Manufacturing at double the speed

The speed of manufacturing processes today depends on a trade-off between the physical processes of production, the wider system that allows these processes to operate and the co-ordination of a supply chain in the pursuit of meeting customer needs. Could the speed of this activity be doubled? This paper explores this hypothetical question, starting with examination of a diverse set of case studies spanning the activities of manufacturing. This reveals that the constraints on increasing manufacturing speed have some common themes, and several of these are examined in more detail, to identify absolute limits to performance. The physical processes of production are constrained by factors such as machine stiffness, actuator acceleration, heat transfer and the delivery of fluids, and for each of these, a simplified model is used to analyse the gap between current and limiting performance. The wider systems of production require the co-ordination of resources and push at the limits of human biophysical and cognitive limits. Evidence about these is explored and related to current practice. Out of this discussion, five promising innovations are explored to show examples of how manufacturing speed is increasing—with line arrays of point actuators, parallel tools, tailored application of precision, hybridisation and task taxonomies. The paper addresses a broad question which could be pursued by a wider community and in greater depth, but even this first examination suggests the possibility of unanticipated innovations in current manufacturing practices.

On the application of optimal control techniques in lossy fieldbuses

The performance of real-time networks is under continuous improvement as a result of several trends in the digital world. However, these tendencies not only cause improvements, but also exacerbates a series of unideal aspects of real-time networks such as communication latency, jitter of the latency and packet drop rate. This Thesis focuses on the communication errors that appear on such realtime networks, from the point-of-view of automatic control. Specifically, it investigates the effects of packet drops in automatic control over fieldbuses, as well as the architectures and optimal techniques for their compensation. Firstly, a new approach to address the problems that rise in virtue of such packet drops, is proposed. This novel approach is based on the simultaneous transmission of several values in a single message. Such messages can be from sensor to controller, in which case they are comprised of several past sensor readings, or from controller to actuator in which case they are comprised of estimates of several future control values. A series of tests reveal the advantages of this approach. The above-explained approach is then expanded as to accommodate the techniques of contemporary optimal control. However, unlike the aforementioned approach, that deliberately does not send certain messages in order to make a more efficient use of network resources; in the second case, the techniques are used to reduce the effects of packet losses. After these two approaches that are based on data aggregation, it is also studied the optimal control in packet dropping fieldbuses, using generalized actuator output functions. This study ends with the development of a new optimal controller, as well as the function, among the generalized functions that dictate the actuator’s behaviour in the absence of a new control message, that leads to the optimal performance. The Thesis also presents a different line of research, related with the output oscillations that take place as a consequence of the use of classic co-design techniques of networked control. The proposed algorithm has the goal of allowing the execution of such classical co-design algorithms without causing an output oscillation that increases the value of the cost function. Such increases may, under certain circumstances, negate the advantages of the application of the classical co-design techniques. A yet another line of research, investigated algorithms, more efficient than contemporary ones, to generate task execution sequences that guarantee that at least a given number of activated jobs will be executed out of every set composed by a predetermined number of contiguous activations. This algorithm may, in the future, be applied to the generation of message transmission patterns in the above-mentioned techniques for the efficient use of network resources. The proposed task generation algorithm is better than its predecessors in the sense that it is capable of scheduling systems that cannot be scheduled by its predecessor algorithms. The Thesis also presents a mechanism that allows to perform multi-path routing in wireless sensor networks, while ensuring that no value will be counted in duplicate. Thereby, this technique improves the performance of wireless sensor networks, rendering them more suitable for control applications. As mentioned before, this Thesis is centered around techniques for the improvement of performance of distributed control systems in which several elements are connected through a fieldbus that may be subject to packet drops. The first three approaches are directly related to this topic, with the first two approaching the problem from an architectural standpoint, whereas the third one does so from more theoretical grounds. The fourth approach ensures that the approaches to this and similar problems that can be found in the literature that try to achieve goals similar to objectives of this Thesis, can do so without causing other problems that may invalidate the solutions in question. Then, the thesis presents an approach to the problem dealt with in it, which is centered in the efficient generation of the transmission patterns that are used in the aforementioned approaches.

