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.

Isolated electrical microgrids employing renewable energy resources:analysis of the electrification of remote communities in Peru.

This project points out a brief overview of several concepts, as Renewable Energy Resources, Distributed Energy Resources, Distributed Generation, and describes the general architecture of an electrical microgrid, isolated or connected to the Medium Voltage Network. Moreover, the project focuses on a project carried out by GRECDH Department in collaboration with CITCEA Department, both belonging to Universitat Politécnica de Catalunya: it concerns isolated microgrids employing renewable energy resources in two communities in northern Peru. Several solutions found using optimization software regarding different generation systems (wind and photovoltaic) and different energy demand scenarios are commented and analyzed from an electrical point of view. Furthermore, there are some proposals to improve microgrid performances, in particular to increase voltage values for each load connected to the microgrid. The extra costs required by the proposed solutions are calculated and their effect on the total microgrid cost are taken into account; finally there are some considerations about the impact the project has on population and on people's daily life.

Whole ship energy optimization: the case study of a chemical tanker

La presente dissertazione investiga la possibilità di ottimizzare l’uso di energia a bordo di una nave per trasporto di prodotti chimici e petrolchimici. Il software sviluppato per questo studio può essere adattato a qualsiasi tipo di nave. Tale foglio di calcolo fornisce la metodologia per stimare vantaggi e miglioramenti energetici, con accuratezza direttamente proporzionale ai dati disponibili sulla configurazione del sistema energetico e sui dispositivi installati a bordo. Lo studio si basa su differenti fasi che permettono la semplificazione del lavoro; nell’introduzione sono indicati i dati necessari per svolgere un’accurata analisi ed è presentata la metodologia adottata. Inizialmente è fornita una spiegazione sul layout dell’impianto, sulle sue caratteristiche e sui principali dispositivi installati a bordo. Vengono dunque trattati separatamente i principali carichi, meccanico, elettrico e termico. In seguito si procede con una selezione delle principali fasi operative della nave: è seguito tale approccio in modo da comprendere meglio la ripartizione della richiesta di potenza a bordo della nave e il suo sfruttamento. Successivamente è svolto un controllo sul dimensionamento del sistema elettrico: ciò aiuta a comprendere se la potenza stimata dai progettisti sia assimilabile a quella effettivamente richiesta sulla nave. Si ottengono in seguito curve di carico meccanico, elettrico e termico in funzione del tempo per tutte le fasi operative considerate: tramite l’uso del software Visual Basic Application (VBA) vengono creati i profili di carico che possono essere gestiti nella successiva fase di ottimizzazione. L’ottimizzazione rappresenta il cuore di questo studio; i profili di potenza ottenuti dalla precedente fase sono gestiti in modo da conseguire un sistema che sia in grado di fornire potenza alla nave nel miglior modo possibile da un punto di vista energetico. Il sistema energetico della nave è modellato e ottimizzato mantenendo lo status quo dei dispositivi di bordo, per i quali sono considerate le configurazioni di “Load following”, “two shifts” e “minimal”. Una successiva investigazione riguarda l’installazione a bordo di un sistema di accumulo di energia termica, così da migliorare lo sfruttamento dell’energia disponibile. Infine, nella conclusione, sono messi a confronto i reali consumi della nave con i risultati ottenuti con e senza l’introduzione del sistema di accumulo termico. Attraverso la configurazione “minimal” è possibile risparmiare circa l’1,49% dell’energia totale consumata durante un anno di attività; tale risparmio è completamente gratuito poiché può essere raggiunto seguendo alcune semplici regole nella gestione dell’energia a bordo. L’introduzione di un sistema di accumulo termico incrementa il risparmio totale fino al 4,67% con un serbatoio in grado di accumulare 110000 kWh di energia termica; tuttavia, in questo caso, è necessario sostenere il costo di installazione del serbatoio. Vengono quindi dibattuti aspetti economici e ambientali in modo da spiegare e rendere chiari i vantaggi che si possono ottenere con l’applicazione di questo studio, in termini di denaro e riduzione di emissioni in atmosfera.

