Ilya Kovalenko

Shih-Jie Shih, Jonghan Lim, Ilya Kovalenko et al.

Supervisory control of discrete-event systems provides formal guarantees of correctness with respect to a plant model and specification. However, these guarantees heavily rely on the plant model, which could deviate from nominal behavior due to modeling errors or faults. Recent notions of discrete robustness model deviations as a set of additional transitions that are added to the plant. The discrete robustness is defined as all sets of extra transitions for which the supervised system still guarantees a desired specification. However, this notion suffers from scalability due to the large solution space and conservatism since most deviations are infeasible in practice. This paper proposes to address these two issues using a neurosymbolic computing framework for discrete robustness analysis of safety properties. First, a neural reasoning layer based on Large Language Models infers a set of feasible deviation transitions from system models, specifications, and domain knowledge. Next, a symbolic layer computes the discrete robustness guarantees over the inferred deviation set. We evaluate our framework on three case studies, demonstrating that our method identifies a smaller set of feasible deviations while preserving robustness guarantees comparable to those of full transition-based analysis.

Ilya Kovalenko, Kira Barton, James Moyne et al.

Rapid advances in artificial intelligence (AI) have the potential to significantly increase the productivity, quality, and profitability in future manufacturing systems. Traditional mass-production will give way to personalized production, with each item made to order, at the low cost and high-quality consumers have come to expect. Manufacturing systems will have the intelligence to be resilient to multiple disruptions, from small-scale machine breakdowns, to large-scale natural disasters. Products will be made with higher precision and lower variability. While gains have been made towards the development of these factories of the future, many challenges remain to fully realize this vision. To consider the challenges and opportunities associated with this topic, a panel of experts from Industry, Academia, and Government was invited to participate in an active discussion at the 2022 Modeling, Estimation and Control Conference (MECC) held in Jersey City, New Jersey from October 3- 5, 2022. The panel discussion focused on the challenges and opportunities to more fully integrate AI into manufacturing systems. Three overarching themes emerged from the panel discussion. First, to be successful, AI will need to work seamlessly, and in an integrated manner with humans (and vice versa). Second, significant gaps in the infrastructure needed to enable the full potential of AI into the manufacturing ecosystem, including sufficient data availability, storage, and analysis, must be addressed. And finally, improved coordination between universities, industry, and government agencies can facilitate greater opportunities to push the field forward. This article briefly summarizes these three themes, and concludes with a discussion of promising directions.

Yifei Li, Ruizhe Fu, Huihang Liu et al.

As the demand for mass customization increases, manufacturing systems must become more flexible and adaptable to produce personalized products efficiently. Additive manufacturing (AM) enhances production adaptability by enabling on-demand fabrication of customized components directly from digital models, but its flexibility remains constrained by fixed equipment layouts. Integrating mobile robots addresses this limitation by allowing manufacturing resources to move and adapt to changing production requirements. Mobile AM Robots (MAMbots) combine AM with mobile robotics to produce and transport components within dynamic manufacturing environments. However, the dynamic manufacturing environments introduce challenges for MAMbots. Disturbances such as obstacles and uneven terrain can disrupt navigation stability, which in turn affects printing accuracy and surface quality. This work proposes a universal mobile printing-and-delivery platform that couples navigation and material deposition, addressing the limitations of earlier frameworks that treated these processes separately. A real-time control framework is developed to plan and control the robot's navigation, ensuring safe motion, obstacle avoidance, and path stability while maintaining print quality. The closed-loop integration of sensing, mobility, and manufacturing provides real-time feedback for motion and process control, enabling MAMbots to make autonomous decisions in dynamic environments. The framework is validated through simulations and real-world experiments that test its adaptability to trajectory variations and external disturbances. Coupled navigation and printing together enable MAMbots to plan safe, adaptive trajectories, improving flexibility and adaptability in manufacturing.

Jonghan Lim, Mostafa Tavakkoli Anbarani, Rômulo Meira-Góes et al.

Manufacturing industries are facing increasing product variability due to the growing demand for personalized products. Under these conditions, ensuring safety becomes challenging as frequent reconfigurations can lead to unintended hazardous behaviors. Multi-agent control architectures have been proposed to improve flexibility through decentralized decision-making and coordination. However, these architectures are based on predefined task models, which limit their ability to adapt task planning to new product requirements while preserving safety. Recently, large language models have been introduced into manufacturing systems to enhance adaptability, but reliability remains a key challenge. To address this issue, we propose a control architecture that leverages the flexibility of large language models while preserving safety on the manufacturing shop floor. Specifically, the proposed framework verifies large language model-enabled task allocations by using temporal logic and discrete event systems. The effectiveness of the proposed framework is demonstrated through a case study that involves a multi-robot assembly scenario, showing that unsafe tasks can be allocated safely before task execution.

