Hasil untuk "Industrial safety. Industrial accident prevention"

Rebin Saleh, Khanh Pham Dinh, Balázs Villányi et al.

Industrial IoT predictive maintenance requires systems capable of real-time anomaly detection without sacrificing interpretability or demanding excessive computational resources. Traditional approaches rely on static, offline-trained models that cannot adapt to evolving operational conditions, while LLM-based monolithic systems demand prohibitive memory and latency, rendering them impractical for on-site edge deployment. We introduce SEMAS, a self-evolving hierarchical multi-agent system that distributes specialized agents across Edge, Fog, and Cloud computational tiers. Edge agents perform lightweight feature extraction and pre-filtering; Fog agents execute diversified ensemble detection with dynamic consensus voting; and Cloud agents continuously optimize system policies via Proximal Policy Optimization (PPO) while maintaining asynchronous, non-blocking inference. The framework incorporates LLM-based response generation for explainability and federated knowledge aggregation for adaptive policy distribution. This architecture enables resource-aware specialization without sacrificing real-time performance or model interpretability. Empirical evaluation on two industrial benchmarks (Boiler Emulator and Wind Turbine) demonstrates that SEMAS achieves superior anomaly detection performance with exceptional stability under adaptation, sustains prediction accuracy across evolving operational contexts, and delivers substantial latency improvements enabling genuine real-time deployment. Ablation studies confirm that PPO-driven policy evolution, consensus voting, and federated aggregation each contribute materially to system effectiveness. These findings indicate that resource-aware, self-evolving 1multi-agent coordination is essential for production-ready industrial IoT predictive maintenance under strict latency and explainability constraints.

Jiyan Qiu, Lyulin Kuang, Guan Wang et al.

Vehicle aerodynamics optimization has become critical for automotive electrification, where drag reduction directly determines electric vehicle range and energy efficiency. Traditional approaches face an intractable trade-off: computationally expensive Computational Fluid Dynamics (CFD) simulations requiring weeks per design iteration, or simplified models that sacrifice production-grade accuracy. While machine learning offers transformative potential, existing datasets exhibit fundamental limitations -- inadequate mesh resolution, missing vehicle components, and validation errors exceeding 5% -- preventing deployment in industrial workflows. We present DrivAerStar, comprising 12,000 industrial-grade automotive CFD simulations generated using STAR-CCM+${}^\unicode{xAE}$ software. The dataset systematically explores three vehicle configurations through 20 Computer Aided Design (CAD) parameters via Free Form Deformation (FFD) algorithms, including complete engine compartments and cooling systems with realistic internal airflow. DrivAerStar achieves wind tunnel validation accuracy below 1.04% -- a five-fold improvement over existing datasets -- through refined mesh strategies with strict wall $y^+$ control. Benchmarks demonstrate that models trained on this data achieve production-ready accuracy while reducing computational costs from weeks to minutes. This represents the first dataset bridging academic machine learning research and industrial CFD practice, establishing a new standard for data-driven aerodynamic optimization in automotive development. Beyond automotive applications, DrivAerStar demonstrates a paradigm for integrating high-fidelity physics simulations with Artificial Intelligence (AI) across engineering disciplines where computational constraints currently limit innovation.

Hanlin Tian, Yuxiang Feng, Wei Zhou et al.

Traffic accidents, especially at intersections, are a major road safety concern. Previous research has extensively studied intersection-related accidents, but the effect of building-induced visibility restrictions at intersections on accident rates has been under-explored, particularly in urban contexts. Using OpenStreetMap data, the UK's geographic and accident datasets, and the UK Traffic Count Dataset, we formulated a novel approach to estimate accident risk at intersections. This method factors in the area visible to drivers, accounting for views blocked by buildings - a distinctive aspect in traffic accident analysis. Our findings reveal a notable correlation between the road visible percentage and accident frequency. In the model, the coefficient for "road visible percentage" is 1.7450, implying a strong positive relationship. Incorporating this visibility factor enhances the model's explanatory power, with increased R-square values and reduced AIC and BIC, indicating a better data fit. This study underscores the essential role of architectural layouts in road safety and suggests that urban planning strategies should consider building-induced visibility restrictions. Such consideration could be an effective approach to mitigate accident rates at intersections. This research opens up new avenues for innovative, data-driven urban planning and traffic management strategies, highlighting the importance of visibility enhancements for safer roads.

