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Achieving long-term stable optimization in complex industrial processes (CIPs) is notoriously challenging due to their unclear physical/chemical reaction mechanisms, fluctuating operating conditions, and stringent regulatory constraints. A significant gap persists between promising artificial intelligence (AI) algorithms developed in academic research and their practical deployment in industrial actual processes. To bridge this gap, this article introduces the AI- and security-empowered end–edge–cloud modular platform (AISE3CMP). It consists of four systems such as whole-process AI modeling, end-side basic loop and AI-assisted decision-making, edge-side security isolation and AI control, and cloud-side security transmission and AI optimization. The data isolation collection module of the platform was deployed at a municipal solid waste incineration (MSWI) power plant in Beijing, where it collected multimodal data from real-world industrial sites. The platform’s functionality and effectiveness were validated through the software and hardware developed at the Smart Environmental Protection Beijing Laboratory. The experimental results show efficient and reliable signal transmission between the systems, confirming the platform’s ability to meet the computational demands of AI-based optimization and control algorithms. Compared to previous platforms, AISE3CMP features a dual-security transmission mechanism to mitigate data exchange risks and a modular design to enhance integration efficiency. To the best of our knowledge, this platform is the first prototype of a portable, end-to-end cloud platform with a dual-layer security mechanism for CIPs. While the platform effectively addresses data transmission security, further strengthening of cloud-side data protection and ensuring operational safety on the end-side remain significant challenges for the future. Additionally, utilizing this architecture to enable multi-region and multi-plant data sharing, in order to develop industry-specific large language models, represents a key research direction.

Automated ventilator controllers have the potential to simplify oxygen and carbon dioxide management for trauma. In the pre-hospital or military medicine environment, trauma care can be required for prolonged periods by personnel with limited ventilator management training. As such, there is a need for closed-loop control systems that can adapt ventilator management to a complex, ever-changing medical environment. Here, we present a novel hardware-in-loop test platform for the independent troubleshooting and evaluation of oxygen and carbon dioxide automated ventilator management capabilities. The oxygen management system provides an analogue blood oxygen signal that is responsive to the fraction of inspired oxygen and the peak inspiratory pressure ventilator settings. A tested oxygenation controller successfully reached the target oxygen saturation within 5 min. The carbon dioxide removal system integrates with commercial ventilator technology and mimics carbon dioxide generation, lung compliance, and airway resistance while providing an end-tidal carbon dioxide level that is responsive to changes in the tidal volume and respiratory rate settings. A test mechanical ventilator controller was able to regulate EtCO2 regardless of the starting value within 10 min. This highlights the system’s functionality and provides proof-of-concept demonstrations for how the hardware-in-loop test platforms can be used for evaluating closed-loop controller technologies.

Hemorrhage remains a leading cause of death, with early goal-directed fluid resuscitation being a pillar of mortality prevention. While closed-loop resuscitation can potentially benefit this effort, development of these systems is resource-intensive, making it a challenge to compare infusion controllers and respective hardware within a range of physiologically relevant hemorrhage scenarios. Here, we present a hardware-in-loop automated testbed for resuscitation controllers (HATRC) that provides a simple yet robust methodology to evaluate controllers. HATRC is a flow-loop benchtop system comprised of multiple PhysioVessels which mimic pressure-volume responsiveness for different resuscitation infusates. Subject variability and infusate switching were integrated for more complex testing. Further, HATRC can modulate fluidic resistance to mimic arterial resistance changes after vasopressor administration. Finally, all outflow rates are computer-controlled, with rules to dictate hemorrhage, clotting, and urine rates. Using HATRC, we evaluated a decision-table controller at two sampling rates with different hemorrhage scenarios. HATRC allows quantification of twelve performance metrics for each controller configuration and scenario, producing heterogeneous results and highlighting the need for controller evaluation with multiple hemorrhage scenarios. In conclusion, HATRC can be used to evaluate closed-loop controllers through user-defined hemorrhage scenarios while rating their performance. Extensive controller troubleshooting using HATRC can accelerate product development and subsequent translation.

Due to the features of complicated test environment, variable parameters, and limited conditions in real car experiment, it has proposed a Hardware-in-Loop test platform for Fuel Cell System (Short for FCS) based on hardware of NI PXI and software of NI Labview to fuel cell vehicle. According to FCS’s control strategy, I/O signal map, CAN communication and sensor characteristics, it has designed the hardware configuration, software program, test interface, and rapidly made validation to control logic and fault diagnosis of Fuel Cell System’s Electronic Control Unit (Short for FCU). The experiment result shows that this test platform is effective for FCU control logic validation, system status monitor, fault injection, fault tracing, and it can shorten the vehicle research and development cycle, reduce the development cost, optimize test environment and promise safety for test engineer. This test platform will make good effect to vehicle electrical system development and supply reference for vehicle test.

