- -
- 09.00 - 09.30: Welding the Future: How AI, Smart & Secure Machines & the New EU Machinery Regulation Are Reshaping Industrial Manufacturing
-
Artificial intelligence is revolutionizing industrial welding by advancing smart machine automation through multimodal signal analysis and adaptive process control. Powered by Agentic and Multimodal AI, these systems enhance precision, efficiency, and flexibility, paving the way for more autonomous and intelligent manufacturing processes.
As AI-driven machines become indispensable, the new EU Machinery Regulation and Equipment-as-a-Service (EaaS) business models are redefining how manufacturers may leverage machine data for equipment Intelligence, cybersecurity and process innovation. In this keynote, the CEO of MYWAI a leading European startup pioneering AI in a set of large Welding Intelligence projects —will provide insights on these disruptive forces, unveiling the opportunities and challenges that lie ahead. What does this shift means for welding in manufacturing and other critical markets whilst AI is reshaping the future of industry? - 09.30 - 10.00: Digital Twin Framework for Detecting and Correcting Static Yaw Misalignment in Wind Turbines
-
Static yaw misalignment in a wind turbine occurs when the rotor plane is not oriented perpendicular to the incoming wind, often due to faulty wind sensors on the nacelle or installation errors. This misalignment leads to decrease turbine efficiency, reduced power generation, and increased mechanical stresses on turbine components.
Digital Twin (DT) modeling enables continuous, real-time evaluation of operational performance, allowing for the detection of anomalies and inefficiencies at an early stage. By integrating real-world data with high-fidelity simulations, DT models offer predictive insights that enhance decision-making, support proactive maintenance strategies, and reduce unplanned downtime.
This paper introduces an advanced DT approach for detecting and correcting static yaw misalignment in micro wind turbines, with the potential for scalability to larger turbines.
The proposed DT method models the aerodynamic behaviour of the micro wind turbine. CFD simulation information is used to analyse the airflow and power generation, enabling the identification of discrepancies between virtual and real operating performance, which indicate the presence of static yaw misalignment. Upon detecting a misalignment, the DT model can provide the necessary corrective measures to realign the turbine with the prevailing wind direction, thereby optimising its aerodynamic performance and enhancing the overall operational efficiency of the system. - 10.00 - 10.30: Predictive Maintenance System for Bridges Based on BIM and Digital Twin
-
Many bridges in Europe are approaching the end of their design service life, leading bridge maintenance to a high priority. Among the existing maintenance methods, Predictive Maintenance
(PdM) is an advanced approach utilizing monitoring data, to predict the future condition of the structure based on its current condition and reduce the chance of failure events by optimizing maintenance actions. This method can increase safety and minimize massive maintenance costs.
However, the limited knowledge level in bridge conditions (geometrical and
structural) proposes significant obstacles, making maintenance planning difficult. Additionally, integrating various information sources and dealing with large monitoring datasets (SHM data) in this method is a major challenge.
Digitalization of the bridge offers potential solutions through Building Information Modelling (BIM) technology, which facilitates the integration of available information, organized chronologically into the past (e.g. inspection results and previous maintenance), present (e.g. current geometry, mechanical properties, defects, and environmental conditions), and future (e.g. maintenance planning and predictions). This approach also allows for efficient database management. Further advancement in BIM maturity level evolves it into Digital Twin (DT) technology, allowing real-time connection between the digital model and physical structure, thus facilitating continuous monitoring and structural assessment for immediate decision-making.
This research explores the development of a digitalized PdM system for a bridge case study by utilizing data obtained from a laser scanner and drone to enhance the knowledge level of the structure and defect detection, providing an effective monitoring system for the structure (Project GIANO), data integration and management, and structural assessment using BIM technology. - 10.30 - 11.00: Coffee Break
- 11.00 - 11.30: Studio sperimentale sul monitoraggio in real time di un processo di saldatura GMAW robotizzato attraverso indagini termografiche
-
Questo studio si propone di identificare i difetti tipici della saldatura nel processo GMAW attraverso tecniche di monitoraggio in tempo reale. Durante l'esecuzione della saldatura, i dati vengono acquisiti da una termocamera che inquadra il bagno di fusione e il cordone. Le informazioni raccolte sono state analizzate per individuare correlazioni tra i parametri monitorati e le eventuali anomalie o difetti riscontrati.
L'obiettivo è gettare le basi per lo sviluppo di sistemi di addestramento e ispezione basati su intelligenza artificiale, al fine di migliorare sia l’apprendimento dei saldatori che la qualità dei manufatti. - 11.30 - 12.00: Intelligent welding technology in robotic applications
-
Inrotech specializes in advanced robotic welding solutions characterized by high automation and user-friendly operation. Their mobile welding robots are designed to adapt to various industries, including shipbuilding, offshore, renewables, and heavy fabrication.
Inrotech's solutions utilize technologies like SensLogic and WeldLogic, enabling their robots to autonomously plan and execute welding tasks without manual programming. - 12.00 - 12.30: Multimodal, Generative, and Agentic AI for Welding Intelligence: The GENAWARE™, WELDWAISE™, and SENECA™ Projects by MYWAI™ and Istituto Italiano della Saldatura
-
This talk will highlight a new wave of R&D projects leveraging advancements in AI, such as multimodal, generative, and multi-agent systems, to enhance human and robotic arc welding in automotive and ENERTECH equipment manufacturing.
The talk will present the following key projects both from the eyes of the leading provider of the AI solutions adopted, MYWAI SRL, and that of the welding subject matter expert, Istituto Italiano di Saldatura (IIS):
- GENAWARE™ (GENerative Artificial intelligence for Welding Automation and REliability): Funded by the CIM4.0 initiative under the Next Generation EU Fund (PNRR) - M4C212.3 , this project led by MYWAI™ and IIS in collaboration with CRF™ (Stellantis™ Group Research Center), this project uses MYWAI's AIoT platform to optimize welding processes for Industry 4.0. Tested on FIAT 500 Electric production, it employs autonomous AI agents with reinforcement learning to improve laser welding control loops, enhancing manufacturing performance and quality.
- WELDWAISE™ (WELDing Worker Assistive Intelligence, Support, and Education): Funded under the "P.R. FESR LIGURIA 2021-2027 - OP 1 - O.S. 1.1” Innovation fund, this project developed by MYWAI and IIS with local startups, SWAHRD and INNOVINA and University departments (Robotics department of University of Genoa, DIME ) this project supports welding processes through multimodal AI for real-time quality assurance, combining arc welding data, acoustics, and human welder tracking with 3D Gaussian Splatting digital twins for immersive training using virtual and augmented reality.
- SENECA™ (SEcured NEuromorphic Computing Architecture for Industry 5.0): Funded by START 4.0 under the Next Generation EU Fund (PNRR) - M4C2I2.3A, the project led by MYWAI and ISS with a case study by Walter Tosto™, world leading Enertech Equipment Manufacturer, aims to provide advanced monitoring and optimization solutions for welding machinery using IoT sensors, AI algorithms, and a cloud-based platform with advanced Cybersecurity by design fearures. The patent-pending SENECA technology integrates hardware and software solutions to ensure compliance with the EU Machinery, Data, and AI Acts coming into force at EU national levels within 2027 latest
