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 Machinery


Generative Modeling and Data Augmentation for Power System Production Simulation

arXiv.org Artificial Intelligence

As a key component of power system production simulation, load forecasting is critical for the stable operation of power systems. Machine learning methods prevail in this field. However, the limited training data can be a challenge. This paper proposes a generative model-assisted approach for load forecasting under small sample scenarios, consisting of two steps: expanding the dataset using a diffusion-based generative model and then training various machine learning regressors on the augmented dataset to identify the best performer. The expanded dataset significantly reduces forecasting errors compared to the original dataset, and the diffusion model outperforms the generative adversarial model by achieving about 200 times smaller errors and better alignment in latent data distributions.


Optimization-Driven Design of Monolithic Soft-Rigid Grippers

arXiv.org Artificial Intelligence

Sim-to-real transfer remains a significant challenge in soft robotics due to the unpredictability introduced by common manufacturing processes such as 3D printing and molding. These processes often result in deviations from simulated designs, requiring multiple prototypes before achieving a functional system. In this study, we propose a novel methodology to address these limitations by combining advanced rapid prototyping techniques and an efficient optimization strategy. Firstly, we employ rapid prototyping methods typically used for rigid structures, leveraging their precision to fabricate compliant components with reduced manufacturing errors. Secondly, our optimization framework minimizes the need for extensive prototyping, significantly reducing the iterative design process. The methodology enables the identification of stiffness parameters that are more practical and achievable within current manufacturing capabilities. The proposed approach demonstrates a substantial improvement in the efficiency of prototype development while maintaining the desired performance characteristics. This work represents a step forward in bridging the sim-to-real gap in soft robotics, paving the way towards a faster and more reliable deployment of soft robotic systems.


Digital Twin-Empowered Voltage Control for Power Systems

arXiv.org Artificial Intelligence

Emerging digital twin technology has the potential to revolutionize voltage control in power systems. However, the state-of-the-art digital twin method suffers from low computational and sampling efficiency, which hinders its applications. To address this issue, we propose a Gumbel-Consistency Digital Twin (GC-DT) method that enhances voltage control with improved computational and sampling efficiency. First, the proposed method incorporates a Gumbel-based strategy improvement that leverages the Gumbel-top trick to enhance non-repetitive sampling actions and reduce the reliance on Monte Carlo Tree Search simulations, thereby improving computational efficiency. Second, a consistency loss function aligns predicted hidden states with actual hidden states in the latent space, which increases both prediction accuracy and sampling efficiency. Experiments on IEEE 123-bus, 34-bus, and 13-bus systems demonstrate that the proposed GC-DT outperforms the state-of-the-art DT method in both computational and sampling efficiency.


Robotic Wire Arc Additive Manufacturing with Variable Height Layers

arXiv.org Artificial Intelligence

--Robotic wire arc additive manufacturing has been widely adopted due to its high deposition rates and large print volume relative to other metal additive manufacturing processes. For complex geometries, printing with variable height within layers offers the advantage of producing overhangs without the need for support material or geometric decomposition. This approach has been demonstrated for steel using precomputed robot speed profiles to achieve consistent geometric quality. In contrast, aluminum exhibits a bead geometry that is tightly coupled to the temperature of the previous layer, resulting in significant changes to the height of the deposited material at different points in the part. This paper presents a closed-loop approach to correcting for variations in the height of the deposited material between layers. We use an IR camera mounted on a separate robot to track the welding flame and estimate the height of deposited material. The robot velocity profile is then updated to account for the error in the previous layer and the nominal planned height profile while factoring in process and system constraints. Implementation of this framework showed significant improvement over the open-loop case and demonstrated robustness to inaccurate model parameters.


Data-Driven, Parameterized Reduced-order Models for Predicting Distortion in Metal 3D Printing

arXiv.org Artificial Intelligence

In Laser Powder Bed Fusion (LPBF), the applied laser energy produces high thermal gradients that lead to unacceptable final part distortion. Accurate distortion prediction is essential for optimizing the 3D printing process and manufacturing a part that meets geometric accuracy requirements. This study introduces data-driven parameterized reduced-order models (ROMs) to predict distortion in LPBF across various machine process settings. We propose a ROM framework that combines Proper Orthogonal Decomposition (POD) with Gaussian Process Regression (GPR) and compare its performance against a deep-learning based parameterized graph convolutional autoencoder (GCA). The POD-GPR model demonstrates high accuracy, predicting distortions within $\pm0.001mm$, and delivers a computational speed-up of approximately 1800x.


GenTact Toolbox: A Computational Design Pipeline to Procedurally Generate Context-Driven 3D Printed Whole-Body Tactile Skins

arXiv.org Artificial Intelligence

Abstract-- Developing whole-body tactile skins for robots remains a challenging task, as existing solutions often prioritize modular, one-size-fits-all designs, which, while versatile, fail to account for the robot's specific shape and the unique demands of its operational context. In this work, we introduce the GenTact Toolbox, a computational pipeline for creating versatile whole-body tactile skins tailored to both robot shape and application domain. Our pipeline includes procedural mesh generation for conforming to a robot's topology, task-driven simulation to refine sensor distribution, and multi-material 3D printing for shape-agnostic fabrication. This work represents a shift from "one-size-fits-all" tactile sensors toward context-driven, highly adaptable designs that can be customized for a wide range of robotic systems and applications. Whole-body tactile skins are sensors designed to give a robot the sense of touch over the full integration levels because it requires manual assembly and surface of its body.


