TY - THES A1 - Mahanta, Arindam T1 - Workflow optimization based on testing of an industrial control application, within a model-based development environment T1 - Workflow-Optimierung basierend auf dem Test einer industriellen Reglerapplikation innerhalb einer modellbasierten Entwicklungsumgebung N2 - This Master’s thesis was written in cooperation with Jungheinrich Moosburg AG & CO. KG as a part of its development of counterbalance forklift trucks with hydrostatic drivetrain. The work in this thesis aims in optimizing the current model-based development workflow of the application software in the context of testing. The failure or malfunction of the drive- or service-hydraulics of a counter- balanced forklift truck is inevitably linked to the endangerment of human life. This calls for ensuring the functional correctness of the entire system throughout the development process. Both in the hardware and software quality assurance, the goal is always to reduce the risk of errors to an acceptable level. Within the scope of the development of automotive control applications, dynamic testing in the form of Model-in-the-Loop (MiL) simulations plays an important role. At this point, the selection of proper test cases is crucial, and to address this point, application of systematic test design techniques and testing methods have been studied as a part of this work. In terms of quality assurance for embedded software, model-based testing enables systematic and effective testing at a relatively low cost. In model-based testing, the test cases in whole or in parts, are generated from the developed model that describes the functional aspects of the system under test (SUT). Both black- box and white-box testing methods have been studied for this work. For black- box testing, test design techniques as the combinatorial testing and classification tree method have been applied and evaluated. The designed test cases have been imported and applied to the SUT in MATLAB/Simulink. A workflow for carrying out the unit testing is proposed and a framework is developed for automating the unit testing process. This thesis aims to provide a road map for effective unit testing through the application of established testing techniques. The application of these techniques have demonstrated their effectiveness in detecting and evaluating potential errors in the software units. Suggestions for improvements in the line of achieving complete automation for the testing process have also been pointed out. N2 - Diese Masterarbeit entstand in Zusammenarbeit mit der Jungheinrich Moosburg AG & CO. KG im Rahmen der Entwicklung von Gegengewichtsstaplern mit hy- drostatischem Antrieb. Die Arbeit zielt darauf ab, den aktuellen modellbasierten Entwicklungsprozess der Regleranwendung im Rahmen des Komponententests zu optimieren. Der Ausfall oder die Fehlfunktion der Antriebs- oder Servicehydraulik eines Gabelstaplers ist zwangsläufig mit der Gefährdung von Menschenleben verbun- den. Dies erfordert die Sicherstellung der funktionalen Korrektheit des gesamten Systems während des gesamten Entwicklungsprozesses. Sowohl in der Hardware- als auch in der Software-Qualitätssicherung ist es immer das Ziel, das Fehlerrisiko auf ein akzeptables Maß zu reduzieren. Im Rahmen der Entwicklung von Auto- motive Regleranwendungen spielt das dynamische Testen in Form von Model-in- the-Loop (MiL) Simulationen eine wichtige Rolle. An dieser Stelle ist die Auswahl geeigneter Testfälle entscheidend, für die im Rahmen dieser Arbeit systematische Testdesigntechniken und Testmethoden untersucht wurden. Im Hinblick auf die Qualitätssicherung für eingebettete Softwareanwendungen ermöglicht das modellbasierte Testen ein systematisches und effektives Testen bei relativ niedrigen Kosten. Beim modellbasierten Testen werden die Testfälle ganz oder in Teilen aus dem entwickelten Modell generiert, das die funktiona- len Aspekte des zu testenden Systems (SUT) beschreibt. Sowohl Black-Box- als auch White-Box-Testmethoden wurden für diese Arbeit untersucht. Für Black- Box-Tests wurden Testdesigntechniken wie die kombinatorische Methode und die Klassifikationsbaum-Methode angewendet und evaluiert. Die entworfenen Testfälle wurden in MATLAB / Simulink importiert und auf das SUT angewendet. Ein Arbeitsablauf zur Durchführung des Komponententests wird vorgeschlagen und ein Rahmen für die Automatisierung des Komponententestprozesses entwickelt. Diese Masterarbeit zielt darauf ab, eine Road-Map für effektive Komponententests durch die Anwendung von etablierten Testtechniken bereitzustellen. Die Anwendung dieser Techniken hat ihre Wirksamkeit beim Erkennen und Bewer- ten potentieller Fehler in den Softwarekomponenten gezeigt. Es wurden auch Verbesserungsvorschläge für die vollständige Automatisierung des Testprozesses gemacht. KW - Model based testing KW - Model based development KW - Modellbasierten Entwicklung KW - Reglerapplikation Y1 - 2018 ER - TY - THES A1 - Chhabra, Vaibhaiv Bobby T1 - Design of a Robust Powertrain of an E-Bike Test Bench N2 - In the last few decades, environmental impacts of petroleum-based transportation have led to a renewed interest in electric transport infrastructure. E-bikes are zero-emission vehicles as they do not emit any combustion by-products. With the increasing demand for electric bikes over the past decades, the production of e-bikes has also rocketed. The purpose of this thesis is to optimize and design a robust power train of an e-bike test bench that is stationed in the Rhine-Waal University of Applied Sciences. The mechanical design of the present test bench is modular and flexible. The current test rig is susceptible to large disturbances due to vibrations in the chain drive mechanism. Due to the large segments in the chain drive, the torque results are also