Continuous phase synchronised drives (for a rod-making machine)

Traditional high speed machinery actuators are powered and coordinated by mechanical linkages driven from a central drive, but these linkages may be replaced by independently synchronised electric drives. Problems associated with utilising such electric drives for this form of machinery were investigated. The research concentrated on a high speed rod-making machine, which required control of high inertias (0.01-0.5kgm2), at continuous high speed (2500 r/min), with low relative phase errors between two drives (0.0025 radians). Traditional minimum energy drive selection techniques for incremental motions were not applicable to continuous applications which require negligible energy dissipation. New selection techniques were developed. A brushless configuration constant enabled the comparison between seven different servo systems; the rate earth brushless drives had the best power rates which is a performance measure. Simulation was used to review control strategies, such that a microprocessor controller with a proportional velocity loop within a proportional position loop with velocity feedforward was designed. Local control schemes were investigated as means of reducing relative errors between drives: the slave of a master/slave scheme compensates for the master's errors: the matched scheme has drives with similar absolute errors so the relative error is minimised, and the feedforward scheme minimises error by adding compensation from previous knowledge. Simulation gave an approximate velocity loop bandwidth and position loop gain required to meet the specification. Theoretical limits for these parameters were defined in terms of digital sampling delays, quantisation, and system phase shifts. Performance degradation due to mechanical backlash was evaluated. Thus any drive could be checked to ensure that the performance specification could be realised. A two drive demonstrator was commissioned with 0.01kgm2 loads. By use of simulation the performance of one drive was improved by increasing the velocity loop bandwidth fourfold. With the master/slave scheme relative errors were within 0.0024 radians at a constant 2500 r/min for two 0.01 kgm^2 loads.

Bragg Grating fast Tunable Filter For Wavelength Division Multiplexing

A Bragg grating fast tunable filter prototype working over a linear tuning range of 45 nm with a maximum tuning speed of 21 nm/ms has been realized. The tunable filter system is based on two piezoelectric stack actuators moving a mechanical device thus compressing an apodized fiber Bragg grating. The filter allows both traction and compression and can work in transmission and in reflection. It is designed to work with a channel spacing of 100 GHz according to the ITU specifications for wavelength division multiplexing systems

Flexible high speed machinery

The thesis describes an investigation into methods for the design of flexible high-speed product processing machinery, consisting of independent electromechanically actuated machine functions which operate under software coordination and control. An analysis is made of the elements of traditionally designed cam-actuated, mechanically coupled machinery, so that the operational functions and principal performance limitations of the separate machine elements may be identified. These are then used to define the requirements for independent actuators machinery, with a discussion of how this type of design approach is more suited to modern manufacturing trends. A distributed machine controller topology is developed which is a hybrid of hierarchical and pipeline control. An analysis is made, with the aid of dynamic simulation modelling, which confirms the suitability of the controller for flexible machinery control. The simulations include complex models of multiple independent actuators systems, which enable product flow and failure analyses to be performed. An analysis is made of high performance brushless d.c. servomotors and their suitability for actuating machine motions is assessed. Procedures are developed for the selection of brushless servomotors for intermittent machine motions. An experimental rig is described which has enabled the actuation and control methods developed to be implemented. With reference to this, an evaluation is made of the suitability of the machine design method and a discussion is given of the developments which are necessary for operational independent actuators machinery to be attained.

Simulation of robot manipulator control strategies

The high capital cost of robots prohibit their economic application. One method of making their application more economic is to increase their operating speed. This can be done in a number of ways e.g. redesign of robot geometry, improving actuators and improving control system design. In this thesis the control system design is considered. It is identified in the literature review that two aspects in relation to robot control system design have not been addressed in any great detail by previous researchers. These are: how significant are the coupling terms in the dynamic equations of the robot and what is the effect of the coupling terms on the performance of a number of typical independent axis control schemes?. The work in this thesis addresses these two questions in detail. A program was designed to automatically calculate the path and trajectory and to calculate the significance of the coupling terms in an example application of a robot manipulator tracking a part on a moving conveyor. The inertial and velocity coupling terms have been shown to be of significance when the manipulator was considered to be directly driven. A simulation of the robot manipulator following the planned trajectory has been established in order to assess the performance of the independent axis control strategies. The inertial coupling was shown to reinforce the control torque at the corner points of the trajectory, where there was an abrupt demand in acceleration in each axis but of opposite sign. This reduced the tracking error however, this effect was not controllable. A second effect was due to the velocity coupling terms. At high trajectory speeds it was shown, by means of a root locus analysis, that the velocity coupling terms caused the system to become unstable.

