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Keywords = real driving cycles

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19 pages, 9297 KB  
Article
Vibration Control of Wheels in Distributed Drive Electric Vehicle Based on Electro-Mechanical Braking
by Yinggang Xu, Zheng Zhu, Zhaonan Li, Xiangyu Wang, Liang Li and Heng Wei
Machines 2025, 13(8), 730; https://doi.org/10.3390/machines13080730 - 17 Aug 2025
Viewed by 274
Abstract
Electro-Mechanical Braking (EMB), as a novel brake-by-wire technology, is rapidly being implemented in vehicle chassis systems. Nevertheless, the integrated design of the EMB caliper contributes to an increased unsprung mass in Distributed Drive Electric Vehicles (DDEVs). Experimental results indicate that when the Anti-lock [...] Read more.
Electro-Mechanical Braking (EMB), as a novel brake-by-wire technology, is rapidly being implemented in vehicle chassis systems. Nevertheless, the integrated design of the EMB caliper contributes to an increased unsprung mass in Distributed Drive Electric Vehicles (DDEVs). Experimental results indicate that when the Anti-lock Braking System (ABS) is activated, these factors can induce high-frequency wheel oscillations. To address this issue, this study proposes an anti-oscillation control strategy tailored for EMB systems. Firstly, a quarter-vehicle model is established that incorporates the dynamics of the drive motor, suspension, and tire, enabling analysis of the system’s resonant behavior. The Discrete Fourier Transform (DFT) is applied to the difference between wheel speed and vehicle speed to extract the dominant frequency components. Then, an Adaptive Braking Intensity Field Regulation (ABIFR) strategy and a Model Predictive and Logic Control (MP-LC) framework are developed. These methods modulate the amplitude and frequency of braking torque reductions executed by the ABS to suppress high-frequency wheel oscillations, while ensuring sufficient braking force. Experimental validation using a real vehicle demonstrates that the proposed method increases the Mean Fully Developed Deceleration (MFDD) by 14.8% on low-adhesion surfaces and 15.2% on high-adhesion surfaces. Furthermore, the strategy significantly suppresses 12–13 Hz high-frequency oscillations, restoring normal ABS control cycles and enhancing both braking performance and ride comfort. Full article
(This article belongs to the Special Issue Advances in Dynamics and Control of Vehicles)
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14 pages, 3088 KB  
Article
CAF-Driven Mechanotransduction via Collagen Remodeling Accelerates Tumor Cell Cycle Progression
by Yating Xiao, Yingying Jiang, Ting Bao, Xin Hu, Xiang Wang, Xiaoning Han and Linhong Deng
Gels 2025, 11(8), 642; https://doi.org/10.3390/gels11080642 - 13 Aug 2025
Viewed by 263
Abstract
Cancer-associated fibroblasts (CAFs) restructure collagen hydrogels via actomyosin-driven fibril bundling and crosslinking, increasing polymer density to generate mechanical stress that accelerates tumor proliferation. Conventional hydrogel models lack spatial heterogeneity, thus obscuring how localized stiffness gradients regulate cell cycle progression. To address this, we [...] Read more.
