UPBAIR participating at Productica 2024 conference

Building on the success of last year’s participation, we are thrilled to share that our team was once again part of the annual Productica conference, this time for its 2024 edition held on May 24-25, 2024. As always, this significant event took place under the auspices of the Polytechnic University of Bucharest and the Municipality of Mioveni.

Celebrating its sixteenth year, Productica 2024 continues to be a focal point for scientific innovation, organized by the Center for Creativity Development. The conference remains a vibrant platform for demonstrating the latest scientific advancements from leading universities, research institutions, and companies.

The conference started with a visit at the Delta Invest factory in Mioveni. They presented the lasted technologies for plastic injection moulding, automation and CNC milling. This factory produces plastic car parts for Renault Dacia factory with the highest precision. After the factory tour, the conference started at the Central of Education Pitesti.

This year our team presented four difference research papers:

1. Methods of reducing mechanical vibrations in FDM

In the rapidly evolving field of 3D printing, achieving high-quality prints at accelerated speeds presents a unique set of challenges, primarily due to the issue of vibrations. These vibrations can significantly degrade the quality of the final product, manifesting as inaccuracies and flaws that compromise the structural integrity and aesthetic of the prints. Recognizing the critical nature of this issue, our recent presentation focused on testing various solutions designed to mitigate these disruptive vibrations.

During our comprehensive study, we explored the effectiveness of implementing linear guide rails and silicone dampers in 3D printing setups. Linear guide rails offer enhanced stability and smooth motion for the printing head, which is crucial when operating at high speeds. They provide a more rigid and controlled movement compared to traditional rod-based systems, which tend to wobble and produce errors in the print due to their less stable design.

Silicone dampers, on the other hand, serve as a buffer between the moving parts of the printer and its frame. These dampers absorb and dissipate the energy generated by the motion, reducing the transfer of vibrations to the crucial components of the printer. This absorption is vital for maintaining the alignment and precision of the print head during the printing process.

In addition to linear guide rails and silicone dampers, our tests also included various other enhancements such as advanced motor drivers that offer better control over the stepping of motors, and modified firmware settings tailored to optimize speed and movement precision. Each of these components was evaluated for its contribution to reducing vibrations and improving print quality.

The results of our experiments showed a marked improvement in print quality with the integration of these modifications. The linear guide rails significantly reduced lateral movements that often lead to errors in layers, while the silicone dampers effectively minimized the vibrations throughout the printing process. These findings underscore the potential of these technologies to revolutionize high-speed 3D printing by allowing for faster production times without sacrificing the quality of the prints.

Our ongoing research and development in this area are aimed at refining these solutions further, exploring new materials and technologies that can contribute to even more significant advancements in the field of 3D printing. By continuing to innovate and test new approaches, we hope to overcome the current limitations of speed and quality, pushing the boundaries of what is possible in 3D printing technology.

2. Pneumatic software simulations compared to real life experiments

In our latest research endeavor, we embarked on an in-depth exploration to ascertain the accuracy and reliability of simScale, a leading pneumatic simulation tool. Our primary objective was to evaluate how closely simScale’s simulations mirror real-world phenomena, particularly focusing on the simulation of pressure drops of compressed air within a tubing run.

To conduct this analysis, we utilized simScale’s sophisticated modeling capabilities to recreate detailed pneumatic conditions and monitored the resulting pressure changes as air traveled through various tubing configurations. This approach allowed us to gather critical data on the dynamics of airflow and pressure alterations within the system, providing insights into the potential performance of pneumatic systems in practical applications.

Furthermore, our research extended into the realm of system efficiency within automated setups. Utilizing Automation Studio, a premier tool for simulating and designing automated systems, we investigated the operational efficiency of key pneumatic components, including cylinders and distributors. The simulations in Automation Studio were meticulously set up to replicate real-life conditions as closely as possible, allowing us to analyze how these components perform under different scenarios and workloads.

The combination of simScale and Automation Studio enabled a comprehensive assessment of both the individual component behavior and the overall system efficiency. This dual-simulation approach not only reinforced our understanding of each tool’s capabilities but also provided a robust framework for predicting the performance of pneumatic systems before physical prototypes are constructed.

This research is instrumental for industries relying heavily on pneumatic systems, as it offers a reliable method of predicting system behavior, optimizing design, and enhancing operational efficiencies, thereby reducing both time and cost in system development. The findings of this study are expected to contribute significantly to the field of pneumatic systems engineering, offering new perspectives and methodologies that can be applied in various industrial applications.

3. Analysis of the results obtained by two different methods of measuring the performance of pneumatic cylinders

In this research paper, we investigated the vibrations of pneumatic cylinder in mechanical systems using the second derivative to find the acceleration of the cylinder and an accelerometer placed at the tip of the cylinder.

By using two different methods of measuring the acceleration we can better see unwanted variations in acceleration in different scenarios.

We first tested the role of adjustable cushioning in pneumatic cylinders. Having more cushioning results in less vibrations because the rod stops with a constant acceleration. Lack of cushioning does make the cylinder do more cycles in the same period of the time, but at the end of each cycle, the violent and sudden stop of the cylinder causes a lot of vibrations and wear.

The second test we did was to limit the flow and speed of the cylinder by using smaller diameter tubing. The results where more consistent acceleration cycles and almost zero vibrations but at the cost of halving the speed of the cylinder and maybe reducing its load capacity.

The third was to see the if we can detect a badly mounted or lose pneumatic cylinder. In this test only the accelerometer detected that the cylinder was not mounted properly. The rod moves too fast for the linear sensor to detect such sudden minor movements from bad mounts.

4. Security systems for processing IP addresses of IIoT devices

In this research paper, we have delved deeply into the critical security concerns associated with the processes of pinging, transmitting, and storing data originating from Industrial Internet of Things (IIoT) devices to a central server system. Our architectural framework consists of three key components: an offsite server, a local server, and the IIoT devices connected on the local network.

The cornerstone of our secure architecture is the local server, which serves as the primary communication hub. This server is exclusively responsible for secure interactions with the offsite server, ensuring that data transmitted over potentially vulnerable networks remains protected against unauthorized access and cyber threats. The communication between the local server and the offsite server is fortified with advanced encryption protocols and robust authentication measures to maintain data integrity and confidentiality.

On the local network, the IIoT devices communicate solely with the local server. This segregation of duties ensures that even if individual devices are compromised, the breach does not extend to the central or offsite servers. Each device is equipped with lightweight security protocols tailored to their processing capabilities, balancing security with operational efficiency. These protocols are designed to authenticate data packets sent to the local server, which adds an additional layer of security by verifying the data’s origin and integrity before it is processed or forwarded.

Furthermore, we implemented a series of rigorous security measures including regular security audits, real-time intrusion detection systems, and continuous monitoring of network traffic. These measures help in quickly identifying and mitigating potential security threats, ensuring the resilience of the network against sophisticated cyber attacks.

The effectiveness of our architecture was evaluated through a series of stress tests and simulated cyber attacks, and the results underscore the robustness of our design. Our system was able to successfully detect and respond to various security threats without compromising the functionality of the IIoT devices or the integrity of the data transmitted.

Our research contributes to the growing field of IIoT security, offering a scalable and secure architecture that can be adapted for diverse industrial environments. This study not only highlights the vulnerabilities in current IIoT infrastructures but also provides a comprehensive strategy for securing data transmission in these increasingly targeted networks.