With the advancements in 3D printing technologies, it is extremely important that the quality of 3D printed objects, and dimensional accuracies should meet the customer's specifications. Various factors during metal printing affect the printed parts' quality, including the power quality, the printing stage parameters, the print part's location inside the print bed, the curing stage parameters, and the metal sintering process. With the large data gathered from HP's MetJet printing process, AI techniques can be used to analyze, learn, and effectively infer the printed part quality metrics, as well as assist in improving the print yield. In-situ thermal sensing data captured by printer-installed thermal sensors contains the part thermal signature of fusing layers. Such part thermal signature contains a convoluted impact from various factors. In this paper, we use a multimodal thermal encoder network to fuse data of a different nature including the video data vectorized printer control data, and exact part thermal signatures with a trained encoder-decoder module. We explored the data fusing techniques and stages for data fusing, the optimized end-to-end model architecture indicates an improved part quality prediction accuracy.

Metal Sintering is a necessary step for Metal Injection Molded parts and binder jet such as HP's metal 3D printer. The metal sintering process introduces large deformation varying from 25 to 50% depending on the green part porosity. In this paper, we use a graph-based deep learning approach to predict the part deformation, which can speed up the deformation simulation substantially at the voxel level. Running a well-trained Metal Sintering inferencing engine only takes a range of seconds to obtain the final sintering deformation value. The tested accuracy on example complex geometry achieves 0.7um mean deviation for a 63mm testing part.

Origami designs and structures have been widely used in many fields, such as morphing structures, robotics, and metamaterials. However, the design and fabrication of origami structures rely on human experiences and skills, which are both time and labor-consuming. In this paper, we present a rapid design and fabrication method for string-driven origami structures and robots. We developed an origami design software to generate desired crease patterns based on analytical models and Evolution Strategies (ES). Additionally, the software can automatically produce 3D models of origami designs. We then used a dual-material 3D printer to fabricate those wrapping-based origami structures with the required mechanical properties. We utilized Twisted String Actuators (TSAs) to fold the target 3D structures from flat plates. To demonstrate the capability of these techniques, we built and tested an origami crawling robot and an origami robotic arm using 3D-printed origami structures driven by TSAs.

Industrial robotic applications such as spraying, welding, and additive manufacturing frequently require fast, accurate, and uniform motion along a 3D spatial curve. To increase process throughput, some manufacturers propose a dual-robot setup to overcome the speed limitation of a single robot. Industrial robot motion is programmed through waypoints connected by motion primitives (Cartesian linear and circular paths and linear joint paths at constant Cartesian speed). The actual robot motion is affected by the blending between these motion primitives and the pose of the robot (an outstretched/close to singularity pose tends to have larger path-tracking errors). Choosing the waypoints and the speed along each motion segment to achieve the performance requirement is challenging. At present, there is no automated solution, and laborious manual tuning by robot experts is needed to approach the desired performance. In this paper, we present a systematic three-step approach to designing and programming a dual-robot system to optimize system performance. The first step is to select the relative placement between the two robots based on the specified relative motion path. The second step is to select the relative waypoints and the motion primitives. The final step is to update the waypoints iteratively based on the actual relative motion. Waypoint iteration is first executed in simulation and then completed using the actual robots. For performance measures, we use the mean path speed subject to the relative position and orientation constraints and the path speed uniformity constraint. We have demonstrated the effectiveness of this method with ABB and FANUC robots on two challenging test curves. The performance improvement over the current industrial practice baseline is over 300%. Compared to the optimized single-arm case that we have previously reported, the improvement is over 14%.

For autonomous crane lifting, optimal trajectories of the crane are required as reference inputs to the crane controller to facilitate feedforward control. Reducing the unactuated payload motion is a crucial issue for under-actuated tower cranes with spherical pendulum dynamics. The planned trajectory should be optimal in terms of both operating time and energy consumption, to facilitate optimum output spending optimum effort. This article proposes an anti-swing tower crane trajectory planner that can provide time-energy optimal solutions for the Computer-Aided Lift Planning (CALP) system developed at Nanyang Technological University, which facilitates collision-free lifting path planning of robotized tower cranes in autonomous construction sites. The current work introduces a trajectory planning module to the system that utilizes the geometric outputs from the path planning module and optimally scales them with time information. Firstly, analyzing the non-linear dynamics of the crane operations, the tower crane is established as differentially flat. Subsequently, the multi-objective trajectory optimization problems for all the crane operations are formulated in the flat output space through consideration of the mechanical and safety constraints. Two multi-objective evolutionary algorithms, namely Non-dominated Sorting Genetic Algorithm (NSGA-II) and Generalized Differential Evolution 3 (GDE3), are extensively compared via statistical measures based on the closeness of solutions to the Pareto front, distribution of solutions in the solution space and the runtime, to select the optimization engine of the planner. Finally, the crane operation trajectories are obtained via the corresponding planned flat output trajectories. Studies simulating real-world lifting scenarios are conducted to verify the effectiveness and reliability of the proposed module of the lift planning system.