Cancer-associated fibroblasts (CAFs) restructure collagen hydrogels via actomyosin-driven fibril bundling and crosslinking, increasing polymer density to generate mechanical stress that accelerates tumor proliferation. Conventional hydrogel models lack spatial heterogeneity, thus obscuring how localized stiffness gradients regulate cell cycle progression. To address this, we developed a collagen hydrogel-based microtissue platform integrated with programmable microstrings (single/double tethering), enabling real-time quantification of gel densification mechanics and force transmission efficiency. Using this system combined with FUCCI cell cycle biosensors and molecular perturbations, we demonstrate that CAF-polarized contraction increases hydrogel stiffness (350 → 775 Pa) and reduces pore diameter (5.0 → 1.9 μm), activating YAP/TAZ nuclear translocation via collagen–integrin–actomyosin cascades. This drives a 2.4-fold proliferation increase and accelerates G1/S transition in breast cancer cells. Pharmacological inhibition of YAP (verteporfin), actomyosin (blebbistatin), or collagen disruption (collagenase) reversed mechanotransduction and proliferation. Partial rescue upon CYR61 knockdown revealed compensatory effector networks. Our work establishes CAF-remodeled hydrogels as biomechanical regulators of tumor growth and positions gel-based mechanotherapeutics as promising anti-cancer strategies. Full article
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26 pages, 16020 KB  
Article
Energy Management of Hybrid Electric Commercial Vehicles Based on Neural Network-Optimized Model Predictive Control
by Jinlong Hong, Fan Yang, Xi Luo, Xiaoxiang Na, Hongqing Chu and Mengjian Tian
Electronics 2025, 14(16), 3176; https://doi.org/10.3390/electronics14163176 - 9 Aug 2025
Viewed by 503
Abstract
Energy management for hybrid electric commercial vehicles, involving continuous power output and discrete gear shifting, constitutes a typical mixed-integer programming (MIP) problem, presenting significant challenges for real-time performance and computational efficiency. To address this, this paper proposes a physics-informed neural network-optimized model predictive [...] Read more.
Energy management for hybrid electric commercial vehicles, involving continuous power output and discrete gear shifting, constitutes a typical mixed-integer programming (MIP) problem, presenting significant challenges for real-time performance and computational efficiency. To address this, this paper proposes a physics-informed neural network-optimized model predictive control (PINN-MPC) strategy. On one hand, this strategy simultaneously optimizes continuous and discrete states within the MPC framework to achieve the integrated objectives of minimizing fuel consumption, tracking speed, and managing battery state-of-charge (SOC). On the other hand, to overcome the prohibitively long solving time of the MIP-MPC, a physics-informed neural network (PINN) optimizer is designed. This optimizer employs the soft-argmax function to handle discrete gear variables and embeds system dynamics constraints using an augmented Lagrangian approach. Validated via hardware-in-the-loop (HIL) testing under two distinct real-world driving cycles, the results demonstrate that, compared to the open-source solver BONMIN, PINN-MPC significantly reduces computation time—dramatically decreasing the average solving time from approximately 10 s to about 5 ms—without sacrificing the combined vehicle dynamic and economic performance. Full article
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20 pages, 2981 KB  
Article
Data-Driven Modelling and Simulation of Fuel Cell Hybrid Electric Powertrain
by Mehroze Iqbal, Amel Benmouna and Mohamed Becherif
Hydrogen 2025, 6(3), 53; https://doi.org/10.3390/hydrogen6030053 - 1 Aug 2025
Viewed by 286
Abstract
Inspired by the Toyota Mirai, this study presents a high-fidelity data-driven approach for modelling and simulation of a fuel cell hybrid electric powertrain. This study utilises technical assessment data sourced from Argonne National Laboratory’s publicly available report, faithfully modelling most of the vehicle [...] Read more.
