Study of Control Methods of a High-Frequency Cycloconverter for Domestic Induction Heating Appliances

A high-frequency cyclonverter acts as a direct ac-to-ac power converter circuit that does not require a diode bidge rectifier. Bridgeless topology makes it possible to remove forward voltage drop losses that are present in a diode bridge. In addition, the on-state losses can be reduced to 1.5 times the on-state resistance of switches in half-bridge operation of the cycloconverter. A high-frequency cycloconverter is reviewed and the charging effect of the dc-capacitors in ``back-to-back'' or synchronous mode operation operation is analyzed. In addition, a control method is introduced for regulating dc-voltage of the ac-side capacitors in synchronous operation mode. The controller regulates the dc-capacitors and prevents switches from reaching overvoltage level. This can be accomplished by variating phase-shift between the upper and the lower gate signals. By adding phase-shift between the gate signal pairs, the charge stored in the energy storage capacitors can be discharged through the resonant load and substantially, the output resonant current amplitude can be improved. The above goals are analyzed and illustrated with simulation. Theory is supported with practical measurements where the proposed control method is implemented in an FPGA device and tested with a high-frequency cycloconverter using super-junction power MOSFETs as switching devices.

Immersioultraäänitutkimuksen kehittäminen

Teräksenvalmistajilta edellytetään jatkuvasti panostusta laadun ja laadunvarmistuksen kehittämiseen. Teräksen laatu ja puhtaus korostuvat varsinkin silloin, kun terästä käytetään vaativiin käyttökohteisiin, kuten autoteollisuuden tarpeisiin. Ultraäänitarkastusmenetelmää käytetään laadun-varmistuksessa teräksen sisävikojen etsimiseen. Ultraäänitarkastuksessa lähetetään suuritaajuuksista ääntä kappaleeseen. Ääni etenee materiaalissa ja heijastuu erilaisista epäjatkuvuuskohdista. Luotaimeen palaavaa ääntä analysoimalla saadaan tietoa teräksestä ja sen sisävioista. Ultraäänitarkastuksen ongelmana on vian tyypin määrittäminen hankaluus sekä herkkyys tutkittavan materiaalin aineominaisuuksille. Työn tavoitteena oli immersioultraäänitarkastuksen kehittäminen sovellettuna teräksenvalmistajan tarpeisiin. Materiaalin aineominaisuuksista tutkittiin seostuksen vaikutusta. Teräslajit tarkastettiin valssitilaisena, karkaistuna ja normalisoituna. Lisäksi tutkittiin kappaleen pinnankarheuden ja -muodon vaikutusta tarkastukseen. Vikatyyppien tunnistamisen mahdollisuuksia ultra-äänitarkastuksessa selvitettiin käyttäen FFT- taajuusanalyysiä. Erilailla lämpökäsitellyillä teräslajeilla näytti eniten tuloksiin vaikuttavan terästen raekoko. Valssitilaisilla teräksillä raekoko on suuri, jolloin ultraääni vaimenee voimakkaasti teräksessä. Huomattavaa kuitenkin oli, että mikäli lämpö-käsittelyillä ei teräksen raekokoa saada juuri pienennettyä, ei myöskään vaimeneminen vähene. Tämän vuoksi lämpökäsittely ei välttämättä ole aina tarpeellinen valmisteltaessa ultraääninäytteitä. Fourier’n taajuusanalyysissä huomattiin olevan eroavaisuuksia verrattaessa huokosista ja sulkeumista palaavien kaikujen taajuusspektrejä. Näiden tulosten perusteella näyttäisi olevan mahdollista käyttää FFT- menetelmää ultraääni-tarkastuksessa vikojen luokitteluun.

