Five-Axis Machine Tool Condition Monitoring Using dSPACE Real-Time System

This paper presents the design, development and SIMULINK implementation of the lumped parameter model of C-axis drive from GEISS five-axis CNC machine tool. The simulated results compare well with the experimental data measured from the actual machine. Also the paper describes the steps for data acquisition using ControlDesk and hardware-in-the-loop implementation of the drive models in dSPACE real-time system. The main components of the HIL system are: the drive model simulation and input – output (I/O) modules for receiving the real controller outputs. The paper explains how the experimental data obtained from the data acquisition process using dSPACE real-time system can be used for the development of machine tool diagnosis and prognosis systems that facilitate the improvement of maintenance activities

Model Advancement And Hil Setup For Testing A P2 Phev Supervisory Controller

Teams participating in Advanced Vehicle Technology Competitions such as EcoCAR3 are often bound by limited time and resources. Moreover, vehicle and component downtime due to mechanical and electrical issues reduce the time available for testing activities demanded by the Controls/Systems Modeling and Simulation teams. Therefore, the teams would benefit from identifying new approaches and being more pragmatic and productive in order to achieve satisfactory progress in the competition. This thesis summarizes the approach taken to improve the simulation accuracy of the Wayne State University EcoCAR3 team’s Pre-transmission Parallel Hybrid Electric Vehicle plant model and HIL setup. Focus is on testing the Hybrid Supervisory Controller energy management and diagnostic functionality to be successful in the emissions and energy consumption event. After thorough literature research it is determined that a varying fidelity forward dynamic HEV plant model can produce accurate energy consumption simulation results. Initially, data obtained from manufacturers is used to model the components such as IC Engine, Electric Machine, Energy Storage System (ESS), transmission, differential, chassis and the ECUs. Later, test benches are setup to optimize and refine the individual model parameters by comparing the simulated results with the actual results obtained from component testing and on-road vehicle testing. Finally, the total vehicle plant model is validated by comparing the simulated results with the P2 PHEV on-road test data. The accuracy of the plant model determines the ability to optimize the Hybrid Supervisory Controller code to achieve maximum energy efficiency. Apart from model accuracy improvement, the Hardware In Loop (HIL) test setup is also discussed. HIL system is essential for validating the Hybrid Supervisory Controller’s functionalities in real time. The challenges during modeling and HIL setup are discussed and more improvements that can be done during the final year are recommended based on the research

Healthy and open phase PMaSynRM model based on virtual reluctance concept

© 2021 IEEE. Personal use of this material is permitted. Permission from IEEE must be obtained for all other uses, in any current or future media, including reprinting/republishing this material for advertising or promotional purposes,creating new collective works, for resale or redistribution to servers or lists, or reuse of any copyrighted component of this work in other works.The trend in the industrial power electronics electrical drives is to reach high power density and high efficiency in variable load conditions at cost-effective unwasteful designs. Currently, motors with permanent magnets (such as IPMSM and PMaSynRM) are of great interest because of compactness, low losses, and high torque capability. The performance of a drive system can be predicted with a motor electromagnetic authentic nonlinear model. In this paper, a novel, fast, and precise motor model of PMaSynRM based on virtual reluctance (VR) is proposed. It takes into account the cross saturation, winding distribution, space harmonics, slotting effect, and stepped skewing. The virtual reluctances are identified by finite element analysis (FEA) and implemented in the time-stepping simulation. The flux inversion is not required. The proposed concept is useful in the rotating field or phase quantities (for open phase simulation). The model is also discretized for SiL and HiL applications. Finally, the validation in FEA and experimental setup was performed.This work was supported in part by Spanish Ministry of Economy and Competitiveness under TRA2016-80472-R Research Project and Secretaria d’Universitats i Recerca del Departament d’Empresa i Coneixement de la Generalitat de Catalunya under 2017SGR967.Peer ReviewedPostprint (author's final draft

Novel sensorless generator control and grid fault ride-through strategies for variable-speed wind turbines and implementation on a new real-time simulation platform

