Dynamic Modeling and Seasonal Performance Evaluation of Air-to-Water Heat Pump Systems

In this Thesis a series of numerical models for the evaluation of the seasonal performance of reversible air-to-water heat pump systems coupled to residential and non-residential buildings are presented. The exploitation of the energy saving potential linked to the adoption of heat pumps is a hard task for designers due to the influence on their energy performance of several factors, like the external climate variability, the heat pump modulation capacity, the system control strategy and the hydronic loop configuration. The aim of this work is to study in detail all these aspects. In the first part of this Thesis a series of models which use a temperature class approach for the prediction of the seasonal performance of reversible air source heat pumps are shown. An innovative methodology for the calculation of the seasonal performance of an air-to-water heat pump has been proposed as an extension of the procedure reported by the European standard EN 14825. This methodology can be applied not only to air-to-water single-stage heat pumps (On-off HPs) but also to multi-stage (MSHPs) and inverter-driven units (IDHPs). In the second part, dynamic simulation has been used with the aim to optimize the control systems of the heat pump and of the HVAC plant. A series of dynamic models, developed by means of TRNSYS, are presented to study the behavior of On-off HPs, MSHPs and IDHPs. The main goal of these dynamic simulations is to show the influence of the heat pump control strategies and of the lay-out of the hydronic loop used to couple the heat pump to the emitters on the seasonal performance of the system. A particular focus is given to the modeling of the energy losses linked to on-off cycling.

Dry grinding technology for automotive gears manufacturing: process modeling and optimization

The following thesis focused on the dry grinding process modelling and optimization for automotive gears production. A FEM model was implemented with the aim at predicting process temperatures and preventing grinding thermal defects on the material surface. In particular, the model was conceived to facilitate the choice of the grinding parameters during the design and the execution of the dry-hard finishing process developed and patented by the company Samputensili Machine Tools (EMAG Group) on automotive gears. The proposed model allows to analyse the influence of the technological parameters, comprising the grinding wheel specifications. Automotive gears finished by dry-hard finishing process are supposed to reach the same quality target of the gears finished through the conventional wet grinding process with the advantage of reducing production costs and environmental pollution. But, the grinding process allows very high values of specific pressure and heat absorbed by the material, therefore, removing the lubricant increases the risk of thermal defects occurrence. An incorrect design of the process parameters set could cause grinding burns, which affect the mechanical performance of the ground component inevitably. Therefore, a modelling phase of the process could allow to enhance the mechanical characteristics of the components and avoid waste during production. A hierarchical FEM model was implemented to predict dry grinding temperatures and was represented by the interconnection of a microscopic and a macroscopic approach. A microscopic single grain grinding model was linked to a macroscopic thermal model to predict the dry grinding process temperatures and so to forecast the thermal cycle effect caused by the process parameters and the grinding wheel specification choice. Good agreement between the model and the experiments was achieved making the dry-hard finishing an efficient and reliable technology to implement in the gears automotive industry.

Study and experimental characterization of the laser welding process for the manufacturing of electric powertrain components in the automotive industry

The PhD project that will be presented in this thesis is focused on the study and optimization of the production process for the manufacturing of electrical powertrain components in the automotive field using the laser beam welding process (LBW). The objective is to define, through experimental activities, an optimized process condition for applications in the electrical field that can be generalized, that is, which guarantees its reproducibility as the types of connections vary and which represents the basis for extending the method to future applications in e-mobility sector. The work developed along two lines of research, the convergence of which made it possible to create prototypes of battery modules based on different types of lithium-ion cells and stator windings for electric motors. On the one hand, the different welding configurations involving the production of batteries based on pouch cells and therefore the welding of aluminum and copper in dissimilar configuration were studied, while for the prismatic cells only one configuration was analyzed. On the other hand, the welding of pure copper hairpins with rectangular shape in edge joint configuration was studied for the production of stator windings. The experimental tests carried out have demonstrated the feasibility of using the LBW process for the production of electric powertrain components entirely designed and developed internally as the types of materials and welding configurations vary; the methodologies required for the characterization methods, necessary for the end-of-line tests, for the evaluation of the properties of the different joint configurations and components (battery and electric motor) were also defined with the aim of obtaining the best performance. The entire doctorate program was conducted in collaboration with Ferrari Auto S.p.A. and the direct industrial application of the issues addressed has been faced.

