239 research outputs found

    Design, manufacture and test of a magnetic encoder

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    An new eddy current based magnetic position encoder structure is proposed and studied in this thesis. The encoder is composed of one read head and one scale with metal plates placed periodically on a substrate. The read head contains one emitter and two receiver pairs which are all rectangular planar coils. The electromagnetic coupling between the emitter and receivers were affected by the relative position of the scale. A system level analytical model of the proposed encoder structure has been derived, from which three different encoder signals forms were generated. An amplification and synchronous demodulation circuit has been designed and fabricated. The circuit board was used successfully to process the encoder output signals in the measurement. Four PCB encoder prototypes were fabricated. These encoder structures were studied using the ANSYS MaxwellTM software package. The simulated and measured results were compared. The best accuracy performance of the PCB encoder is -15 μm to 15 μm from the simulation results and -35 μm to 25 μm from the corresponding measurement. An alternative manufacturing process of the magnetic encoder based on multilayer Low Temperature Co-fired Ceramic (LTCC) technology has also been presented. The fabrication process of the LTCC encoder and equipment used were described. Two different methods were used to characterise the LTCC encoder with good agreement between all approaches attempted. The best accuracy performance of the LTCC encoder was -30 μm to 25 μm and after lookup table correction the improved accuracy ranged from -10 μm to 10 μm

    Improving Dynamics Estimations and Low Level Torque Control Through Inertial Sensing

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    In 1996, professors J. Edward Colgate and Michael Peshkin invented the cobots as robotic equipment safe enough for interacting with human workers. Twenty years later, collaborative robots are highly demanded in the packaging industry, and have already been massively adopted by companies facing issues for meeting customer demands. Meantime, cobots are still making they way into environments where value-added tasks require more complex interactions between robots and human operators. For other applications like a rescue mission in a disaster scenario, robots have to deal with highly dynamic environments and uneven terrains. All these applications require robust, fine and fast control of the interaction forces, specially in the case of locomotion on uneven terrains in an environment where unexpected events can occur. Such interaction forces can only be modulated through the control of joint internal torques in the case of under-actuated systems which is typically the case of mobile robots. For that purpose, an efficient low level joint torque control is one of the critical requirements, and motivated the research presented here. This thesis addresses a thorough model analysis of a typical low level joint actuation sub-system, powered by a Brushless DC motor and suitable for torque control. It then proposes procedure improvements in the identification of model parameters, particularly challenging in the case of coupled joints, in view of improving their control. Along with these procedures, it proposes novel methods for the calibration of inertial sensors, as well as the use of such sensors in the estimation of joint torques

