Hammashihnajohdeakseleiden liikkeiden synkronointi

Nykyisessä valmistusteollisuudessa erilaisten robottien ja automatisoitujen tuotantovaiheiden rooli on erittäin merkittävä. Tarkasti suunnitellut liikkeet ja toimintavaiheet voidaan nykyisillä järjestelmillä ajoittaa tarkasti toisiinsa nähden, jolloin erilaisten virhetilanteidenkin sattuessa järjestelmä pystyy toimimaan tilanteen edellyttämällä tavalla. Automatisoinnin etuna on myös tuotannon muokkaaminen erilaisten tuotteiden valmistamiseen pienillä muutoksilla, jolloin tuotantokustannukset pysyvät matalina myös pienten valmistuserien tapauksissa. Usean akselin laitteissa eli niin sanotuissa moniakselikäytöissä laitteen toimintatarkkuus riippuu jokaisen liikeakselin tarkkuudesta. Liikkeenohjauksessa on perinteisesti ollut käytössä myötäkytketty paikkakaskadi, jonka virityksessä otetaan huomioon akselilla olevat erilaiset dynaamiset tilat ja käytettävät referenssit. Monissa nykyisissä hajautetuissa järjestelmissä eli moniakselikäytöissä, joissa jokaiselle akselille on oma ohjauslaite, ei yksittäisen akselin paikkavirhettä huomioida muiden akseleiden ohjauksessa. Työssä tutkitaan erilaisia moniakselijärjestelmien ohjausmenetelmiä ja myötäkytketyn paikkakaskadin toimintaa moniakselikäytössä pyritään parantamaan tuomalla paikkasäätimen rinnalle toinen säädin, jonka tulona on akseleiden välinen paikkaero.

Broadband excitation in the system identification of active magnetic bearing rotor systems

One of the targets of the climate and energy package of the European Union is to increase the energy efficiency in order to achieve a 20 percent reduction in primary energy use compared with the projected level by 2020. The energy efficiency can be improved for example by increasing the rotational speed of large electrical drives, because this enables the elimination of gearboxes leading to a compact design with lower losses. The rotational speeds of traditional bearings, such as roller bearings, are limited by mechanical friction. Active magnetic bearings (AMBs), on the other hand, allow very high rotational speeds. Consequently, their use in large medium- and high-speed machines has rapidly increased. An active magnetic bearing rotor system is an inherently unstable, nonlinear multiple-input, multiple-output system. Model-based controller design of AMBs requires an accurate system model. Finite element modeling (FEM) together with the experimental modal analysis provides a very accurate model for the rotor, and a linearized model of the magneticactuators has proven to work well in normal conditions. However, the overall system may suffer from unmodeled dynamics, such as dynamics of foundation or shrink fits. This dynamics can be modeled by system identification. System identification can also be used for on-line diagnostics. In this study, broadband excitation signals are adopted to the identification of an active magnetic bearing rotor system. The broadband excitation enables faster frequency response function measurements when compared with the widely used stepped sine and swept sine excitations. Different broadband excitations are reviewed, and the random phase multisine excitation is chosen for further study. The measurement times using the multisine excitation and the stepped sine excitation are compared. An excitation signal design with an analysis of the harmonics produced by the nonlinear system is presented. The suitability of different frequency response function estimators for an AMB rotor system are also compared. Additionally, analytical modeling of an AMB rotor system, obtaining a parametric model from the nonparametric frequency response functions, and model updating are discussed in brief, as they are key elements in the modeling for a control design. Theoretical methods are tested with a laboratory test rig. The results conclude that an appropriately designed random phase multisine excitation is suitable for the identification of AMB rotor systems.

