Search Results (603)

The traditional manufacturing industry is facing the challenge of digital transformation, which involves the enhancement of intelligence and production efficiency. Many robotic applications have been discussed to enable collaborative robots to perform operations smartly rather than just automatically. This article tackles the issues of intelligent robots with cognitive and coordination capability by introducing cyber-physical integration technology. The authors propose a system architecture with open-source software and low-cost hardware based on the 5C hierarchy and then conduct experiments to verify the proposed framework. These experiments involve the collection of real-time data using a depth camera, object detection to recognize obstacles, simulation of collision avoidance for a robotic arm, and cyber-physical integration to perform a robotic task. The proposed framework realizes the scheme of the 5C architecture of Industry 4.0 and establishes a digital twin in cyberspace. By utilizing connection, conversion, calculation, simulation, verification, and operation, the robotic arm is capable of making independent judgments and appropriate decisions to successfully complete the assigned task, thereby verifying the proposed framework. Such a cyber-physical integration system is characterized by low cost but good effectiveness. Full article

The development of Industry 4.0 has accelerated the adoption of sophisticated technologies, including Digital Twins (DTs), Artificial Intelligence (AI), and cybersecurity, within Additive Manufacturing (AM). Enabling real-time monitoring, process optimization, predictive maintenance, and secure data management can redefine conventional manufacturing paradigms. Although their individual importance is increasing, a consistent understanding of how these technologies interact and collectively improve AM procedures is lacking. Focusing on the integration of digital twins (DTs), modular AI, and cybersecurity in AM, this review presents a comprehensive analysis of over 137 research publications from Scopus, Web of Science, Google Scholar, and ResearchGate. The publications are categorized into three thematic groups, followed by an analysis of key findings. Finally, the study identifies research gaps and proposes detailed recommendations along with a framework for future research. The study reveals that traditional AM processes have undergone significant transformations driven by digital threads, digital threads (DTs), and AI. However, this digitalization introduces vulnerabilities, leaving AM systems prone to cyber-physical attacks. Emerging advancements in AI, Machine Learning (ML), and Blockchain present promising solutions to mitigate these challenges. This paper is among the first to comprehensively summarize and evaluate the advancements in AM, emphasizing the integration of DTs, Modular AI, and cybersecurity strategies. Full article

The exponential growth of autonomous systems demands robust security mechanisms that can operate within the extreme constraints of real-time embedded environments. This paper introduces SMART DShot, a groundbreaking machine learning-enhanced framework that transforms the security landscape of unmanned aerial vehicle motor control systems through seamless integration of adaptive timing correction and real-time anomaly detection within Digital Shot (DShot) communication protocols. Our approach addresses critical vulnerabilities in Electronic Speed Controller (ESC) interfaces by deploying four synergistic algorithms—Kalman Filter Timing Correction (KFTC), Recursive Least Squares Timing Correction (RLSTC), Fuzzy Logic Timing Correction (FLTC), and Hybrid Adaptive Timing Correction (HATC)—each optimized for specific error characteristics and attack scenarios. Through comprehensive evaluation encompassing 32,000 Monte Carlo test iterations (500 per scenario × 16 scenarios × 4 algorithms) across 16 distinct operational scenarios and PolarFire SoC Field-Programmable Gate Array (FPGA) implementation, we demonstrate exceptional performance with 88.3% attack detection rate, only 2.3% false positive incidence, and substantial vulnerability mitigation reducing Common Vulnerability Scoring System (CVSS) severity from High (7.3) to Low (3.1). Hardware validation on PolarFire SoC confirms practical viability with minimal resource overhead (2.16% Look-Up Table utilization, 16.57 mW per channel) and deterministic sub-10 microsecond execution latency. The Hybrid Adaptive Timing Correction algorithm achieves 31.01% success rate (95% CI: [30.2%, 31.8%]), representing a 26.5% improvement over baseline approaches through intelligent meta-learning-based algorithm selection. Statistical validation using Analysis of Variance confirms significant performance differences (F(3,1996) = 30.30, p < 0.001) with large effect sizes (Cohen’s d up to 4.57), where 64.6% of algorithm comparisons showed large practical significance. SMART DShot establishes a paradigmatic shift from reactive to proactive embedded security, demonstrating that sophisticated artificial intelligence can operate effectively within microsecond-scale real-time constraints while providing comprehensive protection against timing manipulation, de-synchronization, burst interference, replay attacks, coordinated multi-channel attacks, and firmware-level compromises. This work provides essential foundations for trustworthy autonomous systems across critical domains including aerospace, automotive, industrial automation, and cyber–physical infrastructure. These results conclusively demonstrate that ML-enhanced motor control systems can achieve both superior security (88.3% attack detection rate with 2.3% false positives) and operational performance (31.01% timing correction success rate, 26.5% improvement over baseline) simultaneously, establishing SMART DShot as a practical, deployable solution for next-generation autonomous systems. 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

