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- Air conditioning;Electric potential;Biological system modeling;Production;Automobiles;Next generation networking;Engines (1)
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Sensitive robots are an innovative technology of tomorrow ´s production. The Human–Robot-Collaboration (HRC) with its variable combination of unique skills represents a future-oriented form of work. Yet, there is a lack of experience in process realization, safety requirements are often not given and economic efficiency is still missing. There are a lot of innovative process solutions in research but industrial conditions are less considered. In this work, the approaches for the realization of standardizable HRCs for assembly operations in the automotive sector will be outlined. The aim is to present simple ways from the idea to series production by considering permitted limits. Based on an industrial application, innovative collaborations are realized with only few hardware and software components. In this context, standard compliant safety is ensured through internal system features and adjusted component designs. Additionally, an approach for HRC safety through real-time monitoring of the endeffector area is presented. As an
outlook there is a guideline for HRC realization.
The concept of the digital twin (DT), which accompanies a plant or machine throughout its entire life cycle, has further reinforced the role of Virtual Commissioning (VC). Of decisive importance for the economically and technically sensible use of the DT is its creation as early as possible in the life cycle. In the field of mechanical engineering, therefore, the first digital artifacts of the DT should ideally already be created in parallel with the mechanical design phase. The first step is the kinematization of the CAD model. This paper presents a new method for the semi-automated kinematization of 3D CAD models. The method uses a verbal description of the motion sequence desired by the designer, based on DIN EN 60848 (GRAFCET) [2] and using elements from VDI Guideline 2860 (handling functions) [8]. The presented method is easy to use and self-describing to a large extent. It enables designers to define in their own domain, in parallel to their mechanical designs, the desired motion sequence of the machine they have designed in machine-readable form. The actual kinematization of the CAD model is performed automatically. At the end, the kinematized design is available in COLLADA format and can be imported via the import interfaces of common simulation tools and can therefore be used for the DT.
The magnitude of current harmonics depends on the design of an electrical machine. By suppressing these harmonics noise can be reduced and efficiency improved. Iterative Learning Control (ILC) has proven effective in reducing harmonics. One of the challenges of working with ILC is operation at varying speeds. Variable speeds are particularly important for applications like automotive drives. The ILC period length changes during the learning process at varying speeds. Due to fixed sample rates, the number of values processed by the ILC varies with motor speed.This paper proposes a method to solve this problem and uses ILC at varying speeds. The ILC used to eliminate the harmonics is based on the inverse system. The usage of a two-dimensional memory array is proposed. This data structure holds rows for specific speeds between which interpolation is performed, enabling the elimination of errors which are periodically cyclic to one electrical rotation. This includes the reduction of the motor current harmonics. To verify the presented method a permanent magnet synchronous motor with distinctive 5th and 7th harmonics is used. In real-time implementations, limitations of memory and computational capacity occur.
B8.3 Influence of Temperature on Distributed Strain Sensing with OTDR in Polymer Optical Fibers
(2021)
Strain in ground and earthworks can be measured by polymer optical fibers (POF) applied to geotextiles. We measure the increase of backscatter (IOB) in the fiber under strain using optical time domain reflectometry (OTDR). The effect of temperature on this measurement principle is investigated. The local backscatter changes by 0.003 dB/K for common ambient temperature. In addition it is shown, that temperature depended viscoelastic properties of the polymer does affect IOB.
Finite control set model predictive control (FCS-MPC) is a promising method for the control of multi-phase machines, due to its capability to directly account for nonlinearities and multiple controlled variables. To overcome the drawback of high current ripples and excitation of harmonic currents in the so-called xy-subsystem, several methods have been proposed in the literature so far. This paper proposes an MPC-based method that achieves high granularity of switching by not only switching at the discrete time steps, but also within the sampling interval. In doing so, the discussed algorithm, referred to as variable switching point current control (VSP 2 CC), produces low current distortions, while still keeping the advantages of conventional FCS-MPC, such as fast dynamic behavior during transients. To highlight the above, VSP 2 CC is applied to a six-phase permanent magnet synchronous machine (PMSM) and compared with conventional FCS-MPC and MPC that employs virtual voltage vectors (VV-MPC).
Absolute spectral backscatter measurements of large-core multimode PMMA polymer optical fibers
(2021)
To our knowledge, we are the first to measure the absolute value of the backscattering coefficient of a standard 1 mm core-diameter, multimode (MM) step-index (SI) polymethylmethacrylate (PMMA) polymer optical fiber (POF) for the spectral range of 450 nm to 700 nm. Our optical time domain reflectometer (OTDR) setup consists of a femtosecond supercontinuum laser with an acousto-optical filter as a tunable light source with short pulses and a time-correlated single-photon counting system as a receiver with a high dynamic range. The backscattering coefficient is calculated from the ratio between the energy within the fiber end reflex and the distributed backscattering level. We also measured the spectral attenuation with our OTDR setup and compared it with a standardized measurement method. At the attenuation minima within the measured spectral range the backscattering level of a 1 ns pulse is about −46 dB at 520 nm, −48 dB at 570 nm, and −51 dB at 650 nm. We were also able to show by the observed wavelength dependence that Rayleigh scattering causes a majority of the scattering.