Lesley Wheat, Martin v. Mohrenschildt, Saeid Habibi

Machine learning offers potential solutions to current issues in industrial systems in areas such as quality control and predictive maintenance, but also faces unique barriers in industrial applications. An ongoing challenge is extreme class imbalance, primarily due to the limited availability of faulty data during training. This paper presents a comprehensive evaluation of anomaly detection algorithms using a problem-agnostic simulated dataset that reflects real-world engineering constraints. Using a synthetic dataset with a hyper-spherical based anomaly distribution in 2D and 10D, we benchmark 14 detectors across training datasets with anomaly rates between 0.05% and 20% and training sizes between 1 000 and 10 000 (with a testing dataset size of 40 000) to assess performance and generalization error. Our findings reveal that the best detector is highly dependant on the total number of faulty examples in the training dataset, with additional healthy examples offering insignificant benefits in most cases. With less than 20 faulty examples, unsupervised methods (kNN/LOF) dominate; but around 30-50 faulty examples, semi-supervised (XGBOD) and supervised (SVM/CatBoost) detectors, we see large performance increases. While semi-supervised methods do not show significant benefits with only two features, the improvements are evident at ten features. The study highlights the performance drop on generalization of anomaly detection methods on smaller datasets, and provides practical insights for deploying anomaly detection in industrial environments.

Bowei Ning, Xuejun Zong, Kan He

Industrial control systems (ICS) are vital to modern infrastructure but increasingly vulnerable to cybersecurity threats, particularly through weaknesses in their communication protocols. This paper presents MALF (Multi-Agent LLM Fuzzing Framework), an advanced fuzzing solution that integrates large language models (LLMs) with multi-agent coordination to identify vulnerabilities in industrial control protocols (ICPs). By leveraging Retrieval-Augmented Generation (RAG) for domain-specific knowledge and QLoRA fine-tuning for protocol-aware input generation, MALF enhances fuzz testing precision and adaptability. The multi-agent framework optimizes seed generation, mutation strategies, and feedback-driven refinement, leading to improved vulnerability discovery. Experiments on protocols like Modbus/TCP, S7Comm, and Ethernet/IP demonstrate that MALF surpasses traditional methods, achieving a test case pass rate (TCPR) of 88-92% and generating more exception triggers (ETN). MALF also maintains over 90% seed coverage and Shannon entropy values between 4.2 and 4.6 bits, ensuring diverse, protocol-compliant mutations. Deployed in a real-world Industrial Attack-Defense Range for power plants, MALF identified critical vulnerabilities, including three zero-day flaws, one confirmed and registered by CNVD. These results validate MALF's effectiveness in real-world fuzzing applications. This research highlights the transformative potential of multi-agent LLMs in ICS cybersecurity, offering a scalable, automated framework that sets a new standard for vulnerability discovery and strengthens critical infrastructure security against emerging threats.

Andreas Mershin, Nikolas Stefanou, Adan Rotteveel et al.

Machine olfaction is rapidly emerging as a transformative capability, with applications spanning non-invasive medical diagnostics, industrial monitoring, agriculture, and security and defense. Recent advances in stabilizing mammalian olfactory receptors and integrating them into biophotonic and bioelectronic systems have enabled detection at near single-molecule resolution thus placing machines on par with trained detection dogs. As this technology converges with multimodal AI and distributed sensor networks imbued with embedded AI, it introduces a new, biochemical layer to a sensing ecosystem currently dominated by machine vision and audition. This review and industry roadmap surveys the scientific foundations, technological frontiers, and strategic applications of machine olfaction making the case that we are currently witnessing the rise of a new industry that brings with it a global chemosensory infrastructure. We cover exemplary industrial, military and consumer applications and address some of the ethical and legal concerns arising. We find that machine olfaction is poised to bring forth a planet-wide molecular awareness tech layer with the potential of spawning vast emerging markets in health, security, and environmental sensing via scent.

Sebastián Rojas-Innocenti, Enrique Baeyens, Alejandro Martín-Crespo et al.

