Powertrain Assembly Lines Automatic Configuration Using a Knowledge Based Engineering Approach

Technical knowledge and experience are intangible assets crucial for competitiveness. Knowledge is particularly important when it comes to complex design activities such as the configuration of manufacturing systems. The preliminary design of manufacturing systems relies significantly on experience of designers and engineers, lessons learned and complex sets of rules and is subject to a huge variability of inputs and outputs and involves decisions which must satisfy many competing requirements. This complicated design process is associated with high costs, long lead times and high probability of risks and reworks. It is estimated that around 20% of the designer’s time is dedicated to searching and analyzing past available knowledge, while 40% of the information required for design is identified through personally stored information. At a company level, the design of a new production line does not start from scratch. Based on the basic requirements of the customers, engineers use their own knowledge and try to recall past layout ideas searching for production line designs stored locally in their CAD systems [1]. A lot of knowledge is already stored, and has been used for a long time and evolved over time. There is a need to retrieve this knowledge and integrate it into a common and reachable framework. Knowledge Based Engineering (KBE) and knowledge representation techniques are considered to be a successful way to tackle this design problem at an industrial level. KBE is, in fact, a research field that studies methodologies and technologies for capturing and re-using product and process engineering knowledge to achieve automation of repetitive design tasks [2]. This study presents a methodology to support the configuration of powertrain assembly lines, reducing design times by introducing a best practice for production systems provider companies. The methodology is developed in a real industrial environment, within Comau S.p.A., introducing the role of a knowledge engineer. The approach includes extraction of existing technical knowledge and implementation in a knowledge-based software framework. The macro system design requirements (e.g. cycle time, production mix, etc.) are taken as input. A user driven procedure guides the designer in the definition of the macro layout-related decisions and in the selection of the equipment to be allocated within the project. The framework is then integrated with other software tools allowing the first phase design of the line including a technical description and a 2D and 3D CAD line layout. The KBE application is developed and tested on a specific powertrain assembly case study. Finally, a first validation among design engineers is presented, comparing traditional and new approach and estimating a cost-benefit analysis useful for future possible KBE implementations

Platform-based design, test and fast verification flow for mixed-signal systems on chip

This research is providing methodologies to enhance the design phase from architectural space exploration and system study to verification of the whole mixed-signal system. At the beginning of the work, some innovative digital IPs have been designed to develop efficient signal conditioning for sensor systems on-chip that has been included in commercial products. After this phase, the main focus has been addressed to the creation of a re-usable and versatile test of the device after the tape-out which is close to become one of the major cost factor for ICs companies, strongly linking it to model’s test-benches to avoid re-design phases and multi-environment scenarios, producing a very effective approach to a single, fast and reliable multi-level verification environment. All these works generated different publications in scientific literature. The compound scenario concerning the development of sensor systems is presented in Chapter 1, together with an overview of the related market with a particular focus on the latest MEMS and MOEMS technology devices, and their applications in various segments. Chapter 2 introduces the state of the art for sensor interfaces: the generic sensor interface concept (based on sharing the same electronics among similar applications achieving cost saving at the expense of area and performance loss) versus the Platform Based Design methodology, which overcomes the drawbacks of the classic solution by keeping the generality at the highest design layers and customizing the platform for a target sensor achieving optimized performances. An evolution of Platform Based Design achieved by implementation into silicon of the ISIF (Intelligent Sensor InterFace) platform is therefore presented. ISIF is a highly configurable mixed-signal chip which allows designers to perform an effective design space exploration and to evaluate directly on silicon the system performances avoiding the critical and time consuming analysis required by standard platform based approach. In chapter 3 we describe the design of a smart sensor interface for conditioning next generation MOEMS. The adoption of a new, high performance and high integrated technology allow us to integrate not only a versatile platform but also a powerful ARM processor and various IPs providing the possibility to use the platform not only as a conditioning platform but also as a processing unit for the application. In this chapter a description of the various blocks is given, with a particular emphasis on the IP developed in order to grant the highest grade of flexibility with the minimum area occupation. The architectural space evaluation and the application prototyping with ISIF has enabled an effective, rapid and low risk development of a new high performance platform achieving a flexible sensor system for MEMS and MOEMS monitoring and conditioning. The platform has been design to cover very challenging test-benches, like a laser-based projector device. In this way the platform will not only be able to effectively handle the sensor but also all the system that can be built around it, reducing the needed for further electronics and resulting in an efficient test bench for the algorithm developed to drive the system. The high costs in ASIC development are mainly related to re-design phases because of missing complete top-level tests. Analog and digital parts design flows are separately verified. Starting from these considerations, in the last chapter a complete test environment for complex mixed-signal chips is presented. A semi-automatic VHDL-AMS flow to provide totally matching top-level is described and then, an evolution for fast self-checking test development for both model and real chip verification is proposed. By the introduction of a Python interface, the designer can easily perform interactive tests to cover all the features verification (e.g. calibration and trimming) into the design phase and check them all with the same environment on the real chip after the tape-out. This strategy has been tested on a consumer 3D-gyro for consumer application, in collaboration with SensorDynamics AG

