Engineering design may be viewed as a decision making process that supports design tradeoffs. The designer makes decisions based on information available and engineering judgment. The designer determines the direction in which the design must proceed, the procedures that need to be adopted, and develops a strategy to perform successive decisions. The design is only as good as the decisions made, which is in turn dependent on the information available. Information is time and process dependent. This thesis work focuses on developing a coherent bottom-up framework and methodology to improve information transfer and decision making while designing complex systems. The rotorcraft drive system is used as a test system for this methodology. The traditional serial design approach required the information from one discipline and/or process in order to proceed with the subsequent design phase. The Systems Engineering (SE) implementation of Concurrent Engineering (CE) and Integrated Product and Process Development (IPPD) processes tries to alleviate this problem by allowing design processes to be performed in parallel and collaboratively. The biggest challenge in implementing Concurrent Engineering is the availability of information when dealing with complex systems such as aerospace systems. The information is often incomplete, with large amounts of uncertainties around the requirements, constraints and system objectives. As complexity increases, the design process starts trending back towards a serial design approach. The gap in information can be overcome by either “softening” the requirements to be adaptable to variation in information or to delay the decision. Delayed decisions lead to expensive modifications and longer product design lifecycle. Digitization of IPPD tools for complex system enables the system to be more adaptable to changing requirements. Design can proceed with “soft” information and decisions adapted as information becomes available even at early stages. The advent of modern day computing has made digitization and automation possible and feasible in engineering. Automation has demonstrated superior capability in design cycle efficiency [1]. When a digitized framework is enhanced through automation, design can be made adaptable without the requirement for human interaction. This can increase productivity, and reduce design time and associated cost. An important aspect in making digitization feasible is having the availability of parameterized Computer Aided Design (CAD) geometry [2]. The CAD geometry gives the design a physical form that can interact with other disciplines and geometries. Central common CAD database allows other disciplines to access information and extract requirements; this feature is of immense importance while performing systems syntheses. Through database management using a Product Lifecycle Management (PLM) system, Integrated Product Teams (IPTs) can exchange information between disciplines and develop new designs more efficiently by collaborating more and from far [3]. This thesis focuses on the challenges associated with automation and digitization of design. Making more information available earlier goes jointly with making the design adaptable to new information. Using digitized sizing, synthesis, cost analysis and integration, the drive system design is brought in to early design. With modularity as the objective, information transfer is made streamlined through the use of a software integration suite. Using parametric CAD tools, a novel ‘Fully-Relational Design’ framework is developed where geometry and design are adaptable to related geometry and requirement changes. During conceptual and preliminary design stages, the airframe goes through many stages of modifications and refinement; these changes affect the sub-system requirements and its design optimum. A fully-relational design framework takes this into account to create interfaces between disciplines. A novel aspect of the fully-relational design methodology is to include geometry, spacing and volume requirements in the system design process. Enabling fully-relational design has certain challenges, requiring suitable optimization and analysis automation. Also it is important to ensure that the process does not get overly complicated. So the method is required to possess the capability to intelligently propagate change. There is a need for suitable optimization techniques to approach gear train type design problems, where the design variables are discrete in nature and the values a variables can assume is a result of cascading effects of other variables. A heuristic optimization method is developed to analyze this multimodal problem. Experiments are setup to study constraint dependencies, constraint-handling penalty methods, algorithm tuning factors and innovative techniques to improve the performance of the algorithm. Inclusion of higher fidelity analysis in early design is an important element of this research. Higher fidelity analyses such as nonlinear contact Finite Element Analysis (FEA) are useful in defining true implied stresses and developing rating modification factors. The use of Topology Optimization (TO) using Finite Element Methods (FEM) is proposed here to study excess material removal in the gear web region.

Over the last years, electrical roads have emerged as a cost effective and environmentally friendly solution towards a transportation system with less dependency on fossil fuels. This thesis presents the design of a search and locate system for road-bound conductive electrical roads with position control in two axes. The system is intended to find and follow the position of an electrified rail. The actuator system constitutes a firm groundwork for further research and development in this field. A laboratory test set up has been designed and both hardware and software parts have been constructed. The control of the system uses the CompactRIOTM technology from National Instruments. Results from the practical evaluation suggest that the non-linear characteristic of the system and the lack of direct position feedback from the motor rotation are the main causes of a non-accurate position control. Future development steps should focus on improving the mechanical design and include encoder feedback for the control loop as well as absolute automatic control with the incorporation of rail sensors.

