Neural network modelling of the wave-structure interaction processes

This thesis presents a new Artificial Neural Network (ANN) able to predict at once the main parameters representative of the wave-structure interaction processes, i.e. the wave overtopping discharge, the wave transmission coefficient and the wave reflection coefficient. The new ANN has been specifically developed in order to provide managers and scientists with a tool that can be efficiently used for design purposes. The development of this ANN started with the preparation of a new extended and homogeneous database that collects all the available tests reporting at least one of the three parameters, for a total amount of 16’165 data. The variety of structure types and wave attack conditions in the database includes smooth, rock and armour unit slopes, berm breakwaters, vertical walls, low crested structures, oblique wave attacks. Some of the existing ANNs were compared and improved, leading to the selection of a final ANN, whose architecture was optimized through an in-depth sensitivity analysis to the training parameters of the ANN. Each of the selected 15 input parameters represents a physical aspect of the wave-structure interaction process, describing the wave attack (wave steepness and obliquity, breaking and shoaling factors), the structure geometry (submergence, straight or non-straight slope, with or without berm or toe, presence or not of a crown wall), or the structure type (smooth or covered by an armour layer, with permeable or impermeable core). The advanced ANN here proposed provides accurate predictions for all the three parameters, and demonstrates to overcome the limits imposed by the traditional formulae and approach adopted so far by some of the existing ANNs. The possibility to adopt just one model to obtain a handy and accurate evaluation of the overall performance of a coastal or harbor structure represents the most important and exportable result of the work.

Modelli Digitali e Archivi di Progetto. Sistemi integrati di documentazione per l'architettura.

Le tecniche dell'informazione e i metodi della comunicazione hanno modificato il modo di redigere documenti destinati a trasmettere la conoscenza, in un processo che è a tutt'oggi in corso di evoluzione. Anche l'attività progettuale in ingegneria ed architettura, pure in un settore caratterizzato da una notevole inerzia metodologica e restio all'innovazione quale è quello dell'industria edilizia, ha conosciuto profonde trasformazioni in ragione delle nuove espressioni tecnologiche. Da tempo l'informazione necessaria per realizzare un edificio, dai disegni che lo rappresentano sino ai documenti che ne indicano le modalità costruttive, può essere gestita in maniera centralizzata mediante un unico archivio di progetto denominato IPDB (Integrated Project DataBase) pur essendone stata recentemente introdotta sul mercato una variante più operativa chiamata BIM (Building Information Modelling). Tuttavia l'industrializzazione del progetto che questi strumenti esplicano non rende conto appieno di tutti gli aspetti che vedono la realizzazione dell'opera architettonica come collettore di conoscenze proprie di una cultura progettuale che, particolarmente in Italia, è radicata nel tempo. La semantica della rappresentazione digitale è volta alla perequazione degli elementi costitutivi del progetto con l'obiettivo di catalogarne le sole caratteristiche fabbricative. L'analisi della letteratura scientifica pertinente alla materia mostra come non sia possibile attribuire ai metodi ed ai software presenti sul mercato la valenza di raccoglitori omnicomprensivi di informazione: questo approccio olistico costituisce invece il fondamento della modellazione integrata intesa come originale processo di rappresentazione della conoscenza, ordinata secondo il paradigma delle "scatole cinesi", modello evolvente che unifica linguaggi appartenenti ai differenti attori compartecipanti nei settori impiantistici, strutturali e della visualizzazione avanzata. Evidenziando criticamente i pregi e i limiti operativi derivanti dalla modellazione integrata, la componente sperimentale della ricerca è stata articolata con l'approfondimento di esperienze condotte in contesti accademici e professionali. Il risultato conseguito ha coniugato le tecniche di rilevamento alle potenzialità di "modelli tridimensionali intelligenti", dotati cioè di criteri discriminanti per la valutazione del relazionamento topologico dei componenti con l'insieme globale.

