la fabbrica automatica e i sistemi di controllo integrati

Lo scopo della presente tesi è quello di illustrare alcuni dei principali strumenti messi a disposizione dai controlli automatici a servizio dell’ingegneria, in particolare analizzando la struttura generale di una fabbrica automatica e descrivendone i principali sistemi di controllo. L’elaborato è suddiviso in tre macro parti: la prima ha l’obiettivo di inquadrare quella che è la fabbrica automatica, partendo dal precedente concetto di fabbrica tradizionale fino ad arrivare alla fabbrica moderna, caratterizzata da una spinta flessibilità produttiva determinata da una politica di produzione per lotti con elevati livelli di caratterizzazione. Della fabbrica automatica viene poi approfondita l’integrazione con i calcolatori attraverso il sistema concettuale del CIM, Computer Integrated Manufacturing, e l’impiego di celle di fabbricazione flessibili, ovvero le FMS, Flexible Manufacturing System. La seconda parte è incentrata sull’analisi delle logiche di controllo impiegate all’interno di tutto il processo di progettazione e di produzione, suddivise in tre gruppi: il primo focalizzato sui sistemi per la produzione automatica, NC e DNC; il secondo sui sistemi di simulazione e testing del prodotto, CAD, CAM e CAT; il terzo sui sistemi di controllo e sviluppo dati, SCADA, MES e DCS. La terza ed ultima parte è circoscritta all’approfondimento di un particolare sistema di controllo per la gestione dei processi, ovvero sull’uso del PLC, il Controllore Logico Programmabile. Vengono analizzate le componenti fisiche che lo costituiscono, il funzionamento base, i tempi di esecuzione delle istruzioni, i criteri di scelta e di dimensionamento ed altri aspetti rilevanti. Infine è presente un esempio applicativo di alcuni aspetti sovra citati con il caso dell’azienda bolognese G.D, leader del settore delle macchine automatiche a controllo numerico per la fabbricazione e l’impacchettamento delle sigarette.

Vibro-acoustic analysis of additively manufactured acoustic metamaterials

In the last decade it emerged the interest in new types of acoustic insulating materials, called acoustic metamaterials. These materials are composed by a host and inclusions and are arranged periodically or non-periodically in sub-wavelength elements called meta-atoms. Their inclusions and internal geometries can be manipulated to tailor the acoustic properties, reducing weight, and increasing at the same time their efficiency. Thanks to the high absorbing characteristics that they can achieve, their usage is of particularly interest as material of the core in sandwich panels of aerospace structures to reduce vibrations and noise inside passengers aircraft’s cabin. In addition, since the low frequency signals are difficult to be damped with conventional materials, their usage can guarantee a high transmission loss at low frequencies, obtaining a positive benefit on passengers’ comfort. The performances and efficiency of these materials are enhanced thanks to the new additive manufacturing techniques opposed to the conventional ones uncapable to pro- duce such complex internal geometries. The aim of this work is to study, produce and redesign micro-perforated sandwich panels of a literature case study to achieve high performances in the low frequency range, e.g., below 2000 Hz. Some geometrical parameters, such as perforation ratio and diameter of holes, were considered to realize different models and see the differences in the sound transmission loss. The models were produced by means of Fused Deposition Modelling using an Acrylonitrile Butadiene Styrene (ABS Plus p430) material on a commercial additive manufacturing system. Finally, the frequency response analysis was carried out with Mul2 software, based on the Carrera’s Unified Formulation (CUF) to understand the acoustic and structural properties of the material employed, analyzing the plates’ displacements and the TL results.

Applicazione di un modello bi-obiettivo per la progettazione sostenibile di sistemi produttivi riconfigurabili

