Nollapistekiinnittimen hyödyntäminen työkalun valmistuksessa ja muovausprosessissa

Tämä diplomityö tehtiin Lappeenrannan teknillisen yliopiston konetekniikan osastolle. Työn tavoitteena oli kartoittaa nollapistekiinnittimien tyyppejä ja toimintaperiaatteita sekä luoda muistilista liittyen nollapistekiinnittimen käyttöönottoon kiinnitysratkaisuna. Nollapistekiinnitin on konepajatekniikan kappaleenkiinnitin, joka tarjoaa tarkan paikoituksen, nopean asetusajan ja yksinkertaisen kappaleenvaihdon. Työssä tutkitaan nollapistekiinnittimien ominaisuuksia ja käyttökohteita, esitellään erityyppisiä nollapistekiinnittimiä ja vertaillaan niitä perinteisiin kiinnitysmenetelmiin. Työn kokeellisen osuuden tavoite oli tutkia nollapistekiinnittimen ominaisuuksia ja toimintaa ja pohtia mahdollisuuksia muovaustyökalun valmistuksessa ja kiinnittämisessä muovauspuristimeen. Kokeet tehtiin LTY:n konepajatekniikan laboratoriossa kesä- ja heinäkuussa 2010.

On the development of object functions and restrictions for shapes made with a turret punch press

This study presents the information required to describe the machine and device resources in the turret punch press environment which are needed for the development of the analysing method for automated production. The description of product and device resources and their interconnectedness is the starting point for method comparison the development of expenses, production planning and the performance of optimisation. The manufacturing method cannot be optimized unless the variables and their interdependence are known. Sheet metal parts in particular may then become remarkably complex, and their automatic manufacture may be difficult or, with some automatic equipment, even impossible if not know manufacturing properties. This thesis consists of three main elements, which constitute the triangulation. In the first phase of triangulation, the manufacture occuring on a turret punch press is examined in order to find the factors that affect the efficiency of production. In the second phase of triangulation, the manufacturability of products on turret punch presses is examined through a set of laboratory tests. The third phase oftriangulation involves an examination of five industry parts. The main key findings of this study are: all possible efficiency in high automation level machining cannot be achieved unless the raw materials used in production and the dependencies of the machine and tools are well known. Machine-specific manufacturability factors for turret punch presses were not taken into account in the industrial case samples. On the grounds of the performed tests and industrial case samples, the designer of a sheet metal product can directly influence the machining time, material loss, energy consumption and the number of tools required on a turret punch press by making decisions in the way presented in the hypothesis of thisstudy. The sheet metal parts to be produced can be optimised to bemanufactured on a turret punch press when the material to be used and the kinds of machine and tool options available are known. This provides in-depth knowledge of the machine and tool properties machine and tool-specifically. None of the optimisation starting points described here is a separate entity; instead, they are all connected to each other.

Design and analysis of a transversal-flux switched-reluctance-linear-machine pole-pair

The Switched Reluctance technology is probably best suited for industrial low-speed or zerospeed applications where the power can be small but the torque or the force in linear movement cases might be relatively high. Because of its simple structure the SR-motor is an interesting alternative for low power applications where pneumatic or hydraulic linear drives are to be avoided. This study analyses the basic parts of an LSR-motor which are the two mover poles and one stator pole and which form the “basic pole pair” in linear-movement transversal-flux switchedreluctance motors. The static properties of the basic pole pair are modelled and the basic design rules are derived. The models developed are validated with experiments. A one-sided one-polepair transversal-flux switched-reluctance-linear-motor prototype is demonstrated and its static properties are measured. The modelling of the static properties is performed with FEM-calculations. Two-dimensional models are accurate enough to model the static key features for the basic dimensioning of LSRmotors. Three-dimensional models must be used in order to get the most accurate calculation results of the static traction force production. The developed dimensioning and modelling methods, which could be systematically validated by laboratory measurements, are the most significant contributions of this thesis.

