Simulation and optimization tools in paper machine concept design

The last decade has shown that the global paper industry needs new processes and products in order to reassert its position in the industry. As the paper markets in Western Europe and North America have stabilized, the competition has tightened. Along with the development of more cost-effective processes and products, new process design methods are also required to break the old molds and create new ideas. This thesis discusses the development of a process design methodology based on simulation and optimization methods. A bi-level optimization problem and a solution procedure for it are formulated and illustrated. Computational models and simulation are used to illustrate the phenomena inside a real process and mathematical optimization is exploited to find out the best process structures and control principles for the process. Dynamic process models are used inside the bi-level optimization problem, which is assumed to be dynamic and multiobjective due to the nature of papermaking processes. The numerical experiments show that the bi-level optimization approach is useful for different kinds of problems related to process design and optimization. Here, the design methodology is applied to a constrained process area of a papermaking line. However, the same methodology is applicable to all types of industrial processes, e.g., the design of biorefiners, because the methodology is totally generalized and can be easily modified.

Value co-creation through virtual community participation

Consumers create a great deal of content in the Internet. As they do not get a monetary compensation for doing so, it seems apparent that other types of reward are derived from giving up one's time and other resources. The purpose of this study is to describe value creation and user participation in a virtual community. It can be broken down into three research questions. 1. What is the value creation logic of a virtual community? 2. What value is perceived by virtual community users? 3. What is the association between value perceived by virtual community users and their participation in a community? The study employs the discussion on value co-creation as well as perspectives on the notion of value for consumers to create a theoretical framework for value creation. To understand value creation in the context of virtual communities and to create a theoretical framework for user participation, existing literature and research on virtual communities is discussed. The empirical part of the study employs quantitative methodology to analyze data collected by sending a survey questionnaire to the users of a Finnish wellbeing-based virtual community. The results indicate that virtual community users perceive self-development, enjoyment, reputation-building and community commitment value when using the service and that value perceptions are associated with community participation. Moreover, it was found that different types of value are associated with different forms of participation. Based on the findings, it is suggested that the four types of value make up a considerable share of value for virtual community users. Moreover, as the results indicate that different value types are associated with different forms of participation, it suggested that virtual community organizers consider what forms of participation they want to promote and design their virtual communities to support creation of the different types of value accordingly.

Design of an amplifier and an instrumentation setup for a harsh environment heat flux measurement application – case axial flux electric machine

Measurement is a tool for researching. Therefore, it is important that the measuring process is carried out correctly, without distorting the signal or the measured event. Researches of thermoelectric phenomena have been focused more on transverse thermoelectric phenomena during recent decades. Transverse Seebeck effect enables to produce thinner and faster heat flux sensor than before. Studies about transverse Seebeck effect have so far focused on materials, so in this Master’s Thesis instrumentation of transverse Seebeck effect based heat flux sensor is studied, This Master’s Thesis examines an equivalent circuit of transverse Seebeck effect heat flux sensors, their connectivity to electronics and choosing and design a right type amplifier. The research is carried out with a case study which is Gradient Heat Flux Sensors and an electrical motor. In this work, a general equivalent circuit was presented for the transverse Seebeck effect-based heat flux sensor. An amplifier was designed for the sensor of the case study, and the solution was produced for the measurement of the local heat flux of the electric motor to improve the electromagnetic compatibility.

Electrical Machine Product Development; Transmission to Lean Approach

The requirements set by the market for electrical machines become increasingly demanding requiring more sophisticated technological solutions. Companies producing electrical ma-chines are challenged to develop machines that provide competitive edge for the customer for example through increased efficiency, reliability or some customer specific special requirement. The objective of this thesis is to derive a proposal for the first steps to transform the electrical machine product development process of a manufacturing company towards lean product development. The current product development process in the company is presented together with the processes of four other companies interviewed for the thesis. On the basis of current processes of the electrical machine industry and the related literature, a generalized electrical machine product development process is derived. The management isms and –tools utilized by the companies are analyzed. Adoption of lean Pull-Event –reviews, Oobeya –management and Knowledge based product development are suggested as the initial steps of implementing lean product development paradigm in the manufacturing company. Proposals for refining the cur-rent product development process and increasing the stakeholder involvement in the development projects are made. Lean product development is finding its way to Finnish electrical machine industry, but the results will be available only after the methods have been implemented and adopted by the companies. There is some enthusiasm about the benefits of lean approach and if executed successfully it will provide competitive edge for the Finnish electrical machine industry.

