Digital twin-enabled automated anomaly detection and bottleneck identification in complex manufacturing systems using a multi-agent approach

Digital twin (DT) models are increasingly being used to improve the performance of complex manufacturing systems. In this context, DTs automatically enabling anomaly detection, such as increase in orders, and bottleneck identification, such as shortage of products, can significantly enhance decision-making to mitigate the consequences of the identified bottlenecks. The existing literature has mainly focused on implementing top-down approaches for analysing the bottlenecks without considering the emergent behaviour of micro-level agents, including inventory levels and human resources, and their impact on the macro-level system’s performance. In order to handle the aforementioned challenges, this paper extends the current literature by proposing a novel DT integrated in a multi-agent cyber physical system (CPS) for detecting anomalies in sensor data, while identifying and removing bottlenecks that emerge during the operation of complex manufacturing systems. An extended 5 C CPS architecture, using multi-agent approach, is implemented to allow DT integration. The agent-based simulation technique enables capturing the probabilistic variability, and aggregate parallelism and dynamism of parallel dynamic interactions within the DT-CPS. A new single agent at the exo-level of the multi-level agent-based modelling structure, called the ‘monitoring agent’, is introduced in this research. The agent detects anomalies and identify bottlenecks through communicating with other agents in different levels automatically. The DT-CPS provides feedback automatically to the physical space to remove and mitigate the identified bottlenecks. The proposed DT based multi-agent CPS has been tested successfully on a real case study in a cryogenic warehouse shop-floor from the cell and gene therapy industry. The performance of the studied cryogenic warehouse is continuously measured using real-time sensor data. The analyses of the results show that the proposed DT-CPS improves the utilisation rates of human resources, on average, by 30% supporting decision making and control in complex manufacturing systems.Innovate UK: 104515. Engineering and Physical Sciences Research Council (EPSRC): EP/R032718/

Sensor data-based decision making

Increasing globalization and growing industrial system complexity has amplified the interest in the use of information provided by sensors as a means of improving overall manufacturing system performance and maintainability. However, utilization of sensors can only be effective if the real-time data can be integrated into the necessary business processes, such as production planning, scheduling and execution systems. This integration requires the development of intelligent decision making models that can effectively process the sensor data into information and suggest appropriate actions. To be able to improve the performance of a system, the health of the system also needs to be maintained. In many cases a single sensor type cannot provide sufficient information for complex decision making including diagnostics and prognostics of a system. Therefore, a combination of sensors should be used in an integrated manner in order to achieve desired performance levels. Sensor generated data need to be processed into information through the use of appropriate decision making models in order to improve overall performance. In this dissertation, which is presented as a collection of five journal papers, several reactive and proactive decision making models that utilize data from single and multi-sensor environments are developed. The first paper presents a testbed architecture for Auto-ID systems. An adaptive inventory management model which utilizes real-time RFID data is developed in the second paper. In the third paper, a complete hardware and inventory management solution, which involves the integration of RFID sensors into an extremely low temperature industrial freezer, is presented. The last two papers in the dissertation deal with diagnostic and prognostic decision making models in order to assure the healthy operation of a manufacturing system and its components. In the fourth paper a Mahalanobis-Taguchi System (MTS) based prognostics tool is developed and it is used to estimate the remaining useful life of rolling element bearings using data acquired from vibration sensors. In the final paper, an MTS based prognostics tool is developed for a centrifugal water pump, which fuses information from multiple types of sensors in order to take diagnostic and prognostics decisions for the pump and its components --Abstract, page iv

