Virtualization of Wiring Harness Manipulation Tasks through the PyChrono Simulation Engine

The purpose of this thesis work is the study and creation of a harness modelling system. The model needs to simulate faithfully the physical behaviour of the harness, without any instability or incorrect movements. Since there are various simulation engines that try to model wiring's systems, this thesis work focused on the creation and test of a 3D environment with wiring and other objects through the PyChrono Simulation Engine. Fine-tuning of the simulation parameters were done during the test to achieve the most stable and correct simulation possible, but tests showed the intrinsic limits of the Engine regarding the collisions' detection between the various part of the cables, while collisions between cables and other physical objects such as pavement, walls and others are well managed by the simulator. Finally, the main purpose of the model is to be used to train Artificial Intelligence through Reinforcement Learnings techniques, so we designed, using OpenAI Gym APIs, the general structure of the learning environment, defining its basic functions and an initial framework.

Analysis and improvements of an existing industrial hot stamping machine

The importance of product presentation in the marketing industry is well known. Labels are crucial for providing information to the buyer, but at a modest additional expense, a beautiful label with exquisite embellishments may also give the goods a sensation of high quality and elegance. Enhancing the capabilities of stamping machines is required to keep up with the increasing velocity of the production lines in the modern manufacturing industry and to offer new opportunities for customization. It’s in this context of improvements and refinements that this work takes place. The thesis was developed during an internship at Studio D, the firm that designs the mechanics of the machines produced by Cartes. The The aim of this work is to study possible upgrades for the existing hot stamping machines. The main focus of this work is centred on two objectives: first, evaluating the pressing forces generated by this machine and characterising how the mat used in the stamping process reacts to such forces. Second, propose a new conformation for the press mechanism in order to improve the rigidity and performance of the machines. The first objective is reached through a combined approach: the mat is crudely characterized with experimental data, while the frame of the machine is studied through FEM analysis. The results obtained are combined and used to upgrade a worksheet that allows to estimate the forces exerted by the machines. The second objective is reached with the proposal of new, improved designs for the main components of the machines.

Design and implementation of a synchronous interleaved boost converter for fuel cell-powered catamaran

The present work describes the different stages of design, implementation, and validation procedures for an interleaved DC-DC boost converter intended for the 2022 Futura, a fuel cell-powered racing catamaran developed by the UniBoAT team. The main goal of the entire design has been the significant reduction of the weight of the converter by removing heat sinks and reducing component size while increasing its efficiency by adopting high-end power switches and the interleaved architecture operated with a synchronous control strategy. The obtained converter has been integrated into the structure containing the fuel cell stack obtaining a fully integrated system. The realized device has been based on an interleaved architecture with six phases controlled digitally through the average current mode control. The design has been validated through simulations carried out using the software LT-Spice, whereas experimental validations have been performed by means of laboratory bench tests and on-field tests. Detailed thermal and efficiency analyses are provided with the bench tests under the two synchronous and non-synchronous operating modes and with the adoption of the phase shedding technique. The prototype implementation and its performance in real operating conditions are also discussed. Eventually, it is underlined as the designed converter can be used in other applications requiring a voltage-controlled boost converter.

Machine Learning algorithm on seat comfort level measurement, mapping pressure values with body regions

The comfort level of the seat has a major effect on the usage of a vehicle; thus, car manufacturers have been working on elevating car seat comfort as much as possible. However, still, the testing and evaluation of comfort are done using exhaustive trial and error testing and evaluation of data. In this thesis, we resort to machine learning and Artificial Neural Networks (ANN) to develop a fully automated approach. Even though this approach has its advantages in minimizing time and using a large set of data, it takes away the degree of freedom of the engineer on making decisions. The focus of this study is on filling the gap in a two-step comfort level evaluation which used pressure mapping with body regions to evaluate the average pressure supported by specific body parts and the Self-Assessment Exam (SAE) questions on evaluation of the person’s interest. This study has created a machine learning algorithm that works on giving a degree of freedom to the engineer in making a decision when mapping pressure values with body regions using ANN. The mapping is done with 92% accuracy and with the help of a Graphical User Interface (GUI) that facilitates the process during the testing time of comfort level evaluation of the car seat, which decreases the duration of the test analysis from days to hours.