Prescriptive Maintenance (PsM) transforms industrial asset management by enabling autonomous decisions through simultaneous failure anticipation and optimal maintenance recommendations. Yet, despite increasing research interest, the conceptual clarity, technological maturity, and practical deployment of PsM remains fragmented. Here, we conduct a comprehensive and application-oriented Systematic Literature Review of studies published between 2013–2024. We identify key enablers—artificial intelligence and machine learning, horizontal and vertical integration, and deep reinforcement learning—that map the functional space of PsM across industrial sectors. The results from our multivariate meta-synthesis uncover three main thematic research clusters, ranging from decision-automation of technical (multi)component-level systems to strategic and organisational-support strategies. Notably, while predictive models are widely adopted, the translation of these capabilities to PsM remains limited. Primary reasons include semantic interoperability, real-time optimisation, and deployment scalability. As a response, a structured research agenda is proposed to emphasise hybrid architectures, context-aware prescription mechanisms, and alignment with Industry 5.0 principles of human-centricity, resilience, and sustainability. The review establishes a critical foundation for future advances in intelligent, explainable, and action-oriented maintenance systems. Full article

This paper proposes a low-latency and scalable architecture for Edge-Enabled Digital Twin networked control systems (E-DTNCS) aimed at multi-robot collision avoidance and remote control in dynamic and latency-sensitive environments. Traditional approaches, which rely on centralized cloud processing or direct sensor-to-controller communication, are inherently limited by excessive network latency, bandwidth bottlenecks, and a lack of predictive decision-making, thus constraining their effectiveness in real-time multi-agent systems. To overcome these limitations, we propose a novel framework that seamlessly integrates edge computing with digital twin (DT) technology. By performing localized preprocessing at the edge, the system extracts semantically rich features from raw sensor data streams, reducing the transmission overhead of the original data. This shift from raw data to feature-based communication significantly alleviates network congestion and enhances system responsiveness. The DT layer leverages these extracted features to maintain high-fidelity synchronization with physical robots and to execute predictive models for proactive collision avoidance. To empirically validate the framework, a real-world testbed was developed, and extensive experiments were conducted with multiple mobile robots. The results revealed a substantial reduction in collision rates when DT was deployed, and further improvements were observed with E-DTNCS integration due to significantly reduced latency. These findings confirm the system’s enhanced responsiveness and its effectiveness in handling real-time control tasks. The proposed framework demonstrates the potential of combining edge intelligence with DT-driven control in advancing the reliability, scalability, and real-time performance of multi-robot systems for industrial automation and mission-critical cyber-physical applications. Full article

As cyber threats continue to grow in complexity and persistence, resilience has become a critical requirement for cyber–physical systems (CPSs). Resilience quantitative assessment is essential for supporting secure system design and ensuring reliable operation. Although various methods have been proposed for evaluating CPS resilience, major challenges remain in accurately modeling the interaction between cyber and physical domains and in providing structured guidance for resilience-oriented design. This study proposes an integrated CPS resilience assessment framework that combines cyber-layer anomaly modeling based on Markov chains with mathematical modeling of performance degradation and recovery in the physical domain. The framework establishes a structured evaluation process through parameter normalization and cyber–physical coupling, enabling the generation of resilience curves that clearly represent system performance changes under adverse conditions. A case study involving an industrial controller equipped with a diversity-redundancy architecture is conducted to demonstrate the applicability of the proposed method. Modeling and simulation results indicate that the framework effectively reveals key resilience characteristics and supports performance-informed design optimization. Full article

