Hybrid Adaptive MPC with Edge AI for 6-DoF Industrial Robotic Manipulators

Autonomous robotic manipulators in industrial environments face significant challenges, including time-varying payloads, multi-source disturbances, and real-time computational constraints. Traditional model predictive control frameworks degrade by over 40% under model uncertainties, while conventional adaptive techniques exhibit convergence times incompatible with industrial cycles. This work presents a hybrid adaptive model predictive control framework integrating edge artificial intelligence with dual-stage parameter estimation for 6-DoF industrial manipulators. The approach combines recursive least squares with a resource-optimized neural network (three layers, 32 neurons, <500 KB memory) designed for industrial edge deployment. The system employs innovation-based adaptive forgetting factors, providing exponential convergence with mathematically proven Lyapunov-based stability guarantees. Simulation validation using the Fanuc CR-7iA/L manipulator demonstrates superior performance across demanding scenarios, including precision laser cutting and obstacle avoidance. Results show 52% trajectory tracking RMSE reduction (0.022 m to 0.012 m) under 20% payload variations compared to standard MPC, while achieving sub-5 ms edge inference latency with 99.2% reliability. The hybrid estimator achieves 65% faster parameter convergence than classical RLS, with 18% energy efficiency improvement. Statistical significance is confirmed through ANOVA (F = 24.7, p < 0.001) with large effect sizes (Cohen’s d > 1.2). This performance surpasses recent adaptive control methods while maintaining proven stability guarantees. Hardware validation under realistic industrial conditions remains necessary to confirm practical applicability.