Design optimization of modern machine drive systems for maximum fault tolerant and optimal operation

Modern electric machine drives, particularly three phase permanent magnet machine drive systems represent an indispensable part of high power density products. Such products include; hybrid electric vehicles, large propulsion systems, and automation products. Reliability and cost of these products are directly related to the reliability and cost of these systems. The compatibility of the electric machine and its drive system for optimal cost and operation has been a large challenge in industrial applications. The main objective of this dissertation is to find a design and control scheme for the best compromise between the reliability and optimality of the electric machine-drive system. The effort presented here is motivated by the need to find new techniques to connect the design and control of electric machines and drive systems. ^ A highly accurate and computationally efficient modeling process was developed to monitor the magnetic, thermal, and electrical aspects of the electric machine in its operational environments. The modeling process was also utilized in the design process in form finite element based optimization process. It was also used in hardware in the loop finite element based optimization process. The modeling process was later employed in the design of a very accurate and highly efficient physics-based customized observers that are required for the fault diagnosis as well the sensorless rotor position estimation. Two test setups with different ratings and topologies were numerically and experimentally tested to verify the effectiveness of the proposed techniques. ^ The modeling process was also employed in the real-time demagnetization control of the machine. Various real-time scenarios were successfully verified. It was shown that this process gives the potential to optimally redefine the assumptions in sizing the permanent magnets of the machine and DC bus voltage of the drive for the worst operating conditions. ^ The mathematical development and stability criteria of the physics-based modeling of the machine, design optimization, and the physics-based fault diagnosis and the physics-based sensorless technique are described in detail. ^ To investigate the performance of the developed design test-bed, software and hardware setups were constructed first. Several topologies of the permanent magnet machine were optimized inside the optimization test-bed. To investigate the performance of the developed sensorless control, a test-bed including a 0.25 (kW) surface mounted permanent magnet synchronous machine example was created. The verification of the proposed technique in a range from medium to very low speed, effectively show the intelligent design capability of the proposed system. Additionally, to investigate the performance of the developed fault diagnosis system, a test-bed including a 0.8 (kW) surface mounted permanent magnet synchronous machine example with trapezoidal back electromotive force was created. The results verify the use of the proposed technique under dynamic eccentricity, DC bus voltage variations, and harmonic loading condition make the system an ideal case for propulsion systems.^

Physical dynamic simulation of shipboard power system components in a distributed computational environment

Shipboard power systems have different characteristics than the utility power systems. In the Shipboard power system it is crucial that the systems and equipment work at their peak performance levels. One of the most demanding aspects for simulations of the Shipboard Power Systems is to connect the device under test to a real-time simulated dynamic equivalent and in an environment with actual hardware in the Loop (HIL). The real time simulations can be achieved by using multi-distributed modeling concept, in which the global system model is distributed over several processors through a communication link. The advantage of this approach is that it permits the gradual change from pure simulation to actual application. In order to perform system studies in such an environment physical phase variable models of different components of the shipboard power system were developed using operational parameters obtained from finite element (FE) analysis. These models were developed for two types of studies low and high frequency studies. Low frequency studies are used to examine the shipboard power systems behavior under load switching, and faults. High-frequency studies were used to predict abnormal conditions due to overvoltage, and components harmonic behavior. Different experiments were conducted to validate the developed models. The Simulation and experiment results show excellent agreement. The shipboard power systems components behavior under internal faults was investigated using FE analysis. This developed technique is very curial in the Shipboard power systems faults detection due to the lack of comprehensive fault test databases. A wavelet based methodology for feature extraction of the shipboard power systems current signals was developed for harmonic and fault diagnosis studies. This modeling methodology can be utilized to evaluate and predicate the NPS components future behavior in the design stage which will reduce the development cycles, cut overall cost, prevent failures, and test each subsystem exhaustively before integrating it into the system.