Negli ultimi anni la competitività nei mercati è notevolmente cresciuta, la complessità dei prodotti industriali è considerevolmente aumentata e quest’ultimi devono ora essere accuratamente ottimizzati sotto ogni aspetto. I prodotti, oltre ad avere dei cicli di vita più brevi, sono soggetti a un’alta personalizzazione e a una domanda variabile. Per rimanere competitive, le aziende manifatturiere devono possedere nuovi tipi di sistemi di produzione che siano convenienti e molto reattivi a tutti questi cambiamenti del mercato, quali i Sistemi di produzione riconfigurabili (Reconfigurable Manufacturing System - RMS). La particolarità di tali sistemi risiede nella capacità di cambiare rapidamente le loro strutture hardware e software, aspetto che li renda idonei a soddisfare la produzione moderna. Oltre agli aspetti produttivi, l’attenzione odierna è incentrata anche sulle tematiche ambientali legate al risparmio energetico durante i processi produttivi, alla riduzione delle quantità di CO2 emesse e alla sostenibilità ambientale. L’obiettivo di questa tesi è quello di proporre un modello di ottimizzazione multi-obiettivo che tenga conto sia della minimizzazione del tempo complessivo necessario alla movimentazione dei prodotti e alla riconfigurazione delle macchine, e sia della minimizzazione del consumo energetico. Tale modello è stato applicato ad un caso studio realistico che ha permesso di individuare un trade-off tecnico-ambientale individuando la frontiera di Pareto con punto di ottimo (134.6 min; 9346.3 kWh) che si discosta del 57% dal valore trovato ottimizzando la funzione tempo, e dello 0.76% dal valore ottenuto ottimizzando la funzione energia.

Development of a robotic system for switchgear cabling

Industrial robots are an inalienable part of modern automated production. Typical applications of robots include welding, painting, (dis)assembly, packaging, labeling, palletizing, pick and place and others. Many of that applications includes object manipulation. If the shape and position of the object are known in advance, it is possible to design the trajectory of the robot’s end-effector to take and place. Such a strategy is applicable for rigid objects and widely used in the manufacturing field. But flexible (deformable) objects can change their shape and position upon contact with the robot’s end-effector or environment. That is the reason why the general approach is unacceptable. It means that the robot can fail to grasp such an object and can’t place it in the desired position. This thesis has addressed the problem of cable manipulation by bilateral robotic setup for the industrial manufacturing of electrical switchgear. The considered solution is based on the idea of tensioned cable. If the cable was grasped by the ends and tensioned, it has a line shape. Since the position of the robot’s end-effectors known, the position of the cable is known as well. Such an approach is capable to place cable in cable ducts of switchgear. The considered solution has been tested experimentally on a real bilateral robotic setup.

Development of a Robotic Wires Storage System for Switchgear Manufacturing Automation

Considering the great development of robotics in industrial automation, the Remodel project aims to reproduce, through the use of Cobots, the wiring activity typical of a human operator and to realize an autonomous storage work. My researches focused on this second topic. In this paper, we will see how to realize a gripper compatible with an Omron TM5X-900, able to perform a pick and place of different types of cables, but also how to compute possible trajectories. In particular, what I needed, was a trajectory going from the Komax, the cables production machine, to a Warehouse taking into account the possible entangles of cables with the robot during its motion. The last part has been dedicated to the synchronization between robot and main machine work.

Development and optimization of fibre-shaped dye-sensitized solar cells employing an innovative fully organic sensitizer

The quality of human life depends to a large degree on the availability of energy. In recent years, photovoltaic technology has been growing extraordinarily as a suitable source of energy, as a consequence of the increasing concern over the impact of fossil fuels on climate change. Developing affordable and highly efficiently photovoltaic technologies is the ultimate goal in this direction. Dye-sensitized solar cells (DSSCs) offer an efficient and easily implementing technology for future energy supply. Compared to conventional silicon solar cells, they provide comparable power conversion efficiency at low material and manufacturing costs. In addition, DSSCs are able to harvest low-intensity light in diffuse illumination conditions and then represent one of the most promising alternatives to the traditional photovoltaic technology, even more when trying to move towards flexible and transparent portable devices. Among these, considering the increasing demand of modern electronics for small, portable and wearable integrated optoelectronic devices, Fibre Dye-Sensitized Solar Cells (FDSSCs) have gained increasing interest as suitable energy provision systems for the development of the next-generation of smart products, namely “electronic textiles” or “e-textiles”. In this thesis, several key parameters towards the optimization of FDSSCs based on inexpensive and abundant TiO2 as photoanode and a new innovative fully organic sensitizer were studied. In particular, the effect of various FDSSCs components on the device properties pertaining to the cell architecture in terms of photoanode oxide layer thickness, electrolytic system, cell length and electrodes substrates were examined. The photovoltaic performances of the as obtained FDSSCs were fully characterized. Finally, the metal part of the devices (wire substrate) was substituted with substrates suitable for the textile industry as a fundamental step towards commercial exploitation.

