The Master’s thesis deals with design of digital twins of machine tools and application of designed procedure on a case study – digital twin of the machine tool MCV 754 Quick. In the first part are described current roles of digital twins in the field of machine tools and also hardware and software options for creating them. Software and hardware tools by Siemens (Mechatronics Concept Designer and SIMIT) are used for the case study. The complex procedure of creating the digital twin is designed in the second part, starting with preparation of a model, ending with the virtual commissioning of the machine tool MCV 754 Quick. The procedure is described in detail, including preparation of 3D model of the machine tool, assignment of physical properties and joints, preparation of PLC, connection all the elements of the whole system: Sinumerik – SIMIT – Mechatronics Concept Designer and controlling the twin via CNC automation system. Output of the thesis is the virtually commissioned machine tool, capable of being controlled by Sinumerik 840D sl. This is the first step in development of the full-fledged digital twin of machine tool, which can be used for testing the functionality and capability of this new technology in industry.

Cyber-physikalische Systeme (CPS) sind eine erweitere Sicht auf eingebettete Systeme, die die konkreten umgebenden Elemente in das Systemdesign einbeziehen. Das Design solcher Systeme erfordert neue Herangehensweisen: Während beispielsweise in "normalen" verteilten Systemen Aspekte wie "Bewegung" oder "Ort" möglichst transparent und damit für den Nutzer unsichtbar gestaltet werden, benötigen CPS-Anwendungen häufig Bewusstsein für Bewegung oder Ort, d.h., sie sind _motion aware_ oder _location aware_. Die Professur "Betriebssysteme" der TUC hat sich die Frage gestellt, wie eine generische Unterstützung für solche verteilte mobile Systeme aussehen könnte. Im Vortrag werden Probleme, Konzepte und erste Lösungsansätze für ein künftiges Betriebssystem für diese Art von Systemen vorgestellt.

Technological advances (e.g., high speed communication, artificial intelligence) and affordable computing and sensor hardware have become a key driver of developments like “Industry 4.0” or the “Industrial Internet of Things” (IIoT). Large numbers of machines and products are equipped with sensors to constantly monitor their condition, log usage data or trigger control processes. IIoT has been largely adopted by OEMs in various industries (such as automotive, machinery industry, or healthcare and medical), turning their product into cyber-physical systems. However, the resulting potential is not yet accessible to component manufacturers. Overall, horizontal integration of the value chain is still in its infancy. Specifically, IIoT for fluid powers just started in recent years with first research projects and commercial solutions. This work presents a reference architecture for cyber-physical fluid power systems which depicts how horizontal integration can be achieved and which potentials thus can be released. The architecture is validated in an industrial use case. Furthermore, the paper at hand discusses which components of the architecture should be addressed by which actor in the fluid power ecosystem in order to leverage opportunities from the IIoT.

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This thesis aims to develop and evaluate a dashboard design that visualizes a stream of data from the different entities involved in autonomous warehouses, a subset of cyber-physical systems. I created this dashboard through User-Centered Design (UCD) methodologies based on two feedback iterations with the stakeholders employing semi-structured expert opinion interviews. This thesis also discusses the different stages involved in building this dashboard design, the design decisions, the technical aspects of the libraries used, and the feedback session towards the end of the project. It also presents the implemented dashboard as a proof of development efforts and explains its different functionalities. The project concludes with evaluating the dashboard through a semi-structured interview with the respective stakeholders and suggests features for further development. / Denna studie ämnar att utveckla och utvärdera en design för ett dashboard som visualiserar dataströmmar från olika enheter som kan hittas i autonoma lager. Detta dashboard har utvecklats genom att använda metoder inom användarcentrerad design, som baserades på två iterationer med intressenter som är experter inom området, där semistrukturerade intervjuer gjordes. Denna studie diskuterar också de olika steg som är involverade i att bygga designen av detta dashboard, de olika beslut som togs i designprocessen, de tekniska aspekterna av de bibliotek som används och resultatet från de sessioner som hölls för att få feedback i slutet av projektet. Studien presenterar också det dashboard som utvecklades samt förklarar dess funktionalitet. Slutsatser dras från de semistrukturerade intervjuerna med respektive intressent och föreslår framtida funktioner som skulle vara möjliga att implementera.