Economical and environmental factors together with energy policies towards more efficient systemsare the driving force for the development of the vehicle industry. Significant changes have beenmade to fulfill new emissions legislation but the basic internal combustion vehicle architecture hasbeen kept. New emission treatment systems that increase the thermal loading of the cooling systemhad been added within the same package envelope as before, which means less space to place coolingfans and a greater need for airflow. Changes in the cooling system, namely the replacement of thehydraulic fan drive system by electrical fans is one of the energy efficient alternatives for severalcity buses under certain environments, like the ”typical red city buses”, well-known in the UnitedKingdom. In this thesis study, hydraulic fans are compared with electrical fans and a road-mapof the benefits and drawbacks of the two systems is developed, based on real traffic performanceperformance data and the results of existing simulations and tests. In addition, new simulations arepresented in order to find the most efficient design for the cooling system as well as a comparisonof these results with previous ones. This road map will be used later by Volvo-Buses Group as atool to better understand in which circumstances electrical fans can be beneficial, in terms of fuelconsumption, noise production, cooling performance, control of the fans and associated costs.

Although the design principles of the Switched Reluctance Machines (SRMs) are available in different fragments in numerous bibliography positions, there no exists the complex design procedure of whole drive system taking into account the SR Machine, control system and supply device as well. The hybrid design method for SRM drives with application of new analytical calculation methods, finite element method and simulation models is proposed in this thesis. The calculation/design system is characterised by important effectivity and reliability. The new possibilities in analytical determination of saturation effects and core losses under various modes of control, including sensorless method, are also taken into account. The correctness of the proposed design algorithms are verified by laboratory tests made on three motor prototypes manufactured in industry for concrete application. This dissertation provides the elements indispensable for more accurate and complex analysis and design of drives with switch reluctance motors. The elements of electrical motor and control system design as well as the considerations on the choice of supply device and controller subsystems are jointed in the thesis for final receiving of the design tool for considered industrial drive system.

Over eight decades of research into total artificial hearts (TAHs) has significantly contributed  to saving end-stage heart failure patients. However, at the current stage of development TAHs have several limitations, one of them being their bulkiness. Hence this thesis, with the goal to evaluate the right pump of the TAH developed by Scandinavian Real Heart and propose a compact right drive system without consuming significantly more power than the initial system. In order to do this, the requirements for the right drive systems are evaluated and defined. These requirements are then used to develop a methodology, including a MatLab simulation, for examining and selecting motors for the drive unit of the TAH. Subsequently, the methodology and the simulation are used to identify and assess over 200 motors, as well as select 3 motors for real-world experimental analysis. The suggested motors and the initial motor are then tested in a mock circulatory loop to investigate the performance characteristics and power consumption of the motors. This is done to select the final motor for the right drive unit, as well as verify and validate the created simulation. Based on careful analysis of the mathematical models used in the simulation and presented experimental data, the simulation was accepted to be verified. However, the support for validation of the simulation was lacking, as conflicting outcome for some cases were observed between the simulation and experimental data. Furthermore, given the empirical evidence, a brushless dc motor for the right drive unit and its implementation was proposed. The proposed motor has 11% reduction in size, 20% reduction in power consumption and 34% reduction in weight compared to the initial motor. Therefore, a drive unit with the suggested motor can have a significant impact on the right pump, and potentially even the left pump. Furthermore, the utilisation of the developed simulation can ultimately result in efficient and cost-effective motor selection and provide valuable contribution to the field of drive system development for TAHs. / Över åtta decennier av forskning om totala artificiella hjärtan (TAH) har omfattande bidragit till att rädda patienters liv med kronisk hjärtsvikt. Dessvärre har TAH flera begränsningar i det nuvarande stadiet i utveckling där storleken är ett problem. Därav denna avhandling, med målet att utvärdera den högra pumpen av en TAH utvecklad av Scandinavian Real Heart, för att föreslå ett mer kompakt höger drivsystem utan att det ska förbruka väsentlig mängd mer energi än det ursprungliga systemet. För att åstadkomma detta, har de fysiologiska krav för den högra pumpen analyserats och utifrån den utförda analysen nya krav för drivsystemet har formulerats. Dessa krav har sedan lagt grunden till utveckling av en metodik, inklusive en MatLab-simulering, för att undersöka och välja motorer för drivsystemet av en TAH. Metodiken i samband med simuleringen har använts för att identifiera och bedöma över 200 motorer. Av dessa motorer har tre motorer valts för experimentell utvärdering. I den experimentella utvärderingen, prestandaegenskaper och effektförbrukning av samtliga valda motorer och den ursprungliga motorn har utvärderats i ett konstgjort cirkulationssystem. Syftet med den experimentella utvärderingen är att komma fram till en slutmotor, samt verifiera och validera den utvecklade simuleringen. Baserad på noggrann analys av de använda matematiska modeller i simuleringen och det presenterade experimentella data, ansågs simuleringen vara verifierad. Däremot saknades stöd för validering av simuleringen, på grund av en del motsägande utfall mellan simulering och experimentell data. Därutöver, utifrån den empiriska evidensen föreslogs en borstlös likströmsmotor och dess implementering för det högra drivsystemet. Den föreslagna motorn är 11% mindre i storlek, har 20% lägre effektförbrukning och väger 34% mindre än den ursprungliga motorn. Därför kan en drivenhet med den föreslagna motorn ha en betydande inverkan på den högra pumpen, och potentiellt även den vänstra. Dessutom kan den utvecklade simuleringen användas för att göra urval av motorer för TAH på ett produktivt samt kostnadseffektivt sätt och därmed bidra till framtida utvecklingar av drivenheter för TAH.