Challenges and Opportunities of Machine Learning for Clinical and Omics Data

Clinical and omics data are a promising field of application for machine learning techniques even though these methods are not yet systematically adopted in healthcare institutions. Despite artificial intelligence has proved successful in terms of prediction of pathologies or identification of their causes, the systematic adoption of these techniques still presents challenging issues due to the peculiarities of the analysed data. The aim of this thesis is to apply machine learning algorithms to both clinical and omics data sets in order to predict a patient's state of health and get better insights on the possible causes of the analysed diseases. In doing so, many of the arising issues when working with medical data will be discussed while possible solutions will be proposed to make machine learning provide feasible results and possibly become an effective and reliable support tool for healthcare systems.

In vitro characterization of the three-dimensional strain pattern in human vertebrae affected by metastases

La colonna vertebrale è la principale sede di metastasi, le quali possono alterare la normale distribuzione dei tessuti ossei e ridurre la capacità della vertebra di sostenere carichi. L’instabilità spinale causata dalle metastasi, tuttavia, è di difficile determinazione. La caratterizzazione meccanica delle vertebre metastatiche permetterebbe di identificare e, di conseguenza trattare, quelle ad alto rischio di frattura. In questo studio, ho valutato il comportamento meccanico a rottura di vertebre umane affette da metastasi misurando in vitro il campo di deformazione. Undici provini, costituiti da due vertebre centrali, una metastatica e una sana, sono stati preparati e scansionati applicando carichi graduali di compressione in una micro-tomografia computerizzata (μCT). Le deformazioni principali sono state misurate attraverso un algoritmo globale di Digital Volume Correlation (DVC) e successivamente sono state analizzate. Lo studio ha rivelato che le vertebre con metastasi litiche raggiungono deformazioni maggiori delle vertebre sane. Invece, le metastasi miste non assicurano un comportamento univoco in quanto combinano gli effetti antagonisti delle lesioni litiche e blastiche. Dunque la valutazione è stata estesa a possibili correlazioni tra il campo di deformazione e la microstruttura della vertebra. L'analisi ha identificato le regioni in cui parte la frattura (a più alta deformazione), senza identificare, in termini microstrutturali, una zona preferenziale di rottura a priori. Infatti, alcune zone con un pattern trabecolare denso, presunte più rigide, hanno mostrato deformazioni maggiori di quelle dei tessuti sani, sottolineando l’importanza della valutazione della qualità del tessuto osseo. Questi risultati, generalizzati su un campione più ampio, potrebbero essere utilizzati per implementare nuovi criteri negli attuali sistemi di valutazione dell'instabilità spinale.

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.

Metal additive manufacturing of soft magnetic material for electric machines

This research work concerns the application of additive manufacturing (AM) technologies in new electric mobility sectors. The unmatched freedom that AM offers can potentially change the way electric motors are designed and manufactured. The thesis investigates the possibility of creating optimized electric machines that exploit AM technologies, with potential in various industrial sectors, including automotive and aerospace. In particular, we will evaluate how the design of electric motors can be improved by producing the rotor core using Laser Powder Bed Fusion (LPBF) and how the resulting design choices affect component performance. First, the metallurgical and soft magnetic properties of the pure iron and silicon iron alloy parts (Fe-3% wt.Si) produced by LPBF will be defined and discussed, considering the process parameters and the type of heat treatment. This research shows that using LPBF, both pure iron and iron silicon, the parts have mechanical and magnetic properties different from the laminated ones. Hence, FEM-based modeling will be employed to design the rotor core of an SYN RM machine to minimize torque ripple while maintaining structural integrity. Finally, we suggest that further research should extend the field of applicability to other electrical devices.

On the role of Computational Logic in Data Science: representing, learning, reasoning, and explaining knowledge

In this thesis we discuss in what ways computational logic (CL) and data science (DS) can jointly contribute to the management of knowledge within the scope of modern and future artificial intelligence (AI), and how technically-sound software technologies can be realised along the path. An agent-oriented mindset permeates the whole discussion, by stressing pivotal role of autonomous agents in exploiting both means to reach higher degrees of intelligence. Accordingly, the goals of this thesis are manifold. First, we elicit the analogies and differences among CL and DS, hence looking for possible synergies and complementarities along 4 major knowledge-related dimensions, namely representation, acquisition (a.k.a. learning), inference (a.k.a. reasoning), and explanation. In this regard, we propose a conceptual framework through which bridges these disciplines can be described and designed. We then survey the current state of the art of AI technologies, w.r.t. their capability to support bridging CL and DS in practice. After detecting lacks and opportunities, we propose the notion of logic ecosystem as the new conceptual, architectural, and technological solution supporting the incremental integration of symbolic and sub-symbolic AI. Finally, we discuss how our notion of logic ecosys- tem can be reified into actual software technology and extended towards many DS-related directions.

