首页 > 最新文献

Journal of Manufacturing Systems最新文献

英文 中文
Online sequential decision making of multi-stage assembly process parameters based on deep reinforcement learning and its application in diesel engine production 基于深度强化学习的多阶段装配工艺参数在线顺序决策及其在柴油机生产中的应用
IF 14.2 1区 工程技术 Q1 ENGINEERING, INDUSTRIAL Pub Date : 2025-09-02 DOI: 10.1016/j.jmsy.2025.08.012
Yi-Tian Song , Yan-Ning Sun , Li-Lan Liu , Jie Wu , Zeng-Gui Gao , Wei Qin
Maintaining fixed parameters during batch assembly of complex mechanical products often results in quality inconsistencies due to time-varying operational conditions, including equipment performance degradation, production environment disturbance, and operator skill variations. This operational reality necessitates online parameter adaptation mechanisms to counteract progressive quality deviations. While complex assemblies inherently involve sequential multi-stage workflows across distributed stations, conventional optimization strategies often employ monolithic parameter adjustments that neglect error propagation effects and inter-stage quality interdependencies. To address the dual challenges of dynamic operating conditions and multi-stage coordination, this study proposes an online sequential decision-making framework based on deep reinforcement learning. First, a causal inference model for assembly quality prognosis is constructed by integrating the greedy equivalence search algorithm with domain-specific expert knowledge, enabling systematic modeling of multi-stage quality dependencies. Subsequently, the multi-stage parameters optimization problem is formalized as a Markov decision process, with innovatively defined state space as assembly progress, action space as adjusted parameters range, and physics-informed reward function derived from quality inference results. Building on this, the proximal policy optimization algorithm is improved by stage-aware experience replay and gradient alignment constraints to learn the optimal policy, and then select the optimal action. Experiments on a real-world diesel engine assembly dataset demonstrate a 17.16 % improvement in product qualification probability, significantly outperforming conventional methods. The proposed framework effectively captures time-varying assembly characteristics and achieves cross-stage parameter coordination through sequential decision-making, offering a novel data-driven solution for quality control in complex product assembly systems.
在复杂机械产品的批量装配过程中,由于操作条件的时变,包括设备性能下降、生产环境干扰和操作人员技能的变化,保持固定的参数通常会导致质量不一致。这种操作现实需要在线参数适应机制来抵消渐进式质量偏差。虽然复杂的装配本质上涉及跨分布式工作站的连续多阶段工作流程,但传统的优化策略通常采用单一参数调整,忽略了误差传播效应和阶段间质量的相互依赖性。为了解决动态运行条件和多阶段协调的双重挑战,本研究提出了一种基于深度强化学习的在线顺序决策框架。首先,将贪婪等价搜索算法与特定领域的专家知识相结合,构建了装配质量预测的因果推理模型,实现了多阶段质量依赖关系的系统化建模;随后,将多阶段参数优化问题形式化为马尔可夫决策过程,创新地将状态空间定义为装配进度,将动作空间定义为调整后的参数范围,并根据质量推断结果推导出物理通知的奖励函数。在此基础上,通过阶段感知经验重放和梯度对齐约束对近端策略优化算法进行改进,学习最优策略,进而选择最优动作。在真实柴油机装配数据集上的实验表明,产品合格率提高了17.16 %,显著优于传统方法。该框架有效捕获时变装配特征,并通过序列决策实现跨阶段参数协调,为复杂产品装配系统的质量控制提供了一种新的数据驱动解决方案。
{"title":"Online sequential decision making of multi-stage assembly process parameters based on deep reinforcement learning and its application in diesel engine production","authors":"Yi-Tian Song ,&nbsp;Yan-Ning Sun ,&nbsp;Li-Lan Liu ,&nbsp;Jie Wu ,&nbsp;Zeng-Gui Gao ,&nbsp;Wei Qin","doi":"10.1016/j.jmsy.2025.08.012","DOIUrl":"10.1016/j.jmsy.2025.08.012","url":null,"abstract":"<div><div>Maintaining fixed parameters during batch assembly of complex mechanical products often results in quality inconsistencies due to time-varying operational conditions, including equipment performance degradation, production environment disturbance, and operator skill variations. This operational reality necessitates online parameter adaptation mechanisms to counteract progressive quality deviations. While complex assemblies inherently involve sequential multi-stage workflows across distributed stations, conventional optimization strategies often employ monolithic parameter adjustments that neglect error propagation effects and inter-stage quality interdependencies. To address the dual challenges of dynamic operating conditions and multi-stage coordination, this study proposes an online sequential decision-making framework based on deep reinforcement learning. First, a causal inference model for assembly quality prognosis is constructed by integrating the greedy equivalence search algorithm with domain-specific expert knowledge, enabling systematic modeling of multi-stage quality dependencies. Subsequently, the multi-stage parameters optimization problem is formalized as a Markov decision process, with innovatively defined state space as assembly progress, action space as adjusted parameters range, and physics-informed reward function derived from quality inference results. Building on this, the proximal policy optimization algorithm is improved by stage-aware experience replay and gradient alignment constraints to learn the optimal policy, and then select the optimal action. Experiments on a real-world diesel engine assembly dataset demonstrate a 17.16 % improvement in product qualification probability, significantly outperforming conventional methods. The proposed framework effectively captures time-varying assembly characteristics and achieves cross-stage parameter coordination through sequential decision-making, offering a novel data-driven solution for quality control in complex product assembly systems.</div></div>","PeriodicalId":16227,"journal":{"name":"Journal of Manufacturing Systems","volume":"82 ","pages":"Pages 1252-1268"},"PeriodicalIF":14.2,"publicationDate":"2025-09-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144932313","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
引用次数: 0
Step-time measurement: A scalable sub-cycle time defining methodology for anomaly detection and predictive maintenance in sequential production lines 步进测量:一种可扩展的子周期时间定义方法,用于连续生产线的异常检测和预测性维护
IF 14.2 1区 工程技术 Q1 ENGINEERING, INDUSTRIAL Pub Date : 2025-09-02 DOI: 10.1016/j.jmsy.2025.08.011
Jon Zubieta , Unai Izagirre , Luka Eciolaza , Asier Saez de Buruaga , Lander Galdos
Sub-cycle time periods from machines in production lines offer valuable insights into component-level health. They enable data-driven condition monitoring without the need for additional sensors. However, the lack of a standardized methodology for defining these sub-cycle time periods limits the practicality and scalability of this approach in real-world applications. We propose a scalable methodology to define sub-cycle time periods within the machine cycle time, using Programmable Logic Controllers (PLCs) programmed in compliance with the IEC 60848 standard. To achieve scalability, the proposed methodology makes sub-cycle time period definition automatic, simple and thus, fast. This is achieved by defining each sub-cycle time period as the total activation time of a Step. For this reason, the sub-cycle time periods defined with this methodology are named “Step-time”s. Because the methodology does not depend on the type of action or actuator involved, and because it can be applied to any step without requiring changes to the overall program structure, it can be easily replicated across multiple steps, modules, or even machines. This modularity enables a scalable deployment of Step-time measurements, whether for a few components or across entire production lines. Moreover, our methodology offers deeper insights into machine behavior by distinguishing between different operational contexts for the same component. To assess its feasibility in industrial production environments, we developed two implementation approaches, one based on Structured Text (ST) and another using Sequential Function Charts (SFC). The results demonstrate that machine anomalies such as air leaks, pressure drops and fluctuations in pneumatic circuits, are accurately reflected in Step-times. This confirms the high resolution of the Step-times and highlights its potential for powering data-driven condition monitoring systems in future works. Finally, the data acquisition results indicate that the proposed methodology has minimal impact on the PLC scan-cycle, making it suitable for most industrial use cases.