Rund 70 % der Energieaufnahme von elektrischen Antriebssystemen wird von quasistationären Antrieben in Transportanlagen hervorgerufen. Eine gesteigerte Energieeffizienz führt neben reduzierten Energiekosten zu weiteren Nutzeffekten, wie z.B. einem verringerten Kühlaufwand, einem kleinerem Bauraum und einer höheren Lebensdauer der Komponenten. Zur Steigerung der Energieeffizienz dieser Transportanlagen werden in dieser Arbeit Methoden zur Auslegung der zugehörigen Antriebssysteme unter besonderer Berücksichtigung des Förderprozesses erarbeitet. Als repräsentative Transportanwendungen werden Pumpen- und Förderbandanlagen untersucht. Dabei wird das gesamte elektromechanische System analysiert, um das volle Energiesparpotenzial zu erfassen – beginnend mit dem Lastprofil des transportierten Förderguts bis hin zur elektrischen Energieversorgung. Hierzu werden alle Systemkomponenten modelliert, um die Verluste in verschiedenen Betriebspunkten im Volllast- und Teillastbereich abzuschätzen. Darauf aufbauend erfolgt die Erarbeitung praktikabler Projektierungshinweise und prozessspezifischer Auswahldiagramme, welche eine schnelle Vorauswahl der energieeffizientesten Antriebstopologie ermöglichen. Da die Verlustmodelle auf frei zugänglichen Datenblattangaben basieren, können die vorgestellten Methoden und Auswahlkriterien bereits in einem frühen Projektierungsstadium zur Auslegung einer energieeffizienten Transportanlage angewandt werden.

