Design and characterization of wideband Hall current sensors in BCD technology for smart power and metering applications

Power electronic circuits are moving towards higher switching frequencies, exploiting the capabilities of novel devices to shrink the dimension of passive components. This trend demands sensors capable enough to operate at such high frequencies. This thesis aims to demonstrate through experimental characterization, the broadband capability of a fully integrated CMOS X-Hall current sensor in current mode interfaced with a transimpedance amplifier (TIA), chip CH09, realized in CMOS technology for power electronics applications such as power converters. The system exploits a common-mode control system to operate the dual supply system, 5-V for the X-Hall probe and 1.2-V for the readout. The developed prototype achieves a maximum acquisition bandwidth of 12 MHz, a power consumption of 11.46 mW, resolution of 39 mArms, a sensitivity of 8 % /T, and a FoM of 569-MHz/A2mW, significantly higher than current state-of-the-art. Further enhancements were proposed to CH09 as a new chip CH100, aiming for accuracy levels prerequisite for a real-time power electronic application. The TIA was optimized for a wider bandwidth of 26.7 MHz with nearly 30% reduction of the integrated input referred noise of 26.69 nArms at the probe-AFE interface in the frequency band of DC-30 MHz, and a 10% improvement in the dynamic range. The expected input range is 5-A. The chip incorporates a dual sensing chain for differential sensing to overcome common mode interferences. A novel offset cancellation technique is proposed that would require switching of polarity of bias currents. Thermal gain drift was improved by a factor of 8 and will be digitally calibrated utilizing a new built-in temperature sensor with a post calibration measurement accuracy greater than 1%. The estimated power consumption of the entire system is 55.6 mW. Both prototypes have been implemented through a 90-nm microelectronic process from STMicroelectronics and occupy a silicon area of 2.4 mm2.

Study of low grade temperature CCHP systems for the realization of zero power buildings

Combined Cooling Heat and Power Generation (CCHP) or trigeneration has been considered worldwide as a suitable alternative to traditional energy systems in terms of significant energy saving and environmental conservation. The development and evaluation of a solar driven micro-CCHP system based on a ORC cogenerator and an Adsorption Chiller (AC) experimental prototypes has been the focus of this PhD research. The specific objectives of the overall project are: • To design, construct and evaluate an innovative Adsorption Chiller in order to improve the performances of the AC technology. • To thermodynamically model the proposed micro-scale solar driven CHP system and to prove that the concept of trigeneration through solar energy combined with an organic Rankine turbine cycle (ORC) and an adsorption chiller (AC) is suitable for residential applications.

Power converters in WBG device technology for automotive applications and characterization setups for GaN power transistors

This PhD dissertation envisages the design of innovative power converters exploiting WBG devices to get state-of-the-art performance in products intended for industrial applications of automotive field. The collaborations with different specialized companies, provided the opportunity to access commercially-available state-of-the-art SiC and GaN technologies and the possibility to realize innovative converter prototypes. Concerning SiC technology, the complete design of a $350kW$ Battery Emulator instrument in collaboration with a company leader in the automotive testing sector, was carried out from scratch exploiting state-of-the-art SiC power-modules, planar magnetics and top-notch MCU technologies. Discrete high-voltage GaN switches were exploited in the Power Supplies design for automotive charger application to target improved performances compared to the market state-of-the-art. Specifically, two high-efficiency prototypes, an AC/DC converter and a DC/DC converter of $7.5kW$, have been realized for this purpose. To further investigate the characteristics of state-of-the-art GaN power devices two measurement set-ups have been designed. In particular, the trapping phenomenon causing the collapse of drain current during ON-state with a consequent degradation of ON-resistance has been analyzed.

