The linear actuator is widely used in the industrial and aerospace arenas. The application of the linear actuator varies. The ball screw type linear actuator or ball screw system is one design. The ball screw is a mechanical system that converts rotation motion into a linear motion. The ball screw linear actuator, compared with other linear actuators, has better efficiency, higher speed, less noise, and higher load capacity. Ball screw linear actuators are used in a number of areas, such as coordinated measuring machines, 3D printers, and aerospace actuators. In this research, the industrial sponsor provided a ball screw linear actuator, and they required its accuracy to be improved. The linear actuator suffers from an accuracy problem due to various reasons. One of the major problems is nonlinear friction, which makes it difficult to estimate using the simple friction model. In this thesis, a LuGre friction model is introduced and applied to the ball screw system. The sponsor’s ball screw system includes the ball screw sliding table, AC servo drive, AC servo motor, and a linear encoder sensor. The hardware control system for the ball screw system needs to be built. Therefore, this thesis describes how a custom ball screw control system was built. The control hardware ball screw system includes a microcontroller and a custom-made digital-to-analog converter. The linear encoder position sensor’s reading methods were tested and implemented in the microcontroller. A custom digital-to-analog converter was made and tested. The control algorithms based on the LuGre friction compensator are discussed and were simulated in the Matlab Simulink environment. Then, the physical implementation of the control algorithms on ball screw system hardware were made. Finally, a new proposed control method based on the LuGre friction model performed best in terms of accuracy consistence and tracking compare to the other mentioned controllers. / Thesis / Master of Applied Science (MASc)

This thesis explores two aspects of modeling the behavior of joint friction in structures. The first aspect deals with the accurate and efficient simulation of a simple system that incorporates the LuGre friction law. Energy transfer and dissipation in a structural joint model is the second topic of this thesis. It is hypothesized that friction could serve to pump energy from one frequency to higher frequencies where it might be dissipated more quickly. Motivation for this study stems from the need to have accurate models of high-precision space structures. Because friction at connecting joints plays a major role in the damping capacity of the structure, a good understanding of this mechanism is necessary to predict the vibratory response and enhance the energy dissipation of the structure. Simulation results of a dynamic system with LuGre friction show that the system is relatively well-conditioned when the slip velocity is small, and ill-conditioned for large slip velocities. Furthermore, the most efficient numerical method to simulate this system is determined to be an implicit integration scheme. To study the energy transfer and dissipation, two models of a jointed structure with friction are considered. Results from the steady-state forced responses of the two structural systems indicate that friction converted low frequency, single harmonic excitation to multi-harmonic response through internal resonances. However, differences in energy dissipation results between the models show that the response of a frictional system is highly sensitive to system parameters and friction laws. Conclusions and suggestions for future research are also discussed.

<p>All mechanical systems with moving parts are affected by friction, including industrial robots. Being able to design an accurate friction model would further increase the performance of todays robots. Friction is a complex dynamic phenomena that is constantly changing depending on the state and environment of the robot. It is therefore beneficial to update the parameters of the friction model online. An estimate of the friction will be made using the feedback control signal with the help of a feedforward control scheme in a two axis simulation setup. The friction estimate is then used for an offline identification of three friction model parameters in a static Lugre friction model. Improvements on the identification will be done by introducing some shut-off rules that will improve the estimate. The normalized least mean square method (NLMS) will then be used to update the parameters online. A simulation of friction compensation with a fixed friction model, and with an adaptive friction model will be studied. The method will also be simulated using experimental data taken from a real industrial robot.</p>

All mechanical systems with moving parts are affected by friction, including industrial robots. Being able to design an accurate friction model would further increase the performance of todays robots. Friction is a complex dynamic phenomena that is constantly changing depending on the state and environment of the robot. It is therefore beneficial to update the parameters of the friction model online. An estimate of the friction will be made using the feedback control signal with the help of a feedforward control scheme in a two axis simulation setup. The friction estimate is then used for an offline identification of three friction model parameters in a static Lugre friction model. Improvements on the identification will be done by introducing some shut-off rules that will improve the estimate. The normalized least mean square method (NLMS) will then be used to update the parameters online. A simulation of friction compensation with a fixed friction model, and with an adaptive friction model will be studied. The method will also be simulated using experimental data taken from a real industrial robot.