Hajautetun automaation käyttö osana simulaatiota

Työssä perehdytään simulaatiotekniikkaan, jossa käytetään osana fyysistä laitteistoa, ja siihen tarvittaviin komponentteihin, kuten ohjelmistorajapintoihin sekä kenttäväylään. Työssä tutustutaan myös IEC 61131-3 ja IEC 61499 -standardien mukaisiin toimintolohkomalleihin, joita käytetään automaatiossa. Näiden perusteella kehitetään järjestelmä, jonka avulla Simulink-ympäristössä voidaan oman toimintolohkon avulla käyttää taajuusmuuttajaa osana simulaatiota. Tällaisen reaaliaikaisen systeemin eri osien väliseen synkronointiin kiinnitetään myös huomiota. Järjestelmää testataan simulaatiomallilla, jossa syötetään vääntömomenttiohje taajuusmuuttajalle, joka mittaa siihen kytketyn moottorin pyörimisnopeuden. Mallilla voidaan esimerkiksi arvioida kuorman hitausmomentti. Työssä tutustutaan myös taajuusmuuttajien ohjelmallisiin ominaisuuksiin ja niiden perusteella pohditaan esitetyn kaltaisten järjestelmien käyttöä hajautettuna automaatiojärjestelmänä. Kokeellinen työ tehtiin säätö- ja digitaalitekniikan laboratoriossa vuoden 2010 aikana.

Design Optimization of Modern Machine-drive Systems for Maximum Fault Tolerant and Optimal Operation

Modern electric machine drives, particularly three phase permanent magnet machine drive systems represent an indispensable part of high power density products. Such products include; hybrid electric vehicles, large propulsion systems, and automation products. Reliability and cost of these products are directly related to the reliability and cost of these systems. The compatibility of the electric machine and its drive system for optimal cost and operation has been a large challenge in industrial applications. The main objective of this dissertation is to find a design and control scheme for the best compromise between the reliability and optimality of the electric machine-drive system. The effort presented here is motivated by the need to find new techniques to connect the design and control of electric machines and drive systems. A highly accurate and computationally efficient modeling process was developed to monitor the magnetic, thermal, and electrical aspects of the electric machine in its operational environments. The modeling process was also utilized in the design process in form finite element based optimization process. It was also used in hardware in the loop finite element based optimization process. The modeling process was later employed in the design of a very accurate and highly efficient physics-based customized observers that are required for the fault diagnosis as well the sensorless rotor position estimation. Two test setups with different ratings and topologies were numerically and experimentally tested to verify the effectiveness of the proposed techniques. The modeling process was also employed in the real-time demagnetization control of the machine. Various real-time scenarios were successfully verified. It was shown that this process gives the potential to optimally redefine the assumptions in sizing the permanent magnets of the machine and DC bus voltage of the drive for the worst operating conditions. The mathematical development and stability criteria of the physics-based modeling of the machine, design optimization, and the physics-based fault diagnosis and the physics-based sensorless technique are described in detail. To investigate the performance of the developed design test-bed, software and hardware setups were constructed first. Several topologies of the permanent magnet machine were optimized inside the optimization test-bed. To investigate the performance of the developed sensorless control, a test-bed including a 0.25 (kW) surface mounted permanent magnet synchronous machine example was created. The verification of the proposed technique in a range from medium to very low speed, effectively show the intelligent design capability of the proposed system. Additionally, to investigate the performance of the developed fault diagnosis system, a test-bed including a 0.8 (kW) surface mounted permanent magnet synchronous machine example with trapezoidal back electromotive force was created. The results verify the use of the proposed technique under dynamic eccentricity, DC bus voltage variations, and harmonic loading condition make the system an ideal case for propulsion systems.

Modelling and Optimization of Energy Management Strategies for Hybrid Vehicles

In the last decades the automotive sector has seen a technological revolution, due mainly to the more restrictive regulation, the newly introduced technologies and, as last, to the poor resources of fossil fuels remaining on Earth. Promising solution in vehicles’ propulsion are represented by alternative architectures and energy sources, for example fuel-cells and pure electric vehicles. The automotive transition to new and green vehicles is passing through the development of hybrid vehicles, that usually combine positive aspects of each technology. To fully exploit the powerful of hybrid vehicles, however, it is important to manage the powertrain’s degrees of freedom in the smartest way possible, otherwise hybridization would be worthless. To this aim, this dissertation is focused on the development of energy management strategies and predictive control functions. Such algorithms have the goal of increasing the powertrain overall efficiency and contextually increasing the driver safety. Such control algorithms have been applied to an axle-split Plug-in Hybrid Electric Vehicle with a complex architecture that allows more than one driving modes, including the pure electric one. The different energy management strategies investigated are mainly three: the vehicle baseline heuristic controller, in the following mentioned as rule-based controller, a sub-optimal controller that can include also predictive functionalities, referred to as Equivalent Consumption Minimization Strategy, and a vehicle global optimum control technique, called Dynamic Programming, also including the high-voltage battery thermal management. During this project, different modelling approaches have been applied to the powertrain, including Hardware-in-the-loop, and diverse powertrain high-level controllers have been developed and implemented, increasing at each step their complexity. It has been proven the potential of using sophisticated powertrain control techniques, and that the gainable benefits in terms of fuel economy are largely influenced by the chose energy management strategy, even considering the powerful vehicle investigated.