I progetti di Oswald Mathias Ungers per la città di Treviri. Questioni di composizione architettonica

Abstract This PhD thesis focuses on two projects carried out by Oswald Mathias Ungers in the city of Trier. More specifi cally, this study focuses on the relationship between composition principles, architectural forms, historical context and the nature of the city where these buildings have been built. The works carried out by Ungers in Trier are unique experiences - if taken in this master’s works context - and each one of them refl ects - in its specifi c project and architectural composition theme - the results - in terms of design - of a complex research on the fundamentals of architecture carried out by Ungers in more than fi ve decades of his activity. The theoretical and compositional experiment aspect is one of the main subjects to defi ne these buildings in terms of architecture. This aspect is so crucial that it is possible to consider them as an example of radical and specifi c experiences, referred to a specifi c place and based on a specifi c theoretical corpus. More specifi cally, this study focuses on the design activity carried out by Ungers in this city, mainly between the 80s and 90s and in the fi rst decade of the 21st century. It puts forward an interpretation that does not only defi ne the essential features, elements and questions lying behind these two architectures, but fi rst and foremost analyzes the theoretical, methodological and compositional relationship between Ungers and Trier, his adopted city. An increasingly closer relationship between the architect and his city highlights the wider relationship network established between the place and the projects carried out by Ungers in this city and makes it possible to understand the importance of Trier in the work of this architect, in his education and in his way to see, think and make architecture. The projects analyzed - the Thermen am Forum Museum (1988-1996) and the Kaiserthermen entrance hall (2003-2007) - were analyzed in terms of their architectural composition in an attempt to highlight the poetry of these architectures and to fi nd out their progressive, rational - and therefore transmissible - character. This study is an attempt to assess and unveil the compositional themes characterizing these projects while detecting the compositional principles lying behind the works and verifying the design process through which such principles were translated into architecture. Looking at these works as architectural composition examples makes it possible to clarify Ungers’ hermeneutic relationship established with the city’s history and structure. More specifi cally, the main subject of this thesis is the relationship between the architect, his city and history in the architectural solutions offered by two exemplary case studies, which were both built and placed in the historical city center of Trier and both connected with the ancient core of the city. The Thermen am Forum Museum and the Kaiserthermen entrance hall projects are - though being developed at different times of Ungers’ architectural life and though being extremely different in terms of approach to their context, due to their architectural image - two works that can be compared with the historical heritage of the city and this makes them ideal examples of the relationship between architectural forms, history and environment.

Design and Control of Robotic Hands

The application of dexterous robotic hands out of research laboratories has been limited by the intrinsic complexity that these devices present. This is directly reflected as an economically unreasonable cost and a low overall reliability. Within the research reported in this thesis it is shown how the problem of complexity in the design of robotic hands can be tackled, taking advantage of modern technologies (i.e. rapid prototyping), leading to innovative concepts for the design of the mechanical structure, the actuation and sensory systems. The solutions adopted drastically reduce the prototyping and production costs and increase the reliability, reducing the number of parts required and averaging their single reliability factors. In order to get guidelines for the design process, the problem of robotic grasp and manipulation by a dual arm/hand system has been reviewed. In this way, the requirements that should be fulfilled at hardware level to guarantee successful execution of the task has been highlighted. The contribution of this research from the manipulation planning side focuses on the redundancy resolution that arise in the execution of the task in a dexterous arm/hand system. In literature the problem of coordination of arm and hand during manipulation of an object has been widely analyzed in theory but often experimentally demonstrated in simplified robotic setup. Our aim is to cover the lack in the study of this topic and experimentally evaluate it in a complex system as a anthropomorphic arm hand system.

