Early fault vibration signals from rolling bearings are typically nonlinear, non-stationary, and heavily obscured by background noise, which severely impedes the accurate extraction of fault features. To overcome the limitations of traditional stochastic resonance (SR)—specifically the small-parameter restriction for high-frequency signals and the subjectivity in parameter selection—this paper proposes an adaptive SR envelope spectroscopy method based on particle swarm optimization (PSO) and local mean decomposition (LMD). First, a variable-scale transformation is introduced to compress the high-frequency fault signals into the effective frequency band required by the adiabatic approximation theory. Second, utilizing the global search capability of PSO, the potential well parameters of the bistable system are adaptively optimized by maximizing the output signal-to-noise ratio (SNR), thereby achieving optimal matching between the nonlinear system and the input signal. Finally, the enhanced signal is decomposed by LMD, and the sensitive components are selected for envelope spectrum analysis to identify fault characteristics. Experimental validation using the Case Western Reserve University bearing dataset demonstrates that the proposed method effectively amplifies weak fault signals under strong noise conditions, exhibiting superior feature extraction accuracy and noise robustness compared to traditional methods.

Existing studies on multi-vessel formations rarely combine physically based models of ship–ship hydrodynamic interaction with online formation control, so that energy benefits are typically assessed offline or only approximated through artificial potentials. This paper addresses this gap by embedding a reduced-order, hydrodynamics-aware resistance model into a hierarchical formation control framework for multi vessel systems. A three degree of freedom interaction model is incorporated into the cost function, enabling the supervisory controller to adaptively optimize inter ship spacing and formation geometry in a speed dependent and hydrodynamics aware manner. The lower level MPC ensures accurate trajectory tracking and stability under the guidance of the top level optimization. Four simulation studies are conducted to evaluate the proposed method. The platooning formation is first analyzed as a reference, followed by the triangular formation, which achieves balanced tracking performance and stability. The echelon formation is then examined, demonstrating significant energy savings in medium to high speed regimes while maintaining yaw stability. Finally, an unconstrained optimization scenario is explored, where the system autonomously adapts its geometry without prescribed patterns, revealing emergent energy efficient and stable arrangements across different speed ranges. Results show that the proposed approach not only reduces resistance and improves energy efficiency but also enhances formation adaptability and robustness under varying operating conditions. These findings provide new insights into hydrodynamics aware cooperative control and the development of energy conscious fleet management strategies for future maritime transportation.

Segregation of the ferrous burden during blast furnace (BF) charging can cause uneven layer formation at the furnace throat, reducing bed permeability and disrupting gas–solid interaction. This study applies a discrete element method (DEM) model to the industrial-scale BF charging system (from the skip car to top hopper discharge) to examine segregation under real operating conditions. The model includes the full ferrous mixture (pellets, sinter, lump ore, and nut coke) and the real-scale geometries. A reference case representing current practice is analysed in detail and compared with systematically varied case studies. The results show that segregation generally decreases from the skip car to the top hopper due to partial remixing, but strong segregation is still observed. Lump ore and nut coke exhibit the strongest segregation, while pellets remain the least segregated. The order of pellets and sinter in the weighing bunkers strongly influences their segregation patterns, whereas variations in the sinter particle size distribution (PSD) and particle shape have only limited effects. The insights from this study provide a basis for developing practical strategies to mitigate segregation in industrial BF charging.

In blast furnace ironmaking, a mixture of iron ore pellets and sinter is charged in layers at the furnace top, with particle velocities reaching up to ∼10 m/s at the stock surface. The inherent differences in particle size, shape, and density between pellets and sinter pose challenges for maintaining a uniform mixture during this high-velocity charging, leading to segregation and uneven material distribution. This non-uniformity can negatively affect furnace efficiency and stability. Understanding segregation during charging is therefore crucial for optimizing the ironmaking process. The Discrete Element Method (DEM) can offer valuable insights, provided that the model parameters are calibrated and verified. This study presents a calibrated DEM model for a pellet–sinter mixture with a 50–50 mass ratio of both components. A novel high-velocity laboratory setup was used to simultaneously measure five different key performance indicators (KPIs) related to flow and packing behavior at various discharge heights, corresponding to different flow velocities. Calibration was performed at the highest flow velocity, representative of actual blast furnace conditions. The process involved creating response surface models for each KPI and using a multi-objective optimization approach with a desirability function to determine the model parameters. A step-wise calibration strategy was employed, first optimizing pellet and sinter interaction parameters individually, followed by calibration of the pellet–sinter interaction parameters. This approach proved effective, as the calibrated model accurately reproduced experimental data. Results also suggest that the calibration outcome is flow-invariant in this setup, with the model successfully predicting flow and packing behavior at lower discharge heights.