Perceiving the 3d world from single images

Depth represents a crucial piece of information in many practical applications, such as obstacle avoidance and environment mapping. This information can be provided either by active sensors, such as LiDARs, or by passive devices like cameras. A popular passive device is the binocular rig, which allows triangulating the depth of the scene through two synchronized and aligned cameras. However, many devices that are already available in several infrastructures are monocular passive sensors, such as most of the surveillance cameras. The intrinsic ambiguity of the problem makes monocular depth estimation a challenging task. Nevertheless, the recent progress of deep learning strategies is paving the way towards a new class of algorithms able to handle this complexity. This work addresses many relevant topics related to the monocular depth estimation problem. It presents networks capable of predicting accurate depth values even on embedded devices and without the need of expensive ground-truth labels at training time. Moreover, it introduces strategies to estimate the uncertainty of these models, and it shows that monocular networks can easily generate training labels for different tasks at scale. Finally, it evaluates off-the-shelf monocular depth predictors for the relevant use case of social distance monitoring, and shows how this technology allows to overcome already existing strategies limitations.

Towards Unstructured Knowledge Integration in Natural Language Processing

In the last decades, Artificial Intelligence has witnessed multiple breakthroughs in deep learning. In particular, purely data-driven approaches have opened to a wide variety of successful applications due to the large availability of data. Nonetheless, the integration of prior knowledge is still required to compensate for specific issues like lack of generalization from limited data, fairness, robustness, and biases. In this thesis, we analyze the methodology of integrating knowledge into deep learning models in the field of Natural Language Processing (NLP). We start by remarking on the importance of knowledge integration. We highlight the possible shortcomings of these approaches and investigate the implications of integrating unstructured textual knowledge. We introduce Unstructured Knowledge Integration (UKI) as the process of integrating unstructured knowledge into machine learning models. We discuss UKI in the field of NLP, where knowledge is represented in a natural language format. We identify UKI as a complex process comprised of multiple sub-processes, different knowledge types, and knowledge integration properties to guarantee. We remark on the challenges of integrating unstructured textual knowledge and bridge connections with well-known research areas in NLP. We provide a unified vision of structured knowledge extraction (KE) and UKI by identifying KE as a sub-process of UKI. We investigate some challenging scenarios where structured knowledge is not a feasible prior assumption and formulate each task from the point of view of UKI. We adopt simple yet effective neural architectures and discuss the challenges of such an approach. Finally, we identify KE as a form of symbolic representation. From this perspective, we remark on the need of defining sophisticated UKI processes to verify the validity of knowledge integration. To this end, we foresee frameworks capable of combining symbolic and sub-symbolic representations for learning as a solution.

Adaptive Neural Translation for Enterprises (ANTE). La traduzione automatica neurale a sostegno delle imprese emiliano-romagnole

Il progetto ANTE riguarda i nuovi sistemi di traduzione automatica (TA) e la loro applicazione nel mondo delle imprese. Lo studio prende spunto dai recenti sviluppi legati all’intelligenza artificiale e ai Big Data che negli ultimi anni hanno permesso alla TA di raggiungere livelli qualitativi molto elevati, al punto tale da essere impiegata da grandi multinazionali per raggiungere nuove quote di mercato. La TA può rispondere positivamente anche ai bisogni delle imprese di piccole dimensioni e a basso tenore tecnologico, migliorando la qualità delle comunicazioni multilingue attraverso delle traduzioni in tempi brevi e a costi contenuti. Lo studio si propone quindi di contribuire al rafforzamento della competitività internazionale delle piccole e medie imprese (PMI) emiliano- romagnole, migliorando la loro capacità di comunicazione in una o più lingue straniere attraverso l’introduzione e l’utilizzo efficace e consapevole di soluzioni ICT di ultima generazione e fornire, così, nuove opportunità di internazionalizzazione.

Security enhancements and flaws of emerging communication technologies

The multi-faced evolution of network technologies ranges from big data centers to specialized network infrastructures and protocols for mission-critical operations. For instance, technologies such as Software Defined Networking (SDN) revolutionized the world of static configuration of the network - i.e., by removing the distributed and proprietary configuration of the switched networks - centralizing the control plane. While this disruptive approach is interesting from different points of view, it can introduce new unforeseen vulnerabilities classes. One topic of particular interest in the last years is industrial network security, an interest which started to rise in 2016 with the introduction of the Industry 4.0 (I4.0) movement. Networks that were basically isolated by design are now connected to the internet to collect, archive, and analyze data. While this approach got a lot of momentum due to the predictive maintenance capabilities, these network technologies can be exploited in various ways from a cybersecurity perspective. Some of these technologies lack security measures and can introduce new families of vulnerabilities. On the other side, these networks can be used to enable accurate monitoring, formal verification, or defenses that were not practical before. This thesis explores these two fields: by introducing monitoring, protections, and detection mechanisms where the new network technologies make it feasible; and by demonstrating attacks on practical scenarios related to emerging network infrastructures not protected sufficiently. The goal of this thesis is to highlight this lack of protection in terms of attacks on and possible defenses enabled by emerging technologies. We will pursue this goal by analyzing the aforementioned technologies and by presenting three years of contribution to this field. In conclusion, we will recapitulate the research questions and give answers to them.