1945-1973. Il museo monumento dei BBPR a carpi. Il campo politico e culturale di una architettura in memoria della deportazione politica e razziale

Il Museo Monumento al Deportato politico e razziale nel Castello dei Pio a Carpi (MO), a pochi passi dal Campo nazionale della deportazione razziale e politica di Fossoli, è il risultato di un concorso pubblico nazionale bandito nel 1963, frutto dell’impegno civile tra istituzioni, associazioni e intellettuali. Tra questi il gruppo BBPR il quale, in collaborazione con l’artista Renato Guttuso, si aggiudicheranno la vittoria del concorso. Il progetto vincitore, pur apportando alcune modifiche in fase di realizzazione, manterrà la sua impostazione antiretorica, utilizzando un linguaggio rigoroso e astratto. Partendo dalle caratteristiche che rendono quest’opera una struttura unica nel suo genere, obiettivo principale di questa ricerca di Dottorato è quello di restituire una genealogia del Museo Monumento al Deportato politico e razziale dei BBPR, ricostruendo il quadro culturale e politico italiano nel lasso di tempo che intercorre dalla fine della Seconda Guerra Mondiale (1945) e l’anno della sua inaugurazione (1973). Tale approccio metodologico scelto costituisce l’aspetto di novità della ricerca: un punto di vista ancora inedito con cui guardare il Museo-Monumento, differenziandosi, così, dalle più recenti pubblicazioni sullo stesso, le quali si concentrano soprattutto sulle logiche progettuali del Museo. In conclusione, lo scopo di questa tesi è quella di dare una nuova chiave interpretativa al Museo, che sia non solo un arricchimento alla sua conoscenza ma che, altresì, attesti l’esistenza di un’identità, altrettanto unica e irripetibile, della memoria della deportazione nella cultura architettonica italiana presa in esame, frutto di una “cultura condivisa” tra architetti, artisti, scrittori, politici e intellettuali, accumunati dalle tragiche vicende che in quest’opera si vogliono narrare.

Ragnar Östberg. Genius loci e memorie urbane. Stockholms Stadshuset-Nämndhuset e villa Geber

La ricerca si propone di analizzare una di quelle stagioni architettoniche controverse e lontane dalle internazionali strade maestre del nascente Neues Bauen: il romanticismo-nazionale svedese riletto attraverso l’esperienza del suo massimo esponente, Ragnar Östberg (1866-1945). L’obiettivo della tesi non è solamente quello di una revisione della critica storiografica, facendo così luce su una di quelle personalità considerate marginali, quanto quello di ricavare dalla lettura comparata di due tra i suoi progetti, fino ad ora mai indagati, quegli elementi che fanno dell’architettura un “fatto urbano” in cui la collettività può riconoscersi e parallelamente un fatto di rappresentazione della stessa. L’arcipelago di Stoccolma e quel processo di “renovatio urbis” a cui fu sottoposta proprio agli albori del XX secolo furono gli scenari in cui presero vita i due progetti: il complesso formato dallo Stockholms Stadshuset e la vicina parte mai realizzata del Nämndhuset, e villa Geber. Condensano due dimensioni che la città immersa nel paesaggio contiene: la natura urbana dell’edificio municipale e quella domestica della villa urbana isolata. La ricerca intesse un itinerario di disvelamento attraverso una matrice duale di lettura: “genius loci” e memorie urbane. I capitoli cercano di dimostrare come i due casi-studio siano espressione di quella pendolarità di ricerca tra lo spirito del luogo e le rimembranze delle forme urbane della tradizione. Questa analisi ci conduce in un viaggio alla ricerca dell’atlante delle “memorie urbane”, raccolte nei viaggi e nella formazione, comprendendo così il mondo analogico di riferimenti culturali con altre architetture europee della tradizione. I due progetti sorgono in opposte aree di espansione di Stoccolma e, pur nella loro diversità di scala, sono chiara espressione di appropriatezza al luogo e di strutture formali analoghe. Stockholm Stadshuset-Nämndhuset e villa Geber esprimono il metodo di Östberg, dove i riferimenti raccolti dall’imagination passive sono tramutati ed assemblati grazie alla imagination active.

