Employment of Real-Time/FPGA Architectures for Test and Control of Automotive Engines

Nowadays the production of increasingly complex and electrified vehicles requires the implementation of new control and monitoring systems. This reason, together with the tendency of moving rapidly from the test bench to the vehicle, leads to a landscape that requires the development of embedded hardware and software to face the application effectively and efficiently. The development of application-based software on real-time/FPGA hardware could be a good answer for these challenges: FPGA grants parallel low-level and high-speed calculation/timing, while the Real-Time processor can handle high-level calculation layers, logging and communication functions with determinism. Thanks to the software flexibility and small dimensions, these architectures can find a perfect collocation as engine RCP (Rapid Control Prototyping) units and as smart data logger/analyser, both for test bench and on vehicle application. Efforts have been done for building a base architecture with common functionalities capable of easily hosting application-specific control code. Several case studies originating in this scenario will be shown; dedicated solutions for protype applications have been developed exploiting a real-time/FPGA architecture as ECU (Engine Control Unit) and custom RCP functionalities, such as water injection and testing hydraulic brake control.

Distributed Large-scale Mixed-Integer Optimization with Application to Energy and Multi-robot Networks

Several decision and control tasks in cyber-physical networks can be formulated as large- scale optimization problems with coupling constraints. In these "constraint-coupled" problems, each agent is associated to a local decision variable, subject to individual constraints. This thesis explores the use of primal decomposition techniques to develop tailored distributed algorithms for this challenging set-up over graphs. We first develop a distributed scheme for convex problems over random time-varying graphs with non-uniform edge probabilities. The approach is then extended to unknown cost functions estimated online. Subsequently, we consider Mixed-Integer Linear Programs (MILPs), which are of great interest in smart grid control and cooperative robotics. We propose a distributed methodological framework to compute a feasible solution to the original MILP, with guaranteed suboptimality bounds, and extend it to general nonconvex problems. Monte Carlo simulations highlight that the approach represents a substantial breakthrough with respect to the state of the art, thus representing a valuable solution for new toolboxes addressing large-scale MILPs. We then propose a distributed Benders decomposition algorithm for asynchronous unreliable networks. The framework has been then used as starting point to develop distributed methodologies for a microgrid optimal control scenario. We develop an ad-hoc distributed strategy for a stochastic set-up with renewable energy sources, and show a case study with samples generated using Generative Adversarial Networks (GANs). We then introduce a software toolbox named ChoiRbot, based on the novel Robot Operating System 2, and show how it facilitates simulations and experiments in distributed multi-robot scenarios. Finally, we consider a Pickup-and-Delivery Vehicle Routing Problem for which we design a distributed method inspired to the approach of general MILPs, and show the efficacy through simulations and experiments in ChoiRbot with ground and aerial robots.

Vision-Based Solutions for Human-Robot Collaboration in Industrial Workcells

Industrial robots are both versatile and high performant, enabling the flexible automation typical of the modern Smart Factories. For safety reasons, however, they must be relegated inside closed fences and/or virtual safety barriers, to keep them strictly separated from human operators. This can be a limitation in some scenarios in which it is useful to combine the human cognitive skill with the accuracy and repeatability of a robot, or simply to allow a safe coexistence in a shared workspace. Collaborative robots (cobots), on the other hand, are intrinsically limited in speed and power in order to share workspace and tasks with human operators, and feature the very intuitive hand guiding programming method. Cobots, however, cannot compete with industrial robots in terms of performance, and are thus useful only in a limited niche, where they can actually bring an improvement in productivity and/or in the quality of the work thanks to their synergy with human operators. The limitations of both the pure industrial and the collaborative paradigms can be overcome by combining industrial robots with artificial vision. In particular, vision can be exploited for a real-time adjustment of the pre-programmed task-based robot trajectory, by means of the visual tracking of dynamic obstacles (e.g. human operators). This strategy allows the robot to modify its motion only when necessary, thus maintain a high level of productivity but at the same time increasing its versatility. Other than that, vision offers the possibility of more intuitive programming paradigms for the industrial robots as well, such as the programming by demonstration paradigm. These possibilities offered by artificial vision enable, as a matter of fact, an efficacious and promising way of achieving human-robot collaboration, which has the advantage of overcoming the limitations of both the previous paradigms yet keeping their strengths.