Design and optimization of turbo-expanders for organic rankine cycles

In a world focused on the need to produce energy for a growing population, while reducing atmospheric emissions of carbon dioxide, organic Rankine cycles represent a solution to fulfil this goal. This study focuses on the design and optimization of axial-flow turbines for organic Rankine cycles. From the turbine designer point of view, most of this fluids exhibit some peculiar characteristics, such as small enthalpy drop, low speed of sound, large expansion ratio. A computational model for the prediction of axial-flow turbine performance is developed and validated against experimental data. The model allows to calculate turbine performance within a range of accuracy of ±3%. The design procedure is coupled with an optimization process, performed using a genetic algorithm where the turbine total-to-static efficiency represents the objective function. The computational model is integrated in a wider analysis of thermodynamic cycle units, by providing the turbine optimal design. First, the calculation routine is applied in the context of the Draugen offshore platform, where three heat recovery systems are compared. The turbine performance is investigated for three competing bottoming cycles: organic Rankine cycle (operating cyclopentane), steam Rankine cycle and air bottoming cycle. Findings indicate the air turbine as the most efficient solution (total-to-static efficiency = 0.89), while the cyclopentane turbine results as the most flexible and compact technology (2.45 ton/MW and 0.63 m3/MW). Furthermore, the study shows that, for organic and steam Rankine cycles, the optimal design configurations for the expanders do not coincide with those of the thermodynamic cycles. This suggests the possibility to obtain a more accurate analysis by including the computational model in the simulations of the thermodynamic cycles. Afterwards, the performance analysis is carried out by comparing three organic fluids: cyclopentane, MDM and R245fa. Results suggest MDM as the most effective fluid from the turbine performance viewpoint (total-to-total efficiency = 0.89). On the other hand, cyclopentane guarantees a greater net power output of the organic Rankine cycle (P = 5.35 MW), while R245fa represents the most compact solution (1.63 ton/MW and 0.20 m3/MW). Finally, the influence of the composition of an isopentane/isobutane mixture on both the thermodynamic cycle performance and the expander isentropic efficiency is investigated. Findings show how the mixture composition affects the turbine efficiency and so the cycle performance. Moreover, the analysis demonstrates that the use of binary mixtures leads to an enhancement of the thermodynamic cycle performance.

Geometrical optimization of a short-stem hip implant for the reduction of proximal stress shielding (ottimizzazione geometrica di uno stelo corto di protesi d?anca per la riduzione della schermatura del carico prossimale)

Nowadays the number of hip joints arthroplasty operations continues to increase because the elderly population is growing. Moreover, the global life expectancy is increasing and people adopt a more active way of life. For this reasons, the demand of implant revision operations is becoming more frequent. The operation procedure includes the surgical removal of the old implant and its substitution with a new one. Every time a new implant is inserted, it generates an alteration in the internal femur strain distribution, jeopardizing the remodeling process with the possibility of bone tissue loss. This is of major concern, particularly in the proximal Gruen zones, which are considered critical for implant stability and longevity. Today, different implant designs exist in the market; however there is not a clear understanding of which are the best implant design parameters to achieve mechanical optimal conditions. The aim of the study is to investigate the stress shielding effect generated by different implant design parameters on proximal femur, evaluating which ranges of those parameters lead to the most physiological conditions.