Tool-supported invariant-based programming

The development of correct programs is a core problem in computer science. Although formal verification methods for establishing correctness with mathematical rigor are available, programmers often find these difficult to put into practice. One hurdle is deriving the loop invariants and proving that the code maintains them. So called correct-by-construction methods aim to alleviate this issue by integrating verification into the programming workflow. Invariant-based programming is a practical correct-by-construction method in which the programmer first establishes the invariant structure, and then incrementally extends the program in steps of adding code and proving after each addition that the code is consistent with the invariants. In this way, the program is kept internally consistent throughout its development, and the construction of the correctness arguments (proofs) becomes an integral part of the programming workflow. A characteristic of the approach is that programs are described as invariant diagrams, a graphical notation similar to the state charts familiar to programmers. Invariant-based programming is a new method that has not been evaluated in large scale studies yet. The most important prerequisite for feasibility on a larger scale is a high degree of automation. The goal of the Socos project has been to build tools to assist the construction and verification of programs using the method. This thesis describes the implementation and evaluation of a prototype tool in the context of the Socos project. The tool supports the drawing of the diagrams, automatic derivation and discharging of verification conditions, and interactive proofs. It is used to develop programs that are correct by construction. The tool consists of a diagrammatic environment connected to a verification condition generator and an existing state-of-the-art theorem prover. Its core is a semantics for translating diagrams into verification conditions, which are sent to the underlying theorem prover. We describe a concrete method for 1) deriving sufficient conditions for total correctness of an invariant diagram; 2) sending the conditions to the theorem prover for simplification; and 3) reporting the results of the simplification to the programmer in a way that is consistent with the invariantbased programming workflow and that allows errors in the program specification to be efficiently detected. The tool uses an efficient automatic proof strategy to prove as many conditions as possible automatically and lets the remaining conditions be proved interactively. The tool is based on the verification system PVS and i uses the SMT (Satisfiability Modulo Theories) solver Yices as a catch-all decision procedure. Conditions that were not discharged automatically may be proved interactively using the PVS proof assistant. The programming workflow is very similar to the process by which a mathematical theory is developed inside a computer supported theorem prover environment such as PVS. The programmer reduces a large verification problem with the aid of the tool into a set of smaller problems (lemmas), and he can substantially improve the degree of proof automation by developing specialized background theories and proof strategies to support the specification and verification of a specific class of programs. We demonstrate this workflow by describing in detail the construction of a verified sorting algorithm. Tool-supported verification often has little to no presence in computer science (CS) curricula. Furthermore, program verification is frequently introduced as an advanced and purely theoretical topic that is not connected to the workflow taught in the early and practically oriented programming courses. Our hypothesis is that verification could be introduced early in the CS education, and that verification tools could be used in the classroom to support the teaching of formal methods. A prototype of Socos has been used in a course at Åbo Akademi University targeted at first and second year undergraduate students. We evaluate the use of Socos in the course as part of a case study carried out in 2007.

Pyörivien sähkökoneiden kotelointia koskevat standardit ja aksiaalivuokoneen jäähdytyksen kehittäminen

Tämä diplomityö on osa Lappeenrannan teknillisen yliopiston ja Visedo Oy:n yhteistyöprojektia. Työssä selvitetään pyörivien sähkökoneiden kotelointeja koskevia standardeja ja niiden vaikutukset koneiden suunnittelulle ja valmistukselle. Lisäksi työssä käsitellään aksiaalivuokoneen jäähdytykseen liittyviä ongelmia, kehitetään koneen nykyisiä jäähdytysratkaisuja ja ideoidaan käytettävissä olevia uusia jäähdytysmenetelmiä. Kehitysideoiden rajoitteena toimii koneelta vaadittu kotelointiluokka IP 64 – IP 68 sekä koneelle määritetty kestomagnetoitu aksiaalivuorakenne. Sähkökoneiden kotelointeja koskevien standardien asettamien vaatimusten määrittäminen tapahtui suurilta osin kirjallisuusselvityksenä. Standardien vaikutukset koneiden suunnittelulle ja valmistettavuudelle on selvitetty standardien kotelointien rakenteelle asettamien vaatimusten perusteella. Aksiaalivuokoneen jäähdytysongelmien selvittäminen, käytössä olevien jääh-dytysratkaisujen kehittäminen ja uusien menetelmien ideointi suoritettiin projektiluontoisesti yhdessä eri alojen asiantuntijoista koostuvan jäähdytystyöryhmän kanssa. Työn tuloksena laadittiin Visedo Oy:lle standardikäsikirja, jonka avulla Visedon sähkökoneiden tuoteperheeseen kuuluvien koneiden suunnitteluvaiheessa voidaan varmistaa koneiden standardienmukaisuus. Käsikirjassa on myös esitetty huomioita eri kotelointiluokkien asettamista vaatimuksista koneiden valmistukselle. Aksiaalivuokoneiden jäähdytykseen liittyen tavoitteena oli ratkaista aksiaalivuokoneisiin liittyviä jäähdytysongelmia. Työn tuloksena saa-tiin selville aksiaalivuokoneissa jäähdytyksen kehittämistä vaativat kohteet, laadittiin nykyisten jäähdytysratkaisujen parannusehdotuksia ja kehitettiin täysin uusia jäähdytysmenetelmiä.