Inspired by the Toyota Mirai, this study presents a high-fidelity data-driven approach for modelling and simulation of a fuel cell hybrid electric powertrain. This study utilises technical assessment data sourced from Argonne National Laboratory’s publicly available report, faithfully modelling most of the vehicle subsystems as data-driven entities. The simulation framework is developed in the MATLAB/Simulink environment and is based on a power dynamics approach, capturing nonlinear interactions and performance intricacies between different powertrain elements. This study investigates subsystem synergies and performance boundaries under a combined driving cycle composed of the NEDC, WLTP Class 3 and US06 profiles, representing urban, extra-urban and aggressive highway conditions. To emulate the real-world load-following strategy, a state transition power management and allocation method is synthesised. The proposed method dynamically governs the power flow between the fuel cell stack and the traction battery across three operational states, allowing the battery to stay within its allocated bounds. This simulation framework offers a near-accurate and computationally efficient digital counterpart to a commercial hybrid powertrain, serving as a valuable tool for educational and research purposes. Full article
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21 pages, 1573 KB  
Review
A Novel Real-Time Battery State Estimation Using Data-Driven Prognostics and Health Management
by Juliano Pimentel, Alistair A. McEwan and Hong Qing Yu
Appl. Sci. 2025, 15(15), 8538; https://doi.org/10.3390/app15158538 - 31 Jul 2025
Viewed by 345
Abstract
This paper presents a novel data-driven framework for real-time State of Charge (SOC) estimation in lithium-ion battery systems using a data-driven Prognostics and Health Management (PHM) approach. The method leverages an optimized bidirectional Long Short-Term Memory (Bi-LSTM) network, trained with enhanced datasets filtered [...] Read more.
This paper presents a novel data-driven framework for real-time State of Charge (SOC) estimation in lithium-ion battery systems using a data-driven Prognostics and Health Management (PHM) approach. The method leverages an optimized bidirectional Long Short-Term Memory (Bi-LSTM) network, trained with enhanced datasets filtered via exponentially weighted moving averages (EWMAs) and refined through SHAP-based feature attribution. Compared against a Extended Kalman Filter (EKF) and Unscented Kalman Filter (UKF) across ten diverse drive cycles, the proposed model consistently achieved superior performance, with mean absolute errors (MAEs) as low as 0.40%, outperforming EKF (0.66%) and UKF (1.36%). The Bi-LSTM model also demonstrated higher R2 values (up to 0.9999) and narrower 95% confidence intervals, confirming its precision and robustness. Real-time implementation on embedded platforms yielded inference times of 1.3–2.2 s, validating its deployability for edge applications. The framework’s model-free nature makes it adaptable to other nonlinear, time-dependent systems beyond battery SOC estimation. Full article
(This article belongs to the Special Issue Design and Applications of Real-Time Embedded Systems)
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42 pages, 10454 KB  
Article
State-of-Charge Estimation of Medium- and High-Voltage Batteries Using LSTM Neural Networks Optimized with Genetic Algorithms
by Romel Carrera, Leonidas Quiroz, Cesar Guevara and Patricia Acosta-Vargas
Sensors 2025, 25(15), 4632; https://doi.org/10.3390/s25154632 - 26 Jul 2025
Viewed by 674
Abstract
This study presents a hybrid method for state-of-charge (SOC) estimation of lithium-ion batteries using LSTM neural networks optimized with genetic algorithms (GA), combined with Coulomb Counting (CC) as an initial estimator. Experimental tests were conducted using medium-voltage (48–72 V) lithium-ion battery packs under [...] Read more.
This study presents a hybrid method for state-of-charge (SOC) estimation of lithium-ion batteries using LSTM neural networks optimized with genetic algorithms (GA), combined with Coulomb Counting (CC) as an initial estimator. Experimental tests were conducted using medium-voltage (48–72 V) lithium-ion battery packs under standardized driving cycles (NEDC and WLTP). The proposed method enhances prediction accuracy under dynamic conditions by recalibrating the LSTM output with CC estimates through a dynamic fusion parameter α. The novelty of this approach lies in the integration of machine learning and physical modeling, optimized via evolutionary algorithms, to address limitations of standalone methods in real-time applications. The hybrid model achieved a mean absolute error (MAE) of 0.181%, outperforming conventional estimation strategies. These findings contribute to more reliable battery management systems (BMS) for electric vehicles and second-life applications. Full article
(This article belongs to the Section Electronic Sensors)
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17 pages, 706 KB  
Article
Empirical Energy Consumption Estimation and Battery Operation Analysis from Long-Term Monitoring of an Urban Electric Bus Fleet
by Tom Klaproth, Erik Berendes, Thomas Lehmann, Richard Kratzing and Martin Ufert
World Electr. Veh. J. 2025, 16(8), 419; https://doi.org/10.3390/wevj16080419 - 25 Jul 2025
Viewed by 667
Abstract
Electric buses are key in the strategy towards a greenhouse-gas-neutral fleet. However, their restrictions in terms of range and refueling as well as their increased price point present new challenges for public transport companies. This study aims to address, based on real-world operational [...] Read more.
