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.

High power density electrical machines with hairpin windings

Nowadays, electrical machines are seeing an ever-increasing development and extensive research is currently being dedicated to the improvement of their efficiency and torque/power density. Compared to conventional random windings, hairpin winding inherently features lower DC resistance, higher fill factor, better thermal performance, improved reliability, and an automated manufacturing process. However, several challenges need to be addressed, including electromagnetic, thermal, and manufacturing aspects. Of these, the high ohmic losses at high-frequency operations due to skin and proximity effects are the most severe, resulting in low efficiency or high-temperature values. In this work, the hairpin winding challenges were highlighted at high-frequency operations and at showing the limits of applicability of these standard approaches. Afterward, a multi-objective design optimization is proposed aiming to enhance the exploitation of the hairpin technology in electrical machines. Efficiency and volume power density are considered as main design objectives. Subsequently, a changing paradigm is made for the design of electric motors equipped with hairpin windings, where it is proven that a temperature-oriented approach would be beneficial when designing this type of pre-formed winding. Furthermore, the effect of the rotor topology on AC losses is also considered. After providing design recommendations and FE electromagnetic and thermal evaluations, experimental tests are also performed for validation purposes on a motorette wound with pre-formed conductors. The results show that operating the machine at higher temperatures could be beneficial to efficiency, particularly in high-frequency operations where AC losses are higher at low operating temperatures. The last part of the thesis focuses on comparing the main electromagnetic performance metrics for a conventional hairpin winding, wound onto a benchmark stator with a semi-closed slot opening design, and a continuous hairpin winding, in which the slot opening is open. Lastly, the adoption of semi-magnetic slot wedges is investigated to improve the overall performance of the motor.

Diazene photoswitches in artificial molecular machines and light-effected materials

The research developed in this thesis focused on the spectroscopic and photochemical characterization of molecular diazene photoswitches, both as individual species and as functional components of mechanically interlocked molecules, molecular-based materials and artificial molecular machines and motors. Among the plethora of photochromes reported so far, azobenzene is the most versatile photoswitch due to its reproducible and well-established photochemical properties. Part I of this thesis work focuses on the characterization of light-responsive supramolecular systems based on azobenzene: a photochemically-driven rotary motor, a light-responsive supramolecular polymeric material and a supramolecular system capable of photoinduced entantiodiscrimination. Despite the wide success of azobenzene photoswitches, the tunability of their photochemical properties as a function of the diversified substitution pattern on its aryl ring presents intrinsic limitations. To overcome this issue, in the last decade heteroaryl azoswitches (i.e., azobenzene having heterocyclic rings in place of one or both phenyl groups) have attracted a great deal of attention. Hence, Part II of this thesis work treats the photochemical characterization of two different families of azoheteroarenes embedding imidazolium and thienyl functionalities in their structures. Their potential implementation in water-soluble artificial molecular machines and light-effected semiconductor materials is also assessed.

Hardware-software design of embedded systems for intelligent sensing applications

This Thesis wants to highlight the importance of ad-hoc designed and developed embedded systems in the implementation of intelligent sensor networks. As evidence four areas of application are presented: Precision Agriculture, Bioengineering, Automotive and Structural Health Monitoring. For each field is reported one, or more, smart device design and developing, in addition to on-board elaborations, experimental validation and in field tests. In particular, it is presented the design and development of a fruit meter. In the bioengineering field, three different projects are reported, detailing the architectures implemented and the validation tests conducted. Two prototype realizations of an inner temperature measurement system in electric motors for an automotive application are then discussed. Lastly, the HW/SW design of a Smart Sensor Network is analyzed: the network features on-board data management and processing, integration in an IoT toolchain, Wireless Sensor Network developments and an AI framework for vibration-based structural assessment.

