Dimensionamento de uma ponte metálica de suporte de uma tela transportadora de inertes a utilizar numa instalação industrial

Trabalho de Projeto para obtenção do grau de Mestre em Engenharia Civil na Área de Especialização em Estruturas

Desenvolvimento de um flotador industrial

A presente dissertação apresenta uma investigação teórica e prática na área de Engenharia e Design de Produto com o objetivo principal de desenvolver um Flotador Industrial para a Adventech, procurando indicadores inovadores, competitivos e focando a necessidade de encontrar uma solução que reflita numa relação entre necessidade, utilizador, performance e design. Desta forma, no presente trabalho cruzam-se temas como a Engenharia e o Design de Produto, Tratamentos de Efluentes Líquidos e Flotação de modo a introduzir e compreender o desenvolvimento deste equipamento. Foi efetuada uma pesquisa sobre o tema para compreender, as suas características e limitações, bem como as formas e mecanismos utilizados para dar resposta aos requisitos e produzir um produto eficiente e eficaz. Paralelamente realizou-se uma abordagem teórica sobre Design de Produto e Processo de Flotação, de modo a conhecer o seu desenvolvimento e as suas restrições, preocupações e objetivos. Complementou-se o trabalho desenvolvido com pesquisa e analisaram-se os produtos existentes na concorrência com o objetivo de conhecer características técnicas, funcionais e físicas. Desta forma, o estudo desenvolvido nesta dissertação serviu e auxiliou o projeto no resultado final, incluindo a materialização do conceito para proporcionar uma boa relação entre utilizador, performance e design. Obtendo assim, um resultado final com características adequadas nas diversas aplicações deste produto nas Estações de Águas Residuais, reduzindo custos de operação e manutenção, eficiência do processo de flotação e vida útil do produto. Paralelamente o design proporciona uma apresentação estética do produto que transmite fiabilidade e profissionalismo.

Analysis of competitiveness level in an industrial company using a continuous improvement based approach

International audience

Modelling of metal recovery from industrial wastewater using a biopolymer sorbent

Comunicação selecionada e Artigo publicado no Livro de Actas do Congresso

Nanofibrous-structured polymers and their engineering applications

Monolithic materials cannot always satisfy the demands of today’s advanced requirements. Only by combining several materials at different length-scales, as nature does, the requested performances can be met. Polymer nanocomposites are intended to overcome the common drawbacks of pristine polymers, with a multidisciplinary collaboration of material science with chemistry, engineering, and nanotechnology. These materials are an active combination of polymers and nanomaterials, where at least one phase lies in the nanometer range. By mimicking nature’s materials is possible to develop new nanocomposites for structural applications demanding combinations of strength and toughness. In this perspective, nanofibers obtained by electrospinning have been increasingly adopted in the last decade to improve the fracture toughness of Fiber Reinforced Plastic (FRP) laminates. Although nanofibers have already found applications in various fields, their widespread introduction in the industrial context is still a long way to go. This thesis aims to develop methodologies and models able to predict the behaviour of nanofibrous-reinforced polymers, paving the way for their practical engineering applications. It consists of two main parts. The first one investigates the mechanisms that act at the nanoscale, systematically evaluating the mechanical properties of both the nanofibrous reinforcement phase (Chapter 1) and hosting polymeric matrix (Chapter 2). The second part deals with the implementation of different types of nanofibers for novel pioneering applications, trying to combine the well-known fracture toughness enhancement in composite laminates with improving other mechanical properties or including novel functionalities. Chapter 3 reports the development of novel adhesive carriers made of nylon 6,6 nanofibrous mats to increase the fracture toughness of epoxy-bonded joints. In Chapter 4, recently developed rubbery nanofibers are used to enhance the damping properties of unidirectional carbon fiber laminates. Lastly, in Chapter 5, a novel self-sensing composite laminate capable of detecting impacts on its surface using PVDF-TrFE piezoelectric nanofibers is presented.