Coverage and Time-optimal Motion Planning for Autonomous Vehicles

Autonomous vehicles are rapidly advancing with a variety of applications, such as area surveillance, environment mapping, and intelligent transportation. These applications require coverage and/or time-optimal motion planning, where the major challenges include uncertainties in the environment, motion constraints of vehicles, limited energy resources and potential failures. While dealing with these challenges in various capacities, this dissertation addresses three fundamental motion planning problems: (1) single-robot complete coverage in unknown environment, (2) multi-robot resilient and efficient coverage in unknown environment, and (3) time-optimal risk-aware motion planning for curvature-constrained vehicles. First, the ε* algorithm is developed for online coverage path planning in unknown environment using a single autonomous vehicle. It is computationally efficient, and can generate the desired back-and-forth path with less turns and overlappings. ε* prevents the local extrema problem, thus can guarantee complete coverage. Second, the CARE algorithm is developed which extends ε* for multi-robot resilient and efficient coverage in unknown environment. In case of failures, CARE guarantees complete coverage via dynamic task reallocations of other vehicles, hence provides resilience. Moreover, it reallocates idling vehicles to support others in their tasks, hence improves efficiency. Finally, the T* algorithm is developed to find the time-optimal risk-aware path for curvature-constrained vehicles. We present a novel risk function based on the concept of collision time, and integrate it with the time cost for optimization. The above-mentioned algorithms have been validated via simulations in complex scenarios and/or real experiments, and the results have shown clear advantages over existing popular approaches

Best matching processes in distributed systems

The growing complexity and dynamic behavior of modern manufacturing and service industries along with competitive and globalized markets have gradually transformed traditional centralized systems into distributed networks of e- (electronic) Systems. Emerging examples include e-Factories, virtual enterprises, smart farms, automated warehouses, and intelligent transportation systems. These (and similar) distributed systems, regardless of context and application, have a property in common: They all involve certain types of interactions (collaborative, competitive, or both) among their distributed individuals—from clusters of passive sensors and machines to complex networks of computers, intelligent robots, humans, and enterprises. Having this common property, such systems may encounter common challenges in terms of suboptimal interactions and thus poor performance, caused by potential mismatch between individuals. For example, mismatched subassembly parts, vehicles—routes, suppliers—retailers, employees—departments, and products—automated guided vehicles—storage locations may lead to low-quality products, congested roads, unstable supply networks, conflicts, and low service level, respectively. This research refers to this problem as best matching, and investigates it as a major design principle of CCT, the Collaborative Control Theory. The original contribution of this research is to elaborate on the fundamentals of best matching in distributed and collaborative systems, by providing general frameworks for (1) Systematic analysis, inclusive taxonomy, analogical and structural comparison between different matching processes; (2) Specification and formulation of problems, and development of algorithms and protocols for best matching; (3) Validation of the models, algorithms, and protocols through extensive numerical experiments and case studies. The first goal is addressed by investigating matching problems in distributed production, manufacturing, supply, and service systems based on a recently developed reference model, the PRISM Taxonomy of Best Matching. Following the second goal, the identified problems are then formulated as mixed-integer programs. Due to the computational complexity of matching problems, various optimization algorithms are developed for solving different problem instances, including modified genetic algorithms, tabu search, and neighbourhood search heuristics. The dynamic and collaborative/competitive behaviors of matching processes in distributed settings are also formulated and examined through various collaboration, best matching, and task administration protocols. In line with the third goal, four case studies are conducted on various manufacturing, supply, and service systems to highlight the impact of best matching on their operational performance, including service level, utilization, stability, and cost-effectiveness, and validate the computational merits of the developed solution methodologies

Towards edge robotics: the progress from cloud-based robotic systems to intelligent and context-aware robotic services

