The goal of my master‘s thesis is to create a digital twin of a testbed Barman. The Barman is a school model of autonomous mixed drinks production line that demonstrates the principles of Industry 4.0. In the theoretical part of the thesis, the choice of a suitable tool for virtualization is discussed. The Tecnomatix Process Simulate and the Mechatronic Concept Designer module integrated in the NX platform is compared. The practical part of the work is divided into two phases. The first phase was about looking for a way to integrate the robotic SCARA manipulator. The second phase was focused on the virtualization of the cell Shaker in the latter of the tools mentioned before. This work is designed as a guide for creating and verifying the concept of a digital twin.

The aim of this thesis is to design and implement a toolchaning system for a 3D printer. As a consequence of such expansion, the printer gains the ability of multimaterial printing and switching between a number of active and passive tools during a single production process. In addition to extensive research of other currently available solutions, this thesis describes the complete mechanical and electrical design process of the device. It also documents the implementation of a functional sample, the creation of software both for the base system and the toolchanger expansion, and the implementation of an associated optical measurement and calibration system.

The methods used today for the commissioning and validation of industrial machines requires theconstruction of physical prototypes. Those prototypes help the engineers to e.g. validate if theprogram code meant to control a machine works as intended. In recent years the development ofnew techniques for the commissioning and validation of industrial machines has changed rapidlythanks to the development of new software. The method used in this thesis is called simulationin the loop. Another method that can be benecial to use is hardware in the loop. Using thosemethods for the commissioning of a machine is called virtual commissioning. The simulation inthe loop method is used to simulate both the machine and the control system that operate thatmachine. This is called a digital twin, a virtual copy of the physical hardware and its control systemthat can be used without the need for a real prototype to be available.The software used in this thesis comes all from the company Siemens and those are TIA Portal,Mechatronics Concept Designer, SIMIT and PLCSim Advanced. By using those programs it waspossible to build a digital twin with rigid body dynamics and its control system of the industrialmodel that was given by the company Renholmen AB. This model contained all the necessarycomponents needed for a virtual commissioning project to be done without the need to be at thefactory oor.The results showed that it was possible to achieve a real time simulation, allowing the possibilityto trim the controller parameters without the need of a physical prototype. Design errors were alsofound thanks to the results of the simulation.This new technique has shown to be a useful tool due to most of the work could be done on a digitalmodel of the machine. Simulations can reduce the time to market for industrial machines and alsohelp engineers to validate and optimize the product at an early stage. This tool that can be usedto validate industrial machines before they are created.

Additive mechatronische Systeme (AMS) sind geeignet, die Funktionalität von Werkzeugmaschinen (WZM) zu verbessern. Die Vielfalt und Redundanz der entwickelten Lösungen erschwert jedoch die optimale Berücksichtigung von AMS im frühzeitigen Entwicklungsprozess von WZM. In der vorliegenden Arbeit wird eine Vorgehensweise aufgezeigt, den möglichen Lösungsraum schon frühzeitig einzugrenzen und damit zielführende Lösungen effektiv zu kanalisieren. Hierfür werden im ersten Schritt Funktionalitätsgrenzen von WZM bewertet. Danach erfolgt die Definition von AMS-Funktionsprinzipien und eines geeigneten Beschreibungsansatzes, um daraus allgemeine Eingriffsstrategien für AMS in WZM abzuleiten und vergleichend zu bewerten. Abschließend werden die Auswirkungen der vorgeschlagenen Vorgehensweise auf den Entwicklungsprozess von WZM diskutiert. Anhand dreier Anwendungsbeispiele werden die erarbeiteten Vorgehensweisen und Werkzeuge validiert und Grenzen aufgezeigt. / Additive mechatronic systems (AMS) are suitable for improving the functionality of machine tools. However, the variety and redundancy of the solutions developed make it difficult to optimally take AMS into account in the early development process of machine tools. In the present work a procedure is shown to limit the possible solution space and thus to identify effective solutions at an early stage. For this purpose, the functional limits of machine tools are assessed in the first step. This is followed by the definition of AMS functional principles and a suitable description approach in order to derive general intervention strategies for AMS in machine tools and to evaluate them comparatively. Finally, the effects of the proposed procedure on the development process of machine tools are discussed. Using three application examples, the developed procedures and tools are validated and limits are shown.

