Search Results (16)

From the point of view of the intelligent operation and maintenance of high-speed train tracks, this paper examines the research status of high-speed train rail damage detection technology in the field of high-speed train track operation and maintenance detection in recent years, summarizes the damage detection methods for high-speed trains, and compares and analyzes different detection technologies and application research results. The analysis results show that the detection methods for high-speed train rail damage mainly focus on the research and application of non-destructive testing technology and methods, as well as testing platform equipment. Detection platforms and equipment include a new type of vortex meter, integrated track recording vehicles, laser rangefinders, thermal sensors, laser vision systems, LiDAR, new ultrasonic detectors, rail detection vehicles, rail detection robots, laser on-board rail detection systems, track recorders, self-moving trolleys, etc. The main research and application methods include electromagnetic detection, optical detection, ultrasonic guided wave detection, acoustic emission detection, ray detection, vortex detection, and vibration detection. In recent years, the most widely studied and applied methods have been rail detection based on LiDAR detection, ultrasonic detection, eddy current detection, and optical detection. The most important optical detection method is machine vision detection. Ultrasonic detection can detect internal damage of the rail. LiDAR detection can detect dirt around the rail and the surface, but the cost of this kind of equipment is very high. And the application cost is also very high. In the future, for high-speed railway rail damage detection, the damage standards must be followed first. In terms of rail geometric parameters, the domestic standard (TB 10754-2018) requires a gauge deviation of ±1 mm, a track direction deviation of 0.3 mm/10 m, and a height deviation of 0.5 mm/10 m, and some indicators are stricter than European standard EN-13848. In terms of damage detection, domestic flaw detection vehicles have achieved millimeter-level accuracy in crack detection in rail heads, rail waists, and other parts, with a damage detection rate of over 85%. The accuracy of identifying track components by the drone detection system is 93.6%, and the identification rate of potential safety hazards is 81.8%. There is a certain gap with international standards, and standards such as EN 13848 have stricter requirements for testing cycles and data storage, especially in quantifying damage detection requirements, real-time damage data, and safety, which will be the key research and development contents and directions in the future. Full article

Flexible strain sensors have attracted significant attention due to their critical applications in wearable devices, biological detection, and artificial intelligence. However, achieving both a wide strain range and high sensitivity remains a major challenge in current research. This study aims to develop a novel composite material with a synergistic conductive network to construct high-performance flexible strain sensors. Thermoplastic polyurethane (TPU) nanofiber membranes were first prepared using electrospinning technology, and their surface was modified with polydopamine (PDA) via in-situ polymerization, which significantly enhanced the fibers’ adsorption capacity for conductive materials. Subsequently, carbon nanotubes (CNTs) and carbon black (CB) were coated onto the PDA-modified TPU fibers through ultrasonic anchoring, forming a CB/CNT/PDA/TPU composite with a synergistic conductive network. The results demonstrated that the flexible strain sensor fabricated from this composite material (with a CB-to-CNT mass ratio of 7:3) achieved ultrahigh sensitivity (gauge factor, GF, up to 1063) over a wide strain range (up to 300%), along with a low detection limit (1% strain), fast response and recovery times (137 ms), and exceptional stability and durability. Further evaluations confirmed that this sensor reliably captured biological signals from various joint movements, highlighting its broad application potential in human motion monitoring, human–machine interaction, and soft robotics. Full article

Carbon fiber-reinforced polymer (CFRP)/titanium alloy (Ti6Al4V) stacks are widely used in the aerospace industry due to their excellent physical properties. The substantial demand for drilling components in the aerospace industry necessitates the implementation of enhanced processing efficiency and drilling quality standards. Six-degrees-of-freedom robots are commonly used in the aerospace industry due to their high production efficiency, high flexibility, and low labor costs. However, due to the weak stiffness, chatter is prone to occur during processing, which has a detrimental impact on the quality of the finished product. As an advanced processing technology, ultrasonic-assisted machining technology can effectively reduce the cutting force and suppress the chatter in the drilling process, so it is widely used in production. In this paper, first, the robot kinematic (dexterity) and stiffness performance is analyzed. Then, the appropriate range of the machining plane and the posture of the robot in the workspace are selected. Finally, the vibration and CFRP entrance damage during the machining process are compared and studied in conventional robotic drilling (CRD) and ultrasonic-assisted robotic drilling (UARD). The experimental results demonstrate that the UARD is an effective method for reducing vibration during the machining process. Compared with the CRD, the CFRP entrance delamination damage in UARD is reduced. Under the appropriate processing parameters, the entrance delamination factor could be reduced by 15%, and the burr height could be reduced by 45%. Obviously, the UARD is a promising process to improve the CFRP entrance delamination damage. Full article

