<p>This thesis addresses assembly issues encountered in optical and fluidic microsystem applications.</p><p>In optics, the first subject concerns the active alignment of components in optical fibersystems. A solution for reducing the cost of optical component assembly while retaining submicron accuracy is to integrate the alignment mechanism onto the optical substrate. A polymer V-shaped actuator is presented that can carry the weight of the large components - on a micromechanical scale - and that can generate movement with six degrees of freedom.</p><p>The second subject in optics is the CMOS-compatible fabrication of monocrystalline silicon micromirror arrays that are intended to serve as CMOS-controlled high-quality spatial light modulators in maskless microlithography systems. A wafer-level assembly method is presented that is based on adhesive wafer bonding whereby a monocrystalline layer is transferred onto a substrate wafer in a CMOS-compatible process without needing bond alignment.</p><p>In fluidics, a hybrid assembly method is introduced that combines two separately micromachined structures to create hotwire anemometers that protrude from a surface with minimum interference with the air flow. The assembled sensor enables one to make accurate time-resolved measurements of the wall shear stress, a quantity that has previously been hard to measure with high time resolution. Also in the field of hotwire anemometers, a method using a hotwire anemometer array is presented for measuring the mass flow, temperature and composition of a gas in a duct.</p><p>In biochemistry, a bio-analysis chip is presented. Single nucleotide polymorphism scoring is performed using dynamic allele-specific hybridization (DASH). Using monolayers of beads, multiplexing based on single-bead analysis is achieved at heating rates more than 20 times faster than conventional DASH provides.</p><p>Space and material e±ciency in packaging are the focus of the other two projects in fluidics. The first introduces an assembly based on layering conductive adhesives for the fabrication of miniature polymer electrolyte membrane fuel cells. The fuel cells made with this low-cost approach perform among the best of their type to date. The second project concerns a new cross-flow microvalve concept. Intended as a step towards the mass production of large-flow I/P converters, the silicon footprint area is minimized by an out-of-plane moving gate and in-plane, half-open pneumatic channels.</p>

<p>A method has been developed for flexible modelling of multi-component twin-wire blade formers. Features such as suction devices, loadable blades, curved blades, and partial contact between the blades and the forming fabrics are easily incorporated. New results include a series of calculations demonstrating the non-trivial interaction between the pressure pulses when the blades are positioned successively closer together, the effects of suction on the pressure pulse generated by a blade applied to the opposing wire, and how blades of modest curvature do not necessarily stay in contact with the fabric along their full width and the implications of this on the pressure gradients in the machine direction. </p><p>The behaviour of the fibre mats as they experience the first of the blade pulses (after having been formed over a roll) is then considered in detail. Typically, the thickness of the mats decreases during the pulse, which reduces the rate of deposition of new fibres onto the webs. The amount of fibres in the sheets therefore changes marginally. Nevertheless, the resistance to drainage presented by the fibre network is seen to increase significantly due to the low permeability in highly compressed layers of the mat. As a result of the pressure gradients in the machine direction, the shear stresses in the plane of the fibre sheets can attain several hundred Pascal next to the forming fabrics.</p><p>Further, a model for sheared consolidation of flocculated suspensions is presented that extends the concept of a concentration dependent yield stress, previously employed in studies of uniaxial consolidation, to comprise flocculated phase shear strength. Rate-dependent viscous stresses are also incorporated. The theory is applied to the problem of combined compression and shearing of a strongly flocculated suspension contained between two plates, one being fixed and acting as a perfectly permeable filter, the other movable and acting as a piston by which the load is applied. Qualitatively, the evolution of the volume fraction of solids exhibits the same behaviour as during uniaxial consolidation without shear. Applying shear is however predicted to increase the rate of the drainage process, due to a reduced load bearing capacity of the flocculated phase, and correspondingly higher pore pressures. </p>