Development of CPS Platform for Autonomous Construction

arXiv.org Artificial Intelligence

In recent years, labor shortages due to the declining birthrate and aging population have become significant challenges at construction sites in developed countries, including Japan. To address these challenges, we are developing an open platform called ROS2-TMS for Construction, a Cyber-Physical System (CPS) for construction sites, to achieve both efficiency and safety in earthwork operations. In ROS2-TMS for Construction, the system comprehensively collects and stores environmental information from sensors placed throughout the construction site. Based on these data, a real-time virtual construction site is created in cyberspace. Then, based on the state of construction machinery and environmental conditions in cyberspace, the optimal next actions for actual construction machinery are determined, and the construction machinery is operated accordingly. In this project, we decided to use the Open Platform for Earthwork with Robotics and Autonomy (OPERA), developed by the Public Works Research Institute (PWRI) in Japan, to control construction machinery from ROS2-TMS for Construction with an originally extended behavior tree. In this study, we present an overview of OPERA, focusing on the newly developed navigation package for operating the crawler dump, as well as the overall structure of ROS2-TMS for Construction as a Cyber-Physical System (CPS). Additionally, we conducted experiments using a crawler dump and a backhoe to verify the aforementioned functionalities.


Multi-Robot Scan-n-Print for Wire Arc Additive Manufacturing

arXiv.org Artificial Intelligence

Robotic Wire Arc Additive Manufacturing (WAAM) is a metal additive manufacturing technology, offering flexible 3D printing while ensuring high quality near-net-shape final parts. However, WAAM also suffers from geometric imprecision, especially for low-melting-point metal such as aluminum alloys. In this paper, we present a multi-robot framework for WAAM process monitoring and control. We consider a three-robot setup: a 6-dof welding robot, a 2-dof trunnion platform, and a 6-dof sensing robot with a wrist-mounted laser line scanner measuring the printed part height profile. The welding parameters, including the wire feed rate, are held constant based on the materials used, so the control input is the robot path speed. The measured output is the part height profile. The planning phase decomposes the target shape into slices of uniform height. During runtime, the sensing robot scans each printed layer, and the robot path speed for the next layer is adjusted based on the deviation from the desired profile. The adjustment is based on an identified model correlating the path speed to change in height. The control architecture coordinates the synchronous motion and data acquisition between all robots and sensors. Using a three-robot WAAM testbed, we demonstrate significant improvements of the closed loop scan-n-print approach over the current open loop result on both a flat wall and a more complex turbine blade shape.


Enhancing LLMs for Power System Simulations: A Feedback-driven Multi-agent Framework

arXiv.org Artificial Intelligence

The integration of experimental technologies with large language models (LLMs) is transforming scientific research, positioning AI as a versatile research assistant rather than a mere problem-solving tool. In the field of power systems, however, managing simulations -- one of the essential experimental technologies -- remains a challenge for LLMs due to their limited domain-specific knowledge, restricted reasoning capabilities, and imprecise handling of simulation parameters. To address these limitations, we propose a feedback-driven, multi-agent framework that incorporates three proposed modules: an enhanced retrieval-augmented generation (RAG) module, an improved reasoning module, and a dynamic environmental acting module with an error-feedback mechanism. Validated on 69 diverse tasks from Daline and MATPOWER, this framework achieves success rates of 93.13% and 96.85%, respectively, significantly outperforming the latest LLMs (ChatGPT 4o and o1-preview), which achieved a 27.77% success rate on standard simulation tasks and 0% on complex tasks. Additionally, our framework also supports rapid, cost-effective task execution, completing each simulation in approximately 30 seconds at an average cost of 0.014 USD for tokens. Overall, this adaptable framework lays a foundation for developing intelligent LLM-based assistants for human researchers, facilitating power system research and beyond.


Joint-Space Control of a Structurally Elastic Humanoid Robot

arXiv.org Artificial Intelligence

In this work, the joint-control strategy is presented for the humanoid robot, PANDORA, whose structural components are designed to be compliant. As opposed to contemporary approaches which design the elasticity internal to the actuator housing, PANDORA's structural components are designed to be compliant under load or, in other words, structurally elastic. To maintain the rapid design benefit of additive manufacturing, this joint control strategy employs a disturbance observer (DOB) modeled from an ideal elastic actuator. This robust controller treats the model variation from the structurally elastic components as a disturbance and eliminates the need for system identification of the 3D printed parts. This enables mechanical design engineers to iterate on the 3D printed linkages without requiring consistent tuning from the joint controller. Two sets of hardware results are presented for validating the controller. The first set of results are conducted on an ideal elastic actuator testbed that drives an unmodeled, 1 DoF weighted pendulum with a 10 kg mass. The results support the claim that the DOB can handle significant model variation. The second set of results is from a robust balancing experiment conducted on the 12 DoF lower body of PANDORA. The robot maintains balance while an operator applies 50 N pushes to the pelvis, where the actuator tracking results are presented for the left leg.