A framework for risk analysis in automotive cybersecurity

We address the problem of automotive cybersecurity from the point of view of Threat Analysis and Risk Assessment (TARA). The central question that motivates the thesis is the one about the acceptability of risk, which is vital in taking a decision about the implementation of cybersecurity solutions. For this purpose, we develop a quantitative framework in which we take in input the results of risk assessment and define measures of various facets of a possible risk response; we then exploit the natural presence of trade-offs (cost versus effectiveness) to formulate the problem as a multi-objective optimization. Finally, we develop a stochastic model of the future evolution of the risk factors, by means of Markov chains; we adapt the formulations of the optimization problems to this non-deterministic context. The thesis is the result of a collaboration with the Vehicle Electrification division of Marelli, in particular with the Cybersecurity team based in Bologna; this allowed us to consider a particular instance of the problem, deriving from a real TARA, in order to test both the deterministic and the stochastic framework in a real world application. The collaboration also explains why in the work we often assume the point of view of a tier-1 supplier; however, the analyses performed can be adapted to any other level of the supply chain.

Quantitative analysis of pre- and post-operative valvular annulus deformations following valvular insufficiency

Valvular insufficiency is a growingly common valvular heart disease that frequently is associated with regurgitation. Atrioventricular incompetency can lead to overall ventricular and atrial enlargement, volume overload, heart impairment and, if not treated, can culminate in heart failure. With the advances in technology and the increasing interest in devices that have lower post-operative burden on patients, transcatheter mitral and tricuspid valve repair systems are going through a phase of rapid development and growing use. In this work, we aimed to quantitatively assess the morphology of mitral and tricuspid annuli in patients who underwent transcatheter valve repair with MitraClip/TriClip, before and after the intervention, using three-dimensional transoesophageal echocardiography images, in order to evaluate the geometrical changes of the annulus following the intervention. For our purposes, firstly, we implemented a tool for the visualization and navigation of the volumetric data across the cardiac cycle. Then, in order to track the annulus over the cardiac cycle, we extracted five rotational slices from the volume data, selected two initial points on each slice, and tracked these points across the cardiac cycle using KLT algorithm. In a first stage we led a parameters optimization for the tracking method, and we studied the sensitivity of the KLT algorithm to the initialization points, that are manually chosen by the user. In a second stage, we analysed 10 subjects (5 for mitral regurgitation and 5 for tricuspid regurgitation), tracking their annulus before and after valve repairment. In conclusion, we found in all our 10 subjects that immediately after the intervention there is a shortening of the major diameters of the valves, mainly the shortest diameter, due to the clip application, that leads to a reduction of the perimeter and the area of the annulus.

Analysis and optimisation of books flow among branches through simulation: the case of Trondheim’s Public Library

Il presente lavoro di tesi verte sull’analisi e l’ottimizzazione dei flussi di libri generati tra le diverse sedi della biblioteca pubblica, Trondheim folkebibliotek, situata a Trondheim, città del nord norvegese. La ricerca si inserisce nell’ambito di un progetto pluriennale, SmartLIB, che questa sta intraprendendo con l’università NTNU - Norwegian University of Science and Technology. L’obiettivo di questa tesi è quello di analizzare possibili soluzioni per ottimizzare il flusso di libri generato dagli ordini dei cittadini. Una prima fase di raccolta ed analisi dei dati è servita per avere le informazioni necessarie per procedere nella ricerca. Successivamente è stata analizzata la possibilità di ridurre i flussi andando ad associare ad ogni dipartimento la quantità di copie necessarie per coprire il 90% della domanda, seguendo la distribuzione di Poisson. In seguito, sono state analizzate tre soluzioni per ottimizzare i flussi generati dai libri, il livello di riempimento dei box ed il percorso del camion che giornalmente visita tutte le sedi della libreria. Di supporto per questo secondo studio è stato il Vehicle Routing Problem (VRP). Un modello simulativo è stato creato su Anylogic ed utilizzato per validare le soluzioni proposte. I risultati hanno portato a proporre delle soluzioni per ottimizzare i flussi complessivi, riducendo il delay time di consegna dei libri del 50%, ad una riduzione del 53% del flusso di box e ad una conseguente aumento del 44% del tasso di riempimento di ogni box. Possibili future implementazioni delle soluzioni trovate corrispondono all’installazione di una nuova Sorting Machine nella sede centrale della libreria ed all’implementazione sempre in quest’ultima di un nuovo schedule giornaliero.