Motion Control of an Advanced Electric Implement for Agricultural Autonomous Vehicles

Nowadays, the development of intelligent and autonomous vehicles used to perform agricultural activities is essential to improve quantity and quality of agricultural productions. Moreover, with automation techniques it is possible to reduce the usage of agrochemicals and minimize the pollution. The University of Bologna is developing an innovative system for orchard management called ORTO (Orchard Rapid Transportation System). This system involves an autonomous electric vehicle capable to perform agricultural activities inside an orchard structure. The vehicle is equipped with an implement capable to perform different tasks. The purpose of this thesis project is to control the vehicle and the implement to perform an inter-row grass mowing. This kind of task requires a synchronized motion between the traction motors and the implement motors. A motion control system has been developed to generate trajectories and manage their synchronization. Two main trajectories type have been used: a five order polynomial trajectory and a trapezoidal trajectory. These two kinds of trajectories have been chosen in order to perform a uniform grass mowing, paying a particular attention to the constrains of the system. To synchronize the motions, the electronic cams approach has been adopted. A master profile has been generated and all the trajectories have been linked to the master motion. Moreover, a safety system has been developed. The aim of this system is firstly to improve the safety during the motion, furthermore it allows to manage obstacle detection and avoidance. Using some particular techniques obstacles can be detected and recovery action can be performed to overcome the problem. Once the measured force reaches the predefined force threshold, then the vehicle stops immediately its motion. The whole project has been developed by employing Matlab and Simulink. Eventually, the software has been translated into C code and executed on the TI Lauchpad XL board.

Power sharing e controllo modulare di macchine elettriche multi-trifase

La costante ricerca e lo sviluppo nel campo degli azionamenti e dei motori elettrici hanno portato ad una loro sempre maggiore applicazione ed utilizzo. Tuttavia, la crescente esigenza di sistemi ad alta potenza sempre più performanti da una parte ha evidenziato i limiti di certe soluzioni, dall’altra l’affermarsi di altre. In questi sistemi, infatti, la macchina elettrica trifase non rappresenta più l’unica soluzione possibile: negli ultimi anni si è assistito ad una sempre maggiore diffusione di macchine elettriche multifase. Grazie alle maggiori potenzialità che sono in grado di offrire, per quanto alcune di queste siano ancora sconosciute, risultano già essere una valida alternativa rispetto alla tradizionale controparte trifase. Sicuramente però, fra le varie architetture multifase, quelle multi-trifase (ovvero quelle con un numero di fasi multiplo di tre) rappresentano una soluzione particolarmente vantaggiosa in ambito industriale. Infatti, se impiegate all’interno di architetture multifase, la profonda conoscenza dei tradizionali sistemi trifase consente di ridurre i costi ed i tempi legati alla loro progettazione. In questo elaborato la macchina elettrica multi-trifase analizzata è una macchina sincrona esafase con rotore a magneti permanenti superficiali. Questa particolare tipologia di macchina elettrica può essere modellizzata attraverso due approcci completamente differenti: uno esafase ed uno doppio trifase. Queste possibilità hanno portato molti ricercatori alla ricerca della migliore strategia di controllo per questa macchina. L’obiettivo di questa tesi è di effettuare un’analisi comparativa tra tre diverse strategie di controllo applicate alla stessa macchina elettrica multi-trifase, analizzandone la risposta dinamica in diverse condizioni di funzionamento.

Application of the Extended Kalman filter for speed sensorless control of PM synchronous machines

The increasing interest in the decarbonization process led to a rapidly growing trend of electrification strategies in the automotive industry. In particular, OEMs are pushing towards the development and production of efficient electric vehicles. Moreover, research on electric motors and their control are exploding in popularity. The increase of computational power in embedded control hardware is allowing the development of new control algorithm, such as sensorless control strategy. Such control strategy allows the reduction of the number of sensors, which implies reduced costs and increased system reliability. The thesis objective is to realize a sensorless control for high-performance automotive motors. Several algorithms for rotor angle observers are implemented in the MATLAB and Simulink environment, with emphasis on the Kalman observer. One of the Kalman algorithms already available in the literature has been selected, implemented and benchmarked, with emphasis on its comparison with the Sliding Mode observer. Different models characterized by increasing levels of complexity are simulated. A simplified synchronous motor with ”constant parameters”, controlled by an ideal inverter is first analyzed; followed by a complete model defined by real motor maps, and controlled by a switching inverter. Finally, it was possible to test the developed algorithm on a real electric motor mounted on a test bench. A wide range of different electric motors have been simulated, which led to an exhaustive review of the sensorless control algorithm. The final results underline the capability of the Kalman observer to effectively control the motor on a real test bench.

