Modeling, Component Selection and Optimization of Servo-controlled Automatic Machinery

A servo-controlled automatic machine can perform tasks that involve synchronized actuation of a significant number of servo-axes, namely one degree-of-freedom (DoF) electromechanical actuators. Each servo-axis comprises a servo-motor, a mechanical transmission and an end-effector, and is responsible for generating the desired motion profile and providing the power required to achieve the overall task. The design of a such a machine must involve a detailed study from a mechatronic viewpoint, due to its electric and mechanical nature. The first objective of this thesis is the development of an overarching electromechanical model for a servo-axis. Every loss source is taken into account, be it mechanical or electrical. The mechanical transmission is modeled by means of a sequence of lumped-parameter blocks. The electric model of the motor and the inverter takes into account winding losses, iron losses and controller switching losses. No experimental characterizations are needed to implement the electric model, since the parameters are inferred from the data available in commercial catalogs. With the global model at disposal, a second objective of this work is to perform the optimization analysis, in particular, the selection of the motor-reducer unit. The optimal transmission ratios that minimize several objective functions are found. An optimization process is carried out and repeated for each candidate motor. Then, we present a novel method where the discrete set of available motor is extended to a continuous domain, by fitting manufacturer data. The problem becomes a two-dimensional nonlinear optimization subject to nonlinear constraints, and the solution gives the optimal choice for the motor-reducer system. The presented electromechanical model, along with the implementation of optimization algorithms, forms a complete and powerful simulation tool for servo-controlled automatic machines. The tool allows for determining a wide range of electric and mechanical parameters and the behavior of the system in different operating conditions.

Ship performance modelling for least-CO2 emission routes

Decarbonization of maritime transport requires immediate action. In the short term, ship weather routing can provide greenhouse gas emission reductions, even for existing ships and without retrofitting them. Weather routing is based on making optimal use of both envi- ronmental information and knowledge about vessel seakeeping and performance. Combining them at a state-of-the-art level and making use of path planning in realistic conditions can be challenging. To address these topics in an open-source framework, this thesis led to the development of a new module called bateau , and to its combination with the ship routing model VISIR. bateau includes both hull geometry and propulsion modelling for various vessel types. It has two objectives: to predict the sustained speed in a seaway and to estimate the CO2 emission rate during the voyage. Various semi-empirical approaches were used in bateau to predict the ship hydro- and aerodynamical resistance in both head and oblique seas. Assuming that the ship sails at a constant engine load, the involuntary speed loss due to waves was estimated. This thesis also attempted to clarify the role played by the actual representation of the sea state. In particular, the influence of the wave steepness parameter was assessed. For dealing with ships with a greater superstructure, the wind added resistance was also estimated. Numerical experiments via bateau were conducted for both a medium and a large-size container ships, a bulk-carrier, and a tanker. The simulations of optimal routes were carried out for a feeder containership during voyages in the North Indian Ocean and in the South China Sea. Least-CO2 routes were compared to the least-distance ones, assessing the relative CO2 savings. Analysis fields from the Copernicus Marine Service were used in the numerical experiments.