Search Results (2,228)

In this paper, a novel online detection system is designed to enhance accuracy and operational efficiency in the outbound logistics of automotive components after production. The system consists of a scanning portal system and an improved YOLOv12-based detection algorithm which captures images of automotive parts passing through the scanning portal in real time. By integrating deep learning, the system enables real-time monitoring and identification, thereby preventing misdetections and missed detections of automotive parts, in this way promoting intelligent automotive part recognition and detection. Our system introduces the A2C2f-SA module, which achieves an efficient feature attention mechanism while maintaining a lightweight design. Additionally, Dynamic Space-to-Depth (Dynamic S2D) is employed to improve convolution and replace the stride convolution and pooling layers in the baseline network, helping to mitigate the loss of fine-grained information and enhancing the network’s feature extraction capability. To improve real-time performance, a GFL-MBConv lightweight detection head is proposed. Furthermore, adaptive frequency-aware feature fusion (Adpfreqfusion) is hybridized at the end of the neck network to effectively enhance high-frequency information lost during downsampling, thereby improving the model’s detection accuracy for target objects in complex backgrounds. On-site tests demonstrate that the system achieves a comprehensive accuracy of 97.3% and an average vehicle detection time of 7.59 s, exhibiting not only high precision but also high detection efficiency. These results can make the proposed system highly valuable for applications in the automotive industry. Full article

The safe and reliable operation of autonomous vehicles is contingent on comprehensive testing. However, the operational scenarios are inexhaustible. Corner cases, which critically influence autonomous vehicle safety, occur at an extremely low probability and follow a long-tail distribution. Corner cases can be defined as combinations of driving task and scenario elements. These scenarios are characterized by low probability, high risk, and a tendency to reveal functional limitations inherent to autonomous driving systems, triggering anomalous behavior. This study constructs a novel corner case dataset using naturalistic driving data, specifically tailored for autonomous vehicle testing. A scenario marginality quantification method is designed to analyze multi-source naturalistic driving data, enabling efficient extraction of corner cases. Heterogeneous scenarios are systematically transformed, resulting in a dataset characterized by diverse interaction behaviors and standardized formatting. The results indicate that the scenario marginality of the dataset constructed in this study is 2.78 times that of mainstream naturalistic driving datasets, and the scenarios exhibit considerable diversity. The trajectory and velocity fluctuations, quantified at 0.013 m and 0.021 m/s, respectively, are consistent with the kinematic characteristics of real-world driving scenarios. These results collectively demonstrate the dataset’s high marginality, diversity, and applicability. 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

Understanding vehicle emissions is essential for developing effective carbon reduction strategies in the transport sector. Conventional emission models often assume homogeneity and linearity, overlooking real-world asymmetries that arise from variations in vehicle design and powertrain configurations. This study explores how machine learning and explainable AI techniques can effectively capture both symmetric and asymmetric emission patterns across different vehicle types, thereby contributing to more sustainable transport planning. Addressing a key gap in the existing literature, the study poses the following question: how do structural and behavioral factors contribute to asymmetric emission responses in internal combustion engine vehicles compared to new energy vehicles? Utilizing a large-scale Spanish vehicle registration dataset, the analysis classifies vehicles by powertrain type and applies five supervised learning algorithms to predict CO₂ emissions. SHapley Additive exPlanations (SHAPs) are employed to identify nonlinear and threshold-based relationships between emissions and vehicle characteristics such as fuel consumption, weight, and height. Among the models tested, the Random Forest algorithm achieves the highest predictive accuracy. The findings reveal critical asymmetries in emission behavior, particularly among hybrid vehicles, which challenge the assumption of uniform policy applicability. This study provides both methodological innovation and practical insights for symmetry-aware emission modeling, offering support for more targeted eco-design and policy decisions that align with long-term sustainability goals. Full article

Today, mechatronic systems are required to operate reliably and safely. However, actuators can fail, causing the system to malfunction or, in the worst case, resulting in an accident. A clear example of this is the motors of unmanned aerial vehicles. If any of them fail, the vehicle loses control, resulting in a catastrophe and potentially leading to the partial or total loss of the system. Therefore, there is a need to design robust control strategies that allow the system to continue operating even with the loss of one of its actuators. Based on the above, this work presents a controller capable of performing output regulation while tolerating actuator faults in actuated robotic platforms. In contrast to traditional output regulation theory, where a known exosystem provides the reference signal, the proposed approach employs a High-Gain Observer (HGO) to estimate and generate the reference signal from an unknown exosystem. Additionally, an Unknown Input (UI) observer is used to estimate actuator faults, enabling the computation of a fault-tolerant control. The methodology is tested in simulation and real-time experiments on the well-known Furuta pendulum system to illustrate the effectiveness of the proposed approach. Full article

