EAI Endorsed Transactions on Digital Transformation of Industrial Processes

Cloud-Based Data-Driven Behavior Model Recovery for Distributed Automation Systems

2025-02-02T15:13:31+00:00

Industrial cyber-physical systems provide a bridge between legacy controllers and new edge devices that are usually equipped with massive computing power and storage capacity. The migration from legacy control systems to industrial cyber-physical systems is facing challenges as control code and design documents of legacy systems may not be available. This paper proposes a data-driven behavior model recovery method for the black-box distributed manufacturing system based on cloud computing. This method adopts the IEC 61499 function blocks as meta-models to describe system behaviors. The proposed framework includes three parts: data mining, logic restoration, and application construction. Raw collected data are processed and encapsulated into function block sets, then execution control charts, and finally function block types. This model recovery method is validated with a process control system of the food and beverage industry. A deployable function block network is generated by instantiating and connecting these function blocks.

Soft Robotics in Industrial Automation: Adaptive Industrial Gripper Design and Evaluation

2025-02-15T22:49:39+00:00

The rapid evolution of industrial automation demands more versatile gripping solutions beyond conventional vacuum, magnetic, and fingered grippers. This study introduces the development and evaluation of an adaptive Universal Jamming Gripper (UJG) optimized for industrial applications. Utilizing a flexible membrane filled with granular materials, the UJG transitions between soft and rigid states under vacuum pressure, enabling secure and adaptive grasping of objects with diverse shapes and materials. Three types of membrane fillings—ground coffee, polystyrene microspheres (EPS), and thermoplastic elastomer granules (TPE)—were assessed for grip stability and force efficiency. Experimental results demonstrate that EPS microspheres provide superior adaptability and stability, offering the highest gripping force across various object geometries. Performance tests on a universal testing machine further validate the gripper’s capability to handle differently shaped objects with minimal adjustments. The findings underscore the potential of adaptive gripping technologies in enhancing automation flexibility, reducing operational downtime, and increasing overall industrial efficiency. Future research will focus on long-term durability, integration with robotic automation, and performance assessment in real-world manufacturing environments.

Solving Facility Location and Supply Chain Management Problems Using Modified Population-Based TP-AB Algorithm

2025-01-29T18:16:21+00:00

Locating optimal supply/ storage/ distribution facilities is critical in minimizing the establishment, transportation and distribution costs. This paper proposes one model for estimating the facility centres based on any specific criterion. A modified TP-AB algorithm solves the popular "Mini-Sum" and "Mini-Max" facility location problems by considering 36 European countries. The required population and Gross Domestic Product per capita data for the years 2013, 2018 and 2023 are extracted from the European Union portal. Capital cities of these 36 countries are taken as the representative demand points in the supply chain network and facility centres are located using unweighted and weighted Great Circle Distance. Since the data points are spread over the Earth's surface, Great Circle Distance is preferred over Euclidean Distance. It is observed that the “population centre”, “economic centre" and the "access centre" do not merge showing the variations in the population spread and economic strength among the European countries considered. Also, the feasibility of grouping the countries into any number of clusters based on the need is demonstrated.

Modelling an Electro-hydraulic Proportional Valve in a Closed-Loop Control System using Matlab/Simulink

2025-03-04T19:16:06+00:00

In this paper the main components of a hydraulic positioning unit are modelled and simulated using the software Matlab/Simulink. That includes the actuator, the pressure relief valve, connecting pipes and of course the proportional directional control valve. With this model the positioning unit was tested under different conditions to make predictions on how the system is going to react. The simulation of the proportional directional control valve was divided into a static and dynamic part. Based on flow, pressure and leakage curves given by the manufacturer, pseudo-section functions have been created. These functions characterize the relationship between normalized spool position and flow rate. For simulating dynamic behaviour, a non-linear Simulink model was created. The model was fitted to non-linear frequency response analysis (NFR) data points by using a Nelder-Mead simplex optimization algorithm. Several experiments were carried out to test the methodologies as well as the models with the manufacturer's data and experimentally verifying the adjustability of the results and the validation of the approach. The valve model shows high positioning accuracy and robust behaviour in both simulation and experimentation. The amplitude response curves for 10% and 25% showed some oscillation, but with a stable behaviour around the measurement. On the other hand, the amplitude curve for 100% of the coil path showed a very acceptable approximation and even coincided with the manufacturer's curve.

Exoskeleton-type medical rehabilitation system with embedded sensors, designed using digital-twin solutions

2025-03-22T14:19:17+00:00

INTRODUCTION: Exoskeleton-type medical rehabilitation systems are the main solution for recovery of the mobility of patients affected by strokes, spinal cord injuries, or muscular atrophy. These systems feature detection and actuation components, such as sensors and actuators, whose typology and integration are essential for the device's ability to withstand wear under intensive use conditions.

OBJECTIVES: To increase the lifespan of exoskeletons, the main objective of the project presented in this article is to integrate sensors into the exoskeleton’s structure, for them to be better protected from external factors, such as shocks or moisture.

METHODS: A virtual model of an exoskeleton component for the lower limb that ensures the plantar flexion (movement of the sole), made of polyurethane, was designed using a digital-twin modelling solution, namely the SolidWorks Simulation software. Our choice was motivated by the fact that the use of digital twin solutions allows functional testing, by simulating the impact factors existing in real systems, of the exoskeleton with embedded sensors, by coating with polyethylene and ethylene vinyl acetate (EVA) layers. Thus, it will be possible to observe the inconsistencies and defects that can appear on the surface of the materials used and to determine the best choice of material that can protect against wear.

RESULTS: The values of all parameters analyzed following the simulations demonstrate that polyethylene and EVA are materials that can be used to embedd sensors into the structure of exoskeletons. Layers with thicknesses of 0.5 mm, 1 mm, and 1.5 mm are resistant and display stable structures during the patient's walking, thus protecting the sensors integrated into a lower limb exoskeleton from wear factors.

CONCLUSION: Following the comparative analysis of the results obtained from testing by digital simulations, the main conclusion is that the 1.5 mm thick ethylene vinyl acetate layer is the one that presents superior tribological properties, being the most useful for application in real systems.

Development of a digital model for cooling efficiency of metal working fluids in machining

2025-03-02T10:12:49+00:00

In this manuscript, cutting temperature generated in machining process, it’s sources and dissipation directions are studied. Energy consumption in metal cutting process and metal working fluids have taken as an object of the study. Moreover, the effect of metal working fluids in heat dissipation process and the importance of their cooling capacity is theoretically researched. As a result of the study, dependence model of temperature gradient between cutting face and fluid on fluid’s density and viscosity is mathematically developed. The developed digital model gives an easy way to predict metal working fluid’s cooling capacity before it’s use. It can be concluded that the reduction cutting fluids’ viscosity causes an increase in the cooling capacity of the fluids while high dense fluids show a better cooling capacity.