Towards Artificial General Intelligence (AGI) in the Internet of Things (IoT): Opportunities and Challenges

Artificial General Intelligence (AGI), possessing the capacity to comprehend, learn, and execute tasks with human cognitive abilities, engenders significant anticipation and intrigue across scientific, commercial, and societal arenas. This fascination extends particularly to the Internet of Things (IoT), a landscape characterized by the interconnection of countless devices, sensors, and systems, collectively gathering and sharing data to enable intelligent decision-making and automation. This research embarks on an exploration of the opportunities and challenges towards achieving AGI in the context of the IoT. Specifically, it starts by outlining the fundamental principles of IoT and the critical role of Artificial Intelligence (AI) in IoT systems. Subsequently, it delves into AGI fundamentals, culminating in the formulation of a conceptual framework for AGI's seamless integration within IoT. The application spectrum for AGI-infused IoT is broad, encompassing domains ranging from smart grids, residential environments, manufacturing, and transportation to environmental monitoring, agriculture, healthcare, and education. However, adapting AGI to resource-constrained IoT settings necessitates dedicated research efforts. Furthermore, the paper addresses constraints imposed by limited computing resources, intricacies associated with large-scale IoT communication, as well as the critical concerns pertaining to security and privacy

A generic architecture style for self-adaptive cyber-physical systems

Die aktuellen Konzepte zur Gestaltung von Regelungssystemen basieren auf dynamischen Verhaltensmodellen, die mathematische Ansätze wie Differentialgleichungen zur Ableitung der entsprechenden Funktionen verwenden. Diese Konzepte stoßen jedoch aufgrund der zunehmenden Systemkomplexität allmählich an ihre Grenzen. Zusammen mit der Entwicklung dieser Konzepte entsteht eine Architekturevolution der Regelungssysteme. In dieser Dissertation wird eine Taxonomie definiert, um die genannte Architekturevolution anhand eines typischen Beispiels, der adaptiven Geschwindigkeitsregelung (ACC), zu veranschaulichen. Aktuelle ACC-Varianten, die auf der Regelungstheorie basieren, werden in Bezug auf ihre Architekturen analysiert. Die Analyseergebnisse zeigen, dass das zukünftige Regelungssystem im ACC eine umfangreichere Selbstadaptationsfähigkeit und Skalierbarkeit erfordert. Dafür sind kompliziertere Algorithmen mit unterschiedlichen Berechnungsmechanismen erforderlich. Somit wird die Systemkomplexität erhöht und führt dazu, dass das zukünftige Regelungssystem zu einem selbstadaptiven cyber-physischen System wird und signifikante Herausforderungen für die Architekturgestaltung des Systems darstellt. Inspiriert durch Ansätze des Software-Engineering zur Gestaltung von Architekturen von softwareintensiven Systemen wird in dieser Dissertation ein generischer Architekturstil entwickelt. Der entwickelte Architekturstil dient als Vorlage, um vernetzte Architekturen mit Verfolgung der entwickelten Designprinzipien nicht nur für die aktuellen Regelungssysteme, sondern auch für selbstadaptiven cyber-physischen Systeme in der Zukunft zu konstruieren. Unterschiedliche Auslösemechanismen und Kommunikationsparadigmen zur Gestaltung der dynamischen Verhalten von Komponenten sind in der vernetzten Architektur anwendbar. Zur Bewertung der Realisierbarkeit des Architekturstils werden aktuelle ACCs erneut aufgenommen, um entsprechende logische Architekturen abzuleiten und die Architekturkonsistenz im Vergleich zu den originalen Architekturen basierend auf der Regelungstheorie (z. B. in Form von Blockdiagrammen) zu untersuchen. Durch die Anwendung des entwickelten generischen Architekturstils wird in dieser Dissertation eine künstliche kognitive Geschwindigkeitsregelung (ACCC) als zukünftige ACC-Variante entworfen, implementiert und evaluiert. Die Evaluationsergebnisse zeigen signifikante Leistungsverbesserungen des ACCC im Vergleich zum menschlichen Fahrer und aktuellen ACC-Varianten.Current concepts of designing automatic control systems rely on dynamic behavioral modeling by using mathematical approaches like differential equations to derive corresponding functions, and slowly reach limitations due to increasing system complexity. Along with the development of these concepts, an architectural evolution of automatic control systems is raised. This dissertation defines a taxonomy to illustrate the aforementioned architectural evolution relying on a typical example of control application: adaptive cruise control (ACC). Current ACC variants, with their architectures considering