This work focuses on the possibilities of generating synthetic data for machine learning in hazard prediction in area-based speed monitoring systems. The purpose of the research conducted was to develop a methodology for generating realistic synthetic data to support the design of a continuous vehicle speed monitoring system to minimize the risk of traffic accidents caused by speeding. The SUMO traffic simulator was used to model driver behavior in the analyzed area and within a given road network. Data from OpenStreetMap and field measurements from over a dozen speed detectors were integrated. Preliminary tests were carried out to record vehicle speeds. Based on these data, several simulation scenarios were run and compared to real-world observations using average speed, the percentage of speed limit violations, root mean square error (RMSE), and percentage compliance. A new metric, the Combined Speed Accuracy Score (CSAS), has been introduced to assess the consistency of simulation results with real-world data. For this study, a basic hazard prediction model was developed using LoRaWAN sensor network data and environmental contextual variables, including time, weather, location, and accident history. The research results in a method for evaluating and selecting the simulation scenario that best represents reality and drivers’ propensities to exceed speed limits. The results and findings demonstrate that it is possible to produce synthetic data with a level of agreement exceeding 90% with real data. Thus, it was shown that it is possible to generate synthetic data for machine learning in hazard prediction for area-based speed control systems using traffic simulators. Full article

The energy generated from renewable sources has an intermittent nature since solar irradiation and wind speed vary continuously. Hence, their energy should be stored to be utilized throughout their shortage. There are various forms of energy storage systems while the most widespread technique is the battery storage system since its cost is low compared to other techniques. Therefore, batteries are employed in several applications like power systems, electric vehicles, and smart grids. Due to the merits of the lithium-ion (Li-ion) battery, it is preferred over other kinds of batteries. However, the accuracy of the Li-ion battery model is essential for estimating the state of charge (SOC). Additionally, it is essential for consistent simulation and operation throughout various loading and charging conditions. Consequently, the determination of real battery model parameters is vital. An innovative application of the red-billed blue magpie optimizer (RBMO) for determining the model parameters and the SOC of the Li-ion battery is presented in this article. The Shepherd model parameters are determined using the suggested optimization algorithm. The RBMO-based modeling approach offers excellent execution in determining the parameters of the battery model. The suggested approach is compared to other programmed algorithms, namely dandelion optimizer, spider wasp optimizer, barnacles mating optimizer, and interior search algorithm. Moreover, the suggested RBMO is statistically evaluated using Kruskal–Wallis, ANOVA tables, Friedman rank, and Wilcoxon rank tests. Additionally, the Li-ion battery model estimated via the RBMO is validated under variable loading conditions. The fetched results revealed that the suggested approach achieved the least errors between the measured and estimated voltages compared to other approaches in two studied cases with values of 1.4951 × 10⁻⁴ and 2.66176 × 10⁻⁴. Full article

Reducing gear noise in electric vehicle (EV) drivetrains is crucial due to the absence of internal combustion engine noise, making even minor acoustic disturbances noticeable. Manufacturing parameters significantly influence gear-generated noise, yet traditional analytical methods often fail to predict these complex relationships accurately. This research addresses this gap by introducing a data-driven approach using machine learning (ML) to predict gear noise levels from manufacturing and sensor-derived data. The presented methodology encompasses systematic data collection from various production stages—including soft and hard machining, heat treatment, honing, rolling tests, and end-of-line (EOL) acoustic measurements. Predictive models employing Random Forest, Gradient Boosting (XGBoost), and Neural Network algorithms were developed and compared to traditional statistical approaches. The analysis identified critical manufacturing parameters, such as surface waviness, profile errors, and tooth geometry deviations, significantly influencing noise generation. Advanced ML models, specifically Random Forest, XGBoost, and deep neural networks, demonstrated superior prediction accuracy, providing early-stage identification of gear units likely to exceed acceptable noise thresholds. Integrating these data-driven models into manufacturing processes enables early detection of potential noise issues, reduces quality assurance costs, and supports sustainable manufacturing by minimizing prototype production and resource consumption. This research enhances the understanding of gear noise formation and offers practical solutions for real-time quality assurance. Full article

Intelligent driving is a key technology in the field of automotive manufacturing due to its advantages in environmental protection, energy efficiency, and economy. However, since the intelligent driving model is an uncertain multi-input multi-output dynamic system, especially in an interactive environment, it faces uncertainties such as non-uniform trial lengths, unknown nonlinear parameters, and unknown control direction. In this paper, an adaptive iterative learning control method is proposed for vehicle systems with non-uniform trial lengths and asymmetric control gain matrices. Unlike the existing research on adaptive iterative learning for non-uniform test lengths, this paper assumes that the elements of the system’s control gain matrix are asymmetric. Therefore, the assumption made in traditional adaptive iterative learning methods that the control gain matrix of the system is known or real, symmetric, and positive definite (or negative definite) is relaxed. Finally, to prove the convergence of the system, a composite energy function is designed, and the effectiveness of the adaptive iterative learning method is verified using vehicle systems. This paper aims to address the challenges in intelligent driving control and decision-making caused by environmental and system uncertainties and provides a theoretical basis and technical support for intelligent driving, promoting the high-quality development of intelligent transportation. Full article

