Search Results (3,597)

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

High-precision 6D pose estimation for pick-and-place operations remains a critical problem for industrial robot arms in manufacturing. This study introduces an analytics-based solution for 6D pose estimation designed for a real-world industrial application: it enables the Staubli TX2-60L (manufactured by Stäubli International AG, Horgen, Switzerland) robot arm to pick up metal plates from various locations and place them into a precisely defined slot on a brake pad production line. The system uses a fixed eye-to-hand Intel RealSense D435 RGB-D camera (manufactured by Intel Corporation, Santa Clara, California, USA) to capture color and depth data. A robust software infrastructure developed in LabVIEW (ver.2019) integrated with the NI Vision (ver.2019) library processes the images through a series of steps, including particle filtering, equalization, and pattern matching, to determine the X-Y positions and Z-axis rotation of the object. The Z-position of the object is calculated from the camera’s intensity data, while the remaining X-Y rotation angles are determined using the angle-of-inclination analytics method. It is experimentally verified that the proposed analytical solution outperforms the hybrid-based method (YOLO-v8 combined with PnP/RANSAC algorithms). Experimental results across four distinct picking scenarios demonstrate the proposed solution’s superior accuracy, with position errors under 2 mm, orientation errors below 1°, and a perfect success rate in pick-and-place tasks. Full article

The integration of machine learning (ML) into industrial automation is fundamentally reshaping how manufacturing systems are monitored, inspected, and optimized. By applying machine learning to real-time sensor data and operational histories, advanced models enable proactive fault prediction, intelligent inspection, and dynamic process control—directly enhancing system reliability, product quality, and efficiency. This review explores the transformative role of ML across three key domains: Predictive Maintenance (PdM), Quality Control (QC), and Process Optimization (PO). It also analyzes how Digital Twin (DT) and Edge AI technologies are expanding the practical impact of ML in these areas. Our analysis reveals a marked rise in deep learning, especially convolutional and recurrent architectures, with a growing shift toward real-time, edge-based deployment. The paper also catalogs the datasets used, the tools and sensors employed for data collection, and the industrial software platforms supporting ML deployment in practice. This review not only maps the current research terrain but also highlights emerging opportunities in self-learning systems, federated architectures, explainable AI, and themes such as self-adaptive control, collaborative intelligence, and autonomous defect diagnosis—indicating that ML is poised to become deeply embedded across the full spectrum of industrial operations in the coming years. Full article

Background: While several test-automation maturity models (e.g., CMMI, TMMi, TAIM) exist, none explicitly integrate ISO 9001-based quality management systems (QMS), leaving a gap for organizations that must align E2E test automation with formal quality assurance. Objective: This study proposes a test-automation maturity model (TAMM) that bridges E2E automation capability with ISO 9001/ISO 9004 self-assessment principles, and evaluates its reliability and practical impact in industry. Methods: TAMM comprises eight maturity dimensions, 39 requirements, and 429 checklist items. Three independent assessors applied the checklist to three software teams; inter-rater reliability was ensured via consensus review (Cohen’s κ = 0.75). Short-term remediation actions based on the checklist were implemented over six months and re-assessed. Synergy with the organization’s ISO 9001 QMS was analyzed using ISO 9004 self-check scores. Results: Within 6 months of remediation, mean TAMM score rose from 2.75 → 2.85. Inter-rater reliability is filled with Cohen’s κ = 0.75. Conclusions: The proposed TAMM delivers measurable, short-term maturity gains and complements ISO 9001-based QMS without introducing conflicting processes. Practitioners can use the checklist to identify actionable gaps, prioritize remediation, and quantify progress, while researchers may extend TAMM to other domains or automate scoring via repository mining. Full article

Material Extrusion (MEX) process is increasingly used to fabricate components for structural applications, driven by the availability of advanced materials and greater industrial adoption. In these contexts, understanding the mechanical performance of printed parts is crucial. However, conventional methods for assessing anisotropic elastic behavior often rely on expensive equipment and time-consuming procedures. The aim of this study is to evaluate the applicability of the impulse excitation of vibration (IEV) in characterizing the dynamic mechanical properties of a 3D-printed composite material. Tensile tests were also performed to compare quasi-static properties with the dynamic ones obtained through IEV. The tested material, Nylon 12CF, contains 35% short carbon fibers by weight and is commercially available from Stratasys. It is used in the fused deposition modeling (FDM) process, a Material Extrusion technology, and exhibits anisotropic mechanical properties. This is further reinforced by the filament deposition process, which affects the mechanical response of printed parts. Young’s modulus obtained in the direction perpendicular to the deposition plane (E₃₃), obtained via IEV, was 14.77% higher than the value in the technical datasheet. Comparing methods, the Young’s modulus obtained in the deposition plane, in an inclined direction of 45 degrees in relation to the deposition direction (E₄₅), showed a 22.95% difference between IEV and tensile tests, while Poisson’s ratio in the deposition plane (v₁₂) differed by 6.78%. This data is critical for designing parts subject to demanding service conditions, and the results obtained (orthotropic elastic properties) can be used in finite element simulation software. Ultimately, this work reinforces the potential of the IEV method as an accessible and consistent alternative for characterizing the anisotropic properties of components produced through additive manufacturing (AM). Full article

