Interdisciplinarity and Design Conceptualisation: Contributions from a Small-Scale Design Experiment

Literature emphasises the sparse research focused in collaborative and open approaches in the design conceptualisation stage, also known as the Fuzzy Front-End (FFE). Presently, the most challenging discussion arising from this specific field of research lies in understanding on whether or not to structure the referred conceptual stage. Accordingly, the established hypothesis behind this study sustains that a structured approach in the FFE would benefit the interdisciplinary dialogue. Therefore, two objectives support this study: to understand the benefits of an interdisciplinary approach in the FFE, and to test one proposed model for this conceptual stage. By means of a small-scale design experiment, this paper pretends to give additional contributions to this area of research, in the context of new product development (NPD). The general research supporting this specific study aims to conceptualise in the area of newly and futuristic aircraft configurations. Hence, this same topic based the conceptualisation process in the conducted ideation sessions, which are conducted by five different teams of three elements each. The results of the different ideation sessions reinforce the contemporary paradigm of Open Innovation (OI), which is based in trust and communication to better collaborate. The postulated hypothesis for this study is partially validated as teams testing the proposed and structured model generally consider that its usage would benefit the integration of different disciplines. Besides, a general feeling that a structured approach integrates different perspectives and gives creativity a focus pervades. Nevertheless, the small-scale of the design experiment attributes some limitations to this study, despite giving new insights in how to better organise coming and more sustained studies. Interestingly, the importance of sketching as an interdisciplinary means of communication is underlined with the obtained results.

Does Final Energy Demand in Portugal Exhibit Long Memory? A Fractional Integration Analysis

In this paper, we measure the degree of fractional integration in final energy demand in Portugal using an ARFIMA model with and without adjustments for seasonality. We consider aggregate energy demand as well as final demand for petroleum, electricity, coal, and natural gas. Our findings suggest the presence of long memory in all of the components of energy demand. All fractional-difference parameters are positive and lower than 0.5 indicating that the series are stationary, although with mean reversion patterns slower than in the typical short-run processes. These results have important implications for the design of energy policies. As a result of the long-memory in final energy demand, the effects of temporary policy shocks will tend to disappear slowly. This means that even transitory shocks have long lasting effects. Given the temporary nature of these effects, however, permanent effects on final energy demand require permanent policies. This is unlike what would be suggested by the more standard, but much more limited, unit root approach, which would incorrectly indicate that even transitory policies would have permanent effects

AgroDB - integration of database management systems with crop models.

2016

Development of methodologies supporting the sustainable and safe integration of offshore conventional and renewable energy production

Against a backdrop of rapidly increasing worldwide population and growing energy demand, the development of renewable energy technologies has become of primary importance in the effort to reduce greenhouse gas emissions. However, it is often technically and economically infeasible to transport discontinuous renewable electricity for long distances to the shore. Another shortcoming of non-programmable renewable power is its integration into the onshore grid without affecting the dispatching process. On the other hand, the offshore oil & gas industry is striving to reduce overall carbon footprint from onsite power generators and limiting large expenses associated to carrying electricity from remote offshore facilities. Furthermore, the increased complexity and expansion towards challenging areas of offshore hydrocarbons operations call for higher attention to safety and environmental protection issues from major accident hazards. Innovative hybrid energy systems, as Power-to-Gas (P2G), Power-to-Liquid (P2L) and Gas-to-Power (G2P) options, implemented at offshore locations, would offer the opportunity to overcome challenges of both renewable and oil & gas sectors. This study aims at the development of systematic methodologies based on proper sustainability and safety performance indicators supporting the choice of P2G, P2L and G2P hybrid energy options for offshore green projects in early design phases. An in-depth analysis of the different offshore hybrid strategies was performed. The literature reviews on existing methods proposing metrics to assess sustainability of hybrid energy systems, inherent safety of process routes in conceptual design stage and environmental protection of installations from oil and chemical accidental spills were carried out. To fill the gaps, a suite of specific decision-making methodologies was developed, based on representative multi-criteria indicators addressing technical, economic, environmental and societal aspects of alternative options. A set of five case-studies was defined, covering different offshore scenarios of concern, to provide an assessment of the effectiveness and value of the developed tools.