Intrapartum hypoxia and power spectral analysis of fetal heart rate variability

Reliable detection of intrapartum fetal acidosis is crucial for preventing morbidity. Hypoxia-related changes of fetal heart rate variability (FHRV) are controlled by the autonomic nervous system. Subtle changes in FHRV that cannot be identified by inspection can be detected and quantified by power spectral analysis. Sympathetic activity relates to low-frequency FHRV and parasympathetic activity to both low- and high-frequency FHRV. The aim was to study whether intra partum fetal acidosis can be detected by analyzing spectral powers of FHRV, and whether spectral powers associate with hypoxia-induced changes in the fetal electrocardiogram and with the pH of fetal blood samples taken intrapartum. The FHRV of 817 R-R interval recordings, collected as a part of European multicenter studies, were analyzed. Acidosis was defined as cord pH ≤ 7.05 or scalp pH ≤ 7.20, and metabolic acidosis as cord pH ≤ 7.05 and base deficit ≥ 12 mmol/l. Intrapartum hypoxia increased the spectral powers of FHRV. As fetal acidosis deepened, FHRV decreased: fetuses with significant birth acidosis had, after an initial increase, a drop in spectral powers near delivery, suggesting a breakdown of fetal compensation. Furthermore, a change in excess of 30% of the low-to-high frequency ratio of FHRV was associated with fetal metabolic acidosis. The results suggest that a decrease in the spectral powers of FHRV signals concern for fetal wellbeing. A single measure alone cannot be used to reveal fetal hypoxia since the spectral powers vary widely intra-individually. With technical developments, continuous assessment of intra-individual changes in spectral powers of FHRV might aid in the detection of fetal compromise due to hypoxia.

Ultrasound-assisted electrochemical treatment of wastewaters containing organic pollutants by using novel Ti/Ta2O5-SnO2 electrodes

Advanced oxidation processes (AOPs) are modern methods using reactive hydroxyl radicals for the mineralization of organic pollutants into simple inorganic compounds, such as CO2 and H2O. Among AOPs electrochemical oxidation (EO) is a method suitable for coloured and turbid wastewaters. The degradation of pollutants occurs on electrocatalytic electrodes. The majority of electrodes contain in their structure either expensive materials (diamond and Pt-group metals) or are toxic for the environment compounds (Sb or Pb). One of the main disadvantages of electrochemical method is the polarization and contamination of electrodes due to the deposition of reaction products on their surface, which results in diminishing of the process efficiency. Ultrasound combined with the electrochemical degradation process eliminates electrode contamination because of the continuous mechanical cleaning effect produced by the formation and collapse of acoustic cavitation bubbles near to the electrode surface. Moreover, high frequency ultrasound generates hydroxyl radicals at water sonolysis. Ultrasound-assisted EO is a non-selective method for oxidation of different organic compounds with high degradation efficiencies. The aim of this research was to develop novel sustainable and cost-effective electrodes working as electrocatalysts and test their activity in electrocatalytic oxidation of organic compounds such as dyes and organic acids. Moreover, the goal of the research was to enhance the efficiency of electrocatalytic degradation processes by assisting it with ultrasound in order to eliminate the main drawbacks of a single electrochemical oxidation such as electrodes polarization and passivation. Novel Ti/Ta2O5-SnO2 electrodes were developed and found to be electrocatalytically active towards water (with 5% Ta content, 10 oxide film layers) and organic compounds oxidation (with 7.5% Ta content, 8 oxide film layers) and therefore these electrodes can be applicable in both environmental and energy fields. The synergetic effect of combined electrolysis and sonication was shown while conducting sonoelectrochemical (EO/US) degradation of methylene blue (MB) and formic acid (FA). Complete degradation of MB and FA was achieved after 45 and 120 min of EO/US process respectively in neutral media. Mineralization efficiency of FA over 95% was obtained after 2 h of degradation using high frequency ultrasound (381, 863, 1176 kHz) combined with 9.1 mA/cm2 current density. EO/US degradation of MB provided over 75% mineralization in 8 h. High degradation kinetic rates and mineralization efficiencies of model pollutants obtained in EO/US experiments provide the preconditions for further extrapolation of this treatment method to pilot scale studies with industrial wastewaters.