Energy Efficiency of a Diesel-Electric MobileWorking Machine

The power demand of many mobile working machines such as mine loaders, straddle carriers and harvesters varies significantly during operation, and typically, the average power demand of a working machine is considerably lower than the demand for maximum power. Consequently, for most of the time, the diesel engine of a working machine operates at a poor efficiency far from its optimum efficiency range. However, the energy efficiency of dieseldriven working machines can be improved by electric hybridization. This way, the diesel engine can be dimensioned to operate within its optimum efficiency range, and the electric drive with its energy storages responds to changes in machine loading. A hybrid working machine can be implemented in many ways either as a parallel hybrid, a series hybrid or a combination of these two. The energy efficiency of hybrid working machines can be further enhanced by energy recovery and reuse. This doctoral thesis introduces the component models required in the simulation model of a working machine. Component efficiency maps are applied to the modelling; the efficiency maps for electrical machines are determined analytically in the whole torque–rotational speed plane based on the electricalmachine parameters. Furthermore, the thesis provides simulation models for parallel, series and parallel-series hybrid working machines. With these simulation models, the energy consumption of the working machine can be analysed. In addition, the hybridization process is introduced and described. The thesis provides a case example of the hybridization and dimensioning process of a working machine, starting from the work cycle of the machine. The selection and dimensioning of the hybrid system have a significant impact on the energy consumption of a hybrid working machine. The thesis compares the energy consumption of a working machine implemented by three different hybrid systems (parallel, series and parallel-series) and with different component dimensions. The payback time of a hybrid working machine and the energy storage lifetime are also estimated in the study.

Value Co-Creation Through Virtual Community environment, Case: Oma Olivia

The purpose of this thesis is to examine what elements of value co-creation create value for participants of Oma Olivia magazine through Olivia magazine’s virtual community environment. Furthermore the aim is to discover why readers take part in creating Oma Olivia in order to discover is Oma Olivia worth publishing in the future. The data is collected from secondary and primary sources by scanning the existing academic literature and by conducting interviews and surveys. The empirical results state that the hypothesis model created from the academic literature is statistically significant and the elements of value co- creation process create value for readers. Magazine publishing organization may want to consider publishing Oma Olivia also in the future due to its nature of creating value for customers.

Maastotyökoneen ajomoottorin hybridisointiin soveltuvan napavaihteiston dynamiikan mallinnus.

Työn tavoitteena oli mallintaa maastotyökoneen ajomoottorin hybridisointiin soveltuvan napavaihteiston dynamiikka. Työ tehtiin osana Saimaan ammattikorkeakoulun tutkimusprojektia, jonka tarkoituksena oli ajomoottorin ja integroidun napavaihteiston kaupallistaminen maastotyökoneisiin. Maastotyökoneena simulointimallissa käytettiin tyypillistä maataloustraktoria, johon kytkettiin vielä peräkärry. Traktorin renkaiden napaan oli kytketty ajomoottorina toimiva sähkömoottori, jonka sisään simuloitu napavaihteisto oli integroitu. Napavaihteiston dynamiikan mallintamiseen käytettiin monikappaledynamiikan simulointiohjelmistoa (Adams). Ohjelmalle määritettiin napavaihteiston komponenttien parametrit, joista voitiin simuloida vaihteiston dynaaminen käyttäytyminen. Simuloidusta mallista saatiin kytkimiin kohdistuvat voimat kytkentätilanteessa sekä sähkömoottorin väännön suunnanvaihtotilanteessa eri akselin pituuksilla, eri kytkinten nopeuseroilla, eri traktorin painoilla ja eri kuormilla ajettaessa. Mallissa simuloitiin myös sähkömoottorin käyttäytyminen vaihteenvaihtotilanteessa eri pyörimisnopeuden säätimen kertoimilla. Työssä huomattiin, että akselin mitoituksella voitiin vaikuttaa vaihteistossa ilmeneviin voimiin kytkimen kytkentähetkellä. Myös kytkimen hammastuksessa olevalla hammasvälyksellä voitiin vaikuttaa kytkimiin kohdistuviin voimiin suunnanvaihtotilanteissa. Vaihteistoon kohdistuvista voimista voidaan jatkossa suunnitella kytkimen ja akselin profiili, jotta vaihteisto kestää siihen kohdistuvat voimat.