The suspension system of a vehicle is conventionally designed such that the spring-damper element is configured in the vertical direction, and the longitudinal connection between the vehicle chassis and wheels is always very stiff compared to the vertical one. This mechanism can isolate vibrations and absorb shocks efficiently in the vertical direction but cannot attenuate the longitudinal impacts caused by road obstacles. In order to overcome such a limitation, a planar suspension system (PSS) is proposed. This novel vehicle suspension system has a longitudinal spring-damper strut between the vehicle chassis and wheel. The dynamic performance, including ride comfort, pitch dynamics, handling characteristics and total dynamic behaviour, of a mid-size passenger vehicle equipped with such planar suspension systems is thoroughly investigated and compared with those of a conventional vehicle. To facilitate this investigation, various number of vehicle models are developed considering the relative longitudinal motions of wheels with respect to the chassis. A 4-DOF quarter-car model is used to conduct a preliminary study of the ride quality, and a pitch plane half-car model is employed to investigate the pitch dynamics in both the frequency and time domain. A 5-DOF yaw plane single-track half-car model along with a pitch plane half-car model is proposed to carry out the handling performance study, and also an 18-DOF full-car model is used to perform total dynamics study. In addition to these mathematical models, virtual full-car models are constructed in Adams/car to validate the proposed mathematical models. For the sake of prediction of the tire-ground interaction force, a radial-spring tire model is modified by adding the tire damping to generate the road excitation forces due to road disturbances in the vertical and longitudinal directions. A dynamic 2D tire friction model based on the LuGre friction theory is modified to simulate the dynamic frictional interaction in the tire-ground contact pitch. The ride quality of a PSS vehicle is evaluated in accordance with the ISO 2631 and compared with that of a conventional vehicle. It is shown that the PSS system exhibits good potential to attenuate the impact and isolate the vibration due to road excitations in both the vertical and longitudinal directions, resulting in improved vehicles’ ride and comfort quality. The relatively soft longitudinal strut can absorb the longitudinal impact and, therefore, can protect the components. The investigation of handling performance including the steady-state handling characteristics, transient and frequency responses in various scenarios demonstrates that the PSS vehicle is directionally stable and generally has comparable handling behaviour to a similar conventional vehicle. The application of PSS in vehicles can enhance the understeer trend, i.e. the understeer becomes more understeer, neutral steer becomes slightly understeer, and oversteer becomes less oversteer. The total dynamic behaviour combining the bounce, pitch, roll and the longitudinal dynamics under various scenarios such as differential brake-in-turn and asymmetric obstacle traversing was thoroughly investigated. Simulation results illustrate that the PSS vehicle has a relatively small roll angle in a turning manoeuvre. In some cases such as passing road potholes, the PSS vehicle has a better directional stability.

Ce travail s'inscrit dans le contexte général des nouvelles générations de Direction Assistée Electrique (DAE ou EPAS en anglais pour Electronic Power Assistance Steering), dont l'objectif est de tenir compte des caractéristiques des conducteurs à mobilité réduite. En effet, à ce jour, il n'existe pas de système de direction assistée adapté aux capacités articulaires (rhumatismes divers), musculaires (diminution de force, sénescence), ou encore aux douleurs ressenties par le conducteur, ce qui constitue une insuffisance dès lors que l'on s'intéresse à de telles populations. Le principal objectif de cette thèse est donc de proposer une méthodologie générale permettant d'adapter une DAE standard aux conducteurs à mobilité réduite. La méthodologie proposée a été validé sur une plateforme de type Hardware-In the Loop et les résultats expérimentaux obtenus mettent bien en évidence l'intérêt de la démarche proposée. Ils représentent également un point de départ pour l'implantation de l'aide envisagée sur un véhicule réel et jettent les bases pour l'application de la méthodologie à une large classe de patients affectés par des pathologies différentes.