Electric buses are key in the strategy towards a greenhouse-gas-neutral fleet. However, their restrictions in terms of range and refueling as well as their increased price point present new challenges for public transport companies. This study aims to address, based on real-world operational data, how energy consumption and charging behavior affect battery aging and how operational strategies can be optimized to extend battery life under realistic conditions. This article presents an energy consumption analysis with respect to ambient temperatures and average vehicle speed based exclusively on real-world data of an urban bus fleet, providing a data foundation for range forecasting and infrastructure planning optimized for public transport needs. Additionally, the State of Charge (SOC) window during operation and vehicle idle time as well as the charging power were analyzed in this case study to formulate recommendations towards a more battery-friendly treatment. The central research question is whether battery-friendly operational strategies—such as reduced charging power and lower SOC windows—can realistically be implemented in daily public transport operations. The impact of the recommendations on battery lifetime is estimated using a battery aging model on drive cycles. Finally, the reduction in CO2 emissions compared to diesel buses is estimated. Full article
(This article belongs to the Special Issue Zero Emission Buses for Public Transport)
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20 pages, 28281 KB  
Article
Infrared-Guided Thermal Cycles in FEM Simulation of Laser Welding of Thin Aluminium Alloy Sheets
by Pasquale Russo Spena, Manuela De Maddis, Valentino Razza, Luca Santoro, Husniddin Mamarayimov and Dario Basile
Metals 2025, 15(8), 830; https://doi.org/10.3390/met15080830 - 24 Jul 2025
Viewed by 456
Abstract
Climate concerns are driving the automotive industry to adopt advanced manufacturing technologies that aim to improve energy efficiency and reduce vehicle weight. In this context, lightweight structural materials such as aluminium alloys have gained significant attention due to their favorable strength-to-weight ratio. Laser [...] Read more.
Climate concerns are driving the automotive industry to adopt advanced manufacturing technologies that aim to improve energy efficiency and reduce vehicle weight. In this context, lightweight structural materials such as aluminium alloys have gained significant attention due to their favorable strength-to-weight ratio. Laser welding plays a crucial role in assembling such materials, offering high flexibility and fast joining capabilities for thin aluminium sheets. However, welding these materials presents specific challenges, particularly in controlling heat input to minimize distortions and ensure consistent weld quality. As a result, numerical simulations based on the Finite Element Method (FEM) are essential for predicting weld-induced phenomena and optimizing process performance. This study investigates welding-induced distortions in laser butt welding of 1.5 mm-thick Al 6061 samples through FEM simulations performed in the SYSWELD 2024.0 environment. The methodology provided by the software is based on the Moving Heat Source (MHS) model, which simulates the physical movement of the heat source and typically requires extensive calibration through destructive metallographic testing. This transient approach enables the detailed prediction of thermal, metallurgical, and mechanical behavior, but it is computationally demanding. To improve efficiency, the Imposed Thermal Cycle (ITC) model is often used. In this technique, a thermal cycle, extracted from an MHS simulation or experimental data, is imposed on predefined subregions of the model, allowing only mechanical behavior to be simulated while reducing computation time. To avoid MHS-based calibration, this work proposes using thermal cycles acquired in-line during welding via infrared thermography as direct input for the ITC model. The method was validated experimentally and numerically, showing good agreement in the prediction of distortions and a significant reduction in workflow time. The distortion values from simulations differ from the real experiment by less than 0.3%. Our method exhibits a slight decrease in performance, resulting in an increase in estimation error of 0.03% compared to classic approaches, but more than 85% saving in computation time. The integration of real process data into the simulation enables a virtual representation of the process, supporting future developments toward Digital Twin applications. Full article
(This article belongs to the Special Issue Manufacturing Processes of Metallic Materials)
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23 pages, 4256 KB  
Article
A GAN-Based Framework with Dynamic Adaptive Attention for Multi-Class Image Segmentation in Autonomous Driving
by Bashir Sheikh Abdullahi Jama and Mehmet Hacibeyoglu
Appl. Sci. 2025, 15(15), 8162; https://doi.org/10.3390/app15158162 - 22 Jul 2025
Viewed by 352
Abstract
Image segmentation is a foundation for autonomous driving frameworks that empower vehicles to explore and navigate their surrounding environment. It gives a fundamental setting to the dynamic cycles by dividing the image into significant parts like streets, vehicles, walkers, and traffic signs. Precise [...] Read more.
