arXiv subjects

Ilya Kovalenko

Publications and source records attributed to Ilya Kovalenko.

At least 19 recordsLinked to original sources

arXiv2026

NeuroSymbolic Robustness Analysis for Discrete Systems with Respect to Transition Deviations

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.

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arXiv2026

Logic-Based Verification of Task Allocation for LLM-Enabled Multi-Agent Manufacturing Systems

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.

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arXiv2026

Intelligent Navigation and Obstacle-Aware Fabrication for Mobile Additive Manufacturing Systems

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.

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arXiv2026

Energy-Aware Integrated Proactive Maintenance Planning and Production Scheduling

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.

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arXiv2026

CoViLLM: An Adaptive Human-Robot Collaborative Assembly Framework Using Large Language Models

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 has demonstrated potential to improve system adaptability by leveraging human versatility and decision-making capabilities. However, existing Human-Robot Collaborative frameworks 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 framework 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 a Large Language Model 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 Human-Robot Collaboration beyond predefined product and task settings.

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arXiv2025

Robust Recovery and Control of Cyber-physical Discrete Event Systems under Actuator Attacks

Critical real-world applications strongly rely on Cyber-physical systems (CPS), but their dependence on communication networks introduces significant security risks, as attackers can exploit vulnerabilities to compromise their integrity and availability. This work explores the topic of cybersecurity in the context of CPS modeled as discrete event systems (DES), focusing on recovery strategies following the detection of cyberattacks. Specifically, we address actuator enablement attacks and propose a method that preserves the system's full valid behavior under normal conditions. Upon detecting an attack, our proposed solution aims to guide the system toward a restricted yet robust behavior, ensuring operational continuity and resilience. Additionally, we introduce a property termed AE-robust recoverability, which characterizes the necessary and sufficient conditions for recovering a system from attacks while preventing further vulnerabilities. Finally, we showcase the proposed solution through a case study based on a manufacturing system.

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arXiv2025

Dynamic distributed decision-making for resilient resource reallocation in disrupted manufacturing systems

The COVID-19 pandemic brings many unexpected disruptions, such as frequently shifting markets and limited human workforce, to manufacturers. To stay competitive, flexible and real-time manufacturing decision-making strategies are needed to deal with such highly dynamic manufacturing environments. One essential problem is dynamic resource allocation to complete production tasks, especially when a resource disruption (e.g., machine breakdown) occurs. Though multi-agent methods have been proposed to solve the problem in a flexible and agile manner, the agent internal decision-making process and resource uncertainties have rarely been studied. This work introduces a model-based resource agent (RA) architecture that enables effective agent coordination and dynamic agent decision-making. Based on the RA architecture, a rescheduling strategy that incorporates risk assessment via a clustering agent coordination strategy is also proposed. A simulation-based case study is implemented to demonstrate dynamic rescheduling using the proposed multi-agent framework. The results show that the proposed method reduces the computational efforts while losing some throughput optimality compared to the centralized method. Furthermore, the case study illustrates that incorporating risk assessment into rescheduling decision-making improves the throughput.

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arXiv2025

Bi-level Model Predictive Control for Energy-aware Integrated Product Pricing and Production Scheduling

The manufacturing industry is under growing pressure to enhance sustainability while preserving economic competitiveness. As a result, manufacturers have been trying to determine how to integrate onsite renewable energy and real-time electricity pricing into manufacturing schedules without compromising profitability. To address this challenge, we propose a bi-level model predictive control framework that jointly optimizes product prices and production scheduling with explicit consideration of renewable energy availability. The higher level determines the product price to maximize revenue and renewable energy usage. The lower level controls production scheduling in runtime to minimize operational costs and respond to the product demand. Price elasticity is incorporated to model market response, allowing the system to increase demand by lowering the product price during high renewable energy generation. Results from a lithium-ion battery pack manufacturing system case study demonstrate that our approach enables manufacturers to reduce grid energy costs while increasing profit.