Identifying first graders at risk of reading and writing difficulties : creating a group-based screening tool in kiswahili in Tanzania

Early identification of beginning readers at risk of developing reading and writing difficulties plays an important role in the prevention and provision of appropriate intervention. In Tanzania, as in other countries, there are children in schools who are at risk of developing reading and writing difficulties. Many of these children complete school without being identified and without proper and relevant support. The main language in Tanzania is Kiswahili, a transparent language. Contextually relevant, reliable and valid instruments of identification are needed in Tanzanian schools. This study aimed at the construction and validation of a group-based screening instrument in the Kiswahili language for identifying beginning readers at risk of reading and writing difficulties. In studying the function of the test there was special interest in analyzing the explanatory power of certain contextual factors related to the home and school. Halfway through grade one, 337 children from four purposively selected primary schools in Morogoro municipality were screened with a group test consisting of 7 subscales measuring phonological awareness, word and letter knowledge and spelling. A questionnaire about background factors and the home and school environments related to literacy was also used. The schools were chosen based on performance status (i.e. high, good, average and low performing schools) in order to include variation. For validation, 64 children were chosen from the original sample to take an individual test measuring nonsense word reading, word reading, actual text reading, one-minute reading and writing. School marks from grade one and a follow-up test half way through grade two were also used for validation. The correlations between the results from the group test and the three measures used for validation were very high (.83-.95). Content validity of the group test was established by using items drawn from authorized text books for reading in grade one. Construct validity was analyzed through item analysis and principal component analysis. The difficulty level of most items in both the group test and the follow-up test was good. The items also discriminated well. Principal component analysis revealed one powerful latent dimension (initial literacy factor), accounting for 93% of the variance. This implies that it could be possible to use any set of the subtests of the group test for screening and prediction. The K-Means cluster analysis revealed four clusters: at-risk children, strugglers, readers and good readers. The main concern in this study was with the groups of at-risk children (24%) and strugglers (22%), who need the most assistance. The predictive validity of the group test was analyzed by correlating the measures from the two school years and by cross tabulating grade one and grade two clusters. All the correlations were positive and very high, and 94% of the at-risk children in grade two were already identified in the group test in grade one. The explanatory power of some of the home and school factors was very strong. The number of books at home accounted for 38% of the variance in reading and writing ability measured by the group test. Parents´ reading ability and the support children received at home for schoolwork were also influential factors. Among the studied school factors school attendance had the strongest explanatory power, accounting for 21% of the variance in reading and writing ability. Having been in nursery school was also of importance. Based on the findings in the study a short version of the group test was created. It is suggested for use in the screening processes in grade one aiming at identifying children at risk of reading and writing difficulties in the Tanzanian context. Suggestions for further research as well as for actions for improving the literacy skills of Tanzanian children are presented.

Miehistönkuljetusajoneuvon rungon suunnittelu

Tämän diplomityön tavoitteena oli suunnitella miehistönkuljetusajoneuvon runko. Rungosta suunniteltiin mahdollisimman hyvin energiaa absorboiva. Rakenne toteutettiin kennora-kenteena. Suunnittelussa sovellettiin koneensuunnittelun periaatteiden lisäksi energiaa ab-sorboivien rakenteiden suunnittelun periaatteita. Myös valmistustekniset näkökohdat otet-tiin huomioon. Rakenteessa hyödynnettiin Ruukki Oy:n Ramor 500 suojausterästä sekä OPTIM 500 MC terästä. Lisäksi erilaisten täyteaineiden käyttöä tutkittiin. Suunnittelun työkaluna käytettiin epälineaarista elementtimenetelmää, koska energiaa ab-sorboivien rakenteiden suunnittelussa on otettava huomioon materiaalien epälineaarinen käyttäytyminen. Rakenteen suunnittelu jakaantui viiteen vaiheeseen. Aluksi rakenteeseen kohdistuvat kuormitukset laskettiin elementtimenetelmän avulla. Esisuunnittelussa lasket-tiin plastisuusteorian avulla alustavasti tarvittavat materiaalipaksuudet. Tämän jälkeen ra-kenteen ydingeometria optimoitiin mahdollisimman hyvin energiaa absorboivaksi. Opti-moinnissa hyödynnettiin elementtimenetelmää. Seuraavassa vaiheessa varmistettiin raken-teen globaalit ominaisuudet. Lopuksi rakenteen kestävyyttä tarkasteltiin elementtimene-telmällä. Runko ei mallien mukaan kestänyt siltä vaadittuja kuormitustapauksia. Mallin kaikki ole-tukset pidettiin varmalla puolella. Reunaehdot oletettiin todellisuutta jäykemmiksi. Myös-kään materiaalin venymänopeudesta johtuvaa lujittumista ei otettu huomioon. Koska mii-naräjähdys on monimutkainen tapahtuma, rungon todellinen kestävyys joudutaan ar-viomaan räjähdystesteillä. Elementtimallien perusteella voidaan kuitenkin sanoa, että ener-giaa absorboiva ajoneuvon runko on mahdollista toteuttaa kennorakenteena. Lisäksi voi-daan todeta, että elementtimenetelmää sopii työvälineeksi tämän tyyppisten rakenteiden suunnitteluun.

