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Sustainability assessment for machining processes based on progressive analysis of critical sources 基于关键源逐级分析的加工过程可持续性评价
IF 14.2 1区 工程技术 Q1 ENGINEERING, INDUSTRIAL Pub Date : 2025-12-16 DOI: 10.1016/j.jmsy.2025.12.002
Junjie Hu , Wei Zhao , Liang Li , Ning He , Muhammad Jamil , Aqib Mashood Khan , Chao Wang , Xiaowei Zheng
The machining processes must achieve sustainability due to growing ecological concerns and energy crises. As an effective tool, sustainability assessment guides the implementation of sustainable strategies in machining processes. However, the complex resource consumption across machining processes and the coupling effects among machining parameters have greatly hindered its implementation. To address this challenge, this study proposes a sustainability assessment method based on progressive analysis of critical sources, enabling the identification and evaluation of key factors influencing sustainability. First, critical sources are identified through quantification of contribution degrees and sensitivity analysis. Progressive analysis is employed to focus resources on in-depth research into the fundamental characteristics and operational mechanisms of critical sources, establishing specialized indicators such as specific embodied energy and specific carbon emissions for cutters. Subsequently, a sustainable soft sensor is developed to enable efficient and cost-effective sustainability assessment. Finally, a milling case study incorporating various tool types and cooling-lubrication strategies demonstrates the method’s effectiveness in comprehensively capturing the coupling effects inherent in machining processes. The results confirm the method’s reliability and clearly validate its capability to evaluate sustainability performance in machining. This study not only provides technical support for sustainability assessments but also delivers actionable insights to facilitate the implementation of sustainable machining strategies.
由于日益增长的生态问题和能源危机,机械加工过程必须实现可持续性。作为一种有效的工具,可持续性评估指导了加工过程中可持续战略的实施。然而,加工过程中复杂的资源消耗和加工参数之间的耦合效应极大地阻碍了其实现。为了应对这一挑战,本研究提出了一种基于关键来源逐步分析的可持续性评估方法,从而能够识别和评估影响可持续性的关键因素。首先,通过量化贡献度和敏感性分析,确定关键来源。采用递进分析法,集中资源深入研究关键源的基本特征和运行机制,建立刀具比蕴含能、比碳排放等专项指标。随后,开发了一种可持续软传感器,以实现高效和经济的可持续性评估。最后,结合各种刀具类型和冷却-润滑策略的铣削案例研究表明,该方法在全面捕获加工过程中固有的耦合效应方面是有效的。结果证实了该方法的可靠性,并清楚地验证了其评估加工可持续性能的能力。本研究不仅为可持续性评估提供了技术支持,而且为可持续加工策略的实施提供了可操作的见解。
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引用次数: 0
Resilience-enhancing multi-strategy decision-making for dynamic scheduling in manufacturing systems 制造系统动态调度的弹性增强多策略决策
IF 14.2 1区 工程技术 Q1 ENGINEERING, INDUSTRIAL Pub Date : 2025-12-16 DOI: 10.1016/j.jmsy.2025.12.009
Xin Guo , Mingyue Yang , Pai Zheng , Jiewu Leng , Chong Chen , Kai Zhang , Jun Li , Zechuan Huang
High-impact disruptions can cause significant performance degradation and even failures in manufacturing systems. Resilient manufacturing systems can absorb such disruptions, adapt to changing environments, and accelerate recovery through strategy scheduling based on real-time performance data. However, the nonlinear nature of degradation processes can lead to deviations from expected recovery outcomes and delays in strategy scheduling, which makes strategy scheduling for repairing manufacturing systems a difficult decision-making problem. Therefore, a resilience-enhancing multi-strategy decision-making for dynamic scheduling model in manufacturing systems is proposed, aiming to determine the optimal strategy and reduce performance anomaly duration. First, a component-based evaluation method is proposed to measure the absorption, adaptation, and recovery capabilities of the system, achieving real-time analysis of resilience levels. Then, a dynamic strategy scheduling method based on Markov chains is proposed to plan strategies and predict trajectories based on the real-time performance status, disruption, and resilience level, which solves the nonlinearity changes of performance state. Finally, a multi-strategy decision-making method based on fuzzy-BWM is proposed to achieve the resilient-oriented multi-objective discrete strategy decision-making, considering cost, recovery time, and recovery degree. The die forging press is used to demonstrate the effectiveness of the proposed model. The results show that the strategy decided by the model enables the system to recover quickly to its expected state with an acceptable cost compared to other strategies.