Analysis of Industrial Granular Flow Applications by Using Advanced Collision Models

Granular flow phenomena are frequently encountered in the design of process and industrial plants in the traditional fields of the chemical, nuclear and oil industries as well as in other activities such as food and materials handling. Multi-phase flow is one important branch of the granular flow. Granular materials have unusual kinds of behavior compared to normal materials, either solids or fluids. Although some of the characteristics are still not well-known yet, one thing is confirmed: the particle-particle interaction plays a key role in the dynamics of granular materials, especially for dense granular materials. At the beginning of this thesis, detailed illustration of developing two models for describing the interaction based on the results of finite-element simulation, dimension analysis and numerical simulation is presented. The first model is used to describing the normal collision of viscoelastic particles. Based on some existent models, more parameters are added to this model, which make the model predict the experimental results more accurately. The second model is used for oblique collision, which include the effects from tangential velocity, angular velocity and surface friction based on Coulomb's law. The theoretical predictions of this model are in agreement with those by finite-element simulation. I n the latter chapters of this thesis, the models are used to predict industrial granular flow and the agreement between the simulations and experiments also shows the validation of the new model. The first case presents the simulation of granular flow passing over a circular obstacle. The simulations successfully predict the existence of a parabolic steady layer and show how the characteristics of the particles, such as coefficients of restitution and surface friction affect the separation results. The second case is a spinning container filled with granular material. Employing the previous models, the simulation could also reproduce experimentally observed phenomena, such as a depression in the center of a high frequency rotation. The third application is about gas-solid mixed flow in a vertically vibrated device. Gas phase motion is added to coherence with the particle motion. The governing equations of the gas phase are solved by using the Large eddy simulation (LES) and particle motion is predicted by using the Lagrangian method. The simulation predicted some pattern formation reported by experiment.

Designing Digital Filters for Servo Systems

The aim of this work was to select an appropriate digital filter for a servo application and to filter the noise from the measurement devices. Low pass filter attenuates the high frequency noise beyond the specified cut-off frequency. Digital lowpass filters in both IIR and FIR responses were designed and experimentally compared to understand their characteristics from the corresponding step responses of the system. Kaiser Windowing and Equiripple methods were selected for FIR response, whereas Butterworth, Chebyshev, InverseChebyshev and Elliptic methods were designed for IIR case. Limitations in digital filter design for a servo system were analysed. Especially the dynamic influences of each designed filter on the control stabilityof the electrical servo drive were observed. The criterion for the selection ofparameters in designing digital filters for servo systems was studied. Control system dynamics was given significant importance and the use of FIR and IIR responses in different situations were compared to justify the selection of suitableresponse in each case. The software used in the filter design was MatLab/Simulink® and dSPACE's DSP application. A speed controlled Permanent Magnet Linear synchronous Motor was used in the experimental work.

Kylmämuokatun austeniittisen ruostumattoman teräsputkipalkin hitsaus

Diplomityön tavoitteena on selvittää kylmälujitetusta austeniittisesta ruostumattomasta teräksestä valmistettavan putkipalkin pituussuunnassa hitsaamalla tapahtuvaa valmistusta. Työssä tarkastellaan eri hitsausprosessien lämmöntuonnin ja putkipalkin kylmämuovaamalla tapahtuvan valmistuksen ja hitsin jälkikäsittelynvaikutuksia putkipalkin pituushitsin mekaanisiin ominaisuuksiin. Teoriaosassa on perehdytty austeniittisen ruostumattoman teräksen hitsaukseen, kylmämuokkaamalla lujitetun teräksen käyttäytymiseen hitsauksessa, monipoltinkaari-, TIG-suurtaajuuspulssi- ja kaariavusteiseen laserhitsaukseen. Kokeellisessa osassaon suoritettu koehitsauksia edellä mainituilla menetelmillä kylmälujitetulle austeniittiselle ruostumattomalle teräkselle ja suoritettu saatujen koehitsien mekaanisien ominaisuuksien arviointia. Saatujen koetulosten perusteella ontodettu, että huolimatta hitsauksen lämmöntuonnin kylmämuokatun teräksen lujuusarvoja alentavasta vaikutuksesta on mahdollista valmistaa hitsin osalta perusaineen lujuusluokituksen täyttäviä putkipalkkeja. Tämä johtuu putkipalkin kylmämuovaamalla tapahtuvan valmistuksen ja hitsin jälkikäsittelyn hitsauksessa pehmentyneen vyöhykkeen lujuusarvoja takaisin perusaineen tasolle palauttavasta vaikutuksesta.