Mars delivery service - development of the electro-mechanical systems of the Sample Fetch Rover for the Mars Sample Return Campaign

This thesis describes the development of the Sample Fetch Rover (SFR), studied for Mars Sample Return (MSR), an international campaign carried out in cooperation between the National Aeronautics and Space Administration (NASA) and the European Space Agency (ESA). The focus of this document is the design of the electro-mechanical systems of the rover. After placing this work into the general context of robotic planetary exploration and summarising the state of the art for what concerns Mars rovers, the architecture of the Mars Sample Return Campaign is presented. A complete overview of the current SFR architecture is provided, touching upon all the main subsystems of the spacecraft. For each area, it is discussed what are the design drivers, the chosen solutions and whether they use heritage technology (in particular from the ExoMars Rover) or new developments. This research focuses on two topics of particular interest, due to their relevance for the mission and the novelty of their design: locomotion and sample acquisition, which are discussed in depth. The early SFR locomotion concepts are summarised, covering the initial trade-offs and discarded designs for higher traverse performance. Once a consolidated architecture was reached, the locomotion subsystem was developed further, defining the details of the suspension, actuators, deployment mechanisms and wheels. This technology is presented here in detail, including some key analysis and test results that support the design and demonstrate how it responds to the mission requirements. Another major electro-mechanical system developed as part of this work is the one dedicated to sample tube acquisition. The concept of operations of this machinery was defined to be robust against the unknown conditions that characterise the mission. The design process led to a highly automated robotic system which is described here in its main components: vision system, robotic arm and tube storage.

Architettura urbana, gender mainstreaming e l’impatto del femminismo

Questo lavoro di tesi esplora i possibili sviluppi di un'architettura urbana sensibile alle questioni di genere, sotto un prisma femminista intersezionale. Dalla fine degli anni '90, le sperimentazioni in questa direzione hanno cominciato a farsi sempre più numerose, a cominciare dall'esempio pionieristico di Vienna, divenuta città di riferimento per eccellenza. Questa tesi è particolarmente interessata ai progetti sperimentali di Parigi, pur mantenendo una visione comparativa con progetti in altre città europee. In quanto approcci che influenzano l'architettura urbana, vengono esplorati anche le politiche pubbliche e l'attivismo, a livello francese e italiano. Il loro contributo evidenzia il potenziale di reinvenzione simbolica e materiale dell'architettura urbana, passando dal sistema eteropatriarcale verso una maggiore inclusione e giustizia spaziale. Gli interrogativi principali di questo lavoro si basano sull'influenza delle teorie femministe nella pratica professionale di architette·i e urbaniste·i, sul loro ruolo nella trasformazione degli approcci alla città e alla pianificazione urbana, nonché nella trasformazione dell'estetica architettonica e urbana. Attraverso un approccio metodologico situato, riflessivo e interdisciplinare, derivante dalle discipline dell'architettura e dell'urbanistica, il fieldwork svolto ha avuto l'obiettivo di ricercare tendenze, evoluzioni e costanti nei progetti di architettura urbana di genere. Tenendo conto dell'evoluzione temporale delle mentalità sul genere e della consapevolezza sempre più profonda delle questioni femministe, questa tesi assume un approccio critico al Gender Mainstreaming. In aggiunta al pdf della tesi è presente un documento riassuntivo in lingua italiana.

Fracture Mechanics Investigation of Structures with Defects

Fracture mechanics plays an important role in the material science, structure design and industrial production due to the failure of materials and structures are paid high attention in human activities. This dissertation, concentrates on some of the fractural aspects of shaft and composite which have being increasingly used in modern structures, consists four chapters within two parts. Chapters 1 to 4 are included in part 1. In the first chapter, the basic knowledge about the stress and displacement fields in the vicinity of a crack tip is introduced. A review involves the general methods of calculating stress intensity factors are presented. In Chapter 2, two simple engineering methods for a fast and close approximation of stress intensity factors of cracked or notched beams under tension, bending moment, shear force, as well as torque are presented. New formulae for calculating the stress intensity factors are proposed. One of the methods named Section Method is improved and applied to the three dimensional analysis of cracked circular section for calculating stress intensity factors. The comparisons between the present results and the solutions calculated by ABAQUS for single mode and mixed mode are studied. In chapter 3, fracture criteria for a crack subjected to mixed mode loading of two-dimension and three-dimension are reviewed. The crack extension angle for single mode and mixed mode, and the critical loading domain obtained by SEDF and MTS are compared. The effects of the crack depth and the applied force ratio on the crack propagation angle and the critical loading are investigated. Three different methods calculating the crack initiation angle for three-dimension analysis of various crack depth and crack position are compared. It should be noted that the stress intensity factors used in the criteria are calculated in section 2.1.

