Friction stir welding has become a popular forging technique used in many applications. The Swedish Nuclear Fuel and Waste Management Company (SKB) evaluates this method to seal the 5 cm thick copper canisters that will contain the spent nuclear fuel. To produce repetitive, high quality welds, the process must be controlled, and today a cascade controller is used to keep the desired stir zone temperature. In this thesis, the control system is extended to also include a plunge depth controller. Two different approaches are evaluated; the first attempt is a decentralized solution where the cascaded temperature controller is kept, and the second approach uses a non-linear model predictive controller for both depth and temperature. Suitable models have been derived and used to design the controllers; a simpler model for the decentralized control and a more extensive, full model used in the non-linear model predictive controller that relates all the important process variables. The two controller designs are compared according to important performance measures, and the achieved increase in performance with the more complex non-linear model predictive controller is evaluated. The non-linear model predictive controller has not been implemented on the real process. Hence, simulations of the closed loop systems using the full model have been used to compare and evaluate the control strategies. The decentralized controller has been implemented on the real system. Two welds have been made using plunge depth control with excellent experimental results, confirming that the decentralized controller design proposed in this thesis can be successfully used. Even though the controller manages to regulate the plunge depth with satisfying performance, simulations indicate that the non-linear model predictive controller achieves even better closed loop performance. This controller manages to compensate for the cross-connections between the process variables, and the resulting closed loop system is almost decoupled. Further research will reveal which control design that will finally be used. / ''Friction stir welding'' har blivit en populär svetsmetod inom många olika tillämpningar. På Svensk Kärnbränslehantering AB (SKB) undersöks möjligheten att använda metoden för att försegla de 5 cm tjocka kopparkapslarna som kommer innehålla det använda kärnbränslet. För att kunna producera repeterbara svetsar utav hög kvalité krävs det att processen regleras. Idag löses detta med en temperaturregulator som reglerar svetszonens temperatur. I detta examensarbete utökas styrsystemet med en regulator för svetsdjupet. Två olika lösningar har utvärderats; först en decentraliserad lösning där temperatur-regulatorn behålls och sedan en lösning med en olinjär modellprediktiv reglering (MPC) som reglerar både djup och temperatur. Passande modeller har tagits fram och har använts för att designa regulatorerna; en enklare modell för den decentraliserade regulatorn och en utökad, komplett modell som används i den olinjära MPC:n och som beskriver alla viktiga variabler i processen. Viktiga prestandamått har jämförts för de båda regulatorstrukturerna och även prestandaökningen med den olinjära MPC:n har utvärderats. Då denna regulator inte har implementerats på den verkliga processen har simuleringar av den kompletta modellen använts för att jämföra och utvärdera regulatorstrukturerna. Den decentraliserade regulatorn har implementerats och testats på processen. Två svetsar har gjorts och de har givit utmärkta resultat, vilket visar att regulatorstrukturen som presenteras i rapporten fungerar bra för reglering av svetsdjupet. Trots att den implementerade regulatorn klarar av att reglera svetsdjupet med godkänt resultat, så visar simuleringar att den olinjära MPC:n ger ännu bättre reglerprestanda. Denna regulator kompenserar för korskopplingar i systemet och resulterar i ett slutet system som är nästan helt frikopplat. Ytterligare forskning kommer avgöra vilken av strategierna som kommer att användas i slutprodukten.

In the pulp industry, digesters are used to disolve lignin in wood chips. The concentration of lignin is measured and is called the Kappa number. In this thesis, the question of whether an online Kappa sensor, taking samples from the mid-phase of the digester, is useful or not is analyzed. For the samples to be useful, there has to be a relationship between the measured Kappa at the mid- phase and the measured Kappa in the blowpipe at the bottom of the digester. An ARX model of the lower part of the digester has been estimated. Despite a lot of noise, it seems that it might be possible to use the mid-phase samples and for this model predict the blowpipe flow Kappa signal. It is concluded that the mid-phase samples should be further improved to be more useful. The mid-phase samples have also been used in another ARX model, this time to LP-filter these values without time loss. Another important issue has been to examine if the existing controller is good or not. In order to be able to compare it with other controllers, a simulator has been created in MATLAB - Simulink. Test results from this simulator show that the existing controller's use of the mid-phase Kappa samples improves its performance. For a simplified digester model, the existing controller has also been compared with an MPC controller. This test shows that the MPC controller is significantly better. Hence, the conclusion in this thesis is that it might be interesting to study MPC further using a more advanced model.

