Industrial collaborative robots (cobots) are known for their ability to operate in dynamic environments to perform many different tasks (since they can be easily reprogrammed). Due to their features, they are largely used in flexible manufacturing processes. Since fault diagnosis methods are generally applied to systems where the working conditions are bounded, problems arise when defining condition monitoring architecture, in terms of setting absolute criteria for fault analysis and interpreting the meanings of detected values since working conditions may vary. The same cobot can be easily programmed to accomplish more than three or four tasks in a single working day. The extreme versatility of their use complicates the definition of strategies for detecting abnormal behavior. This is because any variation in working conditions can result in a different distribution of the acquired data stream. This phenomenon can be viewed as concept drift (CD). CD is defined as the change in data distribution that occurs in dynamically changing and nonstationary systems. Therefore, in this work, we propose an unsupervised anomaly detection (UAD) method that is capable of operating under CD. This solution aims to identify data changes coming from different working conditions (the concept drift) or a system degradation (failure) and, at the same time, can distinguish between the two cases. Additionally, once a concept drift is detected, the model can be adapted to the new conditions, thereby avoiding misinterpretation of the data. This paper concludes with a proof of concept (POC) that tests the proposed method on an industrial collaborative robot.

Optimizing energy consumption is an important aspect of industrial competitiveness, as it directly impacts operational efficiency, cost reduction, and sustainability goals. In this context, anomaly detection (AD) becomes a valuable methodology, as it supports maintenance activities in the manufacturing sector, allowing for early intervention to prevent energy waste and maintain optimal performance. Here, an AD-based method is proposed and studied to support energy-saving predictive maintenance of production lines using time series acquired directly from the field. This paper proposes a deep echo state network (DeepESN)-based method for anomaly detection by analyzing energy consumption data sets from production lines. Compared with traditional prediction methods, such as recurrent neural networks with long short-term memory (LSTM), although both models show similar time series trends, the DeepESN-based method studied here appears to have some advantages, such as timelier error detection and higher prediction accuracy. In addition, the DeepESN-based method has been shown to be more accurate in predicting the occurrence of failure. The proposed solution has been extensively tested in a real-world pilot case consisting of an automated metal filter production line equipped with industrial smart meters to acquire energy data during production phases; the time series, composed of 88 variables associated with energy parameters, was then processed using the techniques introduced earlier. The results show that our method enables earlier error detection and achieves higher prediction accuracy when running on an edge device.

Enabling robots to work safely close to humans requires both adherence to safety standards and the development of appropriate strategies to plan and control robot movements in accordance with human movements. Collaboration between humans and robots in a shared environment is a joint activity aimed at completing specific tasks, requiring coordination, synchronisation, and sometimes physical contact, in which each party contributes its own skills and resources. Among the most challenging tasks of human–robot cooperation is the co-transport of deformable materials such as fabrics. This paper proposes a method for generating the trajectory of a collaborative manipulator. The method is designed for the co-transport of materials such as fabrics. It combines a near time-optimal control strategy that ensures responsiveness in following human actions while simultaneously guaranteeing compliance with the safety limits imposed by current regulations. The combination of these two elements results in a viable co-transport solution which preserves the safety of human operators. This is achieved by constraining the path of the robot trajectory with prescribed velocities and accelerations while simultaneously ensuring a near time-optimal control strategy. In short, the robot movement is generated in such a way as to ensure both the tracking of humans in the co-transportation task and compliance with safety limits. As a first attempt to adopt the proposed approach to integrate time-optimal strategies into human–robot interaction, the simulations and preliminary experimental result obtained are promising.

Production efficiency is used to determine the best conditions for manufacturing goods at the lowest possible unit cost. When achieved, production efficiency leads to increased revenues for the manufacturer, enhanced employee safety, and a satisfied customer base. Production efficiency not only measures the amount of resources that are needed for production but also considers the productivity levels and the state of the production lines. In this context, online anomaly detection (AD) is an important tool for maintaining the reliability of the production ecosystem. With advancements in artificial intelligence and the growing significance of identifying and mitigating anomalies across different fields, approaches based on artificial neural networks facilitate the recognition of intricate types of anomalies by taking into account both temporal and contextual attributes. In this paper, a lightweight framework based on the Echo State Network (ESN) model running at the edge is introduced for online AD. Compared to other AD methods, such as Long Short-Term Memory (LSTM), it achieves superior precision, accuracy, and recall metrics while reducing training time, CO₂ emissions, and the need for high computational resources. The preliminary evaluation of the proposed solution was conducted using a low-resource computing device at the edge of the real production machine through an Industrial Internet of Things (IIoT) smart meter module. The machine used to test the proposed solution was provided by the Italian company SIFIM Srl, which manufactures filter mats for industrial kitchens. Experimental results demonstrate the feasibility of developing an AD method that achieves high accuracy, with the ESN-based framework reaching $85\%$ compared to $80.88\%$ for the LSTM-based model. Furthermore, this method requires minimal hardware resources, with a training time of $9.5$ s compared to $2.100$ s for the other model.

Optimising the performance of tokamak operation is not only a matter of tuning individual control loops, but needs a holistic approach with a focus on the effective interplay of all control system components. The ASDEX Upgrade Discharge Control System (DCS) has enabled outstanding results of physics effect studies and operation scenario development. This is facilitated by efficient and highly robust algorithms for measurements data processing and plasma state estimation, a versatile feedback control suite, a powerful actuator management approach that optimises the utilisation of the limited number of actuators, and pulse supervision control reacting to events and plasma state conditions to achieve a maximum exploitation of the pulse and protect device and investment. Moreover, Fenix, a fast ‘flight simulator’ with a full model of the control system and a control-oriented plasma and plant model, assists in scenario design, validation and control method development, thus accelerating the turnaround time from the design of emerging capabilities to their exploitation in plasma pulses. Larger and more complex fusion devices such as ITER and DEMO in particular, will benefit from such a control structure and active contributions are being made to the architectural design of their control systems.