Autonomous Driving Systems (ADS), a subcategory of Cyber-Physical Systems (CPS) are becoming increasingly popular with ubiquitous deployment. They provide advanced operational functions for perception and control, but this also raises the question of their safety capability. Such questions include if the vehicle can stay within its lane, keep a safe distance from the leading vehicle, or avoid obstacles, especially under the presence of uncertainties. In this master thesis, the operational safety of ADS will be addressed, more specifically on the Adaptive Cruise Control (ACC) system by modeling an optimal control problem based on Control Barrier Function (CBF) unified with Model Predictive Control (MPC). The corresponding optimal control problem is robust against measurement uncertainties for an Autonomous Vehicle (AV) driving on a highway, where the measurement uncertainties will represent the common faults in the perception system of the AV. A Kalman Filter (KF) is also added to the system to investigate the performance difference. The resulting framework is implemented and evaluated on a simulation scenario created in the open-source autonomous driving simulator CARLA. Simulations show that MPC-CBF is indeed robust against measurement uncertainties for well-selected horizon and slack variable values. The simulations also show that adding a KF improves the overall performance. The higher the horizon, the more confident the system becomes as the distance to the leading vehicle decreases. However, this may cause infeasibility where there are no solutions to the optimal control problem during sudden braking as the AV cannot brake fast enough before it crashes. Meanwhile, the smaller the slack variable, the more restrictive becomes CBF where it impacts more on the control input than desired which could also cause infeasibility. The results of this thesis will help to facilitate safety-critical CPS development to be deployed in real-world applications. / Autonoma körsystem (ADS), som är en del av cyberfysiska system (CPS), har blivit alltmer populär med allestädes närvarande användning. Det bidra med avancerade operativa funktioner för perception och styrning, men samtidig väcker detta också frågan om dess säkerhetsförmåga. Sådana frågor inkluderar om fordonet kan hålla sig inom sitt körfält, om det kan hålla ett säkert avstånd till det ledande fordonet eller om det kan undvika hinder, speciellt under osäkerheter hos systemet. I detta examensarbete kommer driftsäkerheten hos ADS att behandlas, mer specifik på adaptiv farthållare (ACC) genom att modellera ett optimalt kontrollproblem baserat på kontrollbarriärfunktion (CBF) förenat med modellförutsägande styrning (MPC). Motsvarande optimalt kontrollproblem är robust mot mätosäkerheter för ett autonomt fordon som kör på en motorväg, där mätosäkerheterna representerar vanliga fel i AV:s perceptionssystem. Ett Kalmanfilter (KF) läggs också till i systemet för att undersöka skillnaden i prestanda. Det resulterande ramverket implementeras och utvärderas på ett simuleringsscenario som skapats i den öppna källkodssimulatorn för autonom körning CARLA. Simulationer visar att MPC-CBF är robust mot mätosäkerheter för väl valda värden för horisont och slackvariabler. Det visar också att systemets prestanda förbättrats ännu mer om ett KF läggs till. Ju större horisont, desto mer självsäkert blir systemet när avståndet till det ledande fordonet minskar. Detta kan dock leda till att det inte finns några lösningar på det optimala kontrollproblemet vid plötslig inbromsning, eftersom fordonet inte hinner bromsa tillräckligt snabbt innan det kraschar. Ju mindre slackvariabeln är, desto mer restriktiv blir CBF som påverkar styrningen mer än vad som är önskvärt vilket också kan leda till olösbart optimalt kontrollproblem. Resultatet från detta examensarbete bär syftet att gynna utvecklingen av säkerhetkritisk CPS som ska användas i praktiska tillämpningar.