The modern industry is steadily facing new demands for more energy efficient solutions. These improvements can come from technological advances, using existing technology smarter or a combination of the two. Today a vacuum conveying system is manually tuned for each factory application when installed and is in most cases not handled afterwards except for maintenance reasons. This in combination with the difficulties in tuning a system to run efficiently and robustly whilst offering high capacity indicates that a large number of systems are running with non optimal settings. The aim of this thesis was therefore to explore the possibility of introducing an auto tuning property to the vacuum conveying system and investigate the possible benefits. This thesis has investigated two main components for such an autotuner, the system design and optimisation strategy. The system design is critical for allowing process control and monitoring. In the optimisation the main challenge was to robustly produce good results for a wide variety of materials. Based on this a laboratory system was developed that monitored the capacity, efficiency, gentleness and robustness performance of the conveying. This information was then used in anevolutionary optimisation algorithm based on differential evolution to find the best settings for optimal performance. The results of this thesis indicate that such a system would offer benefits bothin terms of initial tuning and run-time performance. The suggested auto tuner is adaptable to a large set of materials with varying material properties and demands on the conveying process. The time required for the laboratory rig to optimise within a region with only small deviations in performance is comparable to that of a human operator. Also with the added benefit of never having to stop the optimisation process, thus constantly improving performance and counteracting environmental changes. / Den moderna industrin möter ständigt nya krav på ökad effektivitet. Dessa förbättringar kan komma utifrån tillämpning av ny teknologi eller bättre utnyttjande av befintlig teknologi eller en kombination. Idag när en vakuum transportör installeras finjusteras den manuellt för att uppnå önskad prestanda och hanteras därefter ofta inte bortsett från underhållsarbete. Detta i kombination med svårigheten att justera ett system så att det går effektivt och robust samtidigt som en god kapacitet upprätthålls föranleder slutsatsen att många system ute i industrin inte presterar optimalt. Målet med detta examensarbete var därför att utreda möjligheten att skapa en automatisk system inställare samt utvärdera de möjliga fördelarna och nackdelarna. Arbetet har undersökt två huvudkomponenter i en sådan automatisk system inställare, system design och optimerings strategi. System design var vital för att tillåta styrning och monitorering av systemet och optimeringsstrategi för att tillförlitligt kunna prestera goda resultat trots skiftande beteende med olika material i systemet. Baserat på detta utvecklades en laboratorie-utrustning som övervakade kapacitet, effektivitet, robusthet och försiktighet i varje transportcykel. Denna information nyttjades sedan i en evolutionär algoritm baserad på differentierad evolution för att finna de optimala system-inställningarna. Arbetet indikerar att ett sådant system skulle erbjuda prestanda-fördelar både i driftsättande och kontinuerliga driften av en vakuum-transportör. Den föreslagna automatiska systeminställaren kan anpassas till en stor mängd material och skilda krav på önskat driftläge för systemet. Tiden för att optimera systemet så att de större variationerna i prestanda uppnås är jämförbar med en mänsklig operatör menkan fortlöpa över tiden och ständigt söka förbättringar på ett sätt som ej är möjligt för en mänsklig operatör.