The evolution of Industry 4.0 and the emerging paradigm of Industry 5.0 have introduced disruptive technologies that are reshaping modern manufacturing environments. Among these, Digital Twin (DT) and Industrial Metaverse (IM) technologies are increasingly recognized for their potential to enhance Occupational Health and Safety (OHS). However, a comprehensive understanding of how these technologies integrate to support OHS in manufacturing remains limited. This study systematically explores the transformative role of DT and IM in creating immersive, intelligent, and human-centric safety ecosystems. Following the PRISMA guidelines, a Systematic Literature Review (SLR) of 75 peer-reviewed studies from the SCOPUS and Web of Science databases was conducted. The review identifies key enabling technologies such as Virtual Reality (VR), Augmented Reality (AR), Extended Reality (XR), Internet of Things (IoT), Artificial Intelligence (AI), Cyber-Physical Systems (CPS), and Collaborative Robots (COBOTS), and highlights their applications in real-time monitoring, immersive safety training, and predictive hazard mitigation. A conceptual framework is proposed, illustrating a synergistic digital ecosystem that integrates predictive analytics, real-time monitoring, and immersive training to enhance the OHS. The findings highlight both the transformative benefits and the key adoption challenges of these technologies, including technical complexities, data security, privacy, ethical concerns, and organizational resistance. This study provides a foundational framework for future research and practical implementation in Industry 5.0. Full article

Traditional security detection methods struggle to identify zero-day attacks in Industrial Control Systems (ICSs), particularly within critical infrastructures (CIs) integrated with the Industrial Internet of Things (IIoT). These attacks exploit unknown vulnerabilities, leveraging the complexity of physical and digital system interconnections, making them difficult to detect. The integration of legacy ICS networks with modern computing and networking technologies has expanded the attack surface, increasing susceptibility to cyber threats. Anomaly detection systems play a crucial role in safeguarding these infrastructures by identifying deviations from normal operations. This study investigates the effectiveness of deep learning-based anomaly detection models in revealing operational anomalies that could indicate potential cyber-attacks. We implemented and evaluated a hybrid deep learning architecture combining Convolutional Neural Networks (CNNs) and Long Short-Term Memory (LSTM) networks to analyze ICS telemetry data. The CNN-LSTM model excels in identifying time-dependent anomalies and enables near real-time detection of cyber-attacks, significantly improving security monitoring capabilities for IIoT-integrated critical infrastructures. Full article

The evolution of the internet towards supporting time-critical applications, such as industrial cyber-physical systems (CPSs) and autonomous systems, has created an urgent demand for networks capable of providing deterministic, low-latency communication. Autonomous vehicles represent a particularly challenging use case within this domain, requiring both reliability and determinism for massive data streams—a requirement that traditional Ethernet technologies cannot satisfy. This paper addresses this critical gap by proposing a comprehensive scheduling framework based on Time-Aware Shaping (TAS) within the Time-Sensitive Networking (TSN) standard. The framework features two key contributions: (1) a novel baseline scheduling algorithm that incorporates a sub-flow division mechanism to enhance schedulability for high-bandwidth streams, computing Gate Control Lists (GCLs) via an iterative SMT-based method; (2) a separate heuristic-based computation acceleration algorithm to enable fast, scalable GCL generation for large-scale networks. Through extensive simulations, the proposed baseline algorithm demonstrates a reduction in end-to-end latency of up to 59% compared to standard methods, with jitter controlled at the nanosecond level. The acceleration algorithm is shown to compute schedules for 200 data streams in approximately one second. The framework’s effectiveness is further validated on a real-world TSN hardware testbed, confirming its capability to achieve deterministic transmission with low latency and jitter in a physical environment. This work provides a practical and scalable solution for deploying deterministic communication in complex autonomous and cyber-physical systems. Full article

Amid the accelerated digital transformation and with the growing demand for smart manufacturing, the applications of the Internet of Things (IoT) and total quality management (TQM) have attracted increasing attention. Using R for bibliometric analysis, we explored research trends in IoT and TQM in terms of digital transformation and smart manufacturing. Data were gathered from the Web of Science from 1998 to 2025, with a total of 787 publications from 265 sources involving 2326 authors. A total of 31% of the authors collaborated internationally, indicating global interest in this topic. The publications had 33.65 citations on average, totaling 33,599 citations. Wang L.H. and Tao F. were identified as important authors. Keywords of “Industry 4.0”, “cyber-physical systems”, and “big data” underscore the technological significance of IoT and TQM. Major journals such as the Journal of Manufacturing Systems and IEEE Access had notable academic influence. Co-citation analysis results revealed that IoT and TQM played a significant role in driving digital transformation and enhancing production efficiency, offering references for enterprises in strategic planning for smart manufacturing. Full article