Image segmentation is a foundation for autonomous driving frameworks that empower vehicles to explore and navigate their surrounding environment. It gives a fundamental setting to the dynamic cycles by dividing the image into significant parts like streets, vehicles, walkers, and traffic signs. Precise segmentation ensures safe navigation and the avoidance of collisions, while following the rules of traffic is very critical for seamless operation in self-driving cars. The most recent deep learning-based image segmentation models have demonstrated impressive performance in structured environments, yet they often fall short when applied to the complex and unpredictable conditions encountered in autonomous driving. This study proposes an Adaptive Ensemble Attention (AEA) mechanism within a Generative Adversarial Network architecture to deal with dynamic and complex driving conditions. The AEA integrates the features of self, spatial, and channel attention adaptively and powerfully changes the amount of each contribution as per input and context-oriented relevance. It does this by allowing the discriminator network in GAN to evaluate the segmentation mask created by the generator. This explains the difference between real and fake masks by considering a concatenated pair of an original image and its mask. The adversarial training will prompt the generator, via the discriminator, to mask out the image in such a way that the output aligns with the expected ground truth and is also very realistic. The exchange of information between the generator and discriminator improves the quality of the segmentation. In order to check the accuracy of the proposed method, the three widely used datasets BDD100K, Cityscapes, and KITTI were selected to calculate average IoU, where the value obtained was 89.46%, 89.02%, and 88.13% respectively. These outcomes emphasize the model’s effectiveness and consistency. Overall, it achieved a remarkable accuracy of 98.94% and AUC of 98.4%, indicating strong enhancements compared to the State-of-the-art (SOTA) models. Full article
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22 pages, 5966 KB  
Article
Road-Adaptive Precise Path Tracking Based on Reinforcement Learning Method
by Bingheng Han and Jinhong Sun
Sensors 2025, 25(15), 4533; https://doi.org/10.3390/s25154533 - 22 Jul 2025
Viewed by 416
Abstract
This paper proposes a speed-adaptive autonomous driving path-tracking framework based on the soft actor–critic (SAC) and pure pursuit (PP) methods, named the SACPP controller. The framework first analyzes the obstacles around the vehicle and plans an obstacle-free reference path with the minimum curvature [...] Read more.