Increase in the awareness environmental conservation is leading the automotive industry into the adaptation of alternatively fueled vehicles. Electric, Fuel-Cell as well as Hybrid-Electric vehicles focus on this research area with aim to efficiently utilize vehicle powertrain as the first step. Energy and Power Management System control strategies play vital role in improving efficiency of any hybrid propulsion system. However, these control strategies are sensitive to the dynamics of the powertrain components used in the given system. A kinematic mathematical model for Plug-in Hybrid Electric Vehicle (PHEV) has been developed in this study and is further optimized by determining optimal power management strategy for minimal fuel consumption as well as NOx emissions while executing a set drive cycle. A multi-objective optimization using weighted sum formulation is needed in order to observe the trade-off between the optimized objectives. Particle Swarm Optimization (PSO) algorithm has been used in this research, to determine the trade-off curve between fuel and NOx. In performing these optimizations, the control signal consisting of engine speed and reference battery SOC trajectory for a 2-hour cycle is used as the controllable decision parameter input directly from the optimizer. Each element of the control signal was split into 50 distinct points representing the full 2 hours, giving slightly less than 2.5 minutes per point, noting that the values used in the model are interpolated between the points for each time step. With the control signal consisting of 2 distinct signals, speed and SOC trajectory, as 50 element time variant signals, a multidimensional problem was formulated for the optimizer. Novel approaches to balance the optimizer exploration and convergence, as well as seeding techniques are suggested to solve the optimal control problem. The optimization of each involved individual runs at 5 different weight levels with the resulting cost populations being compiled together to visually represent with the help of Pareto front development. The obtained results of simulations and optimization are presented involving performances of individual components of the PHEV powertrain as well as the optimized PMS strategy to follow for given drive cycle. Observations of the trade-off is discussed in the case of Multi-Objective Optimizations.

L'objectif de ce travail est de construire une machine d'essai pour la prothèse. La machine doit être capable de reproduire les mêmes conditions dynamiques et cinématiques appliquées sur la prothèse pendant l'utilisation normale.Le nombre d'amputation et les causes d'amputation ont été recueillis. Différents types de prothèses ont été classés selon la prothèse de jambe par hauteur d'amputation, prothèse passive et active, différenciées par la nature de leur actionneur. La plupart des machines d'essai pour la prothèse ont été étudiées à partir de la prospective technologique et capacitaire. Déterminer toutes les limitations de la plupart des machines d'essai existantes, et les besoins de développer une nouvelle machine pour remplir complètement ces besoins ont été développés.Ensuite, nous avons étudié et analysé la dynamique de la marche et de la course humaines. Les équations du mouvement en prenant en considération les masses et les moments d'inertie des segments squelettiques. La plupart des paramètres de la démarche ont été extraits. En conclusion, nous avons les exigences cinématiques du centre de gravité humain pour générer 6 DOF que la machine d'essai devrait effectuer pour imiter la démarche humaine normale et courir.Trois conceptions ont été proposées pour implanter la machine d'essai; Bras de robot articulé, manipulateur cartésien et Stewart Platform (SP). Après la mise en œuvre des trois solutions, nous avons trouvé la solution la plus appropriée est le SP attaché avec une hanche active artificielle. Nous avons choisi la puissance hydraulique car c'est la technique d'actionnement la plus appropriée pour notre solution, connaissant les forces d'actionnement requises.Pour aider à contrôler le mouvement de SP, une nouvelle solution de modèle géométrique direct pour la planeuse et la plate-forme Stewart 6-6 a été développée en utilisant les capteurs rotatifs au lieu de capteurs de revêtement comme voulu pour les actionneurs hydrauliques. L'analyse de sensibilité a été étudiée pour cette solution, et un calcul analytique pour le calcul de l'espace de travail a également été développé.La conclusion de cette machine d'essai est que nous pouvons créer toute la dynamique du corps humain, c'est-à-dire marcher ou courir ou monter et descendre des escaliers. La solution développée peut porter des procédures d'essai pour la prothèse passive ou active. / The objective of this work is to build a testing machine for prosthesis. The machine should be able to reproduce the same dynamic and kinematics conditions applied on the prosthesis during the normal use.Numbers of amputation, and causes of amputation were collected. Different types of prosthesis were classified according to the leg prosthesis per amputation height, passive and active prosthesis, differentiated by the nature of their actuator. Most of the testing machine for the prosthesis were studied form the technological and capability prospective. Determining all the limitations of most of existing testing machines, and the needs to develop a new machine to full fill these needs were developed.Then we studied and analyzed the dynamics of the human gait and run. The equations of motion by taking into consideration the masses and moments of inertia of skeletal segments. Most of the parameters of gait were extracted. In conclusion, we have the kinematic requirements of the human center of gravity to generate 6 DOF that the testing machine should carry out to emulate the normal human gait and run.Three designs were proposed to implement the testing machine; Articulated robot arm, Cartesian manipulator, and Stewart Platform (SP). After implementing the three solutions we found the most suitable solution is the SP attached with it an artificial active hip. We have chosen the hydraulic power as it is the most suitable actuation technique for our solution knowing the required actuation forces.To help in controlling the SP motion, a novel Closed-form solution of direct Geometric model for planer and 6-6 Stewart Platform using the rotary sensors instead of liner sensors as wanted to the hydraulic actuators was developed. Sensitivity analysis was studied for that solution, and analytical calculation for computing the workspace was also developed.The conclusion from this testing machine is that we can create all the dynamics of the human body, i.e. walking or running or going up and down stairs. The developed solution can carry testing procedures for either passive or active prothesis.