Tolerance optimization with statistical approach in the CAT environment

Nowadays, product development in all its phases plays a fundamental role in the industrial chain. The need for a company to compete at high levels, the need to be quick in responding to market demands and therefore to be able to engineer the product quickly and with a high level of quality, has led to the need to get involved in new more advanced methods/ processes. In recent years, we are moving away from the concept of 2D-based design and production and approaching the concept of Model Based Definition. By using this approach, increasingly complex systems turn out to be easier to deal with but above all cheaper in obtaining them. Thanks to the Model Based Definition it is possible to share data in a lean and simple way to the entire engineering and production chain of the product. The great advantage of this approach is precisely the uniqueness of the information. In this specific thesis work, this approach has been exploited in the context of tolerances with the aid of CAD / CAT software. Tolerance analysis or dimensional variation analysis is a way to understand how sources of variation in part size and assembly constraints propagate between parts and assemblies and how that range affects the ability of a project to meet its requirements. It is critically important to note how tolerance directly affects the cost and performance of products. Worst Case Analysis (WCA) and Statistical analysis (RSS) are the two principal methods in DVA. The thesis aims to show the advantages of using statistical dimensional analysis by creating and examining various case studies, using PTC CREO software for CAD modeling and CETOL 6σ for tolerance analysis. Moreover, it will be provided a comparison between manual and 3D analysis, focusing the attention to the information lost in the 1D case. The results obtained allow us to highlight the need to use this approach from the early stages of the product design cycle.

Life cycle assessment (LCA) of a bio-fuel cell fed with waste biomass: potential for scale-up and process optimization

In this Thesis, a life cycle analysis (LCA) of a biofuel cell designed by a team from the University of Bologna was done. The purpose of this study is to investigate the possible environmental impacts of the production and use of the cell and a possible optimization for an industrial scale-up. To do so, a first part of the paper was devoted to studying the present literature on biomass, and fuel cell treatments and then LCA studies on them. The experimental part presents the work done to create the Life Cycle Inventory and Life Cycle Impact Assessment. Several alternative scenarios were created to study process optimization. Reagents and energy supply were changed. To examine whether this technology can be competitive, a comparison was made with some biofuel cell use scenarios with traditional biomass treatment technologies. The result of this study is that this technology is promising from an environmental point of view in case it is possible to recover nutrients in output, without excessive energy consumption, and to minimize the use of energy used to prepare the solution.

Dosimetric optimization of CT protocols for the preoperative planning of hip arthroplasty

Radiation dose in x-ray computed tomography (CT) has become a topic of great interest due to the increasing number of CT examinations performed worldwide. In fact, CT scans are responsible of significant doses delivered to the patients, much larger than the doses due to the most common radiographic procedures. This thesis work, carried out at the Laboratory of Medical Technology (LTM) of the Rizzoli Orthopaedic Institute (IOR, Bologna), focuses on two primary objectives: the dosimetric characterization of the tomograph present at the IOR and the optimization of the clinical protocol for hip arthroplasty. In particular, after having verified the reliability of the dose estimates provided by the system, we compared the estimates of the doses delivered to 10 patients undergoing CT examination for the pre-operative planning of hip replacement with the Diagnostic Reference Level (DRL) for an osseous pelvis examination. Out of 10 patients considered, only for 3 of them the doses were lower than the DRL. Therefore, the necessity to optimize the clinical protocol emerged. This optimization was investigated using a human femur from a cadaver. Quantitative analysis and comparison of 3D reconstructions were made, after having performed manual segmentation of the femur from different CT acquisitions. Dosimetric simulations of the CT acquisitions on the femur were also made and associated to the accuracy of the 3D reconstructions, to analyse the optimal combination of CT acquisition parameters. The study showed that protocol optimization both in terms of Hausdorff distance and in terms of effective dose (ED) to the patient may be realized simply by modifying the value of the pitch in the protocol, by choosing between 0.98 and 1.37.