Exploring Adaptive Implementation of On-Chip Networks

As technology geometries have shrunk to the deep submicron regime, the communication delay and power consumption of global interconnections in high performance Multi- Processor Systems-on-Chip (MPSoCs) are becoming a major bottleneck. The Network-on- Chip (NoC) architecture paradigm, based on a modular packet-switched mechanism, can address many of the on-chip communication issues such as performance limitations of long interconnects and integration of large number of Processing Elements (PEs) on a chip. The choice of routing protocol and NoC structure can have a significant impact on performance and power consumption in on-chip networks. In addition, building a high performance, area and energy efficient on-chip network for multicore architectures requires a novel on-chip router allowing a larger network to be integrated on a single die with reduced power consumption. On top of that, network interfaces are employed to decouple computation resources from communication resources, to provide the synchronization between them, and to achieve backward compatibility with existing IP cores. Three adaptive routing algorithms are presented as a part of this thesis. The first presented routing protocol is a congestion-aware adaptive routing algorithm for 2D mesh NoCs which does not support multicast (one-to-many) traffic while the other two protocols are adaptive routing models supporting both unicast (one-to-one) and multicast traffic. A streamlined on-chip router architecture is also presented for avoiding congested areas in 2D mesh NoCs via employing efficient input and output selection. The output selection utilizes an adaptive routing algorithm based on the congestion condition of neighboring routers while the input selection allows packets to be serviced from each input port according to its congestion level. Moreover, in order to increase memory parallelism and bring compatibility with existing IP cores in network-based multiprocessor architectures, adaptive network interface architectures are presented to use multiple SDRAMs which can be accessed simultaneously. In addition, a smart memory controller is integrated in the adaptive network interface to improve the memory utilization and reduce both memory and network latencies. Three Dimensional Integrated Circuits (3D ICs) have been emerging as a viable candidate to achieve better performance and package density as compared to traditional 2D ICs. In addition, combining the benefits of 3D IC and NoC schemes provides a significant performance gain for 3D architectures. In recent years, inter-layer communication across multiple stacked layers (vertical channel) has attracted a lot of interest. In this thesis, a novel adaptive pipeline bus structure is proposed for inter-layer communication to improve the performance by reducing the delay and complexity of traditional bus arbitration. In addition, two mesh-based topologies for 3D architectures are also introduced to mitigate the inter-layer footprint and power dissipation on each layer with a small performance penalty.

Control system for forced-air cooling of horticultural products

This work is a study of the implementation of a classical controller using a tuning method referred to as IMC (Internal Model Control) and aimed at the reduction of electrical energy consumption by the appropriate relation between energy consumption and the cooling time with forced air. The supervisory system installed was able to manipulate the variable of frequency of the signal power of the exhaust fan engine (forced air module), to accelerate or decelerate the loss of heat from the product to be cooled by airflow variation that passes through the mass of the produce. The results demonstrated a reduction in energy consumption from 64% and an increase of only 8% in the cooling time to the system using PI/IMC (Proportional - Integral with IMC) tuning method compared with the system in its operating nominal condition. This PI/IMC control may be implemented directly in a frequency converter, without the need to purchase a computer or PLC (programmable logic controller) to run the dedicated application, increasing its economical viability.

Application of fuzzy logic for the evaluation of livestock slaughtering

The fuzzy logic admits infinite intermediate logical values between false and true. With this principle, it developed in this study a system based on fuzzy rules, which indicates the body mass index of ruminant animals in order to obtain the best time to slaughter. The controller developed has as input the variables weight and height, and as output a new body mass index, called Fuzzy Body Mass Index (Fuzzy BMI), which may serve as a detection system at the time of livestock slaughtering, comparing one another by the linguistic variables "Very Low", "Low", "Average ", "High" and "Very High". For demonstrating the use application of this fuzzy system, an analysis was made with 147 Nellore beeves to determine Fuzzy BMI values for each animal and indicate the location of body mass of any herd. The performance validation of the system was based on a statistical analysis using the Pearson correlation coefficient of 0.923, representing a high positive correlation, indicating that the proposed method is appropriate. Thus, this method allows the evaluation of the herd comparing each animal within the group, thus providing a quantitative method of farmer decision. It was concluded that this study established a computational method based on fuzzy logic that mimics part of human reasoning and interprets the body mass index of any bovine species and in any region of the country.

System for studies of control strategies applied in the refrigerated chambers

The process of cold storage chambers contributes largely to the quality and longevity of stored products. In recent years, it has been intensified the study of control strategies in order to decrease the temperature change inside the storage chamber and to reduce the electric power consumption. This study has developed a system for data acquisition and process control, in LabVIEW language, to be applied in the cooling system of a refrigerating chamber of 30m³. The use of instrumentation and the application developed fostered the development of scientific experiments, which aimed to study the dynamic behavior of the refrigeration system, compare the performance of control strategies and the heat engine, even due to the controlled temperature, or to the electricity consumption. This system tested the strategies for on-off control, PID and fuzzy. Regarding power consumption, the fuzzy controller showed the best result, saving 10% when compared with other tested strategies.