Les applications entrainées par des moteurs asynchrones consomment à elles seules la majorité de l’énergie électrique utilisée dans le secteur industriel. Des défauts, majoritairement d’origine mécanique, sont susceptibles de se développer au cours du fonctionnement de ces systèmes et rendent nécessaires la mise en place d’une maintenance souvent onéreuse. Afin de réduire ces coûts et d’optimiser la disponibilité des matériels, des méthodes de diagnostic peuvent être développées afin de détecter au plus tôt l’apparition d’un défaut. Cependant, la fiabilité de ces algorithmes et l’automatisation du diagnostic sont complexifiées par la diversité des systèmes alimentés par les variateurs de vitesse industriels ainsi que par le changement de leur point de fonctionnement. Afin de répondre à ces problématiques, un protocole de diagnostic permettant de réaliser une détection sensible et robuste des défaillances mécaniques est développé dans ce travail. Cette méthode consiste à segmenter le plan couple-vitesse du moteur surveillé et à réaliser des références statistiques caractérisant son fonctionnement sain sur chacune des zones de fonctionnement. Des indicateurs de défaut peuvent ensuite être définis statistiquement afin de quantifier l’écart du système vis-à-vis de son comportement sain. Ces indicateurs sont ainsi indépendants du système surveillé et de son point de fonctionnement. Les principales applications ciblées par ce protocole sont les systèmes de compression, de pompage et de ventilation qui représentent une part importante de l’énergie électrique consommée dans le secteur industriel. Le protocole de diagnostic développé dans cette étude est validé expérimentalement dans le cadre de la détection de différentes niveaux de déséquilibre mécanique mais également pour la surveillance d’un système de transmission de type poulies-courroies. De plus, les campagnes expérimentales sont effectuées sur plusieurs systèmes électromécaniques dont les propriétés sont foncièrement différentes afin de valider les performances de normalisation de ce protocole. / Systems driven by induction motors consume most of the industrial electric supply. Mechanical faults may develop over time and disrupt their proper functioning, resulting in high maintenance expenditure. In order to reduce these costs and to improve machines availability, diagnosis methods can be developped to perform the early detection of incipient faults. However, the variety of industrial applications driven by induction motors complicates the automation of fault detection. To resolve these issues, a sensitive and robust diagnosis protocol has been developed in two stages. First, the torque-speed plane of the monitored motor is segmented in different functioning areas. Then, a statistical reference is achieved on each operating zone in order to characterize the healthy working of the system. Statistic-based indicators may then quantify the system deviation from its healthy behaviour. These indicators are therefore independent of the monitored system and of its functioning point. The applications targeted by this study are fans, pumps and compressors which are widely used in industrial processes. This diagnosis protocol is experimentally validated on the detection of several levels of mechanical unbalance and for the monitoring of V-belts drive health state. Moreover, test campaigns are achieved on varied electromechanical systems in order to validate the normalization performances of the developed protocol.

This diploma thesis deals with FEM analysis and optimization of carriage for top drive system of drilling rig Bentec 350 AC and it is defined as a development contract for company MND Drilling & Services a.s. Intensive drilling leads to damages and repeated occurrence of fatigue cracks on carriage especially along edges of welded ribs in their heat-affected zone. The aim of this thesis is to draft construction improvements of carriage which leads to elimination of damages. Realization of this modifications depends on correct definition of boundary conditions, analysis of damage occurrence as well as verification of carriage drafts with finite element method.

This master´s thesis is focused on now being developed electric taxi system, which is going to be used for aircraft´s ground movement. The content of this work includes description of this system, requirements and developed solutions, next part describes and evaluate the consequences of deployment such system in real traffic.

Rund 70 % der Energieaufnahme von elektrischen Antriebssystemen wird von quasistationären Antrieben in Transportanlagen hervorgerufen. Eine gesteigerte Energieeffizienz führt neben reduzierten Energiekosten zu weiteren Nutzeffekten, wie z.B. einem verringerten Kühlaufwand, einem kleinerem Bauraum und einer höheren Lebensdauer der Komponenten. Zur Steigerung der Energieeffizienz dieser Transportanlagen werden in dieser Arbeit Methoden zur Auslegung der zugehörigen Antriebssysteme unter besonderer Berücksichtigung des Förderprozesses erarbeitet. Als repräsentative Transportanwendungen werden Pumpen- und Förderbandanlagen untersucht. Dabei wird das gesamte elektromechanische System analysiert, um das volle Energiesparpotenzial zu erfassen – beginnend mit dem Lastprofil des transportierten Förderguts bis hin zur elektrischen Energieversorgung. Hierzu werden alle Systemkomponenten modelliert, um die Verluste in verschiedenen Betriebspunkten im Volllast- und Teillastbereich abzuschätzen. Darauf aufbauend erfolgt die Erarbeitung praktikabler Projektierungshinweise und prozessspezifischer Auswahldiagramme, welche eine schnelle Vorauswahl der energieeffizientesten Antriebstopologie ermöglichen. Da die Verlustmodelle auf frei zugänglichen Datenblattangaben basieren, können die vorgestellten Methoden und Auswahlkriterien bereits in einem frühen Projektierungsstadium zur Auslegung einer energieeffizienten Transportanlage angewandt werden.