Design and specification of a modular automatic testing solution

Electric vehicles and electronic components inside the vehicle are becoming increasingly important. The software as well starts to have a significant impact on modern high-end cars therefore a careful validation process needs to be implemented with the aim of having a bug free product when it is released. The software complexity increases and thus also the testing phases is more demanding. Test can be troublesome and, in some cases, boring and easy. The intelligence can be moved in test definition and writing rather than on test execution. The aim of this document is to start the definition of an automatic modular testing system capable to execute test cycles on systems that interacts with the CAN networks and with DUT that can be touched with a robotic arm. The document defines a first version of the system, in particular the hardware interface part with the aim of taking logs and execute test in an automated fashion with the test engineer can have a higher focus on the test definition and analysis rather than execution.

Design and implementation of a vibrational condition monitoring system

Industrial companies, particularly those with induction motors and gearboxes as integral components of their systems, are utilizing Condition Monitoring (CM) systems more frequently in order to discover the need for maintenance in advance, as traditional maintenance only performs tasks when a failure has been identified. Utilizing a CM system is essential to boost productivity and minimize long-term failures that result in financial loss. The more exact and practical the CM system, the better the data analysis, which adds to a more precise maintenance forecast. This thesis project is a cooperation with PEI Vibration Monitoring s.r.l. to design and construct a low-cost vibrational condition monitoring system to check the health of induction motors and gearboxes automatically. Moreover, according to the company's request, such a system should have specs comparable to NI 9234, one of the company's standard Data Acquisition (DAQ) boards, but at a significantly cheaper price. Additionally, PEI VM Company has supplied all hardware and electronic components. The suggested CM system is capable of highprecision autonomous monitoring of induction motors and gearboxes, and it consists of a Raspberry Pi 3B and MCC 172 DAQ board.

Calibration of design strength values of Wire and Arc Additive Manufacturing inclined bars and intersections

Although being studied only for few years, Wire and Arc Additive Manufacturing (WAAM) will become the predominant way of producing stainless-steel elements in a near-like future. The analysis and study of such elements has yet to be defined in a proper way, but the projects regarding this subject are innovating more and more thanks to the findings discovered by the latter. This thesis is focused on an initial stage on the analysis of mechanical and geometrical properties of such stainless-steel elements produced by MX3D laboratories in Amsterdam, and to perform a calibration of the design strength values by means of Annex D of Eurocode 0, which talks about the analysis of the semi-probabilistic safety factors, hence the definition of characteristic values. Moreover, after testing the stainless-steel specimens by means of strain gauges and after obtaining mechanical and geometrical properties, a statistical analysis of such properties and an evaluation of characteristic values is performed. After this, there is to execute the calibration of design strength values of WAAM inclined bars and intersections.

Design and management of a supply chain: a joint location-inventory problem under uncertainty (Part B)

In recent years, global supply chains have increasingly suffered from reliability issues due to various external and difficult to-manage events. The following paper aims to build an integrated approach for the design of a Supply Chain under the risk of disruption and demand fluctuation. The study is divided in two parts: a mathematical optimization model, to identify the optimal design and assignments customer-facility, and a discrete-events simulation of the resulting network. The first one describes a model in which plant location decisions are influenced by variables such as distance to customers, investments needed to open plants and centralization phenomena that help contain the risk of demand variability (Risk Pooling). The entire model has been built with a proactive approach to manage the risk of disruptions assigning to each customer two types of open facilities: one that will serve it under normal conditions and a back-up facility, which comes into operation when the main facility has failed. The study is conducted on a relatively small number of instances due to the computational complexity, a matheuristic approach can be found in part A of the paper to evaluate the problem with a larger set of players. Once the network is built, a discrete events Supply Chain simulation (SCS) has been implemented to analyze the stock flow within the facilities warehouses, the actual impact of disruptions and the role of the back-up facilities which suffer a great stress on their inventory due to a large increase in demand caused by the disruptions. Therefore, simulation follows a reactive approach, in which customers are redistributed among facilities according to the interruptions that may occur in the system and to the assignments deriving from the design model. Lastly, the most important results of the study will be reported, analyzing the role of lead time in a reactive approach for the occurrence of disruptions and comparing the two models in terms of costs.

