Search Results (575)

Digital twin (DT) technology is a key element of Industry 4.0. Despite its rapid development, current research is mainly focused on industrial optimisation and machine-level monitoring. However, its implementation in the educational process lags significantly behind practice. Moreover, existing DT implementations in education often emphasise visualisation or simulation, while neglecting synchronisation and verification of functional equivalence between the physical and virtual systems. This study presents the design, development and experimental verification of a digital twin of a laboratory material handling system. The virtual model created in Tecnomatix Plant Simulation is connected to the physical system controlled by a Siemens PLC SIMATIC S7-1200 and equipped with industrial sensors and an HMI interface. Real-time bidirectional communication is established via the OPC UA protocol using KEPServerEX, ensuring synchronisation between the physical and virtual systems. Experiments confirmed the functional synchronisation of both systems. Additionally, the study presents that DT technology can be adapted for educational purposes and implemented in engineering education. Full article

Corporate food museums are increasingly recognised as strategic heritage infrastructures capable of mediating between industrial memory, territorial identity, and contemporary societal challenges. This paper proposes a conceptual shift that repositions corporate food museums from static repositories of brand heritage to Living Labs for sustainable, inclusive, and participatory food innovation. Drawing on the EU-funded GNAM project, the study adopts a qualitative methodology combining the mapping of Italian corporate food museums with an analysis of European Living Labs in the food and agri-food domain. The comparative framework informs the development of a heritage-driven Living Lab model articulated around three interconnected dimensions: cultural heritage valorisation, community engagement, and sustainable food system innovation. The model is empirically grounded through a series of design-driven workshops, technology-transfer activities, and digital engagement initiatives conducted within corporate museums and academic laboratories in Southern Italy. These include co-creation processes involving students, citizens, companies, and researchers; experimentation with food waste valorisation, biodegradable and hybrid materials, and 3D food printing; and the deployment of digital platforms and immersive virtual environments. The paper contributes to heritage studies by advancing a replicable framework in which corporate food museums act as active agents of sustainable transformation, linking cultural heritage, technological experimentation, and community participation. Full article

Background/Objectives: The vibrotactile system, which is essential for guiding behavior in nocturnal rodents such as mice and rats, provides critical sensory input. To investigate the role of vibrotactile sensory inflow in neonatal locomotion, we used previsual rat pups that underwent bilateral vibrissectomy. Subsequently, their motor behavior was evaluated in an open field test. Methods: A total of 42 previsual pups from four litters were assigned to either bilateral vibrissectomy or sham surgery groups on postnatal days (PND) 9–12, with group allocation balanced across litters. Results: Open-field testing on PND 13 revealed that while vibrissectomy (VE) did not affect gross locomotor activity—such as distance traveled, speed, acceleration, or freezing episodes (all >0.05)—it significantly altered spatial behavior. To quantify spatial patterns of curvy tracks, we analyzed trajectorial compaction within the central zone, lacking the tactile guidance of the walls: trajectories were smoothed using virtual coatings scaled to the vibrissal length (16 mm). For each track, an individual linearized reference path was generated and subjected to identical smoothing. The compaction ratio—calculated as the coated area of the smoothed linearized reference divided by the coated area of the experimental track—was significantly greater in VE pups than in sham controls (p = 0.03). This effect was not attributable to differences in the path length traveled within the central zone. The increased compaction persisted when the smoothing scale was increased 2–3 fold (32–64 mm radii, approximating the pups’ mean body size), but not at smaller scales (2–4 mm). Conclusions: These results demonstrate that tactile input specifically modulates the spatial, rather than locomotor, components of nonvisual navigation. Consequently, the track compaction may serve as a sensitive marker for assessing vibrotactile function in developing laboratory rodents. Full article

This study introduces a computational method for designing realistic, geometrically controlled three-dimensional (3-D) micromodels of porous media to investigate fluid flow in hydrocarbon reservoirs. The methodology utilizes a virtual framework of cubes where an arbitrary, continuous 3-D pore network is generated via two-dimensional (2-D) sketches. A key strength of this deterministic, cube-by-cube approach is the ability to independently control porosity and permeability by adjusting channel size and connectivity, facilitating the systematic study of spatial heterogeneity. Six digital models were developed with porosities ranging from 18.4% to 44.4%. Unlike traditional stochastic algorithms, this explicit geometric control enabled the accurate extraction of pore volume distributions and the establishment of a robust power-law relationship between localized porosity and specific surface area. Statistical analysis confirmed a linear correlation between porosity and pore dimensions. While focusing on design and validation, these models are 3-D printable and provide exact boundary conditions for CFD simulations. Single-phase simulations confirmed the capability to decouple absolute permeability from porosity. Consequently, this framework bridges the gap between numerical simulations and physical laboratory experiments to optimize Enhanced Oil Recovery (EOR) processes. Full article