In the context of Industry 4.0, Total Productive Maintenance (TPM) is undergoing a major shift driven by digital technologies such as the IoT, AI, cloud computing, and Cyber–Physical systems. This study explores how these technologies reshape traditional TPM pillars and practices through a two-phase methodology: bibliometric analysis, which reveals global research trends, key contributors, and emerging themes, and a systematic review, which discusses how core TPM practices are being transformed by advanced technologies. It also identifies key challenges of this transition, including data aggregation, a lack of skills, and resistance. However, despite the growing body of research on digital TPM, a major gap persists: the lack of a standardized model applicable across industries. Existing approaches are often fragmented or too context-specific, limiting scalability. Addressing this gap requires a structured approach that aligns technological advancements with TPM’s foundational principles. Taking a cue from these findings, this article formulates a systematic and scalable framework for TPM 4.0 deployment. The framework is based on four pillars: modular technological architecture, phased deployment, workforce integration, and standardized performance indicators. The ultimate goal is to provide a basis for a universal digital TPM standard that enhances the efficiency, resilience, and efficacy of smart maintenance systems. Full article

Cyber-physical systems such as Supervisory Control and Data Acquisition (SCADA) have been applied in industrial automation and infrastructure management for decades. They are hybrid tools for administration, monitoring, and continuous control of real physical systems through their computational representation. SCADA systems have evolved along with computing technology, from their beginnings with low-performance computers, monochrome monitors and communication networks with a range of a few hundred meters, to high-performance systems with advanced 3D graphics and wired and wireless computer networks. This article presents a methodology for the design of a SCADA system with a 3D Visualization for Drinking Water Supply, and its implementation in the Lerma Basin System of Mexico City as a case study. The monitoring of water consumption from the wells is presented, as well as the pressure levels throughout the system. The 3D visualization is generated from the GIS information and the communication is carried out using a hybrid radio frequency transmission system, satellite, and telephone network. The pumps that extract water from each well are teleoperated and monitored in real time. The developed system can be scaled to generate a simulator of water behavior of the Lerma Basin System and perform contingency planning. Full article

Fault detection and remaining useful life (RUL) prediction are critical tasks in self-healing network (SHN) environments and industrial cyber–physical systems. These domains demand intelligent systems capable of handling dynamic, high-dimensional sensor data. However, existing optimization-based approaches often struggle with imbalanced datasets, noisy signals, and delayed convergence, limiting their effectiveness in real-time applications. This study utilizes two benchmark datasets—EFCD and SFDD—which represent electrical and sensor fault scenarios, respectively. These datasets pose challenges due to class imbalance and complex temporal dependencies. To address this, we propose a novel hybrid framework combining Attention-Augmented Convolutional Neural Networks (AACNN) with transformer encoders, enhanced through Enhanced Ensemble-SMOTE for balancing the minority class. The model captures spatial features and long-range temporal patterns and learns effectively from imbalanced data streams. The novelty lies in the integration of attention mechanisms and adaptive oversampling in a unified fault-prediction architecture. Model evaluation is based on multiple performance metrics, including accuracy, F1-score, MCC, RMSE, and score*. The results show that the proposed model outperforms state-of-the-art approaches, achieving up to 97.14% accuracy and a score* of 0.419, with faster convergence and improved generalization across both datasets. Full article

The global trend toward Industry 4.0 has intensified the demand for intelligent, adaptive, and energy-efficient manufacturing systems. Machine learning (ML) has emerged as a crucial enabler of this transformation, particularly in high-mix, high-precision environments. This review examines the integration of machine learning techniques, such as convolutional neural networks (CNNs), reinforcement learning (RL), and federated learning (FL), within Taiwan’s advanced manufacturing sectors, including semiconductor fabrication, smart assembly, and industrial energy optimization. The present study draws on patent data and industrial case studies from leading firms, such as TSMC, Foxconn, and Delta Electronics, to trace the evolution from classical optimization to hybrid, data-driven frameworks. A critical analysis of key challenges is provided, including data heterogeneity, limited model interpretability, and integration with legacy systems. A comprehensive framework is proposed to address these issues, incorporating data-centric learning, explainable artificial intelligence (XAI), and cyber–physical architectures. These components align with industrial standards, including the Reference Architecture Model Industrie 4.0 (RAMI 4.0) and the Industrial Internet Reference Architecture (IIRA). The paper concludes by outlining prospective research directions, with a focus on cross-factory learning, causal inference, and scalable industrial AI deployment. This work provides an in-depth examination of the potential of machine learning to transform manufacturing into a more transparent, resilient, and responsive ecosystem. Additionally, this review highlights Taiwan’s distinctive position in the global high-tech manufacturing landscape and provides an in-depth analysis of patent trends from 2015 to 2025. Notably, this study adopts a patent-centered perspective to capture practical innovation trends and technological maturity specific to Taiwan’s globally competitive high-tech sector. Full article