Complicated first principles modelling and controller synthesis can be prohibitively slow and expensive for high-mix, low-volume products such as hydraulic excavators. Instead, in a data-driven approach, recorded trajectories from the real system can be used to train local model networks (LMNs), for which feedforward controllers are derived via feedback linearization. However, previous works required LMNs without zero dynamics for feedback linearization, which restricts the model structure and thus modelling capacity of LMNs. In this paper, we overcome this restriction by providing a criterion for when feedback linearization of LMNs with zero dynamics yields a valid controller. As a criterion we propose the bounded-input bounded-output stability of the resulting controller. In two additional contributions, we extend this approach to consider measured disturbance signals and multiple inputs and outputs. We illustrate the effectiveness of our contributions in a hydraulic excavator control application with hardware experiments. To this end, we train LMNs from recorded, noisy data and derive feedforward controllers used as part of a leveling assistance system on the excavator. In our experiments, incorporating disturbance signals and multiple inputs and outputs enhances tracking performance of the learned controller. A video of our experiments is available at https://youtu.be/lrrWBx2ASaE.

Quadruped robots that individual researchers can build by themselves are crucial for expanding the scope of research due to their high scalability and customizability. These robots must be easily ordered and assembled through e-commerce or DIY methods, have a low number of components for easy maintenance, and possess durability to withstand experiments in diverse environments. Various quadruped robots have been developed so far, but most robots that can be built by research institutions are relatively small and made of plastic using 3D printers. These robots cannot withstand experiments in external environments such as mountain trails or rubble, and they will easily break with intense movements. Although there is the advantage of being able to print parts by yourself, the large number of components makes replacing broken parts and maintenance very cumbersome. Therefore, in this study, we develop a metal quadruped robot MEVIUS, that can be constructed and assembled using only materials ordered through e-commerce. We have considered the minimum set of components required for a quadruped robot, employing metal machining, sheet metal welding, and off-the-shelf components only. Also, we have achieved a simple circuit and software configuration. Considering the communication delay due to its simple configuration, we experimentally demonstrate that MEVIUS, utilizing reinforcement learning and Sim2Real, can traverse diverse rough terrains and withstand outside experiments. All hardware and software components can be obtained from https://github.com/haraduka/mevius.

Powder bed fusion (PBF) is an emerging metal additive manufacturing (AM) technology that enables rapid fabrication of complex geometries. However, defects such as pores and balling may occur and lead to structural unconformities, thus compromising the mechanical performance of the part. This has become a critical challenge for quality assurance as the nature of some defects is stochastic during the process and invisible from the exterior. To address this issue, digital twin (DT) using machine learning (ML)-based modeling can be deployed for AM process monitoring and control. Melt pool is one of the most commonly observed physical phenomena for process monitoring, usually by high-speed cameras. Once labeled and preprocessed, the melt pool images are used to train ML-based models for DT applications such as process anomaly detection and print quality evaluation. Nonetheless, the reusability of DTs is restricted due to the wide variability of AM settings, including AM machines and monitoring instruments. The performance of the ML models trained using the dataset collected from one setting is usually compromised when applied to other settings. This paper proposes a knowledge transfer pipeline between different AM settings to enhance the reusability of AM DTs. The source and target datasets are collected from the National Institute of Standards and Technology and National Cheng Kung University with different cameras, materials, AM machines, and process parameters. The proposed pipeline consists of four steps: data preprocessing, data augmentation, domain alignment, and decision alignment. Compared with the model trained only using the source dataset, this pipeline increased the melt pool anomaly detection accuracy by 31% without any labeled training data from the target dataset.

This paper presents the concept of Industry 6.0, introducing the world's first fully automated production system that autonomously handles the entire product design and manufacturing process based on user-provided natural language descriptions. By leveraging generative AI, the system automates critical aspects of production, including product blueprint design, component manufacturing, logistics, and assembly. A heterogeneous swarm of robots, each equipped with individual AI through integration with Large Language Models (LLMs), orchestrates the production process. The robotic system includes manipulator arms, delivery drones, and 3D printers capable of generating assembly blueprints. The system was evaluated using commercial and open-source LLMs, functioning through APIs and local deployment. A user study demonstrated that the system reduces the average production time to 119.10 minutes, significantly outperforming a team of expert human developers, who averaged 528.64 minutes (an improvement factor of 4.4). Furthermore, in the product blueprinting stage, the system surpassed human CAD operators by an unprecedented factor of 47, completing the task in 0.5 minutes compared to 23.5 minutes. This breakthrough represents a major leap towards fully autonomous manufacturing.

Multilayer Perceptrons (MLPs) have long been a cornerstone in deep learning, known for their capacity to model complex relationships. Recently, Kolmogorov-Arnold Networks (KANs) have emerged as a compelling alternative, utilizing highly flexible learnable activation functions directly on network edges, a departure from the neuron-centric approach of MLPs. However, KANs significantly increase the number of learnable parameters, raising concerns about their effectiveness in data-scarce environments. This paper presents a comprehensive comparative study of MLPs and KANs from both algorithmic and experimental perspectives, with a focus on low-data regimes. We introduce an effective technique for designing MLPs with unique, parameterized activation functions for each neuron, enabling a more balanced comparison with KANs. Using empirical evaluations on simulated data and two real-world data sets from medicine and engineering, we explore the trade-offs between model complexity and accuracy, with particular attention to the role of network depth. Our findings show that MLPs with individualized activation functions achieve significantly higher predictive accuracy with only a modest increase in parameters, especially when the sample size is limited to around one hundred. For example, in a three-class classification problem within additive manufacturing, MLPs achieve a median accuracy of 0.91, significantly outperforming KANs, which only reach a median accuracy of 0.53 with default hyperparameters. These results offer valuable insights into the impact of activation function selection in neural networks.