Depending on the application range, there are various recommendations in the literature which converter topology should be used. These are mostly based on experience or more or less deeper considerations. For DC/DC converters, which are operated over a wide input voltage range, such recommendations rarely exist. Therefore, this contribution shows the evolution of two input voltage dependent selection matrices, which should facilitate the selection of future topologies based on known publications and basic considerations. The focus here lies on converters for λ = V i_max /V i_min ≥ 3 with galvanic isolation. First, the data set is introduced, where a distinction is made between flyback converters, forward converters and other 1stage or 2stage converters before the evolution of the novel input voltage dependent matrices is carried out. These two matrices support the selection of a suitable topology and whether the energy transfer should be done by one or two stages.
This paper presents a comparative simulation analysis of an Interior Permanent Magnet Synchronous Machine (IPMSM) performance once fed by a traditional three-phase two-level inverter and then using a three-phase five-level Cascaded H-Bridges Multilevel Inverter (CHBMI). For this purpose, an enhanced mathematical model of the IPMSM, that take into account simultaneously saturation, cross-coupling, spatial harmonics and iron loss effects, has been employed. Furthermore, two different PWM modulation strategies have been considered. The study was conducted for several working conditions, evaluating the impact of CHBMI adoption on the IPMSM performance in terms of improved efficiency and torque ripple reduction.
This paper presents the design, construction and measurements on a transverse flux machine. The lamination concept is designed for easy fabrication and low iron losses. For a good flux guidance and a high magnetic field, electrical sheet is used for the soft magnetic circuit. The design of the machine is performed with a fast semi-analytical calculation and validated by 3D finite element analysis. The calculated quantities are compared with measurements on a prototype. Despite certain deviations, the measurements show good agreement with the calculations for the induced voltage and torque. In terms of efficiency, however, the measurement deviates significantly from the simulation. This is due to the iron losses being calculated much too small, which is evident from the separation of the measured losses.
To guaranty a safe load transfer through adhesively bonded joints, Structural Health Monitoring (SHM) methods that allow for permanent monitoring of the structural bond condition, are becoming more and more important. To meet this increasing demand, a novel approach for SHM of adhesively bonded joints by use of integrated Polymer Optical Fibers (POF) has been demonstrated in previous work. The sensor operating principle is based on strain transfer from the structural adhesive to the integrated POF. This strain transfer leads to a deformation of the POF cross-sectional shape and in that way affects the optical light propagation in the POF.
In the current work, numerical and experimental results are presented into the mechanical behavior of embedded POF in adhesive bulk specimens subjected to tensile loading. Local deformations of both the POF (Asahi Kasei DB 500) and the structural adhesive (3 M Scotch Weld DP410) are evaluated using Digital Image Correlation (DIC). In the loading direction, a linear correlation is shown between strain inside the POF core and strain of the surrounding adhesive. Tests results, as well as fracture analysis, show a highly ductile behavior and failure of the POF cladding material and the interface between the POF core and annular cladding.
We present a robust concept for quasi distributed strain measurement using optical time domain reflectometry (OTDR) in polymer optical fibers (POF). The spatial shifts of discrete reflective events in the OTDR trace are evaluated as reference points. It is shown how such reference reflections can be prepared and which properties can be expected.
In this paper, a flux linkage-based direct model predictive current control approach is presented for small permanent magnet synchronous motor (PMSM) drives. The method aims to minimize the current ripples at steady state by deciding on the optimal switching instant, while exhibiting fast dynamic behavior during transients. To this end, the future trajectory of the stator current is not computed based on the machine inductances or inductance look-up tables, but on the changes of the magnetic flux linkage by utilizing flux linkage maps. As shown, the proposed method can be particularly advantageous for electric drives with a noticeable nonlinearity in terms of saturation and/or cross-coupling effects since it allows for a significantly increased prediction accuracy, which leads to an improved steady-state performance as indicated by the reduced current distortions.
A transformer with variable primary windings for wide input voltage range DC/DC converters is presented. This transformer structure allows three states of the primary winding to be converted by only two individual windings. Based on the evaluations of a two-switch flyback converter, the potential of DC/DC converters with variable structures, the implementation of such a transformer and the advantages and disadvantages are shown and discussed. Real measurement results demonstrate the noticeable increase in efficiency and the reduction in component stress, having a positive influence on the operation of the converter and the component selection during the design process.