Industrial automation laboratories often face limitations related to restricted access to industrial equipment, safety constraints, and limited scalability for hands-on experimentation. To address these challenges, this work proposes a real-time multi-layer Digital Twin architecture integrating a physical Siemens S7-1500 PLC, an immersive Unity-based virtual environment, HMI supervision, and IoT-enabled remote monitoring within a unified communication framework. The architecture is structured into physical, digital, and integration layers, enabling modular scalability and bidirectional synchronization between the physical process and its virtual representation through Ethernet TCP/IP communication. System performance was evaluated using synchronization metrics including communication latency, jitter, deterministic timing deviation, and event synchronization accuracy. Experimental results demonstrated stable PLC–Digital Twin communication with average latencies below 15 ms and jitter below 0.5 ms, ensuring reliable real-time interaction during continuous operation. A comparative evaluation with engineering students also showed improved learning conditions, achieving high perceived usability (SUS = 86/100) and reduced cognitive workload (NASA-TLX = 34/100). These results confirm the effectiveness of the proposed architecture as a scalable platform for Industry 4.0 training environments. Full article

Industrial Control Systems (ICSs) are the backbone of modern critical infrastructure, such as electric power, water treatment, oil and gas distribution, and manufacturing operations. While the convergence of IT and OT has greatly increased efficiency and observability, it has also greatly expanded the attack surface of these once-isolated systems. High-profile cyber-physical attacks, including Stuxnet (2010), TRITON (2017), and the Colonial Pipeline ransomware attack (2021), have shown that ICS-targeted cyberattacks can cause physical damage, disrupt economic stability, and put public safety at risk. Despite the growing prevalence and intensity of such threats, ICS-based cybersecurity education remains largely under-resourced and underfunded. Traditional ICS training laboratories require highly specialized hardware, vendor-specific tools, and expensive licensing that significantly raise barriers to entry. Traditional labs typically require on-site participation and pose physical safety concerns when cyber-physical attack scenarios are performed. These barriers leave students unable to get necessary security training for ICSs. Therefore, this paper introduces ${\mathrm{AE}}^3$GIS: Agile Emulated Educational Environment for Guided Industrial Security—a fully virtual, lightweight, open-source platform designed to democratize ICS cybersecurity education. Based on the GNS3 network simulation tool, ${\mathrm{AE}}^3$GIS enables rapid deployment of comprehensive ICS environments containing IT and OT systems, industrial communication protocols, control logic, and diverse security tools. ${\mathrm{AE}}^3$GIS is designed to provide practical training for students using realistic ICS cybersecurity scenarios through a local or remote training platform without the cost, safety, or accessibility limitations of hardware-based labs. Full article

This study focuses on the challenges and opportunities of integrating industrial robots into robotic bricklaying systems (RBSs) for automation and digital transformation in the construction industry. A mobile RBS was designed, engineered, manufactured and commercially implemented for the first time in Poland. The RBS is designed to perform robotic bricklaying in situ in municipal, residential, and industrial buildings, where sustainable construction tasks are implemented. The details of the design solutions for the RBS, virtual simulation, and real robotic bricklaying processes are presented. The results of bricklaying using the RBS and the factors that influence the robotic bricklaying process are summarized. A 3D digital building information model (BIM) created using Autodesk Revit tools was used for simulated robotic bricklaying in the ABB RobotStudio 2025.5 program, from which they were transferred to the programming of the ABB IRB 4600 bricklaying robot. The laser programming method for the bricklaying robot, bricklaying procedures, and algorithms are also presented. The costs of human labor and robot construction were compared, and the return on investment (ROI) was calculated. RBS evaluations were performed in laboratory settings, on-site demonstrations, and commercial wall-laying in residential apartments. Full article

Microclimatic stress strongly influences the ecological resilience of Vasconcellea stipulata (Toronche), yet current monitoring approaches rely on sparse measurements and lack real-time predictive capability. This work introduces an AI-enhanced virtual sensing framework based on laser-induced graphene (LIG) designed to emulate the thermoresistive response of an LIG transducer and generate high-resolution environmental indicators for microclimatic analysis. Unlike conventional LIG sensors or standalone IoT systems, the proposed framework integrates experimental calibration, data-driven modeling, and embedded inference into a unified architecture suitable for lightweight deployment on edge devices. A multilayer perceptron (MLP) model trained on laboratory data reproduced the temperature- and humidity-dependent electrical behavior of the transducer with high fidelity, achieving an RMSE of 0.016 k$\Omega$ in the calibrated range (10–60 °C) and remaining below 0.09 k$\Omega$ under noisy and extrapolated conditions. Sensitivity analysis identified temperature as the dominant driver (71%), followed by solar irradiance (19%) and relative humidity (10%), consistent with the microstructural mechanisms governing LIG’s response. The virtual sensor enables continuous, low-cost environmental monitoring and provides quantitative variables that can support downstream ecological interpretation. Overall, the results highlight the potential of AI-enhanced LIG–IoT architectures for advancing real-time microclimatic assessment in resource-limited Andean ecosystems. Full article

