Virtual technology and haptic interface solutions for design and control of mobile working machines

Commercially available haptic interfaces are usable for many purposes. However, as generic devices they are not the most suitable for the control of heavy duty mobile working machines like mining machines, container handling equipment and excavators. Alternative mechanical constructions for a haptic controller are presented and analysed. A virtual reality environment (VRE) was built to test the proposed haptic controller mechanisms. Verification of an electric motor emulating a hydraulic pump in the electro-hydraulic system of a mobile working machine is carried out. A real-time simulator using multi-body-dynamics based software with hardware-in-loop (HIL) setup was used for the tests. Recommendations for further development of a haptic controller and emulator electric motor are given.

Development of Generic Simulation Model for Mobile Working Machines

This master’s thesis has been done for Drive! –project in which a new electric motor solution for mobile working machines is developed. Generic simulation model will be used as marketing and development tool. It can be used to model a wide variety of different vehicles with and without electric motor and to show customer the difference between traditionally build vehicles and those with new electric motor solution. Customers can also use simulation model to research different solutions for their own vehicles. At the start of the project it was decided that MeVEA software would be used as main simulation program and Simulink will only be used to simulate the operation of electrical components. Development of the generic model started with the research of these two software applications, simulation models which are made with them and how these simulation models can be build faster. Best results were used for building of generic simulation model. Finished generic model can be used to produce new tractor models for real-time simulations in short notice. All information about model is collected to one datasheet which can be easily filled by the user. After datasheet is filled a script will automatically build new simulation model in seconds. At the moment generic model is capable of building simulation models for wide variety of different tractors but it can be easily altered for other vehicle types too which would also benefit greatly from electric drive solution. Those could be for example wheel loaders and harvesters.

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

Development of control-oriented models of Dual Clutch Transmission systems

A control-oriented model of a Dual Clutch Transmission was developed for real-time Hardware In the Loop (HIL) applications, to support model-based development of the DCT controller. The model is an innovative attempt to reproduce the fast dynamics of the actuation system while maintaining a step size large enough for real-time applications. The model comprehends a detailed physical description of hydraulic circuit, clutches, synchronizers and gears, and simplified vehicle and internal combustion engine sub-models. As the oil circulating in the system has a large bulk modulus, the pressure dynamics are very fast, possibly causing instability in a real-time simulation; the same challenge involves the servo valves dynamics, due to the very small masses of the moving elements. Therefore, the hydraulic circuit model has been modified and simplified without losing physical validity, in order to adapt it to the real-time simulation requirements. The results of offline simulations have been compared to on-board measurements to verify the validity of the developed model, that was then implemented in a HIL system and connected to the TCU (Transmission Control Unit). Several tests have been performed: electrical failure tests on sensors and actuators, hydraulic and mechanical failure tests on hydraulic valves, clutches and synchronizers, and application tests comprehending all the main features of the control performed by the TCU. Being based on physical laws, in every condition the model simulates a plausible reaction of the system. The first intensive use of the HIL application led to the validation of the new safety strategies implemented inside the TCU software. A test automation procedure has been developed to permit the execution of a pattern of tests without the interaction of the user; fully repeatable tests can be performed for non-regression verification, allowing the testing of new software releases in fully automatic mode.

Studio e implementazione di un autopilota su un UAV ad ala fissa

Si riporta inizialmente un’analisi tecnica dell’autopilota Ardupilot, utilizzato con il firmware Arduplane, che predispone la scheda all’utilizzo specifico su velivoli senza pilota ad ala fissa. La parte sostanziale della tesi riguarda invece lo studio delle leggi di controllo implementate su Arduplane e la loro modellazione, assieme ad altre parti del codice, in ambiente Matlab Simulink. Il sistema di controllo creato, chiamato Attitude Flight System, viene verificato con la tecnica del Software In the Loop in un simulatore di volo virtuale modellato anch’esso in Simulink, si utilizza la dinamica di un velivolo UAV di prova e il software FlightGear per l’ambiente grafico. Di fondamentale importanza è la verifica della compatibilità fra il firmware originale e il codice generato a partire dai modelli Simulink, verifica effettuata mediante test di tipo Hardware in the Loop. L’ultima parte della tesi descrive le prove di volo svolte per verificare le prestazioni della scheda su un aeromodello trainer.