Les matériaux composites sont largement utilisés dans l'industrie automobile comme pièces de structure. Alliant légèreté et bonnes propriétés mécaniques, ils ont remplacé les métaux classiquement adoptés dans la fabrication de moyens de transport. Toutefois, l'emploi des matériaux composites doit tenir compte de leur comportement électromagnétique. En effet, les composites à fibres conductrices, généralement moins conducteurs que les métaux, engendrent une interaction avec les ondes électromagnétiques, différente de celle introduite par les alliages métalliques. Il s'avère donc important de développer des outils de modélisation permettant de mieux appréhender le comportement électromagnétique de matériaux composites, et d'éclairer les changements qu'apportent ces matériaux sur la distribution des champs, provenant d'une multitude de sources externes, au voisinage des systèmes mécatroniques. Par ailleurs, l'étude du comportement électromagnétique de matériaux composites permet de tirer parti de leurs propriétés mécaniques attractives afin d'alléger les boîtiers de blindage en gardant un niveau d'atténuation conforme aux normes de l'industrie. Cependant, la modélisation numérique de structures composites de grande taille, telles que les boîtiers de blindage, bien que classiquement adoptée pour les structures métalliques, est rendue complexe par le fait que les composites présentent des hétérogénéités à l'échelle microscopique, et que leurs mécanismes de blindage diffèrent de ceux des conducteurs homogènes. Le calcul numérique s'avère envisageable une fois le composite remplacé par un matériau homogène ayant une réponse identique face à une sollicitation électromagnétique. Ainsi, au travers de ce travail de thèse, nous proposons une technique d'homogénéisation permettant d'estimer les propriétés électriques équivalentes que nous appliquons aux composites à fibres conductrices unidirectionnelles et tissées. Les résultats obtenus sont utilisés pour la simulation numérique d'un boîtier de blindage. / Composite materials are widely used in the automotive industry as structural components. By combining lightness and robust mechanical properties, they are increasigly replacing the conventionnally used metallic alloys, for the manufacturing of vehicle parts. However, the use of composite materials is not without consequences on the electromagnetic behavior of these parts. Since carbon fiber reinforced composites are generally worse conductors of electricity than metals, they interact differently with the electromagnetic waves which surround them. It is therefore important to develop modeling tools to better understand the electromagnetic behavior of composite materials. This is to explain the changes that these materials bring to the distribution of waves, generated by a multitude of external sources, in the vicinity of mechatronic systems. On the other hand, the study of the electromagnetic behavior of composite materials makes it possible to determine the possibility of taking advantage of their attractive mechanical properties in order to further reduce the weight of electromagnetic shielding enclosures while maintaining a level of attenuation in accordance with the standards of the industry. However, numerical modeling of large composite structures, such as shielding enclosures, although conventionally adopted for metal structures, is hindered by the fact that composites exhibit heterogeneities at the microscopic scale. The numerical calculation becomes possible once the composite is replaced by a homogeneous material that exhibits an identical response to an identical electromagnetic solicitation. In this work, we present a homogenization technique, based on finite element simulation and an optimisation method, that computes an estimate of the equivalent electrical properties of unidirectional and woven fiber reinforced composites. The results are then used to simulate the shielding effectiveness of an enclosure constructed by combining composite materials and metallic alloys.