Low-power wireless technology is a part and parcel of our daily life, shaping the way in which we behave, interact, and more generally live. The ubiquity of cheap, tiny, battery-powered devices augmented with sensing, actuation, and wireless communication capabilities has given rise to a ``smart" society, where people, machines, and objects are seamlessly interconnected, among themselves and with the environment. Behind the scenes, low-power wireless protocols are what enables and rules all interactions, organising these embedded devices into wireless networks, and orchestrating their communications. The recent years have witnessed a persistent increase in the pervasiveness and impact of low-power wireless. After having spawned a wide spectrum of powerful applications in the consumer domain, low-power wireless solutions are extending their influence over the industrial context, where their adoption as part of feedback control loops is envisioned to revolutionise the production process, paving the way for the Fourth Industrial Revolution. However, as the scale and relevance of low-power wireless systems continue to grow, so do the challenges posed to the communication substrates, required to satisfy ever more strict requirements in terms of reliability, responsiveness, and energy consumption. Harmonising these conflicting demands is far beyond what is enabled by current network stacks and control architectures; the need to timely bridge this gap has spurred a new wave of interest in low-power wireless networking, and directly motivated our work. In this thesis, we take on this challenge with a main conceptual and technical tool: concurrent transmissions (CTX), a technique that, by enforcing nodes to transmit concurrently, has been shown to unlock unprecedented fast, reliable, and energy efficient multi-hop communications in low-power wireless networks, opening new opportunities for protocol design. We first direct our research endeavour towards industrial applications, focusing on the popular IEEE 802.15.4 narrowband PHY layer, and advance the state of the art along two different directions: interference resilience and aperiodic wireless control. We tackle radio-frequency noise by extensively analysing, for the first time, the dependability of CTX under different types, intensities, and distributions of reproducible interference patterns, and by devising techniques to push it further. Specifically, we concentrate on CRYSTAL, a recently proposed communication protocol that relies on CTX to rapidly and dependably collect aperiodic traffic. By integrating channel hopping and noise detection in the protocol operation, we provide a novel communication stack capable of supporting aperiodic transmissions with near-perfect reliability and a per-mille radio duty cycle despite harsh external interference. These results lay the ground towards the exploitation of CTX for aperiodic wireless control; we explore this research direction by co-designing the Wireless Control Bus (WCB), our second contribution. WCB is a clean-slate CTX-based communication stack tailored to event-triggered control (ETC), an aperiodic control strategy holding the capability to significantly improve the efficiency of wireless control systems, but whose real-world impact has been hampered by the lack of appropriate networking support. Operating in conjunction with ETC, WCB timely and dynamically adapts the network operation to the control demands, unlocking an order-of-magnitude reduction in energy costs w.r.t. traditional periodic approaches while retaining the same control performance, therefore unleashing and concretely demonstrating the true ETC potential for the first time. Nevertheless, low-power wireless communications are rapidly evolving, and new radios striking novel trade-offs are emerging. Among these, in the second part of the thesis we focus on ultra-wideband (UWB). By providing hitherto missing networking primitives for multi-hop dissemination and collection over UWB, we shed light on the communication potentialities opened up by the high data throughput, clock precision, and noise resilience offered by this technology. Specifically, as a third contribution, we demonstrate that CTX not only can be successfully exploited for multi-hop UWB communications but, once embodied in a full-fledged system, provide reliability and energy performance akin to narrowband. Furthermore, the higher data rate and clock resolution of UWB chips unlock up to 80% latency reduction w.r.t. narrowband CTX, along with orders-of-magnitude improvements in network-wide time synchronization. These results showcase how UWB CTX could significantly benefit a multitude of applications, notably including low-power wireless control. With WEAVER, our last contribution, we make an additional step towards this direction, by supporting the key functionality of data collection with an ultra-fast convergecast stack for UWB. Challenging the internal mechanics of CTX, WEAVER interleaves data and acknowledgements flows in a single, self-terminating network-wide flood, enabling the concurrent collection of different packets from multiple senders with unprecedented latency, reliability, and energy efficiency. Overall, this thesis pushes forward the applicability and performance of low-power wireless, by contributing techniques and protocols to enhance the dependability, timeliness, energy efficiency, and interference resilience of this technology. Our research is characterized by a strong experimental slant, where the design of the systems we propose meets the reality of testbed experiments and evaluation. Via our open-source implementations, researchers and practitioners can directly use, extend, and build upon our contributions, fostering future work and research on the topic.