Auger-type granular fertylizer distributor: matemathical model and dynamic simulation

The objective of this study was to model mathematically and to simulate the dynamic behavior of an auger-type fertilizer applicator (AFA) in order to use the variable-rate application (VRA) and reduce the coefficient of variation (CV) of the application, proposing an angular speed controller θ' for the motor drive shaft. The input model was θ' and the response was the fertilizer mass flow, due to the construction, density of fertilizer, fill factor and the end position of the auger. The model was used to simulate a control system in open loop, with an electric drive for AFA using an armature voltage (V A) controller. By introducing a sinusoidal excitation signal in V A with amplitude and delay phase optimized and varying θ' during an operation cycle, it is obtained a reduction of 29.8% in the CV (constant V A) to 11.4%. The development of the mathematical model was a first step towards the introduction of electric drive systems and closed loop control for the implementation of AFA with low CV in VRA.

Low cost driver device for microclimate maintenance in the pre-milking of dairy cattle

Due to the importance of the environment on animal production and thus environmental control, the study aims to build a system for monitoring and control the meteorological variables, temperature and relative humidity, low cost, which can be associated with an evaporative cooling system (ECS). The system development included all the stages of assembly, test and laboratory calibration, and later the validation of the equipment carried in the field. The validation step showed results which allowed concluding that the system can be safely used in the monitoring of these variables. The controller was efficient in management of the microclimate in the waiting corral and allowed the maintenance of the air temperature within the comfort range for dairy cattle in pre-milking with averaged 25.09 ºC during the afternoon. The equipment showed the lower cost (R$ 325.76) when compared to other middle market (R$ 450.00).

Electrically driven fertilizer applicator controlled by fuzzy logic

The present study shows the development, simulation and actual implementation of a closed-loop controller based on fuzzy logic that is able to regulate and standardize the mass flow of a helical fertilizer applicator. The control algorithm was developed using MATLAB's Fuzzy Logic Toolbox. Both open and closed-loop simulations of the controller were performed in MATLAB's Simulink environment. The instantaneous deviation of the mass flow from the set point (SP), its derivative, the equipment´s translation velocity and acceleration were all used as input signals for the controller, whereas the voltage of the applicator's DC electric motor (DCEM) was driven by the controller as output signal. Calibration and validation of the rules and membership functions of the fuzzy logic were accomplished in the computer simulation phase, taking into account the system's response to SP changes. The mass flow variation coefficient, measured in experimental tests, ranged from 6.32 to 13.18%. The steady state error fell between -0.72 and 0.13g s-1 and the recorded average rise time of the system was 0.38 s. The implemented controller was able to both damp the oscillations in mass flow that are characteristic of helical fertilizer applicators, and to effectively respond to SP variations.

