Simion Georgian

Scopus Publications

Internet of Things-Cloud Control of a Robotic Cell Based on Inverse Kinematics, Hardware-in-the-Loop, Digital Twin, and Industry 4.0/5.0
Dan Ionescu, Adrian Filipescu, Georgian Simion, and Adriana Filipescu
MDPI AG
The main task of the research involves creating a Digital Twin (DT) application serving as a framework for Virtual Commissioning (VC) with Supervisory Control and Data Acquisition (SCADA) and Cloud storage solutions. An Internet of Things (IoT) integrated automation system with Virtual Private Network (VPN) remote control for assembly and disassembly robotic cell (A/DRC) equipped with a six-Degree of Freedom (6-DOF) ABB 120 industrial robotic manipulator (IRM) is presented in this paper. A three-dimensional (3D) virtual model is developed using Siemens NX Mechatronics Concept Designer (MCD), while the Programmable Logic Controller (PLC) is programmed in the Siemens Totally Integrated Automation (TIA) Portal. A Hardware-in-the-Loop (HIL) simulation strategy is primarily used. This concept is implemented and executed as part of a VC approach, where the designed PLC programs are integrated and tested against the physical controller. Closed loop control and RM inverse kinematics model are validated and tested in PLC, following HIL strategy by integrating Industry 4.0/5.0 concepts. A SCADA application is also deployed, serving as a DT operator panel for process monitoring and simulation. Cloud data collection, analysis, supervising, and synchronizing DT tasks are also integrated and explored. Additionally, it provides communication interfaces via PROFINET IO to SCADA and Human Machine Interface (HMI), and through Open Platform Communication—Unified Architecture (OPC-UA) for Siemens NX-MCD with DT virtual model. Virtual A/DRC simulations are performed using the Synchronized Timed Petri Nets (STPN) model for control strategy validation based on task planning integration and synchronization with other IoT devices. The objective is to obtain a clear and understandable representation layout of the A/DRC and to validate the DT model by comparing process dynamics and robot motion kinematics between physical and virtual replicas. Thus, following the results of the current research work, integrating digital technologies in manufacturing, like VC, IoT, and Cloud, is useful for validating and optimizing manufacturing processes, error detection, and reducing the risks before the actual physical system is built or deployed.

Cloud/VPN-Based Remote Control of a Modular Production System Assisted by a Mobile Cyber–Physical Robotic System—Digital Twin Approach
Georgian Simion, Adrian Filipescu, Dan Ionescu, and Adriana Filipescu
MDPI AG
This paper deals with a “digital twin” (DT) approach for processing, reprocessing, and scrapping (P/R/S) technology running on a modular production system (MPS) assisted by a mobile cyber–physical robotic system (MCPRS). The main hardware architecture consists of four line-shaped workstations (WSs), a wheeled mobile robot (WMR) equipped with a robotic manipulator (RM) and a mobile visual servoing system (MVSS) mounted on the end effector. The system architecture integrates a hierarchical control system where each of the four WSs, in the MPS, is controlled by a Programable Logic Controller (PLC), all connected via Profibus DP to a central PLC. In addition to the connection via Profibus of the four PLCs, related to the WSs, to the main PLC, there are also the connections of other devices to the local networks, LAN Profinet and LAN Ethernet. There are the connections to the Internet, Cloud and Virtual Private Network (VPN) via WAN Ethernet by open platform communication unified architecture (OPC-UA). The overall system follows a DT approach that enables task planning through augmented reality (AR) and uses virtual reality (VR) for visualization through Synchronized Hybrid Petri Net (SHPN) simulation. Timed Petri Nets (TPNs) are used to control the processes within the MPS’s workstations. Continuous Petri Nets (CPNs) handle the movement of the MCPRS. Task planning in AR enables users to interact with the system in real time using AR technology to visualize and plan tasks. SHPN in VR is a combination of TPNs and CPNs used in the virtual representation of the system to synchronize tasks between the MPS and MCPRS. The workpiece (WP) visits stations successively as it is moved along the line for processing. If the processed WP does not pass the quality test, it is taken from the last WS and is transported, by MCPRS, to the first WS where it will be considered for reprocessing or scrapping.

