Modellazione CAD e ricostruzione virtuale di autobus pubblicitario d'epoca

L’oggetto della presente tesi è sviluppare la ricostruzione virtuale di un autobus pubblicitario progettato negli anni 50, un simbolo del design italiano legato allo sviluppo industriale del secondo dopoguerra. La tesi si sviluppa inizialmente con un’attività di ricerca e documentazione legata all'autobus, con particolare attenzione alla raccolta di immagini e disegni progettuali d’epoca, punto di partenza per la ricostruzione virtuale del mezzo. Si procede quindi alla modellazione CAD della carrozzeria cercando di replicare in modo quanto più dettagliato l’originale. Dal modello ottenuto, sono stati ricavati due prototipi di diverse dimensioni e materiali: un primo di dimensioni ridotte, realizzato tramite la tecnica del rapid prototyping, ed un secondo di dimensioni maggiori, in ureol fresato. Successivamente si procede ad uno studio preliminare di ricostruzione del mezzo con lo scopo di analizzare le principali problematiche di un’eventuale futura costruzione e messa in strada del mezzo. Tale studio parte dalla normativa vigente sulla costruzione e sulle norme di circolazione degli autobus, comprendente sia le leggi italiane sia comunitarie, riguardanti le caratteristiche dimensionali, prestazionali e di sicurezza che qualsiasi autobus con licenza di circolazione deve rispettare. Quindi verrà compiuta la scelta del telaio base da utilizzare tra quelli proposti dai maggiori costruttori europei e verrà realizzato il modello CAD anche del telaio con l’obiettivo di collegarlo alla carrozzeria e ottenere così il modello completo in tutte le sue parti. Per realizzare la scocca, verranno prese in esame le soluzioni costruttive più utilizzate dai progettisti di autobus, e viene svolto un breve studio riguardo i materiali utilizzabili a tale scopo. Sulla base di tali considerazioni si procederà alla modellazione della stessa. In ultimo si procede ad un preliminare studio fluidodinamico attraverso l’analisi CFD, e ad un preliminare studio del comportamento meccanico della struttura reticolare che sostiene la carrozzeria.

Analisi della correlazione tra i parametri di processo e le prestazioni dei materiali polimerici ottenuti tramite fused deposition modeling

Questa tesi si propone di realizzare una caratterizzazione del polimero ABS ottenuto con tecnica Fused Deposition Modeling in modo da ottenere dati utili alla realizzazione di parti strutturali tramite rapid prototyping.

Energy harvesting from piezoelectric devices embedded in a 3D printed wing

This thesis work has been carried out at Clarkson University in Potsdam NY, USA and involved the design of a low elongation wing, consisting of parts made by polylactide (PLA) using the fused deposition model (FDM) technology of Rapid Prototyping, then assembled together in a thin aluminum spar. The aim of the research is to evaluate the feasibility of collecting electrical energy by converting mechanical energy from the vibration of the wing flutter. With this aim piezoelectric stripes were glued in the inner part of the wing, as well as on the aluminum spar, as monomorphic configuration. During the phases of the project, particular attention was given to the geometry and the materials used, in order to trigger the flutter for low flow velocity. The CAD software SolidWorks® was used for the design of the wing and then the drawings were sent to the Clarkson machine shop in order to to produce the parts required by the wing assembly. FEM simulations were performed, using software MSC NASTRAN/PATRAN®, to evaluate the stiffness of the whole wing as well as the natural vibration modes of the structure. These data, in a first approximation, were used to predict the flutter speed. Finally, experimental tests in the Clarkson wind tunnel facility were carried out in order to validate the results obtained from FEM analysis. The power collected by the piezoelectrics under flutter condition was addressed by tuning the resistors downstream the electronic circuit of the piezoelectrics.

Comparazione strutturale di componenti realizzati a terra e nello spazio mediante tecniche additive

Questo lavoro di tesi mira ad indagare, a livello preliminare, quali siano i vantaggi e gli svantaggi a livello strutturale legati alla possibilità di realizzare componenti per mezzi spaziali con tecnologie di Rapid Prototyping direttamente nello spazio: questa possibilità verrà confrontata con il caso in cui gli stessi componenti siano realizzati a terra e poi inviati nello spazio con un lanciatore. Nonostante si siano riscontrati dei limiti derivanti dalla carenza di dati tecnici sulle caratteristiche meccaniche dei materiali, è stata sviluppata una metodologia che ha fornito l’opportunità, seppur con grandi approssimazioni, di valutare il problema. Il punto di partenza dell’attività è stato quello di visionare figure ed immagini di mezzi spaziali e di scegliere alcuni componenti che possano essere oggetto di manutenzione o sostituzione in volo. Sei componenti sono stati poi modellati al CAD, ed è stata condotta un’analisi ad elementi finiti (FEM) mediante il software MSC Patran/Nastran, con lo scopo di simulare la risposta strutturale nelle diverse condizioni di carico prese in considerazione. Seppur a livello qualitativo e del tutto preliminare, sono stati svolti dei confronti in termini di massa e tensioni per valutare in quali casi sembra sia conveniente realizzare un componente a terra con tecnologie tradizionali, e in quali sembra sia vantaggioso utilizzare nuove tecnologie di prototipazione rapida stampando direttamente il componente nello spazio.

