Industrial plants are going to face a deep renewing process within the Industry 4.0 scenario. New paradigms of production lines are foreseen in the very near future, characterized by a strict collaboration between humans and robots and by a high degree of flexibility. Such envisaged improvements will require the smart use of proper sensors at very different levels. This paper investigates three different aspects of this industrial renewing process, based on three different ways of exploiting sensors, toward a new paradigm of a production line. The provided contributions, offering various types of innovation and integration, are relative to: (i) a virtual sensor approach for manual guidance, increasing the potentialities of a standard industrial manipulator, (ii) a smart manufacturing solution to assist the operator’s activity in manual assembly stations, through an original exploitation of multiple sensors, and (iii) the development of an advanced robotic architecture for a flexible production line, in which a team of autonomous mobile robots acts as a meta-sensor net supporting traditional automated guided vehicles. Accurate analyses of existing state-of-the-art solutions compared with the proposed ones are offered for the considered issues.

Collision detection is a fundamental issue for the safety of a robotic cell. While several common methods require specific sensors or the knowledge of the robot dynamic model, the proposed solution is constituted by a virtual collision sensor for industrial manipulators, which requires as inputs only the motor currents measured by the standard sensors that equip a manipulator and the estimated currents provided by an internal dynamic model of the robot (i.e., the one used inside its controller), whose structure, parameters and accuracy are not known. The collision detection is achieved by comparing the absolute value of the current residue with a time-varying, positive-valued threshold function, including an estimate of the model error and a bias term, corresponding to the minimum collision torque to be detected. The value of such a term, defining the sensor sensitivity, can be simply imposed as constant, or automatically customized for a specific robotic application through a learning phase and a subsequent adaptation process, to achieve a more robust and faster collision detection, as well as the avoidance of any false collision warnings, even in case of slow variations of the robot behavior. Experimental results are provided to confirm the validity of the proposed solution, which is already adopted in some industrial scenarios.

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