This paper proposes a speed-adaptive autonomous driving path-tracking framework based on the soft actor–critic (SAC) and pure pursuit (PP) methods, named the SACPP controller. The framework first analyzes the obstacles around the vehicle and plans an obstacle-free reference path with the minimum curvature using the hybrid A* algorithm. Next, based on the generated reference path, the current state of the vehicle, and the vehicle motor energy efficiency diagram, the optimal speed is calculated in real time, and the vehicle dynamics preview point at the future moment—specifically, the look-ahead distance—is predicted. This process relies on the learning of the SAC network structure. Finally, PP is used to generate the front wheel angle control value by combining the current speed and the predicted preview point. In the second layer, we carefully designed the evaluation function in the tracking process based on the uncertainties and performance requirements that may occur during vehicle driving. This design ensures that the autonomous vehicle can not only quickly and accurately track the path, but also effectively avoid surrounding obstacles, while keeping the motor running in the high-efficiency range, thereby reducing energy loss. In addition, since the entire framework uses a lightweight network structure and a geometry-based method to generate the front wheel angle, the computational load is significantly reduced, and computing resources are saved. The actual running results on the i7 CPU show that the control cycle of the control framework exceeds 100 Hz. Full article
(This article belongs to the Special Issue AI-Driving for Autonomous Vehicles)
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13 pages, 1279 KB  
Article
Transcriptome Sequencing-Based Analysis of Premature Fruiting in Amomum villosum Lour.
by Yating Zhu, Shuang Li, Hongyou Zhao, Qianxia Li, Yanfang Wang, Chunyong Yang, Ge Li, Yanqian Wang and Lixia Zhang
Biology 2025, 14(7), 883; https://doi.org/10.3390/biology14070883 - 18 Jul 2025
Viewed by 378
Abstract
Amomum villosum Lour., a perennial medicinal plant in the Zingiber genus, usually requires approximately 3–4 years of vegetative growth from seed germination to first fruiting, resulting in high initial investment costs and a prolonged revenue cycle, which pose significant challenges to the industry’s [...] Read more.
Amomum villosum Lour., a perennial medicinal plant in the Zingiber genus, usually requires approximately 3–4 years of vegetative growth from seed germination to first fruiting, resulting in high initial investment costs and a prolonged revenue cycle, which pose significant challenges to the industry’s sustainable development. Our research team observed a distinct premature fruiting phenomenon in A. villosum. We investigated the regulatory mechanisms underlying premature fruiting in A. villosum by identifying the key differentially expressed genes (DEGs) and metabolic pathways governing the premature fruiting (Precocious) and typical plants (CK) of the ‘Yunsha No.8’ cultivar. Transcriptomic sequencing (RNA-seq) and bioinformatic analyses were performed using the DNBSEQTM platform. The sequencing generated 29.0 gigabases (Gb) of clean data, and 115,965 unigenes were identified, with an average length of 1368 bp. Based on the sequencing results, 1545 DEGs were identified. Gene ontology (GO) analysis and Kyoto Encyclopedia of Genes and Genomes (KEGG) pathway analysis were annotated for these DEGs. This study identifies phytohormone signaling, carbohydrate and lipid metabolism, and polysaccharide degradation as critical pathways controlling premature fruiting in A. villosum. Six randomly selected DEGs were validated using real-time fluorescence quantitative polymerase chain reaction (RT-qPCR), and the results corroborated the transcriptome data, confirming their reliability. This study lays the foundation for the elucidation of the molecular mechanisms and metabolic pathways driving premature fruiting in A. villosum. Full article
(This article belongs to the Special Issue Young Investigators in Biochemistry and Molecular Biology)
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29 pages, 4633 KB  
Article
Failure Detection of Laser Welding Seam for Electric Automotive Brake Joints Based on Image Feature Extraction
by Diqing Fan, Chenjiang Yu, Ling Sha, Haifeng Zhang and Xintian Liu
Machines 2025, 13(7), 616; https://doi.org/10.3390/machines13070616 - 17 Jul 2025
Viewed by 377
Abstract
As a key component in the hydraulic brake system of automobiles, the brake joint directly affects the braking performance and driving safety of the vehicle. Therefore, improving the quality of brake joints is crucial. During the processing, due to the complexity of the [...] Read more.
