2023
Autores
Sousa, J; Darabi, R; Sousa, A; Reis, LP; Brueckner, F; Reis, A; de Sá, JC;
Publicação
PROCEEDINGS OF ASME 2023 INTERNATIONAL MECHANICAL ENGINEERING CONGRESS AND EXPOSITION, IMECE2023, VOL 3
Abstract
Directed Energy Deposition (DED) is crucial in additive manufacturing for various industries like aerospace, automotive, and biomedical. Precise temperature control is essential due to high-power lasers and dynamic environmental changes. Employing Reinforcement Learning (RL) can help with temperature control, but challenges arise from standardization and sample efficiency. In this study, a model-based Reinforcement Learning (MBRL) approach is used to train a DED model, improving control and efficiency. Computational models evaluate melt pool geometry and temporal characteristics during the process. The study employs the Allen-Cahn phase field (AC-PF) model using the Finite Element Method (FEM) with the Multi-physics Object-Oriented Simulation Environment (MOOSE). MBRL, specifically Dyna-Q+, outperforms traditional Q-learning, requiring fewer samples. Insights from this research aid in advancing RL techniques for laser metal additive manufacturing.
2025
Autores
Martins, JG; Nutonen, K; Costa, P; Kuts, V; Otto, T; Sousa, A; Petry, MR;
Publicação
2025 IEEE INTERNATIONAL CONFERENCE ON AUTONOMOUS ROBOT SYSTEMS AND COMPETITIONS, ICARSC
Abstract
Digital twins enable real-time modeling, simulation, and monitoring of complex systems, driving advancements in automation, robotics, and industrial applications. This study presents a large-scale digital twin-testing facility for evaluating mobile robots and pilot robotic systems in a research laboratory environment. The platform integrates high-fidelity physical and environmental models, providing a controlled yet dynamic setting for analyzing robotic behavior. A key feature of the system is its comprehensive data collection framework, capturing critical parameters such as position, orientation, and velocity, which can be leveraged for machine learning, performance optimization, and decision-making. The facility also supports the simulation of discrete operational systems, using predictive modeling to bridge informational gaps when real-time data updates are unavailable. The digital twin was validated through a matrix manufacturing system simulation, with an Augmented Reality (AR) interface on the HoloLens 2 to overlay digital information onto mobile platform controllers, enhancing situational awareness. The main contributions include a digital twin framework for deploying data-driven robotic systems and three key AR/VR integration optimization methods. Demonstrated in a laboratory setting, the system is a versatile tool for research and industrial applications, fostering insights into robotic automation and digital twin scalability while reducing costs and risks associated with real-world testing.
2025
Autores
Rema, C; Sousa, A; Sobreira, H; Costa, P; Silva, MF;
Publicação
2025 IEEE INTERNATIONAL CONFERENCE ON AUTONOMOUS ROBOT SYSTEMS AND COMPETITIONS, ICARSC
Abstract
The rise of Industry 4.0 has revolutionized manufacturing by integrating real-time data analysis, artificial intelligence (AI), automation, and interconnected systems, enabling adaptive and resilient smart factories. Autonomous Mobile Robots (AMRs), with their advanced mobility and navigation capabilities, are a pillar of this transformation. However, their deployment in job shop environments adds complexity to the already challenging Job Shop Scheduling Problem (JSSP), expanding it to include task allocation, robot scheduling, and travel time optimization, creating a multi-faceted, non-deterministic polynomial-time hardness (NP-hard) problem. Traditional approaches such as heuristics, meta-heuristics, and mixed integer linear programming (MILP) are commonly used. Recent AI advancements, particularly large language models (LLM), have shown potential in addressing these scheduling challenges due to significant improvements in reasoning and decision-making from textual data. This paper examines the application of LLM to tackle scheduling complexities in smart job shops with mobile robots. Guided by tailored prompts inserted manually, LLM are employed to generate scheduling solutions, being these compared to an heuristic-based method. The results indicate that LLM currently have limitations in solving complex combinatorial problems, such as task scheduling with mobile robots. Due to issues with consistency and repeatability, they are not yet reliable enough for practical implementation in industrial environments. However, they offer a promising foundation for augmenting traditional approaches in the future.
2025
Autores
Sousa, J; Brandau, B; Hemschik, R; Darabi, R; Sousa, A; Reis, LP; Brueckner, F; Reis, A;
Publicação
ADDITIVE MANUFACTURING
Abstract
Bringing AI models from digital to real-world applications presents significant challenges due to the complexity and variability of physical environments, often leading to unexpected model behaviors. We propose a framework that learns to translate images into control actions by modeling multimodal real-time data and system dynamics. This end-to-end controller offers enhanced explainability and robustness, making it well suited for complex manufacturing processes. This end-to-end framework differs from traditional approaches that rely on manually engineered features by learning complex relationships directly from raw data. Labels are only required during training to define the observable feature to be optimized. This adaptability significantly reduces development time and enhances scalability across varying conditions. This approach was tested in the Directed Energy Deposition (L-DED) process, a laser-based metal additive manufacturing technique that produces near-net-shape parts with exceptional energy efficiency and flexibility in both geometry and material selection. L-DED is inherently complex, involving multiphysics interactions, multiscale phenomena, and dynamic behaviors, which make modeling and optimization difficult. Effective control is crucial to ensure part quality in this dynamic environment. To address these challenges, we introduce Joint Embedding Multimodal Alignment with Sparse Identification of Nonlinear Dynamics for control (JEMA-SINDYc). It combines an image-based JEMA monitoring model, which predicts the melt pool size using only the on-axis sensor with labels provided by the off-axis camera, and dynamic modeling using SINDYc, which acts as a World Model by capturing system dynamics within the embedding space. Together, these components enable the development of an advanced controller trained via Behavioral Cloning. This approach improves part quality by minimizing porosity and reducing deformation. Thin-walled cylindrical parts were produced to validate and compare this approach with other control strategies, including both open-loop and JEMA-PID. This framework improves the reliability of AI-driven manufacturing and enhances control of complex industrial processes, potentially enabling wider adoption of the process.
2025
Autores
Monteiro, F; Sousa, A;
Publicação
EUROPEAN JOURNAL OF ENGINEERING EDUCATION
Abstract
Engineering is considered important in solving unsustainability. However, it is a complex problem that must be viewed, analysed and studied from various perspectives and taking with the contribution of various areas of knowledge. This work studied the use of interdisciplinarity as a contribution to interconnect ethics and sustainability with technical-scientific contents of electrical engineering. The research intended to use interdisciplinarity to help engineering students recognise that engineering is not ethically neutral, and that, therefore, the problems (and solutions) must also be analysed from an ethical and sustainability perspective. A framework was developed, and a pedagogical activity using interdisciplinarity was applied. Results show that, after the activity, students recognise that ethical values influence calculations in the area of electrical installations; and move from a single view to identify different alternatives, perspectives, motivations and multiple objectives. This leads to studying more alternatives and hopefully better overall technical solutions.
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