Real-time PMU monitoring of an IEEE 5-Bus Network implemented on OPAL system

This thesis studies the state-of-the-art of phasor measurement units (PMUs) as well as their metrological requirements stated in the IEEE C37.118.1 and C37.118.2 Standards for guaranteeing correct measurement performances. Communication systems among PMUs and their possible applicability in the field of power quality (PQ) assessment are also investigated. This preliminary study is followed by an analysis of the working principle of real-time (RT) simulators and the importance of hardware-in-the-loop (HIL) implementation, examining the possible case studies specific for PMUs, including compliance tests which are one of the most important parts. The core of the thesis is focused on the implementation of a PMU model in the IEEE 5-bus network in Simulink and in the validation of the results using OPAL RT-4510 as a real-time simulator. An initial check allows one to get an idea about the goodness of the results in Simulink, comparing the PMU data with respect to the load-flow steady-state information. In this part, accuracy indices are also calculated for both voltage and current synchrophasors. The following part consists in the implementation of the same code in OPAL-RT 4510 simulator, after which an initial analysis is carried out in a qualitative way in order to get a sense of the goodness of the outcomes. Finally, the confirmation of the results is based on an examination of the attained voltage and current synchrophasors and accuracy indices coming from Simulink models and from OPAL system, using a Matlab script. This work also proposes suggestions for an upcoming operation of PMUs in a more complex system as the Digital Twin (DT) in order to improve the performances of the already-existing protection devices of the distribution system operator (DSO) for a future enhancement of power systems reliability.

Neptune: a hil simulator for multiple UUVs

This paper overviews the field of graphical simulators used for AUV development, presents the taxonomy of these applications and proposes a classification. It also presents Neptune, a multivehicle, real-time, graphical simulator based on OpenGL that allows hardware in the loop simulations

Graphical simulators for AUV development

A long development time is needed from the design to the implementation of an AUV. During the first steps, simulation plays an important role, since it allows for the development of preliminary versions of the control system to be integrated. Once the robot is ready, the control systems are implemented, tuned and tested. The use of a real-time simulator can help closing the gap between off-line simulation and real testing using the already implemented robot. When properly interfaced with the robot hardware, a real-time graphical simulation with a "hardware in the loop" configuration, can allow for the testing of the implemented control system running in the actual robot hardware. Hence, the development time is drastically reduced. These paper overviews the field of graphical simulators used for AUV development proposing a classification. It also presents NEPTUNE, a multi-vehicle, real-time, graphical simulator based on OpenGL that allows hardware in the loop simulations

Novel virtual environment and real-time simulation based methods for improving life-cycle efficiency of non-road mobile machinery

Virtual environments and real-time simulators (VERS) are becoming more and more important tools in research and development (R&D) process of non-road mobile machinery (NRMM). The virtual prototyping techniques enable faster and more cost-efficient development of machines compared to use of real life prototypes. High energy efficiency has become an important topic in the world of NRMM because of environmental and economic demands. The objective of this thesis is to develop VERS based methods for research and development of NRMM. A process using VERS for assessing effects of human operators on the life-cycle efficiency of NRMM was developed. Human in the loop simulations are ran using an underground mining loader to study the developed process. The simulations were ran in the virtual environment of the Laboratory of Intelligent Machines of Lappeenranta University of Technology. A physically adequate real-time simulation model of NRMM was shown to be reliable and cost effective in testing of hardware components by the means of hardware-in-the-loop (HIL) simulations. A control interface connecting integrated electro-hydraulic energy converter (IEHEC) with virtual simulation model of log crane was developed. IEHEC consists of a hydraulic pump-motor and an integrated electrical permanent magnet synchronous motorgenerator. The results show that state of the art real-time NRMM simulators are capable to solve factors related to energy consumption and productivity of the NRMM. A significant variation between the test drivers is found. The results show that VERS can be used for assessing human effects on the life-cycle efficiency of NRMM. HIL simulation responses compared to that achieved with conventional simulation method demonstrate the advances and drawbacks of various possible interfaces between the simulator and hardware part of the system under study. Novel ideas for arranging the interface are successfully tested and compared with the more traditional one. The proposed process for assessing the effects of operators on the life-cycle efficiency will be applied for wider group of operators in the future. Driving styles of the operators can be analysed statistically from sufficient large result data. The statistical analysis can find the most life-cycle efficient driving style for the specific environment and machinery. The proposed control interface for HIL simulation need to be further studied. The robustness and the adaptation of the interface in different situations must be verified. The future work will also include studying the suitability of the IEHEC for different working machines using the proposed HIL simulation method.