Design of experiment in drug development: optimal allocations in multi-arm clinical trials and design space for multi-step processes

In this thesis, we deal with the design of experiments in the drug development process, focusing on the design of clinical trials for treatment comparisons (Part I) and the design of preclinical laboratory experiments for proteins development and manufacturing (Part II). In Part I we propose a multi-purpose design methodology for sequential clinical trials. We derived optimal allocations of patients to treatments for testing the efficacy of several experimental groups by also taking into account ethical considerations. We first consider exponential responses for survival trials and we then present a unified framework for heteroscedastic experimental groups that encompasses the general ANOVA set-up. The very good performance of the suggested optimal allocations, in terms of both inferential and ethical characteristics, are illustrated analytically and through several numerical examples, also performing comparisons with other designs proposed in the literature. Part II concerns the planning of experiments for processes composed of multiple steps in the context of preclinical drug development and manufacturing. Following the Quality by Design paradigm, the objective of the multi-step design strategy is the definition of the manufacturing design space of the whole process and, as we consider the interactions among the subsequent steps, our proposal ensures the quality and the safety of the final product, by enabling more flexibility and process robustness in the manufacturing.

Dry grinding technology for automotive gears manufacturing: process modeling and optimization

The following thesis focused on the dry grinding process modelling and optimization for automotive gears production. A FEM model was implemented with the aim at predicting process temperatures and preventing grinding thermal defects on the material surface. In particular, the model was conceived to facilitate the choice of the grinding parameters during the design and the execution of the dry-hard finishing process developed and patented by the company Samputensili Machine Tools (EMAG Group) on automotive gears. The proposed model allows to analyse the influence of the technological parameters, comprising the grinding wheel specifications. Automotive gears finished by dry-hard finishing process are supposed to reach the same quality target of the gears finished through the conventional wet grinding process with the advantage of reducing production costs and environmental pollution. But, the grinding process allows very high values of specific pressure and heat absorbed by the material, therefore, removing the lubricant increases the risk of thermal defects occurrence. An incorrect design of the process parameters set could cause grinding burns, which affect the mechanical performance of the ground component inevitably. Therefore, a modelling phase of the process could allow to enhance the mechanical characteristics of the components and avoid waste during production. A hierarchical FEM model was implemented to predict dry grinding temperatures and was represented by the interconnection of a microscopic and a macroscopic approach. A microscopic single grain grinding model was linked to a macroscopic thermal model to predict the dry grinding process temperatures and so to forecast the thermal cycle effect caused by the process parameters and the grinding wheel specification choice. Good agreement between the model and the experiments was achieved making the dry-hard finishing an efficient and reliable technology to implement in the gears automotive industry.

Additive manufacturing e ottimizzazione topologica: massimizzare le prestazioni di una pinza freno per applicazioni motorsport

I veicoli ad alte prestazioni sono soggetti ad elevati carichi per piccoli intervalli di tempo. Questo comporta diverse criticità sulle componenti che costituiscono la vettura: una di queste è la pinza freno. Al fine di renderla performante è necessario il possesso di due proprietà. In primo luogo, la pinza freno deve essere il più leggera possibile poiché essa conferisce un'inerzia nella risposta della sospensione del veicolo, procurando il distacco dello pneumatico dal suolo e causando perdita di aderenza. In secondo luogo, è necessario contenere le deformazioni della pinza freno garantendo un determinato feeling per il pilota. Il compito del progettista è ottimizzare questi due parametri che hanno effetti antitetici. Questa difficoltà porta il progettista a creare design molto complessi per raggiungere l’ottimale e non sempre le geometrie ottenute sono realizzabili con tecnologie convenzionali. Questo studio riguarda il miglioramento prestazionale di una pinza freno costruita con una lega di alluminio 7075-T6 e lavorato dal pieno. Gli obbiettivi sono quello di produrre il nuovo corpo in titanio TI6Al4V, dal momento che le temperature di esercizio portano a grandi decadute di caratteristiche meccaniche dell’alluminio, contenere il più possibile la massa a fronte dell’aumento di densità di materiale e ovviamente limitare le deformazioni. Al fine di ottenere gli obbiettivi prefissati sono utilizzati metodi agli elementi finiti in diverse fasi della progettazione: per acquisire una geometria di partenza (ottimizzazione topologica) e per la validazione delle geometrie ottenute. Le geometrie ricavate tramite l’ottimizzazione topologica devono essere ricostruite tramite software CAD affinché possano essere ingegnerizzate. Durante la modellazione è necessario valutare quale tecnologia è più vantaggiosa per produrre il componente. In questo caso studio si utilizza un processo di addizione di materiale, più specificatamente una tecnica Selective Laser Melting (SLM).

