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.

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.

Progetto e sviluppo di un banco prova per articolazioni protesiche attive ad un grado di libertà basato su programmable automation controller e motion capture

L'elaborato descrive il lavoro svolto in cinque mesi presso il Centro Protesi INAIL di Budrio (BO), che ha portato allo sviluppo di un banco prova per testare articolazioni elettromeccaniche. I dispositivi target, in particolare, sono stati due gomiti mioelettrici: il primo di produzione interna INAIL e il secondo prodotto da Selex ES in collaborazione con il Centro Protesi stesso. Per il controllo del movimento e l'acquisizione dei segnali elettrici si è scelto il PAC CompactRIO (National Instruments), mentre per le acquisizioni cinematiche di angolo e velocità angolare si è sfruttata la stereofotogrammetria.

Ottimizzazione di un'unita di controllo per protesi mioelettrica di arto superiore e confronto prestazionale tramite programmable automation controller e motion capture

Con il passare degli anni le tecnologie nel campo delle protesi mioelettriche di arto superiore stanno compiendo sempre più passi in avanti. In questo elaborato di tesi si darà un iniziale introduzione sulla protesica di arto superiore cercando di coprire tutte le possibili tipologie di protesi, prestando particolare attenzione agli arti artificiali mioelettrici. Gli scopi di questo studio sono in prima analisi una miglioria dell'unità di controllo di una protesi comandata da segnali elettromiografici di superficie, tramite l'utilizzo del nuovo IDE della Microchip (MPLAB X). In seconda analisi, invece, si attuerà un confronto prestazionale a livello di consumo in corrente di un prototipo di protesi mioelettrica nata dalla sinergia tra l'azienda "Selex ES" e il "Centro Protesi INAIL di Vigorso di Budrio". Per questo studio ci si è serviti di stereofotogrammetrica per la determinazione delle grandezze meccaniche, mentre tramite un sistema PAC si è riusciti ad ottenere specifiche grandezze elettriche. Lo studio ha portato, a livello di Firmware, l'inserimento del giusto comando di attuazione di un servofreno comandato in corrente e l'introduzione di una particolare modalità a basso consumo che consente un risparmio energetico di circa il 60% rispetto alla vecchia modalità. Discorso diverso per i risultati del confronto prestazionale che non ha portato ai risultati sperati in fase di progetto.

Progettazione e sviluppo di un'applicazione iOS per il supporto di strategie di mobile marketing automation e di prossimità

In questa tesi vengono presentati la progettazione e lo sviluppo di un'applicazione iOS, denominata "Promotions", che ha lo scopo di essere il supporto alle strategie di mobile marketing automation e di prossimità di un ipotetico brand con una catena di negozi, che vuole proporre alla propria clientela promozioni, messaggi, sondaggi, sistemi di engagement e fidelity definiti in un determinato customer journey. L'elaborato parte da una descrizione e analisi del mobile marketing, del marketing automation e di prossimità, della piattaforma e delle tecnologie utilizzate. Prosegue con un'analisi sullo stato dell'arte di applicazioni e realtà simili a quella sviluppata già presenti sul mercato, per poi passare alla relazione sulla progettazione, sviluppo e realizzazione dell'app. Vengono poi evidenziate le scelte implementative attuate e descritte le simulazioni di utilizzo dell'app, terminando con gli obiettivi raggiunti e con le conclusioni finali.

IoT e progettazione di sistemi di Home Automation: un caso di studio reale basato su framework e standard open

La nascita della Internet of Things, come conseguenza dell'aumento della capacità di calcolo e adozione di connettività in nuovi dispositivi, ha permesso l'apporto di nuove tecnologie negli oggetti di uso quotidiano e ha cambiano il modo in cui le persone utilizzano e interagiscono con questi oggetti. La Home Automation, da sempre orientata al controllo locale e remoto di apparecchiature domestiche, non ha mai raggiunto una grande diffusione per colpa del costo elevato, una controproducente chiusura rispetto ad altri sistemi e una certa difficoltà nella sua programmazione da parte dei possibili utenti. Le possibilità offerte dalla IoT e i limiti della Home Automation hanno suggerito lo sviluppo di un sistema in grado si superare queste limitazioni sfruttando le tecnologie più adatte a integrare Smart Object e sistemi, gli uni con gli altri, in maniera semplice e rapida. Il progetto e lo sviluppo di una soluzione reale di Home Automation basata su un impianto domotico commerciale ha permesso di dimostrare come strumenti opensource e tecnologie orientate alla IoT consentano, se opportunamente integrate, di migliorare sia la fruibilità dei sistemi domotici, attraverso la maggiore apertura verso altri sistemi, sia l'interazione con l'utente che sarà in grado di creare in modo semplice e diretto scenari di utilizzo sempre nuovi.