IoT-Cloud, VPN, and Digital Twin-Based Remote Monitoring and Control of a Multifunctional Robotic Cell in the Context of AI, Industry, and Education 4.0 and 5.0
Adrian Filipescu, Georgian Simion, Dan Ionescu, and Adriana Filipescu
MDPI AG
The monitoring and control of an assembly/disassembly/replacement (A/D/R) multifunctional robotic cell (MRC) with the ABB 120 Industrial Robotic Manipulator (IRM), based on IoT (Internet of Things)-cloud, VPN (Virtual Private Network), and digital twin (DT) technology, are presented in this paper. The approach integrates modern principles of smart manufacturing as outlined in Industry/Education 4.0 (automation, data exchange, smart systems, machine learning, and predictive maintenance) and Industry/Education 5.0 (human–robot collaboration, customization, robustness, and sustainability). Artificial intelligence (AI), based on machine learning (ML), enhances system flexibility, productivity, and user-centered collaboration. Several IoT edge devices are engaged, connected to local networks, LAN-Profinet, and LAN-Ethernet and to the Internet via WAN-Ethernet and OPC-UA, for remote and local processing and data acquisition. The system is connected to the Internet via Wireless Area Network (WAN) and allows remote control via the cloud and VPN. IoT dashboards, as human–machine interfaces (HMIs), SCADA (Supervisory Control and Data Acquisition), and OPC-UA (Open Platform Communication-Unified Architecture), facilitate remote monitoring and control of the MRC, as well as the planning and management of A/D/R tasks. The assignment, planning, and execution of A/D/R tasks were carried out using an augmented reality (AR) tool. Synchronized timed Petri nets (STPN) were used as a digital twin akin to a virtual reality (VR) representation of A/D/R MRC operations. This integration of advanced technology into a laboratory mechatronic system, where the devices are organized in a decentralized, multilevel architecture, creates a smart, flexible, and scalable environment that caters to both industrial applications and educational frameworks.

PLC Inverse Kinematics Model-Driven Digital Twin Focused on HIL for a Flexible Robotic Cell
D. Ionescu, A. Filipescu, G. Simion, R. Şolea, A. Filipescu, and A. Serbencu
IEEE
This paper focuses on the design, implementation and testing of a Digital Twin (DT) application for a assembly/disassembly (A/D) flexible robotic cell (FRC) assisted by ABB robotic manipulator (RM). A 3D virtual model is implemented in Siemens NX Mechatronics Concept Designer (MCD). S7-1200 PLC is programmed in Siemens TIA Portal, for both FRC and virtual model control, the last one based on inverse kinematics computation. A centralized architecture is applied for virtual FRC implementation and validation, to enable product simulation and for the automation control of the A/D manufacturing process. As part of the DT technology, Virtual Commissioning (VC) concept is used, to increase the production and performance, by optimizing tasks and to improve the traceability, by monitoring, analyzing and tracking every aspect of all manufacturing system. Moreover, VC significantly reduces potential human risks, delays and costs associated with the real on-site commissioning. To connect the FRC's PLC controllers with the NX MCD virtual plant model and for controlling the virtual model, Hardware-in-the-Loop (HIL) configuration and simulation strategy is adopted. Therefore Soft Commissioning approach is implemented and performed, by testing the designed PLC software and the behavior of the system using the real physical PLC. A SCADA application is also implemented, acting as a DT operator panel for process monitoring, data acquisition, analysis and visualization of the entire mechatronic system.

IoT-Cloud based Control of a Flexible Assembly/Disassembly Mechatronic System in the Framework of Industries 4.0 and 5.0
A. Filipescu, I. Stamatescu, G. Simion, D. Ionescu, and A. Filipescu
IEEE
The aim of the work is to present the design and implementation of an IoT-Cloud based system for monitoring and controlling a mechatronic system as a flexible robotic cell (FRC) of assembly/disassembly (A/D), equipped with the 6-DOF ABB 120 industrial robotic manipulator (IRM) that satisfies the framework of Industries 4.0 and 5.0. In addition to the ABB 120 IRM, several IoT edge devices are employed, connected in a local network (LAN), for local processing and data acquisition. The system is connected to the Internet and allows remote control via Cloud and VPN. IoT dashboards, as human machine interfaces (HMIs), for remote monitoring and control of FRC status, initiation and management of A/D tasks, have been implemented. Synchronized timed Petri nets (STPN) were used as digital twin like a virtual reality (VR) representation of A/D FRC operations. Moreover, the assignment, planning and execution of A/D tasks were carried out using an augmented reality (AR) tool. The devices, which are organized in a decentralized, multilevel architecture to ensure interoperability between different subsystems., autonomy., and flexibility.