    Optical Rotary Sensors for Avionic Applications

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    RÉSUMÉ Cette thèse concerne des nouveaux capteurs optiques dédiés aux systèmes de contrôle de vol d’avions «fly-by-wire (FBW)». Les capteurs de déplacement sont utilisés dans les systèmes de contrôle de vol pour détecter la distraction du pilote, les déplacements de l'actionneur et ceux de la surface de vol. Actuellement, les capteurs « Rotary variable displacement transducers - RVDTs» utilisés dans les systèmes de contrôle de vol d'avions FBW sont les capteurs basés sur des circuits magnétiques et électroniques analogiques. Donc, une interface électronique est nécessaire pour la démodulation et numérisation des signaux reçus. Par conséquent, des paires de fils longs torsadés sont utilisés pour connecter le RVDT à l’ordinateur installé à bord de l’avion. Les paires de fils torsadés sont lourds et sensibles aux interférences électromagnétiques (IEM) et aux coups de foudre qui peuvent se produire pendant le vol. Nous proposons des capteurs optiques intelligents pour réduire le poids de l’avion, la consommation du carburant pour un environnement vert, l’IEM et pour utiliser moins de pièces métalliques afin de protéger davantage l’avion contre les coups de foudre. La conception des encodeurs de capteurs optiques rotatifs (Optical rotation sensors - ORSs) est basée sur trois exigences importantes, soient la fiabilité, la linéarité, et l’exactitude de mesures. Ces capteurs intégrés dans le système de vol doivent être intelligents. Pour la fiabilité, la réponse du capteur est calculée à partir du ratio des deux puissances optiques ou celui de la différence divisée par la somme de ces deux puissances optiques. Cependant, pour la linéarité, la réponse du capteur consiste en une relation linéaire avec le paramètre à mesurer qui est l’angle de rotation. Quant à l’exactitude, l’erreur doit être moins de 1% sur toute la gamme de mesures. De plus, pour un capteur intelligent, le capteur basé sur des circuits analogiques, les convertisseurs au monde numérique et l’étape de démodulation doivent être emballés dans un boîtier commun. Dans un premier prototype, un capteur de déplacement ratio-métrique, auto-référant, analogique et optique a été proposé pour les applications avioniques. La position de rotation est déterminée par le ratio de deux puissances lumineuses réfléchie et transmise qui rendent le capteur indépendant de fluctuations de puissance. L’encodeur multi-gradient original proposé compense pour l’usage d’une source non-uniforme.----------ABSTRACT This thesis is on novel optical sensors for smart sensor system needed in flight control system (FCS) of fly-by-wire (FBW) aircraft. Displacement sensors are needed in FBW-FCS to detect pilot inceptors, actuator displacements, and flight control surface movement. Currently, the sensors used for rotary variable displacement transducers (RVDTs) are analog electronic sensors, hence an electronic interface is needed for demodulation and digitization of analog signals. As a result, long twisted wires are drawn from the sensor to the flight control computer (FCC) interface which are heavy and susceptible to electromagnetic interference (EMI) and lightning strike. By proposing smart optical sensors, we aim to reduce the aircraft weight to decrease the fuel usage towards a greener environment, reduce EMI, and protect the aircraft against a lightning strike by using fewer metallic parts. The encoders of the optical rotation sensors (ORS) are designed based on three important requirements of reliability, linearity, and accuracy. In addition, they must be smart sensors to be integrated into the smart sensor system needed in FBW aircraft. For reliability requirements, the designed sensor response is the ratio of two optical powers or the ratio of the difference to the sum of two optical powers. For linearity requirement, the sensor response must be a linear relation with the measurand which is the rotation angle. For accuracy requirement, the error should be less than 1% over the full range. In addition, for a smart sensor, the analog sensor and the electronics for digitization and demodulation have to be packaged into a single housing.In the first design, an optical, analog, self-referencing, ratio-metric, smart displacement sensor is proposed for avionic applications. The position of rotation is determined by an encoder by the ratio of the transmitted and reflected light powers, which makes the sensor independent of power fluctuations. A single multi-gradient encoder design compensates for the use of a non-uniform source. An anti-reflection coated glass window with the outer diameter of 27mm is used with an encoder pattern mapped on it using aluminum deposition. The experimental results show that the ratio of the transmitted and reflected powers has an accuracy of 0.53% over the full range, matching the specifications for avionic applications

    Harjattoman tasavirtamoottorin arviointi opto-mekaanisessa paikkasäätösovelluksessa