The inland waterway transport sector is facing increasingly stringent legislation to reduce emissions and improve energy efficiency. Speed planning has the potential to provide logistically compliant, energy-efficient, and emission-reducing voyages for inland vessels. However, current speed planning methods do not consider PM and NO_x emissions, nor do they consider alternative power systems to internal combustion engines (ICE) and full electric systems. These omissions have led to a lack of clarity on the impact of speed planning on the emission profile of inland vessels and the impact of alternative power systems on energy consumption. In this paper we propose a validated speed planning method that considers the emission profile (CO₂, PM₁₀, and NO_x) and different engine types for inland vessels in an leg-based speed planning approach while taking into account varying fairway water depth and speed. Through a use case we show that the vessel can achieve a 7.26% energy, 5.37% CO₂ and fuel, 3.85% NO_x, and 6.77% PM₁₀ reduction while maintaining the same arrival time; showing a distinct difference of this method compared to slow steaming. We also find that CO₂, NO_x, PM₁₀, and energy are not directly proportional when making speed adjustments. Finally, we analyze the adverse effects of emission control areas and emission limits on the energy consumption and arrival times of vessels with non-zero emissions propulsion.

Accurate prediction of mill load parameters is crucial to improving grinding efficiency and saving energy. Traditional prediction models have challenges such as poor interpretability, low prediction efficiency and differences in data distribution. This study innovatively proposed a multi-task prediction model that integrates physical information and domain adaptation. By constructing a physical-data-driven hybrid model, the physical relationship between mill load parameters is embedded into the model as prior knowledge to improve the prediction accuracy of the model. At the same time, multi-task learning is used to predict the material-to-ball volume ratio and the pulp density at the same time, which improves efficiency and reduces repetitive work. The domain adaptation method is introduced to ensure that the model maintains stable prediction performance when the data distribution changes. Laboratory ball mill data verification shows that the proposed model not only improves the prediction accuracy, but also adapts well to variable working conditions, showing significant superiority.

To address the limitations in time–frequency feature representation of shearer arm gear faults and the issues of parameter redundancy and low training efficiency in standard convolutional neural networks (CNNs), this study proposes a diagnostic method based on an improved S-transform and a Depthwise Separable Convolutional Neural Network (DSCNN). First, the improved S-transform is employed to perform time–frequency analysis on the vibration signals, converting the original one-dimensional signals into two-dimensional time–frequency images to fully preserve the fault characteristics of the gear. Then, a neural network model combining standard convolution and depthwise separable convolution is constructed for fault identification. The experimental dataset includes five gear conditions: tooth deficiency, tooth breakage, tooth wear, tooth crack, and normal. The performance of various frequency-domain and time-frequency methods—Wavelet Transform, Fourier Transform, S-transform, and Gramian Angular Field (GAF)—is compared using the same network model. Furthermore, Grad-CAM is applied to visualize the responses of key convolutional layers, highlighting the regions of interest related to gear fault features. Finally, four typical CNN architectures are analyzed and compared: Deep Convolutional Neural Network (DCNN), InceptionV3, Residual Network (ResNet), and Pyramid Convolutional Neural Network (PCNN). Experimental results demonstrate that frequency–domain representations consistently outperform raw time-domain signals in fault diagnosis tasks. Grad-CAM effectively verifies the model’s accurate focus on critical fault features. Moreover, the proposed method achieves high classification accuracy while reducing both training time and the number of model parameters.

Digital twins and visual monitoring of conveyor systems require accurate digital models of dynamic bulk material flows, but existing methods struggle to achieve both speed and precision. This study develops a rapid online method to reconstruct dynamic bulk material flows on conveyor belts. First, a standardized online reconstruction scheme using visual detection of material flow contour lines is presented. Then, a feature detection algorithm is proposed to extract more refined points from laser line skeleton to accelerate the reconstruction process. An iterative-filtering interpolation algorithm that generates smooth interframe point clouds is introduced to improve mesh quality. Experimental results demonstrate that our method outperforms traditional corner detection-based reconstruction techniques in feature point detection, accuracy, mesh quality, and runtime performance. This research provides a practical solution for material handling digitalization, promoting the advancement of conveyor system digital twins and potentially improving operational efficiency and predictive maintenance in bulk material handling industries.