The effect of elevated temperature on the wear of stainless steel in contact with tungsten carbide

The bearings in the air motors of modern jet aircraft engines must operate dry in hostile conditions at temperatures up to 500° C, where the thrust races in the actuators operate at temperatures up to 300° C. One of the few metallurgical combinations which can function efficiently under these conditions is martensitic stainless steel on tungsten carbide. The work described was initiated to isolate the wear mechanisms of two such steels in contact with tungsten carbide at temperatures up to 500° C. Experiments were carried out on angular contact bearings similar to these used in service, where both rolling and sliding is present and also for pure sliding conditions using a pin-on-disc apparatus. Wear measurements of the bearings were obtained with wear rates, friction and surface temperatures from the pin-on-disc machine for a series of loads and speeds. Extensive X-ray diffraction analysis was carried out on the wear debris, with also S.E.M. analysis and hardness tests on the worn surfaces along with profilometry measurements of the disc. The oxidational parameters of the steel were obtained from measurements of oxide growth rates by ellipsometry. Three distinct mechanisms of wear were established and the latter two were found to be present in both configurations. These involve an oxidational-abrasive mechanism at loads below 40 N with pin surface temperatures up to about 300 °C, with the mechanism changing to severe wear for higher loads. As the temperature increases a third wear mechanism appears due to transfer of relatively soft oxide films to the steel surface reducing the wear rate. Theoretical K factors were derived and compared with experimental values which were found to be in good agreement for the severe wear mechanism. The pin-on-disc experiments may be useful as a screening test for material selection, without the considerable cost of producing the angular contact bearings.

Design methodology for the servo control of high speed multi-axis machinery (BL): decoupling and synchronisation of a generic machine by blockwise decentralised MIMO control

Traditional machinery for manufacturing processes are characterised by actuators powered and co-ordinated by mechanical linkages driven from a central drive. Increasingly, these linkages are replaced by independent electrical drives, each performs a different task and follows a different motion profile, co-ordinated by computers. A design methodology for the servo control of high speed multi-axis machinery is proposed, based on the concept of a highly adaptable generic machine model. In addition to the dynamics of the drives and the loads, the model includes the inherent interactions between the motion axes and thus provides a Multi-Input Multi-Output (MIMO) description. In general, inherent interactions such as structural couplings between groups of motion axes are undesirable and needed to be compensated. On the other hand, imposed interactions such as the synchronisation of different groups of axes are often required. It is recognised that a suitable MIMO controller can simultaneously achieve these objectives and reconciles their potential conflicts. Both analytical and numerical methods for the design of MIMO controllers are investigated. At present, it is not possible to implement high order MIMO controllers for practical reasons. Based on simulations of the generic machine model under full MIMO control, however, it is possible to determine a suitable topology for a blockwise decentralised control scheme. The Block Relative Gain array (BRG) is used to compare the relative strength of closed loop interactions between sub-systems. A number of approaches to the design of the smaller decentralised MIMO controllers for these sub-systems has been investigated. For the purpose of illustration, a benchmark problem based on a 3 axes test rig has been carried through the design cycle to demonstrate the working of the design methodology.

Timing continuous or discontinuous movements across effectors specified by different pacing modalities and intervals

Sensorimotor synchronization is hypothesized to arise through two different processes, associated with continuous or discontinuous rhythmic movements. This study investigated synchronization of continuous and discontinuous movements to different pacing signals (auditory or visual), pacing interval (500, 650, 800, 950 ms) and across effectors (non-dominant vs. non-dominant hand). The results showed that mean and variability of asynchronization errors were consistently smaller for discontinuous movements compared to continuous movements. Furthermore, both movement types were timed more accurately with auditory pacing compared to visual pacing and were more accurate with the dominant hand. Shortening the pacing interval also improved sensorimotor synchronization accuracy in both continuous and discontinuous movements. These results show the dependency of temporal control of movements on the nature of the motor task, the type and rate of extrinsic sensory information as well as the efficiency of the motor actuators for sensory integration.

Bragg grating fast tunable filter for wavelength division multiplexing

A Bragg grating fast tunable filter prototype working over a linear tuning range of 45 nm with a maximum tuning speed of 21 nm/ms has been realized. The tunable filter system is based on two piezoelectric stack actuators moving a mechanical device thus compressing an apodized fiber Bragg grating. The filter allows both traction and compression and can work in transmission and in reflection. It is designed to work with a channel spacing of 100 GHz according to the ITU specifications for wavelength division multiplexing systems.