高影响的中断可能导致制造系统的显著性能下降甚至故障。弹性制造系统可以吸收这种中断,适应不断变化的环境,并通过基于实时性能数据的策略调度加速恢复。然而,退化过程的非线性特性会导致策略调度偏离预期的恢复结果和延迟,这使得修复制造系统的策略调度成为一个困难的决策问题。为此,针对制造系统动态调度模型,提出了一种增强弹性的多策略决策,以确定最优策略并减少性能异常持续时间。首先,提出了一种基于组分的评估方法,测量系统的吸收、适应和恢复能力,实现对系统弹性水平的实时分析。在此基础上,提出了一种基于马尔可夫链的动态策略调度方法,根据实时性能状态、中断和弹性水平进行策略规划和轨迹预测,解决了性能状态的非线性变化问题。最后,提出了一种基于模糊bwm的多策略决策方法,在考虑成本、恢复时间和恢复程度的情况下,实现了面向弹性的多目标离散策略决策。以模锻压力机为例,验证了该模型的有效性。结果表明,与其他策略相比,由模型决定的策略使系统能够以可接受的代价快速恢复到预期状态。
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引用次数: 0
A deep reinforcement learning approach driven by temporal knowledge graph for dynamic scheduling in discrete manufacturing workshops 基于时间知识图的离散制造车间动态调度深度强化学习方法
IF 14.2 1区 工程技术 Q1 ENGINEERING, INDUSTRIAL Pub Date : 2025-12-15 DOI: 10.1016/j.jmsy.2025.12.008
Xinyu Liu , Yunlei Zan , Honghui Wang , Xu Han , Guijie Liu
Against the background of low-carbon and efficient sustainable manufacturing, production scheduling must not only focus on efficiency and delivery times but also balance energy consumption and carbon emission constraints. However, modern manufacturing workshops commonly adopt a model where batch production and trial production coexist. Production orders and equipment load evolve over time, with frequent occurrences of order insertion, maintenance. At the same time, workshop data exhibits multisource, heterogeneous, and time-varying characteristics. It leads to underutilized production information and delayed scheduling decisions, resulting in efficiency losses and redundant energy consumption. To address the above issues, a deep reinforcement learning approach driven by temporal knowledge graph is proposed in this paper. Firstly, a knowledge graph-based workshop scheduling framework is established to perform unified semantic modeling of production factors and the scheduling relationships. It constructs a multidimensional information matrix with temporal rule constraints. Then, a temporal knowledge-driven LSTM-TD3 algorithm is proposed by replacing the original policy network with an LSTM and employing dual Q-networks with policy delay updates to improve training convergence in continuous action spaces. On this basis, an adaptive weighting mechanism for reward functions targeting different production events is defined to achieve a reasonable balance and dynamic decision-making among multiple objectives. Finally, a case study is conducted with a boiler screen tube production line, and a prototype system is built. The results indicate that compared to historical production data, the average energy consumption of production line equipment decreased by 4.10 %, and the overall efficiency of the workshop increased by 14.29 %, validating the effectiveness of this approach.
