensive PLC-based and wire-based management system. The system here uses several nodes of networks which are connected through wireless mesh and sending data to the centralized edge computing device (raspberry pi) through MQTT protocol. Then, the edge will update the data on the cloud using Firebase to generate a library and update the data on the cloud on a real-time basis and through the cloud, which will then allow us to monitor and control the system through the website which can be used easily and remotely on any browsing device. Full article

With the explosive growth of data at the edge in the Industrial Internet of Things (IIoT), edge devices are increasingly performing more data processing tasks to alleviate the load on cloud servers. To achieve this goal, Programmable Logic Controllers (PLCs) are gradually transitioning into edge PLCs. However, efficiently executing a large number of computational tasks in memory-limited edge PLCs is a significant challenge. Therefore, there is a need to design an efficient memory allocation strategy for edge PLCs. This paper proposes a dynamic memory allocation strategy for edge PLCs. It adopts an approach of organizing memory into small blocks to handle memory requests from real-time tasks and utilizes a well-performing dynamic programming method for resource allocation problems to handle memory requests from non-real-time tasks. This approach ensures real-time performance while improving the efficiency of non-real-time task processing. In the simulation experiments, the algorithm implemented based on this allocation strategy is compared with the default method and several open-source memory allocators. The experimental results demonstrate that the proposed algorithm, on average, improves the speed of real-time task processing by 13.7% and achieves a maximum speed improvement of 17.0% for non-real-time task processing. The experimental results show that the allocation strategy effectively improves memory allocation efficiency in memory-limited environments. Full article

This article aims to present the real-world implementation of an anomaly detection system of a hydraulic power unit. Implementation involved the Internet of Things approach. A detailed description of the system architecture is provided. The complete path from sensors through PLC and the edge computer to the cloud is presented. Some technical information about hydraulic power units is also given. This article involves the description of several model-at-scale deployment techniques. In addition, the approach to the synthesis of anomaly and novelty detection models was described. Anomaly detection of data acquired from the hydraulic power unit was carried out using two approaches, statistical and black-box, involving the One Class SVM model. The costs of cloud resources and services that were generated in the project are presented. Since the article describes a commercial implementation, the results have been presented as far as the formal and business conditions allow. Full article

This article addresses how to tackle one of the most demanding tasks in manufacturing and industrial maintenance sectors: using robots with a novel and robust solution to detect the fastener and its rotation in (un)screwing tasks over parallel surfaces with respect to the tool. To this end, the vision system is based on an industrial camera with a dynamic exposure time, a tunable liquid crystal lens (TLCL), and active near-infrared reflectance (NIR) illumination. Its camera parameters, combined with a fixed value of working distance (WD) and variable or constant field of view (FOV), make it possible to work with a variety of fastener sizes under several lighting conditions. This development also uses a collaborative robot with an embedded force sensor to verify the success of the fastener localization in a real test. Robust algorithms based on segmentation neural networks (SNN) and vision were developed to find the center and rotation of the hexagon fastener in a flawless condition and worn, scratched, and rusty conditions. SNNs were tested using a graphics processing unit (GPU), central processing unit (CPU), and edge devices, such as Jetson Javier Nx (JJNX), Intel Neural Compute Stick 2 (INCS2), and M.2 Accelerator with Dual Edge TPU (DETPU), with optimization parameters, such as the unsigned integer (UINT) and float (FP), to understand their performance. A virtual program logic controller (PLC) was mounted on a personal computer (PC) as the main control to process the images and save the data. Moreover, a mathematical analysis based on the international standard organization (ISO) and patents of the manual socket wrench was performed to determine the maximum error allowed. In addition, the work was substantiated using exhaustive evaluation tests, validating the tolerance errors, robotic forces for successfully completed tasks, and algorithms implemented. As a result of this work, the translation tolerances increase with higher sizes of fasteners from 0.75 for M6 to 2.50 for M24; however, the rotation decreases with the size from 5.5° for M6 to 3.5° for M24. The proposed methodology is a robust solution to tackle outliers contours and fake vertices produced by distorted masks present in non-constant illumination; it can reach an average accuracy to detect the vertices of 99.86% and the center of 100%, also, the time consumed by the SNN and the proposed algorithms is 73.91 ms on an Intel Core I9 CPU. This work is an interesting contribution to industrial robotics and improves current applications. Full article

