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.

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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.

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