Effective procedure for the optimization of the linear controller in an industrial drive for a nonlinear mechanism

Il progetto di tesi è incentrato sull’ottimizzazione del procedimento di taratura dei regolatori lineari degli anelli di controllo di posizione e velocità presenti negli azionamenti usati industrialmente su macchine automatiche, specialmente quando il carico è ad inerzia variabile in dipendenza dalla posizione, dunque non lineare, come ad esempio un quadrilatero articolato. Il lavoro è stato svolto in collaborazione con l’azienda G.D S.p.A. ed il meccanismo di prova è realmente utilizzato nelle macchine automatiche per il packaging di sigarette. L’ottimizzazione si basa sulla simulazione in ambiente Matlab/Simulink dell’intero sistema di controllo, cioè comprensivo del modello Simulink degli anelli di controllo del drive, inclusa la dinamica elettrica del motore, e del modello Simscape del meccanismo, perciò una prima necessaria fase del lavoro è stata la validazione di tali modelli affinché fossero sufficientemente fedeli al comportamento reale. Il secondo passo è stato fornire una prima taratura di tentativo che fungesse da punto di partenza per l’algoritmo di ottimizzazione, abbiamo fatto ciò linearizzando il modello meccanico con l’inerzia minima e utilizzando il metodo delle formule di inversione per determinare i parametri di controllo. Già questa taratura, seppur conservativa, ha portato ad un miglioramento delle performance del sistema rispetto alla taratura empirica comunemente fatta in ambito industriale. Infine, abbiamo lanciato l’algoritmo di ottimizzazione definendo opportunamente la funzione di costo, ed il risultato è stato decisamente positivo, portando ad un miglioramento medio del massimo errore di inseguimento di circa il 25%, ma anche oltre il 30% in alcuni casi.

A distributed middleware for IT/OT convergence in modern industrial environments

The modern industrial environment is populated by a myriad of intelligent devices that collaborate for the accomplishment of the numerous business processes in place at the production sites. The close collaboration between humans and work machines poses new interesting challenges that industry must overcome in order to implement the new digital policies demanded by the industrial transition. The Industry 5.0 movement is a companion revolution of the previous Industry 4.0, and it relies on three characteristics that any industrial sector should have and pursue: human centrality, resilience, and sustainability. The application of the fifth industrial revolution cannot be completed without moving from the implementation of Industry 4.0-enabled platforms. The common feature found in the development of this kind of platform is the need to integrate the Information and Operational layers. Our thesis work focuses on the implementation of a platform addressing all the digitization features foreseen by the fourth industrial revolution, making the IT/OT convergence inside production plants an improvement and not a risk. Furthermore, we added modular features to our platform enabling the Industry 5.0 vision. We favored the human centrality using the mobile crowdsensing techniques and the reliability and sustainability using pluggable cloud computing services, combined with data coming from the crowd support. We achieved important and encouraging results in all the domains in which we conducted our experiments. Our IT/OT convergence-enabled platform exhibits the right performance needed to satisfy the strict requirements of production sites. The multi-layer capability of the framework enables the exploitation of data not strictly coming from work machines, allowing a more strict interaction between the company, its employees, and customers.

Evaluation of seismic losses of RC buildings: the case of the industrial areas after the 2012 Emilia Earthquake

The topic of seismic loss assessment not only incorporates many aspects of the earthquake engineering, but also entails social factors, public policies and business interests. Because of its multidisciplinary character, this process may be complex to challenge, and sound discouraging to neophytes. In this context, there is an increasing need of deriving simplified methodologies to streamline the process and provide tools for decision-makers and practitioners. This dissertation investigates different possible applications both in the area of modelling of seismic losses, both in the analysis of observational seismic data. Regarding the first topic, the PRESSAFE-disp method is proposed for the fast evaluation of the fragility curves of precast reinforced-concrete (RC) structures. Hence, a direct application of the method to the productive area of San Felice is studied to assess the number of collapses under a specific seismic scenario. In particular, with reference to the 2012 events, two large-scale stochastic models are outlined. The outcomes of the framework are promising, in good agreement with the observed damage scenario. Furthermore, a simplified displacement-based methodology is outlined to estimate different loss performance metrics for the decision-making phase of the seismic retrofit of a single RC building. The aim is to evaluate the seismic performance of different retrofit options, for a comparative analysis of their effectiveness and the convenience. Finally, a contribution to the analysis of the observational data is presented in the last part of the dissertation. A specific database of losses of precast RC buildings damaged by the 2012 Earthquake is created. A statistical analysis is performed, allowing deriving several consequence functions. The outcomes presented may be implemented in probabilistic seismic risk assessments to forecast the losses at the large scale. Furthermore, these may be adopted to establish retrofit policies to prevent and reduce the consequences of future earthquakes in industrial areas.