Optimal dynamic control of laminated adaptive structures using a higher order model and a genetic algorithm

This paper deals with a finite element formulation based on the classical laminated plate theory, for active control of thin plate laminated structures with integrated piezoelectric layers, acting as sensors and actuators. The control is initialized through a previous optimization of the core of the laminated structure, in order to minimize the vibration amplitude. Also the optimization of the patches position is performed to maximize the piezoelectric actuator efficiency. The genetic algorithm is used for these purposes. The finite element model is a single layer triangular plate/shell element with 24 degrees of freedom for the generalized displacements, and one electrical potential degree of freedom for each piezoelectric element layer, which can be surface bonded or embedded on the laminate. To achieve a mechanism of active control of the structure dynamic response, a feedback control algorithm is used, coupling the sensor and active piezoelectric layers. To calculate the dynamic response of the laminated structures the Newmark method is considered. The model is applied in the solution of an illustrative case and the results are presented and discussed.

Core and patch position optimizations for vibration control of piezolaminated structures

This paper deals with a finite formulation baserd on the classical laminated plate tehory, for active control of thin late laminated structures with integrated piezoelectric layers, acting as sensors and actuators. The control is initialized through a previuos optimization of the core of the laminated structure, in order to minimize the vibration amplitude. Also the optimization of the patches position in performed to maximize the piezoelectric actuator efficiency. the simulating annealing mthod is used for these purposes. The finite element model is a single layer triangular nonconforming plate/shell element with 18 degrees of fredom for the generalized displacements, and one electrical potential degree of freedom for each piezoelectric element layer, wich can be surface bonded or imbedded on the laminate. To achieve a mechanism of active control of the structure dynamic response, a feedback control algorirhm is used, coupling the sensor and active piezoelectric layers. To calculate the dynamic response of the laminated structures the Newmark method is considered. The model is applied in the solution of an illustrative case and the results are presented and discussed.

The SmartVision navigation prototype for the blind

The goal of the project "SmartVision: active vision for the blind" is to develop a small and portable but intelligent and reliable system for assisting the blind and visually impaired while navigating autonomously, both outdoor and indoor. In this paper we present an overview of the prototype, design issues, and its different modules which integrate a GIS with GPS, Wi-Fi, RFID tags and computer vision. The prototype addresses global navigation by following known landmarks, local navigation with path tracking and obstacle avoidance, and object recognition. The system does not replace the white cane, but extends it beyond its reach. The user-friendly interface consists of a 4-button hand-held box, a vibration actuator in the handle of the cane, and speech synthesis. A future version may also employ active RFID tags for marking navigation landmarks, and speech recognition may complement speech synthesis.

Atrial assist device, a new alternative to lifelong anticoagulation?

OBJECTIVE: Atrial fibrillation is a very common heart arrhythmia, associated with a five-fold increase in the risk of embolic strokes. Treatment strategies encompass palliative drugs or surgical procedures all of which can restore sinus rhythm. Unfortunately, atria often fail to recover their mechanical function and patients therefore require lifelong anticoagulation therapy. A motorless volume displacing device (Atripump) based on artificial muscle technology, positioned on the external surface of atrium could avoid the need of oral anticoagulation and its haemorrhagic complications. An animal study was conducted in order to assess the haemodynamic effects that such a pump could provide. METHODS: Atripump is a dome-shape siliconecoated nitinol actuator sewn on the external surface of the atrium. It is driven by a pacemaker-like control unit. Five non-anticoagulated sheep were selected for this experiment. The right atrium was surgically exposed, the device sutured and connected. Haemodynamic parameters and intracardiac ultrasound (ICUS) data were recorded in each animal and under three conditions; baseline; atrial fibrillation (AF); atripump assisted AF (aaAF). RESULTS: In two animals, after 20 min of AF, small thrombi appeared in the right atrial appendix and were washed out once the pump was turned on. Assistance also enhanced atrial ejection fraction. 31% baseline; 5% during AF; 20% under aaAF. Right atrial systolic surfaces (cm2) were; 5.2 +/- 0.3 baseline; 6.2 +/- 0.1 AF; 5.4 +/- 0.3 aaAF. CONCLUSION: This compact and reliable pump seems to restore the atrial "kick" and prevents embolic events. It could avoid long-term anticoagulation therapy and open new hopes in the care of end-stage heart failure.