Solid oxide fuel cells are a promising option for distributed stationary power generation that offers efficiencies ranging from 50% in stand-alone applications to greater than 80% in cogeneration. To advance SOFC technology for widespread market penetration, the SOFC should demonstrate improved cell lifetime and load-following capability. This work seeks to improve lifetime through dynamic analysis of critical lifetime variables and advanced control algorithms that permit load-following while remaining in a safe operating zone based on stress analysis. Control algorithms typically have addressed SOFC lifetime operability objectives using unconstrained, single-input-single-output control algorithms that minimize thermal transients. Existing SOFC controls research has not considered maximum radial thermal gradients or limits on absolute temperatures in the SOFC. In particular, as stress analysis demonstrates, the minimum cell temperature is the primary thermal stress driver in tubular SOFCs. This dissertation presents a dynamic, quasi-two-dimensional model for a high-temperature tubular SOFC combined with ejector and prereformer models. The model captures dynamics of critical thermal stress drivers and is used as the physical plant for closed-loop control simulations. A constrained, MIMO model predictive control algorithm is developed and applied to control the SOFC. Closed-loop control simulation results demonstrate effective load-following, constraint satisfaction for critical lifetime variables, and disturbance rejection. Nonlinear programming is applied to find the optimal SOFC size and steady-state operating conditions to minimize total system costs. / text

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The deployment of Renewable Energy (RE)-based generation has experienced a sustained global growth in the recent decades, driven by many countries' interest in reducing greenhouse gas emissions and dependence on fossil fuel for electricity generation. This trend is also observed in remote off-grid systems (isolated microgrids), where local communities, in an attempt to reduce fossil fuel dependency and associated economic and environmental costs, and to increase availability of electricity, are favouring the installation of RE-based generation. This practice has posed several challenges to the operation of such systems, due to the intermittent and hard-to-predict nature of RE sources. In particular, this thesis addresses the problem of reliable and economic dispatch of isolated microgrids, also known as the energy management problem, considering the uncertain nature of those RE sources, as well as loads. Isolated microgrids feature characteristics similar to those of distribution systems, in terms of unbalanced power flows, significant voltage drops and high power losses. For this reason, detailed three-phase mathematical models of the microgrid system and components are presented here, in order to account for the impact of unbalanced system conditions on the optimal operation of the microgrid. Also, simplified three-phase models of Distributed Energy Resources (DERs) are developed to reduce the level of complexity in small units that have limited impact on the optimal operation of the system, thus reducing the number of equations and variables of the problem. The proposed mathematical models are then used to formulate a novel energy management problem for isolated microgrids, as a deterministic, multi-period, Mixed-Integer Nonlinear Programming (MINLP) problem. The multi-period formulation allows for a proper management of energy storage resources and multi-period constraints associated with the commitment decisions of DERs. In order to obtain solutions of the energy management problem in reasonable computational times for real-time, realistic applications, and to address the uncertainty issues, the proposed MINLP formulation is decomposed into a Mixed-Integer Linear Programming (MILP) problem, and a Nonlinear programming (NLP) problem, in the context of a Model Predictive Control (MPC) approach. The MILP formulation determines the unit commitment decisions of DERs using a simplified model of the network, whereas the NLP formulation calculates the detailed three-phase dispatch of the units, knowing the commitment status. A feedback signal is generated by the NLP if additional units are required to correct reactive power problems in the microgrid, triggering a new calculation MINLP problem. The proposed decomposition and calculation routines are used to design a new deterministic Energy Management System (EMS) based on the MPC approach to handle uncertainties; hence, the proposed deterministic EMS is able to handle multi-period constraints, and account for the impact of future system conditions in the current operation of the microgrid. In the proposed methodology, uncertainty associated with the load and RE-based generation is indirectly considered in the EMS by continuously updating the optimal dispatch solution (with a given time-step), based on the most updated information available from suitable forecasting systems. For a more direct modelling of uncertainty in the problem formulation, the MILP part of the energy management problem is re-formulated as a two-stage Stochastic Programming (SP) problem. The proposed novel SP formulation considers that uncertainty can be properly modelled using a finite set of scenarios, which are generated using both a statistical ensembles scenario generation technique and historical data. Using the proposed SP formulation of the MILP problem, the deterministic EMS design is adjusted to produce a novel stochastic EMS. The proposed EMS design is tested in a large, realistic, medium-voltage isolated microgrid test system. For the deterministic case, the results demonstrate the important connection between the microgrid's imbalance, reactive power requirements and optimal dispatch, justifying the need for detailed three-phase models for EMS applications in isolated microgrids. For the stochastic studies, the results show the advantages of using a stochastic MILP formulation to account for uncertainties associated with RE sources, and optimally accommodate system reserves. The computational times in all simulated cases show the feasibility of applying the proposed techniques to real-time, autonomous dispatch of isolated microgrids with variable RE sources.