The accuracy and stability of robotic systems are significantly influenced by joint clearances, especially in precision applications like optical mirror polishing. This study focuses on a 5-DOF (Degree of Freedom) parallel manipulator designed for optical mirror polishing. The study conducts dynamic modeling by incorporating prismatic joint clearance and examines the resulting dynamic response. Previous studies on dynamic modeling have primarily focused on planar mechanisms with rotational or ball joint clearances, whereas research on parallel manipulators with spatial prismatic joint clearances remains limited. This study introduces a comprehensive dynamic modeling framework for parallel manipulators with prismatic joint clearance, utilizing the Lagrange multiplier method (LMD). First, the prismatic joint models of the guideway and slider in the parallel manipulator are simplified, enabling the determination of different contact states and the calculation of friction and contact forces for various contact types. Second, the dynamic equations of the parallel manipulator are derived by establishing system constraint equations. Finally, the dynamic responses of various clearance-related factors are determined through a combination of theoretical calculations and ADAMS simulations. This study provides a framework for modeling the dynamics of parallel manipulators with prismatic joint gaps, offering valuable insights into the design and control of high-precision robotic systems.

To address the challenges of extracting rolling bearing degradation information and the insufficient performance of conventional convolutional networks, this paper proposes a rolling bearing degradation state identification method based on the improved monopulse feature extraction and a one-dimensional dilated residual convolutional neural network (1D-DRCNN). First, the fault pulse envelope waveform features are extracted through phase scanning and synchronous averaging, and a two-stage grid search strategy is employed to achieve FCC calibration. Subsequently, a 1D-DRCNN model is constructed to identify rolling bearing degradation states under different working conditions. The experimental study collects the vibration signals of nine degradation states, including the different sizes of inner and outer ring local faults as well as normal conditions, to comparatively analyze the proposed method’s rapid calibration capability and feature extraction quality. Furthermore, t-SNE visualization is utilized to analyze the network response to bearing degradation features. Finally, the degradation state identification performance across different network architectures is compared in pattern recognition experiments. The results show that the proposed improved feature extraction method significantly reduces the iterative calibration computational burden while effectively extracting local fault degradation information and overcoming complex working condition influence. The established 1D-DRCNN model integrates the advantages of dilated convolution and residual connections and can deeply mine sensitive features and accurately identify different bearing degradation states. The overall recognition accuracy can reach 97.33%.

Calibration of discrete element method (DEM) models is crucial for the realistic simulation of granular materials. However, it remains a challenging task, especially for multi-component mixtures due to their higher complexity and larger number of parameters involved. This study presents a systematic and computationally efficient calibration framework designed to address these challenges, focusing on pellet-sinter mixtures, as a representative case of two-component mixtures commonly used in blast furnace steelmaking. The framework integrates sensitivity analysis, machine learning-based surrogate modelling with adaptive sampling, and genetic algorithm-driven optimisation techniques to minimise the number of required DEM simulations. Using this approach, we achieved a high-accuracy surrogate model (R² = 0.95) for seven DEM parameters with only 110 data points, highlighting the efficiency and robustness of the framework. These parameters were successfully calibrated with a relative error of less than 2 %. Moreover, the calibrated parameters for the base case (i.e., 50–50 pellet-sinter mass ratio) remained valid across different mass ratios and layering orders, eliminating the need for recalibration. Overall, the proposed framework offers a reliable, cost-effective, and adaptable solution for DEM calibration of two-component mixtures. Its flexibility and efficiency make it a promising tool for extending to more complex systems, facilitating the development of DEM models for a wide range of industrial applications involving granular mixtures.

This article presents an innovative visual method for measuring material mass online by quantified conveyor belt deformation with deep learning, which offers a noncontact and safe alternative to traditional pressure- and radioactivity-based weighing techniques. The correlation between the belt deformation and the carried material mass is further investigated through finite element simulations. Then, a visual weighing method by belt deformation is proposed, comprising a calibration algorithm to construct a measurement model using a gated recurrent unit-based network, and an online measurement algorithm to calculate material mass with the trained network. Finally, a case study is presented to analyze the effect of different dimension configurations and networks. The results validate that the proposed method attains a notable accuracy and is suitable for high-velocity conveyor environments. The demonstrated benefits signify an advancement in visual perception of materials, enabling a new approach for intelligent operation and monitoring in material handling field.

