factory automation engineers

Abstract: In the context of Industry 4.0, predictive maintenance is essential to minimize unplanned downtime and ensure operational safety. In machining processes, drill jamming is a critical failure that compromises both workpiece quality and tool integrity. This work proposes an acoustic anomaly detection system using ultrasonic sensors to identify pre-failure patterns in Computer Numerical Control (CNC) machining. We release a public dataset of time- and frequency-domain acoustic features from 17 drills, and benchmark semi-supervised autoencoder-based normality modelling against supervised XGBoost classification using Leave-One-Drill-Out validation. The results demonstrate that the Autoencoder is highly effective for industrial safety, achieving a Recall of 1.00 and a consolidated F1-score of 0.81. Furthermore, the threshold-independent analysis shows that the Autoencoder better separates normal and pre-failure acoustic patterns, achieving a consolidated AUC of 0.8294, compared with 0.7559 for the supervised model under inter-tool covariate shift. In contrast, the supervised XGBoost achieved an average F1-score of 0.55 and failed to detect failures in some of the evaluated drills. The findings highlight that the ultrasonic spectrum provides a reliable window for identifying incipient mechanical instabilities, and the AE model offers a robust safety envelope by anticipating all jamming events across the tested drill bits.

Abstract: Genetic programming (GP) has been widely used to learn scheduling rules for dynamic flexible job shop scheduling (DFJSS). However, trained rules tend to only generalise to tasks of similar scales and distributions, and when task characteristics change, learned rules often suffer significant performance degradation. Moreover, fine-tuning pre-trained rules on new tasks often leads to catastrophic forgetting, where prior knowledge is lost. This motivates the need for GP methods that can adapt to new tasks while preserving past knowledge, leading to a lifelong learning paradigm. However, lifelong learning in GP for DFJSS remains largely under-explored. To address this gap, this paper proposes a surrogate-assisted GP method for lifelong learning to handle sequential heterogeneous DFJSS tasks with job or batch arrivals. The framework includes three key components: an adaptive two-stage training strategy to balance plasticity and stability, a task-similarity-based weighting mechanism to regulate knowledge reuse, and an improved surrogate model with distance constraints to enhance estimation accuracy. Experimental results show that the proposed method effectively mitigates catastrophic forgetting while maintaining strong adaptability, outperforming several compared methods and demonstrating the potential of lifelong GP in dynamic scheduling environments.

Abstract: Reinforcement learning (RL) has shown considerable promise for robotic decision-making, yet deploying multi-agent RL (MARL) on physical multi-robot systems in industrial environments remains challenging. This paper investigates the real-world applicability of decentralized MARL for multi-robot multi-machine tending. We propose Feature-fusion Multi-Agent Proximal Policy Optimization (FMAPPO), which fuses 2D LiDAR measurements with task-specific state information to enable safe decentralized multi-robot task assignment and navigation. A complete simulation-to-reality pipeline was developed using high-fidelity robotic simulation and ROS2 and deployed on physical mobile-manipulator platforms operating under realistic real-world conditions, with the robotic arms disabled during the experiments. We further investigate the sensitivity of the learned policy to command update frequency, an important consideration for real-world deployment. Comparative evaluation in simulation demonstrated that FMAPPO significantly outperformed state-of-the-art baselines with a large effect size, achieving improvements of 106\% and 21\% in parts delivery and 48\% and 11\% in parts collection over MAPPO and SMAPPO, respectively. FMAPPO also increased machine utilization by 31 and 10 percentage points, respectively, while reducing collisions by 18\% and 15\% and increasing the safety score by 14 and 6 percentage points compared with MAPPO and SMAPPO, respectively. Furthermore, real-world experiments demonstrated that the learned decentralized policies can coordinate multiple robots to service multiple machines while maintaining safe operation under real-world sensing and control constraints. Videos of the real-world experiment are available online https://anonymouspapers123.github.io/FMAPPO/.