A Novel Method for Switching and Tuning of PBG Structures

Photonic band-gap (PBG) structures are utilized in microwave components as filters to suppress unwanted signals. In this work, rectangular perforations were created in the ground plane of a microstrip line to construct a PBG structure. A gold-coated alumina substrate was utilized to switch or tune the bandstop characteristics of this structure. It was demonstrated that the bandstop characteristics were switched off from - 35 to - 1 dB at 16 GHz. Tuning of the bandstop edge with a shift of 1.5 GHz was also shown

Elektrochemo- und mikromechanisches Verhalten elektronisch leitfähiger Polymere

Intrinsisch leitfähige Polymere sind durch eine Reihe materialspezifischer Eigenschaften gekennzeichnet. In Abhängigkeit des angelegten Potenzials und der chemischen Umgebung zeigen sie elektrochromes Verhalten, Veränderungen der Masse, des Volumens und der elektronischen Leitfähigkeit. Basierend auf diesen Eigenschaften eignen sich halbleitende organische Polymere als funktionales Material für Anwendungen in der Mikro- und Nanotechnologie, insbesondere für miniaturisierte chemische Sensoren und Aktoren. Im Gegensatz zu konventionellen Piezo-Aktoren operieren diese Aktoren z. B. bei Spannungen unterhalb 1 V. Diese Arbeit befasst sich mit den elektrochemomechanischen Eigenschaften der ausgewählten Polymere Polyanilin und Polypyrrol, d. h. mit den potenzialkontrollierten Veränderungen des Volumens, der Struktur und der mechanischen Eigenschaften. Bei diesem Prozess werden positive Ladungen innerhalb der Polymerphase generiert. Um die für den Ladungsausgleich benötigten Gegenionen bereitzustellen, werden alle Messungen in Anwesenheit eines wässrigen Elektrolyten durchgeführt. Der Ladungstransport und die Volumenänderungen werden mit den Methoden der zyklischen Voltammetrie, der elektrochemischen Quarzmikrowaage und der Rastersondenmikroskopie untersucht. Signifikante Ergebnisse können für dünne homogene Polymerschichten erhalten werden, wobei Schichtdicken oberhalb 150 nm aufgrund der insbesondere bei Polyanilin einsetzenden Bildung von Fadenstrukturen (Fibrillen) vermieden werden. Von besonderem Interesse im Rahmen dieser Arbeit ist die Kombination der funktionalen Polymere mit Strukturen auf Siliziumbasis, insbesondere mit mikrostrukturierten Cantilevern. Die zuvor erhaltenen Ergebnisse bilden die Grundlage für das Design und die Dimensionierung der Mikroaktoren. Diese bestehen aus Siliziumcantilevern, die eine Elektrodenschicht aus Gold oder Platin tragen. Auf der Elektrode wird mittels Elektrodeposition eine homogene Schicht Polymer mit Schichtdicken bis zu 150 nm aufgebracht. Die Aktorcharakteristik, die Biegung des Cantilevers aufgrund des angelegten Potenzials, wird mit dem aus der Rastersondenmikroskopie bekannten Lichtzeigerverfahren gemessen. Das Aktorsystem wird hinsichtlich des angelegten Potenzials, des Elektrolyten und der Redox-Kinetik charakterisiert. Die verschiedenen Beiträge zum Aktorverhalten werden in situ während des Schichtwachstums untersucht. Das beobachtete Verhalten kann als Superposition verschiedener Effekte beschrieben werden. Darunter sind die Elektrodenaufladung (Elektrokapillarität), die Veränderungen der Elektrodenoberfläche durch dünne Oxidschichten und die Elektrochemomechanik des Polymers.