在低碳高效的可持续制造背景下,生产调度不仅要关注效率和交货期,还要平衡能耗和碳排放约束。而现代制造车间普遍采用批量生产与试制并存的生产模式。生产订单和设备负荷随着时间的推移而变化,经常发生订单插入、维护。同时,车间数据具有多源、异构、时变的特点。它导致生产信息未充分利用和调度决策延迟,从而导致效率损失和冗余能源消耗。为了解决上述问题,本文提出了一种基于时间知识图驱动的深度强化学习方法。首先,建立基于知识图的车间调度框架,对生产要素和调度关系进行统一的语义建模;它构造了一个具有时间规则约束的多维信息矩阵。然后,提出了一种时间知识驱动的LSTM- td3算法,用LSTM代替原有的策略网络,并采用具有策略延迟更新的双q网络来提高连续动作空间中的训练收敛性。在此基础上,定义了针对不同生产事件的奖励函数自适应加权机制,实现了多目标之间的合理平衡和动态决策。最后,以某锅炉筛管生产线为例,建立了原型系统。结果表明,与历史生产数据相比,生产线设备平均能耗降低4.10 %,车间整体效率提高14.29 %,验证了该方法的有效性。
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引用次数: 0
A cradle-to-cradle life cycle assessment framework linking machining parameters, tool life and part durability 连接加工参数、刀具寿命和零件耐久性的从摇篮到摇篮的生命周期评估框架
IF 14.2 1区 工程技术 Q1 ENGINEERING, INDUSTRIAL Pub Date : 2025-12-15 DOI: 10.1016/j.jmsy.2025.11.021
I. Rodriguez , P.J. Arrazola , M. Mori , G. Ortiz-de-Zarate , A. Madariaga , M. Cuesta , F. Pušavec
Machining operations influence sustainability not only through immediate energy and resource use but also through their effects on tool longevity and part durability. Conventional life cycle assessments (LCAs) of machining typically adopt gate-to-gate boundaries, overlooking how machining parameters affect surface integrity, fatigue life, and the frequency of cutting-tool and machined component replacement. This study develops a novel cradle-to-cradle LCA framework that incorporates machining-induced tool wear and part durability into system-level environmental impacts. The approach is demonstrated through a real case study of drilling the CFRP/Ti6Al4V stacks used for the Boeing 787 fuselage, comparing dry drilling with liquid carbon dioxide combined with minimum quantity lubrication (LCO₂+MQL). Experimental tests quantified energy demand, resource consumption, tool life, and hole quality, while part durability was evaluated via fatigue testing and finite element simulations. Results show that the cutting tool production was the dominant contributor to the overall environmental impact. Despite requiring additional auxiliary inputs, LCO₂+MQL drilling reduced overall environmental impacts by 60–70 % relative to dry drilling, due to extended tool life and improved component service life. These findings demonstrate that coolant-assisted machining, when durability and tool-life effects are considered, yields a net environmental benefit. The proposed framework provides a transferable method to expand LCAs beyond gate-to-gate boundaries by integrating the influence of machined part quality on durability and in-service repairs, enabling cradle-to-cradle assessments that better capture the system-level implications of machining decisions.