Study of an advanced transport system exploiting magnetic levitation: the Beckhoff XPlanar

The transport system is one of the most important components to be chosen in the design of an automatic machine. There is a wide variety of different choices that can be made in picking this element, each one having its own strengths and its own drawbacks. If it is desired to obtain some elaborate behaviour from the transport system, it is a good idea to think about some flexible and advanced solutions. Among these transport systems, the newest is the Beckhoff XPlanar. This transport system exploits magnetic levitation to move some passive magnetic movers on a completely customizable plane, in an entirely contact-free way. This provides a fast, clean, and noiseless motion, which is extremely desirable in a modern automatic machine. The purpose of this Thesis is to analyse the potentialities and the problems of this new device, starting from the basics. After having presented in detail the topic, an analysis on the hardware components needed to build this system is performed. Then, it is conducted a study on the concepts needed to know how to build a controller having the purpose of dealing with this system. After that, the various types of motion are studied and executed and, later on, some experiments on the real kit are carried out. These studies start from the diagnostic and involve other analyses that are used to test the limits of this transport system. In performing these analyses, it is noticed how the kit presents some problems in reaching the limits of the dynamics. Finally, two different types of station cycle are implemented, which are useful to get a rough idea on the potentialities of this new advanced transport system.

Axis control optimization: autotuning techniques and frequency response analysis of industrial mechatronic systems

In the field of industrial automation, there is an increasing need to use optimal control systems that have low tracking errors and low power and energy consumption. The motors we are dealing with are mainly Permanent Magnet Synchronous Motors (PMSMs), controlled by 3 different types of controllers: a position controller, a speed controller, and a current controller. In this thesis, therefore, we are going to act on the gains of the first two controllers by going to find, through the TwinCAT 3 software, what might be the best set of parameters. To do this, starting with the default parameters recommended by TwinCAT, two main methods were used and then compared: the method of Ziegler and Nichols, which is a tabular method, and advanced tuning, an auto-tuning software method of TwinCAT. Therefore, in order to analyse which set of parameters was the best,several experiments were performed for each case, using the Motion Control Function Blocks. Moreover, some machines, such as large robotic arms, have vibration problems. To analyse them in detail, it was necessary to use the Bode Plot tool, which, through Bode plots, highlights in which frequencies there are resonance and anti-resonance peaks. This tool also makes it easier to figure out which and where to apply filters to improve control.

Fleet Management System for Search and Rescue Operations

Over one million people lost their lives in the last twenty years from natural disasters like wildfires, earthquakes and man-made disasters. In such scenarios the usage of a fleet of robots aims at the parallelization of the workload and thus increasing speed and capabilities to complete time sensitive missions. This work focuses on the development of a dynamic fleet management system, which consists in the management of multiple agents cooperating in order to accomplish tasks. We presented a Mixed Integer Programming problem for the management and planning of mission’s tasks. The problem was solved using both an exact and a heuristic approach. The latter is based on the idea of solving iteratively smaller instances of the complete problem. Alongside, a fast and efficient algorithm for estimation of travel times between tasks is proposed. Experimental results demonstrate that the proposed heuristic approach is able to generate quality solutions, within specific time limits, compared to the exact one.

Realizzazione di uno slave EtherCAT integrante periferiche per applicazioni motion control

The technological enhancement of industrial automation and manufacturing is stricty connected to the innovations of communication technologies. The main impact of the last century is due to the introduction of FieldBus systems. Indeed, they have been fundamental for the lowest levels of the automation hierarchy. Besides factory automation, many processes nowadays would not be feasible without Fieldbus based networks. Indeed, these systems are employed in a large variety of application areas from energy distribution to in-vehicle networking but also in rail-way applications and avionics. In the following document, the main activities executed during the internship in I.M.A. S.p.A. are reported. The objective of the thesis is to develop an EtherCAT (Ethernet Fieldbus) slave integrated with peripherals for motion control applications. The slave is created by exploiting a micro-controller of Renesas Electronics called RX72M. Since, for the specific application the MCU lacks of several components needed for motion control, external devices are employed for developing the project.

Continual learning on nano drones

Miniaturized flying robotic platforms, called nano-drones, have the potential to revolutionize the autonomous robots industry sector thanks to their very small form factor. The nano-drones’ limited payload only allows for a sub-100mW microcontroller unit for the on-board computations. Therefore, traditional computer vision and control algorithms are too computationally expensive to be executed on board these palm-sized robots, and we are forced to rely on artificial intelligence to trade off accuracy in favor of lightweight pipelines for autonomous tasks. However, relying on deep learning exposes us to the problem of generalization since the deployment scenario of a convolutional neural network (CNN) is often composed by different visual cues and different features from those learned during training, leading to poor inference performances. Our objective is to develop and deploy and adaptation algorithm, based on the concept of latent replays, that would allow us to fine-tune a CNN to work in new and diverse deployment scenarios. To do so we start from an existing model for visual human pose estimation, called PULPFrontnet, which is used to identify the pose of a human subject in space through its 4 output variables, and we present the design of our novel adaptation algorithm, which features automatic data gathering and labeling and on-device deployment. We therefore showcase the ability of our algorithm to adapt PULP-Frontnet to new deployment scenarios, improving the R2 scores of the four network outputs, with respect to an unknown environment, from approximately [−0.2, 0.4, 0.0,−0.7] to [0.25, 0.45, 0.2, 0.1]. Finally we demonstrate how it is possible to fine-tune our neural network in real time (i.e., under 76 seconds), using the target parallel ultra-low power GAP 8 System-on-Chip on board the nano-drone, and we show how all adaptation operations can take place using less than 2mWh of energy, a small fraction of the available battery power.