生产线中机器的子周期时间段提供了对组件级健康状况的宝贵见解。它们可以实现数据驱动的状态监测,而无需额外的传感器。然而,由于缺乏定义这些子周期时间段的标准化方法,限制了这种方法在实际应用程序中的实用性和可扩展性。我们提出了一种可扩展的方法来定义机器周期时间内的子周期,使用符合IEC 60848标准的可编程逻辑控制器(plc)编程。为了实现可扩展性,提出的方法使子周期时间段定义自动化、简单、快速。这是通过将每个子周期时间段定义为步骤的总激活时间来实现的。因此,用这种方法定义的子周期时间段称为“步长”。由于该方法不依赖于所涉及的动作或执行器的类型,并且由于它可以应用于任何步骤而不需要更改整个程序结构,因此可以轻松地跨多个步骤、模块甚至机器进行复制。这种模块化支持步进时间测量的可扩展部署,无论是针对几个组件还是跨整个生产线。此外,我们的方法通过区分相同组件的不同操作上下文,为机器行为提供了更深入的见解。为了评估其在工业生产环境中的可行性,我们开发了两种实现方法,一种基于结构化文本(ST),另一种使用顺序功能图(SFC)。结果表明,机器异常,如空气泄漏,压力下降和气动回路波动,准确地反映在步长时间。这证实了步长时间的高分辨率,并突出了其在未来工作中为数据驱动状态监测系统提供动力的潜力。最后,数据采集结果表明,所提出的方法对PLC扫描周期的影响最小,使其适用于大多数工业用例。
{"title":"Step-time measurement: A scalable sub-cycle time defining methodology for anomaly detection and predictive maintenance in sequential production lines","authors":"Jon Zubieta ,&nbsp;Unai Izagirre ,&nbsp;Luka Eciolaza ,&nbsp;Asier Saez de Buruaga ,&nbsp;Lander Galdos","doi":"10.1016/j.jmsy.2025.08.011","DOIUrl":"10.1016/j.jmsy.2025.08.011","url":null,"abstract":"<div><div>Sub-cycle time periods from machines in production lines offer valuable insights into component-level health. They enable data-driven condition monitoring without the need for additional sensors. However, the lack of a standardized methodology for defining these sub-cycle time periods limits the practicality and scalability of this approach in real-world applications. We propose a scalable methodology to define sub-cycle time periods within the machine cycle time, using Programmable Logic Controllers (PLCs) programmed in compliance with the IEC 60848 standard. To achieve scalability, the proposed methodology makes sub-cycle time period definition automatic, simple and thus, fast. This is achieved by defining each sub-cycle time period as the total activation time of a Step. For this reason, the sub-cycle time periods defined with this methodology are named “Step-time”s. Because the methodology does not depend on the type of action or actuator involved, and because it can be applied to any step without requiring changes to the overall program structure, it can be easily replicated across multiple steps, modules, or even machines. This modularity enables a scalable deployment of Step-time measurements, whether for a few components or across entire production lines. Moreover, our methodology offers deeper insights into machine behavior by distinguishing between different operational contexts for the same component. To assess its feasibility in industrial production environments, we developed two implementation approaches, one based on Structured Text (ST) and another using Sequential Function Charts (SFC). The results demonstrate that machine anomalies such as air leaks, pressure drops and fluctuations in pneumatic circuits, are accurately reflected in Step-times. This confirms the high resolution of the Step-times and highlights its potential for powering data-driven condition monitoring systems in future works. Finally, the data acquisition results indicate that the proposed methodology has minimal impact on the PLC scan-cycle, making it suitable for most industrial use cases.</div></div>","PeriodicalId":16227,"journal":{"name":"Journal of Manufacturing Systems","volume":"83 ","pages":"Pages 1-11"},"PeriodicalIF":14.2,"publicationDate":"2025-09-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144934093","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
引用次数: 0
GRU-based real-time scheduling method for production-logistics collaboration in digital twin workshop 基于gru的数字孪生车间生产物流协同实时调度方法
IF 14.2 1区 工程技术 Q1 ENGINEERING, INDUSTRIAL Pub Date : 2025-09-02 DOI: 10.1016/j.jmsy.2025.08.013
Wenchao Yang , Boxuan Zhang , Guofu Luo , Linli Li , Xiaoyu Wen , Hao Li , Haoqi Wang
In modern workshops with high customization requirements, production is typically conducted under a small-batch, multi-variety order mode. Under such conditions, random order arrivals and fuzzy manufacturing times, caused by fluctuations in workshop conditions, present significant challenges to real-time scheduling and control. To address these issues, this study proposes a real-time scheduling method for production-logistics collaboration (RT-SMPLC) based on gated recurrent units (GRUs) in a digital twin (DT) workshop. Firstly, a comprehensive RT-SMPLC framework was constructed. Leveraging virtual-physical interaction, a dynamic mapping environment is established to capture the real-time status information of production elements. Secondly, the scheduling process is guided by a task priority index that facilitates the selection of the optimal production-logistics resource group for each task. This priority index is iteratively optimized through virtual evolution and GRU-based prediction. Finally, the operation assignment result is fed back to the physical workshop for execution in real time via industrial communication protocols and networks, enabling closed-loop control through virtual-to-physical interaction. The proposed method was validated on a DT-based experimental platform using real production cases. Comparative experiments across three different-scale scenarios and three algorithms demonstrate that RT-SMPLC effectively reduces makespan, energy consumption, and tardiness, while exhibiting robust real-time responsiveness.