Taisteluteknisen osaamisen kehittyminen Virtual Battlespace 2-koulutuksessa

Diplomityöni tavoitteena oli tutkia Panssariprikaatin Panssarijääkärikomppaniassa vuonna 2012 toteutetun Virtual Battlespace 2 – simulaattorijärjestelmän hyötypilotoinnin yhteyttä yksikössä palvelleiden varusmiesten taisteluteknisen osaamisen kehittymiseen. Tutkimuksella on liityntäpintoja Puolustusvoimien maapuolustuksen kehittämisohjelmaan ja se tukee jalkaväen taistelukoulutuksen kehittämistä. Kyseessä on laadullinen tutkimus, jossa tutkittava ilmiö on VBS2-järjestelmän koulutuskäytön yhteys ja mahdollinen vaikutus koulutettavien oppimiseen. Ilmiötä tarkastellaan koulutettavien henkilökohtaisten kokemusten ja oppimisen reflektion näkökulmasta. Tutkimuksen viitekehys on muodostettu toimintakyvyn kehittämistä, taisteluteknisen osaamisen rakentumista sekä virtuaalisia oppimisympäristöjä käsittelevistä teorioista. Tutkimusmenetelmänä sovellettiin tapaustutkimusta, jonka empiirinen aineisto kerättiin Panssarijääkärikomppanian varusmiesten ja henkilökunnan teemahaastatteluin. Aineisto käsiteltiin aineistolähtöisen analyysin periaattein. Tutkimuksen tuloksina ilmeni, että VBS2:n käytöllä ja Panssarijääkärikomppanian varusmiesten oppimisella oli heidän kokemuksensa perusteella havaittavissa yhteys. Keskeisenä havaintona VBS2-koulutus auttoi koulutettavia luomaan itselleen mielikuvan tavoitellusta toiminnasta, joka toimi sisäisenä vertailukohtana maastossa toteutettavassa taistelukoulutuksessa. Varusmiesten näkemykset VBS2-koulutuksen vaikutuksista oman taisteluteknisen osaamisensa kehittymiseen vaihtelevat hieman koulutustason ja tehtävän mukaan. Upseerikokelailla ja ryhmänjohtajilla oppimisessa korostuivat taistelukentän tapahtumien sekä oman joukon toiminnan kokonaisuuden hahmottamisen merkitys, jota tuki virtuaalisen oppimisympäristön avulla aikaan saatu poikkeuksellinen havainnollisuus. Miehistön jäsenet kiinnittivät johtajia enemmän huomiota järjestelmän tekniseen toimivuuteen liittyviin seikkoihin sekä eri toiminnallisuuksien realistisuuteen. Henkilökunta koki VBS2-koulutuksen vähentävän erityisesti teoriaoppituntien tarvetta ja nopeuttavan varusmiesten taisteluteknisten aiheiden oppimisprosessia siten, että maastossa toteutettaville soveltaville taisteluharjoituksille on käytettävissä aiempaa enemmän aikaa. VBS2-koulutus tukee käytännön kokemusten perusteella pitkävaikutteisesti maastossa tapahtuvaa taistelukoulutusta. Käytännön taisteluharjoitusten laadun koettiin lisäksi parantuneen varusmiesten ollessa totuttua aiemmin valmiita soveltamaan oppimaansa, sillä tyypillisimmät virheet oli saatu karsittua jo hyvin lyhytkestoisen VBS2-koulutuksen avulla. Yleisesti haastatellut varusmiehet pitivät VBS2:ta mielekkäänä ja motivoivana välineenä nykyaikaisen taistelukentän olosuhteiden ja oman sekä vihollisen toiminnan havainnollistamiseen ja opettamiseen. Myönteisten koulutustulosten aikaan saaminen edellyttää kouluttajilta korkeaa ammattitaitoa sekä VBS2:n käytön monipuolista hallintaa. Järjestelmäalustan tekniseen laatuun, toimivuuteen ja luotettavuuteen on panostettava, sillä erilaisista laitteisto-ongelmista johtuneet häiriötilanteet koettiin yhtenä eniten oppimista haittaavana ja motivaatiota laskevana tekijänä.