In-car sound linear simulation

In recent years, vehicle acoustics have gained significant importance in new car development: increasingly advanced infotainment systems for spatial audio and sound enhancement algorithms have become the norm in modern vehicles. In the past, car manufacturers had to build numerous prototypes to study the sound behaviour inside the car cabin or the effect of new algorithms under development. Nowadays, advanced simulation techniques can reduce development costs and time. In this work, after selecting the reference test vehicle, a modern luxury sedan equipped with a high-end sound system, two independent tools were developed: a simulation tool created in the Comsol Multiphysics environment and an auralization tool developed in the Cycling ‘74 MAX environment. The simulation tool can calculate the impulse response and acoustic spectrum at a specific position inside the cockpit. Its input data are the vehicle’s geometry, acoustic absorption parameters of materials, the acoustic characteristics and position of loudspeakers, and the type and position of virtual microphones (or microphone arrays). The simulation tool can also provide binaural impulse responses thanks to Head Related Transfer Functions (HRTFs) and an innovative algorithm able to compute the HRTF at any distance and angle from the head. Impulse responses from simulations or acoustic measurements inside the car cabin are processed and fed into the auralization tool, enabling real-time interaction by applying filters, changing the channels gain or displaying the acoustic spectrum. Since the acoustic simulation of a vehicle involves multiple topics, the focus of this work has not only been the development of two tools but also the study and application of new techniques for acoustic characterization of the materials that compose the cockpit and the loudspeaker simulation. Specifically, three different methods have been applied for material characterization through the use of a pressure-velocity probe, a Laser Doppler Vibrometer (LDV), and a microphone array.

Developing a methodology for co-creation using extended reality technologies.

Amid the remarkable growth of innovative technologies, particularly immersive technologies like Extended Reality (XR) (comprising of Virtual Reality (VR), Augmented Reality (AR) & Mixed Reality (MR)), a transformation is unfolding in the way we collaborate and interact. The current research takes the initiative to explore XR’s potential for co-creation activities and proposes XR as a future co-creation platform. It strives to develop a XR-based co-creation system, actively engage stakeholders in the co-creation process, with the goal of enhancing their creative businesses. The research leverages XR tools to investigate how they can enhance digital co-creation methods and determine if the system facilitates efficient and effective value creation during XR-based co-creation sessions. In specific terms, the research probes into whether the XR-based co-creation method and environment enhances the quality and novelty of ideas, reduce communication challenges by providing better understanding of the product, problem or process and optimize the process in terms of reduction in time and costs. The research introduces a multi-user, multi-sensory collaborative and interactive XR platform that adapts to various use-case scenarios. This thesis also presents the user testing performed to collect both qualitative and quantitative data, which serves to substantiate the hypothesis. What sets this XR system apart is its incorporation of fully functional prototypes into a mixed reality environment, providing users with a unique dimension within an immersive digital landscape. The outcomes derived from the experimental studies demonstrate that XR-based co-creation surpasses conventional desktop co-creation methods and remarkably, the results are even comparable to a full mock-up test. In conclusion, the research underscores that the utilization of XR as a tool for co-creation generates substantial value. It serves as a method that enhances the process, an environment that fosters interaction and collaboration, and a platform that equips stakeholders with the means to engage effectively.

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.

Calibration of the detector flight models for the HERMES and SPIRIT nanosatellite missions

The High Energy Rapid Modular Ensemble of Satellites (HERMES) is a new mission concept involving the development of a constellation of six CubeSats in low Earth orbit with new miniaturized instruments that host a hybrid Silicon Drift Detector/GAGG:Ce based system for X-ray and γ-ray detection, aiming to monitor high-energy cosmic transients, such as Gamma Ray Bursts and the electromagnetic counterparts of gravitational wave events. The HERMES constellation will also operate together with the Australian-Italian SpIRIT mission, which will house a HERMES-like detector. The HERMES pathfinder mini-constellation, consisting of six satellites plus SpIRIT, is likely to be launched in 2023. The HERMES detectors are based on the heritage of the Italian ReDSoX collaboration, with joint design and production by INFN-Trieste and Fondazione Bruno Kessler, and the involvement of several Italian research institutes and universities. An application-specific, low-noise, low-power integrated circuit (ASIC) called LYRA was conceived and designed for the HERMES readout electronics. My thesis project focuses on the ground calibrations of the first HERMES and SpIRIT flight detectors, with a performance assessment and characterization of the detectors. The first part of this work addresses measurements and experimental tests on laboratory prototypes of the HERMES detectors and their front-end electronics, while the second part is based on the design of the experimental setup for flight detector calibrations and related functional tests for data acquisition, as well as the development of the calibration software. In more detail, the calibration parameters (such as the gain of each detector channel) are determined using measurements with radioactive sources, performed at different operating temperatures between -20°C and +20°C by placing the detector in a suitable climate chamber. The final part of the thesis involves the analysis of the calibration data and a discussion of the results.