Remote Control of a Flexible Robotic Cell as a Cyber Physical System for Assembly and Disassembly Based on SCADA and Industry 4.0
A. Filipescu, G. Simion, D. Ionescu, and A. Filipescu
IEEE
This paper aims to design a remote-controlled Flexible Robotic Cell (FRC) equipped with an ABB 120 industrial robotic manipulator (IRM) as Cyber Physical System (CPS) for assembly and disassembly (A/D) of two workpieces (WP1, WP2) with 5 parts each, based on SCADA and Industry 4.0 concepts. CPS involves integrating various digital devices, connected in a local array network (LAN) and Internet for enhanced automation, connectivity, and intelligence, The digital devices are: PLC, 3D cameras, video processing unit (VPU), powerful, embedded computer, Wi Fi router, remote and local Human Machine Interface (HMI), ethernet switch, servo drive and IoT, the last one being an edge device that allows remote connection via VPN. Synchronized timed Petri nets (STPN), for assembly and disassembly, are used for modeling and simulation. The design of CPS was subordinated to the concept of “Digital Twin”, by integrating, and synchronizing task planning and the simulation results of the STPN models, with real-time control in a supervisory control and data acquisition (SCADA) system connected remotely.

Digital Twin Based a Processing Technology Assisted by a MCPRS, Ready for Industry 5.0
Adrian Filipescu, Eugenia Minca, Daniela. Cernega, Razvan Solea, Adriana Filipescu, Georgian Simion, and Dan Ionescu
IEEE
This paper deals with digital twin (DT) approach for a processing technology (PT) running on a mechatronic processing system (MPS) assisted by a mobile cyber-physical robotic system (MCPRS). The hardware architecture consists of the MPS, four workstation (WS), line-shaped, and MCPRS. MCPRS has in its structure a wheeled mobile robot (WMR) equipped with robotic manipulator (RM) having on the end effector a mobile visual servoing system MVSS). The workpiece (WP) is moved along the four stations for processing, and at the end, if it does not pass the primary quality test (PQT), it is picked up by the MCPRS, transported to the first station for reprocessing or scrapping. If the WP does not pass the second quality test (SQT), then it is stored as scrapped. WP that passes the SQT, through the same processing operations, will be brought to the quality standard. Thus, the WP will go through the MPS twice, for processing/reprocessing (P/R). The virtual world that serves as the subsystems of MCPRS. Additionally, the virtual world includes hybrid modeling with synchronized hybrid Petri nets (SHPN), simulation of the SHPN models, modeling of the MVSS, and simulation of the discrete-time trajectory-tracking sliding-mode control (DT-TTSMC) of MCPRS. The real world, corresponding to the virtual world, consists of communication, synchronization and control of the MPS and MCPRS’s subsystems (WMR, RM and MVSS), the graphical user interface (GUI) and a supervisory control and data acquisition (SCADA) system, implemented on a remote PC.

