Indiana University-Purdue University Indianapolis (IUPUI) / This thesis proposes an automated grid-based alignment system utilizing lasers and an array of light-detecting photodiodes. The intent is to create an inexpensive and scalable alignment system for pick-and-place robotic systems. The system utilizes the transformation matrix, geometry, and trigonometry to determine the movements to align the robot with a grid-based array of photodiodes. The alignment system consists of a sending unit utilizing lasers, a receiving module consisting of photodiodes, a data acquisition unit, a computer-based control system, and the robot being aligned. The control system computes the robot movements needed to position the lasers based on the laser positions detected by the photodiodes. A transformation matrix converts movements from the coordinate system of the grid formed by the photodiodes to the coordinate system of the robot. The photodiode grid can detect a single laser spot and move it to any part of the grid, or it can detect up to four laser spots and use their relative positions to determine rotational misalignment of the robot. Testing the alignment consists of detecting the position of a single laser at individual points in a distinct pattern on the grid array of photodiodes, and running the entire alignment process multiple times starting with different misalignment cases. The first test provides a measure of the position detection accuracy of the system, while the second test demonstrates the alignment accuracy and repeatability of the system. The system detects the position of a single laser or multiple lasers by using a method similar to a center-of-gravity calculation. The intensity of each photodiode is multiplied by the X-position of that photodiode. The summed result from each photodiode intensity and position product is divided by the summed value of all of the photodiode intensities to get the X-position of the laser. The same thing is done with the Y-values to get the Y-position of the laser. Results show that with this method the system can read a single laser position value with a resolution of 0.1mm, and with a maximum X-error of 2.9mm and Y-error of 2.0mm. It takes approximately 1.5 seconds to process the reading. The alignment procedure calculates the initial misalignment between the robot and the grid of photodiodes by moving the robot to two distinct points along the robot’s X-axis so that only one laser is over the grid. Using these two detected points, a movement trajectory is generated to move that laser to the X = 0, Y = 0 position on the grid. In the process, this moves the other three lasers over the grid, allowing the system to detect the positions of four lasers and uses the positions to determine the rotational and translational offset needed to align the lasers to the grid of photodiodes. This step is run in a feedback loop to update the adjustment until it is within a permissible error value. The desired result for the complete alignment is a robot manipulator positioning within ±0.5mm along the X and Y-axes. The system shows a maximum error of 0.2mm in the X-direction and 0.5mm in the Y-direction with a run-time of approximately 4 to 5 minutes per alignment. If the permissible error value of the final alignment is tripled the alignment time goes down to 1 to 1.5 minutes and the maximum error goes up to 1.4mm in both the X and Y-directions. The run time of the alignment decreases because the system runs fewer alignment iterations.

Indiana University-Purdue University Indianapolis (IUPUI) / There have been many endeavors to design humanoid robots that have human characteristics such as dexterity, autonomy and intelligence. Humanoid robots are intended to cooperate with humans and perform useful work that humans can perform. The main advantage of humanoid robots over other machines is that they are flexible and multi-purpose. In this thesis, a human-like robotic arm is designed and used in a task which is typically performed by humans, namely, catching a ball. The robotic arm was designed to closely resemble a human arm, based on anthropometric studies. A rigid multibody dynamics software was used to create a virtual model of the robotic arm, perform experiments, and collect data. The inverse kinematics of the robotic arm was solved using a Newton-Raphson numerical method with a numerically calculated Jacobian. The system was validated by testing its ability to find a kinematic solution for the catch position and successfully catch the ball within the robot's workspace. The tests were conducted by throwing the ball such that its path intersects different target points within the robot's workspace. The method used for determining the catch location consists of finding the intersection of the ball's trajectory with a virtual catch plane. The hand orientation was set so that the normal vector to the palm of the hand is parallel to the trajectory of the ball at the intersection point and a vector perpendicular to this normal vector remains in a constant orientation during the catch. It was found that this catch orientation approach was reliable within a 0.35 x 0.4 meter window in the robot's workspace. For all tests within this window, the robotic arm successfully caught and dropped the ball in a bin. Also, for the tests within this window, the maximum position and orientation (Euler angle) tracking errors were 13.6 mm and 4.3 degrees, respectively. The average position and orientation tracking errors were 3.5 mm and 0.3 degrees, respectively. The work presented in this study can be applied to humanoid robots in industrial assembly lines and hazardous environment recovery tasks, amongst other applications.