Le sujet de thèse concerne le développement de l'architecture de contrôle et la génération de trajectoire pour un exosquelette évolutif appelé SOL. Les résultats de l'étude biomédicale ont révélé que la progressivité de la maladie pouvait être résolue par une réadaptation précoce et continue tout au long de la croissance. Ainsi, l'importance de l'utilisation d'un exosquelette a un impact positif puisqu'il sert à la fois à la locomotion et à la réhabilitation. Cependant, les exosquelettes actuels ne peuvent pas être adaptés au changement continu de la biomécanique de l'adolescent tout au long de sa croissance. Par conséquent, le besoin de développer un exosquelette évolutif capable de faire face aux besoins croissants est un sujet interdisciplinaire. L'architecture de contrôle d'un tel dispositif évolutif a été abordée dans cette thèse, à la fois dans les développements matériels et logiciels pour incorporer autant que possible la fonctionnalité d'évolutivité. Les étapes initiales ont été franchies en vue d'atteindre l'objectif d'un exosquelette évolutif, en contribuant à la fois aux développements matériels qui permettent d'apporter d'autres améliorations tout au long de l'avancement du projet, et aux développements du firmware, qui ont répondu aux besoins en matière d'évolutivité au niveau du contrôle.L'extensibilité a également été abordée aux trois niveaux hiérarchiques de contrôle. Plus spécifiquement, une attention particulière a été accordée à la génération des trajectoires de référence de la marche pour une population en croissance. Enfin, grâce à la connaissance de la biomécanique du sujet, le contrôleur développé est capable d’identifier les trajectoires appropriées et injecter les trajectoires de référence des actionneurs de l’exosquelette SOL.Un premier prototype de l'exosquelette est utilisé pour manifester les résultats du générateur de marche évolutionnaire (E.G.G.) proposé. Comme premier prototype, un mouvement de marche libre dans l'air est testé, où la validation du matériel proposé et des boucles de contrôle sont démontrées. L'étude des réponses de contrôle des exosquelettes contre les perturbations externes probables et des scénarios de sécurité en cas de défaillance est encore un travail futur obligatoire avant de réaliser les premiers tests sur l'exosquelette humain. / The thesis' subject concerns the development of the control architecture and the trajectory generation for a scalable exoskeleton called SOL. The biomedical study outcomes revealed that the progressiveness of the disease could be solved by early and continuous rehabilitation throughout the growth. Thus, the importance of using an exoskeleton has a positive impact since it is used to provide locomotion and rehabilitation, at the same time. However, the current exoskeletons cannot be adapted to fit the continuous change of teenager biomechanics throughout his growth. Hence, the need for developing a scalable exoskeleton that can cope with the growing needs is still a challenging topic. Especially, the control architecture of such a scalable device was tackled in this thesis, in both hardware and software developments to incorporate the scalability features. Initiative steps have been passed towards the goal of achieving a scalable exoskeleton, by contributing in hardware developments that allowing further enhancements to be included throughout the advancement of the project. Firmware developments achieved have addressed the scalability needs in terms of control by considering the three hierarchical levels (which are: High, Middle, and low-levels of control). More specifically, a focus was dedicated to the generation of the gait reference trajectories for the growing population. Data were collected from healthy subjects wearing a passive exoskeleton to extract the proper joint trajectories, then, the data were processed to build a gait library to be deployed on the exoskeleton controller. Finally, by knowledge of the subject biomechanics, the controller is able to fetch the proper trajectories and inject the reference trajectories to the SOL's actuators. A first prototype of the exoskeleton is used to manifest the outcomes of the proposed Evolutionary Gait Generator (E.G.G.). As a first prototype, A free walking in air motion is tested, where the validation of the proposed hardware and control loops are demonstrated. Studying the exoskeletons' control responses against probable external disturbances and fail-safe scenarios are still future work mandatory before achieving first human-exoskeleton testing.