Application of a Pid+fuzzy controller on the motion control system in machine tools

This work deals with an hybrid PID+fuzzy logic controller applied to control the machine tool biaxial table motions. The non-linear model includes backlash and the axis elasticity. Two PID controllers do the primary table control. A third PID+fuzzy controller has a cross coupled structure whose function is to minimise the trajectory contour errors. Once with the three PID controllers tuned, the system is simulated with and without the third controller. The responses results are plotted and compared to analyse the effectiveness of this hybrid controller over the system. They show that the proposed methodology reduces the contour error in a proportion of 70:1.

Tooth-Coil Permanent Magnet Synchronous Machine Design for Special Applications

This doctoral thesis presents a study on the design of tooth-coil permanent magnet synchronous machines. The electromagnetic properties of concentrated non-overlapping winding permanent magnet synchronous machines, or simply tooth-coil permanent magnet synchronous machines (TC-PMSMs), are studied in details. It is shown that current linkage harmonics play the deterministic role in the behavior of this type of machines. Important contributions are presented as regards of calculation of parameters of TC-PMSMs,particularly the estimation of inductances. The current linkage harmonics essentially define the air-gap harmonic leakage inductance, rotor losses and localized temporal inductance variation. It is proven by FEM analysis that inductance variation caused by the local temporal harmonic saturation results in considerable torque ripple, and can influence on sensorless control capabilities. Example case studies an integrated application of TC-IPMSMs in hybrid off-highway working vehicles. A methodology for increasing the efficiency of working vehicles is introduced. It comprises several approaches – hybridization, working operations optimization, component optimization and integration. As a result of component optimization and integration, a novel integrated electro-hydraulic energy converter (IEHEC) for off-highway working vehicles is designed. The IEHEC can considerably increase the operational efficiency of a hybrid working vehicle. The energy converter consists of an axial-piston hydraulic machine and an integrated TCIPMSM being built on the same shaft. The compact assembly of the electrical and hydraulic machines enhances the ability to find applications for such a device in the mobile environment of working vehicles.Usage of hydraulic fluid, typically used in working actuators, enables direct-immersion oil cooling of designed electrical machine, and further increases the torque- and power- densities of the whole device.

Analysis of open CNC architecture for machine tools

The evolution of digital circuit technology, leadind to higher speeds and more reliability allowed the development of machine controllers adapted to new production systems (e.g., Flexible Manufacturing Systems - FMS). Most of the controllers are developed in agreement with the CNC technology of the correspondent machine tool manufacturer. Any alterations or adaptation of their components are not easy to be implemented. The machine designers face up hardware and software restrictions such as lack of interaction among system's elements and impossibility of adding new function. This is due to hardware incompatibility and to software not allowing alterations in the source program. The introduction of open architecture philosophy propitiated the evolution of a new generation of numeric controllers. This brought the conventional CNC technology to the standard IBM - PC microcomputer. As a consequence, the characteristics of the CNC (positioning) and the microcomputer (easy of programming, system configuration, network communication etc) are combined. Some researchers have addressed a flexible structure of software and hardware allowing changes in the hardware basic configuration and all control software levels. In this work, the development of open architecture controllers in the OSACA, OMAC, HOAM-CNC and OSEC architectures is described.