机加工操作不仅通过直接的能源和资源使用,而且通过对刀具寿命和零件耐久性的影响来影响可持续性。传统的加工生命周期评估(lca)通常采用门到门边界,忽略了加工参数如何影响表面完整性、疲劳寿命以及刀具和加工部件更换频率。本研究开发了一种新的从摇篮到摇篮的生命周期分析框架,将加工引起的刀具磨损和零件耐久性纳入系统级环境影响。通过对用于波音787机身的CFRP/Ti6Al4V堆叠进行钻井的实际案例研究,比较了干钻与液体二氧化碳结合最少量润滑(LCO₂+MQL)的方法。实验测试量化了能源需求、资源消耗、刀具寿命和孔质量,同时通过疲劳测试和有限元模拟评估了零件的耐久性。结果表明,刀具生产是整体环境影响的主要贡献者。尽管需要额外的辅助投入,但由于延长了工具寿命和提高了组件的使用寿命,LCO₂+MQL钻井相对于干式钻井减少了60 - 70% %的总体环境影响。这些发现表明,当考虑到耐久性和刀具寿命影响时,冷却剂辅助加工产生净环境效益。所提出的框架提供了一种可转移的方法,通过整合加工零件质量对耐久性和在用维修的影响,将lca扩展到门到门边界之外,使从摇篮到摇篮的评估能够更好地捕捉加工决策的系统级影响。
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引用次数: 0
Frequency-aware and bionic-aligned collaborative modeling for cross-domain tool wear monitoring under small-sample conditions 小样本条件下跨域工具磨损监测的频率感知和仿生对齐协同建模
IF 14.2 1区 工程技术 Q1 ENGINEERING, INDUSTRIAL Pub Date : 2025-12-15 DOI: 10.1016/j.jmsy.2025.11.025
Yezhen Peng , Weimin Kang , Qirui Hu , Fengwen Yu , Wenhong Zhou , Xinhua Yao , Congcong Luan , Songyu Hu , Jianzhong Fu
Tool wear monitoring is crucial for optimizing CNC machining processes in next-generation intelligent manufacturing systems. However, existing methods struggle to capture the dynamic relationship between high-frequency features and wear evolution. Small-sample training and the uneven distribution of labels across the domain exacerbate bias in feature migration, limiting model generalizability and adaptability. To address this, a frequency domain-aware and bionic-aligned collaborative modeling approach for domain shift mitigation is proposed. Firstly, a smoothed wavelet convolution feature extraction method is introduced, enhancing the capture of sensitive frequency bands and stabilizing gradient propagation through a Softplus smoothing mechanism. The method’s ability to suppress domain offset during the initial feature extraction stage is validated by comparing feature activation distributions across two domains. Inspired by bat echolocation, an attention mechanism is proposed that integrates energy guidance, echo alignment, and time-frequency focusing modules to enhance high-frequency signal mapping and mitigate domain shift. The method's effectiveness in high-frequency feature response is validated through enhancement metrics and variance distribution within the attention focus region. Additionally, interpretability of dual-domain feature alignment is improved by calculating working condition similarity, integrating a priori knowledge, and optimizing the MMD loss function. Systematic ablation experiments demonstrate that the proposed method achieves average RMSE, MAE, and R² values of 0.078, 0.063, and 0.817, respectively. It outperforms all ablation models, yielding average reductions of 31.6 % and 32.5 % in RMSE and MAE, and an average improvement of 42.7 % in R². Furthermore, the proposed method outperforms the best-performing method among the four mainstream methods, reducing RMSE and MAE by 13.3 % and 2.5 %, and improving R² by 5.1 %. This method effectively suppresses domain bias in feature extraction, mapping, and training under small sample conditions, providing critical technical support for intelligent manufacturing in complex, variable working environments.
