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Apresenta-se a especificação, projeto e implementação de um controlador de célula flexível aplicado na manufatura, visando ser elemento de um sistema aberto de automação. Este trabalho apresenta uma metodologia de desenvolvimento, cujas fases possuem ferramentas de projeto como a especificação padrão, a análise estruturada e a simulação, que serviram para definir a arquitetura do controlador e a validação do mesmo. A implementação do controlador de célula foi baseada numa arquitetura aberta, e foram utilizados recursos computacionais cujas especificações e interfaces são definidas por padrões reconhecidos internacionalmente. Finalmente, o controlador de célula atingirá um alto grau de flexibilidade permitindo a adaptação do controlador a qualquer processo de manufatura de forma simples, e também poderá ser utilizado como equipamento para o ensino e pesquisa das técnicas modernas aplicadas a automação. / It presents the specification, design, and implementation of the flexible cell controller applied to manufacture, which will be element of the automation open systems. This work presents a suitable development a suitable development methodology, whose steps has design tools as standard specification, structure analysis, and the simulation, which was utilized to the architecture definition and validation of the cell controller. The implementation was based on the open architecture and were used computer resources whose specifications and interfaces are defined by international standards. Finally, the cell controller will achieve a great flexibility which permits the simple adaptation to every manufacture process, and will be an equipment for the education and research of the modern techniques applied to the automation.

Apresenta-se a especificação, projeto e implementação de um controlador de célula flexível aplicado na manufatura, visando ser elemento de um sistema aberto de automação. Este trabalho apresenta uma metodologia de desenvolvimento, cujas fases possuem ferramentas de projeto como a especificação padrão, a análise estruturada e a simulação, que serviram para definir a arquitetura do controlador e a validação do mesmo. A implementação do controlador de célula foi baseada numa arquitetura aberta, e foram utilizados recursos computacionais cujas especificações e interfaces são definidas por padrões reconhecidos internacionalmente. Finalmente, o controlador de célula atingirá um alto grau de flexibilidade permitindo a adaptação do controlador a qualquer processo de manufatura de forma simples, e também poderá ser utilizado como equipamento para o ensino e pesquisa das técnicas modernas aplicadas a automação. / It presents the specification, design, and implementation of the flexible cell controller applied to manufacture, which will be element of the automation open systems. This work presents a suitable development a suitable development methodology, whose steps has design tools as standard specification, structure analysis, and the simulation, which was utilized to the architecture definition and validation of the cell controller. The implementation was based on the open architecture and were used computer resources whose specifications and interfaces are defined by international standards. Finally, the cell controller will achieve a great flexibility which permits the simple adaptation to every manufacture process, and will be an equipment for the education and research of the modern techniques applied to the automation.

Fuel cells are electricity generators which convert chemical energy of hydrogen directly to electricity by means of electrochemical oxidation and reduction reactions. A single proton exchange membrane (PEM) fuel cell can only generate electricity with a potential between 0.5V and 1V. The useful potential can be achieved by stacking cells in series to form a PEM fuel cell stack. There is a potential to utilize 100W class fuel cells. Fuelling is the major problem of the portable fuel cells. The aim of this thesis is to design and manufacture a PEM fuel cell stack which can be used for portable applications. The PEM fuel cell stack is planned to be incorporated to a NaBH4 hydrolysis reactor for H2 supply. Within the scope of this thesis a new coating technique called &ldquo / ultrasonic spray coating technique&rdquo / is developed for membrane electrode assembly (MEA) manufacturing. New metal and graphite bipolar plates are designed and manufactured by CNC technique. A fuel cell controller hardware is developed for fuel supply and system control. The power densities reached with the new method are 0.53, 0.74, 0.77, and 0.88 W/cm2 for 20%, 40%, 50%, 70% Pt/C catalyst by keeping 0.4mg Pt/cm2 platinum loading constant, respectively. The power density increase is 267% compared to &ldquo / spraying of catalyst ink with air pressure atomizing spray gun&rdquo / . All parts of the PEM fuel cell stack designed were produced, assembled, and tested. The current density reached is 12.9A at 12 V stack potential and the corresponding electrical power of the stack is 155W.

Recent innovations in technology and demands for more functionality increased software size in cars up to 100 million lines of code. Explosion in software size is accompanied by an increased number of ECUs. Testing of software became more complex than ever. To be able to test the exact timing behavior of a software, it needs to be put on actual hardware. HIL test benches have become an indispensable part of ECU testing. The hard part of ECU testing is their dependency on each other. ECUs communicate to each other by passing information in the form of CAN messages. This makes testing a single ECU alone without its environment impossible. Because of their dependencies on each other they need to be integrated first to be tested. Before HIL benches those tests were done either on vehicles or in integration labs where ECUs are connected to each other in a lab environment. Advances in software science brought up an invention known as rest-bus simulation. In some sources it is also known as residual bus or rest of the bus simulation. HIL platforms simulate missing nodes and messages as if the actual hardware is there. HIL platforms blend the real world and simulated ones in real time. Device under test thinks it is present in a vehicle. Established HIL platforms solved many problems that existed in software projects. However, because of their cost, only a small number of such platforms are affordable within a company. Developers need to wait in long queues to test their ECUs. These waiting times can be even longer in agile software development methodologies due to their frequent testing needs. It is believed that front-loading tests before the HIL is the solution to this problem. The aim of this thesis is to investigate alternative small form factor HIL platforms which could be placed on every developer’s desk. To place the proposed solution at every desk, the solution must be affordable and portable. The solution will hopefully reduce queues accumulating behind established HIL platforms and shorten testing times. For this end, state-of-the-art HIL solutions will be investigated. Afterwards, a working proof-of-concept will be demonstrated in the form of residual bus simulation and gateway application. Portability of the solution is a must for the gateway application. Test engineers use gateway applications to alter some signal values either on HIL or on-vehicle. Only small and easy to carry solutions are feasible for on-vehicle testing. It will be shown that the proposed solution will reduce the testing time and testing cost. In addition to them, an increase in parallelism, testing frequency, and software quality will be observed by bringing testing equipment to every developer’s desk.