在高定制要求的现代车间中,生产通常采用小批量、多品种的订单模式。在这种情况下,由于车间条件波动造成的订单随机到达和制造时间模糊,对实时调度和控制提出了重大挑战。为了解决这些问题,本研究提出了一种基于数字孪生(DT)车间门控循环单元(gru)的生产物流协作(RT-SMPLC)实时调度方法。首先,构建了RT-SMPLC综合框架。利用虚拟-物理交互,建立动态映射环境,捕捉生产要素的实时状态信息。其次,在任务优先级指标的指导下,为每个任务选择最优的生产物流资源组。该优先级指标通过虚拟进化和基于gru的预测进行迭代优化。最后,将作业分配结果通过工业通信协议和网络实时反馈到物理车间执行,实现虚拟-物理交互闭环控制。利用实际生产案例,在基于3d打印的实验平台上对该方法进行了验证。通过三种不同规模场景和三种算法的对比实验表明,RT-SMPLC有效地减少了完工时间、能耗和延迟,同时表现出强大的实时响应能力。
{"title":"GRU-based real-time scheduling method for production-logistics collaboration in digital twin workshop","authors":"Wenchao Yang ,&nbsp;Boxuan Zhang ,&nbsp;Guofu Luo ,&nbsp;Linli Li ,&nbsp;Xiaoyu Wen ,&nbsp;Hao Li ,&nbsp;Haoqi Wang","doi":"10.1016/j.jmsy.2025.08.013","DOIUrl":"10.1016/j.jmsy.2025.08.013","url":null,"abstract":"<div><div>In modern workshops with high customization requirements, production is typically conducted under a small-batch, multi-variety order mode. Under such conditions, random order arrivals and fuzzy manufacturing times, caused by fluctuations in workshop conditions, present significant challenges to real-time scheduling and control. To address these issues, this study proposes a real-time scheduling method for production-logistics collaboration (RT-SMPLC) based on gated recurrent units (GRUs) in a digital twin (DT) workshop. Firstly, a comprehensive RT-SMPLC framework was constructed. Leveraging virtual-physical interaction, a dynamic mapping environment is established to capture the real-time status information of production elements. Secondly, the scheduling process is guided by a task priority index that facilitates the selection of the optimal production-logistics resource group for each task. This priority index is iteratively optimized through virtual evolution and GRU-based prediction. Finally, the operation assignment result is fed back to the physical workshop for execution in real time via industrial communication protocols and networks, enabling closed-loop control through virtual-to-physical interaction. The proposed method was validated on a DT-based experimental platform using real production cases. Comparative experiments across three different-scale scenarios and three algorithms demonstrate that RT-SMPLC effectively reduces makespan, energy consumption, and tardiness, while exhibiting robust real-time responsiveness.</div></div>","PeriodicalId":16227,"journal":{"name":"Journal of Manufacturing Systems","volume":"82 ","pages":"Pages 1269-1289"},"PeriodicalIF":14.2,"publicationDate":"2025-09-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144932245","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
引用次数: 0
Grating interferometer: The dominant positioning strategy in atomic and close-to-atomic scale manufacturing 光栅干涉仪:原子和近原子尺度制造的主导定位策略
IF 14.2 1区 工程技术 Q1 ENGINEERING, INDUSTRIAL Pub Date : 2025-08-29 DOI: 10.1016/j.jmsy.2025.08.008
Can Cui , Xinghui Li , Xiaohao Wang
The rapid evolution of manufacturing technologies has entered its third phase, with a focus on atomic and close-to-atomic scale manufacturing (ACSM), a pivotal advancement driving progress in precision fabrication. One of the cores of ACSM is ultra-precise positioning technologies, which are critical for achieving the required precision and efficiency in nanoscale manufacturing. Grating interferometer has emerged as the leading strategy due to its accuracy, scalability, and stability. Recent advancements in this technology have further solidified its role as a dominant solution in ultra-precision metrology. This review provides an overview of grating interferometer as a positioning tool for ACSM, starting with its application domains and advantages, followed by a detailed explanation of its fundamental principles. We then present a comprehensive comparison of different representative grating interferometers. Additionally, we perform quantitative multi-source measurement error analysis, discuss methods for compensating errors, and explore various phase measurement techniques. Finally, we conclude with a forward-looking perspective on the future development of grating interferometer, highlighting emerging trends and potential breakthroughs.
制造技术的快速发展已进入第三阶段,重点是原子和近原子尺度制造(ACSM),这是推动精密制造进步的关键进步。超精密定位技术是ACSM的核心之一,它对于实现纳米级制造所需的精度和效率至关重要。光栅干涉仪以其精度高、可扩展性好、稳定性好等优点,已成为测量技术的先导。该技术的最新进展进一步巩固了其作为超精密计量的主导解决方案的作用。本文综述了作为ACSM定位工具的光栅干涉仪,从其应用领域和优点入手,详细介绍了光栅干涉仪的基本原理。然后,我们对不同的代表性光栅干涉仪进行了全面的比较。此外,我们进行定量的多源测量误差分析,讨论补偿误差的方法,并探索各种相位测量技术。最后,对光栅干涉仪的未来发展进行了展望,指出了新兴趋势和潜在突破。
{"title":"Grating interferometer: The dominant positioning strategy in atomic and close-to-atomic scale manufacturing","authors":"Can Cui ,&nbsp;Xinghui Li ,&nbsp;Xiaohao Wang","doi":"10.1016/j.jmsy.2025.08.008","DOIUrl":"10.1016/j.jmsy.2025.08.008","url":null,"abstract":"<div><div>The rapid evolution of manufacturing technologies has entered its third phase, with a focus on atomic and close-to-atomic scale manufacturing (ACSM), a pivotal advancement driving progress in precision fabrication. One of the cores of ACSM is ultra-precise positioning technologies, which are critical for achieving the required precision and efficiency in nanoscale manufacturing. Grating interferometer has emerged as the leading strategy due to its accuracy, scalability, and stability. Recent advancements in this technology have further solidified its role as a dominant solution in ultra-precision metrology. This review provides an overview of grating interferometer as a positioning tool for ACSM, starting with its application domains and advantages, followed by a detailed explanation of its fundamental principles. We then present a comprehensive comparison of different representative grating interferometers. Additionally, we perform quantitative multi-source measurement error analysis, discuss methods for compensating errors, and explore various phase measurement techniques. Finally, we conclude with a forward-looking perspective on the future development of grating interferometer, highlighting emerging trends and potential breakthroughs.</div></div>","PeriodicalId":16227,"journal":{"name":"Journal of Manufacturing Systems","volume":"82 ","pages":"Pages 1227-1251"},"PeriodicalIF":14.2,"publicationDate":"2025-08-29","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144913028","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
引用次数: 0
Large language model-enabled cognitive agent for self-aware manufacturing 支持大型语言模型的自我意识制造认知代理
IF 14.2 1区 工程技术 Q1 ENGINEERING, INDUSTRIAL Pub Date : 2025-08-29 DOI: 10.1016/j.jmsy.2025.08.015
Shanhe Lou, Runjia Tan, Yanxin Zhou, Ziyue Zhao, Yiran Zhang, Chen Lv
Although industrial automation has advanced significantly at the level of manufacturing units and production lines, system-level automation remains constrained by the limited cognitive abilities of current manufacturing systems. To address this challenge, this work proposes a cognitive agent (CA) that leverages a large language model (LLM) as its core to facilitate self-aware manufacturing. The cognitive capabilities of CA are facilitated through the combination of retrieval-augmented generation (RAG) and in-context learning. RAG allows CA to retrieve relevant subgraphs from an industrial knowledge graph (IKG) after interpreting natural language commands, thereby establishing focused context awareness and autonomously generating executable manufacturing instructions. Meanwhile, in-context learning enables CA to adapt to specific requirements based on contextual examples without retraining. These techniques empower CA with domain-specific cognition, fostering self-awareness in a flexible and cost-effective manner. Two case studies on pick-and-place and disassembly validate CA's effectiveness in task planning within a lab-scale manufacturing unit. The results demonstrate that the proposed approach surpasses traditional LLM-based methods in task executability and goal achievement, offering a novel perspective on advancing manufacturing systems.