Indiana University-Purdue University Indianapolis (IUPUI) / Crashworthiness design is gaining more importance in the automotive industry due to high competition and tight safety norms. Further there is a need for light weight structures in the automotive design. Structural optimization in last two decades have been widely explored to improve existing designs or conceive new designs with better crashworthiness and reduced mass. Although many gradient based and heuristic methods for topology and topometry based crashworthiness design are available these days, most of them result in stiff structures that are suitable only for a set of vehicle components in which maximizing the energy absorption or minimizing the intrusion is the main concern. However, there are some other components in a vehicle structure that should have characteristics of both stiffness and flexibility. Moreover, the load paths within the structure and potential buckle modes also play an important role in efficient functioning of such components. For example, the front bumper, side frame rails, steering column, and occupant protection devices like the knee bolster should all exhibit controlled deformation and collapse behavior. This investigation introduces a methodology to design dynamically crushed thin-walled tubular structures for crashworthiness applications. Due to their low cost, high energy absorption efficiency, and capacity to withstand long strokes, thin-walled tubular structures are extensively used in the automotive industry. Tubular structures subjected to impact loading may undergo three modes of deformation: progressive crushing/buckling, dynamic plastic buckling, and global bending or Euler-type buckling. Of these, progressive buckling is the most desirable mode of collapse because it leads to a desirable deformation characteristic, low peak reaction force, and higher energy absorption efficiency. Progressive buckling is generally observed under pure axial loading; however, during an actual crash event, tubular structures are often subjected to oblique impact loads in which Euler-type buckling is the dominating mode of deformation. This undesired behavior severely reduces the energy absorption capability of the tubular structure. The design methodology presented in this paper relies on the ability of a compliant mechanism to transfer displacement and/or force from an input to desired output port locations. The suitable output port locations are utilized to enforce desired buckle zones, mitigating the natural Euler-type buckling effect. The problem addressed in this investigation is to find the thickness distribution of a thin-walled structure and the output port locations that maximizes the energy absorption while maintaining the peak reaction force at a prescribed limit. The underlying design for thickness distribution follows a uniform mutual potential energy density under a dynamic impact event. Nonlinear explicit finite element code LS-DYNA is used to simulate tubular structures under crash loading. Biologically inspired hybrid cellular automaton (HCA) method is used to drive the design process. Results are demonstrated on long straight and S-rail tubes subject to oblique loading, achieving progressive crushing in most cases.

Indiana University-Purdue University Indianapolis (IUPUI) / Hydraulic wind power transfer systems deliver the captured energy by the blades to the generators differently. In the conventional systems this task is carried out by a gearbox or an intermediate medium. New generation of wind power systems transfer the captured energy by means of high-pressure hydraulic fluids. A hydraulic pump is connected to the blades shaft at a high distance from the ground, in nacelle, to pressurize a hydraulic flow down to ground level equipment through hoses. Multiple wind turbines can also pressurize a flow sending to a single hose toward the generator. The pressurized flow carries a large amount of energy which will be transferred to the mechanical energy by a hydraulic motor. Finally, a generator is connected to the hydraulic motor to generate electrical power. This hydraulic system runs under two main disturbances, wind speed fluctuations and load variations. Intermittent nature of the wind applies a fluctuating torque on the hydraulic pump shaft. Also, variations of the consumed electrical power by the grid cause a considerable load disturbance on the system. This thesis studies the hydraulic wind power transfer systems. To get a better understanding, a mathematical model of the system is developed and studied utilizing the governing equations for every single hydraulic component in the system. The mathematical model embodies nonlinearities which are inherited from the hydraulic components such as check valves, proportional valves, pressure relief valves, etc. An experimental prototype of the hydraulic wind power transfer systems is designed and implemented to study the dynamic behavior and operation of the system. The provided nonlinear mathematical model is then validated by experimental result from the prototype. Moreover, this thesis develops a control system for the hydraulic wind power transfer systems. To maintain a fixed frequency electrical voltage by the system, the generator should remain at a constant rotational speed. The fluctuating wind speed from the upstream, and the load variations from the downstream apply considerable disturbances on the system. A controller is designed and implemented to regulate the flow in the proportional valve and as a consequence the generator maintains its constant speed compensating for load and wind turbine disturbances. The control system is applied to the mathematical model as well as the experimental prototype by utilizing MATLAB/Simulink and dSPACE 1104 fast prototyping hardware and the results are compared.