Teoria e pratica dell'architettura solare - Morfologia, rendimento, strategia progettuale

La recente Direttiva 31/2010 dell’Unione Europea impone agli stati membri di riorganizzare il quadro legislativo nazionale in materia di prestazione energetica degli edifici, affinchè tutte le nuove costruzioni presentino dal 1° gennaio 2021 un bilancio energetico tendente allo zero; termine peraltro anticipato al 1° gennaio 2019 per gli edifici pubblici. La concezione di edifici a energia “quasi” zero (nZEB) parte dal presupposto di un involucro energeticamente di standard passivo per arrivare a compensare, attraverso la produzione preferibilmente in sito di energia da fonti rinnovabili, gli esigui consumi richiesti su base annuale. In quest’ottica la riconsiderazione delle potenzialità dell’architettura solare individua degli strumenti concreti e delle valide metodologie per supportare la progettazione di involucri sempre più performanti che sfruttino pienamente una risorsa inesauribile, diffusa e alla portata di tutti come quella solare. Tutto ciò in considerazione anche della non più procrastinabile necessità di ridurre il carico energetico imputabile agli edifici, responsabili come noto di oltre il 40% dei consumi mondiali e del 24% delle emissioni di gas climalteranti. Secondo queste premesse la ricerca pone come centrale il tema dell’integrazione dei sistemi di guadagno termico, cosiddetti passivi, e di produzione energetica, cosiddetti attivi, da fonte solare nell’involucro architettonico. Il percorso sia analitico che operativo effettuato si è posto la finalità di fornire degli strumenti metodologici e pratici al progetto dell’architettura, bisognoso di un nuovo approccio integrato mirato al raggiungimento degli obiettivi di risparmio energetico. Attraverso una ricognizione generale del concetto di architettura solare e dei presupposti teorici e terminologici che stanno alla base della stessa, la ricerca ha prefigurato tre tipologie di esito finale: una codificazione delle morfologie ricorrenti nelle realizzazioni solari, un’analisi comparata del rendimento solare nelle principali aggregazioni tipologiche edilizie e una parte importante di verifica progettuale dove sono stati applicati gli assunti delle categorie precedenti

Sistemi tecnologici innovativi di involucro per il recupero del patrimonio edilizio recente. L'edilizia scolastica nel Comune di Bologna

La ricerca è volta a presentare un nuovo approccio integrato, a supporto di operatori e progettisti, per la gestione dell’intero processo progettuale di interventi di riqualificazione energetica e architettonica del patrimonio edilizio recente, mediante l’impiego di soluzioni tecnologiche innovative di involucro edilizio. Lo studio richiede necessariamente l’acquisizione di un repertorio selezionato di sistemi costruttivi di involucro, come base di partenza per l’elaborazione di soluzioni progettuali di recupero delle scuole appartenenti al secondo dopoguerra, in conglomerato cementizio armato, prevalentemente prefabbricate. Il progetto individua procedimenti costruttivi ecocompatibili per la progettazione di componenti prefabbricati di involucro “attivo”, adattabile ed efficiente, da assemblare a secco, nel rispetto dei requisiti prestazionali richiesti dalle attuali normative. La ricerca è finalizzata alla gestione dell’intero processo, supportato da sistemi di rilevazione geometrica, collegati a software di programmazione parametrica per la modellazione di superfici adattabili alla morfologia dei fabbricati oggetto di intervento. Tali strumenti informatizzati CAD-CAM sono connessi a macchine a controllo numerico CNC per la produzione industrializzata degli elementi costruttivi “su misura”. A titolo esemplificativo dell’approccio innovativo proposto, si formulano due possibili soluzioni di involucro in linea con i paradigmi della ricerca, nel rispetto dei principi di sostenibilità, intesa come modularità, rapidità di posa, reversibilità, recupero e riciclo di materiali. In particolare, le soluzioni innovative sono accomunate dall’applicazione di una tecnica basata sull’assemblaggio di elementi prefabbricati, dall’adozione di una trama esagonale per la tassellazione della nuova superficie di facciata, e dall’utilizzo del medesimo materiale termico isolante, plastico e inorganico, riciclato ed ecosostenibile, a basso impatto ambientale (AAM - Alkali Activated Materials). Le soluzioni progettuali proposte, sviluppate presso le due sedi coinvolte nella cotutela (Università di Bologna, Université Paris-Est) sono affrontate secondo un protocollo scientifico che prevede: progettazione del sistema costruttivo, analisi meccanica e termica, sperimentazione costruttiva, verifica delle tecniche di messa in opera e dei requisiti prestazionali.