Jiabao Zhao, Jonghan Lim, Hongliang Li et al.

With increasing demand for mass customization, traditional manufacturing robots that rely on rule-based operations lack the flexibility to accommodate customized or new product variants. Human-Robot Collaboration (HRC) has demonstrated potential to improve system adaptability by leveraging human versatility and decision-making capabilities. However, existing HRC frame- works typically depend on predefined perception-manipulation pipelines, limiting their ability to autonomously generate task plans for new product assembly. In this work, we propose CoViLLM, an adaptive human-robot collaborative assembly frame- work that supports the assembly of customized and previously unseen products. CoViLLM combines depth-camera-based localization for object position estimation, human operator classification for identifying new components, and an Large Language Model (LLM) for assembly task planning based on natural language instructions. The framework is validated on the NIST Assembly Task Board for known, customized, and new product cases. Experimental results show that the proposed framework enables flexible collaborative assembly by extending HRC beyond predefined product and task settings.

Hongliang Li, Herschel C. Pangborn, Ilya Kovalenko

Demand-side energy management, such as the real-time pricing (RTP) program, offers manufacturers opportunities to reduce energy costs by shifting production to low-price hours. However, this strategy is challenging to implement when machine degradation is considered, as degraded machines have decreased processing capacity and increased energy consumption. Proactive maintenance (PM) can restore machine health but requires production downtime, creating a challenging trade-off: scheduling maintenance during low-price periods sacrifices energy savings opportunities, while deferring maintenance leads to capacity losses and higher energy consumption. To address this challenge, we propose a hierarchical bi-level control framework that jointly optimizes PM planning and runtime production scheduling, considering the machine degradation. A higher-level optimization, with the lower-level model predictive control (MPC) embedded as a sub-problem, determines PM plans that minimize total operational costs under day-ahead RTP. At runtime, the lower-level MPC executes closed-loop production scheduling to minimize energy costs under realized RTP, meeting delivery targets. Simulation results from a lithium-ion battery pack assembly line case study demonstrate that the framework strategically shifts PM away from bottlenecks and high-price hours, meeting daily production targets while reducing energy costs.

Jonghan Lim, Ilya Kovalenko

Manufacturing environments are becoming more complex and unpredictable due to factors such as demand variations and shorter product lifespans. This complexity requires real-time decision-making and adaptation to disruptions. Traditional control approaches highlight the need for advanced control strategies capable of overcoming unforeseen challenges, as they demonstrate limitations in responsiveness within dynamic industrial settings. Multi-agent systems address these challenges through decentralization of decision-making, enabling systems to respond dynamically to operational changes. However, current multi-agent systems encounter challenges related to real-time adaptation, context-aware decision-making, and the dynamic exploration of resource capabilities. Large language models provide the possibility to overcome these limitations through context-aware decision-making capabilities. This paper introduces a large language model-enabled control architecture for multi-agent manufacturing systems to dynamically explore resource capabilities in response to real-time disruptions. A simulation-based case study demonstrates that the proposed architecture improves system resilience and flexibility. The case study findings show improved throughput and efficient resource utilization compared to existing approaches.

Jonghan Lim, Birgit Vogel-Heuser, Ilya Kovalenko

Traditional manufacturing faces challenges adapting to dynamic environments and quickly responding to manufacturing changes. The use of multi-agent systems has improved adaptability and coordination but requires further advancements in rapid human instruction comprehension, operational adaptability, and coordination through natural language integration. Large language models like GPT-3.5 and GPT-4 enhance multi-agent manufacturing systems by enabling agents to communicate in natural language and interpret human instructions for decision-making. This research introduces a novel framework where large language models enhance the capabilities of agents in manufacturing, making them more adaptable, and capable of processing context-specific instructions. A case study demonstrates the practical application of this framework, showing how agents can effectively communicate, understand tasks, and execute manufacturing processes, including precise G-code allocation among agents. The findings highlight the importance of continuous large language model integration into multi-agent manufacturing systems and the development of sophisticated agent communication protocols for a more flexible manufacturing system.