Design of compliant mechanisms and their application to morphing wing technology

This thesis describes a study conducted for the development of a new approach for the design of compliant mechanisms. Currently compliant mechanisms are based on a 2.5D design method. The applications for which compliant mechanisms can be used this way, is limited. The proposed research suggests to use a 3D approach for the design of CM’s, to better exploit its useful properties. To test the viability of this method, a practical application was chosen. The selected application is related to morphing wings. During this project a working prototype of a variable sweep and variable AoA system was designed and made for an SUAV. A compliant hinge allows the system to achieve two DOF. This hinge has been designed using the proposed 3D design approach. To validate the capabilities of the design, two methods were used. One of these methods was by simulation. By using analysis software, a basic idea could be provided of the stress and deformation of the designed mechanism. The second validation was done by means of AM. Using FDM and material jetting technologies, several prototypes were manufactured. The result of the first model showed that the DOF could be achieved. Models manufactured using material jetting technology, proved that the designed model could provide the desired motion and exploit the positive characteristics of CM. The system could be manufactured successfully in one part. Being able to produce the system in one part makes the need for an extensive assembly process redundant. This improves its structural quality. The materials chosen for the prototypes were PLA, VeroGray and Rigur. The material properties were suboptimal for its final purpose, but successful results were obtained. The prototypes proved tough and were able to provide the desired motion. This proves that the proposed design method can be a useful tool for the design of improved CM’s. Furthermore, the variable sweep & AoA system could be used to boost the flight performance of SUAV’s.

Rapid Control Prototyping of an L2+ Highway Assist System

Advanced Driver Assistance Systems (ADAS) are proving to have huge potential in road safety, comfort, and efficiency. In recent years, car manufacturers have equipped their high-end vehicles with Level 2 ADAS, which are, according to SAE International, systems that combine both longitudinal and lateral active motion control. These automated driving features, while only available in highway scenarios, appear to be very promising towards the introduction of hands-free driving. However, as they rely only on an on-board sensor suite, their continuative operation may be affected by the current environmental conditions: this prevents certain functionalities such as the automated lane change, other than requiring the driver to keep constantly the hands on the steering wheel. The enabling factor for hands-free highway driving proposed by Mobileye is the integration of high-definition maps, thus leading to the so-called Level 2+. This thesis was carried out during an internship in Maserati's Virtual Engineering team. The activity consisted of the design of an L2+ Highway Assist System following the Rapid Control Prototyping approach, starting from the definition of the requirements up to the real-time implementation and testing on a simulator of the brand new compact SUV Maserati Grecale. The objective was to enhance the current Level 2 highway driving assistance system with hands-free driving capability; for this purpose an Autonomous Lane Change functionality has been designed, proposing a Model Predictive Control-based decision-maker, in charge of assessing both the feasibility and convenience of performing a lane-change maneuver. The result is a Highway Assist System capable of driving the vehicle in a traffic scenario safely and efficiently, never requiring driver intervention.

Microfluidic microbial fuel cell fabrication and rapid screening of electrochemically microbes

The demand for novel renewable energy sources, together with the new findings on bacterial electron transport mechanisms and the progress in microbial fuel cell design, have raised a noticeable interest in microbial power generation. Microbial fuel cell (MFC) is an electrochemical device that converts organic substrates into electricity via catalytic conversion by microorganism. It has represented a continuously growing research field during the past few years. The great advantage of this device is the direct conversion of the substrate into electricity and in the future, MFC may be linked to municipal waste streams or sources of agricultural and animal waste, providing a sustainable system for waste treatment and energy production. However, these novel green technologies have not yet been used for practical applications due to their low power outputs and challenges associated with scale-up, so in-depth studies are highly necessary to significantly improve and optimize the device working conditions. For the time being, the micro-scale MFCs show great potential in the rapid screening of electrochemically active microbes. This thesis presents how it will be possible to optimize the properties and design of the micro-size microbial fuel cell for maximum efficiency by understanding the MFC system. So it will involve designing, building and testing a miniature microbial fuel cell using a new species of microorganisms that promises high efficiency and long lifetime. The new device offer unique advantages of fast start-up, high sensitivity and superior microfluidic control over the measured microenvironment, which makes them good candidates for rapid screening of electrode materials, bacterial strains and growth media. It will be made in the Centre of Hybrid Biodevices (Faculty of Physical Sciences and Engineering, University of Southampton) from polymer materials like PDMS. The eventual aim is to develop a system with the optimum combination of microorganism, ion exchange membrane and growth medium. After fabricating the cell, different bacteria and plankton species will be grown in the device and the microbial fuel cell characterized for open circuit voltage and power. It will also use photo-sensitive organisms and characterize the power produced by the device in response to optical illumination.

Sviluppo di un sistema RCP per il controllo della combustione diesel basato sull'analisi real-time del rumore di combustione

Lavoro sviluppato attraverso un’attività sperimentale svolta su un motore Diesel 1.3 Multijet, presente al banco nei laboratori hangar della Scuola di Ingegneria e Architettura, sede di Forlì. L’attività è stata incentrata sullo sviluppo di un sistema RCP (Rapid Control Prototyping) per il controllo del pattern di iniezione del motore, basato sull’analisi in tempo reale di un opportuno indice di rumore, calcolato in real time attraverso il processamento del segnale proveniente da un microfono da laboratorio affacciato al blocco motore.

Design and prototyping of electronic PCBs for the study of the atmosphere in harsh environmental conditions

Progettazione, test e creazione di schede elettroniche per lo studio dell'atmosfera in condizioni ambientali difficili.