To address the issues of excessive current stress and the power dead zone associated with conventional phase-shift modulation in dual-active-bridge (DAB) converters, a hybrid optimized modulation strategy based on dual-side asymmetric duty modulation (ADM) is proposed. The proposed strategy aims to minimize the peak-to-peak current stress by introducing two distinct operating modes of the converter. A dynamic compensation mechanism based on mode switching is developed, enabling a coordinated dual-mode modulation to achieve minimum peak-to-peak current stress over the full power operating range. In addition, a virtual voltage control scheme is incorporated to enhance the dynamic response and stability of the system. Finally, experimental results obtained from a laboratory prototype verify that the proposed strategy effectively reduces the peak-to-peak current stress while significantly improving the dynamic performance of the DAB converter. Full article

The power-shift system employed in agricultural multi-range continuously variable transmissions (CVTs) features a complex structure and control logic, presenting significant challenges to the reliability of agricultural machinery. To enable timely detection of faults, constructing an intelligent fault diagnosis classifier to monitor the system’s health status is essential. Typically, fault samples utilized for classifier development originate from ideal bench tests, characterized by uniform patterns and limited diversity, thereby hindering the algorithm’s generalization capability. This study addresses this issue by proposing a generative adversarial network (GAN) model, integrated with a triple loss function and a novel generator architecture, to augment the fault dataset under laboratory conditions. The generator architecture comprises a variational autoencoder module and an oil pressure point attention mechanism, enabling the generation of diverse and fluctuating virtual samples. Building on this augmented dataset, a fault classifier based on one-dimensional ConvNeXt was developed. Experimental results indicate that the classifier achieves an accuracy of 99.73%. While classifier accuracy decreases with increasing noise levels, the GAN-generated dataset provides more comprehensive training, resulting in an accuracy approximately 3% higher than that achieved using the original dataset. Full article

The manufacturing sector drives industrialisation and contributes substantially to economic growth and employment creation. Despite this, it faces the challenges of diminishing size and lack of competitiveness, mainly due to operational uncertainty. The study developed an approach to managing operational uncertainty using Industry 4.0 and 5.0 technologies. It employed a multimethod quantitative design based on the post-positivist paradigm, with data collected from 22 experts and 262 responses from a manufacturing firms’ survey. The study employed an integrated fuzzy decision-making trial and evaluation laboratory (DEMATEL) with partial least squares structural equation modelling (PLS-SEM) and fuzzy set qualitative comparative analysis (fsQCA). The fuzzy DEMATEL results reveal that growing geopolitical tension, cost-of-living-driven consumer behavioural change, pandemic turbulence, lack of energy stability and security, and the entrenched power of large firms are causal dimensions of operational uncertainty. Industry 4.0 and 5.0 technologies, with capabilities for scenario planning and supply chain integration, flexible production and mass customisation, real-time system and process monitoring and response, root cause analysis, and sustainable solutions, can manage operational uncertainty. These technologies include artificial intelligence (AI), the Internet of Things (IoT), big data analytics, and, to a lesser extent, advanced robotics, blockchain, and augmented and virtual reality (AR/VR). This study advanced configuration theory and a new integrated methodology (fuzzy-DEMATEL-PLS-SEM-fsQCA) to develop solutions for sustained performance during operational uncertainty in manufacturing. This research offers valuable information to advance the subject, make meaningful changes in day-to-day manufacturing operations, and promote practical real-world problem solving. Full article

With the transition from Industry 4.0 to Industry 5.0, human–robot collaborative assembly (HRCA) has progressed from physical copresence to cognitive integration and knowledge sharing. Digital twins (DTs) serve as enabling technologies that connect physical and virtual spaces. Support is provided for dynamic, safe, and human-centered collaboration. This study presents a systematic review of the research progress and practical applications of DT-enabled HRCA. First, conceptual boundaries between HRCA and general human–robot collaboration (HRC) in manufacturing are defined. Core elements of DT-driven state perception, task planning, and constraint modeling are described. Second, four task-allocation paradigms are classified and summarized, including optimization-based, constraint satisfaction-based, data-driven intelligent, and large language model (LLM)-assisted approaches. Applicable scenarios are identified. Third, the effects of collaboration modes and interaction modalities on planning logic are analyzed. Collaboration modes are categorized as parallel, sequential, and tightly coupled. Interaction modalities are grouped into AR-based explicit interaction, implicit intention perception, and multimodal fusion. Fourth, cross-domain application characteristics and engineering bottlenecks are summarized. Target domains include precision assembly, disassembly and remanufacturing, and construction on-site operations. Finally, four core challenges are distilled, including dynamic uncertainty, multi-objective conflicts, human factor adaptation, and system integration. Four future directions are outlined: LLM-enabled adaptive planning, safety–efficiency co-optimization, personalized collaboration, and standardized integration. The proposed technology–application–challenge–outlook framework is intended to provide a theoretical reference and practical guidance for transitioning HRCA from laboratory prototypes to large-scale industrial deployment. Full article