Koivun HFV-kuivauksen kustannusvaikutukset

Työn tavoitteena on ollut selvittää HFV-kuivauksen taloudellisia vaikutuksia, kuivausmenetelmän toimintaperiaatteita, ominaisuuksia ja Lahden ammattikorkeakoulun Tekniikan laitoksen kuivaustutkimuksesta saatuja tuloksia. Tutkimuskohteeksi on valittu sydänkeskeinen koivu, joka soveltuu erinomaisesti uuden kuivausmenetelmän raaka-aineeksi, sillä sen hankintakustannukset muodostuvat tavanomaista koivusahatavaraa alhaisemmaksi ja sillä saavutetaan raaka-aineen jatkojalostusarvon huomattava nousu. Työn teoriaosassa on käsitelty puun kuivausta, sen yleisiä piirteitä ja erikuivausvaihtoehtoja. Koivun kuivauksesta ja kuivauskustannuksista löytyy varsinvähän julkaistua tutkimustietoa, jonka johdosta kuivauskustannuksia kartoitettiin myös kotimaisten havupuiden osalta. Tuoreen koivun kuivaus muutamassa tunnissa puusepänkuivaksi aihioksi ilman kuivausvirheitä on Lahden ammattikorkeakoulun Tekniikan laitoksen tutkimuksissa saatujen tuloksien mukaan mahdollista. Tässä tutkimuksessa on käsitelty neljän eri teholuokan kuivaamoinvestointivaihtoehtoa. Vaihtoehdot poikkeavat toisistaan niin hankintahinnan, tuotantokapasiteetin kuinvalmistuskustannuksienkin suhteen. Mikäli kuivaamon tuotantokapasiteetti ei olemääräävä tekijä ja investoinnilla ei ole pääomarajoitetta, niin kannattavimmaksi investointivaihtoehdoksi osoittautuu suurimman kokoluokan HFV-kuivaamolaitteisto.

Improving Dynamic Characteristics of Open-loop Controlled Log Crane

The improvement of the dynamics of flexible manipulators like log cranes often requires advanced control methods. This thesis discusses the vibration problems in the cranes used in commercial forestry machines. Two control methods, adaptive filtering and semi-active damping, are presented. The adaptive filter uses a part of the lowest natural frequency of the crane as a filtering frequency. The payload estimation algorithm, filtering of control signal and algorithm for calculation of the lowest natural frequency of the crane are presented. The semi-active damping method is basedon pressure feedback. The pressure vibration, scaled with suitable gain, is added to the control signal of the valve of the lift cylinder to suppress vibrations. The adaptive filter cuts off high frequency impulses coming from the operatorand semi-active damping suppresses the crane?s oscillation, which is often caused by some external disturbance. In field tests performed on the crane, a correctly tuned (25 % tuning) adaptive filter reduced pressure vibration by 14-17 % and semi-active damping correspondingly by 21-43%. Applying of these methods require auxiliary transducers, installed in specific points in the crane, and electronically controlled directional control valves.

Applicability of Power-Line Communications to Data Transfer of On-line Condition Monitoring of Electrical Drives

The research of power-line communications has been concentrated on home automation, broadband indoor communications and broadband data transfer in a low voltage distribution network between home andtransformer station. There has not been carried out much research work that is focused on the high frequency characteristics of industrial low voltage distribution networks. The industrial low voltage distribution network may be utilised as a communication channel to data transfer required by the on-line condition monitoring of electric motors. The advantage of using power-line data transfer is that it does not require the installing of new cables. In the first part of this work, the characteristics of industrial low voltage distribution network components and the pilot distribution network are measured and modelled with respect topower-line communications frequencies up to 30 MHz. The distributed inductances, capacitances and attenuation of MCMK type low voltage power cables are measured in the frequency band 100 kHz - 30 MHz and an attenuation formula for the cables is formed based on the measurements. The input impedances of electric motors (15-250 kW) are measured using several signal couplings and measurement based input impedance model for electric motor with a slotted stator is formed. The model is designed for the frequency band 10 kHz - 30 MHz. Next, the effect of DC (direct current) voltage link inverter on power line data transfer is briefly analysed. Finally, a pilot distribution network is formed and signal attenuation in communication channels in the pilot environment is measured. The results are compared with the simulations that are carried out utilising the developed models and measured parameters for cables and motors. In the second part of this work, a narrowband power-line data transfer system is developed for the data transfer ofon-line condition monitoring of electric motors. It is developed using standardintegrated circuits. The system is tested in the pilot environment and the applicability of the system for the data transfer required by the on-line condition monitoring of electric motors is analysed.