Advances in hardware design have made wheeled mobile robots (WMRs) exceptionally mobile. To fully exploit this mobility, WMR planning, control, and estimation systems require motion models that are fast and accurate. Much of the published theory on WMR modeling is limited to 2D or kinematics, but 3D dynamic (or force-driven) models are required when traversing challenging terrain, executing aggressive maneuvers, and manipulating heavy payloads. This thesis advances the state of the art in both the formulation and calibration of WMR models We present novel WMR model formulations that are high-fidelity, general, modular, and fast. We provide a general method to derive 3D velocity kinematics for any WMR joint configuration. Using this method, we obtain constraints on wheel ground contact point velocities for our differential algebraic equation (DAE)-based models. Our “stabilized DAE” kinematics formulation enables constrained, drift free motion prediction on rough terrain. We also enhance the kinematics to predict nonzero wheel slip in a principled way based on gravitational, inertial, and dissipative forces. Unlike ordinary differential equation (ODE)-based dynamic models which can be very stiff, our constrained dynamics formulation permits large integration steps without compromising stability. Some alternatives like Open Dynamics Engine also use constraints, but can only approximate Coulomb friction at contacts. In contrast, we can enforce realistic, nonlinear models of wheel-terrain interaction (e.g. empirical models for pneumatic tires, terramechanics-based models) using a novel force-balance optimization technique. Simulation tests show our kinematic and dynamic models to be more functional, stable, and efficient than common alternatives. Simulations run 1K-10K faster than real time on an ordinary PC, even while predicting articulated motion on rough terrain and enforcing realistic wheel-terrain interaction models. In addition, we present a novel Integrated Prediction Error Minimization (IPEM) method to calibrate model parameters that is general, convenient, online, and evaluative. Ordinarily system dynamics are calibrated by minimizing the error of instantaneous output predictions. IPEM instead forms predictions by integrating the system dynamics over an interval; benefits include reduced sensing requirements, better observability, and accuracy over a longer horizon. In addition to calibrating out systematic errors, we simultaneously calibrate a model of stochastic error propagation to quantify the uncertainty of motion predictions. Experimental results on multiple platforms and terrain types show that parameter estimates converge quickly during online calibration, and uncertainty is well characterized. Under normal conditions, our enhanced kinematic model can predict nonzero wheel slip as accurately as a full dynamic model for a fraction of the computation cost. Finally, odometry is greatly improved when using IPEM vs. manual calibration, and when using 3D vs. 2D kinematics. To facilitate their use, we have released open source MATLAB and C++ libraries implementing the model formulation and calibration methods in this thesis.

A typical wastewater effluent of a chemical process can contain several strong acids/bases, weak acids/bases as well as their salts. They must be neutralized before being discharged to the environment in order to protect aquatic life and human welfare. However, neutralization process is highly non&ndash / linear and has time&ndash / varying characteristics. Therefore, the control of pH is a challenging problem where advanced control strategies are often considered. In this study, the aim is to design a pH control system that will be capable of controlling the pH-value of a plant waste-water effluent stream having unknown acids with unknown concentrations using an on&ndash / line identification procedure. A Model Predictive Controller, MPC, and a Fuzzy Logic Controller, FLC, are designed and used in a laboratory scale pH neutralization system. The characteristic of the upstream flow is obtained by a small identification reactor which has ten times faster dynamics and which is working parallel to actual neutralization tank. In the control strategy, steady&ndash / state titration curve of the process stream is obtained using the data collected in terms of pH value from the response of the identification reactor to a pulse input in base flow rate and using the simulated response of the identification reactor for the same input. After obtaining the steady&ndash / state titration curve, it is used in the design of a Proportional&ndash / Integral, PI, and of an Adaptive Model Predictive Controller, AMPC. On the other hand, identification reactor is not used in the FLC scheme. The performances of the designed controllers are tested mainly for disturbance rejection, set&ndash / point tracking and robustness issues theoretically and experimentally. The superiority of the FLC is verified.