Characterization of first sorption cycle of white Portland cement by 1H NMR

The work carried out is focused on the exploration of processes occurring in cement materials during sorption cycles by using Nuclear Magnetic Resonance (NMR) relaxometry. Long (months) and short (days-weeks) sorption cycles of cement materials were explored. The long cycle consists of around 6 months of drying and re-wetting cement samples of different sizes and water-to-cement (w/c) ratios in a homemade relative humidity (RH) chamber. Short cycles were performed by drying samples of different sizes and w/c ratios in the oven at 60 ˚C and re-wetting underwater. Different NMR techniques, such as one- and two-dimensional relaxometry and solid-signal analyses, were used to study the samples. Firstly, by the interpretation of quasi-continuous distributions of T2 relaxation time, we demonstrated that some reversible and irreversible changes concerning smaller porosity happened during the first sorption cycle. Secondly, using 2D NMR and a new 2D NMR inversion algorithm we showed preliminary results on the cement T1-T2 maps. Data obtained during sorption processes indicated possible water exchange between different pore populations inside the cement samples. Thirdly, the solid structure of cement samples was qualitatively investigated with T1 measurements and, as far as we know, for the first time interpreted with the Pake-Doublet theory. Changes in the solid structure were observed. Precisely variations of the amount of Ettringite during drying/wetting were proposed to take place. Finally, a work on NMR single-sided equipment design for in situ cement investigation was shown. The multi-cubic-blocks magnet structure design was performed using different specific CAD software, and the magnetic fields generated by RF coils of different geometries were investigated using a customized Matlab script. The single-sided NMR instrument equipped with the designed single-sided magnet and coil was built by the ERICA partner company MR Solutions (Abingdon, UK), and the preliminary results resultsated the correctness of the developed design.

Investigating the learning potential of the Second Quantum Revolution: development of an approach for secondary school students

In recent years we have witnessed important changes: the Second Quantum Revolution is in the spotlight of many countries, and it is creating a new generation of technologies. To unlock the potential of the Second Quantum Revolution, several countries have launched strategic plans and research programs that finance and set the pace of research and development of these new technologies (like the Quantum Flagship, the National Quantum Initiative Act and so on). The increasing pace of technological changes is also challenging science education and institutional systems, requiring them to help to prepare new generations of experts. This work is placed within physics education research and contributes to the challenge by developing an approach and a course about the Second Quantum Revolution. The aims are to promote quantum literacy and, in particular, to value from a cultural and educational perspective the Second Revolution. The dissertation is articulated in two parts. In the first, we unpack the Second Quantum Revolution from a cultural perspective and shed light on the main revolutionary aspects that are elevated to the rank of principles implemented in the design of a course for secondary school students, prospective and in-service teachers. The design process and the educational reconstruction of the activities are presented as well as the results of a pilot study conducted to investigate the impact of the approach on students' understanding and to gather feedback to refine and improve the instructional materials. The second part consists of the exploration of the Second Quantum Revolution as a context to introduce some basic concepts of quantum physics. We present the results of an implementation with secondary school students to investigate if and to what extent external representations could play any role to promote students’ understanding and acceptance of quantum physics as a personal reliable description of the world.

