Paolo Righettini

Pneumatic actuators are widely used components for industrial automation, primarily due to their high power-to-volume ratio, high speed, simplicity of use, and the ease with which they can satisfy applications’ motion requirements. The accurate evaluation of the energy consumption in pneumatic systems is a topic of increasing importance due to contemporary attention to sustainability. Actuators of the same size have different pneumatic energy needs depending on the specific function they must accomplish, in terms of displacement, force, operational speed, and motion time. The dedicated literature focuses either on the best practices for the configuration of the circuit or on the pneumatic energy consumption in specific sections of the system; when electrical energy consumption is treated, only steady-state conditions are considered. Starting from this state of the art, this paper proposes a new general procedure for the assessment of the electrical energy required to perform specific functions in industrial machinery that relies on pneumatic actuators. The procedure is based on the evaluation of the air mass consumption of the actuator considering its actual application requirements, either through experimental measurements performed on the machinery or through a numerical simulation of the system. Regarding the numerical approach, an experimentally validated dynamic multi-domain model of the pneumatic system is proposed to also properly analyse the relevant transient behaviour. Starting from the evaluation of the air mass consumption, the procedure outlines how to calculate the corresponding electrical energy requirements, considering the application requirements and the operating point of the compressor. To this end, the procedure also includes a method to tailor the ISO 1217 standard to the actual working conditions of the compressor. The procedure, which enables the accurate mapping of the requirements placed by the application on the pneumatic actuator to the ultimately required electrical energy inputs, is validated through several simulations of real cyclic application cases. The results in terms of electrical energy consumption are compared to those obtained with the traditional method based on the steady-state behaviour of the system; the comparison shows that the proposed procedure evaluates the energy consumption with greater accuracy in applications characterized by highly dynamic work cycles.

Energy efficiency and sustainability are core issues in the modern design and management of industrial machinery and plants. These concerns are reflected and reinforced by the Sustainable Development Goal 9 of the United Nations (SDG9), “Industry, innovation and infrastructure”, which enshrines efficiency and optimized energy use as key features of sustainable production systems. As the engineering of industrial machinery reorients itself towards energy sustainability, attention is naturally shifting to actuators, since these components unavoidably waste part of the considerable amount of energy they absorb to execute their functions. Hydraulic actuation systems, while uniquely suited to heavy-duty applications, are particularly affected by poor energy conversion efficiency, in part due to their intrinsic properties but also because of outdated yet still common industrial practices. Consequently, for this actuation technology, there are wide margins for improvement in terms of energy waste reduction and increased environmental sustainability. This paper, therefore, investigates new applications for a management and control method conceived by the authors to drastically and systematically reduce the energy consumption of hydraulic actuators. The method is easily retrofittable to existing plants, being based on the unconventional and non-invasive deployment of a continuous-control electrohydraulic valve (CCEV) to control the supply pressure, whose required value is estimated according to the instantaneous load demands. Through the simulation of several industrial processes characterized by process parameters of varying orders of magnitude, this paper demonstrates that this innovative use of a CCEV for supply pressure regulation is an effective and widely applicable solution for energy savings and CO₂ footprint reduction in production systems that rely on hydraulic servo axes.

Multi-robot ensembles comprising several manipulators are commonly used in industrial settings to process non-deterministic flows of items loaded by an upstream source onto a shared transportation system. After the execution of a given task, the robots regularly deposit the items on a common output flow, which conveys the semi-finished material towards the downstream portion of the plant for further processing. The productivity and reliability of the entire process, which is affected by the plant layout, by the quality of the adopted scheduling and task assignment algorithms, and by the proper balancing of the input and output flows, may be degraded by random disturbances and transient conditions of the input flow. In this paper, a highly accurate event-based simulator of this kind of system is used in conjunction with a rollout algorithm to optimize the performance of the plant in all operating scenarios. The proposed method relies on a simulation of the plant that comprehensively considers the dynamic performance of the manipulators, their actual motion planning algorithms, the adopted scheduling and task assignment methods, and the regulation of the material flows. The simulation environment is built upon computationally efficient maps able to predict the execution time of the tasks assigned to the robots, considering all the determining factors, and on a representation of the manipulators themselves as finite state automata. The proposed formalization of the line balancing problem as a Markov Decision Process and the resulting rollout optimization method are shown to substantially improve the performance of the plant, even in challenging situations, and to be well suited to real-time implementation even on commodity hardware.