尽管工业自动化在制造单元和生产线水平上取得了显著进展,但系统级自动化仍然受到当前制造系统有限的认知能力的制约。为了应对这一挑战,本研究提出了一种认知代理(CA),该代理利用大型语言模型(LLM)作为其核心,以促进自我意识制造。检索增强生成(retrieval-augmented generation, RAG)和语境学习相结合,促进了CA的认知能力。RAG允许CA在解释自然语言命令后从工业知识图(IKG)中检索相关子图,从而建立集中的上下文感知并自主生成可执行的制造指令。同时,上下文学习使CA能够根据上下文示例适应特定需求,而无需重新训练。这些技术赋予CA特定于领域的认知能力,以灵活和经济的方式培养自我意识。两个关于取放和拆卸的案例研究验证了CA在实验室规模制造单元内任务规划中的有效性。结果表明,该方法在任务可执行性和目标实现方面优于传统的基于法学硕士的方法,为推进制造系统提供了新的视角。
{"title":"Large language model-enabled cognitive agent for self-aware manufacturing","authors":"Shanhe Lou,&nbsp;Runjia Tan,&nbsp;Yanxin Zhou,&nbsp;Ziyue Zhao,&nbsp;Yiran Zhang,&nbsp;Chen Lv","doi":"10.1016/j.jmsy.2025.08.015","DOIUrl":"10.1016/j.jmsy.2025.08.015","url":null,"abstract":"<div><div>Although industrial automation has advanced significantly at the level of manufacturing units and production lines, system-level automation remains constrained by the limited cognitive abilities of current manufacturing systems. To address this challenge, this work proposes a cognitive agent (CA) that leverages a large language model (LLM) as its core to facilitate self-aware manufacturing. The cognitive capabilities of CA are facilitated through the combination of retrieval-augmented generation (RAG) and in-context learning. RAG allows CA to retrieve relevant subgraphs from an industrial knowledge graph (IKG) after interpreting natural language commands, thereby establishing focused context awareness and autonomously generating executable manufacturing instructions. Meanwhile, in-context learning enables CA to adapt to specific requirements based on contextual examples without retraining. These techniques empower CA with domain-specific cognition, fostering self-awareness in a flexible and cost-effective manner. Two case studies on pick-and-place and disassembly validate CA's effectiveness in task planning within a lab-scale manufacturing unit. The results demonstrate that the proposed approach surpasses traditional LLM-based methods in task executability and goal achievement, offering a novel perspective on advancing manufacturing systems.</div></div>","PeriodicalId":16227,"journal":{"name":"Journal of Manufacturing Systems","volume":"82 ","pages":"Pages 1213-1226"},"PeriodicalIF":14.2,"publicationDate":"2025-08-29","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144913026","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
引用次数: 0
Tool wear prediction in milling process using physics-informed machine learning and thermo-mechanical force model with monitoring applications 铣削过程中刀具磨损预测使用物理信息的机器学习和热机械力模型与监测应用
IF 14.2 1区 工程技术 Q1 ENGINEERING, INDUSTRIAL Pub Date : 2025-08-28 DOI: 10.1016/j.jmsy.2025.08.014
Farzad Pashmforoush , Arash Ebrahimi Araghizad , Erhan Budak
Accurate wear estimation of milling tools is critical for enhancing the productivity and reliability of machining processes, ensuring consistent product quality while minimizing unexpected tool failure, downtime and machining costs. Traditional approaches, often based on pure experimental and data-driven machine learning (ML) methods, demand extensive, costly wear testing to gather the necessary datasets, which limits their utility in practical industrial monitoring. To address this gap, this work presents a novel physics-informed machine learning (PIML) approach of wear estimation by integrating analytical models with ML techniques. The PIML model utilizes a wear-inclusive thermo-mechanical model to estimating cutting forces considering flank wear and edge forces, with special focus on its adaptation to milling operations and addressing the complexities of milling dynamics. The methodology is demonstrated on Steel 1050, a widely used medium-carbon steel alloy in industrial machining applications. As shown by the results, this hybrid model shows high predictive accuracy, achieving R² values exceeding 98 % for force prediction and 95 % for tool wear estimation, with corresponding RMSE values below 14 N and 8 µm, respectively. Notably, the use of the PIML framework improved tool wear prediction accuracy by over 16 % compared to using ML alone. Another important finding is the significant role of edge forces under severe wear conditions, with their contribution to average cutting forces increasing from 40 % to 57 % at low feed rates, and from 27 % to 45 % at higher feed rates. Using this enhanced model, a simulation-based dataset was generated to train an inverse ML model for estimating tool wear considering milling forces and cutting parameters. The inverse ML model exhibited robust predictive performance, offering a practical and accurate solution for tool wear estimation. This study emphasizes the promising potential of integrating thermo-mechanical model with ML algorithms in machining applications, establishing a foundation of tool wear condition monitoring through milling force data. The presented approach can contribute to enhanced process control, optimized tool usage, and reduced operational costs. Furthermore, it supports the transition to Industry 4.0 by enabling automation and unsupervised manufacturing, where real-time tool wear monitoring and adaptive control can be achieved with minimal human intervention, driving more intelligent and efficient manufacturing systems.