Algorithmic Solutions for Combinatorial Problems in Resource Management of Manufacturing Environments

This thesis studies the use of heuristic algorithms in a number of combinatorial problems that occur in various resource constrained environments. Such problems occur, for example, in manufacturing, where a restricted number of resources (tools, machines, feeder slots) are needed to perform some operations. Many of these problems turn out to be computationally intractable, and heuristic algorithms are used to provide efficient, yet sub-optimal solutions. The main goal of the present study is to build upon existing methods to create new heuristics that provide improved solutions for some of these problems. All of these problems occur in practice, and one of the motivations of our study was the request for improvements from industrial sources. We approach three different resource constrained problems. The first is the tool switching and loading problem, and occurs especially in the assembly of printed circuit boards. This problem has to be solved when an efficient, yet small primary storage is used to access resources (tools) from a less efficient (but unlimited) secondary storage area. We study various forms of the problem and provide improved heuristics for its solution. Second, the nozzle assignment problem is concerned with selecting a suitable set of vacuum nozzles for the arms of a robotic assembly machine. It turns out that this is a specialized formulation of the MINMAX resource allocation formulation of the apportionment problem and it can be solved efficiently and optimally. We construct an exact algorithm specialized for the nozzle selection and provide a proof of its optimality. Third, the problem of feeder assignment and component tape construction occurs when electronic components are inserted and certain component types cause tape movement delays that can significantly impact the efficiency of printed circuit board assembly. Here, careful selection of component slots in the feeder improves the tape movement speed. We provide a formal proof that this problem is of the same complexity as the turnpike problem (a well studied geometric optimization problem), and provide a heuristic algorithm for this problem.

Kestomagneettikoneen roottorin väsymisanalyysi

Työn tavoitteena oli luoda työkalu kestomagneettikoneiden roottoreiden väsymisen analysointia varten. Työkalu toteutettiin siten, että siihen voidaan liittää oikeasta koneesta mitattu kuormitusdata, sekä tarvittavat materiaalitiedot. Kuormitusdata muunnetaan työkalussa jännityshistoriaksi käyttämällä elementtimenetelmän avulla laskettavaa skaalauskerrointa. Kestoiän laskemiseen analyysityökalu käyttää jännitykseen perustuvaa menetelmää sekä rainflowmenetelmää ja Palmgren-Minerin kumulatiivista vauriosääntöä. Lisäksi työkalu tekee tutkittavalle tapaukselle Smithin väsymislujuuspiirroksen. Edellä mainittujen menetelmien lisäksi työn teoriaosassa esiteltiin väsymisanalyysimenetelmistä myös paikalliseen venymään perustuva menetelmä sekä murtumismekaniikka. Nämä menetelmät jäivät monimutkaisuutensa vuoksi toteuttamatta työkalussa. Väsymisanalyysityökalulla laskettiin kestoiät kahdelle esimerkkitapaukselle. Kummassakin tapauksessa saatiin tulokseksi ääretön kestoikä, mutta aksiaalivuokoneen roottorin dynaaminen varmuus oli pieni. Vaikka tulokset vaikuttavat järkeviltä, ne olisi vielä hyvä verifioida esimerkiksi kaupallisen ohjelmiston avulla täyden varmuuden saamiseksi.

Automated Software Testing in Machine Automation

The problem of software (SW) defaults is becoming more and more topical because of increasing amount of the SW and its complication. The majority of these defaults are founded during the test part that consumes about 40-50% of the development efforts. Test automation allows reducing the cost of this process and increasing testing effectiveness. In the middle of 1980 the first tools for automated testing appeared and the automated process was implemented in different kinds of SW testing. In short time, it became obviously, automated testing can cause many problems such as increasing product cost, decreasing reliability and even project fail. This thesis describes automated testing process, its concept, lists main problems, and gives an algorithm for automated test tools selection. Also this work presents an overview of the main automated test tools for embedded systems.

