Photonic low-cost sensors for in-line fluid monitoring. Design methodology

779 p.The paradigm of process monitoring has evolved in the last years, driven by a clear need for improving efficiency, quality and safety of processes and products. Sectors as manufacturing, energy, food and beverages, etc. are fostering the adoption of innovative methods for controlling their processes and products, in a non-destructive, in-place, reliable, fast, accurate and cost-efficient manner. Furthermore, the parameters requested by the industry for the quality assessment are evolving from basic magnitudes as pressures, temperatures, humidity, etc. to complete chemical and physical fingerprints of these products and processes. In this situation, techniques based on the UV/VIS/NIR light-matter interaction appear to be optimum candidates to face the request of the industry. Moreover, at this moment, when we are witnessing a technological revolution in the field of optoelectronic components, which are required for setting up these light-based analyzers.However, being able to integrate these optoelectronic components with the rest of subsystems (electronics, optics, mechanics, hydraulics, data processing, etc.) is not straightforward. The development of these multi-domain and heterogeneous sensor products meeting not just technological but also market objectives poses a considerable technical and organizational challenge for any company.In this context, a methodological hybrid and agile integration of photonic components within the rest of subsystems towards a sensor product development is presented as the main outcome of the thesis. The methodology has been validated in several industrial scenarios, being three of them included in this thesis, which covers from hydraulic fluid quality control to real-time monitoring of alcoholic beverage fermentation process

Photonic Low Cost Micro-Sensor for in-Line Wear Particle Detection in Flowing Lube Oils

The presence of microscopic particles in suspension in industrial fluids is often an early warning of latent or imminent failures in the equipment or processes where they are being used. This manuscript describes work undertaken to integrate different photonic principles with a micro- mechanical fluidic structure and an embedded processor to develop a fully autonomous wear debris sensor for in-line monitoring of industrial fluids. Lens-less microscopy, stroboscopic illumination, a CMOS imager and embedded machine vision technologies have been merged to develop a sensor solution that is able to detect and quantify the number and size of micrometric particles suspended in a continuous flow of a fluid. A laboratory test-bench has been arranged for setting up the configuration of the optical components targeting a static oil sample and then a sensor prototype has been developed for migrating the measurement principles to real conditions in terms of operating pressure and flow rate of the oil. Imaging performance is quantified using micro calibrated samples, as well as by measuring real used lubricated oils. Sampling a large fluid volume with a decent 2D spatial resolution, this photonic micro sensor offers a powerful tool at very low cost and compacted size for in-line wear debris monitoring.This work has been funded in part by the Fondo Europeo de Desarrollo Regional (FEDER); by the Ministerio de Economia y Competitividad under project TEC2015-638263-C03-1-R; by the Gobierno Vasco/Eusko Jaurlaritza under projects IT933-16 and ELKARTEK (KK-2016/0030 and KK-2016/0059

Next-Generation Pedal: Integration of Sensors in a Braking Pedal for a Full Brake-by-Wire System

This article presents a novel approach to designing and validating a fully electronic braking pedal, addressing the growing integration of electronics in vehicles. With the imminent rise of brake-by-wire (BBW) technology, the brake pedal requires electronification to keep pace with industry advancements. This research explores technologies and features for the next-generation pedal, including low-power consumption electronics, cost-effective sensors, active adjustable pedals, and a retractable pedal for autonomous vehicles. Furthermore, this research brings the benefits of the water injection technique (WIT) as the base for manufacturing plastic pedal brakes towards reducing cost and weight while enhancing torsional stiffness. Communication with original equipment manufacturers (OEMs) has provided valuable insights and feedback, facilitating a productive exchange of ideas. The findings include two sensor prototypes utilizing inductive technology and printed-ink gauges. Significantly, reduced power consumption was achieved in a Hall-effect sensor already in production. Additionally, a functional BBW prototype was developed and validated. This research presents an innovative approach to pedal design that aligns with current electrification trends and autonomous vehicles. It positions the braking pedal as an advanced component that has the potential to redefine industry standards. In summary, this research significantly contributes to the electronic braking pedal technology presenting the critical industry needs that have driven technical studies and progress in the field of sensors, electronics, and materials, highlighting the challenges that component manufacturers will inevitably face in the forthcoming years.This work has been partially supported by the grant “Ayudas para el desarrollo de proyectos de I+D mediante la contratación de personas doctoradas y la realización de doctorados industriales, programa BIKAINTEK 2019” by the Department of Economic Development, Sustainability, and Environment of the Basque Government. Additionally, this work has been partially supported by the Government of Spain, through the Center for the Development of Industrial Technology (CDTI) under grant agreement IDI-20200198 and by Eusko Jaularitza-Gobierno Vasco (SOC4CRIS KK-2023/00015)

A Method for Dynamically Selecting the Best Frequency Hopping Technique in Industrial Wireless Sensor Network Applications

Industrial wireless applications often share the communication channel with other wireless technologies and communication protocols. This coexistence produces interferences and transmission errors which require appropriate mechanisms to manage retransmissions. Nevertheless, these mechanisms increase the network latency and overhead due to the retransmissions. Thus, the loss of data packets and the measures to handle them produce an undesirable drop in the QoS and hinder the overall robustness and energy efficiency of the network. Interference avoidance mechanisms, such as frequency hopping techniques, reduce the need for retransmissions due to interferences but they are often tailored to specific scenarios and are not easily adapted to other use cases. On the other hand, the total absence of interference avoidance mechanisms introduces a security risk because the communication channel may be intentionally attacked and interfered with to hinder or totally block it. In this paper we propose a method for supporting the design of communication solutions under dynamic channel interference conditions and we implement dynamic management policies for frequency hopping technique and channel selection at runtime. The method considers several standard frequency hopping techniques and quality metrics, and the quality and status of the available frequency channels to propose the best combined solution to minimize the side effects of interferences. A simulation tool has been developed and used in this work to validate the method.Research partially supported by the European Union's Seventh Framework Programme for research, technological development and demonstration under Grant Agreement Number FP7-SEC-2013-1/607292 ZONeSEC-Towards a EU framework for the security of Widezones, in the scope of the activities related to develop technologies that foster the Plug, Play&Forget paradigm. Also partially supported by the Department of Education, Universities and Research of the Basque Government under Grant IT980-16 and the Spanish Research Council, under grant TIN2016-79897-P

Medical Devices with Embedded Sensor Systems: Design and Development Methodology for Start-Ups

Embedded systems have become a key technology for the evolution of medical devices. However, the regulatory requirements that must be met make designing and developing these devices challenging. As a result, many start-ups attempting to develop medical devices fail. Therefore, this article presents a methodology to design and develop embedded medical devices while minimising the economic investment during the technical risk stages and encouraging customer feedback. The proposed methodology is based on the execution of three stages: Development Feasibility, Incremental and Iterative Prototyping, and Medical Product Consolidation. All this is completed in compliance with the applicable regulations. The methodology mentioned above is validated through practical use cases in which the development of a wearable device for monitoring vital signs is the most relevant. The presented use cases sustain the proposed methodology, for the devices were successfully CE marked. Moreover, ISO 13485 certification is obtained by following the proposed procedures.This research was funded by IBERUS grant number CER-20211003 (Spanish Ministry of Science and Innovation)