IDeS methodology applied to automotive component re-engineering focused on lightweight and high-strength by additive manufacturing

The project aims to gather an understanding of additive manufacturing and other manufacturing 4.0 techniques with an eyesight for industrialization. First the internal material anisotropy of elements created with the most economically feasible FEM technique was established. An understanding of the main drivers for variability for AM was portrayed, with the focus on achieving material internal isotropy. Subsequently, a technique for deposition parameter optimization was presented, further procedure testing was performed following other polymeric materials and composites. A replicability assessment by means of the use of technology 4.0 was proposed, and subsequent industry findings gathered the ultimate need of developing a process that demonstrate how to re-engineer designs in order to show the best results with AM processing. The latest study aims to apply the Industrial Design and Structure Method (IDES) and applying all the knowledge previously stacked into fully reengineer a product with focus of applying tools from 4.0 era, from product feasibility studies, until CAE – FEM analysis and CAM – DfAM. These results would help in making AM and FDM processes a viable option to be combined with composites technologies to achieve a reliable, cost-effective manufacturing method that could also be used for mass market, industry applications.

Modeling and Model Predictive Control of an Industrial Hydraulic System

This thesis aims to illustrate the construction of a mathematical model of a hydraulic system, oriented to the design of a model predictive control (MPC) algorithm. The modeling procedure starts with the basic formulation of a piston-servovalve system. The latter is a complex non linear system with some unknown and not measurable effects that constitute a challenging problem for the modeling procedure. The first level of approximation for system parameters is obtained basing on datasheet informations, provided workbench tests and other data from the company. Then, to validate and refine the model, open-loop simulations have been made for data matching with the characteristics obtained from real acquisitions. The final developed set of ODEs captures all the main peculiarities of the system despite some characteristics due to highly varying and unknown hydraulic effects, like the unmodeled resistive elements of the pipes. After an accurate analysis, since the model presents many internal complexities, a simplified version is presented. The latter is used to linearize and discretize correctly the non linear model. Basing on that, a MPC algorithm for reference tracking with linear constraints is implemented. The results obtained show the potential of MPC in this kind of industrial applications, thus a high quality tracking performances while satisfying state and input constraints. The increased robustness and flexibility are evident with respect to the standard control techniques, such as PID controllers, adopted for these systems. The simulations for model validation and the controlled system have been carried out in a Python code environment.

On the Role of Automatic Guided Vehicles in the 4th Industrial Revolution

Elaborate presents automated guided vehicle state-of-art, describing AGVs' types and employed technologies. AGVs' applications is going to be exposed by means of performed work during Toyota's internship. It will be presented the acquired experience on automatic forklifts' implementation and tools employed in a realization of an AGV system. Morover, it will be presented the development of a python program able to retrieve data, stored in a database, and elaborate them to produce heatmaps on vehicles' errors. The said program has been tested live on customer's sites and obtained result will be explained. Finally, it is going to be presented the analysis on natural navigation technology applied to Toyota's AGVs. Tests on natural navigation have been run in warehouses to estimate capabilities and possible application in logistic field.

Integration of ROS for the control of industrial robotic systems in a proprietary environment

The paper deals with the integration of ROS, in the proprietary environment of the Marchesini Group company, for the control of industrial robotic systems. The basic tools of this open-source software are deeply studied to model a full proprietary Pick and Place manipulator inside it, and to develop custom ROS nodes to calculate trajectories; speaking of which, the URDF format is the standard to represent robots in ROS and the motion planning framework MoveIt offers user-friendly high-level methods. The communication between ROS and the Marchesini control architecture is established using the OPC UA standard; the tasks computed are transmitted offline to the PLC, supervisor controller of the physical robot, because the performances of the protocol don’t allow any kind of active control by ROS. Once the data are completely stored at the Marchesini side, the industrial PC makes the real robot execute a trajectory computed by MoveIt, so that it replicates the behaviour of the simulated manipulator in Rviz. Multiple experiments are performed to evaluate in detail the potential of ROS in the planning of movements for the company proprietary robots. The project ends with a small study regarding the use of ROS as a simulation platform. First, it is necessary to understand how a robotic application of the company can be reproduced in the Gazebo real world simulator. Then, a ROS node extracts information and examines the simulated robot behaviour, through the subscription to specific topics.

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.