A fast response intrinsic humidity sensor based on an etched singlemode polymer fiber Bragg grating

A simple, low cost and fast response time intrinsic relative humidity sensor system based on an etched singlemode polymer fiber Bragg (POFBG) is presented in this paper. A macro-bend linear edge filter which converts the humidity induced wavelength shift into an intensity change is used as the interrogation technique. The singlemode POFBG is etched to micro-meters in diameter to improve the response time of the humidity sensor. A response time of 4.5 s is observed for a polymer FBG with a cladding diameter of 25 μm. The overall sensor system sensitivity was 0.23 mV/%RH. The etched POFBG humidity sensor shows anexponential decrease in response time with a decrease in fiber diameter. The developed sensor might have potential applications in a wide range of applications where fast and accurate real time humidity control is required. © 2013 Elsevier B.V. All rights reserved.

Analysis of femtosecond laser surface patterning on bulk single-crystalline diamond

Preliminary work is reported on 2-D and 3-D microstructures written directly with a Yb:YAG 1026 nm femtosecond (fs) laser on bulk chemical vapour deposition (CVD) single-crystalline diamond. Smooth graphitic lines and other structures were written on the surface of a CVD diamond sample with a thickness of 0.7mm under low laser fluences. This capability opens up the opportunity for making electronic devices and micro-electromechanical structures on diamond substrates. The fabrication process was optimised through testing a range of laser energies at a 100 kHz repetition rate with sub-500fs pulses. These graphitic lines and structures have been characterised using optical microscopy, Raman spectroscopy, X-ray photoelectron spectroscopy and atomic force microscopy. Using these analysis techniques, the formation of sp2 and sp3 bonds is explored and the ratio between sp2 and sp3 bonds after fs laser patterning is quantified. We present the early findings from this study and characterise the relationship between the graphitic line formation and the different fs laser exposure conditions. © 2012 Taylor & Francis.

Simulation of power quality issues in more electric aircraft actuator supplies

To examine the detailed operation of the power distribution network in a future more electric aircraft that employs electric actuation systems, a Micro-Cap SPICE simulation is developed for one of the essential buses. Particular attention is paid to model accurately the most important effects that influence system power quality. Representative system and flight data are used to illustrate the operation of the simulation and to assess the power quality conditions within the network as the flight control surfaces are deployed. The results illustrate the importance of correct cable sizing to ensure stable operation of actuators during transient conditions.

Simultaneous measurement of strain and curvature using superstructure fibre Bragg gratings

We report the first demonstration of the simultaneous measurement of strain and curvature, with temperature compensation, using a single superstructure fibre Bragg grating (SFBG). The SFBG exhibits the properties of both the fibre Bragg grating (FBG) and the long period fibre grating (LPG) such that its spectral response facilitates strain measurement from the wavelength shift of the FBG-like characteristic, and independent measurement of curvature from the LPG-like mode-splitting characteristic. The dependence of the LPG mode-splitting on the mode order has also been investigated and utilised for the measurement of very small curvatures.

High performance liquid level monitoring system based on polymer fiber Bragg gratings embedded in silicone rubber diaphragm