Optimierung von Betriebsstrategien für elektrifizierte Antriebskonzepte

Im Rahmen dieser Arbeit wird eine gemeinsame Optimierung der Hybrid-Betriebsstrategie und des Verhaltens des Verbrennungsmotors vorgestellt. Die Übernahme von den im Steuergerät verwendeten Funktionsmodulen in die Simulationsumgebung für Fahrzeuglängsdynamik stellt eine effiziente Applikationsmöglichkeit der Originalparametrierung dar. Gleichzeitig ist es notwendig, das Verhalten des Verbrennungsmotors derart nachzubilden, dass das stationäre und das dynamische Verhalten, inklusive aller relevanten Einflussmöglichkeiten, wiedergegeben werden kann. Das entwickelte Werkzeug zur Übertragung der in Ascet definierten Steurgerätefunktionen in die Simulink-Simulationsumgebung ermöglicht nicht nur die Simulation der relevanten Funktionsmodule, sondern es erfüllt auch weitere wichtige Eigenschaften. Eine erhöhte Flexibilität bezüglich der Daten- und Funktionsstandänderungen, sowie die Parametrierbarkeit der Funktionsmodule sind Verbesserungen die an dieser Stelle zu nennen sind. Bei der Modellierung des stationären Systemverhaltens des Verbrennungsmotors erfolgt der Einsatz von künstlichen neuronalen Netzen. Die Auswahl der optimalen Neuronenanzahl erfolgt durch die Betrachtung des SSE für die Trainings- und die Verifikationsdaten. Falls notwendig, wird zur Sicherstellung der angestrebten Modellqualität, das Interpolationsverhalten durch Hinzunahme von Gauß-Prozess-Modellen verbessert. Mit den Gauß-Prozess-Modellen werden hierbei zusätzliche Stützpunkte erzeugt und mit einer verminderten Priorität in die Modellierung eingebunden. Für die Modellierung des dynamischen Systemverhaltens werden lineare Übertragungsfunktionen verwendet. Bei der Minimierung der Abweichung zwischen dem Modellausgang und den Messergebnissen wird zusätzlich zum SSE das 2σ-Intervall der relativen Fehlerverteilung betrachtet. Die Implementierung der Steuergerätefunktionsmodule und der erstellten Steller-Sensor-Streckenmodelle in der Simulationsumgebung für Fahrzeuglängsdynamik führt zum Anstieg der Simulationszeit und einer Vergrößerung des Parameterraums. Das aus Regelungstechnik bekannte Verfahren der Gütevektoroptimierung trägt entscheidend zu einer systematischen Betrachtung und Optimierung der Zielgrößen bei. Das Ergebnis des Verfahrens ist durch das Optimum der Paretofront der einzelnen Entwurfsspezifikationen gekennzeichnet. Die steigenden Simulationszeiten benachteiligen Minimumsuchverfahren, die eine Vielzahl an Iterationen benötigen. Um die Verwendung einer Zufallsvariablen, die maßgeblich zur Steigerung der Iterationanzahl beiträgt, zu vermeiden und gleichzeitig eine Globalisierung der Suche im Parameterraum zu ermöglichen wird die entwickelte Methode DelaunaySearch eingesetzt. Im Gegensatz zu den bekannten Algorithmen, wie die Partikelschwarmoptimierung oder die evolutionären Algorithmen, setzt die neu entwickelte Methode bei der Suche nach dem Minimum einer Kostenfunktion auf eine systematische Analyse der durchgeführten Simulationsergebnisse. Mit Hilfe der bei der Analyse gewonnenen Informationen werden Bereiche mit den bestmöglichen Voraussetzungen für ein Minimum identifiziert. Somit verzichtet das iterative Verfahren bei der Bestimmung des nächsten Iterationsschrittes auf die Verwendung einer Zufallsvariable. Als Ergebnis der Berechnungen steht ein gut gewählter Startwert für eine lokale Optimierung zur Verfügung. Aufbauend auf der Simulation der Fahrzeuglängsdynamik, der Steuergerätefunktionen und der Steller-Sensor-Streckenmodelle in einer Simulationsumgebung wird die Hybrid-Betriebsstrategie gemeinsam mit der Steuerung des Verbrennungsmotors optimiert. Mit der Entwicklung und Implementierung einer neuen Funktion wird weiterhin die Verbindung zwischen der Betriebsstrategie und der Motorsteuerung erweitert. Die vorgestellten Werkzeuge ermöglichten hierbei nicht nur einen Test der neuen Funktionalitäten, sondern auch eine Abschätzung der Verbesserungspotentiale beim Verbrauch und Abgasemissionen. Insgesamt konnte eine effiziente Testumgebung für eine gemeinsame Optimierung der Betriebsstrategie und des Verbrennungsmotorverhaltens eines Hybridfahrzeugs realisiert werden.

Modeling Robot Dynamic Performance for Endpoint Force Control

This research aims to understand the fundamental dynamic behavior of servo-controlled machinery in response to various types of sensory feedback. As an example of such a system, we study robot force control, a scheme which promises to greatly expand the capabilities of industrial robots by allowing manipulators to interact with uncertain and dynamic tasks. Dynamic models are developed which allow the effects of actuator dynamics, structural flexibility, and workpiece interaction to be explored in the frequency and time domains. The models are used first to explain the causes of robot force control instability, and then to find methods of improving this performance.