在下一代智能制造系统中,刀具磨损监测对于优化数控加工工艺至关重要。然而,现有的方法很难捕捉到高频特征与磨损演变之间的动态关系。小样本训练和标签在整个领域的不均匀分布加剧了特征迁移的偏差,限制了模型的泛化和适应性。为了解决这个问题,提出了一种频域感知和仿生对齐的协同建模方法来缓解域移。首先,介绍了一种平滑小波卷积特征提取方法,通过Softplus平滑机制增强对敏感频段的捕获,稳定梯度传播;通过比较两个域的特征激活分布,验证了该方法在初始特征提取阶段抑制域偏移的能力。受蝙蝠回声定位的启发,提出了一种集成能量引导、回波对准和时频聚焦模块的注意机制,以增强高频信号映射和减轻域漂移。通过增强指标和关注焦点区域的方差分布验证了该方法对高频特征响应的有效性。此外,通过计算工况相似度、整合先验知识和优化MMD损失函数,提高了双域特征对齐的可解释性。系统烧蚀实验表明,该方法的平均RMSE、MAE和R²值分别为0.078、0.063和0.817。它优于所有消融模型,RMSE和MAE的平均降低率分别为31.6% %和32.5 %,R²的平均改善率为42.7% %。此外,该方法的RMSE和MAE分别降低了13.3 %和2.5 %,R²提高了5.1 %,是四种主流方法中表现最好的方法。该方法有效地抑制了小样本条件下特征提取、映射和训练中的领域偏差,为复杂多变工作环境下的智能制造提供了关键的技术支持。
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引用次数: 0
A comprehensive survey for real-world industrial surface defect detection: Challenges, approaches, and prospects 现实世界工业表面缺陷检测的综合调查:挑战、方法和前景
IF 14.2 1区 工程技术 Q1 ENGINEERING, INDUSTRIAL Pub Date : 2025-12-12 DOI: 10.1016/j.jmsy.2025.11.022
Yuqi Cheng , Yunkang Cao , Haiming Yao , Wei Luo , Cheng Jiang , Hui Zhang , Weiming Shen
Industrial surface defect detection is vital for upholding product quality across contemporary manufacturing systems. As the expectations for precision, automation, and scalability intensify, conventional inspection approaches are increasingly found wanting in addressing real-world demands. Notable progress in computer vision and deep learning has substantially bolstered defect detection capabilities across both 2D and 3D modalities. A significant development has been the pivot from closed-set to open-set defect detection frameworks, which diminishes the necessity for extensive defect annotations and facilitates the recognition of novel anomalies. Despite such strides, a cohesive and contemporary understanding of industrial defect detection remains elusive. Consequently, this survey delivers an in-depth analysis of both closed-set and open-set defect detection strategies within 2D and 3D modalities, charting their evolution in recent years and underscoring the rising prominence of open-set techniques. We distill critical challenges inherent in practical detection environments and illuminate emerging trends, thereby providing a current and comprehensive vista of this swiftly progressing field.
工业表面缺陷检测对于维护当代制造系统的产品质量至关重要。随着对精度、自动化和可扩展性的期望的增强,传统的检查方法越来越难以满足现实世界的需求。计算机视觉和深度学习的显著进步大大增强了2D和3D模式的缺陷检测能力。一个重要的发展是从闭集缺陷检测框架转向开集缺陷检测框架,这减少了大量缺陷注释的必要性,并促进了对新异常的识别。尽管取得了这样的进步,但对工业缺陷检测的连贯和现代理解仍然难以捉摸。因此,本调查对2D和3D模式下的闭集和开集缺陷检测策略进行了深入分析,绘制了它们近年来的演变图表,并强调了开集技术的日益突出。我们提炼了实际检测环境中固有的关键挑战,并阐明了新兴趋势,从而为这一迅速发展的领域提供了当前和全面的前景。
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引用次数: 0
Deep unsupervised learning-based supplier selection and ranking for assembly manufacturing 基于深度无监督学习的装配制造供应商选择与排序
IF 14.2 1区 工程技术 Q1 ENGINEERING, INDUSTRIAL Pub Date : 2025-12-12 DOI: 10.1016/j.jmsy.2025.12.004
Suyoung Park, Shreyes N. Melkote
Conventional supplier selection methods for assembled products have primarily relied on qualitative or business-level assessments of supplier capabilities, since manufacturing-related metrics such as product geometry, cost, time, and tolerance are heterogeneous and difficult to integrate into a unified evaluation. This reliance makes the identification of suppliers with adequate manufacturing capability particularly challenging as global supply chains grow increasingly complex. To address this gap, we propose the Deep Unsupervised Assembly Supplier Matcher (DU-ASM), an integrated data-driven framework that jointly embeds geometry, topology, and quantitative manufacturing attributes into a unified latent space for assembly-level supplier selection and ranking. Leveraging a graph autoencoder, DU-ASM reconstructs manufacturing attributes and supports robust supplier selection even with incomplete inputs. Experimental validation across multiple case studies demonstrates that DU-ASM achieves over 95 % supplier selection accuracy under complete requirements and over 90 % with partially masked inputs, while attaining mean normalized Discounted Cumulative Gain scores at top-k positions (nDCG@k) exceeding 0.99 in ranking tasks. By linking geometric, topological, and quantitative data, DU-ASM demonstrates both methodological novelty and strong quantitative performance, providing a scalable foundation for supplier matching at the assembly level and supporting multi-tier decision-making in future manufacturing supply networks.