control theory, are analyzed. The analysis results indicate that the future automatic control system in ACC requires more substantial self-adaptation capability and scalability. For this purpose, more complicated algorithms requiring different computation mechanisms must be integrated into the system and further increase system complexity. This makes the future automatic control system evolve into a self-adaptive cyber-physical system and consistitutes significant challenges for the system’s architecture design. Inspired by software engineering approaches for designing architectures of software-intensive systems, a generic architecture style is proposed. The proposed architecture style serves as a template by following the developed design principle to construct networked architectures not only for the current automatic control systems but also for self-adaptive cyber-physical systems in the future. Different triggering mechanisms and communication paradigms for designing dynamic behaviors are applicable in the networked architecture. To evaluate feasibility of the architecture style, current ACCs are retaken to derive corresponding logical architectures and examine architectural consistency compared to the previous architectures considering the control theory (e.g., in the form of block diagrams). By applying the proposed generic architecture style, an artificial cognitive cruise control (ACCC) is designed, implemented, and evaluated as a future ACC in this dissertation. The evaluation results show significant performance improvements in the ACCC compared to the human driver and current ACC variants

A knowledge based approach to integration of products, processes and reconfigurable automation resources

The success of next generation automotive companies will depend upon their ability to adapt to ever changing market trends thus becoming highly responsive. In the automotive sector, the assembly line design and reconfiguration is an especially critical and extremely complex job. The current research addresses some of the aspects of this activity under the umbrella of a larger ongoing research project called Business Driven Automation (BDA) project. The BDA project aims to carry out complete virtual 3D modeling-based verifications of the assembly line for new or revised products in contrast to the prevalent practice of manual evaluation of effects of product change on physical resources. [Continues.

Intelligent fault detection and classification based on hybrid deep learning methods for Hardware-in-the-Loop test of automotive software systems

Hardware-in-the-Loop (HIL) has been recommended by ISO 26262 as an essential test bench for determining the safety and reliability characteristics of automotive software systems (ASSs). However, due to the complexity and the huge amount of data recorded by the HIL platform during the testing process, the conventional data analysis methods used for detecting and classifying faults based on the human expert are not realizable. Therefore, the development of effective means based on the historical data set is required to analyze the records of the testing process in an efficient manner. Even though data-driven fault diagnosis is superior to other approaches, selecting the appropriate technique from the wide range of Deep Learning (DL) techniques is challenging. Moreover, the training data containing the automotive faults are rare and considered highly confidential by the automotive industry. Using hybrid DL techniques, this study proposes a novel intelligent fault detection and classification (FDC) model to be utilized during the V-cycle development process, i.e., the system integration testing phase. To this end, an HIL-based real-time fault injection framework is used to generate faulty data without altering the original system model. In addition, a combination of the Convolutional Neural Network (CNN) and Long Short-Term Memory (LSTM) is employed to build the model structure. In this study, eight types of sensor faults are considered to cover the most common potential faults in the signals of ASSs. As a case study, a gasoline engine system model is used to demonstrate the capabilities and advantages of the proposed method and to verify the performance of the model. The results prove that the proposed method shows better detection and classification performance compared to other standalone DL methods. Specifically, the overall detection accuracies of the proposed structure in terms of precision, recall and F1-score are 98.86%, 98.90% and 98.88%, respectively. For classification, the experimental results also demonstrate the superiority under unseen test data with an average accuracy of 98.8%