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    This thesis evaluates the applicability of a micro-sized brushless direct current (DC) mo- tor in an opto-mechanical positioning application. Brushless DC motors are electronically commutated motors that use permanent magnets to produce the airgap magnetic field. The motor is powered through an inverter or switching power supply which produces an AC electric current to drive each phase of the motor. Optimal current waveforms are determined by the motor controller based on the desired torque, speed or position requirements. The benefits of a brushless motor over conventional brushed DC motors are a high power to weight ratio, low noise and a long operating life. The purpose of this thesis is to find out the performance potential of such motors and determine methods to achieve it. Firstly, a motor model and an exact motor classification is presented. A literature review is made to discuss state of the art control methods and hardware configurations for dynamic position control. Based on the literature review, a control scheme with field-oriented control based torque control and cascaded PI controlled speed and position loops was selected for further evaluation. Experimental positioning tests were executed for two motors with different power transmission setups. Tests were performed with both, a hardware and software implemented, motor controllers. Results show promising performance. It was shown that the required acceleration is feasible with both, geared and direct drive, transmissions. Field-oriented control was shown as a well performing method to control torque but special caution was needed to implement a reliable position sensing solution in a small size as the control algorithm is intolerant for inaccurate and noisy position data. The conventional PI based position controller was effective in cases with no feedback related harmonics or motor related torque ripple but was not capable in handling ripple caused by a non-ideal system. Quality variances were seen between motors which were originated from mechanical defects and non-idealities in the stator structure. Further research is needed to achieve a better settling performance through filtering undesired feedback harmonics, better tuning and thus minimizing undesired vibrations.Tämän diplomityön tarkoituksena on arvioida pienikokoisen harjattoman tasavirtamoottorin soveltuvuutta opto-mekaaniseen paikkasäätösovellukseen. Harjattomat tasavirtamoottorit ovat elektronisesti ohjattuja moottoreita, joissa ilmavälin magneettivuo luodaan kestomagneeteilla. Moottorille syötetään virtaa taajuusmuuttajalta, joka muodostaa halutunlaisen vaihtovirran jokaiselle moottorin vaiheelle. Syötettävää virtaa ohjataan moottorinohjaimelta määritettyjen vääntö-, nopeus- ja paikkavaatimusten perusteella. Harjattoman DC-moottorin edut verrattuna perinteiseen harjalliseen DC-moottoriin ovat hyvä teho-painosuhde, hiljainen käyntiääni ja pitkä käyttöikä. Diplomityön tavoitteena on kartoittaa kyseisen moottorityypin suorituskyky paikkasäädössä ja tutkia keinoja saavuttaa haluttu taso. Alan tutkimuksessa ja kirjallisuudessa tunnettuja suorituskykyisiä säätömenetelmiä ja laite- sekä komponenttikokoonpanoja on koostettu kirjallisuuskatsauksessa. Tämän perusteella kokeellisiin testeihin valittiin säätöarkkitehtuuri vektorisäätöön perustuvalla virransäädöllä sekä PI-pohjaisilla nopeus- ja paikkasäätimillä. Kokeellisilla paikoitustesteillä arvioitiin kahden moottorin suorituskykyä erilaisilla voimansiirtovaihtoehdoilla. Testit suoritettiin sekä ohjelmistopohjaisella että sovelluskohtaiseen mikropiiriin toteutetulla laitepohjaisella säätimellä. Tulokset osoittavat että vaaditun kiihtyvyyden saavuttaminen on mahdollista sekä vaihteellisella että suoravetoisella voimansiirrolla. Vektorisäätö osoittautui suorituskykyiseksi virransäätömenetelmäksi, mutta moottorin asentomittauksen luotettava toteutus vaati erityishuomiota, sillä vektorisäätöalgoritmi on herkkä paikkadatan tarkkuudelle. PI-säätimillä toteutettu paikkasäätö osoittautui toimivaksi, mutta herkäksi moottorin epäideaalisuuksille sekä häiriöille takaisinkytkennässä. Moottoreiden välillä havaittiin laatueroja mekaanisissa toleransseissa ja staattorin rakenteessa. Lopullisen asettumisajan saavuttaminen vaatii lisätutkimusta. Erityishuomiota on kiinnitettävä harmonisten komponenttien suodattamiseen sekä systeemin säätöön, jotta ei-toivotut värinät saadaan minimoitua

    Permanently-Installed Distributed Pressure Sensors for Downhole Applications

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    Technology advancements (e.g., hydraulic fracturing and horizontal drilling) to recover unconventional oil and gas (UOG) resources are critical in maintaining future U.S. oil and gas production levels. Permanently installed distributed downhole pressure sensors could monitor fracture propagation, assess the effectiveness of hydraulic fracturing, and optimize hydraulic fracturing placement so that overall UOG recovery efficiency can be increased. However, the harsh environment (high temperatures, high pressures, strong vibration, and presence of brine, mud, debris, hydrate, and various gases), the long data telemetry distance, and the requirements of reliability and service lifetime make the downhole monitoring a very challenging task. To combat these challenges, this thesis presents three sensing systems for downhole pressure monitoring. First, A microwave-photonic low-coherence interferometry (MPLCI) system is proposed for optical fiber based distributed sensing. The system can be used to interrogate the intrinsic Fabry–Pérot interferometers (IFPIs) based distributed downhole pressure sensors. Assisted by an unbalanced Michelson interferometer (MI), a low-coherence laser source is used to interrogate IFPIs along with an optical fiber for a dark zone-free (or spatially continuous) distributed measurement. By combining the advantages of microwaves and photonics, the MPLCI system can synergistically achieve high sensitivity and high spatial resolution. Second, to solve the packaging and drift problems in optical fiber sensors, an all-digital sensing method based on an electrical encoder is developed for downhole pressure monitoring. The key innovation of the all-digital sensor concept is the built-in nonelectric analog-to-digital converter (ADC), which eliminates the need for downhole electronics for signal conditioning and telemetry in conventional electrical downhole sensors. As such, the sensors are more robust, less expensive, and have less drift in comparison with the existing sensors. Because the sensor outputs are digital in nature, the developed sensors can be remotely logged over a long distance, and many sensors can be digitally multiplexed for distributed sensing using a single surface instrument. The all-digital pressure sensors and their surface instrument were designed, engineered, fabricated, and calibrated. The integrated sensing system was tested/validated at both laboratory and research wellbores. Third, to solve the hysteresis problem induced by the electrical encoder, a non-contact optical encoder based all-digital pressure sensor for downhole applications is proposed. The proposed sensor combines the advantages of both optical fiber and all-digital sensing method. The noncontact-type encoder, which is composed of an encoding pad and an all-glass optical fiber sensing head. A glass additive and subtractive manufacturing (ASM) system was used to embed the multi-channel optical fibers into a bulk-fused silica glass substrate with high positioning accuracy and good thermal stability even at elevated temperatures. The optical fiber only serves as the telemetry channel to directly transmit the data in digital format, such that the system has long-distance telemetry capability as well as low drift. The proposed pressure sensor was manufactured and experimentally verified to have a high SNR, linear pressure response, and good long-term stability. In addition, a mathematical model to study the relationships between the sensor’s performances and design parameters was established