Wet ball mill plays a key role in the grinding process, and its load state directly affects production efficiency, energy consumption and product quality. Aiming at the problems of poor interpretability of pure data-driven models and complex modeling of mechanism models under variable working conditions, a hybrid prediction model DAPINN combining deep learning and physical information is proposed. By introducing the deep hidden physics model principle and using the characteristics of neural networks to approximate arbitrary functions to simulate complex physical partial differential equations, the physical interpretability of the model is enhanced. At the same time, the model introduces domain adaptation technology to improve the prediction accuracy and generalization of the model under variable working conditions. Experiments were conducted on data collected from a small ball mill in the laboratory. The experimental results show that under variable working conditions, the prediction accuracy of the DAPINN model is better than that of the pure data-driven model.

Multiagent reinforcement learning (RL) training is usually difficult and time-consuming due to mutual interference among agents. Safety concerns make an already difficult training process even harder. This study proposes a safe adaptive policy transfer RL approach for multiagent cooperative control. Specifically, a pioneer and follower off-policy policy transfer learning (PFOPT) method is presented to help follower agents acquire knowledge and experience from a single well-trained pioneer agent. Notably, the designed approach can transfer both the policy representation and sample experience provided by the pioneer policy in the off-policy learning. More importantly, the proposed method can adaptively adjust the learning weight of prior experience and exploration according to the Wasserstein distance between the policy probability distributions of the pioneer and the follower. Case studies show that the distributed agents trained by the proposed method can complete a collaborative task and acquire the maximum rewards while minimizing the violation of constraints. Moreover, the proposed method can also achieve satisfactory performance in terms of learning speed and success rate.

The manufacturing extremity and surface convergence efficiency of high-precision, large optical free-form surfaces produced through computer-controlled optical surfacing and industrial robotics face significant challenges. These challenges arise from task-related stiffness deficiencies of industrial robots and dynamic uncertainties in the tool influence function, which severely impact low spatial frequency (LSF) errors and the clarity of imaging in high-resolution optical systems. To address these issues and achieve consistent optical polishing outcomes, we propose a novel polishing dwell time modification framework. This framework is based on the spatial compliance field linked to the specific machining task and the Frenet frame, dynamically adjusting the polishing dwell time to mitigate LSF errors and enhance surface convergence efficiency. The efficacy of this modification framework was evaluated through a series of multilevel gradient experiments in Sim2Real machining environments. The experimental results show a significant reduction in low-frequency spatial errors, underscoring the potential of our approach to improve precision in high-resolution optical systems.

The stiffness model plays a crucial role in improving the performance of robots. During the operation of an underground mining cable-driven parallel robot (UMCDPR), insufficient stiffness can lead to motion instability, posing safety hazards. Additionally, the complexity of the underground mining environment, which is often accompanied by external disturbances, leads to offline stiffness indices failing when used underground as an optimal criterion. To address these problems, this article proposes a robust optimal stiffness direction (ROSD) index grounded in Rayleigh's theorem, which is characterized by three primary features: (1) strong robustness, (2) suitable for multi-trajectory optimization engineering problems, and (3) global visualization. Firstly, considering the influence of pulleys on the end-effector, the stiffness model of UMCDPR is modified. Secondly, a trajectory optimization method utilizing ROSD is introduced, incorporating the Kepler Conjecture and stiffness model correction. Finally, the characteristics of ROSD are validated through numerical simulations. Based on two numerical simulations, the ROSD index can serve as an optimal criterion for guiding stiffness optimization of UMCDPR. Furthermore, an optimal stiffness trajectory is obtained to meet the task objectives of UMCDPR.

Deep-sea mining activities have lately attracted growing interest. Recent research has led to the development of a hydraulic–mechanical hybrid vertical lifting system for deep-sea mining. Predicting the resistance of vertical plug flow in this system is critical for its engineering design. In this paper, an analytical model was developed to determine the resistance of vertical plug flow in a hydraulic–mechanical hybrid vertical lifting system in the presence of coarse particles. A recent model of the stress transmission ratio for pneumatic plug flow was verified and applied to the proposed model of resistance. In addition, it is considered that the co-existence of turbulent and laminar flows in the fluid flowing through the particles provides the necessary pressure gradient. A test setup was built to measure the resistance of vertical plug flow with/without water, along with varying particle diameters, plug lengths, and lifting speeds. Comparisons between the predictions of the analytical model and experimental measurements showed that they deviated by less than 13.6% on average. This shows that the proposed analytical model can be used to predict the resistance of vertical plug flow involving coarse particles.