Analyzing the two-phase flow behavior in bearing lubrication is crucial for understanding friction and wear mechanisms, optimizing lubrication design, and improving bearing operational efficiency and reliability. However, the complexity of oil–air two-phase flow in high-speed bearings poses significant research challenges. Currently, there is a lack of comparative studies employing different simulation strategies to address this issue, leaving a gap in evidence-based guidance for selecting appropriate simulation approaches in practical applications. This study begins with a comparative analysis between experimental and simulation results to validate the reliability of the adopted simulation approach. Subsequently, a comparative evaluation of different simulation methods is conducted to provide a scientific basis for relevant decision-making. Evaluated from three dimensions—adaptability to rotational speed conditions, research focuses (oil distribution and power loss), and computational economy—the findings reveal that FVM excels at medium-to-high speeds, accurately predicting continuous oil film distribution and power loss, while MPS, leveraging its meshless Lagrangian characteristics, demonstrates superior capability in describing physical phenomena under extreme conditions, albeit with higher computational costs. Economically, FVM, supported by mature software ecosystems and parallel computing optimization, is more suitable for industrial design applications, whereas MPS, being more reliant on high-performance hardware, is better suited for academic research and customized scenarios. The study further proposes that future research could adopt an FVM-MPS coupled approach to balance efficiency and precision, offering a new paradigm for multi-scale lubrication analysis in bearings. Full article

Rotating compressors are foundational in various industrial processes, particularly in the oil-and-gas sector, where reliable fault detection is crucial for maintaining operational continuity. While Graph Attention Network (GAT) frameworks are widely available, this study advances the state of the art by introducing a Bayesian GAT method specifically tailored for vibration-based compressor fault diagnosis. The approach integrates domain-specific digital-twin simulations built with Rotordynamic software (1.3.0), and constructs dual adjacency matrices to encode both physically informed and data-driven sensor relationships. Additionally, a hybrid forecasting-and-reconstruction objective enables the model to capture short-term deviations as well as long-term waveform fidelity. Monte Carlo dropout further decomposes prediction uncertainty into aleatoric and epistemic components, providing a more robust and interpretable model. Comparative evaluations against conventional Long Short-Term Memory (LSTM)-based autoencoder and forecasting methods demonstrate that the proposed framework achieves superior fault-detection performance across multiple fault types, including misalignment, bearing failure, and unbalance. Moreover, uncertainty analyses confirm that fault severity correlates with increasing levels of both aleatoric and epistemic uncertainty, reflecting heightened noise and reduced model confidence under more severe conditions. By enhancing GAT fundamentals with a domain-tailored dual-graph strategy, specialized Bayesian inference, and digital-twin data generation, this research delivers a comprehensive and interpretable solution for compressor fault diagnosis, paving the way for more reliable and risk-aware predictive maintenance in complex rotating machinery. Full article

Industrial Vision Inspection Systems (VISs) often struggle to adapt to increasing variability of modern manufacturing due to the inherent rigidity of their hardware architectures. Although the Reconfigurable Manufacturing System (RMS) paradigm was introduced in the early 2000s to overcome these limitations, designing such reconfigurable machines remains a complex, expert-dependent, and time-consuming task. This is primarily due to the lack of structured methodologies and the reliance on trial-and-error processes. In this context, this study proposes a novel theoretical framework to facilitate the design of fully reconfigurable handling systems for VISs, with a particular focus on fixture design. The framework is grounded in Model-Based Definition (MBD), embedding semantic information directly into the 3D CAD models of the inspected product. As an additional contribution, a general hardware architecture for the inspection of axisymmetric components is presented. This architecture integrates an anthropomorphic robotic arm, Numerically Controlled (NC) modules, and adaptable software and hardware components to enable automated, software-driven reconfiguration. The proposed framework and architecture were applied in an industrial case study conducted in collaboration with a leading automotive half-shaft manufacturer. The resulting system, implemented across seven automated cells, successfully inspected over 200 part types from 12 part families and detected more than 60 defect types, with a cycle below 30 s per part. Full article