铣削刀具的准确磨损估计对于提高加工过程的生产率和可靠性,确保一致的产品质量,同时最大限度地减少意外的刀具故障,停机时间和加工成本至关重要。传统的方法通常基于纯实验和数据驱动的机器学习(ML)方法,需要大量、昂贵的磨损测试来收集必要的数据集,这限制了它们在实际工业监测中的实用性。为了解决这一差距,本研究提出了一种新的基于物理的机器学习(PIML)方法,通过将分析模型与机器学习技术相结合来进行磨损估计。PIML模型利用一种包含磨损的热机械模型来估计考虑侧面磨损和边缘力的切削力,特别关注其对铣削操作的适应性,并解决铣削动力学的复杂性。以工业加工中广泛使用的中碳钢合金1050钢为例进行了验证。结果表明,该混合模型具有较高的预测精度,力预测的R²值超过98 %,刀具磨损估计的R²值超过95 %,相应的RMSE值分别小于14 N和8 µm。值得注意的是,与单独使用ML相比,使用PIML框架可将刀具磨损预测精度提高16% %以上。另一个重要的发现是在严重磨损条件下,边缘力的重要作用,它们对平均切削力的贡献在低进给量下从40 %增加到57 %,在高进给量下从27 %增加到45 %。利用该增强模型,生成了一个基于仿真的数据集,用于训练考虑铣削力和切削参数的刀具磨损逆ML模型。逆ML模型表现出稳健的预测性能,为刀具磨损估计提供了实用、准确的解决方案。本研究强调了将热-机械模型与ML算法集成在加工应用中的潜力,为通过铣削力数据监测刀具磨损状态奠定了基础。所提出的方法有助于增强过程控制,优化工具使用,并降低操作成本。此外,它通过实现自动化和无监督制造来支持向工业4.0的过渡,在这种情况下,可以在最小的人为干预下实现实时工具磨损监测和自适应控制,从而推动更智能、更高效的制造系统。
{"title":"Tool wear prediction in milling process using physics-informed machine learning and thermo-mechanical force model with monitoring applications","authors":"Farzad Pashmforoush ,&nbsp;Arash Ebrahimi Araghizad ,&nbsp;Erhan Budak","doi":"10.1016/j.jmsy.2025.08.014","DOIUrl":"10.1016/j.jmsy.2025.08.014","url":null,"abstract":"<div><div>Accurate wear estimation of milling tools is critical for enhancing the productivity and reliability of machining processes, ensuring consistent product quality while minimizing unexpected tool failure, downtime and machining costs. Traditional approaches, often based on pure experimental and data-driven machine learning (ML) methods, demand extensive, costly wear testing to gather the necessary datasets, which limits their utility in practical industrial monitoring. To address this gap, this work presents a novel physics-informed machine learning (PIML) approach of wear estimation by integrating analytical models with ML techniques. The PIML model utilizes a wear-inclusive thermo-mechanical model to estimating cutting forces considering flank wear and edge forces, with special focus on its adaptation to milling operations and addressing the complexities of milling dynamics. The methodology is demonstrated on Steel 1050, a widely used medium-carbon steel alloy in industrial machining applications. As shown by the results, this hybrid model shows high predictive accuracy, achieving R² values exceeding 98 % for force prediction and 95 % for tool wear estimation, with corresponding RMSE values below 14 N and 8 µm, respectively. Notably, the use of the PIML framework improved tool wear prediction accuracy by over 16 % compared to using ML alone. Another important finding is the significant role of edge forces under severe wear conditions, with their contribution to average cutting forces increasing from 40 % to 57 % at low feed rates, and from 27 % to 45 % at higher feed rates. Using this enhanced model, a simulation-based dataset was generated to train an inverse ML model for estimating tool wear considering milling forces and cutting parameters. The inverse ML model exhibited robust predictive performance, offering a practical and accurate solution for tool wear estimation. This study emphasizes the promising potential of integrating thermo-mechanical model with ML algorithms in machining applications, establishing a foundation of tool wear condition monitoring through milling force data. The presented approach can contribute to enhanced process control, optimized tool usage, and reduced operational costs. Furthermore, it supports the transition to Industry 4.0 by enabling automation and unsupervised manufacturing, where real-time tool wear monitoring and adaptive control can be achieved with minimal human intervention, driving more intelligent and efficient manufacturing systems.</div></div>","PeriodicalId":16227,"journal":{"name":"Journal of Manufacturing Systems","volume":"82 ","pages":"Pages 1192-1212"},"PeriodicalIF":14.2,"publicationDate":"2025-08-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144913027","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
引用次数: 0
Time series prediction for lock nuts production quality driven by information fusion and data-model hybrid 基于信息融合和数据模型混合驱动的锁紧螺母生产质量时间序列预测
IF 14.2 1区 工程技术 Q1 ENGINEERING, INDUSTRIAL Pub Date : 2025-08-27 DOI: 10.1016/j.jmsy.2025.08.005
Tianzi Tian , Dunwang Qin , Ning Wang , Jun Yang , Kai Wu
The locking performance of nuts directly impacts the lifespan and reliability of assembled products. However, certain aerospace nuts undergo over 120 h of rigorous testing per batch, causing increased costs and delayed product delivery. Therefore, accurately predicting production quality and remaining testing time (RTT) is crucial for improving efficiency. Facing this new challenge, this paper proposes a data-model hybrid time series prediction method based on quality information fusion. First, considering that the monitoring data contains two sets of related features, we introduce a multi-task parallel deep learning (MTL) network with a temporal self-attention mechanism (TSAM). The TSAM assigns importance to key degradation information, while MTL leverages shared feature information to capture more accurate long-term trends. Next, considering the multi-stage nature and uncertainty of the degradation process, a semi-empirical physical degradation model is constructed, where stage identification is achieved using the Pruned Exact Linear Time (PELT) method, and uncertainty is estimated through Particle Filtering (PF). The Bayesian framework enables hybrid correction between the data-based and the model-based methods, integrating the strengths of both. Finally, experimental results demonstrate that the proposed method outperforms traditional models, effectively achieving more accurate quality predictions.