    Automation of garment assembly processes

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    Robotic automation in apparel manufacturing is reviewed and investigated. Gripper design for separation and de-stacking of batch cut fabric components is identified as an important factor in implementing such automation and a study of existing gripper mechanisms is presented. New de-stacking gripper designs and processes are described together with experimental results. Single fabric component handling, alignment and registration techniques are investigated. Some of these techniques are integrated within a demonstrator robotic garment assembly cell automating the common edge binding process. Performance results are reported

    Pneumatic motion control systems for modular robots

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    This thesis describes a research study in the design, implementation, evaluation and commercialisation of pneumatic motion control systems for modular robots. The research programme was conducted as part of a collaborative study, sponsored by the Science and Engineering Research Council, between Loughborough University and Martonair (UK) Limited. Microprocessor based motion control strategies have been used to produce low cost pneumatic servo-drives which can be used for 'point-to-point' positioning of payloads. Software based realtime control strategies have evolved which accomplish servo-controlled positioning while compensating for drive system non-linearities and time delays. The application of novel compensation techniques has resulted in a significant improvement in both the static and dynamic performance of the drive. A theoretical foundation is presented based on a linearised model of a pneumatic actuator, servo-valve, and load system. The thesis describes the design and evolution of microprocessor based hardware and software for motion control of pneumatic drives. A British Standards based test-facility has allowed control strategies to be evaluated with reference to standard performance criteria. It is demonstrated in this research study that the dynamic and static performance characteristics of a pneumatic motion control system can be dramatically improved by applying appropriate software based realtime control strategies. This makes the application of computer controlled pneumatic servos in manufacturing very attractive with cost performance ratios which match or better alternative drive technologies. The research study has led to commercial products (marketed by Martonair Ltd), in which realtime control algorithms implementing these control strategy designs are executed within a microprocessor based motion controller

    Development of a multi-modal tactile force sensing system for deep-sea applications

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    With the increasing demand for autonomy in robotic systems, there is a rising need for sensory data sensed via different modalities. In this way system states and the aspects of unstructured environments can be assessed in the most detailed fashion possible, thus providing a basis for making decisions regarding the robotâ s task. Com- pared to other sensing modalities, the sense of touch is underrepresented in todayâ s robots. That is where this thesis comes in. A tactile sensing system is developed that combines several modalities of contact sensing. The use of the tactile sense in robotic grippers is of great relevance especially for robotic systems in the deep sea. Up to now manipulation systems in master-slave control mode have been used in this area of application. An operator performing the manipulation task has to rely on visual feedback coming from cameras. Working on the oceanâ s seafloor means having to cope with conditions of limited visibility caused by swirled-up sediment

    New technologies for radiation-hardening analog to digital converters

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    Surveys of available Analog to Digital Converters (ADC) suitable for precision applications showed that none have the proper combination of accuracy and radiation hardness to meet space and/or strategic weapon requirements. A development program which will result in an ADC device which will serve a number of space and strategic applications. Emphasis was placed on approaches that could be integrated onto a single chip within three to five years

    Micro/Nano Manufacturing

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    Micro manufacturing involves dealing with the fabrication of structures in the size range of 0.1 to 1000 µm. The scope of nano manufacturing extends the size range of manufactured features to even smaller length scales—below 100 nm. A strict borderline between micro and nano manufacturing can hardly be drawn, such that both domains are treated as complementary and mutually beneficial within a closely interconnected scientific community. Both micro and nano manufacturing can be considered as important enablers for high-end products. This Special Issue of Applied Sciences is dedicated to recent advances in research and development within the field of micro and nano manufacturing. The included papers report recent findings and advances in manufacturing technologies for producing products with micro and nano scale features and structures as well as applications underpinned by the advances in these technologies
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