Chao Liu

Chao Liu
Aston University · College of Engineering and Physical Sciences

PhD
CALL FOR PAPERS - Sensors - Special Issue on 'Advanced Sensing Technology and Data Analytics in Smart Manufacturing'.

About

46
Publications
71,478
Reads
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2,336
Citations
Citations since 2017
46 Research Items
2332 Citations
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Introduction
Lecturer in Digital Manufacturing at Aston University, UK. My research interests include Smart Manufacturing, Digital Twin, Industry 4.0, Cyber-Physical Production Systems (CPPS), Industrial Internet of Things (IIoT), big data analytics, Augmented Reality (AR), Machine Learning, Metal Additive Manufacturing, Ultra-Precision Machining, etc.
Additional affiliations
September 2020 - present
The Hong Kong Polytechnic University
Position
  • Professor (Assistant)
May 2019 - September 2020
Cardiff University
Position
  • Research Associate
Description
  • Working on H2020 project MANUELA.
February 2018 - May 2018
Technical University of Kosice - Technicka univerzita v Kosiciach
Position
  • Researcher
Education
October 2014 - November 2018
University of Auckland
Field of study
  • Mechanical Engineering

Publications

Publications (46)
Article
Full-text available
Nowadays, precision components have been extensively used in various industries such as biomedicine, photonics, and optics. To achieve nanometric surface roughness, high-precision polishing is mandatory. Compared with the conventional polishing techniques, the robot-assisted polishing has the advantages of flexible working ranges and low cost. Ther...
Article
The Cyber-Physical Machine Tool (CPMT) is a promising solution for the next generation of machine tool digitalization and servitization due to its excellent interconnection, intelligence, adaptability, and autonomy. The rapid development of next-generation information technologies, such as the Internet of Things (IoT) and artificial intelligence (A...
Article
Full-text available
The accurate diagnosis of the compound fault of industrial robots can be highly beneficial to maintenance management. In the actual noisy working environment of industrial robots, the mixed and feeble failure features are easy to be overwhelmed, which poses a major challenge for the industrial robot compound fault diagnosis. Meanwhile, in the exist...
Article
In practical machine fault diagnosis, the obtained data samples under faulty conditions are usually far less than those under normal conditions, resulting in a class-imbalanced dataset issue. The existing solutions for class-imbalanced scenarios include data-level and model-level strategies which are either subject to over-generalization or time-co...
Poster
Full-text available
Figure 4. Learning process of different algorithms; (a) policy gradient (PG), (b) trust region policy optimization (TRPO), and (c) proximal policy optimization (PPO). Figure 6. Gantt chart of operating state working with random policy Figure 7. Gantt chart of operating state working with optimal policy trained by the PPO algorithm Reward Function C...
Poster
Full-text available
https://www.mdpi.com/journal/sensors/special_issues/Data_Smart_Manufacturing
Article
Full-text available
Fluid Jet Polishing (FJP) is an Ultra-Precision Machining (UPM) technology for super-fine finishing of small and complex components. FJP has distinctive advantages compared to other polishing methods, including high polishing accuracy, no heat generation, no tool wear, applicability for various types of materials, and suitability for various freefo...
Article
Full-text available
With the rapid development of information technology, data-driven fault diagnosis has gained more and more attention because it provides a new way for enterprises to save costs. Considering that there are few abnormalities in equipment operation in actual industrial applications, it is still a challenge to implement data-driven fault diagnosis that...
Article
Bearing fault diagnosis is a critical and challenging task for prognostics and health management of motors. The ability to efficiently and accurately classify the fault categories based on sensor signals is the key to successful bearing fault diagnosis. Although various data-driven methods have been developed for fault diagnosis in recent years, au...
Article
Full-text available
Gears are the most important parts of rotating machinery and power transmission devices. When gears are engaged in meshing transmission, vibration will occur due to factors such as gear machining errors, meshing rigidity, and meshing impact. The traditional FxLMS algorithm, as a common active vibration algorithm, has been widely studied and applied...
Article
Cloud manufacturing represents a service-oriented manufacturing paradigm that allows ubiquitous and on-demand access to various customisable manufacturing services in the cloud. While a vast amount of research in cloud manufacturing has focused on high-level decision-making tasks, such as service composition and scheduling, the link between field-l...
Poster
Full-text available
Details can be found on RCIM journal website: https://www.sciencedirect.com/journal/robotics-and-computer-integrated-manufacturing/about/call-for-papers#special-issue-on-digitalization-and-servitization-of-machine-tools-in-the-era-of-industry-4-0
Article
Full-text available
Machine tools play a pivotal role in the manufacturing world since their performance significantly affects the product quality and production efficiency. In the era of Industry 4.0, machine tools are expected to have a higher level of accessibility, connectivity, intelligence, adaptivity, and autonomy. With the rapid development and application of...
Conference Paper
