Organizations: Politecnico di Milano · STMicroelectronics
Abstract
Reinforcement learning promises to optimize sequential decisions in large-scale systems. Semiconductor manufacturing systems are stochastic and highly constrained environments where heterogeneous wafers traverse hundreds of processing steps across extensive equipment networks. These characteristics yield complex, high-dimensional decision problems with delayed feedback and long-horizon requirements, complicating production planning and control. We propose a deep reinforcement learning framework for multi-objective policy optimization at this scale. Specifically, we formulate control as a centralized-agent problem, where a core policy coordinates system-wide decisions, while system evolution is represented as an interconnected temporal process driven by discrete events. Accordingly, we develop a tailored event-driven temporal-difference formulation that remains general and can be integrated with various policy optimization methods under relevant training settings. We investigate several core model-free algorithms incorporated into this framework and evaluate their effectiveness using high-fidelity simulations of diverse, industry-real operating scenarios. Across extensive validation experiments, agents trained in both offline and online settings show significant and consistent gains in throughput and utilization. We further evaluate performance and generalization across training phases, clarifying the relative strengths of alternative reinforcement learning formulations and algorithms. Overall, the results support the scalability, generality, and transferability of the proposed framework for controlling event-driven complex adaptive systems.
This paper presents a novel approach for data-driven self-learning control of highly flexible, modular manufacturing systems. Specifically, we employ a novel framework for model-based reinforcement learning which introduces approximate inverse process models within the training of reinforcement policies. This approach disentangles the learning of actuation dynamics and the dynamics in state space, resulting in RL-based training solely within the task space. We propose a lightweight feedforward architecture for approximate inverse models and integrate them within the policy network of standard RL algorithms. We apply the approach to a laboratory modular production testbed with heterogeneous production modules. The results underline the efficiency improvements for modular manufacturing units in terms of both performance and training speed, particularly for off-policy algorithms.
Andreas Schwung, Steve Yuwono, Sofiene Lassoued +1
Reinforcement learning (RL) has recently emerged as a promising feedback control strategy for nonlinear and complex dynamical systems. However, RL algorithms are sample inefficient and require a large number of interaction with the environment to synthesize optimal control strategies. Consequently, applications of RL are typically limited to sparse sensors and actuators due to the curse of dimensionality entailed by the exploration-exploitation dilemma in high-dimensional spaces. In this work, we bridge RL and traditional optimal control for dynamical system with a novel Physics-EnhAnced Reinforcement Learning (PEARL) paradigm tailored to the control of high-dimensional and parametric dynamical systems, exploiting the differentibility of their dynamics. Specifically, PEARL employs an actor-adjoint algorithm that leverages automatic differentiation to compute policy gradients over short horizons and adjoint-based sensitivities of future returns approximated via neural networks, significantly reducing the number of environment interactions, while mitigating long-term gradient instabilities. Through two challenging parametric navigation problems in unsteady flows, we show that PEARL (i) effectively exploits differentiable environments to outperform state-of-the-art RL algorithms, (ii) is sample efficient, thanks to the physics-guided policy learning, (iii) generalizes across multiple scenarios, which is crucial when dealing with parametric systems, and (iv) enables scaling RL to high-dimensional state and action spaces, without requiring low-dimensional state representations or multi-agent strategies.
Soft robots are challenging to control due to their nonlinear and time-varying dynamics. Data-enabled predictive control (DeePC) offers a model-free alternative by directly leveraging measured input-output trajectories to construct a predictive controller. However, its receding-horizon formulation requires solving a constrained optimization problem at every sampling instant, which can be computationally demanding for real-time deployment on resource-limited robotic platforms. To address this limitation, we propose an adaptive reinforcement-learning-based event-triggered DeePC (RL-ET-DeePC) framework for soft robotic control. A model-free RL policy is trained to determine when to invoke the DeePC optimizer based on the current system state representation, thereby reducing unnecessary optimization calls while preserving closed-loop performance. Simulation results show that RL-ET-DeePC reduces optimization frequency by up to 66% compared to periodic DeePC, while maintaining comparable tracking accuracy. Hardware experiments on a three-dimensional cable-driven soft robotic arm demonstrate zero-shot transfer, achieving a 34% reduction in optimization frequency with tracking accuracy comparable to periodic DeePC and more consistent performance than a static threshold-based event-triggered baseline.