<p>This thesis presents solutions to some of the problems facing Autonomous Surface Vehicle (ASV) deployments in inland waterways through the development of navigational and control systems. Fluvial systems are one of the hardest inland waterways to navigate and are thus used as a use-case for system development. The systems are built to reduce the reliance on a-prioris during ASV operation. This is crucial for exceptionally dynamic environments such as fluvial bodies of water that have poorly defined routes and edges, can change course in short time spans, carry away and deposit obstacles, and expose or cover shoals and man-made structures as their water level changes. While navigation of fluvial systems is exceptionally difficult potential autonomous data collection can aid in important scientific missions in under studied environments.</p> <p><br></p> <p>The work has four contributions targeting solutions to four fundamental problems present in fluvial system navigation and control. To sense the course of fluvial systems for navigable path determination a fluvial segmentation study is done and a novel dataset detailed. To enable rapid path computations and augmentations in a fast moving environment a Dubins path generator and augmentation algorithm is presented ans is used in conjunction with an Integral Line-Of-Sight (ILOS) path following method. To rapidly avoid unseen/undetected obstacles present in fluvial environments a Deep Reinforcement Learning (DRL) agent is built and tested across domains to create dynamic local paths that can be rapidly affixed to for collision avoidance. Finally, a custom low-cost and deployable ASV, BREAM (Boat for Robotic Engineering and Applied Machine-Learning), capable of operating in fluvial environments is presented along with an autonomy package used in providing base level sensing and autonomy processing capability to varying platforms.</p> <p><br></p> <p>Each of these contributions form a part of a larger documented Fluvial Navigation Control Architecture (FNCA) that is proposed as a way to aid in a-priori free navigation of fluvial waterways. The architecture relates the navigational structures into high, mid, and low-level controller Guidance and Navigational Control (GNC) layers that are designed to increase cross vehicle and domain deployments. Each component of the architecture is documented, tested, and its application to the control architecture as a whole is reported.</p>

<p>The purpose of this research experiment was to explore and implement a cost-effective automation solution into a low volume production line for loading parts onto a coordinate measuring machine (CMM) for dimensional inspection. Quality control practices have historically been separated from production process by inspection routines being performed in a controlled lab. The system demonstrated the possibilities of an in-process automation of the quality control process that was feasible to be implemented for small and mid-sized manufacturing companies. The process involved an APSX horizontal injection mold machine dispensing parts onto the conveyor belt. The conveyor belt was controlled by a Phoenix Contact PLC and two line sensors that provided two stopping point for cooldown before inspection. A MyCobot 320-M5 robotic arm was used to select the part off the line and places it into a fixture on a Hexagon coordinate measuring machine (CMM).</p>