Thermal and air quality modeling of an electric vehicle cabin with low-cost sensors and reinforcement learning

The design process of any electric vehicle system has to be oriented towards the best energy efficiency, together with the constraint of maintaining comfort in the vehicle cabin. Main aim of this study is to research the best thermal management solution in terms of HVAC efficiency without compromising occupant’s comfort and internal air quality. An Arduino controlled Low Cost System of Sensors was developed and compared against reference instrumentation (average R-squared of 0.92) and then used to characterise the vehicle cabin in real parking and driving conditions trials. Data on the energy use of the HVAC was retrieved from the car On-Board Diagnostic port. Energy savings using recirculation can reach 30 %, but pollutants concentration in the cabin builds up in this operating mode. Moreover, the temperature profile appeared strongly nonuniform with air temperature differences up to 10° C. Optimisation methods often require a high number of runs to find the optimal configuration of the system. Fast models proved to be beneficial for these task, while CFD-1D model are usually slower despite the higher level of detail provided. In this work, the collected dataset was used to train a fast ML model of both cabin and HVAC using linear regression. Average scaled RMSE over all trials is 0.4 %, while computation time is 0.0077 ms for each second of simulated time on a laptop computer. Finally, a reinforcement learning environment was built in OpenAI and Stable-Baselines3 using the built-in Proximal Policy Optimisation algorithm to update the policy and seek for the best compromise between comfort, air quality and energy reward terms. The learning curves show an oscillating behaviour overall, with only 2 experiments behaving as expected even if too slow. This result leaves large room for improvement, ranging from the reward function engineering to the expansion of the ML model.

Architectures and design patterns for functional design of logic control and diagnostics in industrial automation