Sviluppo di un sistema di Realta Aumentata applicato a un modello 3D della prostata, sviluppato a partire da immagini RM, al fine di facilitare la dissezione del tumore e la conservazione dei fasci neuro vascolari durante l'intervento chirurgico di prostatectomia radicale robot-assistita

La realtà aumentata (AR) è una nuova tecnologia adottata in chirurgia prostatica con l'obiettivo di migliorare la conservazione dei fasci neurovascolari (NVB) ed evitare i margini chirurgici positivi (PSM). Abbiamo arruolato prospetticamente pazienti con diagnosi di cancro alla prostata (PCa) sul base di biopsia di fusione mirata con mpMRI positiva. Prima dell'intervento, i pazienti arruolati sono stati indirizzati a sottoporsi a ricostruzione del modello virtuale 3D basato su mpMRI preoperatoria immagini. Infine, il chirurgo ha eseguito la RARP con l'ausilio del modello 3D proiettato in AR all'interno della console robotica (RARP guidata AR-3D). I pazienti sottoposti a AR RARP sono stati confrontati con quelli sottoposti a "RARP standard" nello stesso periodo. Nel complesso, i tassi di PSM erano comparabili tra i due gruppi; I PSM a livello della lesione indice erano significativamente più bassi nei pazienti riferiti al gruppo AR-3D (5%) rispetto a quelli nel gruppo di controllo (20%; p = 0,01). La nuova tecnica di guida AR-3D per l'analisi IFS può consentono di ridurre i PSM a livello della lesione dell'indice

PCM-based in-memory computing: architectures, circuits and applications

Analog In-memory Computing (AIMC) has been proposed in the context of Beyond Von Neumann architectures as a valid strategy to reduce internal data transfers energy consumption and latency, and to improve compute efficiency. The aim of AIMC is to perform computations within the memory unit, typically leveraging the physical features of memory devices. Among resistive Non-volatile Memories (NVMs), Phase-change Memory (PCM) has become a promising technology due to its intrinsic capability to store multilevel data. Hence, PCM technology is currently investigated to enhance the possibilities and the applications of AIMC. This thesis aims at exploring the potential of new PCM-based architectures as in-memory computational accelerators. In a first step, a preliminar experimental characterization of PCM devices has been carried out in an AIMC perspective. PCM cells non-idealities, such as time-drift, noise, and non-linearity have been studied to develop a dedicated multilevel programming algorithm. Measurement-based simulations have been then employed to evaluate the feasibility of PCM-based operations in the fields of Deep Neural Networks (DNNs) and Structural Health Monitoring (SHM). Moreover, a first testchip has been designed and tested to evaluate the hardware implementation of Multiply-and-Accumulate (MAC) operations employing PCM cells. This prototype experimentally demonstrates the possibility to reach a 95% MAC accuracy with a circuit-level compensation of cells time drift and non-linearity. Finally, empirical circuit behavior models have been included in simulations to assess the use of this technology in specific DNN applications, and to enhance the potentiality of this innovative computation approach.