Ruostumattoman teräksen TIG-hitsauksen hitsausnopeuden lisääminen

Diplomityön tavoitteena oli ruostumattoman teräksen koneellisen TIG-hitsauksen hitsausnopeuden lisääminen. Työssä tutkittiin suojakaasun koostumuksen vaikutusta hitsausnopeuteen sekä kahta uudehkoa prosessivariaatiota. Tutkitut prosessit olivat TIG-suurtaajuuspulssihitsaus sekä kaksoiskaasu-TIG-hitsaus. Kirjallisessa osassa perehdyttiin TIG-hitsauksen prosessiparametreihin ja -variaatioihin. Kokeellisessa osassa suoritettiin koehitsauksia hitsausnopeuksien selvittämiseksi. Tavoitteena oli tunkeuman kasvattaminen, mikä mahdollistaa hitsausnopeuden noston läpihitsattaessa. Suojakaasuina käytettiin sekä argonpohjaisia että heliumpohjaisia kaasuja, joihin oli lisätty vetyä. Vedyn avulla hitsausnopeus lisääntyi nykykäytäntöä suuremmillakin pitoisuuksilla. Uutena ilmiönä TIG-hitsauksessa havaittiin keyholen eli lävistysreiän syntyminen korkeita vetypitoisuuksia heliumpohjaisessa suojakaasussa käytettäessä. Keyhole oli kuitenkin erittäin epävakaa, joten jatkotutkimuksien tehtäväksi jää selvittää tarkemmin tämän ilmiön vaikutus. Tutkittuihin prosessivariaatioihin todettiin liittyvän useita laiteteknisiä ongelmia. Hitsausnopeuden suhteen tulokset jäivät vaatimattomiksi. Lähinnä keyholen aukaisemisessa ja aukipitämisessä menetelmistä havaittu hyöty antaa selvän aiheen jatkotutkimuksille.

Reconstruction and analysis of surface variation using photometric stereo

In many industrial applications, accurate and fast surface reconstruction is essential for quality control. Variation in surface finishing parameters, such as surface roughness, can reflect defects in a manufacturing process, non-optimal product operational efficiency, and reduced life expectancy of the product. This thesis considers reconstruction and analysis of high-frequency variation, that is roughness, on planar surfaces. Standard roughness measures in industry are calculated from surface topography. A fast and non-contact method to obtain surface topography is to apply photometric stereo in the estimation of surface gradients and to reconstruct the surface by integrating the gradient fields. Alternatively, visual methods, such as statistical measures, fractal dimension and distance transforms, can be used to characterize surface roughness directly from gray-scale images. In this thesis, the accuracy of distance transforms, statistical measures, and fractal dimension are evaluated in the estimation of surface roughness from gray-scale images and topographies. The results are contrasted to standard industry roughness measures. In distance transforms, the key idea is that distance values calculated along a highly varying surface are greater than distances calculated along a smoother surface. Statistical measures and fractal dimension are common surface roughness measures. In the experiments, skewness and variance of brightness distribution, fractal dimension, and distance transforms exhibited strong linear correlations to standard industry roughness measures. One of the key strengths of photometric stereo method is the acquisition of higher frequency variation of surfaces. In this thesis, the reconstruction of planar high-frequency varying surfaces is studied in the presence of imaging noise and blur. Two Wiener filterbased methods are proposed of which one is optimal in the sense of surface power spectral density given the spectral properties of the imaging noise and blur. Experiments show that the proposed methods preserve the inherent high-frequency variation in the reconstructed surfaces, whereas traditional reconstruction methods typically handle incorrect measurements by smoothing, which dampens the high-frequency variation.