The use of advanced brittle composites in engineering systems has necessitated robotic rotary ultrasonic machining to attain high precision with minimal machining defects such as delamination, burrs, and cracks. Longitudinal–torsional coupled (LTC) vibrations are created by introducing helical slots to a horn’s profile to enhance the quality of ultrasonic machining. In this investigative research, modified ultrasonic horns were designed for a giant magnetostrictive transducer by generating helical slots in catenoidal and cubic polynomial profiles to attain a high amplitude ratio ($T_A/L_A$) and low stress concentrations. Novel ultrasonic horns with a giant magnetostrictive transducer were modelled to compute impedances and harmonic excitation responses. A structural dynamic analysis was conducted to investigate the effect of the location, width, depth and angle of helical slots on the Eigenfrequencies, torsional vibration amplitude, longitudinal vibration amplitude, stresses and amplitude ratio in novel LTC ultrasonic horns for different materials using the finite element method (FEM) based on the block Lanczos and full-solution methods. The newly designed horns achieved a higher amplitude ratio and lower stresses in comparison to the Bezier and industrial stepped LTC horns with the same length, end diameters and operating conditions. The novel cubic polynomial LTC ultrasonic horn was found superior to its catenoidal counterpart as a result of an $8.45\%$ higher amplitude ratio. However, the catenoidal LTC ultrasonic horn exhibited 1.87% lower stress levels. The position of the helical slots was found to have the most significant influence on the vibration characteristics of LTC ultrasonic horns followed by the width, depth and angle. This high amplitude ratio will contribute to the improved vibration characteristics that will help realize good surface morphology when machining advanced materials. Full article

Resistance spot welding is widely adopted in manufacturing and is characterized by high reliability and simple automation in the production line. The detection of defective welds is a difficult task that requires either destructive or expensive and slow non-destructive testing (e.g., ultrasound). The robots performing the welding automatically collect contextual and process-specific data. In this paper, we test whether these data can be used to predict defective welds. To do so, we use a dataset collected in a real industrial plant that describes welding-related data labeled with ultrasonic quality checks. We use these data to develop several pipelines based on shallow and deep learning machine learning algorithms and test the performance of these pipelines in predicting defective welds. Our results show that, despite the development of different pipelines and complex models, the machine-learning-based defect detection algorithms achieve limited performance. Using a qualitative analysis of model predictions, we show that correct predictions are often a consequence of inherent biases and intrinsic limitations in the data. We therefore conclude that the automatically collected data have limitations that hamper fault detection in a running production plant. Full article

In order to enhance the automation level and achieve high precision in the ultrasonic strengthening of aviation blade surfaces, this study focuses on investigating the intelligent control strategy and optimizing the machining parameters for robotic ultrasonic surface strengthening. By designing an intelligent compliance control method, the end-effector can achieve the compliant output of contact force. The fuzzy PID control method is used to optimize the regulation performance of the compliant force control system. This compliance control strategy enables the optimization of the compliance device, effectively improving the static and dynamic characteristics of the compliance controller. Based on this, an experimental method (RSM) is designed to analyze the interaction effects of contact force, feed rate, and repetition times on the surface quality of the blade. The optimal combination of robotic strengthening parameters is determined, providing a practical reference for the application of robotic compliance control in the ultrasonic strengthening of aviation blade surfaces. Full article

Recent advances in roller coasters accelerate the creation of complex tracks to provide stimulation and excitement for humans. As the main load-bearing component, tracks are prone to damage such as loose connecting bolts, paint peeling, corroded sleeper welds, corroded butt welds, reduced track wall thickness and surface cracks under complex environments and long-term alternating loads. However, inspection of the roller coaster tracks, especially the high-altitude rolling tracks, is a crucial problem that traditional manual detection methods have difficulty solving. In addition, traditional inspection is labor-intensive, time-consuming, and provides only discrete information. Here, a concept of the multifunctional detection robot with a mechanical structure, electrical control system, camera, electromagnetic ultrasonic probes and an array of eddy current probes for detecting large roller coaster tracks is reported. By optimizing the design layout, integrating multiple systems and completing machine testing, the multifunctional roller coaster track detection robot exhibits outstanding performance in track appearance, thickness and crack detection. This study provides great potential for intelligent detection in amusement equipment, railcar, train and so on. Full article