装配产品的传统供应商选择方法主要依赖于对供应商能力的定性或业务级评估,因为与制造相关的指标(如产品几何形状、成本、时间和公差)是异构的,难以集成到统一的评估中。随着全球供应链变得越来越复杂,这种依赖使得识别具有足够制造能力的供应商尤其具有挑战性。为了解决这一差距,我们提出了深度无监督装配供应商匹配器(DU-ASM),这是一个集成的数据驱动框架,它将几何、拓扑和定量制造属性共同嵌入到一个统一的潜在空间中,用于装配级供应商的选择和排名。利用图形自动编码器,DU-ASM重建制造属性,即使在输入不完整的情况下也支持稳健的供应商选择。跨多个案例研究的实验验证表明,在完全要求下,DU-ASM的供应商选择准确率超过95 %,在部分屏蔽输入下,该方法的供应商选择准确率超过90 %,而在排名任务中,排名前k位(nDCG@k)的平均标准化贴现累积增益得分超过0.99。通过连接几何、拓扑和定量数据,DU-ASM展示了方法的新颖性和强大的定量性能,为装配级供应商匹配提供了可扩展的基础,并支持未来制造供应网络的多层决策。
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引用次数: 0
Process mining-driven modeling and simulation to enhance fault diagnosis in cyber–physical systems 过程挖掘驱动的建模和仿真,以增强网络物理系统的故障诊断
IF 14.2 1区 工程技术 Q1 ENGINEERING, INDUSTRIAL Pub Date : 2025-12-12 DOI: 10.1016/j.jmsy.2025.12.005
Francesco Vitale , Nicola Dall’Ora , Sebastiano Gaiardelli , Enrico Fraccaroli , Nicola Mazzocca , Franco Fummi
Cyber–Physical Systems (CPSs) tightly interconnect digital and physical operations within production environments, enabling real-time monitoring, control, optimization, and autonomous decision-making that directly enhance manufacturing processes and productivity. The inherent complexity of these systems can lead to faults that require robust and interpretable diagnoses to maintain system dependability and operational efficiency. However, manual modeling of faulty behaviors requires extensive domain expertise and cannot leverage the low-level sensor data of the CPS. Furthermore, although powerful, deep learning-based techniques produce black-box diagnostics that lack interpretability, limiting their practical adoption. To address these challenges, we set forth a method that performs unsupervised characterization of system states and state transitions from low-level sensor data, uses several process mining techniques to model faults through interpretable stochastic Petri nets, simulates such Petri nets for a comprehensive understanding of system behavior under faulty conditions, and performs Petri net-based fault diagnosis. The method begins with detecting collective anomalies involving multiple samples in low-level sensor data. These anomalies are then transformed into structured event logs, enabling the data-driven discovery of interpretable Petri nets through process mining. By enhancing these Petri nets with timing distributions, the approach supports the simulation of faulty behaviors. Finally, faults can be diagnosed online by checking collective anomalies with the Petri nets and the corresponding simulations. The method is applied to the Robotic Arm Dataset (RoAD), a benchmark collected from a robotic arm deployed in a scale-replica smart manufacturing assembly line. The application to RoAD demonstrates the method’s effectiveness in modeling, simulating, and classifying faulty behaviors in CPSs. The modeling results demonstrate that our method achieves a satisfactory interpretability-simulation accuracy trade-off with up to 0.676 arc-degree simplicity, 0.395 R2, and 0.088 RMSE. In addition, the fault identification results show that the method achieves an F1 score of up to 98.925%, while maintaining a low conformance checking time of 0.020 s, which competes with other deep learning-based methods.
