The innovation-driven Industry 5.0 leads us to consider humanity in a prominent position as the center of the manufacturing field even more than Industry 4.0. This pushes us towards the hybridization of manufacturing plants promoting a full collaboration between humans and robots. However, there are currently very few workplaces where effective Human–Robot Collaboration takes place. Layout designing plays a key role in assuring safe and efficient Human–Robot Collaboration. The layout design, especially in the context of collaborative robotics, is a complex problem to face, since it is related to safety, ergonomics, and productivity aspects. In the current work, a Knowledge-Based Approach (KBA) is adopted to face the complexity of the layout design problem. The framework resulting from the KBA allows for developing a modeling paradigm that enables us to define a streamlined approach for the layout design. The proposed approach allows for placing resource within the workplace according to a defined optimization criterion, and also ensures compliance with various standards. This approach is applied to an industrial case study in order to prove its feasibility. A what-if analysis is performed by applying the proposed approach. Changing three control factors (i.e., minimum distance, robot speed, logistic space configuration) on three levels, in a Design of Experiments, 27 layout configurations of the same workplace are generated. Consequently, the inputs that most affect the layout design are identified by means of an Analysis of Variance (ANOVA). The results show that only one layout is eligible to be the best configuration, and only two out of three control factors are very significant for the designing of the HRC workplace layout. Hence, the proposed approach enables the designing of standard compliant and optimized HRC workplace layouts. Therefore, several alternatives of the layout for the same workplace can be easily generated and investigated in a systematic manner.

Enabling technologies that drive Industry 4.0 and smart factories are pushing in new equipment and system development also to prevent human workers from repetitive and non-ergonomic tasks inside manufacturing plants. One of these tasks is the order-picking which consists in collecting parts from the warehouse and distributing them among the workstations and vice-versa. That task can be completely performed by a Mobile Manipulator that is composed by an industrial manipulator assembled on a Mobile Robot. Although the Mobile Manipulators implementation brings advantages to industrial applications, they are still not widely used due to the lack of dedicated standards on control and safety. Furthermore, there are few integrated solutions and no specific or reference point allowing the safe integration of mobile robots and cobots (already owned by company). This work faces the integration of a generic mobile robot and collaborative robot selected from an identified set of both systems. The paper presents a safe and flexible mechatronic interface developed by using MBSE principles, multi-domain modeling, and adopting preliminary assumptions on the hardware and software synchronization level of both involved systems. The interface enables the re-using of owned robot systems differently from their native tasks. Furthermore, it provides an additional and redundant safety level by enabling power and force limiting both during cobot positioning and control system faulting.

Mechatronic systems become ever more complex because of their increasing number of interconnected safety critical components and sophistication. MBSE (Model‐based Systems Engineering) and MBSA (Model‐Based Safety Assessment) are the most commonly adopted approaches to deal with the design and safety analysis of mechatronic systems. Unfortunately, both approaches are normally adopted separately, especially in the earlier phases of system design, thus leading to a lack of communication between system engineers and the safety team. This work aims to fill that gap at a high level, that is, through process interaction. This paper proposes an enhanced V‐model for the design of safety‐critical mechatronic systems. It relates a system development process with specific safety assessment methods. Specifically, the proposed workflow details exchange flows between the RFLP (Requirements, Functional, Logical, Physical) method, the FHA (Functional Hazard Analysis), the FMEA (Failure Mode and Effects Analysis), the MBSA and simulation, and the FTA (Fault Tree Analysis). These analyses are complemented with multiphysics modeling and simulation to observe system behavior in functional and failure scenarios, with the aim of requirements verification. The design workflow has been applied to a winged Unmanned Aerial Vehicle to apply the parallel process and the necessary interaction of MBSE and MBSA approaches. The information flows between the individual activities proved effective for designing a safe system before the verification phase. The main benefit of the proposed workflow is providing both the design and safety team with some interaction points, thus avoiding a lack of safety‐critical analysis in the early phases of system design.

In recent years, the Digital Twin has attracted significant attention in academia and industry as a powerful technology for creating virtual replicas of physical systems tailored to specific purposes. Digital Twins can be developed at various levels of maturity, accommodating different system types and scopes. Consequently, diverse domain-specific approaches to Digital Twins development exist, yet no standardized method defines, verifies, and validates their requirements. This is essential for a consistent and reliable implementation of Digital Twins. This paper explores the application of Model-Based Systems Engineering in the design, development, verification, and validation of a Digital Twin System. It presents a comprehensive methodology that encompasses all phases of a Digital Twin System’s life cycle. The methodology was applied to model the requirements and the functional, behavioral, and structural aspects of a Digital Twin System for an aircraft seat testbench, supporting its design, implementation, and operation at the prototype level. The Digital Twin replicates the seat testbench, enabling simulations for early system validation under various conditions. Integrating Model-Based Systems Engineering with Digital Twin technologies enhances the clear definition of scope and technical requirements, contributing to more effective testing and development processes in the aeronautical industry. This work underscores the benefits of a model-driven approach for Digital Twin design, laying the foundation for future applications in complex engineering systems due to its repeatability.

The innovation driven Industry 5.0, in agreement with Industry 4.0, leads to consider human in a prominence position as the center of manufacturing field. This pushes towards the hybridization of manufacturing plants promoting a fully collaboration between human and robot. Furthermore, the new paradigm of "human centred design" and "anthropocentric design" allows enabling a synergistic combination of human and robot skills. However, properly collaborative workplaces are currently very few. Industry is still not confident, and systems integrators hesitate to venture into Human-Robot Collaboration (HRC). Despite the effort in collaborative robotics, a general solution to overcome the current limitations in designing of collaborative workplaces still misses. In the current work, a Knowledge-Based Approach (KBA) is adopted to face collaborative workplace designing problem. The framework resulting from the KBA allows developing a modelling paradigm that enable to define a streamlined approach for the layout designing of a collaborative workplace. Finally, a what-if analysis and a ANOVA analysis are performed to generate and evaluate a set of scenarios related to a collaborative workplace for quality inspection of welded parts. Facing the high complexity and multidisciplinary of HRC can be conveyed to develop a general design approach aimed at overcoming the difficulties that limit the spread of HRC in the manufacturing field.

In the context of Industry 4.0 and Industry 5.0, the introduction of collaborative workplaces, where humans and robots work together, represents a growing trend to improve the productivity, adaptability, and flexibility of production plants. Indeed, human–robot collaboration (HRC) is a very deepened topic in the scientific community and the designing of collaborative workplaces is a challenging issue due to the high level of complexity and multidisciplinary of its features. This work tackles the complexity of collaborative workplaces and proposes a structured framework to support strategic decisions in designing. A multi-level designing framework is proposed as a supporting tool for designers. Within five domains of collaborative robotics, the elements of a collaborative workplace are identified and proposed in a framework in order to better consider human safety and working conditions during the designing process. A decomposition matrix and an adjacency matrix are used to develop a multi-level designing workflow. Finally, an interactive tool is presented, named “Smart Graph Interface” (SGI), to read and exploit the contents of the framework. The SGI is applied to three case studies from the literature, to spread out principal outcomes in terms of applicability and robustness.