预测工具未来功能与疲劳寿命,实现循环工厂的智能再利用决策
Uncertainty Aware Functional Behavior Prediction and Material Fatigue Assessment for Circular Factory

- 融合力矩历史与深度学习,预测九项功能变量及其不确定性
- 同步评估转子疲劳损伤,实现材料与系统可靠性联合追踪
- 适合循环制造、设备健康管理与可持续生产场景
循环工厂中返厂产品具有异质性退化状态、使用历史和剩余能力,仅凭当前检测无法判断是否可再利用,因未来功能表现与部件完整性可能随新工况变化。现有故障预测与健康管理方法多针对固定工况或单一部件,且材料疲劳评估很少与系统级功能预测联动。本文以角磨机为例,提出一种实例化的可靠性工作流,结合不确定性感知的功能预测与部件级疲劳评估。该框架融合当前工具状态与近期力矩-扭矩使用窗口,通过卷积编码器提取主轴受力模式,以LSTM模型预测九个功能变量的高斯均值与方差。同时,相同载荷历史经有限元支持的应力重构,结合S-N/Miner损伤评估(含Haibach修正)与Paris裂纹扩展分析,生成输出轴疲劳信息。流式回放算法整合双分支,生成功能、材料与系统可靠性轨迹。留出测试显示九个输出平均2%容差精度达0.9652,热变量预测近乎完美,驱动电机电流与负载转速最具挑战,决定系数分别为0.9750与0.9924。扭矩历史对这些变量尤为关键,传统LSTM在短时序下优于GRU与xLSTM。可靠性校准对驱动电机电流最具信息量,预测与观测超越概率匹配良好。
原文摘要 · Abstract (English)
Returned products in circular factories re-enter production with heterogeneous degradation states, usage histories, and remaining capability. Reuse cannot be decided from the current inspection alone, because future function fulfillment and component integrity may evolve differently under the next service scenario. Existing PHM approaches support degradation prediction, but often target fixed operating conditions or isolated component benchmarks, while material-fatigue assessment is rarely linked to system-level functional prognosis. This paper addresses this gap for an angle grinder by combining uncertainty-aware functional prediction with component-level fatigue assessment in an instance-specific reliability workflow. The proposed framework combines the current tool state with recent force--torque usage windows. A convolutional encoder extracts loading patterns from spindle forces and shaft torque, and an LSTM backbone predicts nine functional variables as Gaussian mean and variance estimates. In parallel, the same loading history is translated into output-shaft fatigue information through finite-element-supported stress reconstruction, S--N/Miner damage evaluation with Haibach extension, and Paris-law crack-growth analysis. A streaming replay algorithm consolidates both branches into functional, material, and system reliability trajectories. Held-out tests show mean \(2\%\)-tolerance accuracy of 0.9652 across nine outputs. Thermal variables are predicted near-perfectly, while drive motor current and load speed remain the most demanding dynamic outputs, with \(R^2\) values of 0.9750 and 0.9924. Torque history is especially important for these variables, and the conventional LSTM outperforms GRU and xLSTM in the short-history setting. Reliability calibration is most informative for drive motor current, where predicted and observed exceedance probabilities ...
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