<p>Two new aspects of the dynamic behaviour in the audible frequency range of magneto-sensitive (MS) rubber are highlighted: the existence of an amplitude dependence of the shear modulus—referred to as the Fletcher–Gent effect—for even small displacements, and the appearance of large MS effects. These results have been obtained experimentally and are subsequently used to model two examples of magneto-sensitive rubber isolators to show how by means of MS rubber they can be improved. The first model calculates the transfer stiffness of a torsionally excited isolator and the second one the energy flow into the foundation for a bushing inserted between a vibrating mass and an infinite plate. In both examples notable improvements in isolation can be obtained</p>

<p>Den här rapporten handlar om det examensarbete som utförts mot Volvo 3P genom forskningsprojektet Viktor. Viktor är ett projekt som ska visa möjligheten med virtuell produktframtagning av gjutna komponenter. Volvo 3P är ett företag som utvecklar lastbilar. Uppgiften har varit att visa möjligheten att använda topologioptimering som ett verktyg i konstruktionsfasen. Detta har gjorts med hjälp av ett case som erhållits från Volvo 3P. Ett nytt koncept för en av deras lastbilsnav har tagits fram. Konceptet visar på högre styvhet och en lägre spänningsnivå än dagens originalnav. Konceptet hade förmodligen aldrig uppkommit om det inte hade varit för topologioptimeringen. Rapporten behandlar de steg som utförs vid en topologioptimering med programvaran Altair Hypermesh Optistruct. För att verifiera de resultat som erhållits från topologioptimeringen har koncepten analyserats i Abaqus. Rapporten tar även upp begränsningar och svårigheter som användaren kan komma att stöta på under arbetets gång.</p> / <p>This report documents the final project which has been performed in collaboration with Volvo 3P through the science project named Viktor. Viktor is a project which will show the opportunities with virtual product development of cast iron products. Volvo 3P is a company which among other things develops trucks. The task has been to show opportunities with topology optimization as a tool in the construction phase. This has been done with help from a case that has been received from Volvo 3P. A new concept for one of their hubs has been developed. The concept shows greater stiffness and a lower stresses compared to the original hub. The concept would probably not have been developed without using topology optimization. This report concerns the multiple steps which are used to perform optimization with the computer program Altair Hypermesh Optistruct. To verify the results which has been received from the topology optimization Abaqus has been used as a FE-tool. The report also contains the limits and difficulties which can occur during the process</p>

Condition based monitoring of Thermal Protection Systems (TPS) is necessary for safe operations of space shuttles. In the current research Terahertz radiation (T-ray) has been used to detect mechanical and heat induced damages in TPS tiles. Voids and cracks inside the foam tile are denoted as mechanical damage while property changes due to long and short term exposures of tiles to high heat are denoted as heat induced damage.Ultrasonic waves cannot detect cracks and voids inside the tile because the tile material (silica foam) has high attenuation for ultrasonic energy. Instead, electromagnetic terahertz radiation can easily penetrate into the foam material and detect the internal voids although this electromagnetic radiation finds it difficult to detect delaminations between the foam tile and the substrate plate. Thus these two technologies are complementary to each other for TPS inspection.Ultrasonic and T-ray field modeling in free and mounted tiles with different types of mechanical and thermal damages has been the focus of this research. Shortcomings and limitations of FEM method in modeling 3D problems especially at high-frequencies has been discussed and a newly developed semi-analytical technique called Distributed Point Source Method (DPSM) has been used for this purpose.A FORTRAN code called DPSM3D has been developed to model both ultrasonic and electromagnetic problems using the conventional DPSM method. DPSM has been extended from ultrasonic applications to electromagnetic to model THz Gaussian beams, multilayered dielectrics and Gaussian beam-scatterer interaction problems. Since the conventional DPSM has some drawbacks, to overcome it two modification methods called G-DPSM and ESM have been proposed.The conventional DPSM in the past was only capable of solving time harmonic (frequency domain) problems. In this research DPSM has been extended to model DPSM transient problems. This modified technique has been denoted as t-DPSM.Using DPSM, scattering of focused ultrasonic fields by single and multiple cavities in fluid&solid media is studied. A comparison between the radiation forces generated by the ultrasonic energies reflected from two small cavities versus a single big cavity is also carried out.