<p dir="ltr">The growing movement toward sustainable use of ocean resources is driven by the pressing need to alleviate environmental and human stressors on the planet and its oceans. From monitoring the food web to supporting sustainable fisheries and observing environmental shifts to protect against the effects of climate change, ocean observations significantly impact the Blue Economy. Acknowledging the critical role of Autonomous Underwater Vehicles (AUVs) in achieving persistent ocean exploration, this research addresses challenges focusing on the limited energy and storage capacity of AUVs, introducing a comprehensive underwater docking solution with a specific emphasis on enhancing the terminal homing phase through innovative vision algorithms leveraging neural networks.</p><p dir="ltr">The primary goal of this work is to establish a docking procedure that is failure-tolerant, scalable, and systematically validated across diverse environmental conditions. To fulfill this objective, a robust dock detection mechanism has been developed that ensures the resilience of the docking procedure through \comment{an} improved detection in different challenging environmental conditions. Additionally, the study addresses the prevalent issue of data sparsity in the marine domain by artificially generating data using CycleGAN and Artistic Style Transfer. These approaches effectively provide sufficient data for the docking detection algorithm, improving the localization of the docking station.</p><p dir="ltr">Furthermore, this work introduces methods to compress the learned docking detection model without compromising performance, enhancing the efficiency of the overall system. Alongside these advancements, a station-keeping algorithm is presented, enabling the mobile docking station to maintain position and heading while awaiting the arrival of the AUV. To leverage the sensors onboard and to take advantage of the computational resources to their fullest extent, this research has demonstrated the feasibility of simultaneously learning docking detection and marine wildlife classification through multi-task and transfer learning. This multifaceted approach not only tackles the limitations of AUVs' energy and storage capacity but also contributes to the robustness, scalability, and systematic validation of underwater docking procedures, aligning with the broader goals of sustainable ocean exploration and the blue economy.</p>

<p>    </p> <p>This thesis studies networked Gaussian linear control systems with random delays. Networked control systems is a popular topic these years because of their versatile applications in daily life, such as smart grid and unmanned vehicles. With the development of these systems, researchers have explored this area in two directions. The first one is to derive the inherent rate-cost relationship in the systems, that is the minimal transmission rate needed to achieve an arbitrarily given stability requirement. The other one is to design achievability schemes, which aim at using as less as transmission rate to achieve an arbitrarily given stability requirement. In this thesis, we explore both directions. We assume the sensor-to-controller channels experience independently and identically distributed random delays of bounded support. Our work separates into two parts. In the first part, we consider networked systems with only one sensor. We focus on deriving a lower bound, R_{LB}(D), of the rate-cost tradeoff with the cost function to be E{| <strong>x^</strong>T<strong>x </strong>|} ≤ D, where <strong>x </strong>refers to the state to be controlled. We also propose an achievability scheme as an upper bound, R_{UB}(D), of the optimal rate-cost tradeoff. The scheme uses lattice quantization, entropy encoder, and certainty-equivalence controller. It achieves a good performance that roughly requires 2 bits per time slot more than R_{LB}(D) to achieve the same stability level. We also generalize the cost function to be of both the state and the control actions. For the joint state-and-control cost, we propose the minimal cost a system can achieve. The second part focuses on to the covariance-based fusion scheme design for systems with multiple > 1 sensors. We notice that in the multi-sensor scenario, the outdated arrivals at the controller, which many existing fusion schemes often discard, carry additional information. Therefore, we design an implementable fusion scheme (CQE) which is the MMSE estimator using both the freshest and outdated information at the controller. Our experiment demonstrates that CQE out-performances the MMSE estimator using the freshest information (LQE) exclusively by achieving a 15% smaller average L2 norm using the same transmission rate. As a benchmark, we also derive the minimal achievable L2 norm, Dmin, for the multi-sensor systems. The simulation shows that CQE approaches Dmin significantly better than LQE. </p>