According to the current state of the art, adhesively bonded joints cannot be tested completely non-destructively. This is the main motivation to permanently monitor adhesively bonded joints in order to record their structural integrity and - as a result - to ensure safe load transmission. By the use of permanent non-destructive Structural Health Monitoring (SHM) methods, structural damages in the adhesive bond can be detected at an early stage. This paper presents a new method for monitoring the structural integrity of adhesively bonded joints by integrating a Polymer Optical Fiber (POF) into the adhesive layer. The sensor concept is based on a deformation transfer from the adhesive to the POF, which results in a change in the cross-sectional shape of the POF. The cross-sectional shape influences the optical light propagation in the POF, which can be detected by simple optical measuring devices. The paper describes the general principle and first results of investigations on a structural adhesive (3M Scotch-Weld DP 609). The sensor signal is in a good relation to the stress state of the adhesive layer.
Machine learning algorithms are increasingly used in industrial applications for a multitude of use-cases. However, using them in control tasks is a challenge due to real-time requirements and limited resources. In this paper, an implementation scheme for real-time inference of multilayer perceptron (MLP) neural networks on FPGAs is proposed. Design constraints for using MLPs in reinforcement learning agents for motor control applications are derived and accounted for in the implementation. Two MLP architectures are evaluated on an FPGA, and the timing and resource-usage data are reported. The real-time capability of the implementation for motor control applications is investigated for standard control frequencies. It is shown by experimental validation that real-time interference with an area-efficient implementation for motor control applications is achievable. Therefore, the proposed implementation scheme can be applied to deep reinforcement learning controllers with hard real-time requirements.
PMMA polymer optical fibers embedded in semi-structural polyurethane adhesive bonds serve as economical load sensor for structural health monitoring by evaluating load-dependent optical transmission as well as modal distribution measured by a far-field camera. Scaling of sensor quantities by the sensitive fiber length is shown.
Design of a Wide Input Voltage Range Current-Fed DC/DC Converter Within a Reduced Duty-Cycle Range
(2020)
A design of a current-fed push-pull converter for wide input voltage ranges within a reduced duty-cycle range is presented. Based on the converter conversion ratios of three different clamping configurations, the potential of the input clamping is shown analytical, simulative and by measurements. A differentiation is made between the four possible operating modes, which can be distinguished in the control of the semiconductors and the magnetomotive force in the reactor. By optimizing the turn ratios of both transformers, the wide input voltage range capability of the input clamped current-fed push-pull converter was improved, which has been proved by measurements on a real prototype.
According to the current state of the art, adhesively bonded joints cannot be tested completely non-destructively. This is the main motivation to permanently monitor adhesively bonded joints in order to record their structural integrity and - as a result - to ensure safe load transmission. By the us e of permanent non-destructive Structural Health Monitoring (SHM) methods, structural damages in the adhesive bond can be detected at an early stage. This paper presents a new method for monitoring the structural integrity of adhesively bonded joints by integrating a Polymer Optical Fiber (POF) into the adhesive layer. The sensor concept is based on a deformation transfer from the adhesive to the POF, which results in a change in the cross-sectional shape of the POF. The cross-sectional shape influences the optical light propagation in the POF, which can be detected by simple optical measuring devices. The paper describes the general principle and first results of investigations on a structural adhesive (3M Scotch-Weld DP 609). The sensor signal is in a good relation to the stress state of the adhesive layer.
Design Concept of a Wound Field Transverse Flux Machine using Soft Magnetic Composite Claw-Poles
(2020)
This paper presents the machine concept of a wound field transverse flux machine (WFTFM). In contrast to permanent magnet transverse flux machines (PMTFM), here the magneto motive force (mmf) of the rotor is generated by a current. The magnetic circuit of the WFTFM is made of soft magnetic composite (SMC) and is designed as claw-poles. Thus the magnetic circuit consists of only a few components. Together with the simple ring coils in stator and rotor, the WFTFM offers advantages in the production of electrical machines. The basic structure of the machine and a first design is described here. The results generated by numerical three-dimensional finite element analysis (FEA) are compared with those of conventional machines.
This article presents a flux linkage-based direct model predictive current control approach that achieves favorable performance both during steady-state and transient operation. The former is achieved by computing the optimal time instants at which a new switch position is applied to the converter. To this end, the future current behavior is not computed based on the machine inductances or inductance look-up tables; instead, flux linkage maps are utilized to predict the trajectory of the magnetic flux linkage, and subsequently of the current. This is advantageous for electric drives with noticeable magnetic nonlinearity in terms of saturation and/or cross-coupling effects. Hence, by using flux linkage maps in the prediction process, the evolution of the stator current can be calculated more accurately, enabling the controller to make better switching decisions. Moreover, the discussed predictive controller exhibits excellent dynamic performance owing to its direct control nature, i.e., the control and modulation tasks are performed in one computational stage rendering a dedicated modulation stage redundant. Three different drive systems based on permanent magnet synchronous motors are examined to demonstrate the effectiveness of the presented control approach.