Axis control optimization: autotuning techniques and frequency response analysis of industrial mechatronic systems

In the field of industrial automation, there is an increasing need to use optimal control systems that have low tracking errors and low power and energy consumption. The motors we are dealing with are mainly Permanent Magnet Synchronous Motors (PMSMs), controlled by 3 different types of controllers: a position controller, a speed controller, and a current controller. In this thesis, therefore, we are going to act on the gains of the first two controllers by going to find, through the TwinCAT 3 software, what might be the best set of parameters. To do this, starting with the default parameters recommended by TwinCAT, two main methods were used and then compared: the method of Ziegler and Nichols, which is a tabular method, and advanced tuning, an auto-tuning software method of TwinCAT. Therefore, in order to analyse which set of parameters was the best,several experiments were performed for each case, using the Motion Control Function Blocks. Moreover, some machines, such as large robotic arms, have vibration problems. To analyse them in detail, it was necessary to use the Bode Plot tool, which, through Bode plots, highlights in which frequencies there are resonance and anti-resonance peaks. This tool also makes it easier to figure out which and where to apply filters to improve control.

Integration of ROS for the control of industrial robotic systems in a proprietary environment

The paper deals with the integration of ROS, in the proprietary environment of the Marchesini Group company, for the control of industrial robotic systems. The basic tools of this open-source software are deeply studied to model a full proprietary Pick and Place manipulator inside it, and to develop custom ROS nodes to calculate trajectories; speaking of which, the URDF format is the standard to represent robots in ROS and the motion planning framework MoveIt offers user-friendly high-level methods. The communication between ROS and the Marchesini control architecture is established using the OPC UA standard; the tasks computed are transmitted offline to the PLC, supervisor controller of the physical robot, because the performances of the protocol don’t allow any kind of active control by ROS. Once the data are completely stored at the Marchesini side, the industrial PC makes the real robot execute a trajectory computed by MoveIt, so that it replicates the behaviour of the simulated manipulator in Rviz. Multiple experiments are performed to evaluate in detail the potential of ROS in the planning of movements for the company proprietary robots. The project ends with a small study regarding the use of ROS as a simulation platform. First, it is necessary to understand how a robotic application of the company can be reproduced in the Gazebo real world simulator. Then, a ROS node extracts information and examines the simulated robot behaviour, through the subscription to specific topics.

Industrial Demilitarized Zone and Zero Trust cybersecurity models for Industrial Control Systems

Today more than ever, with the recent war in Ukraine and the increasing number of attacks that affect systems of nations and companies every day, the world realizes that cybersecurity can no longer be considered just as a “cost”. It must become a pillar for our infrastructures that involve the security of our nations and the safety of people. Critical infrastructure, like energy, financial services, and healthcare, have become targets of many cyberattacks from several criminal groups, with an increasing number of resources and competencies, putting at risk the security and safety of companies and entire nations. This thesis aims to investigate the state-of-the-art regarding the best practice for securing Industrial control systems. We study the differences between two security frameworks. The first is Industrial Demilitarized Zone (I-DMZ), a perimeter-based security solution. The second one is the Zero Trust Architecture (ZTA) which removes the concept of perimeter to offer an entirely new approach to cybersecurity based on the slogan ‘Never Trust, always verify’. Starting from this premise, the Zero Trust model embeds strict Authentication, Authorization, and monitoring controls for any access to any resource. We have defined two architectures according to the State-of-the-art and the cybersecurity experts’ guidelines to compare I-DMZ, and Zero Trust approaches to ICS security. The goal is to demonstrate how a Zero Trust approach dramatically reduces the possibility of an attacker penetrating the network or moving laterally to compromise the entire infrastructure. A third architecture has been defined based on Cloud and fog/edge computing technology. It shows how Cloud solutions can improve the security and reliability of infrastructure and production processes that can benefit from a range of new functionalities, that the Cloud could offer as-a-Service.We have implemented and tested our Zero Trust solution and its ability to block intrusion or attempted attacks.

Design and Implementation of Single phase 230V to Three Phase Inverter Based on the Embedded System STM-32 Applied to motor control

In the field of Power Electronics, several types of motor control systems have been developed using STM microcontroller and power boards. In both industrial power applications and domestic appliances, power electronic inverters are widely used. Inverters are used to control the torque, speed, and position of the rotor in AC motor drives. An inverter delivers constant-voltage and constant-frequency power in uninterruptible power sources. Because inverter power supplies have a high-power consumption and low transfer efficiency rate, a three-phase sine wave AC power supply was created using the embedded system STM32, which has low power consumption and efficient speed. It has the capacity of output frequency of 50 Hz and the RMS of line voltage. STM32 embedded based Inverter is a power supply that integrates, reduced, and optimized the power electronics application that require hardware system, software, and application solution, including power architecture, techniques, and tools, approaches capable of performance on devices and equipment. Power inverters are currently used and implemented in green energy power system with low energy system such as sensors or microcontroller to perform the operating function of motors and pumps. STM based power inverter is efficient, less cost and reliable. My thesis work was based on STM motor drives and control system which can be implemented in a gas analyser for operating the pumps and motors. It has been widely applied in various engineering sectors due to its ability to respond to adverse structural changes and improved structural reliability. The present research was designed to use STM Inverter board on low power MCU such as NUCLEO with some practical examples such as Blinking LED, and PWM. Then we have implemented a three phase Inverter model with Steval-IPM08B board, which converter single phase 230V AC input to three phase 380 V AC output, the output will be useful for operating the induction motor.