Current robotic systems handle a different range of applications such as video surveillance, delivery of goods, cleaning, material handling, assembly, painting, or pick and place services. These systems have been embraced not only by the general population but also by the vertical industries to help them in performing daily activities. Traditionally, the robotic systems have been deployed in standalone robots that were exclusively dedicated to performing a specific task such as cleaning the floor in indoor environments. In recent years, cloud providers started to offer their infrastructures to robotic systems for offloading some of the robot’s functions. This ultimate form of the distributed robotic system was first introduced 10 years ago as cloud robotics and nowadays a lot of robotic solutions are appearing in this form. As a result, standalone robots became software-enhanced objects with increased reconfigurability as well as decreased complexity and cost. Moreover, by offloading the heavy processing from the robot to the cloud, it is easier to share services and information from various robots or agents to achieve better cooperation and coordination. Cloud robotics is suitable for human-scale responsive and delay-tolerant robotic functionalities (e.g., monitoring, predictive maintenance). However, there is a whole set of real-time robotic applications (e.g., remote control, motion planning, autonomous navigation) that can not be executed with cloud robotics solutions, mainly because cloud facilities traditionally reside far away from the robots. While the cloud providers can ensure certain performance in their infrastructure, very little can be ensured in the network between the robots and the cloud, especially in the last hop where wireless radio access networks are involved. Over the last years advances in edge computing, fog computing, 5G NR, network slicing, Network Function Virtualization (NFV), and network orchestration are stimulating the interest of the industrial sector to satisfy the stringent and real-time requirements of their applications. Robotic systems are a key piece in the industrial digital transformation and their benefits are very well studied in the literature. However, designing and implementing a robotic system that integrates all the emerging technologies and meets the connectivity requirements (e.g., latency, reliability) is an ambitious task. This thesis studies the integration of modern Information andCommunication Technologies (ICTs) in robotic systems and proposes some robotic enhancements that tackle the real-time constraints of robotic services. To evaluate the performance of the proposed enhancements, this thesis departs from the design and prototype implementation of an edge native robotic system that embodies the concepts of edge computing, fog computing, orchestration, and virtualization. The proposed edge robotics system serves to represent two exemplary robotic applications. In particular, autonomous navigation of mobile robots and remote-control of robot manipulator where the end-to-end robotic system is distributed between the robots and the edge server. The open-source prototype implementation of the designed edge native robotic system resulted in the creation of two real-world testbeds that are used in this thesis as a baseline scenario for the evaluation of new innovative solutions in robotic systems. After detailing the design and prototype implementation of the end-to-end edge native robotic system, this thesis proposes several enhancements that can be offered to robotic systems by adapting the concept of edge computing via the Multi-Access Edge Computing (MEC) framework. First, it proposes exemplary network context-aware enhancements in which the real-time information about robot connectivity and location can be used to dynamically adapt the end-to-end system behavior to the actual status of the communication (e.g., radio channel). Three different exemplary context-aware enhancements are proposed that aim to optimize the end-to-end edge native robotic system. Later, the thesis studies the capability of the edge native robotic system to offer potential savings by means of computation offloading for robot manipulators in different deployment configurations. Further, the impact of different wireless channels (e.g., 5G, 4G andWi-Fi) to support the data exchange between a robot manipulator and its remote controller are assessed. In the following part of the thesis, the focus is set on how orchestration solutions can support mobile robot systems to make high quality decisions. The application of OKpi as an orchestration algorithm and DLT-based federation are studied to meet the KPIs that autonomously controlledmobile robots have in order to provide uninterrupted connectivity over the radio access network. The elaborated solutions present high compatibility with the designed edge robotics system where the robot driving range is extended without any interruption of the end-to-end edge robotics service. While the DLT-based federation extends the robot driving range by deploying access point extension on top of external domain infrastructure, OKpi selects the most suitable access point and computing resource in the cloud-to-thing continuum in order to fulfill the latency requirements of autonomously controlled mobile robots. To conclude the thesis the focus is set on how robotic systems can improve their performance by leveraging Artificial Intelligence (AI) and Machine Learning (ML) algorithms to generate smart decisions. To do so, the edge native robotic system is presented as a true embodiment of a Cyber-Physical System (CPS) in Industry 4.0, showing the mission of AI in such concept. It presents the key enabling technologies of the edge robotic system such as edge, fog, and 5G, where the physical processes are integrated with computing and network domains. The role of AI in each technology domain is identified by analyzing a set of AI agents at the application and infrastructure level. In the last part of the thesis, the movement prediction is selected to study the feasibility of applying a forecast-based recovery mechanism for real-time remote control of robotic manipulators (FoReCo) that uses ML to infer lost commands caused by interference in the wireless channel. The obtained results are showcasing the its potential in simulation and real-world experimentation.Programa de Doctorado en Ingeniería Telemática por la Universidad Carlos III de MadridPresidente: Karl Holger.- Secretario: Joerg Widmer.- Vocal: Claudio Cicconett