This paper presents a scenario based robust optimization framework for short term energy scheduling in electricity intensive industrial plants, explicitly addressing uncertainty in planning decisions. The model is formulated as a two-stage Mixed Integer Linear Program (MILP) and integrates a hybrid scenario generation method capable of representing uncertain inputs such as electricity prices, renewable generation, and internal demand. A convex objective function combining expected and worst case operational costs allows for tunable risk aversion, enabling planners to balance economic performance and robustness. The resulting schedule ensures feasibility across all scenarios and supports coordinated use of industrial flexibility assets, including battery energy storage and shiftable production. To isolate the effects of market volatility, the framework is applied to a real world cement manufacturing case study considering only day-ahead electricity price uncertainty, with all other inputs treated deterministically. Results show improved resilience to forecast deviations, reduced cost variability, and more consistent operations. The proposed method offers a scalable and risk-aware approach for industrial flexibility planning under uncertainty.

Alejandro Mata Ali, Iñigo Perez Delgado, Aitor Moreno Fdez. de Leceta

In this paper we present a study of the applicability and feasibility of quantum-inspired algorithms and techniques in tensor networks for industrial environments and contexts, with a compilation of the available literature and an analysis of the use cases that may be affected by such methods. In addition, we explore the limitations of such techniques in order to determine their potential scalability.

Davide Allegro, Matteo Terreran, Stefano Ghidoni

In industrial scenarios, effective human-robot collaboration relies on multi-camera systems to robustly monitor human operators despite the occlusions that typically show up in a robotic workcell. In this scenario, precise localization of the person in the robot coordinate system is essential, making the hand-eye calibration of the camera network critical. This process presents significant challenges when high calibration accuracy should be achieved in short time to minimize production downtime, and when dealing with extensive camera networks used for monitoring wide areas, such as industrial robotic workcells. Our paper introduces an innovative and robust multi-camera hand-eye calibration method, designed to optimize each camera's pose relative to both the robot's base and to each other camera. This optimization integrates two types of key constraints: i) a single board-to-end-effector transformation, and ii) the relative camera-to-camera transformations. We demonstrate the superior performance of our method through comprehensive experiments employing the METRIC dataset and real-world data collected on industrial scenarios, showing notable advancements over state-of-the-art techniques even using less than 10 images. Additionally, we release an open-source version of our multi-camera hand-eye calibration algorithm at https://github.com/davidea97/Multi-Camera-Hand-Eye-Calibration.git.

Firas Bayram, Bestoun S. Ahmed, Erik Hallin

Within data-driven artificial intelligence (AI) systems for industrial applications, ensuring the reliability of the incoming data streams is an integral part of trustworthy decision-making. An approach to assess data validity is data quality scoring, which assigns a score to each data point or stream based on various quality dimensions. However, certain dimensions exhibit dynamic qualities, which require adaptation on the basis of the system's current conditions. Existing methods often overlook this aspect, making them inefficient in dynamic production environments. In this paper, we introduce the Adaptive Data Quality Scoring Operations Framework, a novel framework developed to address the challenges posed by dynamic quality dimensions in industrial data streams. The framework introduces an innovative approach by integrating a dynamic change detector mechanism that actively monitors and adapts to changes in data quality, ensuring the relevance of quality scores. We evaluate the proposed framework performance in a real-world industrial use case. The experimental results reveal high predictive performance and efficient processing time, highlighting its effectiveness in practical quality-driven AI applications.

Jinbo Wen, Jiawen Kang, Dusit Niyato et al.

Industrial Cyber-Physical Systems (ICPSs) are an integral component of modern manufacturing and industries. By digitizing data throughout product life cycles, Digital Twins (DTs) in ICPSs enable a shift from current industrial infrastructures to intelligent and adaptive infrastructures. Thanks to data process capability, Generative Artificial Intelligence (GenAI) can drive the construction and update of DTs to improve predictive accuracy and prepare for diverse smart manufacturing. However, mechanisms that leverage Industrial Internet of Things (IIoT) devices to share sensing data for DT construction are susceptible to adverse selection problems. In this paper, we first develop a GenAI-driven DT architecture in ICPSs. To address the adverse selection problem caused by information asymmetry, we propose a contract theory model and develop a sustainable diffusion-based soft actor-critic algorithm to identify the optimal feasible contract. Specifically, we leverage dynamic structured pruning techniques to reduce parameter numbers of actor networks, allowing sustainability and efficient implementation of the proposed algorithm. Numerical results demonstrate the effectiveness of the proposed scheme and the algorithm, enabling efficient DT construction and updates to monitor and manage ICPSs.

