Unidade de Investigação - INESCC-DL – Instituto de Engenharia de Sistemas e Computadores de Coimbra [delegação Politécnico de Leiria]
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- Energy audit as an input for energy management and energy efficiency improvement in a gypsum manufacturing plantPublication . Bernardo, Hermano; Oliveira, Filipe Tadeu; Serrano, LuisThis paper aims at presenting the main results of an energy audit performed to a gypsum production plant, in Portugal, which due to the amount of energy consumed must comply with the Portuguese program SGCIE (Intensive Energy Consumption Management System). The program was created in 2008 to promote energy efficiency and energy consumption monitoring in intensive energy consuming facilities (energy consumption higher than 500 toe per year). Facilities operators are required to perform energy audits and take actions to draw up an action plan for energy efficiency, establishing targets for energy consumption reduction and greenhouse gases emissions indexes. An energy audit was carried out to identify potential energy conservation measures for improving energy efficiency, and also typical energy consumption patterns, sector/equipment load profiles and thermal equipment performance. This tool gives managers the information to support decision making on improving energy performance and reducing greenhouse gas emissions. A number of tangible targets and measures were devised and set to be implemented in the next few years. Results show that there is a considerable potential for reduction in the energy consumption and greenhouse gases emissions of gypsum manufacturing plants. Here, as elsewhere in the industrial sector, energy efficiency can only be achieved through a continuous energy monitoring and management system.
- Heatsinks to Cool Batteries for Unmanned Aerial VehiclesPublication . Galvão, J.; Faria, P.; Mateus, A.; Pereira, T.; Fernandes, S.This study aims to develop several different models of heatsinks, designed to cool a vertical take-off and landing unmanned aerial vehicle (UAV) battery, through topology optimization, aimed at being manufactured through selective laser melting (SLM) technology. A battery’s temperature must be properly managed for a safe and efficient operation. The methodology developed was with the support of software to carry out several simulations which, starting from several scenarios and restrictions imposed by the small space available to accommodate these small batteries in this type of aircraft. The conception resulted in several battery thermal management systems (BTMS) models, with different applications and efficiency degrees. A relevant aspect is the topology optimization being coupled to computational thermal analysis to reduce the mass of the heatsink whilst ensuring a maximum battery temperature threshold. Together with the use of topology optimization, the SLM process was selected to manufacture the heat sinks, under conditions of geometric freedom, using several high thermal conductivity metal alloys, such as, aluminium and copper to obtain the designed models.
- Industrial Robot Trajectory Generation and Execution for 3D Printing using an ABB IRB 1200Publication . Cavalcanti, Marcella; Costelha, Hugo; Neves, CarlosThe use of industrial robots in additive manufacturing processes has become increasingly important, offering more flexibility and the capability of multi-directional printing. This integration facilitates the production of more complex geometries, free from the limitations of small build volumes and support structures, opening new possibilities for innovation in advanced manufacturing systems. As the complexity of the printed structures grows, optimizing robot trajectories is essential to ensure high-quality results. This work presents a comparative analysis of robot trajectory generation and execution using ABB's 3D Printing Power Pack and generated RAPID coding in both simulated and real environments. The objective is to assess the use of the Power Pack in term of trajectory accuracy and efficiency, as well as how the simulated results compare with the real ones, considering the use-case of 3D printing. To support this analysis, a "test pattern" was designed to account for different trajectories, consisting of a single line extrusion path featuring long linear segments, corners, and curved sections. The path was converted into both G-code and RAPID code. The G-code was first validated on a standard 3D printer and then used as input in the 3D Printing Power Pack application to generate a RAPID program for the robot. Separately, another RAPID program was created manually to execute the same path, based on the G-code. Both programs were executed on a simulated environment in RobotStudio, and on an ABB IRB 1200 robot. Throughout the tests, the robot’s Tool Center Point (TCP) position was captured using ABB’s Externally Guided Motion (EGM) application.
- Industry 4.0 Machine-to-Machine Communication Protocols and Architectures on the Shop FloorPublication . Cavalcanti, Marcella; Costelha, Hugo; Neves, CarlosThe concept of Industry 4.0 and the introduction of the Internet of Things (IoT) on industrial applications, known as Industrial Internet of Things (IIoT), have been changing the scenario of industrial automation. This new paradigm is expected to optimize industrial processes, increase productivity, lower costs and improve operations integration. For that, structured Machine-to-Machine (M2M) communication is key to ensure agility, interoperability and reliability, with several solutions currently available in the literature and in industry. This paper reviews the state of the art on industrial communication protocols and architectures, providing a classification and comparison of these different solutions based on their most relevant features in the context of Industry 4.0.
- A review on Robot-Assisted Additive Manufacturing Systems and TechnologiesPublication . Cavalcanti, M.; Costelha, Hugo; Neves, CarlosAbstract. The general use of robot manipulators in the Additive Manufacturing (AM) world could cause a paradigm shift on how these technologies are used today. Adding more degrees of freedom to the AM systems decreases the limita tions of current mainstream additive technologies, such as restricted build volume, high manufacturing times, and the use of support structures. However, existing traditional techniques for slicing 3D models and path planning generation do not translate smoothly into the requirements and constraints of robot manipulator systems. This paper presents a state-of-the-art review on the current systems and technologies, as well as advantages and challenges on the use of robot manipulators in AM, focusing on extrusion-based processes.
- Robotic Path Planning Algorithms for Additive Manufacturing Using Advanced Simulation ToolsPublication . Ferreira, Marco; Costelha, Hugo; Conde Bento, Luis; Neves, CarlosRobotics-based additive manufacturing (AM), or 3D printing, enables flexible printing systems. This paper analyses path planning algorithms for robotic manipulators aiming at dynamic AM environments. Using the cuRobo library, the study evaluates the path planning algorithm MotionGen and Model Predictive Control (MPC) using NVIDIA’s Isaac Sim with ROS2 and MoveIt2. Docker provided a modular development environment, and an Intel RealSense camera was used to enable real-world and real-time obstacle detection. Results show that MotionGen outperforms MPC in energy consumption and time efficiency, generating smoother and more efficient trajectories, more suitable for real-time AM contexts. The project shows the potential of advanced robotic control algorithms to optimize AM, using NVIDIA’s Isaac platform. Future work will focus on applying this to real robots.
- Trajectory Generation for Robotic Additive Manufacturing: A Comparative StudyPublication . Cavalcanti, Marcella; Costelha, Hugo; Neves, CarlosThe integration of robot manipulators into additive manufacturing processes, particularly in fused filament fabrication, presents opportunities to overcome limitations of traditional three-axis systems. By leveraging the additional degrees of freedom, more versatile and efficient manufacturing solutions can be developed. However, this increased complexity introduces new challenges, including the need for trajectory planning that accounts for reachability, singularities, collision avoidance, and material deposition in various build orientations. This study focuses on the development and evaluation of trajectory generation approaches for robotic FFF using an ABB CRB 15000 manipulator. All approaches began with the same G-code input, and tests were conducted both in simulation and on the real robot. The results were analyzed in terms of trajectory accuracy, joint speed and acceleration profiles, parameters influence, and the Quality of the printed parts.