网络物理系统(cps)紧密连接生产环境中的数字和物理操作,实现实时监控、控制、优化和自主决策,直接提高制造过程和生产力。这些系统固有的复杂性可能导致故障,需要健壮和可解释的诊断来维持系统的可靠性和操作效率。然而,故障行为的手动建模需要广泛的领域专业知识,并且不能利用CPS的低级传感器数据。此外,尽管基于深度学习的强大技术产生了缺乏可解释性的黑箱诊断,限制了它们的实际应用。为了应对这些挑战,我们提出了一种方法,该方法从低级传感器数据中执行系统状态和状态转换的无监督特征,使用几种过程挖掘技术通过可解释的随机Petri网来建模故障,模拟这种Petri网以全面了解故障条件下的系统行为,并执行基于Petri网的故障诊断。该方法首先检测涉及低水平传感器数据中多个样本的集体异常。然后将这些异常转换为结构化事件日志,通过过程挖掘实现数据驱动的可解释Petri网发现。通过用时序分布增强这些Petri网,该方法支持故障行为的模拟。最后,利用Petri网对集体异常进行检测,并进行相应的仿真,实现故障在线诊断。该方法应用于机器人手臂数据集(RoAD),该数据集是从部署在按比例复制的智能制造装配线上的机器人手臂收集的基准。在RoAD中的应用证明了该方法在cps故障行为建模、仿真和分类方面的有效性。建模结果表明,我们的方法达到了令人满意的可解释性-模拟精度权衡,简单性高达0.676弧度,R2为0.395,RMSE为0.088。此外,故障识别结果表明,该方法达到了高达98.925%的F1分数,同时保持了较低的一致性检查时间(0.020 s),与其他基于深度学习的方法相竞争。
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引用次数: 0
PI-KAF: A physics-informed constrained online interpretable monitoring method for tool wear PI-KAF:一种基于物理信息的工具磨损约束在线可解释监测方法
IF 14.2 1区 工程技术 Q1 ENGINEERING, INDUSTRIAL Pub Date : 2025-12-10 DOI: 10.1016/j.jmsy.2025.11.024
Liguo Zhang , Qinghua Song , Haifeng Ma , Zhanqiang Liu
Deep learning-based tool wear monitoring methods often suffer from poor interpretability, parameter redundancy, and limited cross-domain generalization, especially under variable operating conditions and when only small sample sizes are available. These limitations hinder their practical deployment in practical manufacturing environments. To overcome these challenges, this study proposes a highly interpretable and lightweight tool wear monitoring framework tailored for small-sample, variable-condition scenarios. The method randomly extracts fixed-length segments from vibration signals to construct small-sample datasets, utilizing both signal envelope spectrum and cutting time as input features. Guided by the degradation law of tool wear, explicit physical constraints are imposed on the solution space of a Kolmogorov‑Arnold Fourier neural network, yielding a physics‑informed data‑driven model. SHAP analysis is employed to quantify the contribution of each feature, enhancing model transparency. Validation on public datasets under both single‑ and multi‑condition settings demonstrates that the proposed method delivers excellent performance across diverse operating conditions, achieving a stable prediction R² of up to 95 %, an inference latency of only 2 ms, and a reduction of approximately 90 % in model parameters. This solution can be integrated into the edge computing platform of CNC systems, making it particularly suitable for machining scenarios with high real-time requirements. It offers a lightweight, precise, and efficient monitoring capability for smart factories, contributing simultaneously to improvements in product quality and manufacturing efficiency.