Small towns in mountainous regions face significant challenges in formulating effective landscape zoning strategies due to pronounced landscape fragmentation, which is driven by both the dominance of large-scale forest resources and the lack of coordination between administrative planning departments. To tackle this problem, this study focused on Yuqian, a quintessential small mountainous town in Hangzhou, Zhejiang Province. The town’s layout was divided into a grid network measuring 70 m × 70 m. A two-step cluster process was employed using ArcGIS and SPSS software to analyze five landscape variables: altitude, slope, land use, heritage density, and visual visibility. Further, eCognition software’s semi-automated segmentation technique, complemented by manual adjustments, helped delineate landscape character types and areas. The overlay analysis integrated these areas with administrative village units, identifying four landscape character types across 35 character areas, which were recategorized into four planning and management zones: urban comprehensive service areas, agricultural and cultural tourism development areas, industrial development growth areas, and mountain forest ecological conservation areas. This result optimizes the current zoning types. These zones closely match governmental sustainable development zoning requirements. Based on these findings, we propose integrated landscape management and conservation strategies, including the cautious expansion of urban areas, leveraging agricultural and cultural tourism, ensuring industrial activities do not impact the natural and village environment adversely, and prioritizing ecological conservation in sensitive areas. This approach integrates spatial and administrative dimensions to enhance landscape connectivity and resource sustainability, providing key guidance for small town development in mountainous regions with unique environmental and cultural contexts. Full article

The increasing complexity of modern automotive lighting systems requires advanced validation strategies that ensure both functional performance and regulatory compliance. This study presents a structured integration of Software-in-the-Loop (SiL) and Hardware-in-the-Loop (HiL) testing within a digital twin (DT) framework for validating headlamp systems. A gated validation process (G10–G120) is proposed, aligning each development phase with corresponding simulation stages from early requirements and concept validation to real-world scenario testing and continuous integration. A key principle of this approach is the adoption of a framework built upon the V-Cycle, adapted to integrate DT technology with SiL and HiL workflows. This architectural configuration ensures a continuous data flow between the physical system, the digital twin, and embedded software components, enabling real-time feedback, iterative model refinement, and traceable system verification throughout the development lifecycle. The paper also explores strategies for effective DT integration, such as digital twin-as-a-service, which combines virtual testing with physical validation to support earlier fault detection, streamlined simulation workflows, and reduced dependency on physical prototypes during lighting system development. Unlike the existing literature, which often treats SiL, HiL, and DTs in isolation, this work proposes a unified, domain-specific validation framework. The methodology addresses a critical gap by aligning simulation-based testing with development milestones and regulatory standards, offering a foundation for industrial adoption. Full article

Unmanned aerial vehicles (UAVs) are commonly used in various fields and industries, but their limited battery life has become a key constraint for their development. Wireless Power Transmission (WPT) technology, with its convenience, durability, intelligence, and unmanned features, significantly enhances UAVs’ battery life and operational range. However, the variety of UAV models and different sizes pose challenges for designing couplers in the WPT system. This paper presents a design method for an array-type coupler in a UAV WPT system that uses a deep neural network. By establishing an electromagnetic 3D structure of the array-type coupler using electromagnetic simulation software, the dimensions of the transmitting and receiving coils are modified to assess how changes in the aperture of the transmitting coil and the length of the receiving coil affect the mutual inductance of the coupler. Furthermore, deep learning methods are utilized to train a high-precision model using the calculated data as the training and testing sets. Finally, taking the FAIRSER-X model UAV as an example, the transmitting and receiving coils are wound, and the feasibility and accuracy of the proposed method are verified through an LCR meter, which notably enhances the design efficiency of UAV WPT systems. Full article

Antibiotic residues in poultry pose health and resistance risks, necessitating breed-specific WDTs. In this study, the residue elimination patterns of seven antibiotics in Taihang chicken tissues under free-range conditions were studied and the appropriate WDT was formulated. A total of 240 healthy Taihang chickens aged 100 days were randomly divided into 8 groups, each comprising 30 chickens. Chickens in groups 1 to 7 were administered oxytetracycline, chlortetracycline, erythromycin, tylosin, tylvalosin, lincomycin, and tiamulin, respectively. Regarding the administration method, we adopted the highest dose and maximum course of treatment recommended by the Veterinary Pharmacopoeia of the People’s Republic of China. Group 8 served as the control group. Muscle, sebum, liver, and kidney samples were collected at 4 h, 1 d, 2 d, 3 d, 5 d, 7 d, 10 d, 13 d, and 16 d after drug withdrawal. Our results demonstrated that the drug residues after drug withdrawal gradually decreased with the increase in drug withdrawal days, and the elimination rate in the early stage of drug withdrawal was significantly faster than that in the later stage. At 4 h after drug withdrawal, the drug residues in various tissues reached their highest values. In most cases, the drug concentrations in the kidney and liver were higher than those in the muscles and sebum; however, some drugs also exhibited concentration peaks in the sebum. On the first day of drug withdrawal, the amount of residues in various tissues decreased rapidly. In general, the elimination rate of various drugs in the muscles, liver, and kidneys is faster but slower in the sebum. Based on the WDT calculation software WT1.4, the recommended WDTs for oxytetracycline, chlortetracycline, erythromycin, tylosin, tylvalosin, lincomycin, and tiamulin chickens are 4 d, 5 d, 11 d, 8 d, 13 d, 13 d, and 7 d, respectively. These findings support food safety and industry development. Full article