Dalla Sintesi di Leganti Polimerici alla Realizzazione di Adesivi da Parquet

This final report is part of a research project by Kerakoll S.P.A aimed to the realization and optimization of hybrid adhesive for the parquet using hybrid polyurethane silanizated (STPU). Hybrid polymers belong to polyurethane polymers which undergo an hybridization process where the classic isocyanate groups are converted into a alkoxysilylether terminated chain. The aim of this thesis was to realize hybrid polymers with specific proprieties compared to the indexes wanted by the company; another goal of this project was to use this polymers STPU to realize adhesive for the parquet which should be competitive in the adhesive market. All activities were carried out in a chemistry laboratory with specific tools for the synthesis of polymers and characterization of the finals products. The study led to two prototypes; the second was obtained thanks to the use of the experimental design procedure known as DOE (Design Of Experiment), a recently acquired approach by the company, which allows the rationalization of the formulas and the creation of a database that can be extended and implemented indefinitely.

Comparison of different solutions for the hybridization of a motorcycle engine for Formula Student applications and evaluation of the effectiveness on the simulated lap time

Following the latest environmental concerns, the importance of minimising the detrimental effect of emissions of terrestrial vehicles has become a major goal for the whole automotive field. The key to achieve an emission-free long term future is the electrification of vehicle fleets; this huge step cannot be taken without intermediate technologies. In this context, hybrid vehicles are fundamental to reach this goal. Specifically, mild hybrid vehicles represent a trade-off between cost and emissions that could act now as a bridge towards electrification. Like the industry, also student engineering competitions are likely to take the same route: Combustion vehicles may well turn into hybrid vehicles. For this reason, a preliminary design overview is necessary to pinpoint the key performance indicators for the prototypes of the future.

A new concept for a Sport-Coupè car developed with the Industrial Design Structure method (IDeS)

The aim of this study, conducted in collaboration with Lawrence Technological University in Detroit, is to create, through the method of the Industrial Design Structure (IDeS), a new concept for a sport-coupe car, based on a restyling of a retro model (Ford Mustang 1967). To date, vintage models of cars always arouse great interest both for the history behind them and for the classic and elegant style. Designing a model of a vehicle that can combine the charm of retro style with the innovation and comfort of modern cars would allow to meet the needs and desires of a large segment of the market that today is forced to choose between past and future. Thanks to a well-conceived concept car an automaker company is able to express its future policy, to make a statement of intent as, such a prototype, ticks all the boxes, from glamour and visual wow-factor to technical intrigue and design fascination. IDeS is an approach that makes use of many engineering tools to realize a study developed on several steps that must be meticulously organized and timed. With a deep analysis of the trends dominating the automotive industry it is possible to identify a series of product requirements using quality function deployment (QFD). The considerations from this first evaluation led to the definition of the technical specifications via benchmarking (BM) and top-flop analysis (TFA). Then, the structured methodology of stylistic design engineering (SDE) is applied through six phases: (1) stylistic trends analysis; (2) sketches; (3) 2D CAD drawings; (4) 3D CAD models; (5) virtual prototyping; (6) solid stylistic model. Finally, Developing the IDeS method up to the final stages of Prototypes and Testing you get a product as close as possible to the ideal vehicle conceptualized in the initial analysis.