A new concept for a Sport-Coupè car developed with the Industrial Design Structure method (IDeS)

The aim of this study, conducted in collaboration with Lawrence Technological University in Detroit, is to create, through the method of the Industrial Design Structure (IDeS), a new concept for a sport-coupe car, based on a restyling of a retro model (Ford Mustang 1967). To date, vintage models of cars always arouse great interest both for the history behind them and for the classic and elegant style. Designing a model of a vehicle that can combine the charm of retro style with the innovation and comfort of modern cars would allow to meet the needs and desires of a large segment of the market that today is forced to choose between past and future. Thanks to a well-conceived concept car an automaker company is able to express its future policy, to make a statement of intent as, such a prototype, ticks all the boxes, from glamour and visual wow-factor to technical intrigue and design fascination. IDeS is an approach that makes use of many engineering tools to realize a study developed on several steps that must be meticulously organized and timed. With a deep analysis of the trends dominating the automotive industry it is possible to identify a series of product requirements using quality function deployment (QFD). The considerations from this first evaluation led to the definition of the technical specifications via benchmarking (BM) and top-flop analysis (TFA). Then, the structured methodology of stylistic design engineering (SDE) is applied through six phases: (1) stylistic trends analysis; (2) sketches; (3) 2D CAD drawings; (4) 3D CAD models; (5) virtual prototyping; (6) solid stylistic model. Finally, Developing the IDeS method up to the final stages of Prototypes and Testing you get a product as close as possible to the ideal vehicle conceptualized in the initial analysis.

Design and Performance Analysis of the Electrical Power System of a Petrochemical Facility

This thesis deals with the sizing and analysis of the electrical power system of a petrochemical plant. The activity was carried out in the framework of an electrical engineering internship. The sizing and electrical calculations, as well as the study of the dynamic behavior of network quantities, are accomplished by using the ETAP (Electrical Transient Analyzer Program) software. After determining the type and size of the loads, the calculation of power flows is carried out for all possible network layout and different power supply configurations. The network is normally operated in a double radial configuration. However, the sizing must be carried out taking into account the most critical configuration, i.e., the temporary one of single radial operation, and also considering the most unfavorable power supply conditions. The calculation of shortcircuit currents is then carried out and the appropriate circuit breakers are selected. Where necessary, capacitor banks are sized in order to keep power factor at the point of common coupling within the preset limits. The grounding system is sized by using the finite element method. For loads with the highest level of criticality, UPS are sized in order to ensure their operation even in the absence of the main power supply. The main faults that can occur in the plant are examined, determining the intervention times of the protections to ensure that, in case of failure on one component, the others can still properly operate. The report concludes with the dynamic and stability analysis of the power system during island operation, in order to ensure that the two gas turbines are able to support the load even during transient conditions.

Data analysis and hydrological modelling of rainfall and discharge extremes along the Tione River: implications for the design of water structures

There are many natural events that can negatively affect the urban ecosystem, but weather-climate variations are certainly among the most significant. The history of settlements has been characterized by extreme events like earthquakes and floods, which repeat themselves at different times, causing extensive damage to the built heritage on a structural and urban scale. Changes in climate also alter various climatic subsystems, changing rainfall regimes and hydrological cycles, increasing the frequency and intensity of extreme precipitation events (heavy rainfall).  From an hydrological risk perspective, it is crucial to understand future events that could occur and their magnitude in order to design safer infrastructures. Unfortunately, it is not easy to understand future scenarios as the complexity of climate is enormous.  For this thesis, precipitation and discharge extremes were primarily used as data sources. It is important to underline that the two data sets are not separated: changes in rainfall regime, due to climate change, could significantly affect overflows into receiving water bodies. It is imperative that we understand and model climate change effects on water structures to support the development of adaptation strategies.   The main purpose of this thesis is to search for suitable water structures for a road located along the Tione River. Therefore, through the analysis of the area from a hydrological point of view, we aim to guarantee the safety of the infrastructure over time.   The observations made have the purpose to underline how models such as a stochastic one can improve the quality of an analysis for design purposes, and influence choices.