This work illustrates an innovative localisation sensor network that uses multiple PIR and ultrasonic sensors installed on a mobile social robot to localise occupants in indoor environments. The system presented aims to measure movement direction and distance to reconstruct the movement of a person in an indoor environment by using sensor activation strategies and data processing techniques. The data collected are then analysed using both a supervised (Decision Tree) and an unsupervised (K-Means) machine learning algorithm to extract the direction and distance of occupant movement from the measurement system, respectively. Tests in a controlled environment have been conducted to assess the accuracy of the methodology when multiple PIR and ultrasonic sensor systems are used. In addition, a qualitative evaluation of the system’s ability to reconstruct the movement of the occupant has been performed. The system proposed can reconstruct the direction of an occupant with an accuracy of 70.7% and uncertainty in distance measurement of 6.7%. Full article

According to the advantages of ultrasonic vibration cutting, an ultrasound-assisted corneal trepanation robotic system is developed to improve the accuracy of corneal trephination depth and corneal incision quality in corneal trephination operations. Firstly, we analyzed the reasons for the difficulty in controlling the depth of trephination in corneal transplantations from the perspective of the biomechanical properties of the cornea. Based on the advantages of ultrasonic vibration cutting, we introduced an ultrasonic-vibration-assisted cutting method for corneal trephination and analyzed the cutting mechanism. Secondly, we described the surgical demands of corneal trephination and listed the design requirements of a robotic system. Thirdly, we introduced the design details of said system, including the system’s overall structure, the ultrasound-assisted end effector, the key mechanisms of the robotic system, and the human–machine interaction interface. We designed the end effector based on ultrasonic vibration cutting and its eccentric adjustment system in an innovative way. Additionally, we then presented a procedure for robot-assisted corneal trephination. Finally, we performed several cutting experiments on grapes and porcine eyeballs in vitro. The results show that, compared with manual trephine, ultrasound-assisted corneal trephination has a better operation effect on the accuracy of corneal trephination depth and corneal incision quality. Full article

With the popularization of humans working in tandem with robots and artificial intelligence (AI) by Industry 5.0, ultrasonic non-destructive testing (NDT)) technology has been increasingly used in quality inspections in the industry. As a crucial part of handling ultrasonic testing results–signal processing, the current approach focuses on professional training to perform signal discrimination but automatic and intelligent signal optimization and estimation lack systematic research. Though the automated and intelligent framework for ultrasonic echo signal processing has already exhibited essential research significance for diagnosing defect locations, the real-time applicability of the algorithm for the time-of-flight (ToF) estimation is rarely considered, which is a very important indicator for intelligent detection. This paper conducts a systematic comparison among different ToF algorithms for the first time and presents the auto-diagnosis of the ToF approach based on the Defect Peaks Tracking Model (DPTM). The proposed DPTM is used for ultrasonic echo signal processing and recognition for the first time. The DPTM using the Hilbert transform was verified to locate the defect with the size of 2–10 mm, in which the wavelet denoising method was adopted. With the designed mechanical fixture through 3D printing technology on the pipeline to inspect defects, the difficulty of collecting sufficient data could be conquered. The maximum auto-diagnosis error could be reduced to 0.25% and 1.25% for steel plate and pipeline under constant pressure, respectively, which were much smaller than those with the DPTM adopting the cross-correlation. The real-time auto-diagnosis identification feature of DPTM has the potential to be combined with AI in future work, such as machine learning and deep learning, to achieve more intelligent approaches for industrial health inspection. Full article

Techniques for the detection and recognition of objects have experienced continuous development over recent years, as their application and benefits are so very obvious. Whether they are involved in driving a car, environment surveillance and security, or assistive living for people with different disabilities, not to mention advanced robotic surgery, these techniques are almost indispensable. This article presents the research results of a distance assessment using object detection and recognition techniques. The first is a new technique based on low-cost photo cameras and special sign detection. The second is a classic approach based on a LIDAR sensor and an HQ photo camera. Its novelty, in this case, consists of the concept and prototype of the hardware subsystem for high-precision distance measurement, as well as fast and accurate object recognition. The experimentally obtained results are used for the motion control strategy (directional inverse kinematics) of the robotic arm (virtual prototype) component in special assistive devices designed for visually impaired persons. The advantages of the original technical solution, experimentally validated by a prototype system with modern equipment, are the precision and the short time required for the identification and recognition of objects at relatively short distances. The research results obtained, in both the real and virtual experiments, stand as a basis for the further development of the visually impaired mechatronic system prototype using additional ultrasonic sensors, stereoscopic or multiple cameras, and the implementation of machine-learning models for safety-critical tasks. Full article

