Analysis and development of interface components and procedures for the design and commissioning toolchains in automation systems

The objective of the thesis project, developed within the Line Control & Software Engineering team of G.D company, is to analyze and identify the appropriate tool to automate the HW configuration process using Beckhoff technologies by importing data from an ECAD tool. This would save a great deal of time, since the I/O topology created as part of the electrical planning is presently imported manually in the related SW project of the machine. Moreover, a manual import is more error-prone because of human mistake than an automatic configuration tool. First, an introduction about TwinCAT 3, EtherCAT and Automation Interface is provided; then, it is analyzed the official Beckhoff tool, XCAD Interface, and the requirements on the electrical planning to use it: the interface is realized by means of the AutomationML format. Finally, due to some limitations observed, the design and implementation of a company internal tool is performed. Tests and validation of the tool are performed on a sample production line of the company.

Ingegnerizzazione e design di nanoparticelle core-shell di magnetite/silice

In the past decade the study of superparamagnetic nanoparticles has been intensively developed for many biomedical applications such as magnetically assisted drug delivery, MRI contrast agents, cells separation and hyperthermia therapy. All of these applications require nanoparticles with high magnetization, equipped also with a suitable surface coating which has to be non-toxic and biocompatible. In this master thesis, the silica coating of commercially available magnetic nanoparticles was investigated. Silica is a versatile material with many intrinsic features, such as hydrophilicity, low toxicity, proper design and derivatization yields particularly stable colloids even in physiological conditions. The coating process was applied to commercial magnetite particles dispersed in an aqueous solution. The formation of silica coated magnetite nanoparticles was performed following two main strategies: the Stöber process, in which the silica coating of the nanoparticle was directly formed by hydrolysis and condensation of suitable precursor in water-alcoholic mixtures; and the reverse microemulsions method in which inverse micelles were used to confine the hydrolysis and condensation reactions that bring to the nanoparticles formation. Between these two methods, the reverse microemulsions one resulted the most versatile and reliable because of the high control level upon monodispersity, silica shell thickness and overall particle size. Moving from low to high concentration, within the microemulsion region a gradual shift from larger particles to smaller one was detected. By increasing the amount of silica precursor the silica shell can also be tuned. Fluorescent dyes have also been incorporated within the silica shell by linking with the silica matrix. The structure of studied nanoparticles was investigated by using transmission electron microscope (TEM) and dynamic light scattering (DLS). These techniques have been used to monitor the syntetic procedures and for the final characterization of silica coated and silica dye doped nanoparticles. Finally, field dependent magnetization measurements showed the magnetic properties of core-shell nanoparticles were preserved. Due to a very well defined structure that combines magnetic and luminescent properties together with the possibility of further functionalization, these multifunctional nanoparticles are potentially useful platforms in biomedical fields such as labeling and imaging.

Application of the Equivalent Static Analysis method to the design of a steel frame structure with added viscous dampers

All the structures designed by engineers are vulnerable to natural disasters including floods and earthquakes. The energy released during strong ground motions should be dissipated by structural elements. Before 1990’s, this energy was expected to be dissipated through the beams and columns which at the same time were a part of gravity-load-resisting system. However, the main disadvantage of this idea was that gravity-resisting-frame was not repairable. Hence, during 1990’s, the idea of designing passive energy dissipation systems, including dampers, emerged. At the beginning, main problem was lack of guidelines for passive energy dissipation systems. Although till 2000 many guidelines and procedures where published, yet most of them were based on complicated analysis which was not so convenient for engineers and practitioners. In order to solve this problem recently some alternative design methods are proposed including 1. Lopez Garcia (2001) simple procedure for optimal damper configuration in MDOF structures 2. Christopoulos and Filiatrault (2006) trial and error procedure 3. Silvestri et al. (2010) Five-Step Method. 4. Palermo et al. (2015) Direct Five-Step Method. 5. Palermo et al. (2016) Simplified Equivalent Static Analysis (ESA). In this study, effectiveness and differences between last three alternative methods have been evaluated.

Design of an innovative electric vehicle simulator for Charging Systems' End-of-Line Testing

The trend related to the turnover of internal combustion engine vehicles with EVs goes by the name of electrification. The push electrification experienced in the last decade is linked to the still ongoing evolution in power electronics technology for charging systems. This is the reason why an evolution in testing strategies and testing equipment is crucial too. The project this dissertation is based on concerns the investigation of a new EV simulator design. that optimizes the structure of the testing equipment used by the company who commissioned this work. Project requirements can be summarized in the following two points: space occupation reduction and parallel charging implementation. Some components were completely redesigned, and others were substituted with equivalent ones that could perform the same tasks. In this way it was possible to reduce the space occupation of the simulator, as well as to increase the efficiency of the testing device. Moreover, the possibility of conjugating different charging simulations could be investigated by parallelly launching two testing procedures on a unique machine, properly predisposed for supporting the two charging protocols used. On the back of the results achieved in the body of this dissertation, a new design for the EV simulator was proposed. In this way, space reduction was obtained, and space occupation efficiency was improved with the proposed new design. The testing device thus resulted to be way more compact, enabling to gain in safety and productivity, along with a 25% cost reduction. Furthermore, parallel charging was implemented in the proposed new design since the conducted tests clearly showed the feasibility of parallel charging sessions. The results presented in this work can thus be implemented to build the first prototype of the new EV simulator.

Design and implementation of a synchronous interleaved boost converter for fuel cell-powered catamaran

The present work describes the different stages of design, implementation, and validation procedures for an interleaved DC-DC boost converter intended for the 2022 Futura, a fuel cell-powered racing catamaran developed by the UniBoAT team. The main goal of the entire design has been the significant reduction of the weight of the converter by removing heat sinks and reducing component size while increasing its efficiency by adopting high-end power switches and the interleaved architecture operated with a synchronous control strategy. The obtained converter has been integrated into the structure containing the fuel cell stack obtaining a fully integrated system. The realized device has been based on an interleaved architecture with six phases controlled digitally through the average current mode control. The design has been validated through simulations carried out using the software LT-Spice, whereas experimental validations have been performed by means of laboratory bench tests and on-field tests. Detailed thermal and efficiency analyses are provided with the bench tests under the two synchronous and non-synchronous operating modes and with the adoption of the phase shedding technique. The prototype implementation and its performance in real operating conditions are also discussed. Eventually, it is underlined as the designed converter can be used in other applications requiring a voltage-controlled boost converter.