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Abstract We propose a novel framework that combines state-of-the-art deep learning approaches with pre- and post-processing algorithms for particle detection in complex/heterogeneous backgrounds common in the manufacturing domain. Traditional methods, like size analyzers and those based on dilution, image processing, or deep learning, typically excel with homogeneous backgrounds. Yet, they often fall short in accurately detecting particles against the intricate and varied backgrounds characteristic of heterogeneous particle–substrate (HPS) interfaces in manufacturing. To address this, we've developed a flexible framework designed to detect particles in diverse environments and input types. Our modular framework hinges on model selection and AI-guided particle detection as its core, with preprocessing and postprocessing as integral components, creating a four-step process. This system is versatile, allowing for various preprocessing, AI model selections, and post-processing strategies. We demonstrate this with an entrainment-based particle delivery method, transferring various particles onto substrates that mimic the HPS interface. By altering particle and substrate properties (e.g., material type, size, roughness, shape) and process parameters (e.g., capillary number) during particle entrainment, we capture images under different ambient lighting conditions, introducing a range of HPS background complexities. In the preprocessing phase, we apply image enhancement and sharpening techniques to improve detection accuracy. Specifically, image enhancement adjusts the dynamic range and histogram, while sharpening increases contrast by combining the high pass filter output with the base image. We introduce an image classifier model (based on the type of heterogeneity), employing Transfer Learning with MobileNet as a Model Selector, to identify the most appropriate AI model (i.e., YOLO model) for analyzing each specific image, thereby enhancing detection accuracy across particle–substrate variations. Following image classification based on heterogeneity, the relevant YOLO model is employed for particle identification, with a distinct YOLO model generated for each heterogeneity type, improving overall classification performance. In the post-processing phase, domain knowledge is used to minimize false positives. Our analysis indicates that the AI-guided framework maintains consistent precision and recall across various HPS conditions, with the harmonic mean of these metrics comparable to those of individual AI model outcomes. This tool shows potential for advancing in-situ process monitoring across multiple manufacturing operations, including high-density powder-based 3D printing, powder metallurgy, extreme environment coatings, particle categorization, and semiconductor manufacturing. 

Abstract Battery electric vehicles (BEVs) have emerged as a promising alternative to traditional internal combustion engine (ICE) vehicles due to benefits in improved fuel economy, lower operating cost, and reduced emission. BEVs use electric motors rather than fossil fuels for propulsion and typically store electric energy in lithium-ion cells. With rising concerns over fossil fuel depletion and the impact of ICE vehicles on the climate, electric mobility is widely considered as the future of sustainable transportation. BEVs promise to drastically reduce greenhouse gas emissions as a result of the transportation sector. However, mass adoption of BEVs faces major barriers due to consumer worries over several important battery-related issues, such as limited range, long charging time, lack of charging stations, and high initial cost. Existing solutions to overcome these barriers, such as building more charging stations, increasing battery capacity, and stationary vehicle-to-vehicle (V2V) charging, often suffer from prohibitive investment costs, incompatibility to existing BEVs, or long travel delays. In this paper, we propose P eer-to- P eer C ar C harging (P2C2), a scalable approach for charging BEVs that alleviates the need for elaborate charging infrastructure. The central idea is to enable BEVs to share charge among each other while in motion through coordination with a cloud-based control system. To re-vitalize a BEV fleet, which is continuously in motion, we introduce Mobile Charging Stations (MoCS), which are high-battery-capacity vehicles used to replenish the overall charge in a vehicle network. Unlike existing V2V charging solutions, the charge sharing in P2C2 takes place while the BEVs are in-motion, which aims at minimizing travel time loss. To reduce BEV-to-BEV contact time without increasing manufacturing costs, we propose to use multiple batteries of varying sizes and charge transfer rates. The faster but smaller batteries are used for charge transfer between vehicles, while the slower but larger ones are used for prolonged charge storage. We have designed the overall P2C2 framework and formalized the decision-making process of the cloud-based control system. We have evaluated the effectiveness of P2C2 using a well-characterized simulation platform and observed dramatic improvement in BEV mobility. Additionally, through statistical analysis, we show that a significant reduction in carbon emission is also possible if MoCS can be powered by renewable energy sources.