Fractional Order Modeling and Control of a Flexible Satellite

Researchers have engrossed fractional-order modeling because of its ability to capture phenomena that are nearly impossible to describe owing to its long-term memory and inherited properties. Motivated by the research in fractional modeling, a fractional-order prototype for a flexible satellite whose dynamics are governed by fractional differential equations is proposed for the first time. These relations are derived using fractional attitude dynamic description of rigid body simultaneously coupled with the fractional Lagrange equation that governs the vibration of the appendages. Two attitude controls are designed in the presence of the faults and uncertainties of the system. The first is the fractional-order feedback linearization controller, in which the stability of the internal dynamics of the system is proved. The second is the fractional-order sliding mode control, whose asymptotic stability is demonstrated using the quadratic Lyapunov function. Several nonlinear simulations are implemented to analyze the performance of the proposed controllers.

Computer vision in aseptic pharmaceutical manufacturing: a deep learning-based approach to vial inspection and pack formation during a lyophilizer loading cycle

Vision systems are powerful tools playing an increasingly important role in modern industry, to detect errors and maintain product standards. With the enlarged availability of affordable industrial cameras, computer vision algorithms have been increasingly applied in industrial manufacturing processes monitoring. Until a few years ago, industrial computer vision applications relied only on ad-hoc algorithms designed for the specific object and acquisition setup being monitored, with a strong focus on co-designing the acquisition and processing pipeline. Deep learning has overcome these limits providing greater flexibility and faster re-configuration. In this work, the process to be inspected consists in vials’ pack formation entering a freeze-dryer, which is a common scenario in pharmaceutical active ingredient packaging lines. To ensure that the machine produces proper packs, a vision system is installed at the entrance of the freeze-dryer to detect eventual anomalies with execution times compatible with the production specifications. Other constraints come from sterility and safety standards required in pharmaceutical manufacturing. This work presents an overview about the production line, with particular focus on the vision system designed, and about all trials conducted to obtain the final performance. Transfer learning, alleviating the requirement for a large number of training data, combined with data augmentation methods, consisting in the generation of synthetic images, were used to effectively increase the performances while reducing the cost of data acquisition and annotation. The proposed vision algorithm is composed by two main subtasks, designed respectively to vials counting and discrepancy detection. The first one was trained on more than 23k vials (about 300 images) and tested on 5k more (about 75 images), whereas 60 training images and 52 testing images were used for the second one.

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.

Characterization Of Single Use Reactor Used For The Manufacturing Of Formulated Products Within The Pharmaceutical Industry

Mixing is a fundamental unit operation in the pharmaceutical industry to ensure consistent product quality across different batches. It is usually carried out in mechanically stirred tanks, with a large variety of designs according to the process requirements. A key aspect of pharmaceutical manufacturing is the extensive and meticulous cleaning of the vessels between runs to prevent the risk of contamination. Single-use reactors represent an increasing trend in the industry since they do not require cleaning and sterilization, reducing the need for utilities such as steam to sterilize equipment and the time between production batches. In contrast to traditional stainless steel vessels, single-use reactors consist of a plastic bag used as a vessel and disposed of after use. This thesis aims to characterize the fluid dynamics features and the mixing performance of a commercially available single-use reactor. The characterization employs a combination of various experimental techniques. The analysis starts with the visual observation of the liquid behavior inside the vessel, focusing on the vortex shape evolution at different impeller speeds. The power consumption is then measured using a torque meter to quantify the power number. Particle Image Velocimetry (PIV) is employed to investigate local fluid dynamics properties such as mean flow field and mean and rms velocity profiles. The same experimental setup of PIV is exploited for another optical measurement technique, the Planar Laser-Induced Fluorescence (PLIF). The PLIF measurements complete the characterization of the reactor with the qualitative visualization of the turbulent flow and the quantitative assessment of the system performance through the mixing time. The results confirm good mixing performances for the single-use reactor over the investigated impeller speeds and reveal that the filling volume plays a significant role in the fluid dynamics of the system.