Dinamička simulacija mehaničkih opterećenja – pristup zasnovan na svojstvima industrijskih elektromotornih pogona

Dynamic emulation of mechanical loads presents a modern and interesting approach for testing and validating performance of electrical drives without a real mechanical load included in the test rig. The paper presents an approach to dynamic emulation of mechanical loads when the load torque and inertia mass of emulated load can be significantly greater than that of laboratory test rig. Closed-loop control of load torque and feedforward compensation of inertia and friction torques are used in a test rig. The approach is focused on the use with standard industrial converters. The described method can be used for design and validation of speed control algorithms in mechatronic applications. Experimental results with the emulation of linear loads are presented in end of the paper.Dinamička simulacija mehaničkih opterećenja predstavlja moderan i zanimljiv pristup testiranju i validaciji ponašanja elektromotornih pogona bez uključenog stvarnog mehaničkog opterećenja u eksperimentalni postav. U radu je predstavljen pristup s dinamičkom simulacijom mehaničkih opterećenja za slučaj kada moment tereta ili moment tromosti simuliranog tereta mogu biti daleko veći od onih dostupnih u eksperimentalnom postavu. U postavu se koristi upravljanje momentom tereta u zatvorenoj petlji uz unaprijednu petlju kompenzacije momenta tromosti i momenata trenja. Pristup je usmjeren na upotrebu standardnih industrijskih pretvarača. Opisana metoda može se koristiti za sintezu i validaciju algoritama za upravljanje po brzini u mehatroničkim primjenama. U radu su predstavljeni eksperimentalni rezultati za slučaj simulacije linearnih tereta

Mechanical Decoupling Algorithm Applied to Electric Drive Test Bed

New approach and analysis are proposed in this paper to enhance the steady and rapidity of the electric drive test bed. Based on a basic drive motor dynamometer system (DMDS) test bed, detailed mathematical model and process control are established and analyzed. Relative gain array (RGA) method and diagonal matrix method are used to analyze the mechanical coupling caused by mechanical connection on the DMDS test bed, and the structure and algorithm of dynamic decoupling are proposed. Simulation and experiment all indicate that the designed decoupling method can efficiently improve the control accuracy and response speed

Automated robust control system design for variable speed drives

Traditional PI controllers have been largely employed for the control of industrial variable speed drives due to the design ease and performance satisfaction they provide but, the problem is that these controllers do not always provide robust performance under variable loads. Existing solutions present themselves as complex control strategies that demand specialist expertise for their implementation. As a direct consequence, these factors have limited their adoption for the industrial control of drives. To counter this trend, the thesis proposes two techniques for robust control system design. The developed strategies employ particular Evolutionary Algorithms EA), which enable their simple and automated implementation. More specifically, the EA employed and tested are the Genetic Algorithms (GA), Bacterial Foraging (BF) and the novel Hybrid Bacterial Foraging, which combines specific desirable features of the GA and BF. The first technique, aptly termed Robust Experimental Control Design, employs the above mentioned EA in an automated trial-and-error approach that involves directly testing control parameters on the experimental drive system, while it operates under variable mechanical loads, evolving towards the best possible solutions to the control problem. The second strategy, Robust Identification-based Control Design, involves a GA system identification procedure employed in automatically defining an uncertainty model for the variable mechanical loads and, through the adoption of the Frequency Domain H-infinity Method in combination with the developed EA, robust controllers for drive systems are designed. The results that highlight the effectiveness of the robust control system design techniques are presented. Performance comparisons between the design techniques and amongst the employed EA are also shown. The developed techniques possess commercially viable qualities because they elude the need for skilled expertise in their implementation and are deployed in a simple and automated fashion