Deep learning based transient stability assessment (TSA) has achieved great success, yet the lack of interpretability hinders its industrial application. Although a great number of studies have tried to explore the interpretability of network solutions, many problems still remain unsolved: (1) the difference between the widely accepted power system knowledge and the generated interpretive rules is large, (2) the probability characteristics of the neural network have not been fully considered during generating the interpretive rules, (3) the cost of the trade-off between accuracy and interpretability is too heavy to take. To address these issues, an interpretable power system Transient Stability Assessment method with Expert guiding Neural-Regression-Tree (TSA-ENRT) is proposed. TSA-ENRT utilizes an expert guiding nonlinear regression tree to approximate the neural network prediction and the neural network can be explained by the interpretive rules generated by the tree model. The nonlinearity of the expert guiding nonlinear regression tree is endowed with the extracted knowledge from a simple two-machine three-bus power system, which forms an expert knowledge base and thus the generated interpretive rules are more consistent with human cognition. Besides, the expert guiding tree model can build a bridge between the interpretive rules and the probability prediction of neural network in a regression way. By regularizing the neural network with the average decision length of ENRT, the association of the neural network and tree model is constructed in the model training level which provides a better trade-off between accuracy and interpretability. Extensive experiments indicate the interpretive rules generated by the proposed TSA-ENRT are highly consistent with the neural network prediction and more agreed with human expert cognition.

Abstract--Machine learning (ML) methods are widely used most informative data points benefiting the downstream tasks in manufacturing applications, which usually require a large and mitigate the impact of low-quality data. We collected realworld amount of training data. However, data collection needs extensive in-situ monitoring data of the same additive manufacturing costs and time investments in the manufacturing system, and process from three different machines, two of which are more data scarcity commonly exists. The proposed method is applied to train an industrial internet of things (IIoT), data-sharing is widely enabled anomaly detection model for those two similar machines, and the among multiple machines with similar functionality to augment entire data pool from all three machines is available for selecting the dataset for building ML models. The results demonstrated that our proposed designed similarly, the distribution mismatch inevitably exists in method outperforms the benchmark methods by only requiring their data due to different working conditions, process parameters, 26% of labeled training samples. In addition, all selected data measurement noise, etc. However, the effective application samples are from machines with similar conditions, while the of ML methods is built upon the assumption that the training data from the different machines are prevented from misleading and testing data are sampled from the same distribution. In this work, we propose an Active Data-sharing (ADs) framework to ensure the quality of the shared data among multiple machines. Low-quality data here refers to data samples collected from machines/processes different from the target one.

We describe DeepMachining, a deep learning-based AI system for online prediction of machining errors of lathe machine operations. We have built and evaluated DeepMachining based on manufacturing data from factories. Specifically, we first pretrain a deep learning model for a given lathe machine's operations to learn the salient features of machining states. Then, we fine-tune the pretrained model to adapt to specific machining tasks. We demonstrate that DeepMachining achieves high prediction accuracy for multiple tasks that involve different workpieces and cutting tools. To the best of our knowledge, this work is one of the first factory experiments using pre-trained deep-learning models to predict machining errors of lathe machines.

We present HiRA-Pro, a novel procedure to align, at high spatio-temporal resolutions, multimodal signals from real-world processes and systems that exhibit diverse transient, nonlinear stochastic dynamics, such as manufacturing machines. It is based on discerning and synchronizing the process signatures of salient kinematic and dynamic events in these disparate signals. HiRA-Pro addresses the challenge of aligning data with sub-millisecond phenomena, where traditional timestamp, external trigger, or clock-based alignment methods fall short. The effectiveness of HiRA-Pro is demonstrated in a smart manufacturing context, where it aligns data from 13+ channels acquired during 3D-printing and milling operations on an Optomec-LENS MTS 500 hybrid machine. The aligned data is then voxelized to generate 0.25 second aligned data chunks that correspond to physical voxels on the produced part. The superiority of HiRA-Pro is further showcased through case studies in additive manufacturing, demonstrating improved machine learning-based predictive performance due to precise multimodal data alignment. Specifically, testing classification accuracies improved by almost 35% with the application of HiRA-Pro, even with limited data, allowing for precise localization of artifacts. The paper also provides a comprehensive discussion on the proposed method, its applications, and comparative qualitative analysis with a few other alignment methods. HiRA-Pro achieves temporal-spatial resolutions of 10-1000 us and 100 um in order to generate datasets that register with physical voxels on the 3D-printed and milled part. These resolutions are at least an order of magnitude finer than the existing alignment methods that employ individual timestamps, statistical correlations, or common clocks, which achieve precision of hundreds of milliseconds.

Load frequency control (LFC) is widely employed in power systems to stabilize frequency fluctuation and guarantee power quality. However, most existing LFC methods rely on accurate power system modeling and usually ignore the nonlinear characteristics of the system, limiting controllers' performance. To solve these problems, this paper proposes a model-free LFC method for nonlinear power systems based on deep deterministic policy gradient (DDPG) framework. The proposed method establishes an emulator network to emulate power system dynamics. After defining the action-value function, the emulator network is applied for control actions evaluation instead of the critic network. Then the actor network controller is effectively optimized by estimating the policy gradient based on zeroth-order optimization (ZOO) and backpropagation algorithm. Simulation results and corresponding comparisons demonstrate the designed controller can generate appropriate control actions and has strong adaptability for nonlinear power systems.