Linear and nonlinear optimal control have been investigated in transitional channel and boundary layer .ows. The flow phenomena that we study are governed by the incompressible Navier–Stokes equations and the main aim with the control is to prevent transition from laminar to turbulent flows. A linear model-based feedback control approach, that minimizes an objective function which measures the perturbation energy, can be formulated where the Orr– Sommerfeld/Squire equations model the flow dynamics. A limitation with the formulation is that it requires complete state information. However, the control problem can be combined with a state estimator to relax this requirement. The estimator requires only wall measurements to reconstruct the flow in an optimal manner. Physically relevant stochastic models are suggested for the estimation problem which turns out to be crucial for fast convergence. Based on these models the estimator is shown to work for both in.nitesimal as well as finite amplitude perturbations in direct numerical simulations of a channel flow at Recl = 3000. A stochastic model for external disturbances is also constructed based on statistical data from a turbulent channel flow at ReT = 100. The model is successfully applied to estimate a turbulent channel flow at the same Reynolds number. The combined control and estimation problem, also known as a compensator, is applied to spatially developing boundary layers. The compensator is shown to successfully reduce the perturbation energy for Tollmien–Schlichting waves and optimal perturbations in the Blasius boundary layer. In a Falkner– Skan–Cooke boundary layer the perturbation energy of traveling and stationary cross-flow disturbances are also reduced. A nonlinear control approach using the Navier–Stokes equations and the associated adjoint equations are derived and implemented in the context of direct numerical simulations of spatially-developing three-dimensional boundary layer .ows and the gradient computation is veri.ed with .nite-di.erences. The nonlinear optimal control is shown to be more e.cient in reducing the disturbance energy than feedback control when nonlinear interactions are becoming signi.cant in the boundary layer. For weaker disturbances the two methods are almost indistinguishable.

Electric vehicles represent a major accomplishment in the energy and transportation industry. Unfortunately, they are restricted to a small travel range because of limited battery life. Successful integration of wireless power transfer (WPT) systems into the infrastructure would remove the range restrictions of EVs. To successfully integrate this technology, several requirements must be met. First, the embedment process cannot interfere with the electrical performance of the inductive power transfer (IPT) system. Second, the presence of the IPT system in the pavement structure cannot negatively affect the roadway’s lifespan. Several systems were directly embedded in roadway materials. The electrical properties of the systems were monitored during the embedment process. Then modifications were made to the IPT systems to optimize the embedment process. These modifications were then applied to a full scale IPT system which is being used to dynamically charge EVs. To test the structural performance of the systems, tensile stresses were applied to the pads to simulate traffic loading conditions. These tensile stresses were applied under cyclic loading conditions to simulate fatigue conditions found in roadways. The number of cycles, and stress at failure was recorded an analyzed. The electrical properties of the IPT pads was also measured and analyzed during the fatigue loading conditions.

<p>Detta examensarbete behandlar utformning av inredning i Bombardier Transportations tågmodell Regina. Arbetet omfattar en teknisk rapport med översikt av arbetsgången genom det utförda arbetet och de olika tillämpade tekniker som använts för att nå fram till slutgiltigt resultat. Arbetet omfattar även byggnation av en fullskalemodell vilken finns att beskåda på Mälardalens högskola i Eskilstuna.</p>

<p>Denna rapport behandlar examensarbete utfört för industridesignföretaget Cate & Nelson Design. Företaget ligger i Eskilstuna och jobbar i huvudsakligen med möbeldesign och inredningsprodukter. Projektgruppensuppgift har varit att ta fram en ny möbel för företaget och arbetet har omfattat utveckling av hela produkten från idé till prototyp.</p>