Considering the serious hazard of respiratory dust in underground coal mines and the low efficiency of traditional dust-reduction technology, this study optimizes the atomisation parameters of the gas–liquid two-phase flow nozzle through numerical simulation and experimental testing, and designs an on-board dust-reduction system. Based on the Fluent software (version 2023 R2), a flow field model outside the nozzle was established, and the effects of the air supply pressure, gas-phase inlet velocity, and droplet mass flow rate on the atomisation characteristics were analyzed. The results show that increasing the air supply pressure can effectively reduce the droplet particle size and increase the range and atomisation angle, and that the dust-reduction efficiency is significantly improved with the increase in pressure. The dust-reduction efficiency reached 69.3% at 0.6 MPa, which was the economically optimal operating condition. Based on the parameter optimization, this study designed an annular airborne gas–liquid two-phase flow dust-reduction system, and a field test showed that the dust-reduction efficiency of this system could reach up to 86.0%, which is 53.5% higher than that of traditional high-pressure spraying, and that the dust concentration was reduced to less than 6 mg/m³. This study provides an efficient and reliable technical solution for the management of underground coal mine dust and guidance for promoting the development of the coal industry. Full article

The increasing complexity of modern control systems highlights the need for reliable and robust fault detection, isolation, and identification (FDII) methods, particularly in safety-critical and industrial applications. The study focuses on the FDII of multiplicative faults in a DC motor and its electronic amplifier. To simulate such scenarios, a complete laboratory platform was developed for real-time FDII, using relay-based switching and custom LabVIEW software 2009. This platform enables real-time experimentation and represents an important component of the study. Two estimation-based fault detection (FD) algorithms were implemented: the Sliding Window Algorithm (SWA) for discrete-time models and a modified Sliding Integral Algorithm (SIA) for continuous-time models. The modification introduced to the SIA limits the data length used in least squares estimation, thereby reducing the impact of transient effects on parameter accuracy. Both algorithms achieved high model output-to-measured signal agreement, up to 98.6% under nominal conditions and above 95% during almost all fault scenarios. Moreover, the proposed fault isolation and identification methods, including a decision algorithm and an indirect estimation approach, successfully isolated and identified faults in key components such as amplifier resistors (R₁, R₉, R₁₂), capacitor (C₈), and motor parameters, including armature resistance (R_a), inertia (J), and friction coefficient (B). The decision algorithm, based on continuous-time model coefficients, demonstrated reliable fault isolation and identification, while the reduced Jacobian-based approach in the discrete model enhanced fault magnitude estimation, with deviations typically below 10%. Additionally, the platform supports remote experimentation, offering a valuable resource for advancing model-based FDII research and engineering education. Full article

This paper presents a numerical simulation study evaluating carbon dioxide capture and storage (CCS) feasibility for the Turceni Power Plant in Oltenia, Romania, using the nearby depleted Bibești-Bulbuceni gas reservoir. A comprehensive reservoir model was developed using Petrel software, integrating geological and reservoir engineering data for the formations of the Bibești-Bulbuceni structure, which is part of the western Moesian Platform. The static model incorporated realistic petrophysical inputs for the Meotian reservoirs. Dynamic simulations were performed using Eclipse compositional simulator with Peng–Robinson equation of state for a CH4-CO₂ system. The model was initialized with natural gas initially in place at 149 bar reservoir pressure, then produced through depletion to 20.85 bar final pressure, achieving 80% recovery factor. CO₂ injection simulations modeled a phased 19-well injection program over 25 years, with individual well constraints of 100 bar bottom-hole pressure and 200,000 Sm³/day injection rates. Results demonstrate successful injection of a 60 Mt CO₂, with final reservoir pressure reaching 101 bar. The modeling framework validates the technical feasibility of transforming Turceni’s power generation into a net-zero process through CCS implementation. Key limitations include simplified geochemical interactions and relying on historical data with associated uncertainties. This study provides quantitative evidence for CCS viability in depleted hydrocarbon reservoirs, supporting industrial decarbonization strategies. The strategy not only aligns with the EU’s climate-neutral policy but also enhances local energy security by repurposing existing geological resources. The findings highlight the potential of CCS to bridge the gap between current energy systems and a sustainable, climate-neutral future. Full article