Modeling and Control an A/DT Served by an ACPS based on SCADA, Industry 4.0 and 5.0
Adrian Filipescu, Daniela Cernega, Razvan Solea, Adriana Filipescu, Eugenia Minca, Dan Ionescu, and Georgian Simion
IEEE
Modeling, monitoring and control of a multilevel architecture for an assembly/disassembly technology (A/DT) assisted by an autonomous cyber-physical system (ACPS). The hardware architecture consists of six workstations (6-WS), A/D mechatronics line (A/DML) connected to an A/D flexible cell (A/DFC) equipped with a 6-DOF industrial robotic manipulator (IRM). ACPS has in its structure two driving wheels and one free wheel (2DW/1FW)-wheeled mobile robot (WMR) equipped with a 7-DOF robotic manipulator (RM). A mobile visual servoing system (MVSS) is mounted on the end effector of the RM. A/DT assembles two different workpieces (WP1 and WP2), while disassembly only covers products that do not meet the quality test and component recovery through ACPS. ACPS takes the components from the disassembly locations and stores them in the appropriate warehouses for reuse. Synchronized Petri nets (SPN), for assembly, and synchronized hybrid Petri nets (SHPN), for disassembly, are used for modeling and simulation. Discrete-time trajectory-tracking sliding-mode control (DT-TTSMC), for WMR displacement, inverse kinematic (IKC) for 7-DOF RM control, and image moments for MVSS positioning are used to control ACPS subsystems. The design of the A/DT served by ACPS, was subordinated to the concept of Digital twin, by integrating, interfacing and synchronizing the simulation results of the SPN and SHPN models, with real-time management in a supervisory control and data acquisition (SCADA) system located on a Remote PC (RPC). The design and real-time control of A/DT served by ACPS were made in the vision of Industry 4.0 and Industry 5.0.

Digital Twin for a Multifunctional Technology of Flexible Assembly on a Mechatronics Line with Integrated Robotic Systems and Mobile Visual Sensor—Challenges towards Industry 5.0 †
Eugenia Mincă, Adrian Filipescu, Daniela Cernega, Răzvan Șolea, Adriana Filipescu, Dan Ionescu, and Georgian Simion
MDPI AG
A digital twin for a multifunctional technology for flexible manufacturing on an assembly, disassembly, and repair mechatronics line (A/D/RML), assisted by a complex autonomous system (CAS), is presented in the paper. The hardware architecture consists of the A/D/RML and a six-workstation (WS) mechatronics line (ML) connected to a flexible cell (FC) and equipped with a six-degree of freedom (DOF) industrial robotic manipulator (IRM). The CAS has in its structure two driving wheels and one free wheel (2DW/1FW)-wheeled mobile robot (WMR) equipped with a 7-DOF robotic manipulator (RM). On the end effector of the RM, a mobile visual servoing system (eye-in-hand MVSS) is mounted. The multifunctionality is provided by the three actions, assembly, disassembly, and repair, while the flexibility is due to the assembly of different products. After disassembly or repair, CAS picks up the disassembled components and transports them to the appropriate storage depots for reuse. Disassembling or repairing starts after assembling, and the final assembled product fails the quality test. The virtual world that serves as the digital counterpart consists of tasks assignment, planning and synchronization of A/D/RML with integrated robotic systems, IRM, and CAS. Additionally, the virtual world includes hybrid modeling with synchronized hybrid Petri nets (SHPN), simulation of the SHPN models, modeling of the MVSS, and simulation of the trajectory-tracking sliding-mode control (TTSMC) of the CAS. The real world, as counterpart of the digital twin, consists of communication, synchronization, and control of A/D/RML and CAS. In addition, the real world includes control of the MVSS, the inverse kinematic control (IKC) of the RM and graphic user interface (GUI) for monitoring and real-time control of the whole system. The “Digital twin” approach has been designed to meet all the requirements and attributes of Industry 4.0 and beyond towards Industry 5.0, the target being a closer collaboration between the human operator and the production line.

Mobile Visual Servoing Based Control of a Complex Autonomous System Assisting a Manufacturing Technology on a Mechatronics Line
Georgian Simion, Adrian Filipescu, Dan Ionescu, Răzvan Șolea, Daniela Cernega, Eugenia Mincă, and Adriana Filipescu
MDPI AG
The main contribution of this paper is the modeling and control for a complex autonomous system (CAS). It is equipped with a visual sensor to operate precision positioning in a technology executed on a laboratory mechatronics line. The technology allows the retrieval of workpieces which do not completely pass the quality test. Another objective of this paper is the implementation of an assisting technology for a laboratory processing/reprocessing mechatronics line (P/RML) containing four workstations, assisted by the following components: a complex autonomous system that consists of an autonomous robotic system (ARS), a wheeled mobile robot (WMR) PeopleBot, a robotic manipulator (RM) Cyton 1500 with seven degrees of freedom (7 DOF), and a mobile visual servoing system (MVS) with a Logitech camera as visual sensor used in the process of picking, transporting and placing the workpieces. The purpose of the MVS is to increase the precision of the RM by utilizing the look and move principle, since the initial and final positions of the CAS can slightly deviate from their trajectory, thus increasing the possibility of errors to appear during the process of catching and releasing the pieces. If the processed piece did not pass the quality test and has been rendered as defective, it is retrieved from the last station of the P/RML and transported to the first station for reprocessing. The control of the WMR is done using the trajectory-tracking sliding-mode control (TTSMC). The RM control is based on inverse kinematics model, and the MVS control is implemented with the image moments method.