The suspension system of a vehicle is conventionally designed such that the spring-damper element is configured in the vertical direction, and the longitudinal connection between the vehicle chassis and wheels is always very stiff compared to the vertical one. This mechanism can isolate vibrations and absorb shocks efficiently in the vertical direction but cannot attenuate the longitudinal impacts caused by road obstacles. In order to overcome such a limitation, a planar suspension system (PSS) is proposed. This novel vehicle suspension system has a longitudinal spring-damper strut between the vehicle chassis and wheel. The dynamic performance, including ride comfort, pitch dynamics, handling characteristics and total dynamic behaviour, of a mid-size passenger vehicle equipped with such planar suspension systems is thoroughly investigated and compared with those of a conventional vehicle. To facilitate this investigation, various number of vehicle models are developed considering the relative longitudinal motions of wheels with respect to the chassis. A 4-DOF quarter-car model is used to conduct a preliminary study of the ride quality, and a pitch plane half-car model is employed to investigate the pitch dynamics in both the frequency and time domain. A 5-DOF yaw plane single-track half-car model along with a pitch plane half-car model is proposed to carry out the handling performance study, and also an 18-DOF full-car model is used to perform total dynamics study. In addition to these mathematical models, virtual full-car models are constructed in Adams/car to validate the proposed mathematical models. For the sake of prediction of the tire-ground interaction force, a radial-spring tire model is modified by adding the tire damping to generate the road excitation forces due to road disturbances in the vertical and longitudinal directions. A dynamic 2D tire friction model based on the LuGre friction theory is modified to simulate the dynamic frictional interaction in the tire-ground contact pitch. The ride quality of a PSS vehicle is evaluated in accordance with the ISO 2631 and compared with that of a conventional vehicle. It is shown that the PSS system exhibits good potential to attenuate the impact and isolate the vibration due to road excitations in both the vertical and longitudinal directions, resulting in improved vehicles’ ride and comfort quality. The relatively soft longitudinal strut can absorb the longitudinal impact and, therefore, can protect the components. The investigation of handling performance including the steady-state handling characteristics, transient and frequency responses in various scenarios demonstrates that the PSS vehicle is directionally stable and generally has comparable handling behaviour to a similar conventional vehicle. The application of PSS in vehicles can enhance the understeer trend, i.e. the understeer becomes more understeer, neutral steer becomes slightly understeer, and oversteer becomes less oversteer. The total dynamic behaviour combining the bounce, pitch, roll and the longitudinal dynamics under various scenarios such as differential brake-in-turn and asymmetric obstacle traversing was thoroughly investigated. Simulation results illustrate that the PSS vehicle has a relatively small roll angle in a turning manoeuvre. In some cases such as passing road potholes, the PSS vehicle has a better directional stability.

For internal combustion engines used in heavy-duty vehicles, increased engine efficiency and consequently reduced CO2 emissions can be obtained if the engine speed can be kept within an optimal speed range. This requires swift and frequent gear shifts where the dry friction clutch is utilized. Enhanced dry clutch simulation models and a better understanding of the involved phenomena can assist the development towards swifter gear shifts and help reduce CO2 emissions. The work presented in this thesis focuses on the modelling of dry clutch systems for heavy-duty applications and their effect on the torsional response of the driveline during transient events such as clutch engagement and disengagement. During these events it is primarily the first vibration mode of the driveline that is active and consequently it is possible to greatly reduce theof degrees of freedom (DOFs) of the powertrain model and still capture the relevant dynamics of the powertrain. The reduced set of differential equationsdescribe the torsional motion of the powertrain and the equations of motion are solved numerically in the time-domain. From a mathematical point ofview, the equations of motion turn "stiff" when the clutch is locked. This issue is resolved by utilizing numerical solution techniques suitable for stiff differential equations. In the simulations it was observed that no engine torque fluctuations were transferred through the slipping clutch. Consequently the response of the driveline is purely modal during sliding. If the gradient of the coefficient of friction is negative the modal response is possibly unstable with exponentially growing vibration amplitudes as an effect. Moreover, the way in which the clamp load evolves during clutch engagement is found to severely effect the excitation of transient vibrations during clutch synchronization. It can be shown that reducing the gradient of the evolving clamp load at the onset of sliding will reduce the amplitude of the friction induced vibrations. Reducing the torsional vibration amplitudes will help avoid the jerky motion of the vehicle during launch and increase comfort for driver and passengers. / Reduced transmission vibrations - reduced energy consumption and environmental impacts together with an increased competitiveness. Swedish Energy Agency (project No. 42100-1)