螺母的锁紧性能直接影响装配产品的使用寿命和可靠性。然而,某些航空航天螺母每批都要经过超过120小时的严格测试,导致成本增加和产品交付延迟。因此,准确预测产品质量和剩余测试时间(RTT)对提高效率至关重要。面对这一新的挑战,本文提出了一种基于质量信息融合的数据模型混合时间序列预测方法。首先,考虑到监测数据包含两组相关特征,我们引入了一个具有时间自注意机制的多任务并行深度学习(MTL)网络。TSAM强调关键的退化信息,而MTL利用共享的特征信息来捕获更准确的长期趋势。其次,考虑到降解过程的多阶段性和不确定性,构建了半经验物理降解模型,其中使用精确线性时间(PELT)方法进行阶段识别,并通过粒子滤波(PF)估计不确定性。贝叶斯框架能够在基于数据和基于模型的方法之间进行混合校正,集成了两者的优点。最后,实验结果表明,该方法优于传统模型,有效地实现了更准确的质量预测。
{"title":"Time series prediction for lock nuts production quality driven by information fusion and data-model hybrid","authors":"Tianzi Tian ,&nbsp;Dunwang Qin ,&nbsp;Ning Wang ,&nbsp;Jun Yang ,&nbsp;Kai Wu","doi":"10.1016/j.jmsy.2025.08.005","DOIUrl":"10.1016/j.jmsy.2025.08.005","url":null,"abstract":"<div><div>The locking performance of nuts directly impacts the lifespan and reliability of assembled products. However, certain aerospace nuts undergo over 120 h of rigorous testing per batch, causing increased costs and delayed product delivery. Therefore, accurately predicting production quality and remaining testing time (RTT) is crucial for improving efficiency. Facing this new challenge, this paper proposes a data-model hybrid time series prediction method based on quality information fusion. First, considering that the monitoring data contains two sets of related features, we introduce a multi-task parallel deep learning (MTL) network with a temporal self-attention mechanism (TSAM). The TSAM assigns importance to key degradation information, while MTL leverages shared feature information to capture more accurate long-term trends. Next, considering the multi-stage nature and uncertainty of the degradation process, a semi-empirical physical degradation model is constructed, where stage identification is achieved using the Pruned Exact Linear Time (PELT) method, and uncertainty is estimated through Particle Filtering (PF). The Bayesian framework enables hybrid correction between the data-based and the model-based methods, integrating the strengths of both. Finally, experimental results demonstrate that the proposed method outperforms traditional models, effectively achieving more accurate quality predictions.</div></div>","PeriodicalId":16227,"journal":{"name":"Journal of Manufacturing Systems","volume":"82 ","pages":"Pages 1171-1191"},"PeriodicalIF":14.2,"publicationDate":"2025-08-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144902874","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
引用次数: 0
Optimisation method for semiconductor wafer manufacturing system scheduling: Reinforcement learning with decision graph guiding 半导体晶圆制造系统调度优化方法:决策图导向强化学习
IF 14.2 1区 工程技术 Q1 ENGINEERING, INDUSTRIAL Pub Date : 2025-08-27 DOI: 10.1016/j.jmsy.2025.08.004
Da Chen , Jie Zhang , Lihui Wu , Peng Zhang , Youlong Lv , Junliang Wang , Hong Wang
Semiconductor wafer fabrication, as a large-scale and complex discrete manufacturing system, presents significant challenges in shop floor scheduling due to its scale, uncertainty, and re-entrant processing. Additionally, effectively leveraging historical scheduling decision data remains a challenge, limiting the ability of scheduling algorithms to accurately assess the current system state. To address these issues, this paper proposes a reinforcement learning-based optimisation method guided by decision graphs. First, we introduce a multidimensional heterogeneous disambiguation graph to comprehensively represent the operational state of the wafer manufacturing system. Second, we design a graph neural network to characterise the multidimensional disambiguation graph and learn from historical decision-making experiences. Finally, we propose a decision graph-guided action strategy that optimises the reinforcement learning policy, improving training efficiency and the accuracy of action selection. Experimental results demonstrate that our method achieves superior generalisation performance and outperforms traditional approaches. This study provides an effective solution for optimising scheduling in semiconductor wafer manufacturing systems.
半导体晶圆制造作为一个大规模、复杂的离散制造系统,由于其规模、不确定性和可重复加工的特点,对车间调度提出了重大挑战。此外,有效地利用历史调度决策数据仍然是一个挑战,限制了调度算法准确评估当前系统状态的能力。为了解决这些问题,本文提出了一种基于决策图的强化学习优化方法。首先,我们引入一个多维异构消歧图来全面表征晶圆制造系统的运行状态。其次,我们设计了一个图神经网络来表征多维消歧图,并从历史决策经验中学习。最后,我们提出了一种决策图引导的行动策略,该策略优化了强化学习策略,提高了训练效率和行动选择的准确性。实验结果表明,该方法具有较好的泛化性能,优于传统方法。该研究为半导体晶圆制造系统的调度优化提供了有效的解决方案。
{"title":"Optimisation method for semiconductor wafer manufacturing system scheduling: Reinforcement learning with decision graph guiding","authors":"Da Chen ,&nbsp;Jie Zhang ,&nbsp;Lihui Wu ,&nbsp;Peng Zhang ,&nbsp;Youlong Lv ,&nbsp;Junliang Wang ,&nbsp;Hong Wang","doi":"10.1016/j.jmsy.2025.08.004","DOIUrl":"10.1016/j.jmsy.2025.08.004","url":null,"abstract":"<div><div>Semiconductor wafer fabrication, as a large-scale and complex discrete manufacturing system, presents significant challenges in shop floor scheduling due to its scale, uncertainty, and re-entrant processing. Additionally, effectively leveraging historical scheduling decision data remains a challenge, limiting the ability of scheduling algorithms to accurately assess the current system state. To address these issues, this paper proposes a reinforcement learning-based optimisation method guided by decision graphs. First, we introduce a multidimensional heterogeneous disambiguation graph to comprehensively represent the operational state of the wafer manufacturing system. Second, we design a graph neural network to characterise the multidimensional disambiguation graph and learn from historical decision-making experiences. Finally, we propose a decision graph-guided action strategy that optimises the reinforcement learning policy, improving training efficiency and the accuracy of action selection. Experimental results demonstrate that our method achieves superior generalisation performance and outperforms traditional approaches. This study provides an effective solution for optimising scheduling in semiconductor wafer manufacturing systems.</div></div>","PeriodicalId":16227,"journal":{"name":"Journal of Manufacturing Systems","volume":"82 ","pages":"Pages 1158-1170"},"PeriodicalIF":14.2,"publicationDate":"2025-08-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144902873","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
引用次数: 0
Self-supervised time–frequency feature alignment for process monitoring of cyber–physical CNC machines 网络物理数控机床过程监控的自监督时频特征对齐
IF 14.2 1区 工程技术 Q1 ENGINEERING, INDUSTRIAL Pub Date : 2025-08-26 DOI: 10.1016/j.jmsy.2025.08.007
Yadong Xu , J.C. Ji , Yuxin Sun , Sihan Huang , Zhiheng Zhao , George Q. Huang
Self-supervised learning excels at uncovering latent features from incomplete data, thereby providing robust support for downstream applications. Capitalizing on this strength, a growing number of fault diagnosis models have been developed to monitor CNC machine tools, which are essential to modern manufacturing. These machines operate under demanding conditions – characterized by high speeds and heavy loads – and consequently generate mechanical signals with pronounced nonlinearity. Such inherent nonlinearity poses significant challenges for conventional feature extraction methods, necessitating advanced self-supervised techniques to effectively capture and interpret the underlying fault-related features for reliable condition monitoring. In this research, we introduce a self-supervised time–frequency feature alignment (STFA) algorithm for monitoring the manufacturing processes of industrial CNC machine tools. The STFA algorithm initially employs two domain-specific modules to extract time–frequency features from surveillance signals. A modern CNN is utilized to extract spatiotemporal information from the time domain, while a multi-scale CNN captures multi-granular features from the frequency domain. Subsequently, a dedicated time–frequency feature alignment module (TFAM) maps these features into a unified space, thereby exploiting their complementarity and enabling a more comprehensive representation. The STFA algorithm is trained through a dual-stage process—first, a pre-training phase to establish robust feature representations from unlabeled data, followed by a fine-tuning stage using a limited number of labeled samples to adapt the model for precise fault diagnosis. The effectiveness of the proposed STFA algorithm is validated using two manufacturing datasets collected from industrial CNC machine tools.