Several types of self-balancing vehicles have been successfully developed and commercialized in the past two decades, both as manned vehicles and as autonomous mobile robots. At the same time, due to their characteristic instability and underactuation, a large body of research has been devoted to their control. However, despite this practical and theoretical interest, the current publicly available literature does not cover their systematic design and development. In particular, overall processes that lead to a finished vehicle starting from a set of requirements and specifications have not been examined in the literature. Within this context, this paper contributes a comprehensive mechatronic, dynamics-based procedure for the design of this class of vehicles; to promote clarity of exposition, the procedure is systematically presented using Model-Based Systems Engineering tools and principles. In particular, the proposed design method is developed and formalized starting from an original description of the vehicle, which is treated as a complex system composed of several interconnected multi-domain components that exchange power and logical flows through suitable interfaces. A key focus of this work is the analysis of these exchanges, with the goal of defining a minimal set of quantities that should be necessarily considered to properly design the vehicle. As a salient result, the design process is organized in a logical sequence of steps, each having well-defined inputs and outputs. The procedure is also graphically outlined using standardized formalisms. The design method is shown to cover all the mechanical, electrical, actuation, measurement and control components of the system, and to allow the unified treatment of a large variety of different vehicle variants. The procedure is then applied to a specific case study, with the goal of developing the detailed design of a full-scale vehicle. The main strengths of the proposed approach are then widely highlighted and discussed.

The mechatronic design approach to robotics deploys, inter alia, widely available mechanical design engineering tools that, together with standard production techniques, allow the accurate quantification of the system’s mass properties. While this enables the synthesis of model-based centralized controllers, friction still limits the achievable dynamic performances, as its prediction at the design stage is hampered by complex dependencies on loads, temperature, wear, and lubrication. Further uncertainties affecting mechatronic devices stem from the actuation systems, whose parameters are specified by the manufacturer with relatively loose accuracy. These challenges are addressed here through a method based on MEMS IMUs for the real-time estimation of both friction effects and uncertain actuator parameters. The resulting model, inclusive of the frictionless dynamics, is applied in a closed loop to improve the control performance. An experimental comparison with decentralized and non-adaptive regulators highlights severalfold reductions in tracking errors; the ability to track temperature-dependent friction variations is also shown. From this work, it may be concluded that the use of MEMS sensors, together with identification and adaptive control algorithms, sensibly increases the dynamic performance of robotic systems. The real-time properties of the method also enable future investigations into topics such as MEMS-based diagnostics and predictive maintenance.

High-speed pick-and-place industrial applications often use parallel kinematic robots due to their high stiffness and dynamic performance; furthermore, the latter not only depends on the mechanical characteristics of the robots but also on the control algorithm. The literature shows several theoretical contributions to such controllers, mainly tested at the simulation level or on simple proof-of-concept laboratory equipment that execute low-speed and simple trajectories. This paper presents an experimental investigation of the dynamic performance of an industrial high-speed 4-DOF 5R parallel robot designed for pick-and-place applications on moving objects. The inverse dynamics control in the task space is used as a control algorithm. The results show the contribution of all the components of the control algorithm to the motor torque, and the inverse dynamics controller performances are discussed also in comparison to those achievable with simpler PD or PID controllers in a joint space. Moreover, the paper shows the controller synthesis from a modern mechatronic point of view, and the effectiveness of the proposed solution for the tracking of complex high-speed trajectories in an industrial application.