Deep Integration of Sensing Technology and Smart Manufacturing: Leading the Technological Upgrade of the Precision Manufacturing Industry

Abstract

Aiming at the technical bottlenecks in core links of the precision manufacturing industry, such as ultra-precision measurement and flexible production—including insufficient machining accuracy (traditional machining error ≥±0.025 μm), response lag (process adjustment delay >100 ms), and data silos—this paper proposes a full-chain integrated architecture of “perception-modeling-decision-execution”. It reveals the signal crosstalk mechanism of multi-physics field coupled sensing units and systematically elaborates the deep collaboration mechanism between multi-parameter collaborative perception and digital twin, AI adaptive control, and industrial interconnection. By developing a four-parameter integrated MEMS sensing module based on frequency domain isolation, an attention mechanism-improved LSTM algorithm, and a cross-protocol adaptive conversion middleware, three core technological breakthroughs are achieved: (1) The measurement accuracy is improved from ±0.025 μm to ±0.006 μm (a relative increase of 76%), with a complex surface detection error ≤4.2 μm; (2) The response delay is reduced from >100 ms to 0.8 ms (a reduction of 99.2%), and the equipment fault early warning accuracy reaches 94.7%; (3) The changeover efficiency of flexible production lines is increased by 45%, and the product defect rate is reduced from 3.2% to 0.5% (a reduction of 84.4%). Empirical verification in three typical industrial scenarios shows that the integrated system increases production efficiency by 32%-48% and reduces comprehensive manufacturing costs by 18%-26%. The research results provide a systematic solution for the transformation of the precision manufacturing industry. Relevant technologies have formed 15 authorized patents and 11 software copyrights, possessing significant academic value and industrial application prospects.