Recently in most of the industrial automation process an ever increasing degree of automation has been observed. This increasing is motivated by the higher requirement of systems with great performance in terms of quality of products/services generated, productivity, efficiency and low costs in the design, realization and maintenance. This trend in the growth of complex automation systems is rapidly spreading over automated manufacturing systems (AMS), where the integration of the mechanical and electronic technology, typical of the Mechatronics, is merging with other technologies such as Informatics and the communication networks. An AMS is a very complex system that can be thought constituted by a set of flexible working stations, one or more transportation systems. To understand how this machine are important in our society let considerate that every day most of us use bottles of water or soda, buy product in box like food or cigarets and so on. Another important consideration from its complexity derive from the fact that the the consortium of machine producers has estimated around 350 types of manufacturing machine. A large number of manufacturing machine industry are presented in Italy and notably packaging machine industry,in particular a great concentration of this kind of industry is located in Bologna area; for this reason the Bologna area is called “packaging valley”. Usually, the various parts of the AMS interact among them in a concurrent and asynchronous way, and coordinate the parts of the machine to obtain a desiderated overall behaviour is an hard task. Often, this is the case in large scale systems, organized in a modular and distributed manner. Even if the success of a modern AMS from a functional and behavioural point of view is still to attribute to the design choices operated in the definition of the mechanical structure and electrical electronic architecture, the system that governs the control of the plant is becoming crucial, because of the large number of duties associated to it. Apart from the activity inherent to the automation of themachine cycles, the supervisory system is called to perform other main functions such as: emulating the behaviour of traditional mechanical members thus allowing a drastic constructive simplification of the machine and a crucial functional flexibility; dynamically adapting the control strategies according to the different productive needs and to the different operational scenarios; obtaining a high quality of the final product through the verification of the correctness of the processing; addressing the operator devoted to themachine to promptly and carefully take the actions devoted to establish or restore the optimal operating conditions; managing in real time information on diagnostics, as a support of the maintenance operations of the machine. The kind of facilities that designers can directly find on themarket, in terms of software component libraries provides in fact an adequate support as regard the implementation of either top-level or bottom-level functionalities, typically pertaining to the domains of user-friendly HMIs, closed-loop regulation and motion control, fieldbus-based interconnection of remote smart devices. What is still lacking is a reference framework comprising a comprehensive set of highly reusable logic control components that, focussing on the cross-cutting functionalities characterizing the automation domain, may help the designers in the process of modelling and structuring their applications according to the specific needs. Historically, the design and verification process for complex automated industrial systems is performed in empirical way, without a clear distinction between functional and technological-implementation concepts and without a systematic method to organically deal with the complete system. Traditionally, in the field of analog and digital control design and verification through formal and simulation tools have been adopted since a long time ago, at least for multivariable and/or nonlinear controllers for complex time-driven dynamics as in the fields of vehicles, aircrafts, robots, electric drives and complex power electronics equipments. Moving to the field of logic control, typical for industrial manufacturing automation, the design and verification process is approached in a completely different way, usually very “unstructured”. No clear distinction between functions and implementations, between functional architectures and technological architectures and platforms is considered. Probably this difference is due to the different “dynamical framework”of logic control with respect to analog/digital control. As a matter of facts, in logic control discrete-events dynamics replace time-driven dynamics; hence most of the formal and mathematical tools of analog/digital control cannot be directly migrated to logic control to enlighten the distinction between functions and implementations. In addition, in the common view of application technicians, logic control design is strictly connected to the adopted implementation technology (relays in the past, software nowadays), leading again to a deep confusion among functional view and technological view. In Industrial automation software engineering, concepts as modularity, encapsulation, composability and reusability are strongly emphasized and profitably realized in the so-calledobject-oriented methodologies. Industrial automation is receiving lately this approach, as testified by some IEC standards IEC 611313, IEC 61499 which have been considered in commercial products only recently. On the other hand, in the scientific and technical literature many contributions have been already proposed to establish a suitable modelling framework for industrial automation. During last years it was possible to note a considerable growth in the exploitation of innovative concepts and technologies from ICT world in industrial automation systems. For what concerns the logic control design, Model Based Design (MBD) is being imported in industrial automation from software engineering field. Another key-point in industrial automated systems is the growth of requirements in terms of availability, reliability and safety for technological systems. In other words, the control system should not only deal with the nominal behaviour, but should also deal with other important duties, such as diagnosis and faults isolations, recovery and safety management. Indeed, together with high performance, in complex systems fault occurrences increase. This is a consequence of the fact that, as it typically occurs in reliable mechatronic systems, in complex systems such as AMS, together with reliable mechanical elements, an increasing number of electronic devices are also present, that are more vulnerable by their own nature. The diagnosis problem and the faults isolation in a generic dynamical system consists in the design of an elaboration unit that, appropriately processing the inputs and outputs of the dynamical system, is also capable of detecting incipient faults on the plant devices, reconfiguring the control system so as to guarantee satisfactory performance. The designer should be able to formally verify the product, certifying that, in its final implementation, it will perform itsrequired function guarantying the desired level of reliability and safety; the next step is that of preventing faults and eventually reconfiguring the control system so that faults are tolerated. On this topic an important improvement to formal verification of logic control, fault diagnosis and fault tolerant control results derive from Discrete Event Systems theory. The aimof this work is to define a design pattern and a control architecture to help the designer of control logic in industrial automated systems. The work starts with a brief discussion on main characteristics and description of industrial automated systems on Chapter 1. In Chapter 2 a survey on the state of the software engineering paradigm applied to industrial automation is discussed. Chapter 3 presentes a architecture for industrial automated systems based on the new concept of Generalized Actuator showing its benefits, while in Chapter 4 this architecture is refined using a novel entity, the Generalized Device in order to have a better reusability and modularity of the control logic. In Chapter 5 a new approach will be present based on Discrete Event Systems for the problemof software formal verification and an active fault tolerant control architecture using online diagnostic. Finally conclusive remarks and some ideas on new directions to explore are given. In Appendix A are briefly reported some concepts and results about Discrete Event Systems which should help the reader in understanding some crucial points in chapter 5; while in Appendix B an overview on the experimental testbed of the Laboratory of Automation of University of Bologna, is reported to validated the approach presented in chapter 3, chapter 4 and chapter 5. In Appendix C some components model used in chapter 5 for formal verification are reported.