This dissertation investigates a new design for a magnetostrictive actuator that employs individually controlled coils distributed axially along the magnetostrictive rod. As a quantitative goal, the objective is to show that the multi-coil actuator can operate effectively at frequencies as high as 10,000 Hz with 900 N force and 50 microns of displacement. Conventional, single coil actuators with the same parameters for force and displacement develop significant attenuation in their response at frequencies above the first longitudinal vibration resonance at about 2750 Hz. The goal of the research is to investigate whether multiple coils can effectively increase the frequency range a least four times the range of conventional magnetostrictive actuators. This document derives a new mathematical model of the actuator that represents the spatial distributions of magnetic field and vibration, devises a control design that takes advantage of the multiple inputs to control the displacement of the actuator while consuming minimum electrical power, and describes a prototype multi-coil actuator and experimental system developed to test the idea. The simulations of the multi-coil actuator and control design demonstrate successful transient operation of the actuator over the targeted frequency range with feasible levels of input power and current. Experimental tests of the design, although limited by a computer sampling rate less than 10,000 Hz, are able to validate the predictions of the developed model of the actuator and reproduce the simulated control performance within the constraints of the experimental system.

This thesis investigates the questions of where to grasp and how to grasp a given object with an articulated robotic grasping device. To this end, aspects of grasp synthesis and hand motion planning and control are investigated. Grasp synthesis is the process of determining a palm pose with respect to the target object, as well as a hand joint configuration and/or grasp contact points such that a successful grasp execution is allowed. Existing methods tackling the grasp synthesis problem can be categorized in analytical and empirical approaches. Analytical approaches are based on geometric, kinematic and/or dynamic formulations, whereas empirical methods aim at mimicking human strategies.An overarching idea throughout this thesis is to circumvent the curse of dimensionality, which is inherent in high-dimensional planning problems, by incorporating empirical data in analytical approaches. To this end, tools from the field of constrained optimization are used (i) to synthesize grasp families based on available prototype grasps, (ii) to incorporate heuristics capturing human grasp strategies in the grasp synthesis process and (iii) to encode demonstrated grasp motions in primitive motion controllers.The first contribution is related to the computation and analysis of grasp families which are represented as Independent Contact Regions (ICR) on a target object’s surface. To this end, the well-known concept of the Grasp Wrench Space for a single grasp is extended to be applicable for a set of grasps. Applications of ICR include grasp qualification by capturing the robustness of a grasp to position inaccuracies and the visual guidance of a demonstrator in a teleoperating scenario. In the second main contribution of this thesis, it is shown how to reduce the grasp solution space during the synthesis process by accounting for human approach strategies. This is achieved by imposing appropriate constraints to a corresponding optimization problem. A third contribution in this dissertation is made to reactive motion planning. Here, primitive controllers are synthesized by estimating the free parameters of corresponding dynamical systems from multiple demonstrated trajectories. The approach is evaluated on an anthropomorphic robot hand/arm platform. Also, an extension to a Model Predictive Control (MPC) scheme is presented which allows to incorporate state constraints for auxiliary tasks such as obstacle avoidance.

In order to meet tight product quality specifications for chemical batch processes, it is vital to monitor and control product quality throughout the batch duration. However, the frequent lack of in situ sensors for continuous monitoring of batch product quality complicates the control problem and calls for novel control approaches. This thesis focuses on the study and application of multivariate statistical methods to control product quality in chemical batch processes. These multivariate statistical methods can be used to identify data-driven prediction models that can be integrated within a model predictive control (MPC) framework. The ideal MPC control strategy achieves end-product quality specifications by performing trajectory tracking during the batch operating time. However, due to the lack of in-situ sensors, measurements of product quality are usually obtained by laboratory assays and are, therefore, inherently intermittent. This thesis proposes a new approach to realise trajectory tracking control of batch product quality in those situations where only intermittent measurements are available. The scope of this methodology consists of: 1) the identification of a partial least squares (PLS) model that works as an estimator of product quality, 2) the transformation of the PLS model into a recursive formulation utilising a moving window technique, and 3) the incorporation of the recursive PLS model as a predictor into a standard MPC framework for tracking the desired trajectory of batch product quality. The structure of the recursive PLS model allows a straightforward incorporation of process constraints in the optimisation process. Additionally, a method to incorporate a nonlinear inner relation within the proposed PLS recursive model is introduced. This nonlinear inner relation is a combination of feedforward artificial neural networks (ANNs) and linear regression. Nonlinear models based on this method can predict product quality of highly nonlinear batch processes and can, therefore, be used within an MPC framework to control such processes. The use of linear regression in addition to ANNs within the PLS model reduces the risk of overfitting and also reduces the computational e↵ort of the optimisation carried out by the controller. The benefits of the proposed modelling and control methods are demonstrated using a number of simulated batch processes.