自监督学习擅长于从不完整的数据中发现潜在的特征,从而为下游应用提供强大的支持。利用这一优势,越来越多的故障诊断模型已经被开发出来,以监测对现代制造业至关重要的数控机床。这些机器在苛刻的条件下运行-以高速和重载为特征-因此产生具有明显非线性的机械信号。这种固有的非线性对传统的特征提取方法提出了重大挑战,需要先进的自监督技术来有效地捕获和解释潜在的故障相关特征,以实现可靠的状态监测。在本研究中,我们引入了一种自监督时频特征对准(STFA)算法来监控工业数控机床的制造过程。STFA算法最初采用两个特定域模块从监控信号中提取时频特征。现代CNN从时域提取时空信息,而多尺度CNN从频域捕获多颗粒特征。随后,一个专用的时频特征对准模块(TFAM)将这些特征映射到一个统一的空间中,从而利用它们的互补性,实现更全面的表示。STFA算法通过两个阶段的过程进行训练,首先是预训练阶段,从未标记的数据中建立鲁棒特征表示,然后是使用有限数量的标记样本调整模型以进行精确故障诊断的微调阶段。利用两个工业数控机床制造数据集验证了STFA算法的有效性。
{"title":"Self-supervised time–frequency feature alignment for process monitoring of cyber–physical CNC machines","authors":"Yadong Xu ,&nbsp;J.C. Ji ,&nbsp;Yuxin Sun ,&nbsp;Sihan Huang ,&nbsp;Zhiheng Zhao ,&nbsp;George Q. Huang","doi":"10.1016/j.jmsy.2025.08.007","DOIUrl":"10.1016/j.jmsy.2025.08.007","url":null,"abstract":"<div><div>Self-supervised learning excels at uncovering latent features from incomplete data, thereby providing robust support for downstream applications. Capitalizing on this strength, a growing number of fault diagnosis models have been developed to monitor CNC machine tools, which are essential to modern manufacturing. These machines operate under demanding conditions – characterized by high speeds and heavy loads – and consequently generate mechanical signals with pronounced nonlinearity. Such inherent nonlinearity poses significant challenges for conventional feature extraction methods, necessitating advanced self-supervised techniques to effectively capture and interpret the underlying fault-related features for reliable condition monitoring. In this research, we introduce a self-supervised time–frequency feature alignment (STFA) algorithm for monitoring the manufacturing processes of industrial CNC machine tools. The STFA algorithm initially employs two domain-specific modules to extract time–frequency features from surveillance signals. A modern CNN is utilized to extract spatiotemporal information from the time domain, while a multi-scale CNN captures multi-granular features from the frequency domain. Subsequently, a dedicated time–frequency feature alignment module (TFAM) maps these features into a unified space, thereby exploiting their complementarity and enabling a more comprehensive representation. The STFA algorithm is trained through a dual-stage process—first, a pre-training phase to establish robust feature representations from unlabeled data, followed by a fine-tuning stage using a limited number of labeled samples to adapt the model for precise fault diagnosis. The effectiveness of the proposed STFA algorithm is validated using two manufacturing datasets collected from industrial CNC machine tools.</div></div>","PeriodicalId":16227,"journal":{"name":"Journal of Manufacturing Systems","volume":"82 ","pages":"Pages 1145-1157"},"PeriodicalIF":14.2,"publicationDate":"2025-08-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144896625","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
引用次数: 0
Cerebrum twin: A 6D semantic digital twin of multi-lobe digital brain functions for human-centric Industry 5.0 大脑双胞胎:为以人为中心的工业5.0提供多叶数字大脑功能的6D语义数字双胞胎
IF 14.2 1区 工程技术 Q1 ENGINEERING, INDUSTRIAL Pub Date : 2025-08-19 DOI: 10.1016/j.jmsy.2025.08.009
Hanwei Teng , Shuo Chen , Changping Li , Shujian Li , Rendi Kurniawan , Moran Xu , Jielin Chen , Tae Jo Ko
Industry 5.0 highlights the need for human-centric and adaptive intelligence in smart manufacturing. This paper proposes the Cerebrum Twin (CT), a brain-inspired, six-dimensional semantic digital twin (SDT) system that unifies five human-like senses, including listening, speaking, reading, writing, and looking, within a cohesive multi-lobe digital brain framework. CT integrates real-time physical signals from force, vibration, and vision sensors by leveraging a synergistic ensemble of advanced artificial intelligence (AI) modules, such as Extreme Gradient Boosting (XGBoost), ConvNeXt V2, Efficient Sub-Pixel Convolutional Networks (ESPCN), stacked sparse autoencoder with supervision (SSAES), large language models (LLM), and reinforcement learning (RL). Uniquely, CT establishes a closed-loop semantic feedback mechanism, enabling dynamic perception, multimodal semantic abstraction, signal-driven prediction, adaptive parameter optimization, and intuitive voice-based human interaction. This holistic integration bridges the physical, semantic, and cognitive layers of CNC machining, supporting robust, transparent, and operator-oriented decision-making. The proposed system was validated through ultrasonic vibration-assisted blade dicing (UVABD) experiments. CT reduced dicing force prediction error by 39.86 %, improved tool wear prediction accuracy by 29.59 %, and decreased edge chipping severity by 60.47 % compared to the baseline model. These results demonstrate that a semantically empowered, multisensory digital twin (DT), enabled by real-time physical–semantic–AI fusion and human-in-the-loop optimization, can significantly enhance intelligent manufacturing performance and fulfill the vision of Industry 5.0.