Preventing worker’s musculoskeletal disorders with wearable inertial sensors: ergonomics and modelling of physical human-robot interactions

The most widespread work-related diseases are musculoskeletal disorders (MSD) caused by awkward postures and excessive effort to upper limb muscles during work operations. The use of wearable IMU sensors could monitor the workers constantly to prevent hazardous actions, thus diminishing work injuries. In this thesis, procedures are developed and tested for ergonomic analyses in a working environment, based on a commercial motion capture system (MoCap) made of 17 Inertial Measurement Units (IMUs). An IMU is usually made of a tri-axial gyroscope, a tri-axial accelerometer, and a tri-axial magnetometer that, through sensor fusion algorithms, estimates its attitude. Effective strategies for preventing MSD rely on various aspects: firstly, the accuracy of the IMU, depending on the chosen sensor and its calibration; secondly, the correct identification of the pose of each sensor on the worker’s body; thirdly, the chosen multibody model, which must consider both the accuracy and the computational burden, to provide results in real-time; finally, the model scaling law, which defines the possibility of a fast and accurate personalization of the multibody model geometry. Moreover, the MSD can be diminished using collaborative robots (cobots) as assisted devices for complex or heavy operations to relieve the worker's effort during repetitive tasks. All these aspects are considered to test and show the efficiency and usability of inertial MoCap systems for assessing ergonomics evaluation in real-time and implementing safety control strategies in collaborative robotics. Validation is performed with several experimental tests, both to test the proposed procedures and to compare the results of real-time multibody models developed in this thesis with the results from commercial software. As an additional result, the positive effects of using cobots as assisted devices for reducing human effort in repetitive industrial tasks are also shown, to demonstrate the potential of wearable electronics in on-field ergonomics analyses for industrial applications.

A ROS-based software architecture for a versatile collaborative dual-armed autonomous mobile robot for the manufacturing industry

The industrial context is changing rapidly due to advancements in technology fueled by the Internet and Information Technology. The fourth industrial revolution counts integration, flexibility, and optimization as its fundamental pillars, and, in this context, Human-Robot Collaboration has become a crucial factor for manufacturing sustainability in Europe. Collaborative robots are appealing to many companies due to their low installation and running costs and high degree of flexibility, making them ideal for reshoring production facilities with a short return on investment. The ROSSINI European project aims to implement a true Human-Robot Collaboration by designing, developing, and demonstrating a modular and scalable platform for integrating human-centred robotic technologies in industrial production environments. The project focuses on safety concerns related to introducing a cobot in a shared working area and aims to lay the groundwork for a new working paradigm at the industrial level. The need for a software architecture suitable to the robotic platform employed in one of three use cases selected to deploy and test the new technology was the main trigger of this Thesis. The chosen application consists of the automatic loading and unloading of raw-material reels to an automatic packaging machine through an Autonomous Mobile Robot composed of an Autonomous Guided Vehicle, two collaborative manipulators, and an eye-on-hand vision system for performing tasks in a partially unstructured environment. The results obtained during the ROSSINI use case development were later used in the SENECA project, which addresses the need for robot-driven automatic cleaning of pharmaceutical bins in a very specific industrial context. The inherent versatility of mobile collaborative robots is evident from their deployment in the two projects with few hardware and software adjustments. The positive impact of Human-Robot Collaboration on diverse production lines is a motivation for future investments in research on this increasingly popular field by the industry.

Hierarchical active inference for cognitive architectures

This thesis explores the methods based on the free energy principle and active inference for modelling cognition. Active inference is an emerging framework for designing intelligent agents where psychological processes are cast in terms of Bayesian inference. Here, I appeal to it to test the design of a set of cognitive architectures, via simulation. These architectures are defined in terms of generative models where an agent executes a task under the assumption that all cognitive processes aspire to the same objective: the minimization of variational free energy. Chapter 1 introduces the free energy principle and its assumptions about self-organizing systems. Chapter 2 describes how from the mechanics of self-organization can emerge a minimal form of cognition able to achieve autopoiesis. In chapter 3 I present the method of how I formalize generative models for action and perception. The architectures proposed allow providing a more biologically plausible account of more complex cognitive processing that entails deep temporal features. I then present three simulation studies that aim to show different aspects of cognition, their associated behavior and the underlying neural dynamics. In chapter 4, the first study proposes an architecture that represents the visuomotor system for the encoding of actions during action observation, understanding and imitation. In chapter 5, the generative model is extended and is lesioned to simulate brain damage and neuropsychological patterns observed in apraxic patients. In chapter 6, the third study proposes an architecture for cognitive control and the modulation of attention for action selection. At last, I argue how active inference can provide a formal account of information processing in the brain and how the adaptive capabilities of the simulated agents are a mere consequence of the architecture of the generative models. Cognitive processing, then, becomes an emergent property of the minimization of variational free energy.

