Most online tool condition monitoring (TCM) methods easily cause machining interference. To solve this problem, we propose a method based on the analysis of the spindle motor current signal of a machine tool. Firstly, cutting experiments under multi-conditions were carried out at a Fanuc vertical machining center, using the Fanuc Servo Guide software to obtain the spindle motor current data of the built-in current sensor of the machine tool, which can not only apply to the actual processing conditions but, also, save costs. Secondly, we propose the variational mode decomposition (VMD) algorithm for feature extraction, which can describe the tool conditions under different cutting conditions due to its excellent performance in processing the nonstationary current signal. In contrast with the popular wavelet packet decomposition (WPD) method, the VMD method was verified as a more effective signal-processing technique according to the experimental results. Thirdly, the most indicative features that relate to the tool condition were fed into the ensemble learning (EL) classifier to establish a nonlinear mapping relationship between the features and the tool wear level. Compared with existing TCM methods based on current sensor signals, the operation process and experimental results show that using the proposed method for the monitoring signal acquisition is suitable for the actual processing conditions, and the established tool wear prediction model has better performance in both accuracy and robustness due to its good generalization capability.

Aiming at the shortcomings of single-sensor sensing information characterization ability, which is easily interfered with by external environmental factors, a method of intelligent perception is proposed in this paper. This method integrates multi-source and multi-level information, including spindle temperature field, spindle thermal deformation, operating parameters, and motor current. Firstly, the internal and external thermal-error-related signals of the spindle system are collected by sensors, and the feature parameters are extracted; then, the radial basis function (RBF) neural network is utilized to realize the preliminary integration of the feature parameters because of the advantages of the RBF neural network, which offers strong multi-dimensional solid nonlinear mapping ability and generalization ability. Thermal-error decision values are then generated by a weighted fusion of different pieces of evidence by considering uncertain information from multiple sources. The spindle thermal-error sensing experiment was based on the spindle system of the VMC850 (Yunnan Machine Tool Group Co., LTD, Yunnan, China) vertical machining center of the Yunnan Machine Tool Factory. Experiments were designed for thermal-error sensing of the spindle under constant speed (2000 r/min and 4000 r/min), standard variable speed, and stepped variable speed conditions. The experiment’s results show that the prediction accuracy of the intelligent-sensing model with multi-source information fusion can reach 98.1%, 99.3%, 98.6%, and 98.8% under the above working conditions, respectively. The intelligent-perception model proposed in this paper has higher accuracy and lower residual error than the traditional BP neural network perception and wavelet neural network models. The research in this paper provides a theoretical basis for the operation, maintenance management, and performance optimization of machine tool spindle systems.

The linear motor feed system has been in service in complex working conditions for a long time, thus causing the nonuniform distribution of the temperature field distribution. Thus, the thermal error has become a key factor affecting system motion accuracy. In order to maximize the accuracy and efficiency of thermal error compensation for linear motor feed systems, an improved modeling method for the thermal error of the linear motor feed system based on Bayesian neural networks is proposed in combination with the strong generalization performance and avoidance of overfitting of Bayesian neural networks. And the specific modeling ideas are as follows: Firstly, the X-Y cross-type two-axis linear motor feed system is taken as the test object. Due to the traditional neural network’s slow convergence, overfitting, and underfitting problems, the Bayesian neural network is used to model the thermal error of the linear motor feed system. Secondly, to avoid the influence of multicollinearity data on the final results, the grey relation analysis method is used to screen the temperature measuring points. The data with a large relation degree is selected for modeling to ensure the prediction accuracy of the neural network. Thirdly, the temperature variables of sensitive points and thermal positioning errors are taken as data input samples. Fourthly, a Bayesian neural network model is established. Fifthly, the hyperparameters of the Bayesian neural network are determined by a calculating method of Hessian matrix by Gauss-Newton approximation. And finally, a thermal error prediction model is established. The comparison and analysis with the neural network constructed by the ordinary Levenberg-Marquardt algorithm after a series of experimental demonstrations see that the prediction accuracy of the proposed method can be enhanced by up to 10%. It also shows that the prediction model has the advantages of high precision, strong generalization ability, anti-disturbance solid ability, and strong robustness, etc. Therefore, the prediction model is expected to be widely used in predicting and compensating thermal error of the feed system of high-speed CNC machine tools in practical machining occasions.