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arXiv2025

A Model Predictive Control Framework to Enhance Safety and Quality in Mobile Additive Manufacturing Systems

In recent years, the demand for customized, on-demand production has grown in the manufacturing sector. Additive Manufacturing (AM) has emerged as a promising technology to enhance customization capabilities, enabling greater flexibility, reduced lead times, and more efficient material usage. However, traditional AM systems remain constrained by static setups and human worker dependencies, resulting in long lead times and limited scalability. Mobile robots can improve the flexibility of production systems by transporting products to designated locations in a dynamic environment. By integrating AM systems with mobile robots, manufacturers can optimize travel time for preparatory tasks and distributed printing operations. Mobile AM robots have been deployed for on-site production of large-scale structures, but often neglect critical print quality metrics like surface roughness. Additionally, these systems do not have the precision necessary for producing small, intricate components. We propose a model predictive control framework for a mobile AM platform that ensures safe navigation on the plant floor while maintaining high print quality in a dynamic environment. Three case studies are used to test the feasibility and reliability of the proposed systems.

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arXiv2025

Energy-Aware Model Predictive Control for Batch Manufacturing System Scheduling Under Different Electricity Pricing Strategies

Manufacturing industries are among the highest energy-consuming sectors, facing increasing pressure to reduce energy costs. This paper presents an energy-aware Model Predictive Control (MPC) framework to dynamically schedule manufacturing processes in response to time-varying electricity prices without compromising production goals or violating production constraints. A network-based manufacturing system model is developed to capture complex material flows, batch processing, and capacities of buffers and machines. The scheduling problem is formulated as a Mixed-Integer Quadratic Program (MIQP) that balances energy costs, buffer levels, and production requirements. A case study evaluates the proposed MPC framework under four industrial electricity pricing schemes. Numerical results demonstrate that the approach reduces energy usage expenses while satisfying production goals and adhering to production constraints. The findings highlight the importance of considering the detailed electricity cost structure in manufacturing scheduling decisions and provide practical insights for manufacturers when selecting among different electricity pricing strategies.

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arXiv2025

Dynamic Task Adaptation for Multi-Robot Manufacturing Systems with Large Language Models

Recent manufacturing systems are increasingly adopting multi-robot collaboration to handle complex and dynamic environments. While multi-agent architectures support decentralized coordination among robot agents, they often face challenges in enabling real-time adaptability for unexpected disruptions without predefined rules. Recent advances in large language models offer new opportunities for context-aware decision-making to enable adaptive responses to unexpected changes. This paper presents an initial exploratory implementation of a large language model-enabled control framework for dynamic task reassignment in multi-robot manufacturing systems. A central controller agent leverages the large language model's ability to interpret structured robot configuration data and generate valid reassignments in response to robot failures. Experiments in a real-world setup demonstrate high task success rates in recovering from failures, highlighting the potential of this approach to improve adaptability in multi-robot manufacturing systems.

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arXiv2025

A Large Language Model-Enabled Control Architecture for Dynamic Resource Capability Exploration in Multi-Agent Manufacturing Systems

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.

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arXiv2024

Model-Based Control of Water Treatment with Pumped Water Storage

Water treatment facilities are critical infrastructure they must accommodate dynamic demand patterns without system disruption. These patterns can be scheduled, such as daily residential irrigation, or unexpected, such as demand spikes from withdrawals for fire management. The critical necessity of clean, safe, and reliable water requires water treatment control strategies that are insensitive to disturbances to guarantee that demand will be met. One essential problem in achieving this is the minimization of energy costs in the process of meeting water demand, especially as the need for decarbonization persists. This work develops a control-oriented hydraulic model of a water treatment facility with integrated pumped storage and introduces a model predictive control strategy for scheduling treatment plant system operations to minimize greenhouse gas emissions and safely meet water demand.