Robotic grasping: State of the art and modular real-world implementation

Robotic Grasping is an important research topic in robotics since for robots to attain more general-purpose utility, grasping is a necessary skill, but very challenging to master. In general the robots may use their perception abilities like an image from a camera to identify grasps for a given object usually unknown. A grasp describes how a robotic end-effector need to be positioned to securely grab an object and successfully lift it without lost it, at the moment state of the arts solutions are still far behind humans. In the last 5–10 years, deep learning methods take the scene to overcome classical problem like the arduous and time-consuming approach to form a task-specific algorithm analytically. In this thesis are present the progress and the approaches in the robotic grasping field and the potential of the deep learning methods in robotic grasping. Based on that, an implementation of a Convolutional Neural Network (CNN) as a starting point for generation of a grasp pose from camera view has been implemented inside a ROS environment. The developed technologies have been integrated into a pick-and-place application for a Panda robot from Franka Emika. The application includes various features related to object detection and selection. Additionally, the features have been kept as generic as possible to allow for easy replacement or removal if needed, without losing time for improvement or new testing.

Scripting automation e modelli bayesiani: Applicazioni cliniche in radioterapia e sviluppo di tecniche innovative per adaptive radiation therapy

La presente ricerca consiste nel validare ed automatizzare metodiche di Adaptive Radiation Therapy (ART), che hanno come obiettivo la personalizzazione continua del piano di trattamento radioterapico in base alle variazioni anatomiche e dosimetriche del paziente. Tali variazioni (casuali e/o sistematiche) sono identificabili mediante l’utilizzo dell’imaging diagnostico. Il lavoro svolto presso la struttura di Fisica Medica dell’Azienda Ospedaliera Universitaria del Policlinico di Modena, si inserisce in un progetto del Ministero della Salute del bando Giovani Ricercatori dal titolo: “Dose warping methods for IGRT and ADAPTIVERT: dose accumulation based on organ motion and anatomical variations of the patients during radiation therapy treatments”. Questa metodica si sta affermando sempre più come nuova opportunità di trattamento e, per tale motivo, nasce l’esigenza di studiare e automatizzare processi realizzabili nella pratica clinica, con un utilizzo limitato di risorse. Si sono sviluppati script che hanno permesso l’automazione delle operazioni di Adaptive e deformazioni, raccogliendo i dati di 51 pazienti sottoposti a terapia mediante Tomotherapy. L’analisi delle co-registrazioni deformabili delle strutture e delle dosi distribuite, ha evidenziato criticità del software che hanno reso necessario lo sviluppo di sistemi di controllo dei risultati, per facilitare l’utente nella revisione quotidiana dei casi clinici. La letteratura riporta un numero piuttosto limitato di esperienze sulla validazione e utilizzo su larga scala di questi tools, per tale motivo, si è condotto un esame approfondito della qualità degli algoritmi elastici e la valutazione clinica in collaborazione di fisici medici e medici radioterapisti. Sono inoltre stati sviluppati principi di strutturazione di reti Bayesiane, che consentono di predirre la qualità delle deformazioni in diversi ambiti clinici (H&N, Prostata, Polmoni) e coordinare il lavoro quotidiano dei professionisti, identificando i pazienti, per i quali sono apprezzabili variazioni morfo-dosimetriche significative. Da notare come tale attività venga sviluppata automaticamente durante le ore notturne, sfruttando l’automation come strumento avanzato e indipendente dall’operatore. Infine, il forte sviluppo, negli ultimi anni della biomeccanica applicata al movimento degli organi (dimostrato dalla numerosa letteratura al riguardo), ha avuto come effetto lo sviluppo, la valutazione e l’introduzione di algoritmi di deformazione efficaci. In questa direzione, nel presente lavoro, si sono analizzate quantitivamente le variazioni e gli spostamenti delle parotidi, rispetto all’inizio del trattamento, gettando le basi per una proficua linea di ricerca in ambito radioterapico.

Computing primal solutions with exact arithmetics in SCIP.