Hybrid LC Filter for Power Electronic Drives: Theory and Implementation

Power electronic converter drives use, for the sake of high efficiency, pulse-width modulation that results in sequences of high-voltage high-frequency steep-edged pulses. Such a signal contains a set of high harmonics not required for control purposes. Harmonics cause reflections in the cable between the motor and the inverter leading to faster winding insulation ageing. Bearing failures and problems with electromagnetic compatibility may also result. Electrical du/dt filters provide an effective solution to problems caused by pulse-width modulation, thereby increasing the performance and service life of the electrical machines. It is shown that RLC filters effectively decrease the reflection phenomena in the cable. Improved (simple, but effective) solutions are found for both differential- and common-mode signals; these solutions use a galvanic connection between the RLC filter star point and the converter DC link. Foil chokes and film capacitors are among the most widely used components in high-power applications. In actual applications they can be placed in different parts of the cabinet. This fact complicates the arrangement of the cabinet and decreases the reliability of the system. In addition, the inductances of connection wires may prevent filtration at high frequencies. This thesis introduces a new hybrid LC filter that uses a natural capacitance between the turns of the foil choke based on integration of an auxiliary layer into it. The main idea of the hybrid LC filter results from the fact that both the foil choke and the film capacitors have the same roll structure. Moreover, the capacitance between the turns (“intra capacitance”) of the foil inductors is the reason for the deterioration of their properties at high frequencies. It is shown that the proposed filter has a natural cancellation of the intra capacitance. A hybrid LC filter may contain two or more foil layers isolated from each other and coiled on a core. The core material can be iron or even air as in the filter considered in this work. One of the foils, called the main foil, can be placed between the inverter and the motor cable. Other ones, called auxiliary foils, may be connected in star to create differential-mode noise paths, and then coupled to the DC link midpoint to guarantee a traveling path, especially for the common-mode currents. This way, there is a remarkable capacitance between the main foil and the auxiliary foil. Investigations showed that such a system can be described by a simple equivalent LC filter in a wide range of frequencies. Because of its simple hybrid construction, the proposed LC filter can be a cost-effective and competitive solution for modern power drives. In the thesis, the application field of the proposed filter is considered and determined. The basics of hybrid LC filter design are developed further. High-frequency behaviour of the proposed filter is analysed by simulations. Finally, the thesis presents experimental data proving that the hybrid LC filter can be used for du/dt of PWM pulses and reduction of common-mode currents.

Tasasähkönjakeluverkon vaihtosuuntaaja galvaanisella erotuksella

Suomessa sähkönjakeluverkko koostuu pääasiassa 20 kV ja 400 V jännitetasoista. Tällöin sähkö viedään lähelle kuluttajia suuremmalla jännitetasolla ja muunnetaan alhaisemmaksi lähellä asiakkaita. Haittapuolena on se, että haja-asutusalueilla jakelumuuntajien määrä kasvaa suureksi, koska ne täytyy sijoittaa lähelle kuluttajaa. Vaihtoehtona on toteuttaa osa sähkönjakelusta tasajännitteellä, jolloin tehollinen jännite olisi suurempi. Tällöin sähköä voitaisiin siirtää pidempiä matkoja ilman, että asiakaskohtaisia tai muutaman asiakkaan kattavia 20 kV siirtolinjoja tarvitsisi käyttää. Tämä taasen edellyttää asiakaskohtaisien vaihtosuuntaajien käyttöä. Tässä työssä esiteltävällä 1 kVA vaihtosuuntaajalla muodostetaan tasasähköjakeluverkosta saatavasta 750 V tasasähköstä yksivaiheista (230 VRMS, 50 Hz) verkkojännitettä. Laite on suunniteltu toteuttamaan galvaaninen erotus mahdollisimman hyvän hyötysuhteen puitteissa. Vaihtosuuntaaja on toteutettu käyttämällä resonanssikonvertteria, joka vaihtosuuntaa jakelujännitteen korkeataajuiseksi vaihtojännitteeksi. Tämän jälkeen toteutetaan galvaaninen erotus käyttäen suurtaajuusmuuntajaa. Tätä seuraa syklokonvertteri, joka pulssintiheysmodulaatiota soveltaen muodostaa lähtöjännitteen. Tämä suodatetaan lopuksi LC- alipäästösuotimella säröltään standardin mukaiseksi. Laite on jaettu työssä kolmeen osaan, joista jokaisen toiminta on selitetty ja simuloitu itsenäisesti. Lopussa koko järjestelmä on simuloitu yhtenä kokonaisuutena. Hyötysuhteeksi arvioitiin karkeasti 94 % ja lopullisista tuloksista voidaan päätellä, että laitteen toteuttaminen prototyypiksi voisi olla kannattavaa.