interrupted. These issues have been overcome by the substitution of the chain-drive mechanism to a belt-drive mechanism. The optimized power transmission system remains the same ensuring a smooth power flow in the system. In order to optimize the powertrain, three different concepts were proposed. Each concept was graded on the basis of different criteria with the help of Decision Matrix Analysis in order to choose the most promising concept. A conceptual 3D CAD model and 2D Drawings of the powertrain have been designed on SolidWorks for better reference. The substituted or the new parts that were essential for the new optimizing concept were decided with the help of a Morphological Box followed by a detailed Bill of Materials (BOM). The new powertrain was commissioned with the new parts as per the concept. The thesis further expands on the characteristics of the present test bench and the optimized test bench, the results and readings of the present test bench and the commissioning of the new powertrain. The thesis concludes with the possibility of the future work on the test bench and structural changes that are necessary for the e-bike that is to be tested. Y1 - 2020 ER - TY - THES A1 - Vasovic, Luka T1 - Development, Controller Design and Validation of a Torque Vectoring System for an All-Wheel Drive Electric Go-Kart N2 - This thesis investigates the design and simulation-based evaluation of a yaw-rate control system using torque vectoring for an all-wheel-drive electric go-kart with independently driven wheels. The work is conducted within a purely model-based framework, employing MATLAB and Simulink to replicate the vehicle dynamics and control interactions in a controlled virtual environment. Torque vectoring describes the distribution of drive torque between individual wheels to influence the yaw moment of the vehicle. This enables targeted improvements in stability, responsiveness, and cornering performance beyond what is achievable with steering input alone. In this study, yaw rate is selected as the primary control variable. A reference yaw rate is derived from the linear bicycle model, and the control objective is to minimize the error between the reference and the simulated actual yaw rate by applying corrective yaw moments through differential torque allocation. A Proportional-Integral-Derivative (PID) controller is implemented to track the reference yaw rate. Gain tuning is performed using MATLAB’s PID Tuner, leveraging the system transfer function extracted from the simulation model. The complete control system is integrated into a modular Simulink model of the go-kart, which incorporates the 2-DOF bicycle model for lateral and yaw dynamics, as well as subsystems for maneuver generation and torque vectoring logic. Controller performance is assessed through standard vehicle dynamics test maneuvers, including ramp steer, step steer, and double lane change. For each maneuver, simulations are performed both with and without torque vectoring, allowing quantitative comparison of yaw rate tracking accuracy, stability, and trajectory. The results demonstrate that torque vectoring substantially improves yaw rate tracking and reduces the understeer tendency of the simulated vehicle, particularly during transient maneuvers. Even in a simplified small-scale vehicle model, the benefits of active yaw moment control are evident, underscoring the relevance of torque vectoring for enhancing dynamic performance in electric vehicles with independent wheel actuation. The modular simulation framework developed in this work also provides a foundation for future experimental validation on the physical research platform as well as further developments on the simulation model. KW - Torque Vectoring KW - Vehicle Dynamics KW - Vehicle Simulation KW - Bicycle Model Y1 - 2025 ER - TY - THES A1 - Mohajeri Nejad, Mostafa T1 - Development and implementation of an adaptive control system for automizing and optimizing the performance of a rolling fluid (setur) hydro-turbine N2 - This thesis presents the design and implementation of an automated control system for a laboratory-scale SETUR (Sedlacek's Blade-less Rolling Fluid Turbine) hydro turbine test rig. The goal was to enable precise and repeatable experiments by automating the regulation of the turbine’s water level and data acquisition process. The developed system integrates multiple sensors, including discrete liquid level sensors, pressure transducers, and a flow meter, interfaced with an Arduino-based controller. A PID-based control algorithm with gain scheduling was designed to adapt to the nonlinear flow dynamics across different operating regimes of the turbine. The control loop operates at a 0.5 s sampling rate and employs layered signal filtering and calibration routines to compensate for sensor noise, offset, and scaling errors. The complete hardware setup includes signal conditioning circuits for analog sensors, digital communication for actuator control, and real-time data monitoring via serial output. Experimental results demonstrate that the system achieves stable water-level regulation within approximately two minutes after pump activation and maintains steady-state operation without overshoot or sustained valve saturation. The overall measurement uncertainties were quantified as ±3.06 % FS for pressure and ±5.2 % FS for flow, meeting the predefined accuracy requirement of ≤ 5 % FS. The developed automation platform provides a reliable foundation for further research on the SETUR turbine, including efficiency characterization, advanced control development, and future integration of IoT-based supervisory monitoring and data analysis tools. KW - SETUR KW - Automated Test-bench KW - Process Automation KW - Renewable Energies KW - Hydro Turbines KW - SCADA Y1 - 2025 ER -