Voimalaitoksen käytönaikaisen optimoinnin määrittely

Tässä diplomityössä määritellään biopolttoainetta käyttävän voimalaitoksen käytönaikainen tuotannon optimointimenetelmä. Määrittelytyö liittyy MW Powerin MultiPower CHP –voimalaitoskonseptin jatkokehitysprojektiin. Erilaisten olemassa olevien optimointitapojen joukosta valitaan tarkoitukseen sopiva, laitosmalliin ja kustannusfunktioon perustuva menetelmä, jonka tulokset viedään automaatiojärjestelmään PID-säätimien asetusarvojen muodossa. Prosessin mittaustulosten avulla lasketaan laitoksen energia- ja massataseet, joiden tuloksia käytetään seuraavan optimointihetken lähtötietoina. Optimoinnin kohdefunktio on kustannusfunktio, jonka termit ovat voimalaitoksen käytöstä aiheutuvia tuottoja ja kustannuksia. Prosessia optimoidaan säätimille annetut raja-arvot huomioiden niin, että kokonaiskate maksimoituu. Kun laitokselle kertyy käyttöikää ja historiadataa, voidaan prosessin optimointia nopeuttaa hakemalla tilastollisesti historiadatasta nykytilanteen olosuhteita vastaava hetki. Kyseisen historian hetken katetta verrataan kustannusfunktion optimoinnista saatuun katteeseen. Paremman katteen antavan menetelmän laskemat asetusarvot otetaan käyttöön prosessin ohjausta varten. Mikäli kustannusfunktion laskenta eikä historiadatan perusteella tehty haku anna paranevaa katetta, niiden laskemia asetusarvoja ei oteta käyttöön. Sen sijaan optimia aletaan hakea deterministisellä optimointialgoritmilla, joka hakee nykyhetken ympäristöstä paremman katteen antavia säätimien asetusarvoja. Säätöjärjestelmä on mahdollista toteuttaa myös tulevaisuutta ennustavana. Työn käytännön osuudessa voimalaitosmalli luodaan kahden eri mallinnusohjelman avulla, joista toisella kuvataan kattilan ja toisella voimalaitosprosessin toimintaa. Mallinnuksen tuloksena saatuja prosessiarvoja hyödynnetään lähtötietoina käyttökatteen laskennassa. Kate lasketaan kustannusfunktion perusteella. Tuotoista suurimmat liittyvät sähkön ja lämmön myyntiin sekä tuotantotukeen, ja suurimmat kustannukset liittyvät investoinnin takaisinmaksuun ja polttoaineen ostoon. Kustannusfunktiolle tehdään herkkyystarkastelu, jossa seurataan katteen muutosta prosessin teknisiä arvoja muutettaessa. Tuloksia vertaillaan referenssivoimalaitoksella suoritettujen verifiointimittausten tuloksiin, ja havaitaan, että tulokset eivät ole täysin yhteneviä. Erot johtuvat sekä mallinnuksen puutteista että mittausten lyhyehköistä tarkasteluajoista. Automatisoidun optimointijärjestelmän käytännön toteutusta alustetaan määrittelemällä käyttöön otettava optimointitapa, siihen liittyvät säätöpiirit ja tarvittavat lähtötiedot. Projektia tullaan jatkamaan järjestelmän ohjelmoinnilla, testauksella ja virityksellä todellisessa voimalaitosympäristössä ja myöhemmin ennustavan säädön toteuttamisella.

Energian talteenotto liikkuvassa raskaassa työkoneessa

Tämä työ on osa Integrated Serial and Parallel Hybrid Drives in Working Machines projektia. Työssä simuloidaan ja lasketaan energian palautuspotentiaalia raskaassa liikkuvassa työkoneessa. Työn alussa aihetta käsitellään yleisesti kirjallisuuskatsauksen muodossa. Tukkikurottaja valittiin simulointien ja laskennan kohteeksi. Työssä suoritettiin alustavat simuloinnit, joiden tarkoituksena oli varmistua, että palautettavaa energiaa on olemassa. Tulokset osoittavat, että energian palauttaminen on mahdollista. Mittaukset ovat osa työtä. Mitatut muuttujat ovat paineet ja pituudet hydraulisylintereistä, rungon kiihtyvyys, sekä kaikki CAN-väylään kytkettyjen antureiden mittaustiedot. Lopulliset simuloinnit perustuvat mitattuihin työkiertoihin. Työsylintereiden ja ajovoimansiirron tehotarpeet valittiin simulointien tarkasteltaviksi mittaussuureiksi. Mahdollinen palautettavan energian määrä eri työkierroissa on työn lopputulos. Tulokset osoittavat, että palautettavan energian määrä on talteenoton kannalta riittävä.

Design and Control of Permanent Magnet Synchronous Machine for Hybrid Electric Vehicle

This master’s thesis mainly focuses on the design requirements of an Electric drive for Hybrid car application and its control strategy to achieve a wide speed range. It also emphasises how the control and performance requirements are transformed into its design variables. A parallel hybrid topology is considered where an IC engine and an electric drive share a common crank shaft. A permanent magnet synchronous machine (PMSM) is used as an electric drive machine. Performance requirements are converted into Machine design variables using the vector model of PMSM. Main dimensions of the machine are arrived using analytical approach and Finite Element Analysis (FEA) is used to verify the design and performance. Vector control algorithm was used to control the machine. The control algorithm was tested in a low power PMSM using an embedded controller. A prototype of 10 kW PMSM was built according to the design values. The prototype was tested in the laboratory using a high power converter. Tests were carried out to verify different operating modes. The results were in agreement with the calculations.