The research for exact solutions of mixed integer problems is an active topic in the scientific community. State-of-the-art MIP solvers exploit a floating- point numerical representation, therefore introducing small approximations. Although such MIP solvers yield reliable results for the majority of problems, there are cases in which a higher accuracy is required. Indeed, it is known that for some applications floating-point solvers provide falsely feasible solutions, i.e. solutions marked as feasible because of approximations that would not pass a check with exact arithmetic and cannot be practically implemented. The framework of the current dissertation is SCIP, a mixed integer programs solver mainly developed at Zuse Institute Berlin. In the same site we considered a new approach for exactly solving MIPs. Specifically, we developed a constraint handler to plug into SCIP, with the aim to analyze the accuracy of provided floating-point solutions and compute exact primal solutions starting from floating-point ones. We conducted a few computational experiments to test the exact primal constraint handler through the adoption of two main settings. Analysis mode allowed to collect statistics about current SCIP solutions' reliability. Our results confirm that floating-point solutions are accurate enough with respect to many instances. However, our analysis highlighted the presence of numerical errors of variable entity. By using the enforce mode, our constraint handler is able to suggest exact solutions starting from the integer part of a floating-point solution. With the latter setting, results show a general improvement of the quality of provided final solutions, without a significant loss of performances.

Applicazione di tecniche di Reliability, Availability e Maintainability analysis in un’azienda produttrice di macchine automatiche. Il caso Ima S.p.A.

Il seguente lavoro di tesi è nato durante un’attività di stage della durata di 7 mesi svolto all’interno della divisione Tea&Coffe di IMA S.p.A., azienda leader mondiale nella produzione di macchine automatiche per il confezionamento di prodotti farmaceutici, cosmetici, alimentari, tè e caffè. Le attività svolte si collocano all’interno di un progetto avviato da IMA per promuovere il passaggio ad un modello di industria necessariamente più evoluta, facendo leva sull’attitudine ad integrare e sviluppare nuove conoscenze e nuove tecnologie interdisciplinari e, allo stesso tempo, di massimizzare la sinergia tra le dimensioni tecnica ed economica, comportando una reale riduzione di sprechi nella filiera produttiva, commerciale ed ambientale. I moderni impianti di produzione devono infatti affrontare una sfida che li vede alla continua ricerca della produttività, ovvero di una produzione che remuneri velocemente e con ampi margini gli investimenti effettuati, della qualità dei prodotti e dei processi di produzione, ovvero della garanzia di soddisfacimento delle aspettative espresse ed inespresse del cliente, e della sicurezza per la salvaguardia della collettività e dell’ambiente. L’obiettivo di questo elaborato è stato quello di effettuare lo studio affidabilistico di una macchina automatica per la produzione di bustine di tè al fine di poterne studiare il suo comportamento al guasto e di elaborare in un secondo momento le politiche manutentive ottimizzate che ne permettano una gestione più efficiente. In questo ambito la macchina è stata scomposta in gruppi e sono stati esaminati tutti i pezzi di ricambio che sono stati richiesti in un arco temporale di durata pari a dieci anni, il fine è quello di poter individuare ed effettuare un’analisi affidabilistica dei componenti critici per poi procedere, attraverso l’uso di piattaforme software quali Weibull++ e Blocksim, col modellarne le distribuzioni statistiche e simulare il funzionamento del sistema nel suo complesso.

Comparison between 5G private network and Wifi6 in industrial environment

Industry 4.0 refers to the 4th industrial revolution and at its bases, we can see the digitalization and the automation of the assembly line. The whole production process has improved and evolved thanks to the advances made in networking, and AI studies, which include of course machine learning, cloud computing, IoT, and other technologies that are finally being implemented into the industrial scenario. All these technologies have in common a need for faster, more secure, robust, and reliable communication. One of the many solutions for these demands is the use of mobile communication technologies in the industrial environment, but which technology is better suited for these demands? Of course, the answer isn’t as simple as it seems. The 4th industrial revolution has a never seen incomparable potential with respect to the previous ones, every factory, enterprise, or company have different network demands, and even in each of these infrastructures, the demands may diversify by sector, or by application. For example, in the health care industry, there may be e a need for increased bandwidth for the analysis of high-definition videos or, faster speeds in order to have analytics occur in real-time, and again another application might be higher security and reliability to protect patients’ data. As seen above, choosing the right technology for the right environment and application, considers many things, and the ones just stated are but a speck of dust with respect to the overall picture. In this thesis, we will investigate a comparison between the use of two of the available technologies in use for the industrial environment: Wi-Fi 6 and 5G Private Networks in the specific case of a steel factory.