<p dir="ltr">Recent advancements in autonomous vehicle research and development have significantly enhanced their capabilities, largely due to innovations in sensor technology. Infrared (IR) sensing, in particular, has rapidly advanced to the point where sensors have been miniaturized and made commercially viable for integration into autonomous vehicles. While hardware advancements are notable, large-scale deployment requires rigorous testing to ensure reliability and safety.</p><p dir="ltr">Autonomous vehicle technology heavily relies on machine learning (ML) and object detection algorithms, which necessitate precisely annotated image data for effective training. Although IR sensors are commercially available, their acquisition at scale remains economically challenging, making it difficult to generate the necessary volume of data. Furthermore, annotating this data is resource-intensive, requiring significant human effort.</p><p dir="ltr">This research addresses these challenges by proposing a cost-effective and scalable solution: developing a virtual IR model within a virtual simulation environment using the hyper-realistic open-source graphics engine, Unreal Engine. While some proprietary solutions offer virtual IR sensing simulations, there is a significant gap in open-source options that are economically accessible to most researchers.</p><p dir="ltr">The proposed IR camera model is designed using Unreal Engine’s blueprint scripting and open-source object models, creating a virtual simulation environment capable of generating auto-annotated IR images at a rate of 60 frames per second. These images are then used to train a YOLO object detection model, which is subsequently applied to open-source real infrared images, simulating the actual use of IR camera-based object detection in autonomous vehicles. The resulting model demonstrates promising potential in providing a user-friendly, open-source virtual IR camera that can generate annotated images suitable for training object detection models.</p>

Les machines électriques jouent un rôle très important dans la conversion d'énergie dans plusieurs applications et domaines. Les contraintes thermiques jouent ainsi un rôle indispensable dans la conception des machines électriques de plus en plus petites et performantes. En effet, la performance des machines électriques est limitée par les températures maximales admissibles dans certaines zones critiques telles que le bobinage, les aimants permanents et les roulements. Deux approches principales peuvent être utilisées pour étudier le comportement thermique de la machine: la méthode nodale ou le circuit à constantes localisées ou les modèles numériques. Dans notre étude, nous proposons d'appliquer la méthode nodale sur une machine électrique intégrée dans un environnement mécatronique complexe. Le modèle thermique développé de la machine est ainsi présenté avec ses différents éléments. En effet, un modèle précis dépend fortement de plusieurs paramètres thermiques tels que les coefficients d'échange convectif, les conductances de contact, les conductivités équivalentes du bobinage, et autres paramètres. En conséquence, des techniques d'analyse de sensibilité sont ensuite appliquées sur le modèle thermique pour identifier les paramètres d'influence significative sur les températures de la machine ainsi que pour la réduction de ce modèle. Ensuite, nous appliquons deux méthodologies d'identification des paramètres thermiques incertains sont développées et appliquées afin de recaler le modèle thermique de la machine. Cette étape permet la validation de ce modèle par rapport à des mesures thermiques sur une machine synchrone à aimants permanents internes installée sur un banc de caractérisation de machine électriques. Finalement, nous intégrons le modèle recalé dans une approche système mécatronique comportant les lois de commande de la machine ainsi que son convertisseur. Ceci permettra ainsi d'étudier l'influence de la température d'une machine électrique sur le système mécatronique complet. / Electric machines play an important role in power conversion in several applications and fields. With the increasing demand for designing lighter and more efficient machines and optimizing the existing structures, thermal analysis becomes a necessary; in fact, the performance of electric machines islimited by the allowable temperatures in many critical components like windings, permanent magnetsand bearings. Two main approaches can be employed in order to study the machine thermal behavior : the lumped parameter thermal network (LPTN) or numerical models. Considering low-computationtime-consuming and the possibility to be integrated in a mechatronics system design, the LPTN method is considered in our study. The latter is mainly applied on electric machine integrated in a complex mechatronics environment. The thermal network is presented along with the definition of the principal elements constituting this network. In fact, an accurate and reliable network strongly depends on many critical parameters like heat transfer coefficients, interface gaps, impregnation goodness, among others. For this reason, different sensitivity analysis techniques are carried out in order to, first, identify the significance of uncertainties in the evaluation of these parameters on machine temperatures and second, to reduce the thermal network. Next, we propose two optimization algorithm-based identification methodologies in order to calibrate results of the thermal network with measured temperatures obtained from a test-bench of a permanent magnet based integrated starter-generator machine. The calibrated model is then integrated in a mechatronics system consisting of an electric model of the electric machine, along with its control strategy and the power converter. This final study allows us to evaluate the impact of the machine temperature rise on the mechatronic system.