Communication and Control of an Assembly, Disassembly and Repair Flexible Manufacturing Technology on a Mechatronics Line Assisted by an Autonomous Robotic System
Dan Ionescu, Adrian Filipescu, Georgian Simion, Eugenia Mincă, Daniela Cernega, Răzvan Șolea, and Adriana Filipescu
MDPI AG
This paper aims to describe modeling and control in what concerns advanced manufacturing technology running on a flexible assembly, disassembly and repair on a mechatronic line (A/D/RML) assisted by an Autonomous Robotic System (ARS), two robotic manipulators (RM) and visual servoing system (VSS). The A/D/RML consists of a six workstations (WS) mechatronics line (ML) connected to a flexible cell (FC) equipped with a 6-DOF ABB industrial robotic manipulator (IRM) and an ARS used for manipulation and transport. A hybrid communication and control based on programmable logic controller (PLC) architecture is used, which consists of two interconnected systems that feature both distributed and centralized topology, with specific tasks for all the manufacturing stages. Profinet communication link is used to interconnect and control FC and A/D/RML. The paper also discusses how to synchronize data between different field equipment used in the industry and the control systems. Synchronization signals between the master PLC and ARS is performed by means of Modbus TCP protocol and OPC UA. The structure of the ARS consists of a wheeled mobile robot (WMR) with two driving wheels and one free wheel (2DW/1FW) equipped with a 7-DOF RM. Trajectory tracking sliding-mode control (TTSMC) is used to control WMR. The end effector of the ARS RM is equipped with a mobile eye-in-hand VSS technology for the precise positioning of RM to pick and place the workparts in the desired location. Technology operates synchronously with signals from sensors and from the VSS HD camera. If the workpiece does not pass the quality test, the process handles it by transporting back from the end storage unit to the flexible cell where it will be considered for reprocessing, repair or disassembling with the recovery of the dismantled parts. The recovered or replaced components are taken over by the ARS from disassembling location and transported back to the dedicated storage warehouses to be reused in the further assembly processes.

Complex Autonomous System Assisting a Manufacturing Technology on a Mechatronics Line. A Digital Twin Approach
Adrian Filipescu, Razvan Solea, Daniela Cristina Cernega, Dan Ionescu, Georgian Simion, and Adriana Filipescu
IEEE
The main contribution of this paper is to present the implementation of an assisting technology digital twin based for a processing/reprocessing mechatronics line (P/RML). The implemented technology allows the reprocessing of the workpieces which do not pass the quality test. The digital twin approach considers the P/RML equipped with a complex autonomous system (CAS). The CAS is an autonomous robotic system (ARS) with a robotic manipulator (RM) equipped with a mobile visual servoing system (MVS) used for precise positioning in the technology executed on the laboratory mechatronics line. Modeling and control for the P/RML with CAS are presented. The P/RML has four workstations. The assisting technology uses the complex autonomous system (CAS). The MVS is involved in picking, transporting, and placing processes of the workpieces and it aims at increasing the precision of the RM operations. The reprocessing feature of the system is performed for the processed pieces that do not pass the quality test. To be reprocessed these workpieces are transferred by the CAS to the first station. The control of this complex process is presented. For this flexible manufacturing process, a digital twin control is designed.