As a key component in the hydraulic brake system of automobiles, the brake joint directly affects the braking performance and driving safety of the vehicle. Therefore, improving the quality of brake joints is crucial. During the processing, due to the complexity of the welding material and welding process, the weld seam is prone to various defects such as cracks, pores, undercutting, and incomplete fusion, which can weaken the joint and even lead to product failure. Traditional weld seam detection methods include destructive testing and non-destructive testing; however, destructive testing has high costs and long cycles, and non-destructive testing, such as radiographic testing and ultrasonic testing, also have problems such as high consumable costs, slow detection speed, or high requirements for operator experience. In response to these challenges, this article proposes a defect detection and classification method for laser welding seams of automotive brake joints based on machine vision inspection technology. Laser-welded automotive brake joints are subjected to weld defect detection and classification, and image processing algorithms are optimized to improve the accuracy of detection and failure analysis by utilizing the high efficiency, low cost, flexibility, and automation advantages of machine vision technology. This article first analyzes the common types of weld defects in laser welding of automotive brake joints, including craters, holes, and nibbling, and explores the causes and characteristics of these defects. Then, an image processing algorithm suitable for laser welding of automotive brake joints was studied, including pre-processing steps such as image smoothing, image enhancement, threshold segmentation, and morphological processing, to extract feature parameters of weld defects. On this basis, a welding seam defect detection and classification system based on the cascade classifier and AdaBoost algorithm was designed, and efficient recognition and classification of welding seam defects were achieved by training the cascade classifier. The results show that the system can accurately identify and distinguish pits, holes, and undercutting defects in welds, with an average classification accuracy of over 90%. The detection and recognition rate of pit defects reaches 100%, and the detection accuracy of undercutting defects is 92.6%. And the overall missed detection rate is less than 3%, with both the missed detection rate and false detection rate for pit defects being 0%. The average detection time for each image is 0.24 s, meeting the real-time requirements of industrial automation. Compared with infrared and ultrasonic detection methods, the proposed machine-vision-based detection system has significant advantages in detection speed, surface defect recognition accuracy, and industrial adaptability. This provides an efficient and accurate solution for laser welding defect detection of automotive brake joints. Full article
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20 pages, 3567 KB  
Article
Cycle-Informed Triaxial Sensor for Smart and Sustainable Manufacturing
by Parisa Esmaili, Luca Martiri, Parvaneh Esmaili and Loredana Cristaldi
Sensors 2025, 25(14), 4431; https://doi.org/10.3390/s25144431 - 16 Jul 2025
Cited by 1 | Viewed by 816
Abstract
Advances in Industry 4.0 and the emergence of Industry 5.0 are driving the development of intelligent, sustainable manufacturing systems, where embedded sensing and real-time health diagnostics play a critical role. However, implementing robust predictive maintenance in production environments remains challenging due to the [...] Read more.
Advances in Industry 4.0 and the emergence of Industry 5.0 are driving the development of intelligent, sustainable manufacturing systems, where embedded sensing and real-time health diagnostics play a critical role. However, implementing robust predictive maintenance in production environments remains challenging due to the variability in machine operations and the lack of access to internal control data. This paper introduces a lightweight, embedded-compatible framework for health status signature extraction based on empirical mode decomposition (EMD), leveraging only data from a single triaxial accelerometer. The core of the proposed method is a cycle-synchronized segmentation strategy that uses accelerometer-derived velocity profiles and cross-correlation to align signals with machining cycles, eliminating the need for controller or encoder access. This ensures process-aware decomposition that preserves the operational context across diverse and dynamic machining conditions to address the inadequate segmentation of unstable process data that often fails to capture the full scope of the process, resulting in misinterpretation. The performance is evaluated on a challenging real-world manufacturing benchmark where the extracted intrinsic mode functions (IMFs) are analyzed in the frequency domain, including quantitative evaluation. As results show, the proposed method shows its effectiveness in detecting subtle degradations, following a low computational footprint, and its suitability for deployment in embedded predictive maintenance systems on brownfield or controller-limited machinery. Full article
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24 pages, 17098 KB  
Article
A Combined Energy Management Strategy for Heavy-Duty Trucks Based on Global Traffic Information Optimization
by Haishan Wu, Liang Li and Xiangyu Wang
Sustainability 2025, 17(14), 6361; https://doi.org/10.3390/su17146361 - 11 Jul 2025
Viewed by 314
Abstract
As public concern over environmental pollution and the urgent need for sustainable development grow, the popularity of new-energy vehicles has increased. Hybrid electric vehicles (HEVs) represent a significant segment of this movement, undergoing robust development and playing an important role in the global [...] Read more.