Parallel Coupled Micro-Macro Actuators

This thesis presents a new actuator system consisting of a micro-actuator and a macro-actuator coupled in parallel via a compliant transmission. The system is called the Parallel Coupled Micro-Macro Actuator, or PaCMMA. In this system, the micro-actuator is capable of high bandwidth force control due to its low mass and direct-drive connection to the output shaft. The compliant transmission of the macro-actuator reduces the impedance (stiffness) at the output shaft and increases the dynamic range of force. Performance improvement over single actuator systems was expected in force control, impedance control, force distortion and reduction of transient impact forces. A set of quantitative measures is proposed and the actuator system is evaluated against them: Force Control Bandwidth, Position Bandwidth, Dynamic Range, Impact Force, Impedance ("Backdriveability'"), Force Distortion and Force Performance Space. Several theoretical performance limits are derived from the saturation limits of the system. A control law is proposed and control system performance is compared to the theoretical limits. A prototype testbed was built using permanenent magnet motors and an experimental comparison was performed between this actuator concept and two single actuator systems. The following performance was observed: Force bandwidth of 56Hz, Torque Dynamic Range of 800:1, Peak Torque of 1040mNm, Minimum Torque of 1.3mNm. Peak Impact Force was reduced by an order of magnitude. Distortion at small amplitudes was reduced substantially. Backdriven impedance was reduced by 2-3 orders of magnitude. This actuator system shows promise for manipulator design as well as psychophysical tests of human performance.

Virtual Model Control of a Biped Walking Robot

The transformation from high level task specification to low level motion control is a fundamental issue in sensorimotor control in animals and robots. This thesis develops a control scheme called virtual model control which addresses this issue. Virtual model control is a motion control language which uses simulations of imagined mechanical components to create forces, which are applied through joint torques, thereby creating the illusion that the components are connected to the robot. Due to the intuitive nature of this technique, designing a virtual model controller requires the same skills as designing the mechanism itself. A high level control system can be cascaded with the low level virtual model controller to modulate the parameters of the virtual mechanisms. Discrete commands from the high level controller would then result in fluid motion. An extension of Gardner's Partitioned Actuator Set Control method is developed. This method allows for the specification of constraints on the generalized forces which each serial path of a parallel mechanism can apply. Virtual model control has been applied to a bipedal walking robot. A simple algorithm utilizing a simple set of virtual components has successfully compelled the robot to walk eight consecutive steps.

Virtual Model Control of a Hexapod Walking Robot

Since robots are typically designed with an individual actuator at each joint, the control of these systems is often difficult and non-intuitive. This thesis explains a more intuitive control scheme called Virtual Model Control. This thesis also demonstrates the simplicity and ease of this control method by using it to control a simulated walking hexapod. Virtual Model Control uses imagined mechanical components to create virtual forces, which are applied through the joint torques of real actuators. This method produces a straightforward means of controlling joint torques to produce a desired robot behavior. Due to the intuitive nature of this control scheme, the design of a virtual model controller is similar to the design of a controller with basic mechanical components. The ease of this control scheme facilitates the use of a high level control system which can be used above the low level virtual model controllers to modulate the parameters of the imaginary mechanical components. In order to apply Virtual Model Control to parallel mechanisms, a solution to the force distribution problem is required. This thesis uses an extension of Gardner`s Partitioned Force Control method which allows for the specification of constrained degrees of freedom. This virtual model control technique was applied to a simulated hexapod robot. Although the hexapod is a highly non-linear, parallel mechanism, the virtual models allowed text-book control solutions to be used while the robot was walking. Using a simple linear control law, the robot walked while simultaneously balancing a pendulum and tracking an object.

A mixed H2/H∞-based semiactive control for vibration mitigation in flexible structures

In this paper, we address this problem through the design of a semiactive controller based on the mixed H2/H∞ control theory. The vibrations caused by the seismic motions are mitigated by a semiactive damper installed in the bottom of the structure. It is meant by semiactive damper, a device that absorbs but cannot inject energy into the system. Sufficient conditions for the design of a desired control are given in terms of linear matrix inequalities (LMIs). A controller that guarantees asymptotic stability and a mixed H2/H∞ performance is then developed. An algorithm is proposed to handle the semiactive nature of the actuator. The performance of the controller is experimentally evaluated in a real-time hybrid testing facility that consists of a physical specimen (a small-scale magnetorheological damper) and a numerical model (a large-scale three-story building)

Development of smart variable stiffness actuators using polymer hydrogels

In this work, compliant actuators are developed by coupling braided structures and polymer gels, able to produce work by controlled gel swelling in the presence of water. A number of aspects related to the engineering of gel actuators were studied, including gel selection, modelling and experimentation of constant force and constant displacement behaviour, and response time. The actuator was intended for use as vibration neutralizer: with this aim, generation of a force of 10 N in a time not exceeding a second was needed. Results were promising in terms of force generation, although response time was still longer than required. In addition, the easiest way to obtain the reversibility of the effect is still under discussion: possible routes for improvement are suggested and will be the object of future work.