A Framework for the Automation of Discrete-Event Simulation Experiments

Simulation is an important resource for researchers in diverse fields. However, many researchers have found flaws in the methodology of published simulation studies and have described the state of the simulation community as being in a crisis of credibility. This work describes the project of the Simulation Automation Framework for Experiments (SAFE), which addresses the issues that undermine credibility by automating the workflow in the execution of simulation studies. Automation reduces the number of opportunities for users to introduce error in the scientific process thereby improvingthe credibility of the final results. Automation also eases the job of simulation users and allows them to focus on the design of models and the analysis of results rather than on the complexities of the workflow.

Automation of shear-wave splitting parameter determination of local earthquakes at Yellowstone : application as indicator of crustal stress and temporal variation

Shear-wave splitting can be a useful technique for determining crustal stress fields in volcanic settings and temporal variations associated with activity. Splitting parameters were determined for a subset of local earthquakes recorded from 2000-2010 at Yellowstone. Analysis was automated using an unsupervised cluster analysis technique to determine optimum splitting parameters from 270 analysis windows for each event. Six stations clearly exhibit preferential fast polarization values sub-orthogonal to the direction of minimum horizontal compression. Yellowstone deformation results in a local crustal stress field differing from the regional field dominated by NE-SW extension, and fast directions reflect this difference rotating around the caldera maintaining perpendicularity to the rim. One station exhibits temporal variations concordant with identified periods of caldera subsidence and uplift. From splitting measurements, we calculated a crustal anisotropy of ~17-23% and crack density ~0.12-0.17 possibly resulting from stress-aligned fluid filled microcracks in the upper crust and an active hydrothermal system.

Efficiency and automation in ATM

Sustainable growth of aviation whilst respecting the environment. • ANSPs and Aircraft Operators (AO) have to improve the way they operate

HALA!'s White Paper. Towards Higher Levels of Automation in ATM

• Objectives of HALA! • Main Activities • HALA! Magement Team • Participants • Intended Audience • Heritage in ATM and Automation • The new paradigm shift in Automation in ATM • Overall system performance as main driver for ATM Automation • The three interdependent dimensions for the paradigm change. • New roles assignment based on : • “best time” • “decision place” • “best player” • HALA! main research areas

Sequential origin in the high performance properties of spider dragline silk

Major ampullate (MA) dragline silk supports spider orb webs, combining strength and extensibility in the toughest biomaterial. MA silk evolved ~376 MYA and identifying how evolutionary changes in proteins influenced silk mechanics is crucial for biomimetics, but is hindered by high spinning plasticity. We use supercontraction to remove that variation and characterize MA silk across the spider phylogeny. We show that mechanical performance is conserved within, but divergent among, major lineages, evolving in correlation with discrete changes in proteins. Early MA silk tensile strength improved rapidly with the origin of GGX amino acid motifs and increased repetitiveness. Tensile strength then maximized in basal entelegyne spiders, ~230 MYA. Toughness subsequently improved through increased extensibility within orb spiders, coupled with the origin of a novel protein (MaSp2). Key changes in MA silk proteins therefore correlate with the sequential evolution high performance orb spider silk and could aid design of biomimetic fibers.

Functional modeling applied to HAZOP automation

In this paper we present a new tool to perform guided HAZOP analyses. This tool uses a functional model of the process that merges its functional and its structural information in a natural way. The functional modeling technique used is called D-higraphs. This tool solves some of the problems and drawbacks of other existing methodologies for the automation of HAZOPs. The applicability and easy understanding of the proposed methodology is shown in an industrial case.

AUTOFLY-Aid: Flight Deck Automation Support with Dynamic 4D Trajectory Management for Responsive and Adaptive Airborne Collision Avoidance

AUTOFLY-Aid Project aims to develop and demonstrate novel automation support algorithms and tools to the flight crew for flight critical collision avoidance using “dynamic 4D trajectory management”. The automation support system is envisioned to improve the primary shortcomings of TCAS, and to aid the pilot through add-on avionics/head-up displays and reality augmentation devices in dynamically evolving collision avoidance scenarios. The main theoretical innovative and novel concepts to be developed by AUTOFLY-Aid project are a) design and development of the mathematical models of the full composite airspace picture from the flight deck’s perspective, as seen/measured/informed by the aircraft flying in SESAR 2020, b) design and development of a dynamic trajectory planning algorithm that can generate at real-time (on the order of seconds) flyable (i.e. dynamically and performance-wise feasible) alternative trajectories across the evolving stochastic composite airspace picture (which includes new conflicts, blunder risks, terrain and weather limitations) and c) development and testing of the Collision Avoidance Automation Support System on a Boeing 737 NG FNPT II Flight Simulator with synthetic vision and reality augmentation while providing the flight crew with quantified and visual understanding of collision risks in terms of time and directions and countermeasures.