Metal additive manufacturing of soft magnetic material for electric machines

This research work concerns the application of additive manufacturing (AM) technologies in new electric mobility sectors. The unmatched freedom that AM offers can potentially change the way electric motors are designed and manufactured. The thesis investigates the possibility of creating optimized electric machines that exploit AM technologies, with potential in various industrial sectors, including automotive and aerospace. In particular, we will evaluate how the design of electric motors can be improved by producing the rotor core using Laser Powder Bed Fusion (LPBF) and how the resulting design choices affect component performance. First, the metallurgical and soft magnetic properties of the pure iron and silicon iron alloy parts (Fe-3% wt.Si) produced by LPBF will be defined and discussed, considering the process parameters and the type of heat treatment. This research shows that using LPBF, both pure iron and iron silicon, the parts have mechanical and magnetic properties different from the laminated ones. Hence, FEM-based modeling will be employed to design the rotor core of an SYN RM machine to minimize torque ripple while maintaining structural integrity. Finally, we suggest that further research should extend the field of applicability to other electrical devices.

Advanced voxel-based CAD modelling for FSI simulations for automotive structures design

Additive Manufacturing (AM) is nowadays considered an important alternative to traditional manufacturing processes. AM technology shows several advantages in literature as design flexibility, and its use increases in automotive, aerospace and biomedical applications. As a systematic literature review suggests, AM is sometimes coupled with voxelization, mainly for representation and simulation purposes. Voxelization can be defined as a volumetric representation technique based on the model’s discretization with hexahedral elements, as occurs with pixels in the 2D image. Voxels are used to simplify geometric representation, store intricated details of the interior and speed-up geometric and algebraic manipulation. Compared to boundary representation used in common CAD software, voxel’s inherent advantages are magnified in specific applications such as lattice or topologically structures for visualization or simulation purposes. Those structures can only be manufactured with AM employment due to their complex topology. After an accurate review of the existent literature, this project aims to exploit the potential of the voxelization algorithm to develop optimized Design for Additive Manufacturing (DfAM) tools. The final aim is to manipulate and support mechanical simulations of lightweight and optimized structures that should be ready to be manufactured with AM with particular attention to automotive applications. A voxel-based methodology is developed for efficient structural simulation of lattice structures. Moreover, thanks to an optimized smoothing algorithm specific for voxel-based geometries, a topological optimized and voxelized structure can be transformed into a surface triangulated mesh file ready for the AM process. Moreover, a modified panel code is developed for simple CFD simulations using the voxels as a discretization unit to understand the fluid-dynamics performances of industrial components for preliminary aerodynamic performance evaluation. The developed design tools and methodologies perfectly fit the automotive industry’s needs to accelerate and increase the efficiency of the design workflow from the conceptual idea to the final product.

Development of a Computer-Based methodology for tolerance selection and optimization applied to the automotive sector

The design optimization of industrial products has always been an essential activity to improve product quality while reducing time-to-market and production costs. Although cost management is very complex and comprises all phases of the product life cycle, the control of geometrical and dimensional variations, known as Dimensional Management (DM), allows compliance with product and process requirements. Hence, the tolerance-cost optimization becomes the main practice to provide an effective application of Design for Tolerancing (DfT) and Design to Cost (DtC) approaches by enabling a connection between product tolerances and associated manufacturing costs. However, despite the growing interest in this topic, a profitable application in the industry of these techniques is hampered by their complexity: the definition of a systematic framework is the key element to improving design optimization, enhancing the concurrent use of Computer-Aided tools and Model-Based Definition (MBD) practices. The present doctorate research aims to define and develop an integrated methodology for product/process design optimization, to better exploit the new capabilities of advanced simulations and tools. By implementing predictive models and multi-disciplinary optimization, a Computer-Aided Integrated framework for tolerance-cost optimization has been proposed to allow the integration of DfT and DtC approaches and their direct application for the design of automotive components. Several case studies have been considered, with the final application of the integrated framework on a high-performance V12 engine assembly, to achieve both functional targets and cost reduction. From a scientific point of view, the proposed methodology provides an improvement for the tolerance-cost optimization of industrial components. The integration of theoretical approaches and Computer-Aided tools allows to analyse the influence of tolerances on both product performance and manufacturing costs. The case studies proved the suitability of the methodology for its application in the industrial field, providing the identification of further areas for improvement and refinement.