As public concern over environmental pollution and the urgent need for sustainable development grow, the popularity of new-energy vehicles has increased. Hybrid electric vehicles (HEVs) represent a significant segment of this movement, undergoing robust development and playing an important role in the global transition towards sustainable mobility. Among the various factors affecting the fuel economy of HEVs, energy management strategies (EMSs) are particularly critical. With continuous advancements in vehicle communication technology, vehicles are now equipped to gather real-time traffic information. In response to this evolution, this paper proposes an optimization method for the adaptive equivalent consumption minimization strategy (A-ECMS) equivalent factor that incorporates traffic information and efficient optimization algorithms. Building on this foundation, the proposed method integrates the charge depleting–charge sustaining (CD-CS) strategy to create a combined EMS that leverages traffic information. This approach employs the CD-CS strategy to facilitate vehicle operation in the absence of comprehensive global traffic information. However, when adequate global information is available, it utilizes both the CD-CS strategy and the A-ECMS for vehicle control. Simulation results indicate that this combined strategy demonstrates effective performance, achieving fuel consumption reductions of 5.85% compared with the CD-CS strategy under the China heavy-duty truck cycle, 4.69% under the real vehicle data cycle, and 3.99% under the custom driving cycle. Full article
(This article belongs to the Special Issue Powertrain Design and Control in Sustainable Electric Vehicles)
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29 pages, 7365 KB  
Article
Energy Management Design of Dual-Motor System for Electric Vehicles Using Whale Optimization Algorithm
by Chien-Hsun Wu, Chieh-Lin Tsai and Jie-Ming Yang
Sensors 2025, 25(14), 4317; https://doi.org/10.3390/s25144317 - 10 Jul 2025
Viewed by 445
Abstract
Dual-motor electric vehicles enhance power performance and overall output capabilities by enabling the real-time control of the torque distribution between the front and rear wheels, thereby improving handling, stability, and safety. In addition to increased energy efficiency, a dual-motor system provides redundancy: if [...] Read more.
Dual-motor electric vehicles enhance power performance and overall output capabilities by enabling the real-time control of the torque distribution between the front and rear wheels, thereby improving handling, stability, and safety. In addition to increased energy efficiency, a dual-motor system provides redundancy: if one motor fails, the other can still supply partial power, further enhancing driving safety. This study aimed to optimize the energy management strategies of the front- and rear-axis motors, examining the application effects of rule-based control (RBC), global grid search (GGS), and the whale optimization algorithm (WOA). A simulation platform based on MATLAB/Simulink® (R2021b, MATLAB, Natick, MA, USA) was constructed and validated through hardware-in-the-loop (HIL) testing to ensure the authenticity and reliability of the simulation results. Detailed tests and analyses of the dual-motor system were conducted under FTP-75 driving cycles. Compared to the RBC strategy, GGS and WOA achieved energy efficiency improvements of 9.1% and 8.9%, respectively, in the pure simulation, and 4.2% and 3.8%, respectively, in the HIL simulation. Compared to the pure RBC strategy, the RBC and GGS strategies incorporating regenerative braking achieved energy efficiency improvements of 26.1% and 29.4%, respectively, in the HIL simulation. Overall, GGS and WOA each present distinct advantages, with WOA emerging as a highly promising alternative energy management strategy. Future research should further explore WOA applications to enhance energy savings in real-world vehicle operations. Full article
(This article belongs to the Topic Innovation, Communication and Engineering)
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