Liquid-level sensing technologies have attracted great prominence, because such measurements are essential to industrial applications, such as fuel storage, flood warning and in the biochemical industry. Traditional liquid level sensors are based on electromechanical techniques; however they suffer from intrinsic safety concerns in explosive environments. In recent years, given that optical fiber sensors have lots of well-established advantages such as high accuracy, costeffectiveness, compact size, and ease of multiplexing, several optical fiber liquid level sensors have been investigated which are based on different operating principles such as side-polishing the cladding and a portion of core, using a spiral side-emitting optical fiber or using silica fiber gratings. The present work proposes a novel and highly sensitive liquid level sensor making use of polymer optical fiber Bragg gratings (POFBGs). The key elements of the system are a set of POFBGs embedded in silicone rubber diaphragms. This is a new development building on the idea of determining liquid level by measuring the pressure at the bottom of a liquid container, however it has a number of critical advantages. The system features several FBG-based pressure sensors as described above placed at different depths. Any sensor above the surface of the liquid will read the same ambient pressure. Sensors below the surface of the liquid will read pressures that increase linearly with depth. The position of the liquid surface can therefore be approximately identified as lying between the first sensor to read an above-ambient pressure and the next higher sensor. This level of precision would not in general be sufficient for most liquid level monitoring applications; however a much more precise determination of liquid level can be made by linear regression to the pressure readings from the sub-surface sensors. There are numerous advantages to this multi-sensor approach. First, the use of linear regression using multiple sensors is inherently more accurate than using a single pressure reading to estimate depth. Second, common mode temperature induced wavelength shifts in the individual sensors are automatically compensated. Thirdly, temperature induced changes in the sensor pressure sensitivity are also compensated. Fourthly, the approach provides the possibility to detect and compensate for malfunctioning sensors. Finally, the system is immune to changes in the density of the monitored fluid and even to changes in the effective force of gravity, as might be obtained in an aerospace application. The performance of an individual sensor was characterized and displays a sensitivity (54 pm/cm), enhanced by more than a factor of 2 when compared to a sensor head configuration based on a silica FBG published in the literature, resulting from the much lower elastic modulus of POF. Furthermore, the temperature/humidity behavior and measurement resolution were also studied in detail. The proposed configuration also displays a highly linear response, high resolution and good repeatability. The results suggest the new configuration can be a useful tool in many different applications, such as aircraft fuel monitoring, and biochemical and environmental sensing, where accuracy and stability are fundamental. © (2015) COPYRIGHT Society of Photo-Optical Instrumentation Engineers (SPIE). Downloading of the abstract is permitted for personal use only.

Formation and precise geometry control of SNAP microresonators by external electrostatic fields

In SNAP (Surface nanoscale axial photonics) resonators propagation of a slow whispering gallery mode along an optical fiber is controlled by nanoscale variation of the effective radius of the fiber [1]. Similar behavior can be realized in so - called nanobump microresonators in which the introduced variation of the effective radius is asymmetric, i.e. depends on the axial coordinate [2]. The possibilities of realization of such structures “on the fly” in an optical fiber by applying external electrostatic fields to it is discussed in this work. It is shown that local variations in effective radius of the fiber and in its refractive index caused by external electric fields can be large enough to observe SNAP structure - like behavior in an originally flat optical fiber. Theoretical estimations of the introduced refractive index and effective radius changes and results of finite element calculations are presented. Various effects are taken into account: electromechanical (piezoelectricity and electrostriction), electro-optical (Pockels and Kerr effects) and elasto-optical effect. Different initial fibre cross-sections are studied. The aspects of use of linear isotropic (such as silica) and non-linear anisotropic (such as lithium niobate) materials of the fiber are discussed. REFERENCES [1] M. Sumetsky, J. M. Fini, Opt. Exp. 19, 26470 (2011). [2] L. A. Kochkurov, M. Sumetsky, Opt. Lett. 40, 1430 (2015).

Autonomic and embedded wireless sensor protocols for critical infrastructures

The tragic events of September 11th ushered a new era of unprecedented challenges. Our nation has to be protected from the alarming threats of adversaries. These threats exploit the nation's critical infrastructures affecting all sectors of the economy. There is the need for pervasive monitoring and decentralized control of the nation's critical infrastructures. The communications needs of monitoring and control of critical infrastructures was traditionally catered for by wired communication systems. These technologies ensured high reliability and bandwidth but are however very expensive, inflexible and do not support mobility and pervasive monitoring. The communication protocols are Ethernet-based that used contention access protocols which results in high unsuccessful transmission and delay. An emerging class of wireless networks, named embedded wireless sensor and actuator networks has potential benefits for real-time monitoring and control of critical infrastructures. The use of embedded wireless networks for monitoring and control of critical infrastructures requires secure, reliable and timely exchange of information among controllers, distributed sensors and actuators. The exchange of information is over shared wireless media. However, wireless media is highly unpredictable due to path loss, shadow fading and ambient noise. Monitoring and control applications have stringent requirements on reliability, delay and security. The primary issue addressed in this dissertation is the impact of wireless media in harsh industrial environment on the reliable and timely delivery of critical data. In the first part of the dissertation, a combined networking and information theoretic approach was adopted to determine the transmit power required to maintain a minimum wireless channel capacity for reliable data transmission. The second part described a channel-aware scheduling scheme that ensured efficient utilization of the wireless link and guaranteed delay. Various analytical evaluations and simulations are used to evaluate and validate the feasibility of the methodologies and demonstrate that the protocols achieved reliable and real-time data delivery in wireless industrial networks.