This report covers a project on a partially automated aeroponic and fungi growing system. The purpose is to evaluate if an enclosed space system can be automated to produce healthy crops of greens and fungi, and investigate how well the system can switch between these two growth modes. Factors that will be automated include regulation of temperature, humidity, air ventilation, and light exposure time. The research will be focused on Romaine lettuce and Golden Oyster mushroom. The methods used include research, hardware setup, software programming, chassis construction, and experiments. Relevant factors for the growing environment, such as lighting, temperature, and nutrient solutions were studied. The hardware components used in the project can shortly be described as follows. A real time clock ensure accurate timing for the microcontroller that regulates the indoor climate based on sensor readings. LEDs light up the chamber and a humidifier provide the roots access to a nutrient solution. A fan provides cooling, and filters block out unwanted microorganisms and fungi spores from the ventilation air. A display provides the user with relevant information. The system code written in C++ contain six main functions and two support functions. Depending on the growth mode, climate control functions are selected. The system has control variables allowing the administrator to set threshold levels for humidity and nutrient spray periods. The outer case of the chassis was made out of painted acrylic to block out light and retain moisture. The water-nutrient solution basin was designed to avoid leakage, net cups hold the plants in a raised bed, a base plate acts as flooring for the mushrooms, as well as a placement enforcer for the humidifier. An inner roof separates the moist growth chamber from the electronics compartment above. Two experiments were conducted in separate prototypes simultaneously for green sand mushrooms. For the mushroom experiment, a grow kit was installed after thorough cleaning. The fruiting process was monitored and photographed daily. Results showed successful mushroom growth and healthy fruiting bodies. For the greens experiment, a nutrient solution was mixed and lettuce seeds were placed in rock wool cylinders that were installed in net cups. Photographs were taken every three days to track the progress. The lettuce seeds germinated and started growing. Control variables were altered multiple times to maximize performance but optimal settings were not found. The plants died whilst unsupervised. The experiments were partially successful and demonstrated potential for growing both greens and mushrooms. The prototype was effective in maintaining set temperature and humidity levels. The parameters necessary for successful growth was effectively automated and the system has great potential for further improvements and automation. / Målet med projektet är att studera hur väl det går att odla både svamp och fotosyntetiserande växter i samma slutna, delvis automatiserande aeroponiskasystem. I projektet undersöks om det går att byta mellan de två odlingssätten och hur automatiserad processen kan vara. Produkten är tänkt att fylla utrymmet som hittats på marknaden för enkla odlingssystem hemma för i synnerhet svamp. Faktorer att ta hänsyn till är temperatur, luftfuktighet och ljusexponeringstid. Andra faktorer som pH värde eller byte av vattnet utesluts till följd av tid- och resursbegränsningar. Metoden är indelad i forskning, hårdvara, mjukvara, chassi och experiment. Forskningen täcker nödvändig information om faktorer relaterade till odling av både svamp och gröna växter i aeroponiska system. Exempelvis hur mycket ljus, vatten och näring som behövs. Kapitlet om hårdvara tar upp vilka komponenter som används och varför. I centrum är en microkontroller, en Arduino micro, som med hjälp av en realtidskolocka styr när belysningen ska lysa, när luftfuktaren ska vara på samt när fläktarna ska gå. En DHT11 sensor skickar information till Arduinon att agera utifrån. I mjukvara ingår hur koden är uppbyggd för att styra microkontrollern och hur användaren kan anpassa värden till sitt tycke. För att hjälpa användaren visas relevant data på en skärm. Produkten är uppbyggd med ett mörklagt och tätande skal av akrylplast. Vatten med eventuell näring för växtläget är samlat i en tät balja längst ner i lådan där luftfuktaren även är placerad. Över baljan vilar antingen ett svampodlingskit på en perforerad yta eller en hållare för odling av växter i nätkorgar med stenull. I taket är en 20W LED fäst på en kylfläns för kylning tillsamman med en närliggande fläkt. Allra högst upp är elektroniken, skyddad från fukten nere i lådan av ett lager akrylplast.Två experiment hölls parallellt med varandra i två likadana odlingskammare för att hinna utvärdera både svamp och fotosyntetiserande växter. Citronmussling valdes som svamp och Romansallad som växt. Experimenten dokumenterades regelbundet med fotografier och kommentarer om det som observerats. Experimenten var till stor del lyckade även om vissa parametrar behövde justeras under förloppet. Det aeroponiska systemet producerar svamp och växter av god kvalitet. Slutsatsen som kan dras är att det går att odla både svamp och växter i samma produkt. De parametrar som inkluderats inom projektets avgränsningar gick att automatisera. Det finns även goda möjligheter att förbättra automatiseringsnivån.