工业5.0强调了智能制造对以人为中心和自适应智能的需求。本文提出了大脑双生体(CT),这是一个受大脑启发的六维语义数字双生体(SDT)系统,它将五种类似人类的感官,包括听、说、读、写和看,统一在一个有凝聚力的多叶数字大脑框架内。CT通过利用先进人工智能(AI)模块的协同集成,集成了来自力、振动和视觉传感器的实时物理信号,例如极端梯度增强(XGBoost)、ConvNeXt V2、高效亚像素卷积网络(ESPCN)、带监督的堆叠稀疏自编码器(SSAES)、大型语言模型(LLM)和强化学习(RL)。独特的是,CT建立了闭环语义反馈机制,实现了动态感知、多模态语义抽象、信号驱动预测、自适应参数优化和基于语音的直观人机交互。这种整体集成连接了CNC加工的物理、语义和认知层,支持稳健、透明和面向操作员的决策。通过超声振动辅助刀片切割(UVABD)实验对该系统进行了验证。与基线模型相比,CT将切削力预测误差降低了39.86 %,刀具磨损预测精度提高了29.59 %,边缘切屑严重程度降低了60.47 %。这些结果表明,通过实时物理-语义-人工智能融合和人在环优化,语义授权的多感官数字孪生(DT)可以显着提高智能制造性能并实现工业5.0的愿景。
{"title":"Cerebrum twin: A 6D semantic digital twin of multi-lobe digital brain functions for human-centric Industry 5.0","authors":"Hanwei Teng ,&nbsp;Shuo Chen ,&nbsp;Changping Li ,&nbsp;Shujian Li ,&nbsp;Rendi Kurniawan ,&nbsp;Moran Xu ,&nbsp;Jielin Chen ,&nbsp;Tae Jo Ko","doi":"10.1016/j.jmsy.2025.08.009","DOIUrl":"10.1016/j.jmsy.2025.08.009","url":null,"abstract":"<div><div>Industry 5.0 highlights the need for human-centric and adaptive intelligence in smart manufacturing. This paper proposes the Cerebrum Twin (CT), a brain-inspired, six-dimensional semantic digital twin (SDT) system that unifies five human-like senses, including listening, speaking, reading, writing, and looking, within a cohesive multi-lobe digital brain framework. CT integrates real-time physical signals from force, vibration, and vision sensors by leveraging a synergistic ensemble of advanced artificial intelligence (AI) modules, such as Extreme Gradient Boosting (XGBoost), ConvNeXt V2, Efficient Sub-Pixel Convolutional Networks (ESPCN), stacked sparse autoencoder with supervision (SSAES), large language models (LLM), and reinforcement learning (RL). Uniquely, CT establishes a closed-loop semantic feedback mechanism, enabling dynamic perception, multimodal semantic abstraction, signal-driven prediction, adaptive parameter optimization, and intuitive voice-based human interaction. This holistic integration bridges the physical, semantic, and cognitive layers of CNC machining, supporting robust, transparent, and operator-oriented decision-making. The proposed system was validated through ultrasonic vibration-assisted blade dicing (UVABD) experiments. CT reduced dicing force prediction error by 39.86 %, improved tool wear prediction accuracy by 29.59 %, and decreased edge chipping severity by 60.47 % compared to the baseline model. These results demonstrate that a semantically empowered, multisensory digital twin (DT), enabled by real-time physical–semantic–AI fusion and human-in-the-loop optimization, can significantly enhance intelligent manufacturing performance and fulfill the vision of Industry 5.0.</div></div>","PeriodicalId":16227,"journal":{"name":"Journal of Manufacturing Systems","volume":"82 ","pages":"Pages 1125-1144"},"PeriodicalIF":14.2,"publicationDate":"2025-08-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144864294","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
引用次数: 0
期刊
Journal of Manufacturing Systems
全部 Acc. Chem. Res. ACS Applied Bio Materials ACS Appl. Electron. Mater. ACS Appl. Energy Mater. ACS Appl. Mater. Interfaces ACS Appl. Nano Mater. ACS Appl. Polym. Mater. ACS BIOMATER-SCI ENG ACS Catal. ACS Cent. Sci. ACS Chem. Biol. ACS Chemical Health & Safety ACS Chem. Neurosci. ACS Comb. Sci. ACS Earth Space Chem. ACS Energy Lett. ACS Infect. Dis. ACS Macro Lett. ACS Mater. Lett. ACS Med. Chem. Lett. ACS Nano ACS Omega ACS Photonics ACS Sens. ACS Sustainable Chem. Eng. ACS Synth. Biol. Anal. Chem. BIOCHEMISTRY-US Bioconjugate Chem. BIOMACROMOLECULES Chem. Res. Toxicol. Chem. Rev. Chem. Mater. CRYST GROWTH DES ENERG FUEL Environ. Sci. Technol. Environ. Sci. Technol. Lett. Eur. J. Inorg. Chem. IND ENG CHEM RES Inorg. Chem. J. Agric. Food. Chem. J. Chem. Eng. Data J. Chem. Educ. J. Chem. Inf. Model. J. Chem. Theory Comput. J. Med. Chem. J. Nat. Prod. J PROTEOME RES J. Am. Chem. Soc. LANGMUIR MACROMOLECULES Mol. Pharmaceutics Nano Lett. Org. Lett. ORG PROCESS RES DEV ORGANOMETALLICS J. Org. Chem. J. Phys. Chem. J. Phys. Chem. A J. Phys. Chem. B J. Phys. Chem. C J. Phys. Chem. Lett. Analyst Anal. Methods Biomater. Sci. Catal. Sci. Technol. Chem. Commun. Chem. Soc. Rev. CHEM EDUC RES PRACT CRYSTENGCOMM Dalton Trans. Energy Environ. Sci. ENVIRON SCI-NANO ENVIRON SCI-PROC IMP ENVIRON SCI-WAT RES Faraday Discuss. Food Funct. Green Chem. Inorg. Chem. Front. Integr. Biol. J. Anal. At. Spectrom. J. Mater. Chem. A J. Mater. Chem. B J. Mater. Chem. C Lab Chip Mater. Chem. Front. Mater. Horiz. MEDCHEMCOMM Metallomics Mol. Biosyst. Mol. Syst. Des. Eng. Nanoscale Nanoscale Horiz. Nat. Prod. Rep. New J. Chem. Org. Biomol. Chem. Org. Chem. Front. PHOTOCH PHOTOBIO SCI PCCP Polym. Chem.
×
引用
GB/T 7714-2015
复制
MLA
复制
APA
复制
导出至
BibTeX EndNote RefMan NoteFirst NoteExpress
×
0
微信
客服QQ
Book学术公众号 扫码关注我们
反馈
×
意见反馈
请填写您的意见或建议
请填写您的手机或邮箱
×
提示
您的信息不完整,为了账户安全,请先补充。
现在去补充
×
提示
您因"违规操作"
具体请查看互助需知
我知道了
×
提示
现在去查看 取消
×
提示
确定
Book学术官方微信
Book学术文献互助
Book学术文献互助群
群 号:604180095
Book学术
文献互助 智能选刊 最新文献 互助须知 联系我们:info@booksci.cn
Book学术提供免费学术资源搜索服务,方便国内外学者检索中英文文献。致力于提供最便捷和优质的服务体验。
Copyright © 2023 Book学术 All rights reserved.
ghs 京公网安备 11010802042870号 京ICP备2023020795号-1