Federated Transfer Learning with Task Personalization for Condition Monitoring in Ultrasonic Metal Welding

Ultrasonic metal welding (UMW) is a key joining technology with widespread industrial applications. Condition monitoring (CM) capabilities are critically needed in UMW applications because process anomalies significantly deteriorate the joining quality. Recently, machine learning models emerged as a promising tool for CM in many manufacturing applications due to their ability to learn complex patterns. Yet, the successful deployment of these models requires substantial training data that may be expensive and time-consuming to collect. Additionally, many existing machine learning models lack generalizability and cannot be directly applied to new process configurations (i.e., domains). Such issues may be potentially alleviated by pooling data across manufacturers, but data sharing raises critical data privacy concerns. To address these challenges, this paper presents a Federated Transfer Learning with Task Personalization (FTL-TP) framework that provides domain generalization capabilities in distributed learning while ensuring data privacy. By effectively learning a unified representation from feature space, FTL-TP can adapt CM models for clients working on similar tasks, thereby enhancing their overall adaptability and performance jointly. To demonstrate the effectiveness of FTL-TP, we investigate two distinct UMW CM tasks, tool condition monitoring and workpiece surface condition classification. Compared with state-of-the-art FL algorithms, FTL-TP achieves a 5.35%--8.08% improvement of accuracy in CM in new target domains. FTL-TP is also shown to perform excellently in challenging scenarios involving unbalanced data distributions and limited client fractions. Furthermore, by implementing the FTL-TP method on an edge-cloud architecture, we show that this method is both viable and efficient in practice. The FTL-TP framework is readily extensible to various other manufacturing applications.

WeldMon: A Cost-effective Ultrasonic Welding Machine Condition Monitoring System

Ultrasonic welding machines play a critical role in the lithium battery industry, facilitating the bonding of batteries with conductors. Ensuring high-quality welding is vital, making tool condition monitoring systems essential for early-stage quality control. However, existing monitoring methods face challenges in cost, downtime, and adaptability. In this paper, we present WeldMon, an affordable ultrasonic welding machine condition monitoring system that utilizes a custom data acquisition system and a data analysis pipeline designed for real-time analysis. Our classification algorithm combines auto-generated features and hand-crafted features, achieving superior cross-validation accuracy (95.8% on average over all testing tasks) compared to the state-of-the-art method (92.5%) in condition classification tasks. Our data augmentation approach alleviates the concept drift problem, enhancing tool condition classification accuracy by 8.3%. All algorithms run locally, requiring only 385 milliseconds to process data for each welding cycle. We deploy WeldMon and a commercial system on an actual ultrasonic welding machine, performing a comprehensive comparison. Our findings highlight the potential for developing cost-effective, high-performance, and reliable tool condition monitoring systems.