Windows are key elements of the building’s system; they connect workers with the outdoor environment, influence daylight penetration, sound insulation, and thermal exchanges of façades, but they also moderate the workers’ well-being and productivity. This research investigates how the window-to-wall ratio, as well as the position and orientation of mullions, in movable offices affect the combination of workers’ perceptual and emotional responses. A smart co-working prefabricated movable office was modelled in virtual reality to include dynamic visual elements and acoustic stimuli. Experiments were performed in a laboratory under controlled thermal conditions involving 32 volunteers. The Igroup Presence and Emotional Salience Questionnaires were used to collect subjective responses. ANOVA analysis and post hoc test with the Bonferroni correction were used for data elaboration. Results revealed that window design affects emotional salience. High window-to-wall ratio and no mullions achieved the highest scores. Increasing the number of mullions, particularly when they obstruct key visual elements, reduced the positive emotional salience rating. Horizontal mullions diminish the outdoors’ spatial perception, interrupting visual continuity and restricting users’ capacity to recognise variations in the views. Finally, the results suggest some valuable insights and suggestions that can help designers improve window design and people’s well-being and satisfaction. Full article

The cement industry is central to sustainable manufacturing due to its high energy demand and associated CO₂ emissions. In cement production, a substantial share of electrical energy is consumed in the clinker grinding circuit, where Blaine fineness (specific surface area, cm²/g), a key quality output, affects both cement performance and specific energy consumption. However, laboratory Blaine measurements are typically available with a 30–60 min delay, which limits timely process interventions and may promote conservative operating practices (e.g., precautionary over-grinding) to secure quality. This study develops machine-learning models to predict the finished-product Blaine fineness (Blaine-F) from routinely recorded industrial quality-control inputs, including XRF-based oxide composition, derived chemical moduli (lime saturation factor, LSF; silica modulus, SM; alumina modulus, AM), laser-diffraction particle-size distribution descriptors (Q10/Q50/Q90 corresponding to D10/D50/D90 percentile diameters; and R3 residual fractions at selected cut sizes), and intermediate in-process fineness (Blaine-P). The models were trained on over 200 finished-product samples obtained from the quality-control laboratory information management system (LIMS) of Seza Cement Factory (SYCS Group, Turkey). Ridge regression, Random Forest, XGBoost, LightGBM, and CatBoost were tuned using RandomizedSearchCV with five-fold cross-validation and evaluated on a held-out test set using MAE, RMSE, and R². The results show that the linear baseline provides limited explanatory power (Ridge: R² ≈ 0.50), consistent with the strongly non-linear behavior of the grinding–separation system, whereas tree-based ensemble methods achieve higher predictive accuracy. XGBoost yields the best overall performance (R² = 0.754; RMSE = 76.9 cm²/g), while Random Forest attains R² = 0.744 with the lowest MAE (61.7 cm²/g). Explainability analyses indicate that Blaine-F is primarily influenced by the fine-tail PSD descriptor Q10 (D10 particle size) and the intermediate fineness Blaine-P, whereas chemistry-related variables (e.g., LSF and SiO₂, and particularly SM) provide secondary yet meaningful contributions. These findings support the use of the proposed model as a virtual sensor to reduce decision latency associated with delayed laboratory Blaine measurements and to enable tighter fineness targeting. Potential energy and CO₂ implications should be quantified using site-specific, plant-calibrated relationships between kWh/t and Blaine fineness, rather than inferred as measured outcomes within the present study. Full article

Traditional hydraulic transmission education is often hindered by the subject’s theoretical complexity and abstract nature. To address these challenges, this study introduces the Immersive Hydraulic Transmission Laboratory (IHTL), a virtual teaching system designed to enhance practical learning and theoretical comprehension. The IHTL comprises three key modules: hydraulic components, disassembly experiments, and hydraulic circuits. The system’s effectiveness was evaluated through a comparative study of 80 mechanical engineering students. Results showed that the experimental group exhibited a 20% higher rate of inquiry and achieved average test scores 20.475 points higher than the control group. Statistical analysis confirms that the IHTL significantly outperforms traditional teaching methods in both stimulating student interest and improving learning outcomes. Full article