Networked Predictive Control and Intelligent Diagnostics for Automated Mechatronic Manufacturing and Intralogistics Systems

As automation increases, mechatronic manufacturing systems require supervisory solutions that combine precise control, intelligent diagnostics, and intralogistics awareness. This paper presents a networked sensor–actuator–information architecture integrating model predictive control (MPC), Random Forest (RF)-based diagnostics, and logistics-aware coordination for automated mechatronic manufacturing systems. The main contribution is the explicit coupling of logistics-related supervisory variables with the predictive control problem and the diagnostic feature space. Buffer occupancy, transport delay, and logistics-induced waiting state are incorporated into an augmented reduced-order model to support constrained control and health-state interpretation. The framework is evaluated through a comparative simulation-based feasibility study using a low-order model of a robotic production axis affected by disturbances, degradation, and logistics-related constraints. The proposed approach is compared with classical feedback control, predictive control without diagnostics, and predictive control with diagnostics but without explicit intralogistics coupling. In the reduced-order simulation scenario, the proposed method achieved the lowest mean RMSE of 0.330 ± 0.015 and the lowest mean constraint violation rate of 3.133 ± 0.280% across 40 repeated simulation runs. However, the improvement in nominal tracking accuracy over the strongest diagnostic-assisted MPC baseline was marginal. Adding logistics-related diagnostic features improved mean accuracy from 0.848 ± 0.014 to 0.874 ± 0.012 and mean F1-score from 0.844 ± 0.016 to 0.872 ± 0.013. The main advantage of the proposed architecture was observed in reliability- and continuity-oriented indicators, including reduced downtime, lower final damage accumulation, fewer cooling cycles, and improved differentiation between machine-related and logistics-induced abnormal conditions.