Experimentation on Wind Powered Hydraulic Heating System

It is common knowledge of the world’s dependency on fossil fuel for energy, its unsustainability on the long run and the changing trend towards renewable energy as an alternative energy source. This aims to cut down greenhouse gas emission and its impact on the rate of ecological and climatic change. Quite remarkably, wind energy has been one of many focus areas of renewable energy sources and has attracted lots of investment and technological advancement. The objective of this research is to explore wind energy and its application in household heating. This research aims at applying experimental approach in real time to study and verify a virtually simulated wind powered hydraulic house heating system. The hardware components comprise of an integrated hydraulic pump, flow control valve, hydraulic fluid and other hydraulic components. The system design and control applies hardware in-the-loop (HIL) simulation setup. Output signal from the semi-empirical turbine modelling controls the integrated motor to generate flow. Throttling the volume flow creates pressure drop across the valve and subsequently thermal power in the system to be outputted using a heat exchanger. Maximum thermal power is achieved by regulating valve orifice to achieve optimum system parameter. Savonius rotor is preferred for its low inertia, high starting torque and ease of design and maintenance characteristics, but lags in power efficiency. A prototype turbine design is used; with power output in range of practical Savonius turbine. The physical mechanism of the prototype turbine’s augmentation design is not known and will not be a focus in this study.

Zur Identifikation mechatronischer Stellglieder mit Reibung bei Kraftfahrzeugen

Diese Arbeit befasst sich mit der Modellbildung mechatronischer Systeme mit Reibung. Geeignete dynamische Modelle sind die Grundlage für verschiedenste Aufgabenstellungen. Sind dynamische Prozessmodelle verfügbar, so können leistungsfähige modellbasierte Entwurfsmethoden angewendet werden sowie modellbasierte Anwendungen entwickelt werden. Allerdings ist der Aufwand für die Modellbildung ein beschränkender Faktor für eine weite Verbreitung modellbasierter Applikationen in der Praxis. Eine Automatisierung des Modellbildungsprozesses ist deshalb von großem Interesse. Die vorliegende Arbeit stellt für die Klasse „mechatronischer Systeme mit Reibung“ drei Modellierungsmethoden vor: semi-physikalische Modellierung, Sliding-Mode-Beobachter-basierte Modellierung und empirische Modellierung mit einem stückweise affinen (PWA) Modellansatz. Zum Ersten wird die semi-physikalische Modellierung behandelt. Gegenüber anderen Verfahren, die häufig umfangreiche Vorkenntnisse und aufwändige Experimente erfordern, haben diese neuen Verfahren den Vorteil, dass die Modellierung von Systemen mit Reibung selbst bei begrenzten Vorkenntnissen und minimalem Experimentaufwand automatisiert werden kann. Zum Zweiten wird ein neuer Ansatz zur Reibkraftrekonstruktion und Reibmodellierung mittels Sliding-Mode-Beobachter präsentiert. Durch Verwendung des vorgestellten Sliding-Mode- Beobachters, der basierend auf einem einfachen linearen Zustandsraummodell entworfen wird, lässt sich die Reibung datengetrieben aus den Ein-/Ausgangsmessdaten (im offenen Regelkreis) rekonstruieren und modellieren. Im Vergleich zu anderen Reibmodellierungsmethoden, die häufig umfangreiche Vorkenntnisse und aufwändige Messungen im geschlossenen Regelkreis erfordern, haben diese neuen Verfahren den Vorteil, dass die Modellierung von Systemen mit Reibung selbst bei begrenzten Vorkenntnissen und minimalem Experimentaufwand weitgehend automatisiert werden kann. Zum Dritten wird ein PWA-Modellierungsansatz mit einer clusterungsbasierten Identifikationsmethode für Systeme mit Reibung vorgestellt. In dieser Methode werden die Merkmale in Hinblick auf Reibeffekte ausgewählt. Und zwar wird der klassische c-Means-Algorithmus verwendet, welcher bedienfreundlich, effizient und geeignet für große und reale Datensätze ist. Im Gegensatz zu anderen Methoden sind bei dieser Methode nur wenige Entwurfsparameter einzustellen und sie ist für reale Systeme mit Reibung einfach anwendbar. Eine weitere Neuheit der vorgestellten PWA-Methode liegt darin, dass die Kombination der Clustervaliditätsmaße und Modellprädiktionsfehler zur Festlegung der Anzahl der Teilmodelle benutzt wird. Weiterhin optimiert die vorgestellte Methode die Parameter der lokalen Teilmodelle mit der OE (Output-Fehler)-Schätzmethode. Als Anwendungsbeispiele werden Drosselklappen, Drallklappen und AGR-Ventile (Abgasrückführventil) im Dieselfahrzeug betrachtet und die erzeugten Modelle werden in der industriellen HiL-Simulation eingesetzt. Aufgrund der Effizienz und Effektivität der Modellierungsmethoden sind die vorgestellten Methoden direkt in der automobilen Praxis einsetzbar.