Acquisition of Vibration Signals for Predictive Maintenance: a Practical Case

As predictive maintenance becomes more and more relevant in industrial environment, the possible range of applications for this maintenance strategy grows. The progresses in components technology and their reduction in price, together with the late years' advances in machine learning and in computational power, are making the implementation of predictive maintenance possible in plants where it would have previously been unreasonably costly. This is leading major pharmaceutical industries to explore the possibility of the application of condition monitoring systems on progressively less and less critical equipment. The focus of this thesis is on the implementation of a system to gather vibrational data from the motors installed in a pre-existing machine using off-the-shelf components. The final goal for the system is to provide the necessary vibration data, in the form of frequency spectra, to a machine learning system developed by IMA Digital, which will be leveraging such data to predict possible upcoming faults and to give the final client all the information necessary to plan maintenance activity according to the estimated machine condition.

Design and Implementation of Single phase 230V to Three Phase Inverter Based on the Embedded System STM-32 Applied to motor control

In the field of Power Electronics, several types of motor control systems have been developed using STM microcontroller and power boards. In both industrial power applications and domestic appliances, power electronic inverters are widely used. Inverters are used to control the torque, speed, and position of the rotor in AC motor drives. An inverter delivers constant-voltage and constant-frequency power in uninterruptible power sources. Because inverter power supplies have a high-power consumption and low transfer efficiency rate, a three-phase sine wave AC power supply was created using the embedded system STM32, which has low power consumption and efficient speed. It has the capacity of output frequency of 50 Hz and the RMS of line voltage. STM32 embedded based Inverter is a power supply that integrates, reduced, and optimized the power electronics application that require hardware system, software, and application solution, including power architecture, techniques, and tools, approaches capable of performance on devices and equipment. Power inverters are currently used and implemented in green energy power system with low energy system such as sensors or microcontroller to perform the operating function of motors and pumps. STM based power inverter is efficient, less cost and reliable. My thesis work was based on STM motor drives and control system which can be implemented in a gas analyser for operating the pumps and motors. It has been widely applied in various engineering sectors due to its ability to respond to adverse structural changes and improved structural reliability. The present research was designed to use STM Inverter board on low power MCU such as NUCLEO with some practical examples such as Blinking LED, and PWM. Then we have implemented a three phase Inverter model with Steval-IPM08B board, which converter single phase 230V AC input to three phase 380 V AC output, the output will be useful for operating the induction motor.

Axis control optimization: autotuning techniques and frequency response analysis of industrial mechatronic systems

In the field of industrial automation, there is an increasing need to use optimal control systems that have low tracking errors and low power and energy consumption. The motors we are dealing with are mainly Permanent Magnet Synchronous Motors (PMSMs), controlled by 3 different types of controllers: a position controller, a speed controller, and a current controller. In this thesis, therefore, we are going to act on the gains of the first two controllers by going to find, through the TwinCAT 3 software, what might be the best set of parameters. To do this, starting with the default parameters recommended by TwinCAT, two main methods were used and then compared: the method of Ziegler and Nichols, which is a tabular method, and advanced tuning, an auto-tuning software method of TwinCAT. Therefore, in order to analyse which set of parameters was the best,several experiments were performed for each case, using the Motion Control Function Blocks. Moreover, some machines, such as large robotic arms, have vibration problems. To analyse them in detail, it was necessary to use the Bode Plot tool, which, through Bode plots, highlights in which frequencies there are resonance and anti-resonance peaks. This tool also makes it easier to figure out which and where to apply filters to improve control.

Design and implementation of a vibrational condition monitoring system

Industrial companies, particularly those with induction motors and gearboxes as integral components of their systems, are utilizing Condition Monitoring (CM) systems more frequently in order to discover the need for maintenance in advance, as traditional maintenance only performs tasks when a failure has been identified. Utilizing a CM system is essential to boost productivity and minimize long-term failures that result in financial loss. The more exact and practical the CM system, the better the data analysis, which adds to a more precise maintenance forecast. This thesis project is a cooperation with PEI Vibration Monitoring s.r.l. to design and construct a low-cost vibrational condition monitoring system to check the health of induction motors and gearboxes automatically. Moreover, according to the company's request, such a system should have specs comparable to NI 9234, one of the company's standard Data Acquisition (DAQ) boards, but at a significantly cheaper price. Additionally, PEI VM Company has supplied all hardware and electronic components. The suggested CM system is capable of highprecision autonomous monitoring of induction motors and gearboxes, and it consists of a Raspberry Pi 3B and MCC 172 DAQ board.