基于深度学习的工具磨损监测方法通常存在可解释性差、参数冗余和有限的跨域泛化等问题,特别是在可变操作条件下和只有小样本量的情况下。这些限制阻碍了它们在实际制造环境中的实际部署。为了克服这些挑战,本研究提出了一个高度可解释和轻量级的工具磨损监测框架,为小样本、可变条件的场景量身定制。该方法利用信号包络谱和切割时间作为输入特征,从振动信号中随机提取固定长度的片段,构建小样本数据集。在刀具磨损退化规律的指导下,对Kolmogorov - Arnold傅里叶神经网络的解空间施加了明确的物理约束,从而产生了一个物理信息数据驱动的模型。采用SHAP分析来量化每个特征的贡献,提高模型的透明度。在单条件和多条件设置下对公共数据集的验证表明,所提出的方法在不同的操作条件下提供了出色的性能,实现了高达95 %的稳定预测R²,推理延迟仅为2 ms,模型参数减少了约90 %。该解决方案可集成到数控系统的边缘计算平台中,特别适合实时性要求高的加工场景。它为智能工厂提供了轻量级、精确和高效的监控能力,同时有助于提高产品质量和制造效率。
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引用次数: 0
Towards perceptive assembly: An edge vision network-enabled augmented reality (AR) monitoring method for global shape and mechanical information in large aerospace components 面向感知装配:一种支持边缘视觉网络的增强现实(AR)监测方法,用于大型航空航天部件的全局形状和机械信息
IF 14.2 1区 工程技术 Q1 ENGINEERING, INDUSTRIAL Pub Date : 2025-12-10 DOI: 10.1016/j.jmsy.2025.11.017
Yang Zhang, Xu Wang, Jiacheng Cui, Yulin Jin, Qihang Chen, Yongkang Lu, Wei Liu
Real-time, high-fidelity, and interactive monitoring of global mechanical responses during the assembly of large-scale, flexible aerospace structures remains a critical and unresolved challenge. Here, we present a perceptive assembly framework that integrates a distributed edge vision network, physics-informed sparse sensing, and immersive augmented reality (AR) visualization to enable full-field structural state monitoring. A modular edge sensing system is deployed to achieve fast, high-precision measurement of distributed displacements across meter-scale components. To overcome view discontinuities, a hierarchical coordinate transformation pipeline is introduced for global registration under non-overlapping camera views. Building on sparse displacement data, we develop a constrained sensor optimization strategy that enables real-time reconstruction of global displacement and strain fields. Through HoloLens 2, the system provides intuitive AR overlays that deliver immersive, in-situ mechanical feedback during assembly. Validation experiments on composite panels demonstrate sub-millimeter reconstruction accuracy and real-time performance, significantly enhancing transparency and decision-making in the assembly process. This work establishes a scalable AR-based perception infrastructure for next-generation intelligent manufacturing of large aerospace structures.
在大型柔性航空航天结构装配过程中,实时、高保真和交互式的整体机械响应监测仍然是一个关键且未解决的挑战。在这里,我们提出了一个感知组装框架,该框架集成了分布式边缘视觉网络,物理信息稀疏感知和沉浸式增强现实(AR)可视化,以实现全场结构状态监测。部署了模块化边缘传感系统,以实现跨米尺度组件的分布式位移的快速、高精度测量。为了克服视图不连续的问题,在非重叠摄像机视图下引入了层次坐标变换流水线进行全局配准。基于稀疏位移数据,我们开发了一种约束传感器优化策略,可以实时重建全局位移和应变场。通过HoloLens 2,系统提供直观的AR叠加,在组装过程中提供身临其境的现场机械反馈。复合材料面板的验证实验证明了亚毫米级重构的精度和实时性,显著提高了装配过程的透明度和决策能力。这项工作为下一代大型航空航天结构的智能制造建立了可扩展的基于ar的感知基础设施。
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Journal of Manufacturing Systems
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