Automated robust control system design for variable speed drives

Traditional PI controllers have been largely employed for the control of industrial variable speed drives due to the design ease and performance satisfaction they provide but, the problem is that these controllers do not always provide robust performance under variable loads. Existing solutions present themselves as complex control strategies that demand specialist expertise for their implementation. As a direct consequence, these factors have limited their adoption for the industrial control of drives. To counter this trend, the thesis proposes two techniques for robust control system design. The developed strategies employ particular Evolutionary Algorithms EA), which enable their simple and automated implementation. More specifically, the EA employed and tested are the Genetic Algorithms (GA), Bacterial Foraging (BF) and the novel Hybrid Bacterial Foraging, which combines specific desirable features of the GA and BF. The first technique, aptly termed Robust Experimental Control Design, employs the above mentioned EA in an automated trial-and-error approach that involves directly testing control parameters on the experimental drive system, while it operates under variable mechanical loads, evolving towards the best possible solutions to the control problem. The second strategy, Robust Identification-based Control Design, involves a GA system identification procedure employed in automatically defining an uncertainty model for the variable mechanical loads and, through the adoption of the Frequency Domain H-infinity Method in combination with the developed EA, robust controllers for drive systems are designed. The results that highlight the effectiveness of the robust control system design techniques are presented. Performance comparisons between the design techniques and amongst the employed EA are also shown. The developed techniques possess commercially viable qualities because they elude the need for skilled expertise in their implementation and are deployed in a simple and automated fashion

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

Test stand design and automated sequences implementation

Chemnitz University of Technology has been involved since 2018 in an academic automotive championship gathering 1:10 fuel cell/battery-powered vehicles. The goal of the race being to travel the longest distance with a limited amount of hydrogen and electricity, it would be meaningful to predict the vehicle fuel consumption prior to the race for a given driving style. For this purpose, the present work proposes a new approach which consisted in designing a chassis dynamometer allowing to implement race driving cycles and to emulate the related road load thanks to a real time industrial automation PLC software. In particular, the chassis dynamometer was designed with PTC CREO and is composed of four trunnionmounted hub dynamometers whose power absorption is performed by hysteresis brakes. The four modules can be controlled independently to adapt the type of 1:10 vehicle powertrain and are controlled from sequences that are implemented by using TwinCAT 3. The data acquisition system from Beckho Automation based on the real time eld bus EtherCAT has enabled the system to be tested under high transient driving cycles. The work has resulted of a chassis dynamometer capable of assessing the vehicle speed from 0 to 30 km=h with an accuracy lower than 3%. The vehicle battery voltage can be measuredin the range 0 to 10 V with an uncertainty lower than 0.1 %. Moreover, the test bench allow to compute the wheel's torque with a proper stability but considering a long delay between the reference torque value and dynamometer response. Finally, a driving cycle has been implemented and the vehicle associated to the PID controller has showed a response time lower than 80 ms.Chemnitz University of Technology has been involved since 2018 in an academic automotive championship gathering 1:10 fuel cell/battery-powered vehicles. The goal of the race being to travel the longest distance with a limited amount of hydrogen and electricity, it would be meaningful to predict the vehicle fuel consumption prior to the race for a given driving style. For this purpose, the present work proposes a new approach which consisted in designing a chassis dynamometer allowing to implement race driving cycles and to emulate the related road load thanks to a real time industrial automation PLC software. In particular, the chassis dynamometer was designed with PTC CREO and is composed of four trunnionmounted hub dynamometers whose power absorption is performed by hysteresis brakes. The four modules can be controlled independently to adapt the type of 1:10 vehicle powertrain and are controlled from sequences that are implemented by using TwinCAT 3. The data acquisition system from Beckho Automation based on the real time eld bus EtherCAT has enabled the system to be tested under high transient driving cycles. The work has resulted of a chassis dynamometer capable of assessing the vehicle speed from 0 to 30 km=h with an accuracy lower than 3%. The vehicle battery voltage can be measuredin the range 0 to 10 V with an uncertainty lower than 0.1 %. Moreover, the test bench allow to compute the wheel's torque with a proper stability but considering a long delay between the reference torque value and dynamometer response. Finally, a driving cycle has been implemented and the vehicle associated to the PID controller has showed a response time lower than 80 ms

Design and implementation of a pem fuel cell emulator for static and dynamic behavior

This paper presents the design, implementation, and experimental validation of a digitally-controlled emulator of proton exchange membrane (PEM) fuel cells for static and dynamic behavior. The emulator is a low cost, easy to use, and portable device designed to evaluate power systems and control strategies for fuel cell-based generation systems. For the implementation of this emulator, an appropriate mathematical model is chosen, parameterized, and experimentally validated. The resulting model is processed digitally by the emulator, which generates the appropriate electrical behavior to a load. The emulator power stage is implemented by using a two-inductor step-down DC/DC switching converter, which is controlled directly by the digital processing system. Later, the electrical scheme of the power stage and the block diagram of the system are presented, and the behavior of the emulator is illustrated with a simulation. Finally, the emulator is validated using experimental data