This paper presents the development of the Auriga @Work robot, designed by the Robotics and Intelligent Automation Lab at Shahid Beheshti University, Department of Electrical Engineering, for the RoboCup 2024 competition. The robot is tailored for industrial applications, focusing on enhancing efficiency in repetitive or hazardous environments. It is equipped with a 4-wheel Mecanum drive system for omnidirectional mobility and a 5-degree-of-freedom manipulator arm with a custom 3D-printed gripper for object manipulation and navigation tasks. The robot's electronics are powered by custom-designed boards utilizing ESP32 microcontrollers and an Nvidia Jetson Nano for real-time control and decision-making. The key software stack integrates Hector SLAM for mapping, the A* algorithm for path planning, and YOLO for object detection, along with advanced sensor fusion for improved navigation and collision avoidance.

This paper introduces a novel Soft Acoustic Curvature (SAC) sensor. SAC incorporates integrated audio components and features an acoustic channel within a flexible structure. A reference acoustic wave, generated by a speaker at one end of the channel, propagates and is received by a microphone at the other channel's end. Our previous study revealed that acoustic wave energy dissipation varies with acoustic channel deformation, leading us to design a novel channel capable of large deformation due to bending. We then use Machine Learning (ML) models to establish a complex mapping between channel deformations and sound modulation. Various sound frequencies and ML models were evaluated to enhance curvature detection accuracy. The sensor, constructed using soft material and 3D printing, was validated experimentally, with curvature measurement errors remaining within 3.5 m-1 for a range of 0 to 60 m-1 curvatures. These results demonstrate the effectiveness of the proposed method for estimating curvatures. With its flexible structure, the SAC sensor holds potential for applications in soft robotics, including shape measurement for continuum manipulators, soft grippers, and wearable devices.

One of the main concerns in design and process planning for multi-axis additive and subtractive manufacturing is collision avoidance between moving objects (e.g., tool assemblies) and stationary objects (e.g., a part unified with fixtures). The collision measure for various pairs of relative rigid translations and rotations between the two pointsets can be conceptualized by a compactly supported scalar field over the 6D non-Euclidean configuration space. Explicit representation and computation of this field is costly in both time and space. If we fix $O(m)$ sparsely sampled rotations (e.g., tool orientations), computation of the collision measure field as a convolution of indicator functions of the 3D pointsets over a uniform grid (i.e., voxelized geometry) of resolution $O(n^3)$ via fast Fourier transforms (FFTs) scales as in $O(mn^3 \log n)$ in time and $O(mn^3)$ in space. In this paper, we develop an implicit representation of the collision measure field via deep neural networks (DNNs). We show that our approach is able to accurately interpolate the collision measure from a sparse sampling of rotations, and can represent the collision measure field with a small memory footprint. Moreover, we show that this representation can be efficiently updated through fine-tuning to more efficiently train the network on multi-resolution data, as well as accommodate incremental changes to the geometry (such as might occur in iterative processes such as topology optimization of the part subject to CNC tool accessibility constraints).

Interactable objects are ubiquitous in our daily lives. Recent advances in 3D generative models make it possible to automate the modeling of these objects, benefiting a range of applications from 3D printing to the creation of robot simulation environments. However, while significant progress has been made in modeling 3D shapes and appearances, modeling object physics, particularly for interactable objects, remains challenging due to the physical constraints imposed by inter-part motions. In this paper, we tackle the problem of physically plausible part completion for interactable objects, aiming to generate 3D parts that not only fit precisely into the object but also allow smooth part motions. To this end, we propose a diffusion-based part generation model that utilizes geometric conditioning through classifier-free guidance and formulates physical constraints as a set of stability and mobility losses to guide the sampling process. Additionally, we demonstrate the generation of dependent parts, paving the way toward sequential part generation for objects with complex part-whole hierarchies. Experimentally, we introduce a new metric for measuring physical plausibility based on motion success rates. Our model outperforms existing baselines over shape and physical metrics, especially those that do not adequately model physical constraints. We also demonstrate our applications in 3D printing, robot manipulation, and sequential part generation, showing our strength in realistic tasks with the demand for high physical plausibility.

Industry 4.0 has revolutionized manufacturing by driving digitalization and shifting the paradigm toward additive manufacturing (AM). Fused Deposition Modeling (FDM), a key AM technology, enables the creation of highly customized, cost-effective products with minimal material waste through layer-by-layer extrusion, posing a significant challenge to traditional subtractive methods. However, the susceptibility of material extrusion techniques to errors often requires expert intervention to detect and mitigate defects that can severely compromise product quality. While automated error detection and machine learning models exist, their generalizability across diverse 3D printer setups, firmware, and sensors is limited, and deep learning methods require extensive labeled datasets, hindering scalability and adaptability. To address these challenges, we present a process monitoring and control framework that leverages pre-trained Large Language Models (LLMs) alongside 3D printers to detect and address printing defects. The LLM evaluates print quality by analyzing images captured after each layer or print segment, identifying failure modes and querying the printer for relevant parameters. It then generates and executes a corrective action plan. We validated the effectiveness of the proposed framework in identifying defects by comparing it against a control group of engineers with diverse AM expertise. Our evaluation demonstrated that LLM-based agents not only accurately identify common 3D printing errors, such as inconsistent extrusion, stringing, warping, and layer adhesion, but also effectively determine the parameters causing these failures and autonomously correct them without any need for human intervention.