Automation Concept for Electrically Excited LV Synchronous Motor: Implementation into AC500 Programmable Logic Environment

This bachelor’s thesis is a part of the research project realized in the summer 2011 in Lappeenranta University of Technology. The goal of the project was to develop an automation concept for controlling the electrically excited synchronous motor. Thesis concentrates on the implementation of the automation concept into the ABB’s AC500 programmable logic enviroment. The automation program was developed as a state machine with the ABB’s PS501 Control Builder software. For controlling the automation program is developed a fieldbus control and with CodeSys Visualization Tool a local control with control panel. The fieldbus control is done to correspond the ABB drives communication profile and the local control is implemented with a function block which feeds right control words into the statemachine. A field current control of the synchronous motor is realized as a method presented in doctoral thesis of Olli Pyrhönen (Pyrhönen 1998). The Method combines stator flux and torque based openloop control and power factor based feedback control.

Risk Parity: A Modern Tool for Diversification

The purpose of this study is to examine how well risk parity works in terms of risk, return and diversification relative to more traditional minimum variance, 1/N and 60/40 portfolios. Risk parity portfolios were constituted of five risk sources; three common asset classes and two alternative beta investment strategies. The three common asset classes were equities, bonds and commodities, and the alternative beta investment strategies were carry trade and trend following. Risk parity portfolios were constructed using five different risk measures of which four were tail risk measures. The risk measures were standard deviation, Value-at-Risk, Expected Shortfall, modified Value-at-Risk and modified Expected Shortfall. We studied also how sensitive risk parity is to the choice of risk measure. The hypothesis is that risk parity portfolios provide better return with the same amount of risk and are better diversified than the benchmark portfolios. We used two data sets, monthly and weekly data. The monthly data was from the years 1989-2011 and the weekly data was from the years 2000-2011. Empirical studies showed that risk parity portfolios provide better diversification since the diversification is made at the risk level. Risk based portfolios provided superior return compared to the asset based portfolios. Using tail risk measures in risk parity portfolios do not necessarily provide better hedge from tail events than standard deviation.

Externally excited synchronous machine: Testing the automation concept

This bachelor’s thesis is a part of the research project realized in the summer 2011 in Lappeenranta University of Technology. The goal of the project was to develop an automation concept for controlling the externally excited synchronous motor. Thesis concentrates on the testing planning and testing the system. Testing plan was made for three sectors: For the PLC program testing, for the communication testing and for the whole system testing. PLC program was tested with white box and destructive methods. Communication testing was done by switching maximum com-munication speed and checked if communication was reliable. Whole system testing included among other things speed and torque controlling. The system was tested with exploratory testing also. This enabled more reliable and broader testing than with systematical testing only.

Virtuaalimallin hyödyntäminen harvesteripään tuotekehityksessä

Virtuaalimallinnuksella tarkoitetaan koneen simulointia, jossa huomioidaan koneen mekaniikka, toimilaitteet ja ohjausjärjestelmä. Työn tavoitteena oli luoda virtuaalimalli harvesteripäästä. Kyseinen virtuaalimalli sisälsi harvesteripään tärkeimmät mekaaniset osat, pituusmittalaitteen hydrauliikkapiirin ja tämän ohjauksen. Luodussa virtuaalimallissa huomioitiin myös harvesteripään ja puun väliset kontaktit. Lisäksi työssä tutkittiin mahdollista virtuaalimallinnuksen implementoimista osaksi yrityksen tuotekehitysprosessia. Työssä suoritettiin verifiointimittaukset pituusmittalaitteen hydrauliikkapiirille sekä virtuaalimallin hydrauliikkakomponentit parametrisoitiin. Mittauksista saatuja tuloksia verrattiin virtuaalimallista saatuihin tuloksiin. Työssä esitellään myös ehdotus kuinka virtuaalimallinnusta kannattaisi hyödyntää osana yrityksen tuotekehitysprosessia. Virtuaalimallin eri osa-alueilla saavutetut tulokset osoittavat, että virtuaalimallinuksen hyödyntäminen tuotekehitysprosessin aikana mahdollistaa harvesteripään toimintojen tarkastelun ennen prototyypin rakentamista ja testaamista. Lisäksi hydrauliikkapiirin parametrisoimisella pystytään tutkimaan parametrien vaikutusta kokonaisuuteen.