The electrification of road vehicles is a relatively mature sector, while other areas of mobility, such as construction machinery, are just beginning their transition to electric solutions. This work presents the design and realization of an integrated drive system specifically developed for retrofitting fan drives in heavy machinery, like bulldozers and tractors, utilizing existing 48 VDC batteries. By replacing or complementing internal combustion and hydraulic technologies with electric solutions, significant advantages in efficiency, reduced environmental impact, and versatility can be achieved. Focusing on the fan drive system addresses the critical challenge of thermal management in high ambient temperatures and harsh environments, particularly given the high current requirements for $3\mathrm{k}\mathrm{W}$-class applications. A sensorless architecture has been selected to enhance reliability by eliminating mechanical position sensors. The developed fan drive has been extensively tested both on a braking bench and in real-world applications, demonstrating its effectiveness and robustness. Future work will extend this prototype to electrify additional onboard hydraulic motors in these machines, further advancing the electrification of heavy-duty equipment and improving overall efficiency and environmental impact. Full article

In recent years, a growing number of real-time semantic segmentation networks have been developed to improve segmentation accuracy. However, these advancements often come at the cost of increased computational complexity, which limits their inference efficiency, particularly in scenarios such as autonomous driving, where strict real-time performance is essential. Achieving an effective balance between speed and accuracy has thus become a central challenge in this field. To address this issue, we present a lightweight semantic segmentation model tailored for the perception requirements of autonomous vehicles. The architecture follows an encoder–decoder paradigm, which not only preserves the capability for deep feature extraction but also facilitates multi-scale information integration. The encoder leverages a high-efficiency backbone, while the decoder introduces a dynamic fusion mechanism designed to enhance information interaction between different feature branches. Recognizing the limitations of convolutional networks in modeling long-range dependencies and capturing global semantic context, the model incorporates an attention-based feature extraction component. This is further augmented by positional encoding, enabling better awareness of spatial structures and local details. The dynamic fusion mechanism employs an adaptive weighting strategy, adjusting the contribution of each feature channel to reduce redundancy and improve representation quality. To validate the effectiveness of the proposed network, experiments were conducted on a single RTX 3090 GPU. The Dynamic Real-time Integrated Vision Encoder–Segmenter Network (DriveSegNet) achieved a mean Intersection over Union (mIoU) of 76.9% and an inference speed of 70.5 FPS on the Cityscapes test dataset, 74.6% mIoU and 139.8 FPS on the CamVid test dataset, and 35.8% mIoU with 108.4 FPS on the ADE20K dataset. The experimental results demonstrate that the proposed method achieves an excellent balance between inference speed, segmentation accuracy, and model size. Full article

In modern vehicles, Autonomous Driving Systems (ADSs) are designed to operate partially or fully without human intervention. The ADS pipeline comprises multiple layers, including sensors, perception, localization, mapping, path planning, and control. The Robot Operating System (ROS) is a widely adopted framework that supports the modular development and integration of these layers. Among them, the path-planning and control layers remain particularly challenging due to several limitations. Classical path planners often struggle with non-smooth trajectories and high computational demands. Meta-heuristic optimization algorithms have demonstrated strong theoretical potential in path planning; however, they are rarely implemented in real-time ROS-based systems due to integration challenges. Similarly, traditional PID controllers require manual tuning and are unable to adapt to system disturbances. This paper proposes a ROS-based ADS architecture composed of eight integrated nodes, designed to address these limitations. The path-planning node leverages a meta-heuristic optimization framework with a cost function that evaluates path feasibility using occupancy grids from the Hector SLAM and obstacle clusters detected through the DBSCAN algorithm. A dynamic goal-allocation strategy is introduced based on the LiDAR range and spatial boundaries to enhance planning flexibility. In the control layer, a modified Pure Pursuit algorithm is employed to translate target positions into velocity commands based on the drift angle. Additionally, an adaptive PID controller is tuned in real time using the Differential Evolution (DE) algorithm, ensuring robust speed regulation in the presence of external disturbances. The proposed system is practically validated on a four-wheel differential drive robot across six scenarios. Experimental results demonstrate that the proposed planner significantly outperforms state-of-the-art methods, ranking first in the Friedman test with a significance level less than 0.05, confirming the effectiveness of the proposed architecture. Full article

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 $\alpha$. 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 study aims to develop a method for analyzing real-world battery degradation in electric vehicles in order to identify the optimal battery management system (BMS) during the early digital phase of vehicle development. Battery management of lithium-ion batteries (LiBs) in electric vehicles is important to ensure a stable output and to counteract degradation and thermal runaway. To design the optimal system, it is most effective to use a 1D (one-dimensional) vehicle system simulation model, which connects each unit model inside the vehicle, due to the system’s complexity. In order to create a long-term degradation simulation in a vehicle system model, it is important to reduce computational load. Therefore, in this paper, we studied a suitable battery degradation calculation for the vehicle system model based on an equivalent circuit model (ECM) and degradation approximation formulas. After implementing these models, we analyzed long-term degradation behavior through the real-world operation of an electric vehicle driver. We first implemented a high-accuracy ECM using transient charge–discharge tests and Bayesian Optimization. Next, we formulated approximation formulas for degradation prediction based on calendar and cycle degradation tests. Finally, we simulated real-world degradation behavior using these models. The simulation results revealed that even for users who frequently use electric vehicles, degradation under storage conditions is the dominant factor in overall degradation. Full article

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