Due to the features of complicated test environment, variable parameters, and limited conditions in real car experiment, it has proposed a Hardware-in-Loop test platform in this paper for Hydrogen Management System (Short for HMS) based on hardware of NI PXI and software of NI Labview to plug-in fuel cell vehicle. According to HMS’s control strategy, I/O signal map, CAN communication and sensor characteristics, it has designed the hardware configuration, software program, test interface, and rapidly made validation to control logic and fault diagnosis of Hydrogen Management Unit (Short for HMU). The experiment result shows that this test platform is effective for HMU control logic validation, system status monitor, fault injection, fault tracing, and it can shorten the vehicle research and development cycle, reduce the development cost, optimize test environment and promise safety for test engineer. This test platform will make good effect to vehicle electrical system development and supply reference for vehicle test.

Path-tracking control occupies a critical role within autonomous driving systems, directly reflecting vehicle motion and impacting both safety and user experience. However, the ever-changing vehicle states, road conditions, and delay characteristics of control systems present new challenges to the path tracking of autonomous vehicles, thereby limiting further enhancements in performance. This article introduces a path-tracking controller, time-varying gain-scheduled path-tracking controller with delay compensation (TGDC), which utilizes a linear parameter-varying system and optimal control theory to account for time-varying vehicle states, road conditions, and steering control system delays. Subsequently, a polytopic-based path-tracking model is applied to design the control law, reducing the computational complexity of TGDC. To evaluate the effectiveness and real-time capability of TGDC, it was tested under a series of complex conditions using a hardware-in-the-loop platform. The results demonstrate that through the polytopic-based path-tracking model and delay compensation strategy in TGDC, it can effectively enhance path-tracking performance with minimal computational load, even under conditions of parameter variability and control delays.

This paper introduces a sensorless nonlinear control scheme based on feedback linearization control (FLC) of an open-end winding five-phase induction motor (OeW-5PIM) topology fed by a dual neutral point clamped (NPC) inverter. The suggested sensorless control is combined with the sliding mode (SM) controller to improve the dynamic performance (i.e., rising time, overshoot, etc.) of the studied motor. Furthermore, a stator-current-based model reference adaptive system (SC-MRAS) estimator is designed for the estimation of the rotor flux and the motor speed. In parallel, to enhance the robustness of the designed sensorless control against motor parameter changes, an adaptive estimation method is suggested to estimate the rotor and stator resistances during low-speed ranges. The estimation method of motor resistances is associated with the suggested sensorless control to further improve the speed estimation accuracy and minimize the speed estimation error. Finally, the effectiveness and correctness of the suggested control with the examined estimators are validated in real-time implementation using a hardware-in-the-loop (HIL) based on the dSpace 1103 board.

In order to improve the obstacle avoidance control performance and anti-interference ability of a stubble breaking device of a no-tillage planter, a back-propagation neural network (BPNN)-optimized fuzzy active disturbance rejection control (ADRC) controller was designed to optimize the control performance of a servo motor. Firstly, a negative feedback mathematical model was established for the obstacle avoidance control system. Then, the nonlinear state error feedback (NLSEF) parameters in the fuzzy ADRC were intelligently optimized by the BPNN algorithm. In this way, a fuzzy ADRC controller based on BPNN optimization was formed to optimize the control process of a servo motor. Matlab/Simulink (R2022b) was used to complete the simulation model design and parameter adjustment. Consequently, the response time was 0.089 s using the BPNN fuzzy ADRC controller, which was shorter than the 0.303 s of the ADRC controller and the 0.100 s of the fuzzy ADRC controller. The overshoot was 0.1% using a BPNN fuzzy ADRC controller, which was less than the 2% of the ADRC controller and the 1% of the fuzzy ADRC controller. After noise signal interference was introduced into the control system, the regression steady state time of the BPNN fuzzy ADRC controller was 0.22 s, which was shorter than the 0.56 s of the ADRC controller and the 0.45 s of the fuzzy ADRC controller. A hardware-in-the-loop simulation experimental platform of the obstacle avoidance control system was constructed. The experiment results show that the servo motor control system has a fast dynamic response, small steady-state error and strong anti-interference ability for obstacle avoidance at the target height. Then, the control system error was within the allowable range. The servo motor control effect of the BPNN fuzzy ADRC was better than the ADRC and fuzzy ADRC. This optimized servo motor control method can provide a reference for improving the obstacle avoidance control effect problem of no-tillage seeders in stubble breaking operations on rocky desertification areas.