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arXiv2024

Large Language Model-Enabled Multi-Agent Manufacturing Systems

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.

cs.MA↗

arXiv2024

Enhancing Human-Robot Collaborative Assembly in Manufacturing Systems Using Large Language Models

The development of human-robot collaboration has the ability to improve manufacturing system performance by leveraging the unique strengths of both humans and robots. On the shop floor, human operators contribute with their adaptability and flexibility in dynamic situations, while robots provide precision and the ability to perform repetitive tasks. However, the communication gap between human operators and robots limits the collaboration and coordination of human-robot teams in manufacturing systems. Our research presents a human-robot collaborative assembly framework that utilizes a large language model for enhancing communication in manufacturing environments. The framework facilitates human-robot communication by integrating voice commands through natural language for task management. A case study for an assembly task demonstrates the framework's ability to process natural language inputs and address real-time assembly challenges, emphasizing adaptability to language variation and efficiency in error resolution. The results suggest that large language models have the potential to improve human-robot interaction for collaborative manufacturing assembly applications.

cs.RO↗

arXiv2024

A Mobile Additive Manufacturing Robot Framework for Smart Manufacturing Systems

Recent technological innovations in the areas of additive manufacturing and collaborative robotics have paved the way toward realizing the concept of on-demand, personalized production on the shop floor. Additive manufacturing process can provide the capability of printing highly customized parts based on various customer requirements. Autonomous, mobile systems provide the flexibility to move custom parts around the shop floor to various manufacturing operations, as needed by product requirements. In this work, we proposed a mobile additive manufacturing robot framework for merging an additive manufacturing process system with an autonomous mobile base. Two case studies showcase the potential benefits of the proposed mobile additive manufacturing framework. The first case study overviews the effect that a mobile system can have on a fused deposition modeling process. The second case study showcases how integrating a mobile additive manufacturing machine can improve the throughput of the manufacturing system. The major findings of this study are that the proposed mobile robotic AM has increased throughput by taking advantage of the travel time between operations/processing sites. It is particularly suited to perform intermittent operations (e.g., preparing feedstock) during the travel time of the robotic AM. One major implication of this study is its application in manufacturing structural components (e.g., concrete construction, and feedstock preparation during reconnaissance missions) in remote or extreme terrains with on-site or on-demand feedstocks.

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arXiv2023

Ontology-Based Feedback to Improve Runtime Control for Multi-Agent Manufacturing Systems

Improving the overall equipment effectiveness (OEE) of machines on the shop floor is crucial to ensure the productivity and efficiency of manufacturing systems. To achieve the goal of increased OEE, there is a need to develop flexible runtime control strategies for the system. Decentralized strategies, such as multi-agent systems, have proven effective in improving system flexibility. However, runtime multi-agent control of complex manufacturing systems can be challenging as the agents require extensive communication and computational efforts to coordinate agent activities. One way to improve communication speed and cooperation capabilities between system agents is by providing a common language between these agents to represent knowledge about system behavior. The integration of ontology into multi-agent systems in manufacturing provides agents with the capability to continuously update and refine their knowledge in a global context. This paper contributes to the design of an ontology for multi-agent systems in manufacturing, introducing an extendable knowledge base and a methodology for continuously updating the production data by agents during runtime. To demonstrate the effectiveness of the proposed framework, a case study is conducted in a simulated environment, which shows improvements in OEE during runtime.

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arXiv2023

A System-Level Energy-Efficient Digital Twin Framework for Runtime Control of Batch Manufacturing Processes

The manufacturing sector has a substantial influence on worldwide energy consumption. Therefore, improving manufacturing system energy efficiency is becoming increasingly important as the world strives to move toward a more resilient and sustainable energy paradigm. Batch processes are a major contributor to energy consumption in manufacturing systems. In batch manufacturing, a number of parts are grouped together before starting a batch process. To improve the scheduling and control of batch manufacturing processes, we propose a system-level energy-efficient Digital Twin framework that considers Time-of-Use (TOU) energy pricing for runtime decision-making. As part of this framework, we develop a model that combines batch manufacturing process dynamics and TOU-based energy cost. We also provide an optimization-based decision-making algorithm that makes batch scheduling decisions during runtime. A simulated case study showcases the benefits of the proposed framework.

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