The usage of MW-size variable-speed wind turbines as sources of energy has increased significantly during the last decade. Advantages over fixed-speed wind turbines include more efficient wind power extraction, reduced grid power fluctuation, and improved grid reactive power support. Two types of typical generation systems for large-size variable-speed wind turbines exist. One is the doubly-fed induction generator (DFIG) with a partial-scale power electronic converter. The other is the permanent-magnet synchronous generator (PMSG) with a full-scale power electronic converter. This research is to develop the model of these two wind turbine systems for real-time simulation, including the complete aerodynamic and mechanical and electrical components. The special focus of this dissertation addresses the mechanical sensorless control of wind generators and grid fault ride-through strategies. In the electrical controller of a DFIG, A mechanical speed sensor is normally required to provide accurate information of the machine speed and rotor position. However, sensorless operation is desirable because the use of a mechanical speed sensor coupled with the machine shaft has several drawbacks in terms of degraded robustness, extra cost and cabling, and difficult maintenance. In this dissertation, design and analysis of a novel sensorless vector controller using a reduced-order state observer is addressed in detail. Results have revealed that the proposed sensorless observer is more robust against parameter variations than other speed estimation schemes. Nowadays, almost all the grid code specifications over the world have included fault ride-through requirements for grid-connected wind turbines. In US, as mandated by the Federal Energy Regulatory Commission (FERC) Order 661-A, wind farms are required to remain online in the presence of severe voltage disturbances as low as 0.0 pu, as measured at the high voltage side of the wind generator step-up transformer, for up to 9 cycles (150 ms). These strict requirements present a significant challenge to the existing wind turbine technologies. In this dissertation, an improved technique combining the traditional crowbar protection circuit and the demagnetizing current injection to ride-through symmetrical grid voltage dips is analyzed and verified for a DFIG-based wind turbine. Also, an improved fault ride-through control strategy without using any extra protection hardware for a PMSG-based wind turbine to mitigate the dc-link overvoltage is developed. In this dissertation, a new real-time simulation platform is developed based on industry standard simulation tools, RTDS and dSPACE. The aforementioned wind turbine models and proposed sensorless controller as well as fault ride-through strategies are all implemented in real-time on this hardware-in-the-loop type of simulation platform. The necessary measures in hardware and software aspects to enable the collaborative simulation of these two industry standard simulators are addressed. Results have shown this integrated real-time simulation platform has broad application prospects in wind turbine controller design and grid interconnection studies

Overview of Real-Time Simulation as a Supporting Effort to Smart-Grid Attainment

abstract: The smart-grid approach undergoes many difficulties regarding the strategy that will enable its actual implementation. In this paper, an overview of real-time simulation technologies and their applicability to the smart-grid approach are presented as enabling steps toward the smart-grid’s actual implementation. The objective of this work is to contribute with an introductory text for interested readers of real-time systems in the context of modern electric needs and trends. In addition, a comprehensive review of current applications of real-time simulation in electric systems is provided, together with the basis to understand real-time simulation and the topologies and hardware used to implement it. Furthermore, an overview of the evolution of real-time simulators in the industrial and academic background and its current challenges are introduced.The final version of this article, as published in Energies, can be viewed online at: http://www.mdpi.com/1996-1073/10/6/81

Testialustan suunnittelu hybridiajoneuvojen hardware-in-the-loop simulaatioihin

Recent changes to vehicle type-approval regulations have increased demand for testing methods, which better represent real-world driving conditions. Hardware-in-the-Loop (HIL) simulation is seen as an attractive alternative for pure simulations and real-world operation measurements. The goal of this work was to provide a functional testbed for engine testing, as well as for HIL simulations of Hybrid Electric Vehicles (HEVs). In addition, a state-of-the-art review of HIL was considered an important goal of the work. The theory behind HIL, and real-time systems in general, is depicted using a wide variety of examples from automotive applications relating to hybrid power sources. The knowledge gained from the literature was used to design and build a testbed in a form of an engine dynamometer. The testbed can be used to emulate rotational forces, such as load torques on a driveshaft. The testbed’s fast hardware connections enable real-time testing. The scope of the design was in mechanical design and in specification of the hardware components. Initial Internal Combustion Engine (ICE) steady-state and transient tests were done to partially validate the testbed. However, the performance was assessed to not be at an acceptable level. For example, only speed tracking passed the non-road transient cycle tracking assessment. Torque tracking and the derived power curves failed the assessment narrowly. However, the test results indicate that with proper tuning of the control software, the system performance should get better. The system response was slow at this point, but the transient behavior itself was fast. Also, in steady-state, torque and speed ripple were low. Only the preparations for HIL simulation were carried out, since the testbed was not validated to be functional enough for the much more demanding HIL tests. The preparations involved building a simulation model of a series-parallel hybrid Refuse-Collecting Vehicle (RCV), which is to be used for the verification of the designed system’s HIL capabilities. The model was independently verified to be suitable to be used for the physical tests.Viimeaikaiset muutokset ajoneuvojen tyyppihyväksyntään ovat lisänneet tarvetta testausmetodeille, jotka paremmin vastaavat oikean elämän ajo-olosuhteita. HIL-simulaatio nähdään houkuttelevana vaihtoehtona pelkälle simulaatiolle sekä ajoneuvon ajonaikaisille mittauksille. Tämän työn tavoitteena on tarjota toimiva testilaite moottoridynamometritestaukseen sekä hybridiajoneuvojen HIL-simulaatioihin. Lisäksi, HIL:in nykytilanteen kuvausta pidettiin tärkeänä työn tavoitteena. HIL:in, ja yleisemmin reaaliaikaisen testauksen, tausta ja teoria selvitettiin laaja alaisesti käyttäen esimerkkejä hybridivoimanlähteisiin liittyvistä ajoneuvoalan käyttökohteista. Kirjallisuutta hyödyntäen, testipenkki suunniteltiin ja rakennettiin. Testipenkkiä voidaan käyttää emuloimaan pyöriviä voimia, kuten vetoakseliin kohdistuvia vääntöjä. Testipenkin nopeat yhteydet mahdollistavat reaaliaikaisen testauksen. Suunnittelu oli rajattu pääasiassa mekaaniseen suunnitteluun ja komponenttien määrittelyyn. Sähkö- ja ohjelmistosuunnittelu määriteltiin yleisellä tasolla. Alustavat polttomoottorilla tehdyt vakaiden ajopisteiden ja transienttiajojen testit toteutettiin testipenkin osittaiseksi validoinniksi. Kuitenkin, laitteen suorituskyky ei yltänyt halutulle tasolle. Esimerkiksi, ainoastaan nopeusseuranta läpäisi transienttiajo testin, mutta vääntö- ja voimaseurannat epäonnistuivat täpärästi. Tulokset kuitenkin osoittavat luottamusta siitä että testipenkki saadaan aikanaan halutulle tasolle ohjelmistopuolen kontrollereja säätämällä. Tällä hetkellä systeemin vasteaika on liian pitkä, vaikka muuten dynamiikka on nopeaa. Lisäksi, vakaissa ajopisteissä vääntö- ja nopeushuojunta ovat alhaisia. Ainoastaan valmistelut HIL-simulaatiota varten saatiin toteutettua, sillä testipenkkiä ei saatu reaaliaikasta testausta vaativalle tasolle. Valmistelut sisälsivät hybridijäteauton simulaatiomallin rakentamisen, jota tullaan aikanaan käyttämään testipenkin HIL toimivuuden validointiin. Simulaatiomalli varmistettiin itsenäisenä toimivaksi, ja siten soveltuvaksi tuleviin fyysisiin testiajoihin