Intelligent and Efficient Transport Systems

The aim of this book is to present a number of digital and technology solutions to real-world problems across transportation sectors and infrastructures. Nine chapters have been well prepared and organized with the core topics as follows: -A guideline to evaluate the energy efficiency of a vehicle -A guideline to design and evaluate an electric propulsion system -Potential opportunities for intelligent transportation systems and smart cities -The importance of system control and energy-power management in transportation systems and infrastructures -Bespoke modeling tools and real-time simulation platforms for transportation system development This book will be useful to a wide range of audiences: university staff and students, engineers, and business people working in relevant fields

INTELIGENTNY WÓZEK INWALIDZKI Z NAPĘDEM ELEKTRYCZNYM: PROBLEMY I WYZWANIA W PODEJŚCIU PRODUKTOWYM

This paper focuses on intelligent assistant for power wheelchair (PW) usage in home conditions. Especially in the context of PW intelligent assistant as a consumer product. The main problematic aspects and challenges of smart PW in real application are noted. The approach to formation of system requirements and their classification is offered. The research results proposed and implemented in the ongoing Mobilis project for smart PW. Further prospects of research and development are noted. Also, it is stated that the implementation of smart PW technology opens possibilities to effective integration with new control methods (including brain-computer interfaces).Niniejszy artykuł koncentruje się na omówieniu problemów i wyzwań dotyczących nowego produktu, jakim jest Smart Power Wheelchair (SPW), czyli inteligentny asystent używany w elektrycznych wózkach inwalidzkich w warunkach domowych. Zwrócono szczególnie uwagę na ukazanie SPW jako nowego produktu konsumenckiego na rynku dóbr. Przedstawione zostały główne problematyczne aspekty i wyzwania dla SPW, które mogą pojawić się w warunkach rzeczywistych. Artykuł zawiera również propozycje dotyczące tworzenia wymagań systemowych oraz ich klasyfikacji. W kolejnej części artykułu przedstawiono wyniki badań, zrealizowanych w ramach projektu Mobilis, dzięki którym wdrożono szereg zmian w produkcie. Ponadto autorzy zapewniają o planowanych dalszych badaniach nad rozwojem produktu. Należy zwrócić uwagę, że wprowadzenie technologii SPW otwiera możliwości efektywnej integracji z nowymi metodami komunikacji (w tym z interfejsami mózg-komputer, z ang. brain-computer interfaces – BCI), z których szczególną korzyść będą miały osoby z niepełnosprawnością ruchową

Validation of a Real-Time Capable Multibody Vehicle Dynamics Formulation for Automotive Testing Frameworks Based on Simulation

The growing functionalities implemented on vehicles have increased the importance of simulation in the design process. This complexity is mainly driven by the introduction of electrified powertrains, Advanced Driver Assistance Systems (ADAS) and Automated Driving Systems (ADS). Additionally, the automotive industry must reduce development times and cost, while keeping flexible development capabilities and fulfilling demanding regulation standards for safety-critical systems. Existing testing frameworks based on simulation implement typically analytical models to ensure real-time performance, and provide limited flexibility to perform Hardware in the Loop (HiL) setup based tests. In this work a vehicle modelling approach which guarantees high accuracy and real-time capabilities is proposed. Moreover, the proposed approach is validated firstly with real vehicle data, demonstrating that it can fairly reproduce the behaviour of the vehicle tested; and secondly, in a HiL setup to demonstrate the real-time execution capabilities of the approach