Ángel Luis Perales Gómez, Enrique Tomás Martínez Beltrán, Pedro Miguel Sánchez Sánchez et al.

Industry 4.0 has brought numerous advantages, such as increasing productivity through automation. However, it also presents major cybersecurity issues such as cyberattacks affecting industrial processes. Federated Learning (FL) combined with time-series analysis is a promising cyberattack detection mechanism proposed in the literature. However, the fact of having a single point of failure and network bottleneck are critical challenges that need to be tackled. Thus, this article explores the benefits of the Decentralized Federated Learning (DFL) in terms of cyberattack detection and resource consumption. The work presents TemporalFED, a software module for detecting anomalies in industrial environments using FL paradigms and time series. TemporalFED incorporates three components: Time Series Conversion, Feature Engineering, and Time Series Stationary Conversion. To evaluate TemporalFED, it was deployed on Fedstellar, a DFL framework. Then, a pool of experiments measured the detection performance and resource consumption in a chemical gas industrial environment with different time-series configurations, FL paradigms, and topologies. The results showcase the superiority of the configuration utilizing DFL and Semi-Decentralized Federated Learning (SDFL) paradigms, along with a fully connected topology, which achieved the best performance in anomaly detection. Regarding resource consumption, the configuration without feature engineering employed less bandwidth, CPU, and RAM than other configurations.

Federico Rollo, Gennaro Raiola, Nikolaos Tsagarakis et al.

Robots with a high level of autonomy are increasingly requested by smart industries. A way to reduce the workers' stress and effort is to optimize the working environment by taking advantage of autonomous collaborative robots. A typical task for Human-Robot Collaboration (HRC) which improves the working setup in an industrial environment is the \textit{"bring me an object please"} where the user asks the collaborator to search for an object while he/she is focused on something else. As often happens, science fiction is ahead of the times, indeed, in the \textit{Iron Man} movie, the robot \textit{Dum-E} helps its creator, \textit{Tony Stark}, to create its famous armours. The ability of the robot to comprehend the semantics of the environment and engage with it is valuable for the human execution of more intricate tasks. In this work, we reproduce this operation to enable a mobile robot with manipulation and grasping capabilities to leverage its geometric and semantic understanding of the environment for the execution of the \textit{Bring Me} action, thereby assisting a worker autonomously. Results are provided to validate the proposed workflow in a simulated environment populated with objects and people. This framework aims to take a step forward in assistive robotics autonomy for industries and domestic environments.

JunKyu Jang, Eugene Hwang, Sung-Hyuk Park

Identifying defects in the images of industrial products has been an important task to enhance quality control and reduce maintenance costs. In recent studies, industrial anomaly detection models were developed using pre-trained networks to learn nominal representations. To employ the relative positional information of each pixel, we present \textit{\textbf{N-pad}}, a novel method for anomaly detection and segmentation in a one-class learning setting that includes the neighborhood of the target pixel for model training and evaluation. Within the model architecture, pixel-wise nominal distributions are estimated by using the features of neighboring pixels with the target pixel to allow possible marginal misalignment. Moreover, the centroids from clusters of nominal features are identified as a representative nominal set. Accordingly, anomaly scores are inferred based on the Mahalanobis distances and Euclidean distances between the target pixel and the estimated distributions or the centroid set, respectively. Thus, we have achieved state-of-the-art performance in MVTec-AD with AUROC of 99.37 for anomaly detection and 98.75 for anomaly segmentation, reducing the error by 34\% compared to the next best performing model. Experiments in various settings further validate our model.