Production and characterization of novel thermoplastic (nano)composite materials for additive manufacturing applications

The increasing environmental global regulations have directed scientific research towards more sustainable materials, even in the field of composite materials for additive manufacturing. In this context, the presented research is devoted to the development of thermoplastic composites for FDM application with a low environmental impact, focusing on the possibility to use wastes from different industrial processes as filler for the production of composite filaments for FDM 3D printing. In particular carbon fibers recycled by pyro-gasification process of CFRP scraps were used as reinforcing agent for PLA, a biobased polymeric matrix. Since the high value of CFs, the ability to re-use recycled CFs, replacing virgin ones, seems to be a promising option in terms of sustainability and circular economy. Moreover, wastes from different agricultural industries, i.e. wheat and rice production processes, were valorised and used as biofillers for the production of PLA-biocomposites. The integration of these agricultural wastes into PLA bioplastic allowed to obtain biocomposites with improved eco-sustainability, biodegradability, lightweight, and lower cost. Finally, the study of novel composites for FDM was extended towards elastomeric nanocomposite materials, in particular TPU reinforced with graphene. The research procedure of all projects involves the optimization of production methods of composite filaments with a particular attention on the possible degradation of polymeric matrices. Then, main thermal properties of 3D printed object are evaluated by TGA, DSC characterization. Additionally, specific heat capacity (CP) and Coefficient of Linear Thermal Expansion (CLTE) measurements are useful to estimate the attitude of composites for the prevention of typical FDM issues, i.e. shrinkage and warping. Finally, the mechanical properties of 3D printed composites and their anisotropy are investigated by tensile test using distinct kinds of specimens with different printing angles with respect to the testing direction.

Development of numerical tools for the simulation, design and optimization of a Helicon Plasma Thruster

This work thesis focuses on the Helicon Plasma Thruster (HPT) as a candidate for generating thrust for small satellites and CubeSats. Two main topics are addressed: the development of a Global Model (GM) and a 3D self-consistent numerical tool. The GM is suitable for preliminary analysis of HPTs with noble gases such as argon, neon, krypton, and xenon, and alternative propellants such as air and iodine. A lumping methodology is developed to reduce the computational cost when modelling the excited species in the plasma chemistry. A 3D self-consistent numerical tool is also developed that can treat discharges with a generic 3D geometry and model the actual plasma-antenna coupling. The tool consists of two main modules, an EM module and a FLUID module, which run iteratively until a steady state solution is converged. A third module is available for solving the plume with a simplified semi-analytical approach, a PIC code, or directly by integration of the fluid equations. Results obtained from both the numerical tools are benchmarked against experimental measures of HPTs or Helicon reactors, obtaining very good qualitative agreement with the experimental trend for what concerns the GM, and an excellent agreement of the physical trends predicted against the measured data for the 3D numerical strategy.

Mechanical design and hybrid control strategies for overconstrained cable-driven parallel robots