Novel Methods for Error Modeling and Parameter Identification of a Redundant Serial-Parallel Hybrid Robot

To obtain the desirable accuracy of a robot, there are two techniques available. The first option would be to make the robot match the nominal mathematic model. In other words, the manufacturing and assembling tolerances of every part would be extremely tight so that all of the various parameters would match the “design” or “nominal” values as closely as possible. This method can satisfy most of the accuracy requirements， but the cost would increase dramatically as the accuracy requirement increases. Alternatively, a more cost-effective solution is to build a manipulator with relaxed manufacturing and assembling tolerances. By modifying the mathematical model in the controller, the actual errors of the robot can be compensated. This is the essence of robot calibration. Simply put, robot calibration is the process of defining an appropriate error model and then identifying the various parameter errors that make the error model match the robot as closely as possible. This work focuses on kinematic calibration of a 10 degree-of-freedom (DOF) redundant serial-parallel hybrid robot. The robot consists of a 4-DOF serial mechanism and a 6-DOF hexapod parallel manipulator. The redundant 4-DOF serial structure is used to enlarge workspace and the 6-DOF hexapod manipulator is used to provide high load capabilities and stiffness for the whole structure. The main objective of the study is to develop a suitable calibration method to improve the accuracy of the redundant serial-parallel hybrid robot. To this end, a Denavit–Hartenberg (DH) hybrid error model and a Product-of-Exponential (POE) error model are developed for error modeling of the proposed robot. Furthermore, two kinds of global optimization methods, i.e. the differential-evolution (DE) algorithm and the Markov Chain Monte Carlo (MCMC) algorithm, are employed to identify the parameter errors of the derived error model. A measurement method based on a 3-2-1 wire-based pose estimation system is proposed and implemented in a Solidworks environment to simulate the real experimental validations. Numerical simulations and Solidworks prototype-model validations are carried out on the hybrid robot to verify the effectiveness, accuracy and robustness of the calibration algorithms.

Sähköavusteisen polkupyörän vääntömomenttisäädön toteuttaminen amplitudimodulaatiolla

Sähköavusteinen polkupyörä on hieman tavallista polkupyörää vahvarakenteisempi ja painavampi. Lisäpainoa tuovat muun muassa akut ja sähkömoottori, joka avustaa polke-mista. Moottori asennetaan yleensä eturenkaan keskiöön. Suurimmassa osassa, jollei kaikissa, kaupallisista sähköavusteisissa polkupyörissä moottori on hiiliharjaton tasavirta-moottori. Hiiliharjattoman tasavirtamoottorin pyörimisnopeutta ja vääntömomenttia voidaan säätää usealla eri tavalla. Markkinoilla olevat säätimet perustuvat poikkeuksetta pulssinleveys-modulaatioon. Tämän työn tarkoituksena on tutkia, onko säätöjärjestelmä mahdollista to-teuttaa muulla tavalla kuin pulssinleveysmodulaattorilla. Tutkimuksessa päädytään käyt-tämään amplitudimodulointia, jolloin taajuus voidaan pitää vakiona. Tämän tutkimuksen rinnalla samaan polkupyörään rakennetaan polkemisenergian avulla akkuja lataava la-tausjärjestelmä. Tämän kandityön puitteissa tutkimus jää kesken, mutta toiminta osoitetaan teoreettisesti ja simuloimalla. Suurin syy kokeellisen testauksen epäonnistumiseen on käytettyjen kom-ponenttien sopimattomuus sovellukseen.

AMB system for high-speed motors using automatic commissioning

The general trend towards increasing e ciency and energy density drives the industry to high-speed technologies. Active Magnetic Bearings (AMBs) are one of the technologies that allow contactless support of a rotating body. Theoretically, there are no limitations on the rotational speed. The absence of friction, low maintenance cost, micrometer precision, and programmable sti ness have made AMBs a viable choice for highdemanding applications. Along with the advances in power electronics, such as signi cantly improved reliability and cost, AMB systems have gained a wide adoption in the industry. The AMB system is a complex, open-loop unstable system with multiple inputs and outputs. For normal operation, such a system requires a feedback control. To meet the high demands for performance and robustness, model-based control techniques should be applied. These techniques require an accurate plant model description and uncertainty estimations. The advanced control methods require more e ort at the commissioning stage. In this work, a methodology is developed for an automatic commissioning of a subcritical, rigid gas blower machine. The commissioning process includes open-loop tuning of separate parts such as sensors and actuators. The next step is to apply a system identi cation procedure to obtain a model for the controller synthesis. Finally, a robust model-based controller is synthesized and experimentally evaluated in the full operating range of the system. The commissioning procedure is developed by applying only the system components available and a priori knowledge without any additional hardware. Thus, the work provides an intelligent system with a self-diagnostics feature and an automatic commissioning.