Evoluzione di un sistema di automazione della guida di motoveicoli per test su banco a rulli

Evoluzione di un sistema Hardware in the Loop per l'automazione della guida di motoveicoli su banco a rulli. Questo sistema HIL, simulando un certo tipo di condizioni, permette di svolgere test su strategia centralina, implementate per il controllo motore.

A novel interface for hybrid mock circulations to evaluate ventricular assist devices

This paper presents a novel mock circulation for the evaluation of ventricular assist devices (VADs), which is based on a hardware-in-the-loop concept. A numerical model of the human blood circulation runs in real time and computes instantaneous pressure, volume, and flow rate values. The VAD to be tested is connected to a numerical-hydraulic interface, which allows the interaction between the VAD and the numerical model of the circulation. The numerical-hydraulic interface consists of two pressure-controlled reservoirs, which apply the computed pressure values from the model to the VAD, and a flow probe to feed the resulting VAD flow rate back to the model. Experimental results are provided to show the proper interaction between a numerical model of the circulation and a mixed-flow blood pump.

STATE OF CHARGE BASED DROOP SURFACE FOR OPTIMAL CONTROL OF DC MICROGRIDS

For a microgrid with a high penetration level of renewable energy, energy storage use becomes more integral to the system performance due to the stochastic nature of most renewable energy sources. This thesis examines the use of droop control of an energy storage source in dc microgrids in order to optimize a global cost function. The approach involves using a multidimensional surface to determine the optimal droop parameters based on load and state of charge. The optimal surface is determined using knowledge of the system architecture and can be implemented with fully decentralized source controllers. The optimal surface control of the system is presented. Derivations of a cost function along with the implementation of the optimal control are included. Results were verified using a hardware-in-the-loop system.

Emulation of an OWC Ocean Energy Plant With PMSG and Irregular Wave Model

Ocean energy is a promising resource for renewable electricity generation that presents many advantages, such as being more predictable than wind energy, but also some disadvantages such as large and slow amplitude variations in the generated power. This paper presents a hardware-in-the-loop prototype that allows the study of the electric power profile generated by a wave power plant based on the oscillating water column (OWC) principle. In particular, it facilitates the development of new solutions to improve the intermittent profile of the power fed into the grid or the test of the OWC behavior when facing a voltage dip. Also, to obtain a more realistic model behavior, statistical models of real waves have been implemented.

Parameter optimization for noise and vibration reduction associated with position and speed sensorless control of permanent magnet machines at low speed

With the advantages and popularity of Permanent Magnet (PM) motors due to their high power density, there is an increasing incentive to use them in variety of applications including electric actuation. These applications have strict noise emission standards. The generation of audible noise and associated vibration modes are characteristics of all electric motors, it is especially problematic in low speed sensorless control rotary actuation applications using high frequency voltage injection technique. This dissertation is aimed at solving the problem of optimizing the sensorless control algorithm for low noise and vibration while achieving at least 12 bit absolute accuracy for speed and position control. The low speed sensorless algorithm is simulated using an improved Phase Variable Model, developed and implemented in a hardware-in-the-loop prototyping environment. Two experimental testbeds were developed and built to test and verify the algorithm in real time.^ A neural network based modeling approach was used to predict the audible noise due to the high frequency injected carrier signal. This model was created based on noise measurements in an especially built chamber. The developed noise model is then integrated into the high frequency based sensorless control scheme so that appropriate tradeoffs and mitigation techniques can be devised. This will improve the position estimation and control performance while keeping the noise below a certain level. Genetic algorithms were used for including the noise optimization parameters into the developed control algorithm.^ A novel wavelet based filtering approach was proposed in this dissertation for the sensorless control algorithm at low speed. This novel filter was capable of extracting the position information at low values of injection voltage where conventional filters fail. This filtering approach can be used in practice to reduce the injected voltage in sensorless control algorithm resulting in significant reduction of noise and vibration.^ Online optimization of sensorless position estimation algorithm was performed to reduce vibration and to improve the position estimation performance. The results obtained are important and represent original contributions that can be helpful in choosing optimal parameters for sensorless control algorithm in many practical applications.^