More dynamic markets, shorter product life cycles and comprehensive variant management are challenges that dominate today's market. These maxims apply to the automotive sector, which is currently highly exposed to trade wars, changing mobility patterns and the emergence of new technologies and competitors. To meet these challenges, this thesis presents the creation of a digital twin of an existing production line of electric motors using discrete event simulation. Based on a detailed literature research, a step-by-step establishment of the simulation model of the production line using the software Plant Simulation is presented and argued. Finally, different experiments are carried out with the created model to show how a production line can be examined and optimized by means ofsimulation using different parameters. Within the scope of the different experiments regarding the number of workpiece carriers, number of operators as well as buffer sizes, the line was examined concerning the increase of the output. Furthermore, the simulation model was used to make decisions for future investments in additional XXX machines. Four different scenarios were examined and optimized. By examining the different parameters, optimization potentials of XXX% in the first scenario and up to XXX% in the fourth scenario were achieved. Finally, it was proven that the developed simulation model can be used as a tool for optimizing an existing production line and can generate useful investment information. Beyond that, the development of the simulation model can be employed to investigate further business questions at hand for the specific production line in question. / Mer dynamiska marknader, kortare produktlivscykler och omfattande varianthantering är utmaningar som dominerar dagens marknad. Dessa maximer gäller bilindustrin, som för närvarande är mycket utsatt för handelskrig, förändrade rörlighetsmönster och framväxten av ny teknik och nya konkurrenter. För att möta dessa utmaningar innebär denna avhandling skapandet av en digital tvilling av en befintlig produktionslinje av elmotorer med diskret händelsesimulering. Baserat på en detaljerad litteraturforskning presenteras och argumenteras en steg-för-steg-etablering av simuleringsmodellen för produktionslinjen med hjälp av programvaran Plant Simulation. Slutligen utförs olika experiment med den skapade modellen för att visa hur en produktionslinje kan undersökas och optimeras med hjälp av simulering med hjälp av olika parametrar. Inom ramen för de olika experimenten när det gäller antalet arbetsstyckesbärare, antalet operatörer samt buffertstorlekar undersöktes linjen om ökningen av produktionen. Dessutom användes simuleringsmodellen för att fatta beslut för framtida investeringar i ytterligare hårnålsmaskiner. Fyra olika scenarier undersöktes och optimerades. Genom att undersöka de olika parametrarna uppnåddes optimeringspotentialer på XXX % i det första scenariot och upp till XXX % i det fjärde scenariot. Slutligen bevisades det att den utvecklade simuleringsmodellen kan användas som ett verktyg för att optimera en befintlig produktionslinje och kan generera användbar investeringsinformation. Utöver detta kan utvecklingen av simuleringsmodellen användas för att undersöka ytterligare affärsfrågor till hands för den specifika produktionslinjen i fråga.

Cyber-physical systems are networked through IT infrastructure and susceptible to malware. Threats targeting process control are much more safety-critical than traditional computing systems since they jeopardize the integrity of physical infrastructure. Existing defence mechanisms address security at the network nodes but do not protect the physical infrastructure if network integrity is compromised. An interface guardian architecture is implemented on cyber-physical control leaf nodes to maintain process integrity by enforcing high-level safety and stability policies. Preemptive detection schemes are implemented to monitor process behavior and anticipate malicious activity before process safety and stability are compromised. Autonomic properties are employed to automatically protect process integrity by initiating switch-over to a verified backup controller. Subsystems adhere to strict trust requirements safeguarding them from adversarial intrusion. The preemptive detection schemes, switch-over logic, backup controller, and process communication are all trusted components that are separated from the untrusted production controller. The proposed architecture is applied to a rotary inverted pendulum experiment and implemented on a Xilinx Zynq-7000 configurable SoC. The leaf node implementation is integrated into a cyber-physical control topology. Simulated attack scenarios show strengthened resilience to both network integrity and reconfiguration attacks. Threats attempting to disrupt process behavior are successfully thwarted by having a backup controller maintain process stability. The system ensures both safety and liveness properties even under adversarial conditions. / Master of Science