Digital Twin for a Mechatronics Line with Integrated Mobile Robotic Systems
Adrian Filipescu, Daniela Cristina Cernega, Eugenia Minca, Razvan Solea, Dan Ionescu, Georgian Simion, and Adriana Filipescu
IEEE
The paper presents digital twin multi-functional technology for flexible production on an assembly, disassembly and repair (A/D/RML) mechatronics line assisted by a complex autonomous system (CAS). The real world consists of A/D/RML a mechatronic line (ML) with six workstations (WS) connected to a flexible cell (FC) equipped with an industrial robotic manipulator (IRM). The multifunctionality of the system is given by the three actions, assembly, disassembly and repair (the flexibility is due to the assembly of different types of products). After disassembly or repair, CAS picks up and transports the disassembled components to the appropriate storage positions for reuse. The technology works synchronously with signals from various sensors and a mobile visual servo system (VSS eye-in-hand). The virtual representation serving as a digital counterpart consists of task assignment, scheduling and A/D/RML synchronisation with integrated robotic systems. The virtual world also includes hybrid modeling and simulation with synchronized hybrid Petri nets (SHPN), VSS eye-in-hand modeling and implementation, simulation in MobileSim and graphical user interface (GUI) for real-time control monitoring, so that the whole system becomes fully automated.

Multifunctional technology of flexible manufacturing on a mechatronics line with IRM and CAS, ready for industry 4.0
Adriana Filipescu, Dan Ionescu, Adrian Filipescu, Eugenia Mincă, and Georgian Simion
MDPI AG
A communication and control architecture of a multifunctional technology for flexible manufacturing on an assembly, disassembly, and repair mechatronics line (A/D/RML), assisted by a complex autonomous system (CAS), is presented in the paper. A/D/RML consists of a six-work station (WS) mechatronics line (ML) connected to a flexible cell (FC) equipped with a six-degree of freedom (DOF) industrial robotic manipulator (IRM). The CAS has in its structure two driving wheels and one free wheel (2 DW/1 FW)-wheeled mobile robot (WMR) equipped with a 7-DOF robotic manipulator (RM). On the end effector of the RM, a mobile visual servoing system (eye-in-hand VSS) is mounted. The multifunctionality is provided by the three actions, assembly, disassembly, and repair, while the flexibility is due to the assembly of different products. After disassembly or repair, CAS picks up the disassembled components and transports them to the appropriate storage depots for reuse. Technology operates synchronously with signals from sensors and eye-in-hand VSS. Disassembling or repairing starts after assembling and the final assembled product fails the quality test. Due to the diversity of communication and control equipment such as PLCs, robots, sensors or actuators, the presented technology, although it works on a laboratory structure, has applications in the real world and meets the specific requirements of Industry 4.0.

CAS and IRM Integrated into a Multifunctional Flexible Manufacturing Technology on an A/D/RML
Dan Ionescu, Daniela Cernega, Razvan Solea, Adrian Filipescu, Georgian Simion, and Adriana Filipescu
IEEE
The aim of this paper is to model, control and implement an assisting technology for a flexible assembly, disassembly and repair on a mechatronic line (A/D/RML), using autonomous robotic system (ARS), two robotic manipulators (RMs) and visual servoing system (VSS).The A/D/RML consists of 6-work stations (WS) mechatronics line (ML) connected to a flexible cell (FC) equipped with a 6-DOF ABB IRM industrial robotic manipulator (IRM) and a Complex Autonomous System (CAS)-used for manipulation and transport. The structure of the CAS consists of 2DW/1FW wheeled mobile robot (WMR) equipped with a 7-DOF robotic manipulator (RM). Sliding mode control (TTSMC) is used to control WMR. On the end effector of the RM, a mobile (eye in hand) visual servoing system (VSS) is mounted, used for precise positioning of RMs - to catch and release the workpiece. If the workpiece does not pass the quality test, the process handles it by transporting back from the storage unit to the flexible cell (FC) where it will be considered for reprocessing - repair or disassembling with recovery of replacement parts. The recovered or replaced components are taken over by the CAS from disassembling location and transported to the appropriate storage depots, to be reused in the further assembly processes. Technology operates synchronously with signals from sensors and from VSS “eye in hand” camera, located at the end effector of the RM. A hybrid PLC architecture is used-consists of 2 PLC controlled subsystems/ modules with specific tasks for all the manufacturing stages features both a decentralized, distributed architecture and a centralized architecture

Simion Georgian

EDUCATION

Scopus Publications