Neptune: a hil simulator for multiple UUVs

This paper overviews the field of graphical simulators used for AUV development, presents the taxonomy of these applications and proposes a classification. It also presents Neptune, a multivehicle, real-time, graphical simulator based on OpenGL that allows hardware in the loop simulations

Graphical simulators for AUV development

A long development time is needed from the design to the implementation of an AUV. During the first steps, simulation plays an important role, since it allows for the development of preliminary versions of the control system to be integrated. Once the robot is ready, the control systems are implemented, tuned and tested. The use of a real-time simulator can help closing the gap between off-line simulation and real testing using the already implemented robot. When properly interfaced with the robot hardware, a real-time graphical simulation with a "hardware in the loop" configuration, can allow for the testing of the implemented control system running in the actual robot hardware. Hence, the development time is drastically reduced. These paper overviews the field of graphical simulators used for AUV development proposing a classification. It also presents NEPTUNE, a multi-vehicle, real-time, graphical simulator based on OpenGL that allows hardware in the loop simulations

Plasmodium falciparum Rosetting Epitopes Converge in the SD3-Loop of PfEMP1-DBL1α

The ability of Plasmodium falciparum parasitized RBC (pRBC) to form rosettes with normal RBC is linked to the virulence of the parasite and RBC polymorphisms that weaken rosetting confer protection against severe malaria. The adhesin PfEMP1 mediates the binding and specific antibodies prevent sequestration in the micro-vasculature, as seen in animal models. Here we demonstrate that epitopes targeted by rosette disrupting antibodies converge in the loop of subdomain 3 (SD3) which connects the h6 and h7 α-helices of PfEMP1-DBL1α. Both monoclonal antibodies and polyclonal IgG, that bound to epitopes in the SD3-loop, stained the surface of pRBC, disrupted rosettes and blocked direct binding of recombinant NTS-DBL1α to RBC. Depletion of polyclonal IgG raised to NTS-DBL1α on a SD3 loop-peptide removed the anti-rosetting activity. Immunizations with recombinant subdomain 1 (SD1), subdomain 2 (SD2) or SD3 all generated antibodies reacting with the pRBC-surface but only the sera of animals immunized with SD3 disrupted rosettes. SD3-sequences were found to segregate phylogenetically into two groups (A/B). Group A included rosetting sequences that were associated with two cysteine-residues present in the SD2-domain while group B included those with three or more cysteines. Our results suggest that the SD3 loop of PfEMP1-DBL1α is an important target of anti-rosetting activity, clarifying the molecular basis of the development of variant-specific rosette disrupting antibodies.

Dynamic whole system testing of combined renewable heating systems : the current state of the art

Objective: For the evaluation of the energetic performance of combined renewable heating systems that supply space heat and domestic hot water for single family houses, dynamic behaviour, component interactions, and control of the system play a crucial role and should be included in test methods. Methods: New dynamic whole system test methods were developed based on “hardware in the loop” concepts. Three similar approaches are described and their differences are discussed. The methods were applied for testing solar thermal systems in combination with fossil fuel boilers (heating oil and natural gas), biomass boilers, and/or heat pumps. Results: All three methods were able to show the performance of combined heating systems under transient operating conditions. The methods often detected unexpected behaviour of the tested system that cannot be detected based on steady state performance tests that are usually applied to single components. Conclusion: Further work will be needed to harmonize the different test methods in order to reach comparable results between the different laboratories. Practice implications: A harmonized approach for whole system tests may lead to new test standards and improve the accuracy of performance prediction as well as reduce the need for field tests.