Ces travaux portent sur la conception multidisciplinaire de systèmes intégrés. Ces systèmes sont soumis à un nombre d’exigences toujours croissant, entraînant des besoins en termes d’intégration fonctionnelle et spatiale. Ces différents types d’intégration relative au produit sont également la source d’une complexité organisationnelle, provenant à la fois de la multitude d’acteurs réalisant différentes activités d’ingénierie, mais également de la diversité des domaines impliqués, désignée dans ce manuscrit par « intégration multidisciplinaire ». Pour favoriser cette intégration multidisciplinaire, les phases de « conception préliminaire » et de « conception détaillée » ont été identifiées comme déterminantes, notamment car elles se caractérisent par la collaboration de nombreux experts, manipulant un grand nombre de données techniques de définition. Les systèmes conçus lors de conceptions multidisciplinaires restent faiblement intégrés. Cela est en partie dû au cloisonnement entre les disciplines et à un mode d’organisation projet basé sur une planification prédominante, caractérisé notamment par une diffusion de l’information principalement descendante (top-down). Afin d’assurer une meilleure collaboration entre ces différentes disciplines, de permettre des prises de décision éclairées par des indicateurs opérationnels et de pouvoir analyser et mieux comprendre les phénomènes d’intégration des expertises, l’introduction d’une méthode inspirée des principes fondateurs des méthodes agiles est proposée pour la conception collaborative de systèmes intégrés.La contribution de ces travaux s’appuie sur trois concepts complémentaires. Le premier, intitulé Collaborative Actions Framework correspond à un cadre de collaboration opérationnelle autour d’actions. Un des objectifs de ce framework est de faciliter la collaboration des acteurs des projets de conception, quelle que soit leur origine disciplinaire, mais également d’assurer une traçabilité entre les prises de décision et les corrections/modifications apportées sur les données techniques. Cette traçabilité est rendue possible grâce aux liens existants avec le second concept intitulé Workspace. Apportant un nouvel éclairage sur les possibilités offertes par la collaboration autour de ces espaces de collaboration, ce concept offre un certain nombre de possibilités,notamment la mise en commun continue des travaux, l’intégration multidisciplinaire et la validation des modifications. Les échanges de données techniques entre les workspaces, ou le travail simultané sur les mêmes données techniques, s’appuient quant à eux sur la possibilité de pouvoir gérer de façon parallèle différentes versions d’une même donnée technique. Ces possibilités sont proposées par le troisième concept, intitulé branch & merge, qui permet également à différents acteurs de travailler simultanément sur les mêmes données. Enfin, ces trois concepts sont ensuite illustrés par l’intermédiaire d’un démonstrateur composé d’un scénario et d’un prototype informatique. Un produit mécatronique, combinaison synergique et systémique de la mécanique, de l'électronique et de l'informatique temps réel, est utilisé afin d’illustrer les possibilités offertes par nos travaux en termes d'intégration multidisciplinaire lors de la conception collaborative. / This work focuses on the multidisciplinary and collaborative design of integrated systems. These systems are subject to an ever increasing number of requirements, leading to the need for more comprehensive functional and spatial integration. These different types of product integration are also at the origin of organizational complexity. This complexity arises not only from the great number of actors performing various engineering activities but also from the diversity of disciplines involved (designated in this manuscript as “multidisciplinary integration”). To encourage this multidisciplinary integration, “preliminary design” and “detailed design” have been identified as the most significant steps, especially since they are characterized by the collaboration of multiple experts handling a large number of product definition’ technical data. Systems that have been designed thanks to multidisciplinary approaches are generally poorly integrated. This is partially due to the compartmentalization of disciplines, as well as to the “project-planned” method, where project planning is predominant and information is mainly spread out “top-down”. To ensure better cooperation between the various disciplines, to enable decision making based on operational indicators and to analyze and understand the multidisciplinary integration processes, a method inspired by the founding principles of agile methods (the agile manifesto) is proposed for the collaborative design of integrated systems. This work is based on three complementary concepts. The first is, the Collaborative Actions Framework, an operational framework for collaboration around actions. One objective of this framework is to improve the collaboration among designers, whatever their disciplinary origin. It also ensures traceability between decision making and corrections/changes made to technical data. This traceability is made possible by the useof the second concept, called Workspace. Even if this term is already well known, we propose a new definition/usage to transform it into collaboration spaces. This concept offers great possibilities, including the continuous delivering/sharing of experts’ contributions, multidisciplinary integration and change validation. The exchange of technical data between workspaces, or simultaneous work on the same data, relies on the ability to manage several parallel versions of the same item into a single datamanagement system. These opportunities are offered by the third concept, called Branch & Merge. Finally, these three concepts are illustrated through a scenario and a computer prototype. A mechatronic product, “the synergistic combination of mechanical and electrical engineering, computer science, and information technology” (Harashima et al., 1996), is used to illustrate the opportunities offered by our work in terms of multidisciplinary integration during collaborative design.