We develop a deep-learning-based multicrane visual sorting system with virtualized programmable logic controllers (PLCs) in intelligent manufacturing, which enables the accurate location and suction of the materials on the conveyor belt. First, virtualized PLCs are deployed in the field and the cloud to break data islands for efficient communication between low-level devices. Second, artificial intelligence algorithms are integrated into the physical industrial control system in which cooperation between virtualized PLCs and the visual recognition model is developed to complete the industrial control closed loop. Third, we establish a visual recognition model in which object detection algorithms are used to process the original image and then obtain the position and type of the object in the pixel coordinate system. In addition, a new linear interpolation-based backpropagation neural network is presented to provide the transform relation between the pixel coordinate system and the world coordinate system that the crane needs to precisely suck the material. The whole system is applied in a time-sensitive network environment in a highly reliable and stable manner. The experimental prototype system demonstrates that high recognition accuracy can be achieved for the visual sorting system within an acceptable time frame. The accuracy of the sorting task reaches 96.5% and the average consumption time of each object is approximately 2.317 s when the speed of the conveyor belt is 5.2 m/min.

The digitization and intellectualization have been envisioned as the fundamental basis for future Industrial Internet of Things, which integrates sensor technology, industrial control technology, communication technology, and artificial intelligence (AI). Specifically, the collaboration among these above techniques is crucial for the successful implementation of intelligent applications. This article develops an end-to-end visual control framework to accomplish multicrane collaborative sorting in wireless time sensitive networking (TSN) networks. The design primarily incorporates field devices, data transmission, AI, and industrial control. An advanced binocular stereo visual recognition model based on deep learning is investigated to accurately obtain the world coordinates and types. A cooperative control scheduling model that combines a scheduling strategy with an anti-collision strategy is presented to effectively control multiple cranes for sorting tasks. The device data and commands are transmitted through industrial 5G-TSN integrated network for ultrareliable, low-latency, and deterministic transmission. The proposed visual sorting system is further validated through the establishment of an experimental prototype, demonstrating its exceptional real-time performance while enabling flexible intelligent manufacturing.

Intelligent manufacturing is a challenging and compelling topic in Industry 4.0. Many computer vision (CV)-based applications have attracted widespread interest from researchers and industries around the world. However, it is difficult to integrate visual recognition algorithms with industrial control systems. The low-level devices are controlled by traditional programmable logic controllers (PLCs) that cannot realize data communication due to different industrial control protocols. In this article, we develop a multi-crane visual sorting system with cloud PLCs in a 5G environment, in which deep convolutional neural network (CNN)-based character recognition and dynamic scheduling are designed for materials in intelligent manufacturing. First, an YOLOv5-based algorithm is applied to locate the position of objects on the conveyor belt. Then, we propose a Chinese character recognition network (CCRNet) to significantly recognize each object from the original image. The position, type, and timestamp of each object are sent to cloud PLCs that are virtualized in the cloud to replace the function of traditional PLCs in the terminal. After that, we propose a dynamic scheduling method to sort the materials in minimum time. Finally, we establish a real experimental platform of a multi-crane visual sorting system to verify the performance of the proposed methods.

The demands for industrial ubiquitous communications promote the development of real-time and high-reliability wireless communication techniques. Accurate time synchronization is a critical foundation for deterministic communications. However, many wireless time synchronization methods achieve poor accuracy, while others take the high hardware costs and can not be used in practice. How to design high precision wireless time synchronization method with reasonable hardware costs is still a big challenge. Therefore, without affecting Wi-Fi protocol stack, a new medium access control (MAC) layer-based approach is proposed in this article to implement precision time synchronization with an open-source Wi-Fi design. The software protocol stack only needs to send handshake messages carrying identifiers, and timestamps are inserted and extracted from handshake messages as they pass through the MAC synchronization architecture designed in field programmable gate array. In the single-hop synchronization experiment, the synchronization accuracy is tested with and without network load. Comparing with other methods in several literatures, the results of the proposed solution unequivocally demonstrate the effectiveness and excellent wireless time synchronization precision, with 99% absolute time synchronization errors under 50% and 100% loads within 200 ns and 1 $\mu$s, respectively.

Mold level fluctuation significantly affects the stability and quality of the slab during the continuous casting process. However, traditional mechanism models are insufficient for providing accurate time-series predictions under complex and multivariable operating conditions. Additionally, the dynamic interdependencies between process variables and transient abnormal fluctuation events have been largely overlooked in existing studies. To address these limitations, we propose an integrated time–frequency characterization and prediction framework that combines multi-domain feature extraction with a long-sequence Informer model. First, the preprocessing pipeline transforms heterogeneous sensor data into standardized time series through normalization and standardization, thereby establishing a robust foundation for subsequent feature extraction and predictive modeling. Second, the time–domain and frequency–domain feature extraction methods are integrated to capture essential patterns in casting signals with improved resolution and interpretability. Third, the fusion features are embedded into a time-series prediction model, which performs robust forecasting of mold level behavior and enhances the identification of root causes behind fluctuation anomalies. Compared with conventional LSTM and Transformer models, the proposed framework achieves over 90% reduction in prediction error and provides interpretable insights into the correlations between casting parameters and mold level variations. Finally, real industrial experimental results demonstrate the performance of the proposed framework in enhancing prediction reliability and providing insight into fluctuations with scalable implementation.

5G delivers ultrareliable low-latency communications and mobile edge computing (MEC) for industrial applications, enabling distributed computing resource collaboration and promoting traditional automation systems toward networked control paradigms. However, industrial networked automation systems face significant challenges in optimally allocating limited computing and communication resources to meet strict QoS requirements for massive control tasks while maintaining system stability and efficiency. Thus, we propose a computing-communication-control collaboration mechanism to enhance coordination between MEC and local controllers, enabling complex control tasks to be processed despite limited local computing resources. To jointly optimize hybrid control tasks migration with communication constraints and computing resources allocation with incomplete information, we design a dual double deep Q-network embedded with the Stackelberg game (SG) model. Simulation results demonstrate that the proposed mechanism achieves better performance compared with other benchmarks, and extremely decreases the convergence time compared with the classical SG solution.