Les actionneurs électropneumatiques sont très utilisés dans l'industrie automobile car ils offrent de grands avantages, en termes d'encombrement, de puissance élevée et de simplicité de commande. Ces actionneurs sont utilisés plus particulièrement pour le contrôle des Turbocompresseurs à Géométrie Variable (TGV). Le TGV joue un rôle très important dans les performances de la boucle d'air du moteur, en particulier sur la qualité de l'air à l'admission et à l'échappement. Les nouvelles réglementations gouvernementales concernant les émissions polluantes des véhicules ont poussé les équipementiers automobiles à s'intéresser davantage au contrôle du Turbocompresseur à Géométrie Variable. Ces exigences ne peuvent pas être realisées à travers des techniques classiques de contrôle de type PID. En effet, le contrôle doit tenir compte de la complexité du modèle et de ses incertitudes ainsi que des exigences en termes de performances statiques et dynamiques et du nombre limité de mesures. De plus, il faut également tenir compte des conditions agressives dans lesquelles travaillent l'actionneur, notamment la température, les forces de frottement et les forces aérodynamiques à l'entrée du turbo. Dans le cadre de cette thèse, ce sont tous ces aspects qui ont motivé notre travail de modélisation et de commande robuste de l'actionneur électropneumatique du turbo. Dans un premier temps, nous avons établi un modèle de simulation de l'actionneur. Nous avons commencé par élaborer un modèle physique détaillé de l'actionneur, en prenant en compte les caractéristiques non linéaires provenant de la compressibilité de l'air et du frottement. Ensuite, deux modèles des forces aérodynamiques qui agissement sur l'actionneur ont été proposés. Le modèle global de l'actionneur a été validé expérimentalement et une analyse de sensibilité expérimentale a été menée sur plusieurs actionneurs afin d'identifier les paramètres ayant le plus d'impact sur les performances de l'actionneur. Dans un second temps, nous avons proposé une simplification du modèle obtenu dans le but de le rendre utilisable pour le contrôle, tout en préservant ses caractéristiques statiques et dynamiques. Enfin, nous nous sommes intéressés à la résolution du problème de commande robuste par retour de sortie de l'actionneur. Les algorithmes de contrôle et d'estimation élaborés ont été validés d'abord par des simulations, puis expérimentalement sur un banc d'essai moteur. / The choice of technology for automotive actuators is driven by the need of high power to size ratio. In general, electro-pneumatic actuators are preferred for application around the engine as they are compact, powerful and require simple controlling devices. Specially, Variable Geometry Turbochargers (VGTs) are almost always controlled with electro-pneumatic actuators. This is a challenging application because the VGT is an important part of the engine air path and the latter is responsible for intake and exhaust air quality and exhaust emissions control. With government regulations on vehicle pollutant emissions getting stringent by the year, VGT control requirements have also increased. These regulations and requirements can only be fulfilled with precise dynamic control of the VGT through its actuator. The demands on actuator control include robustness against uncertainty in operating conditions, fast and smooth positioning without vibration, limited number of measurements. Added constraints such as nonlinear dynamic behavior of the actuator, friction and varying aerodynamic forces in the VGT render classical control methods ineffective. These are the main problems that form the core of this thesis.In this work, we have addressed the above mentioned problems, using model based control complemented with robust control methods to overcome operational uncertainties and parametric variations. In the first step, a detailed physical model of an electro-pneumatic actuator has been developed; taking into account the nonlinear characteristics originating from air compressibility and friction. Means to compensate for aerodynamic force have been studied and implemented in the next step. These include model parametric adaptation and one dimensional CFD (Computational Fluid Dynamics) modeling. The complete model has been experimentally validated and a sensitivity analysis has been conducted to identify the parameters which have the greatest impact upon the actuator's behavior. The detailed simulation model has then been simplified to make it suitable for control purposes while keeping its essential behavioral characteristics (i.e. transients and dynamics). Next, robust controllers have been developed around the model for the control objective of accurate actuator positioning in presence of operational uncertainty. An important constraint in commercial actuators is that they provide output feedback only, as they are only equipped with low-cost position sensors. This hurdle has been overcome by introducing observers in the control loop, which estimate other system states from the output feedback. The estimation and control algorithms have been validated in simulation and experimentally on diesel engine test benches.

Friction compensation is challenging but imperative for control engineers. For high-performance engineering systems, a friction-model-based controller is typically required to accommodate the nonlinearities arisen from the friction model employed. It is well known that the parameters of the friction model used in the friction compensation are nearly impossible to be accurately identified. Therefore, the objective of this research is to study the effect of these parametric uncertainties on the stability of a set-point position control system. With the above goal in mind, a variety of aspects are investigated in this work. Firstly, several common friction features and friction models are surveyed to provide background knowledge which helps select the friction model with the highest accuracy for our study. Secondly, an experimental setup is proposed and fabricated to validate the levels of accuracy given by the candidate friction models. The comparisons between the numerical and experimental results confirm that the LuGre friction model is the best approximation of the observed friction behaviours among all models selected. Moreover, a series of profound discussions addressing the relation between the candidate models’ structures and their numerical friction feature predictions are provided and followed by a summary table that recapitulates the properties of the candidate friction models. Last but not least, the state space models of the proposed setup formulated by the improved version of the LuGre model and the two controllers of interest, namely input-output linearization controller and nominal characteristic trajectory following (NCTF) controller, are derived for the stability analysis under the parametric uncertainties. Two parameters in the friction model used, σ_0 and σ_1, are perturbed for the stability analysis in which the results applying the concept of Lyapunov exponents (LEs) clearly illustrate the significant effect of the varying σ_0 and σ_1 values on the system stability. The effect of parametric uncertainties can depend quite significantly on the incorporated controller, and the stability results obtained here are applicable to the design and analysis of other systems that are inherently similar to our setup. The stability analysis conducted is this work is recommended for other control systems to avoid unwanted qualitative behaviours under parametric perturbations. / October 2016