Methods for integrating machine learning and constrained optimization

In the framework of industrial problems, the application of Constrained Optimization is known to have overall very good modeling capability and performance and stands as one of the most powerful, explored, and exploited tool to address prescriptive tasks. The number of applications is huge, ranging from logistics to transportation, packing, production, telecommunication, scheduling, and much more. The main reason behind this success is to be found in the remarkable effort put in the last decades by the OR community to develop realistic models and devise exact or approximate methods to solve the largest variety of constrained or combinatorial optimization problems, together with the spread of computational power and easily accessible OR software and resources. On the other hand, the technological advancements lead to a data wealth never seen before and increasingly push towards methods able to extract useful knowledge from them; among the data-driven methods, Machine Learning techniques appear to be one of the most promising, thanks to its successes in domains like Image Recognition, Natural Language Processes and playing games, but also the amount of research involved. The purpose of the present research is to study how Machine Learning and Constrained Optimization can be used together to achieve systems able to leverage the strengths of both methods: this would open the way to exploiting decades of research on resolution techniques for COPs and constructing models able to adapt and learn from available data. In the first part of this work, we survey the existing techniques and classify them according to the type, method, or scope of the integration; subsequently, we introduce a novel and general algorithm devised to inject knowledge into learning models through constraints, Moving Target. In the last part of the thesis, two applications stemming from real-world projects and done in collaboration with Optit will be presented.

Continual learning for computer vision applications

One of the most visionary goals of Artificial Intelligence is to create a system able to mimic and eventually surpass the intelligence observed in biological systems including, ambitiously, the one observed in humans. The main distinctive strength of humans is their ability to build a deep understanding of the world by learning continuously and drawing from their experiences. This ability, which is found in various degrees in all intelligent biological beings, allows them to adapt and properly react to changes by incrementally expanding and refining their knowledge. Arguably, achieving this ability is one of the main goals of Artificial Intelligence and a cornerstone towards the creation of intelligent artificial agents. Modern Deep Learning approaches allowed researchers and industries to achieve great advancements towards the resolution of many long-standing problems in areas like Computer Vision and Natural Language Processing. However, while this current age of renewed interest in AI allowed for the creation of extremely useful applications, a concerningly limited effort is being directed towards the design of systems able to learn continuously. The biggest problem that hinders an AI system from learning incrementally is the catastrophic forgetting phenomenon. This phenomenon, which was discovered in the 90s, naturally occurs in Deep Learning architectures where classic learning paradigms are applied when learning incrementally from a stream of experiences. This dissertation revolves around the Continual Learning field, a sub-field of Machine Learning research that has recently made a comeback following the renewed interest in Deep Learning approaches. This work will focus on a comprehensive view of continual learning by considering algorithmic, benchmarking, and applicative aspects of this field. This dissertation will also touch on community aspects such as the design and creation of research tools aimed at supporting Continual Learning research, and the theoretical and practical aspects concerning public competitions in this field.

Edge and Big Data technologies for Industry 4.0 to create an integrated pre-sale and after-sale environment

The fourth industrial revolution, also known as Industry 4.0, has rapidly gained traction in businesses across Europe and the world, becoming a central theme in small, medium, and large enterprises alike. This new paradigm shifts the focus from locally-based and barely automated firms to a globally interconnected industrial sector, stimulating economic growth and productivity, and supporting the upskilling and reskilling of employees. However, despite the maturity and scalability of information and cloud technologies, the support systems already present in the machine field are often outdated and lack the necessary security, access control, and advanced communication capabilities. This dissertation proposes architectures and technologies designed to bridge the gap between Operational and Information Technology, in a manner that is non-disruptive, efficient, and scalable. The proposal presents cloud-enabled data-gathering architectures that make use of the newest IT and networking technologies to achieve the desired quality of service and non-functional properties. By harnessing industrial and business data, processes can be optimized even before product sale, while the integrated environment enhances data exchange for post-sale support. The architectures have been tested and have shown encouraging performance results, providing a promising solution for companies looking to embrace Industry 4.0, enhance their operational capabilities, and prepare themselves for the upcoming fifth human-centric revolution.