Real-time PMU monitoring of an IEEE 5-Bus Network implemented on OPAL system

This thesis studies the state-of-the-art of phasor measurement units (PMUs) as well as their metrological requirements stated in the IEEE C37.118.1 and C37.118.2 Standards for guaranteeing correct measurement performances. Communication systems among PMUs and their possible applicability in the field of power quality (PQ) assessment are also investigated. This preliminary study is followed by an analysis of the working principle of real-time (RT) simulators and the importance of hardware-in-the-loop (HIL) implementation, examining the possible case studies specific for PMUs, including compliance tests which are one of the most important parts. The core of the thesis is focused on the implementation of a PMU model in the IEEE 5-bus network in Simulink and in the validation of the results using OPAL RT-4510 as a real-time simulator. An initial check allows one to get an idea about the goodness of the results in Simulink, comparing the PMU data with respect to the load-flow steady-state information. In this part, accuracy indices are also calculated for both voltage and current synchrophasors. The following part consists in the implementation of the same code in OPAL-RT 4510 simulator, after which an initial analysis is carried out in a qualitative way in order to get a sense of the goodness of the outcomes. Finally, the confirmation of the results is based on an examination of the attained voltage and current synchrophasors and accuracy indices coming from Simulink models and from OPAL system, using a Matlab script. This work also proposes suggestions for an upcoming operation of PMUs in a more complex system as the Digital Twin (DT) in order to improve the performances of the already-existing protection devices of the distribution system operator (DSO) for a future enhancement of power systems reliability.

Implementazione dell'algoritmo filtered back-projection (FBP) per architetture low-power di tipo systems-on-chip

Il presente lavoro di tesi, svolto presso i laboratori dell'X-ray Imaging Group del Dipartimento di Fisica e Astronomia dell'Università di Bologna e all'interno del progetto della V Commissione Scientifica Nazionale dell'INFN, COSA (Computing on SoC Architectures), ha come obiettivo il porting e l’analisi di un codice di ricostruzione tomografica su architetture GPU installate su System-On-Chip low-power, al fine di sviluppare un metodo portatile, economico e relativamente veloce. Dall'analisi computazionale sono state sviluppate tre diverse versioni del porting in CUDA C: nella prima ci si è limitati a trasporre la parte più onerosa del calcolo sulla scheda grafica, nella seconda si sfrutta la velocità del calcolo matriciale propria del coprocessore (facendo coincidere ogni pixel con una singola unità di calcolo parallelo), mentre la terza è un miglioramento della precedente versione ottimizzata ulteriormente. La terza versione è quella definitiva scelta perché è la più performante sia dal punto di vista del tempo di ricostruzione della singola slice sia a livello di risparmio energetico. Il porting sviluppato è stato confrontato con altre due parallelizzazioni in OpenMP ed MPI. Si è studiato quindi, sia su cluster HPC, sia su cluster SoC low-power (utilizzando in particolare la scheda quad-core Tegra K1), l’efficienza di ogni paradigma in funzione della velocità di calcolo e dell’energia impiegata. La soluzione da noi proposta prevede la combinazione del porting in OpenMP e di quello in CUDA C. Tre core CPU vengono riservati per l'esecuzione del codice in OpenMP, il quarto per gestire la GPU usando il porting in CUDA C. Questa doppia parallelizzazione ha la massima efficienza in funzione della potenza e dell’energia, mentre il cluster HPC ha la massima efficienza in velocità di calcolo. Il metodo proposto quindi permetterebbe di sfruttare quasi completamente le potenzialità della CPU e GPU con un costo molto contenuto. Una possibile ottimizzazione futura potrebbe prevedere la ricostruzione di due slice contemporaneamente sulla GPU, raddoppiando circa la velocità totale e sfruttando al meglio l’hardware. Questo studio ha dato risultati molto soddisfacenti, infatti, è possibile con solo tre schede TK1 eguagliare e forse a superare, in seguito, la potenza di calcolo di un server tradizionale con il vantaggio aggiunto di avere un sistema portatile, a basso consumo e costo. Questa ricerca si va a porre nell’ambito del computing come uno tra i primi studi effettivi su architetture SoC low-power e sul loro impiego in ambito scientifico, con risultati molto promettenti.