QoS-aware architectures, technologies, and middleware for the cloud continuum

The recent trend of moving Cloud Computing capabilities to the Edge of the network is reshaping how applications and their middleware supports are designed, deployed, and operated. This new model envisions a continuum of virtual resources between the traditional cloud and the network edge, which is potentially more suitable to meet the heterogeneous Quality of Service (QoS) requirements of diverse application domains and next-generation applications. Several classes of advanced Internet of Things (IoT) applications, e.g., in the industrial manufacturing domain, are expected to serve a wide range of applications with heterogeneous QoS requirements and call for QoS management systems to guarantee/control performance indicators, even in the presence of real-world factors such as limited bandwidth and concurrent virtual resource utilization. The present dissertation proposes a comprehensive QoS-aware architecture that addresses the challenges of integrating cloud infrastructure with edge nodes in IoT applications. The architecture provides end-to-end QoS support by incorporating several components for managing physical and virtual resources. The proposed architecture features: i) a multilevel middleware for resolving the convergence between Operational Technology (OT) and Information Technology (IT), ii) an end-to-end QoS management approach compliant with the Time-Sensitive Networking (TSN) standard, iii) new approaches for virtualized network environments, such as running TSN-based applications under Ultra-low Latency (ULL) constraints in virtual and 5G environments, and iv) an accelerated and deterministic container overlay network architecture. Additionally, the QoS-aware architecture includes two novel middlewares: i) a middleware that transparently integrates multiple acceleration technologies in heterogeneous Edge contexts and ii) a QoS-aware middleware for Serverless platforms that leverages coordination of various QoS mechanisms and virtualized Function-as-a-Service (FaaS) invocation stack to manage end-to-end QoS metrics. Finally, all architecture components were tested and evaluated by leveraging realistic testbeds, demonstrating the efficacy of the proposed solutions.

Contributions to the performance analysis of continuum parallel robots

Continuum parallel robots (CPRs) are manipulators employing multiple flexible beams arranged in parallel and connected to a rigid end-effector. CPRs promise higher payload and accuracy than serial CRs while keeping great flexibility. As the risk of injury during accidental contacts between a human and a CPR should be reduced, CPRs may be used in large-scale collaborative tasks or assisted robotic surgery. There exist various CPR designs, but the prototype conception is rarely based on performance considerations, and the CPRs realization in mainly based on intuitions or rigid-link parallel manipulators architectures. This thesis focuses on the performance analysis of CPRs, and the tools needed for such evaluation, such as workspace computation algorithms. In particular, workspace computation strategies for CPRs are essential for the performance assessment, since the CPRs workspace may be used as a performance index or it can serve for optimal-design tools. Two new workspace computation algorithms are proposed in this manuscript, the former focusing on the workspace volume computation and the certification of its numerical results, while the latter aims at computing the workspace boundary only. Due to the elastic nature of CPRs, a key performance indicator for these robots is the stability of their equilibrium configurations. This thesis proposes the experimental validation of the equilibrium stability assessment on a real prototype, demonstrating limitations of some commonly used assumptions. Additionally, a performance index measuring the distance to instability is originally proposed in this manuscript. Differently from the majority of the existing approaches, the clear advantage of the proposed index is a sound physical meaning; accordingly, the index can be used for a more straightforward performance quantification, and to derive robot specifications.