Classification and regression employing a simple Deep Neural Network (DNN) are investigated to perform touch localization on a tactile surface using ultrasonic guided waves. A robotic finger first simulates the touch action and captures the data to train a model. The model is then validated with data from experiments conducted with human fingers. The localization root mean square errors (RMSE) in time and frequency domains are presented. The proposed method provides satisfactory localization results for most human–machine interactions, with a mean error of 0.47 cm and standard deviation of 0.18 cm and a computing time of 0.44 ms. The classification approach is also adapted to identify touches on an access control keypad layout, which leads to an accuracy of 97% with a computing time of 0.28 ms. These results demonstrate that DNN-based methods are a viable alternative to signal processing-based approaches for accurate and robust touch localization using ultrasonic guided waves. Full article

Since the COVID-19 Pandemic began, there have been several efforts to create new technology to mitigate the impact of the COVID-19 Pandemic around the world. One of those efforts is to design a new task force, robots, to deal with fundamental goals such as public safety, clinical care, and continuity of work. However, those characteristics need new products based on features that create them more innovatively and creatively. Those products could be designed using the S4 concept (sensing, smart, sustainable, and social features) presented as a concept able to create a new generation of products. This paper presents a low-cost robot, Robocov, designed as a rapid response against the COVID-19 Pandemic at Tecnologico de Monterrey, Mexico, with implementations of artificial intelligence and the S4 concept for the design. Robocov can achieve numerous tasks using the S4 concept that provides flexibility in hardware and software. Thus, Robocov can impact positivity public safety, clinical care, continuity of work, quality of life, laboratory and supply chain automation, and non-hospital care. The mechanical structure and software development allow Robocov to complete support tasks effectively so Robocov can be integrated as a technological tool for achieving the new normality’s required conditions according to government regulations. Besides, the reconfiguration of the robot for moving from one task (robot for disinfecting) to another one (robot for detecting face masks) is an easy endeavor that only one operator could do. Robocov is a teleoperated system that transmits information by cameras and an ultrasonic sensor to the operator. In addition, pre-recorded paths can be executed autonomously. In terms of communication channels, Robocov includes a speaker and microphone. Moreover, a machine learning algorithm for detecting face masks and social distance is incorporated using a pre-trained model for the classification process. One of the most important contributions of this paper is to show how a reconfigurable robot can be designed under the S3 concept and integrate AI methodologies. Besides, it is important that this paper does not show specific details about each subsystem in the robot. Full article

Mobile robots are endeavoring toward full autonomy. To that end, wheeled mobile robots have to function under non-holonomic constraints and uncertainty derived by feedback sensors and/or internal dynamics. Speed control is one of the main and challenging objectives in the endeavor for efficient autonomous collision-free navigation. This paper proposes an intelligent technique for speed control of a wheeled mobile robot using a combination of fuzzy logic and supervised machine learning (SML). The technique is appropriate for flexible leader-follower formation control on straight paths where a follower robot maintains a safely varying distance from a leader robot. A fuzzy controller specifies the ultimate distance of the follower to the leader using the measurements obtained from two ultrasonic sensors. An SML algorithm estimates a proper speed for the follower based on the ultimate distance. Simulations demonstrated that the proposed technique appropriately adjusts the follower robot’s speed to maintain a flexible formation with the leader robot. Full article

The current nondestructive testing methods such as ultrasonic, magnetic, or eddy current signals, and even the existing image processing methods, present certain challenges and show a lack of flexibility in building an effective and real-time quality estimation system of the resistance spot welding (RSW). This paper provides a significant improvement in the theory and practices for designing a robotized inspection station for RSW at the car manufacturing plants using image processing and fuzzy support vector machine (FSVM). The weld nuggets’ positions on each of the used car underbody models are detected mathematically. Then, to collect perfect pictures of the weld nuggets on each of these models, the required end-effector path is planned in real-time by establishing the Denavit-Hartenberg (D-H) model and solving the forward and inverse kinematics models of the used six-degrees of freedom (6-DOF) robotic arm. After that, the most frequent resistance spot-welding failure modes are reviewed. Improved image processing methods are employed to extract new features from the elliptical-shaped weld nugget’s surface and obtain a three-dimensional (3D) reconstruction model of the weld’s surface. The extracted artificial data of thousands of samples of the weld nuggets are divided into three groups. Then, the FSVM learning algorithm is formed by applying the fuzzy membership functions to each group. The improved image processing with the proposed FSVM method shows good performance in classifying the failure modes and dealing with the image noise. The experimental results show that the improvement of comprehensive automatic real-time quality evaluation of RSW surfaces is meaningful: the quality estimation could be processed within 0.5 s in very high accuracy. Full article