Chao Zhang, Sthitie Bom

With the proliferation of IoT devices, the distributed control systems are now capturing and processing more sensors at higher frequency than ever before. These new data, due to their volume and novelty, cannot be effectively consumed without the help of data-driven techniques. Deep learning is emerging as a promising technique to analyze these data, particularly in soft sensor modeling. The strong representational capabilities of complex data and the flexibility it offers from an architectural perspective make it a topic of active applied research in industrial settings. However, the successful applications of deep learning in soft sensing are still not widely integrated in factory control systems, because most of the research on soft sensing do not have access to large scale industrial data which are varied, noisy and incomplete. The results published in most research papers are therefore not easily reproduced when applied to the variety of data in industrial settings. Here we provide manufacturing data sets that are much larger and more complex than public open soft sensor data. Moreover, the data sets are from Seagate factories on active service with only necessary anonymization, so that they reflect the complex and noisy nature of real-world data. We introduce a variance weighted multi-headed auto-encoder classification model that fits well into the high-dimensional and highly imbalanced data. Besides the use of weighting or sampling methods to handle the highly imbalanced data, the model also simultaneously predicts multiple outputs by exploiting output-supervised representation learning and multi-task weighting.

Anna-Pia Lohfink, Simon D. Duque Anton, Hans Dieter Schotten et al.

Operation technology networks, i.e. hard- and software used for monitoring and controlling physical/industrial processes, have been considered immune to cyber attacks for a long time. A recent increase of attacks in these networks proves this assumption wrong. Several technical constraints lead to approaches to detect attacks on industrial processes using available sensor data. This setting differs fundamentally from anomaly detection in IT-network traffic and requires new visualization approaches adapted to the common periodical behavior in OT-network data. We present a tailored visualization system that utilizes inherent features of measurements from industrial processes to full capacity to provide insight into the data and support triage analysis by laymen and experts. The novel combination of spiral plots with results from anomaly detection was implemented in an interactive system. The capabilities of our system are demonstrated using sensor and actuator data from a real-world water treatment process with introduced attacks. Exemplary analysis strategies are presented. Finally, we evaluate effectiveness and usability of our system and perform an expert evaluation.

Niels Hendrik Fliedner, Dimitri Block, Uwe Meier

Novel industrial wireless applications require wideband, real-time channel characterization due to complex multipath propagation. Rapid machine motion leads to fast time variance of the channel's reflective behavior, which must be captured for radio channel characterization. Additionally, inhomogeneous radio channels demand highly flexible measurements. Existing approaches for radio channel measurements either lack flexibility or wide-band, real-time performance with fast time variance. In this paper, we propose a correlative channel sounding approach utilizing a software-defined architecture. The approach enables real-time, wide-band measurements with fast time variance immune to active interference. The desired performance is validated with a demanding industrial application example.

Gurvan Le Guernic, Benoit Combemale, José A. Galindo

Many project-specific languages, including in particular filtering languages, are defined using non-formal specifications written in natural languages. This leads to ambiguities and errors in the specification of those languages. This paper reports on an industrial experiment on using a tool-supported language specification framework (K) for the formal specification of the syntax and semantics of a filtering language having a complexity similar to those of real-life projects. This experimentation aims at estimating, in a specific industrial setting, the difficulty and benefits of formally specifying a packet filtering language using a tool-supported formal approach.

Sarmen Keshishzadeh, Arjan J. Mooij, Jozef Hooman

A domain specific language (DSL) abstracts from implementation details and is aligned with the way domain experts reason about a software component. The development of DSLs is usually centered around a grammar and transformations that generate implementation code or analysis models. The semantics of the language is often defined implicitly and in terms of a transformation to implementation code. In the presence of multiple transformations from the DSL, the correctness of the generated artifacts with respect to the semantics of the DSL is a relevant issue. We show that a formal semantics is essential for checking the correctness of the generated artifacts. We exploit the formal semantics in an industrial project and use formal techniques based on equivalence checking and model-based testing for validating the correctness of the generated artifacts. We report about our experience with this approach in an industrial development project.

Sarmen Keshishzadeh, Arjan J. Mooij, Jozef Hooman

A domain specific language (DSL) abstracts from implementation details and is aligned with the way domain experts reason about a software component. The development of DSLs is usually centered around a grammar and transformations that generate implementation code or analysis models. The semantics of the language is often defined implicitly and in terms of a transformation to implementation code. In the presence of multiple transformations from the DSL, the consistency of the generated artifacts with respect to the semantics of the DSL is a relevant issue. We show that a formal semantics is essential for checking the consistency between the generated artifacts. We exploit the formal semantics in an industrial project and use formal techniques based on equivalence checking and model-based testing for consistency checking. We report about our experience with this approach in an industrial development project.