Enabling New Functionally Embedded Mechanical Systems Via Cutting, Folding, and 3D Printing

Traditional design tools and fabrication methods implicitly prevent mechanical engineers from encapsulating full functionalities such as mobility, transformation, sensing and actuation in the early design concept prototyping stage. Therefore, designers are forced to design, fabricate and assemble individual parts similar to conventional manufacturing, and iteratively create additional functionalities. This results in relatively high design iteration times and complex assembly strategies

A fast remotely operable digital twin of a generic electric powertrain for geographically distributed hardware-in-the-loop simulation testbed

The automotive industry today is seeing far-reaching and portentous changes that will change the face of it in the foreseeable future. Digitalisation and Electrification are two of the key megatrends that is changing the way vehicles are developed and produced. A recent development in R&D process is the Hardware-in-the-Loop (HIL) method that uses a hybrid approach of testing a physical prototype immersed in a virtual environment, which is nowadays being creatively re-applied towards geographically separated multi-centre testing strategies, that suits the horizontally integrated and supply-chain driven industry very well. Geographical separation entails the deployment of a “Digital Twin” in remote centre(s) participating in multi-centre testing. This PhD aims to produce a highly robust, efficient, and rapidly computable Digital Twin of a generic electric powertrain using the multi-frequency averaging (MFA) technique that has been extended for variable frequency operation. This PhD also aims to commission a local HIL simulation testbed for a generic electric power inverter testing. The greater goal is to co-simulate the local HIL centre testing a prototype inverter, and its Digital Twin in a different location “twinning” the prototype inverter as best as possible. A novel approach for the Digital Twin has been proposed that employs Dynamic Phasors to solve the system in the frequency domain. An original method of multiplication of two signals in the frequency domain has been proposed. The resultant model has been verified against an equivalent time domain switching model and shown to outperform appreciably. A distinctive advantage the MFA Digital Twin offers is the “fidelity customisability”; based on application, the Twin can be set to compute a low (or high)-fi model at different computational cost. Finally, a novel method of communicating high-speed motor shaft position information using a low-speed processing system has been developed and validated. This has been applied to run real-life HIL simulation cycles on a test inverter and effects studied. The two ends of a multi-HIL testbed, i.e., local HIL environment for an inverter, and its Digital Twin, has been developed and validated. The last piece of the puzzle, i.e., employing a State Convergence algorithm to ensure the Digital Twin is accurate duplicating the performance of its “master”, is required to close the loop. Several ideas and process plans have been proposed to do the same

Advanced laboratory testing methods using real-time simulation and hardware-in-the-loop techniques : a survey of smart grid international research facility network activities

The integration of smart grid technologies in interconnected power system networks presents multiple challenges for the power industry and the scientific community. To address these challenges, researchers are creating new methods for the validation of: control, interoperability, reliability of Internet of Things systems, distributed energy resources, modern power equipment for applications covering power system stability, operation, control, and cybersecurity. Novel methods for laboratory testing of electrical power systems incorporate novel simulation techniques spanning real-time simulation, Power Hardware-in-the-Loop, Controller Hardware-in-the-Loop, Power System-in-the-Loop, and co-simulation technologies. These methods directly support the acceleration of electrical systems and power electronics component research by validating technological solutions in high-fidelity environments. In this paper, members of the Survey of Smart Grid International Research Facility Network task on Advanced Laboratory Testing Methods present a review of methods, test procedures, studies, and experiences employing advanced laboratory techniques for validation of range of research and development prototypes and novel power system solutions