The linear motor feeding system is a typical electromechanical coupling system. Conventional characteristic analyses of electromechanical coupling often overlook the influence of flexible deformation in critical components of the linear motor feeding system. Moreover, when employing genetic algorithms to optimize servo system PID control parameters, slow convergence, nonconvergence, or premature convergence problems may arise. To address these issues, this paper proposes a new performance optimization method for a linear motor feeding system. The method uses a combination of “multi-body theory + finite element” to accurately account for the flexible deformation of critical components of the feeding system, establishes a rigid–flexible electromechanical coupling model of the linear motor feeding system, and optimizes the PID parameters of the established model with an improved adaptive genetic algorithm. Simulation results demonstrate that, when utilizing an adaptive genetic algorithm to optimize the rigid–flexible electromechanical coupling model and a control system model that disregards flexible body deformation, the system achieves stability in 0.02 s and 0.027 s with overshoots of 13% and 27%, respectively. These outcomes confirm the accuracy and importance of considering flexible body deformation in the optimization performance of a linear motor feeding system. At the same time, the time required to reach the steady state of the rigid–flexible electromechanical coupling model optimized by the adaptive genetic algorithm is shortened from 0.035 s to 0.02 s. The sinusoidal signal response curve of the optimized system does not exhibit any peak overshoot compared with that of the nonoptimized system, and the response speed is also faster. These results demonstrate the effectiveness of the rigid–flexible electromechanical coupling model optimized by the nonlinear adaptive genetic algorithm. The displacement response curves of the linear motor feeding system under different workbench loads are obtained through experiments and compared with those obtained from simulations to verify the established model and the correctness of the proposed method.

Because the linear motor feeding system always runs in complex working conditions for a long time, its performance and state transition have great randomness. Therefore, abnormal detection is particularly significant for predictive maintenance to promptly discover the running state degradation trend. Aiming at the problem that the abnormal samples of linear motor feed system are few and the samples have time-series features, a method of abnormal operation state detection of a linear motor feed system based on normal sample training was proposed, named GANomaly-LSTM. The method constructs an encoding-decoding-reconstructed encoding network model. Firstly, the time-series features of vibration, current and composite data samples are extracted by the long short-term memory (LSTM) network; Secondly, the three-layer fully connected layer is employed to extract potential feature vectors; Finally, anomaly detection of the system is completed by comparing the potential feature vectors of the two encodings. An experimental platform of the X-Y two-axis linkage linear motor feeding system is built to verify the rationality of the proposed method. Compared with other classical methods such as GANomaly and GAN-AE, the average AUROC index of this method is improved by 17.5% and 9.3%, the average accuracy is enhanced by 11.6% and 15.5%, and the detection time is shortened by 223 ms and 284 ms, respectively. GANomaly-LSTM has successfully proved its superiority for abnormal detection for running state of linear motor feeding systems.

Pears are susceptible to internal defects during growth and post-harvest handling, compromising their quality and market value. Traditional detection methods, such as manual inspection and physicochemical analysis, face limitations in efficiency, objectivity, and non-destructiveness. To address these challenges, this study investigates a non-destructive approach integrating X-ray imaging and multi-criteria decision (MCD) theory for non-destructive internal defect detection in pears. Internal defects were identified by analyzing grayscale variations in X-ray images. The proposed method combines manual feature-based classifiers, including Local Binary Pattern (LBP) and Histogram of Oriented Gradients (HOG), with a deep convolutional neural network (DCNN) model within an MCD-based fusion framework. Experimental results demonstrated that the fused model achieved a detection accuracy of 97.1%, significantly outperforming individual classifiers. This approach effectively reduced misclassification caused by structural similarities in X-ray images. The study confirms the efficacy of X-ray imaging coupled with multi-classifier fusion for accurate and non-destructive internal quality evaluation of pears, offering practical value for fruit grading and post-harvest management in the pear industry.