<p>A protection helmet for young people (3-7 years) in winter environment has been developed in this thesis. The result is a concept proposal for development at STIGA Sports AB in Eskilstuna. This thesis work has been performed during 20 weeks, for a Master of Science in Product and Process development at Mälardalen University Eskilstuna Sweden in September 2009 to January 2010. The helmet is shown as a CAD model with detailed solutions to the outer shell, interior and adjustability (in sizes 50-56 cm) which are the three focused areas in the development. Also a physical model in scale 1:1 has been developed and is shown in this thesis work.</p><p>To achieve the best result possible the process started with an analysis of the market and the product. All decisions during the development process were made according to European Standard SS EN 1080 Impact protection helmets for young people, which are the requirements necessary for market interest, security and to be CE approved. In the product development process scientific methods have been used to guarantee quality. A function analysis and a product specification formed the basis of the QFD tool, which measured the concept in relation to the requirements and existing products on the market.</p><p>The analysis of current competitors on the market combined with a SWOT analysis showed that there is potential for STIGA Sports AB to develop a play helmet. That since there is only one direct competitor on the market today. Due to the fact that they do not have their own product development department it is, in a safety perspective, important for STIGA Sports AB to keep a continuous contact with the production. It will guarantee the product’s quality and meet all the requirements of SS EN 1080. A product decomposition was performed to understand the construction of a helmet. Eight developed concepts led, through an evaluation of three concepts with the highest ranking score, to one final combined concept.</p><p>The concept consists of a two-piece outer shell for the ability to adjust size and a three-piece interior to ensure comfort and safety regarding the essential parts of the head (forehead, rear, sides, temples and crown of the head). The shape and color have been chosen with the intention to appeal the user (children) and at the same time provide a feeling of safety to the purchaser (adults). Stiga Sports AB current product range and design profile has influenced the design throughout the project.</p> / <p>En lekhjälm för användning vid vintermiljö har i detta examensarbete tagits fram. Resultatet är ett konceptförslag för utveckling inom STIGA Sports AB i Eskilstuna. Arbetet har utförts som ett examensarbete på 30 Högskolepoäng för civilingenjör inom produkt- och processutveckling på Mälardalens högskola i Eskilstuna september 2009- januari 2010. Hjälmen visas som en CAD-modell med detaljerade lösningar på ytterskal, inredning och ställbarhet (storlek 50-56 cm), de tre områdena har varit fokus i arbetet. För att arbeta fram bästa resultat har omvärlden och produkten först bearbetats och analyserats. Dessutom har en modell i skala 1:1 tagits fram och visas i detta examensarbete.</p><p>Besluten i arbetet har Europeiska Standarden SS EN 1080 Impact protection helmets for young people legat till grund för få produkten i de riktlinjer och följa de krav som krävs för godkännande på marknaden i säkerhet och därmed vara CE-godkänd. I produktutvecklingsprocessen och konceptskapandet har vetenskapliga metoder använts för att säkerhetsställa att rätt arbete utförs. En funktionsanalys har uppförts och en kravspecifikation på produkten, dessa verktyg har legat till grund för metodverktyget QFD, som använts för att mäta konceptet i förhållande till krav och befintliga produkter på marknaden.</p><p>För att ta reda på hur marknaden ser ut har omvärlden bevakats genom en konkurrentanalys och SWOT-analys samt informationsökning på företaget. Resultatet visade på att det finns potential för STIGA Sports AB att ge sig ut på marknaden med en lekhjälm eftersom att det idag bara finns en direkt konkurrent på marknaden. I säkerhetsåsyn så är det viktigt att STIGA Sports AB har en fortlöpande kontakt med tillverkningen för att säkerhetsställa detaljutvecklingen och kvalitén av konceptet för att möjliggöra att produkten klarar alla krav enligt SS EN 1080. I kombination har det varit viktigt att förstå hur en hjälm är uppbyggd och därför har en produktnedbrytning utförts. Arbetet med produktnedbrytningen i samband med litteratursökning och kunskapsinhämtning gav tre områden att rikta produktutvecklingen kring; yttre skal, inredning och ställbarhet.</p><p>Efter koncept hade tagits fram har värdering av de olika koncepten lett till att produkten har fått ett tvådelat ytterskal som medger ställbarhet på enklaste sätt med en tredelad inredning för att skydda och ge komfort till de viktigaste delar på huvudet. Färg och form har valts utifrån användaren för att tilltala den primära användaren barnet och förmedla säkerhet till den primära köparen vuxna. Samtidigt har Stiga Sports nuvarande produktsortiment och designprofil utgjort de val som påverkat formgivningen.</p>