Recently, a novel approach in the field of Industry 4.0 factory operations was proposed for a new generation of automated guided vehicles (AGVs) that are connected to a virtualized programmable logic controller (PLC) via a 5G multi-access edge-computing (MEC) platform to enable remote control. However, this approach faces a critical challenge as the 5G network may encounter communication disruptions that can lead to AGV deviations and, with this, potential safety risks and workplace issues. To mitigate this problem, several works have proposed the use of fixed-horizon forecasting techniques based on deep-learning models that can anticipate AGV trajectory deviations and take corrective maneuvers accordingly. However, these methods have limited prediction flexibility for the AGV operator and are not robust against network instability. To address this limitation, this study proposes a novel approach based on multi-horizon forecasting techniques to predict the deviation of remotely controlled AGVs. As its primary contribution, the work presents two new versions of the state-of-the-art transformer architecture that are well-suited to the multi-horizon prediction problem. We conduct a comprehensive comparison between the proposed models and traditional deep-learning models, such as the long short-term memory (LSTM) neural network, to evaluate the performance and capabilities of the proposed models in relation to traditional deep-learning architectures. The results indicate that (i) the transformer-based models outperform LSTM in both multi-horizon and fixed-horizon scenarios, (ii) the prediction accuracy at a specific time-step of the best multi-horizon forecasting model is very close to that obtained by the best fixed-horizon forecasting model at the same step, (iii) models that use a time-sequence structure in their inputs tend to perform better in multi-horizon scenarios compared to their fixed horizon counterparts and other multi-horizon models that do not consider a time topology in their inputs, and (iv) our experiments showed that the proposed models can perform inference within the required time constraints for real-time decision making. Full article

Advertisements play an important role in communicating with target customers. A higher advertisement frequency increases costs but may increase the chances of acquiring new customers. Moreover, faced with a wide-ranging array of products that might fit specific needs, customers usually buy according to expectations about value and satisfaction. When customers are satisfied with a purchasing experience, they are more likely to buy again and share their experiences with others. Hence, companies are concerned about increasing customer value and service satisfaction to develop and manage customer relationships. This maintains a company’s competitive edge and can improve its market share. In this article, we incorporate the frequency of advertisements and the cost of customer relationship management (CRM) into the demand function under a product life cycle (PLC). Customers can return products in the appreciation period offered by a retailer. A profit-maximizing model is developed to analyze the joint marketing and ordering policy of each stage of a product’s life cycle with a product return guarantee. We construct an algorithm to identify the optimal decisions. Finally, numerical examples are presented to illustrate the proposed model, and managerial insights are obtained from a sensitivity analysis, followed by conclusions and future research. Full article

The rapid evolution of industrial components, the paradigm of Industry 4.0, and the new connectivity features introduced by 5G technology all increase the likelihood of cybersecurity incidents. Such incidents are caused by the vulnerabilities present in these components. Designing a secure system is critical, but it is also complex, costly, and an extra factor to manage during the lifespan of the component. This paper presents a model to analyze the known vulnerabilities of industrial components over time. The proposed Extended Dependency Graph (EDG) model is based on two main elements: a directed graph representation of the internal structure of the component, and a set of quantitative metrics based on the Common Vulnerability Scoring System (CVSS). The EDG model can be applied throughout the entire lifespan of a device to track vulnerabilities, identify new requirements, root causes, and test cases. It also helps prioritize patching activities. The model was validated by application to the OpenPLC project. The results reveal that most of the vulnerabilities associated with OpenPLC were related to memory buffer operations and were concentrated in the libssl library. The model was able to determine new requirements and generate test cases from the analysis. Full article

A manufacturing paradigm shift from conventional control pyramids to decentralized, service-oriented, and cyber-physical systems (CPSs) is taking place in today’s 4th industrial revolution. Generally accepted roles and implementation recipes of cyber systems are expected to be standardized in the future of manufacturing industry. The authors intend to develop a novel CPS-enabled control architecture that accommodates: (1) intelligent information systems involving domain knowledge, empirical model, and simulation; (2) fast and secured industrial communication networks; (3) cognitive automation by rapid signal analytics and machine learning (ML) based feature extraction; (4) interoperability between machine and human. Semantic integration of process indicators is fundamental to the success of such implementation. This work proposes an automated semantic integration of data-intensive process signals that is deployable to industrial signal-based control loops. The proposed system rapidly infers manufacturing events from image-based data feeds, and hence triggers process control signals. Two image inference approaches are implemented: cloud-based ML model query and edge-end object shape detection. Depending on use cases and task requirements, these two approaches can be designated with different event detection tasks to provide a comprehensive system self-awareness. Coupled with conventional industrial sensor signals, machine vision system can rapidly understand manufacturing scenes, and feed extracted semantic information to a manufacturing ontology developed by either expert or ML-enabled cyber systems. Moreover, extracted signals are interpreted by Programmable Logical Controllers (PLCs) and field devices for cognitive automation towards fully autonomous industrial systems. Full article