Cable-driven parallel robots offer significant advantages in terms of workspace dimensions and payload capability. They are attractive for many industrial tasks to be performed on a large scale, such as handling and manufacturing, without a substantial increase in costs and mechanical complexity with respect to a small-scale application. However, since cables can only sustain tensile stresses, cable tensions must be kept within positive limits during the end-effector motion. This problem can be managed by overconstraining the end-effector and controlling cable tensions. Tension control is typically achieved by mounting a load sensor on all cables, and using specific control algorithms to avoid cable slackness or breakage while the end-effector is controlled in a desired position. These algorithms require multiple cascade control loops and they can be complex and computationally demanding. To simplify the control of overconstrained cable-driven parallel robots, this Thesis proposes suitable mechanical design and hybrid control strategies. It is shown how a convenient design of the cable guidance system allows kinematic modeling to be simplified, without introducing geometric approximations. This guidance system employs swiveling pulleys equipped with position and tension sensors and provides a parallelogram arrangement of cables. Furthermore, a hybrid force/position control in the robot joint space is adopted. According to this strategy, a particular set of cables is chosen to be tension-controlled, whereas the other cables are length-controlled. The force-controlled cables are selected based on the computation of a novel index called force-distribution sensitivity to cable-tension errors. This index aims to evaluate the maximum expected cable-tension error in the length-controlled cables if a unit tension error is committed in the force-controlled cables. In practice, the computation of the force-distribution sensitivity allows determining which cables are best to be force-controlled, to ensure the lowest error in the overall force distribution when a hybrid force/position joint-space strategy is used.

A ROS-based software architecture for a versatile collaborative dual-armed autonomous mobile robot for the manufacturing industry

The industrial context is changing rapidly due to advancements in technology fueled by the Internet and Information Technology. The fourth industrial revolution counts integration, flexibility, and optimization as its fundamental pillars, and, in this context, Human-Robot Collaboration has become a crucial factor for manufacturing sustainability in Europe. Collaborative robots are appealing to many companies due to their low installation and running costs and high degree of flexibility, making them ideal for reshoring production facilities with a short return on investment. The ROSSINI European project aims to implement a true Human-Robot Collaboration by designing, developing, and demonstrating a modular and scalable platform for integrating human-centred robotic technologies in industrial production environments. The project focuses on safety concerns related to introducing a cobot in a shared working area and aims to lay the groundwork for a new working paradigm at the industrial level. The need for a software architecture suitable to the robotic platform employed in one of three use cases selected to deploy and test the new technology was the main trigger of this Thesis. The chosen application consists of the automatic loading and unloading of raw-material reels to an automatic packaging machine through an Autonomous Mobile Robot composed of an Autonomous Guided Vehicle, two collaborative manipulators, and an eye-on-hand vision system for performing tasks in a partially unstructured environment. The results obtained during the ROSSINI use case development were later used in the SENECA project, which addresses the need for robot-driven automatic cleaning of pharmaceutical bins in a very specific industrial context. The inherent versatility of mobile collaborative robots is evident from their deployment in the two projects with few hardware and software adjustments. The positive impact of Human-Robot Collaboration on diverse production lines is a motivation for future investments in research on this increasingly popular field by the industry.

Hybrid ground-aerial mesh networks for IoT monitoring applications: network design and software platform development

The Internet of Things (IoT) has grown rapidly in recent years, leading to an increased need for efficient and secure communication between connected devices. Wireless Sensor Networks (WSNs) are composed of small, low-power devices that are capable of sensing and exchanging data, and are often used in IoT applications. In addition, Mesh WSNs involve intermediate nodes forwarding data to ensure more robust communication. The integration of Unmanned Aerial Vehicles (UAVs) in Mesh WSNs has emerged as a promising solution for increasing the effectiveness of data collection, as UAVs can act as mobile relays, providing extended communication range and reducing energy consumption. However, the integration of UAVs and Mesh WSNs still poses new challenges, such as the design of efficient control and communication strategies. This thesis explores the networking capabilities of WSNs and investigates how the integration of UAVs can enhance their performance. The research focuses on three main objectives: (1) Ground Wireless Mesh Sensor Networks, (2) Aerial Wireless Mesh Sensor Networks, and (3) Ground/Aerial WMSN integration. For the first objective, we investigate the use of the Bluetooth Mesh standard for IoT monitoring in different environments. The second objective focuses on deploying aerial nodes to maximize data collection effectiveness and QoS of UAV-to-UAV links while maintaining the aerial mesh connectivity. The third objective investigates hybrid WMSN scenarios with air-to-ground communication links. One of the main contribution of the thesis consists in the design and implementation of a software framework called "Uhura", which enables the creation of Hybrid Wireless Mesh Sensor Networks and abstracts and handles multiple M2M communication stacks on both ground and aerial links. The operations of Uhura have been validated through simulations and small-scale testbeds involving ground and aerial devices.