Material removal rate (MRR) plays a critical role in the operation of chemical mechanical planarization (CMP) process in the semiconductor industry. To date, many physics-based and data-driven approaches have been proposed to predict the MRR. Nevertheless, most of the existing methodologies neglect the potential source of its well-organized and und...
Article
Full-text available
Silicon nitride ceramic bearings are widely used for their excellent performance. However, due to their special manufacturing method, cracks will occur on ceramic ball surface, and this initial surface crack will propagate under the action of cyclic stress, which will lead to material spalling. This will greatly limit its service life in practical...
Article
Full-text available
The material removal rate (MRR) plays a critical role in the chemical mechanical planarization (CMP) process in the semiconductor industry. Many physics-based and data-driven approaches have been proposed to-date to predict the MRR. Nevertheless, most of them neglect the underlying equipment structure containing essential interaction mechanisms amo...
Article
Full-text available
Additive manufacturing (AM) has gained high research interests in the past but comes with some drawbacks, such as the difficulty to do in-situ quality monitoring. In this paper, deep learning is used on electron-optical images taken during the Electron Beam Melting (EBM) process to classify the quality of AM layers to achieve automatized quality as...
Poster
Full-text available
e aim of this Special Issue is to promote the accuracy of identication of initial faults in rotor systems and provide a communication platform for new ideas for intelligent diagnosis methods. We warmly welcome high-quality original research articles presenting newmethods, and reviewarticles stating recent developments and future directions.
Article
Full-text available
Metal Powder Bed Fusion (PBF) has been attracting an increasing attention as an emerging metal Additive Manufacturing (AM) technology. Despite its distinctive advantages compared to traditional subtractive manufacturing such as high design flexibility, short development time, low tooling cost, and low production waste, the inconsistent part quality...
Article
Full-text available
The application of intelligence to manufacturing has emerged as a compelling topic for researchers and industries around the world. However, different terminologies, namely Intelligent Manufacturing (IM) and Smart Manufacturing (SM), have been applied to what may be broadly characterized as a similar paradigm by some researchers and practitioners....
Article
To estimate the meshing frequencies of the gearbox online from its vibration signal, an adaptive notch filter with normalized lattice structure is proposed as estimator. The notch filter has high robustness and low estimation error due to the dynamic range of the node energies of the normalized lattice structure is minimal. A novel lattice recursiv...
Preprint
Full-text available
Pandemics like COVID-19 have created a spreading and ever-higher healthy threat to the humans in the manufacturing system which incurs severe disruptions and complex issues to industrial networks. The intelligent manufacturing (IM) systems are promising to create a safe working environment by using the automated manufacturing assets which are monit...
Article
Full-text available
Metal Additive Manufacturing (AM) has been attracting a continuously increasing attention due to its great advantages compared to traditional subtractive manufacturing in terms of higher design flexibility, shorter development time, lower tooling cost, and fewer production wastes. However, the lack of process robustness, stability and repeatability...
Conference Paper
Full-text available
Manufacturing is becoming smart with capabilities of self-awareness, autonomous decision-making, and adaptive excitation and collaboration. Standardization is a crucial enabler for achieving the required intelligence for smart manufacturing. Though a large number of efforts have been made to the development of manufacturing standards, there is stil...
Preprint
Full-text available
This paper reviews the recent development of Digital Twin technologies in manufacturing systems and processes, to analyze the connotation, application scenarios, and research issues of Digital Twin-driven smart manufacturing in the context of Industry 4.0. To understand Digital Twin and its future potential in manufacturing, we summarized the defin...
Article
Full-text available
With the wave of Industry 4.0, Digital Twin is attracting more and more attention world-wide. The term might have been coined some time ago, today the concept is increasingly being used in the field of smart manufacturing. Digital Twin provides advantages in different fields of manufacturing, such as production and design, remote diagnostics and se...
Article
Full-text available
Cyber-Physical Machine Tools (CPMT) represent a new generation of machine tools that are smarter, well connected, widely accessible, more adaptive and more autonomous. Development of CPMT requires standardized information modelling method and communication protocols for machine tools. This paper proposes a CPMT Platform based on OPC UA and MTConnec...
Conference Paper
Full-text available
Cyber-Physical Machine Tools (CPMT) represent a new generation of complete Cyber-Physical Systems (CPS)-based machine tools that deeply integrate machine tool and machining processes with computation and networking. CPMT have a higher level of connectivity, intelligence and autonomy compared to current machine tools. Digital Twin is a critical comp...
Conference Paper
Full-text available
This paper presents an implementation of a control algorithm to a cloud system. The motivation is that cloud implementations of low-level systems in the production industry are gradually becoming more common. Microsoft Azure platform is utilized for the cloud-based control and the case is tested using a customized laboratory model, which can be pre...
Conference Paper
Full-text available
Cyber-Physical Machine Tool (CPMT) is one of the main concepts that has emerged with the rise of Industry 4.0 and Machine Tool 4.0. It integrates the physical machine tool and machining processes with computation and networking by creating a Machine Tool Digital Twin (MTDT). Standard for the Exchange of Product data compliant Numerical Control (STE...
Conference Paper
Full-text available
The aim of next-generation Computer Numerical Control (CNC) is shifting from an open architecture, which has better flexibility, adaptability, versatility and expansibility, to a cyber-physical model, which offers real-time monitoring and control of the machining processes. This paper introduces a real case study to demonstrate such tendency from O...
Poster
Detailed information please refer to: https://cie48.com/program/special-sessions/#digitaltwin
Conference Paper
The advancement of various product development technologies is contributing to a total integrated manufacturing process. And model-based design (MBD) is a key enabler for such a total integration. The current MBD approach still does not support retaining of information needed at different stages of a product lifecycle. Collaboration among different...
Article
Full-text available
Recent advancements in Information and Communication Technology have shown immense potential of advancing current CNC machine tools to Cyber-Physical Machine Tools (CPMT). CPMT deeply integrates machine tool and machining processes with computation and networking, thus becoming more intelligent, interconnected and autonomous. However, challenges of...
Article
Full-text available
Machine Tool 4.0 introduces a new generation of machine tools that are smarter, well connected, widely accessible, more adaptive and more autonomous. Cyber-Physical Machine Tools (CPMT), based on recent advancements of the Information and Communication Technology, provides a promising solution for Machine Tool 4.0. This paper proposes a systematic...
Article
Full-text available
Information and communication technology is undergoing rapid development, and many disruptive technologies, such as cloud computing, Internet of Things, big data, and artificial intelligence, have emerged. These technologies are permeating the manufacturing industry and enable the fusion of physical and virtual worlds through cyber-physical systems...
Article
Full-text available
In the past five years, several industrial initiatives such as “Industry 4.0”, “Industrial Internet of Things”, “Factories of the Future” and “Made in China 2025”, have been announced by different governments and industrial leaders. These initiatives lead to an urgent need to advance current manufacturing systems into a high level of intelligence a...
Article
Full-text available
Cyber-Physical Production Systems (CPPS) often use wireless sensor networks (WSNs) for monitoring purposes. However, data from WSNs may be inaccurate and unreliable due to power exhaustion, noise and other issues. In order to achieve a reliable and accurate data acquisition while ensuring low energy consumption and long lifetime of WSNs, data clean...
Article
Full-text available
Aiming to advance current machine tools to a higher level of intelligence and autonomy, this paper presents a new generation of machine tools, i.e. Cyber-Physical Machine Tool (CPMT), inspired by the recent advances in Cyber-Physical Systems (CPS). CPMT refers to a CPS-enabled machine tool that integrates physical machine tool and machining process...
Article
Full-text available
Product configuration system, as an effective tool to bridge the gap between customer requirements and product offerings, enables customer-centric product development in a cost-efficient way. Despite its advantages, however, most existing product configurators are centralized, i.e. the configuration process is conducted in a single company within i...

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Projects

Projects (4)
Project
To overcome the bottlenecks of the high maintenance cost, long cycle time, and dependence on human experience for complex equipment maintenance, this project aims to develop a complete set of artificial intelligence-driven smart maintenance methodologies for complex equipment based on industrial big data. By leveraging the cutting-edge cloud-edge industrial Internet-of-Things architecture and communication technology, the main research content includes the reliable acquisition and fusion of multi-source heterogeneous sensing equipment big data, the efficient domain-specific knowledge management, and the predictive maintenance scheme of the key components. Finally, the research outcomes will be implemented in a certain type of oil drilling platform for demonstrative purposes.
Project
Promote the research, innovation, and applications of new-generation intelligent/smart manufacturing and robotics based on human-cyber-physical system (HCPS) development theory.
Project
Funded by the H2020 project MANUELA, this project aims to develop data analytics tools (e.g. machine learning, data mining) to support the understanding, the optimisation and the multi-scale and multi-physics simulation, and the real-time feedback control of Metal Additive Manufacturing. This project covers the following topics: 1) Communication and data storage strategy for metal AM 2) Information management and process interoperability for metal AM 3) Intelligent data analytics for metal AM 4) Real-time intelligent feedback control for metal AM