The Cal Poly CubeSat Laboratory (CPCL) is currently facing unprecedented engineering challenges—both technically and programmatically—due to the increasing cost and complexity of CubeSat flight missions. In responding to recent RFPs, the CPCL has been forced to find commercially available solutions to entire mission critical spacecraft subsystems such as propulsion and attitude determination & control, because currently no in-house options exist for consideration. The commercially available solutions for these subsystems are often extremely expensive and sometimes provide excessively good performance with respect to mission requirements. Furthermore, use of entire commercial subsystems detracts from the hands-on learning objectives of the CPCL by removing engineering responsibility from students. Therefore, if these particular subsystems can be designed, tested, and integrated in-house at Cal Poly, the result would be twofold: 1) the space of missions supportable by the CPCL under tight budget constraints will grow, and 2) students will be provided with unique, hands-on guidance, navigation, and control learning opportunities. In this thesis, the CPCL’s attitude determination and control system design and analysis toolkit is significantly improved to support in-house ADCS development. The toolkit—including the improvements presented in this work—is then used to complete the existing, partially complete CPCL ADCS design. To fill in missing gaps, particular emphasis is placed on guidance and control algorithm design and selection of attitude actuators. Simulation results show that the completed design is competitive for use in a large class of small satellite missions for which pointing accuracy requirements are on the order of a few degrees.

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The Hybrid Electric Vehicle Team of Virginia Tech (HEVT) is participating in the 2012-2014 EcoCAR 2: Plugging in to the Future Advanced Vehicle Technology Competition series organized by Argonne National Lab (ANL), and sponsored by General Motors Corporation (GM) and the U.S. Department of Energy (DOE). The goals of the competition are to reduce well-to-wheel (WTW) petroleum energy consumption (PEU), WTW greenhouse gas (GHG) and criteria emissions while maintaining vehicle performance, consumer acceptability and safety. Following the EcoCAR 2 Vehicle Development Process (VDP) of designing, building, and refining an advanced technology vehicle over the course of the three year competition using a 2013 Chevrolet Malibu donated by GM as a base vehicle, the selected powertrain is a Series-Parallel Plug-In Hybrid Electric Vehicle (PHEV) with P2 (between engine and transmission) and P4 (rear axle) motors, a lithium-ion battery pack, an internal combustion engine, and an automatic transmission. Development of a charge sustaining control strategy for this vehicle involves coordination of controls for each of the main powertrain components through a distributed control strategy. This distributed control strategy includes component controllers for each individual component and a single supervisory controller responsible for interpreting driver demand and determining component commands to meet the driver demand safely and efficiently. For example, the algorithm accounts for a variety of system operating points and will penalize or reward certain operating points for other conditions. These conditions include but are not limited to rewards for discharging the battery when the state of charge (SOC) is above the target value or penalties for operating points with excessive emissions. Development of diagnostics and remedial actions is an important part of controlling the powertrain safely. In order to validate the control strategy prior to in-vehicle operation, simulations are run against a plant model of the vehicle systems. This plant model can be run in both controller Software- and controller Hardware-In-the-Loop (SIL and HIL) simulations. This paper details the development of the controls for diagnostics, major selection algorithms, and execution of commands and its integration into the Series-Parallel PHEV through the supervisory controller. This paper also covers the plant model development and testing of the control algorithms using controller SIL and HIL methods. This paper details reasons for any changes to the control system, and describes improvements or tradeoffs that had to be made to the control system architecture for the vehicle to run reliably and meet its target specifications. Test results illustrate how changes to the plant model and control code properly affect operation of the control system in the actual vehicle. The VT Malibu is operational and projected to perform well at the final competition. / Master of Science

Les contrôleurs industriels font l’objet de changements de paramètres, de modifications, d’améliorations en permanence. Ils subissent les évolutions technologiques aussi bien matérielles que logicielles (librairies, système d’exploitation, loi de commande...). Malgré ces contraintes, ces contrôleurs doivent obligatoirement assurer toutes les fonctionnalités recouvrant le séquentiel, les protections, l’interface homme machine et la stabilité du système à contrôler. Ces fonctionnalités doivent être couvertes pour une large gamme d’applications. Chaque modification (matérielle ou logicielle) quoique mineure est risquée. Le debogage, l’analyse et la programmation sur site sont énormément coûteux surtout pour des sites de type offshore ou marine. Les conditions de travail sont difficiles et les tests sont réduits au strict minimum. Cette thèse propose deux niveaux de validation en plateforme d’expérimentation : un niveau de validation algorithmique que l’on appelle Validation par Interface Logicielle (VIL) traitée au chapitre 2 ; un niveau de validation physique que l’on appelle Validation par Interface Matérielle (VIM) traitée au chapitre 3. La VIL valide uniquement l’aspect algorithme, la loi de commande et la conformité des références au niveau calcul sans prendre en compte les signaux de commande physiques et les signaux de retour gérés par l’Unité de Gestion des Entrées/Sorties (UGES). Un exemple de validation d’un contrôleur industriel d’un ensemble convertisseur trois niveaux et machine asynchrone est traité dans le deuxième chapitre avec une modélisation particulièrement adaptée à la VIL. Le dernier chapitre traite la VIM sur différentes bases matérielles (Field Programmable Gate Array (FPGA), processeurs). Cette validation prend en compte l’aspect algorithme et les signaux de commande physique ainsi que les signaux de retour. On y présente plusieurs approches de modélisation, choisies selon la base matérielle d’implémentation du simulateur temps réel. Ces travaux ont contribué aujourd’hui à au processus de validation des contrôleurs dédiés aux applications Oil and Gaz et Marine de General Electric - Power Conversion © (GE-PC) / Industrial controllers are always subjected to parameters change, modifications and permanent improvements. They have to follow off-the-shelf technologies as well as hardware than software (libraries, operating system, control regulations ...). Apart from these primary necessities, additional aspects concerning the system operation that includes sequential, protections, human machine interface and system stability have to be implemented and interfaced correctly. In addition, these functions should be generically structured to be used in common for wide range of applications. All modifications (hardware or software) even slight ones are risky. In the absence of a prior validation system, these modifications are potentially a source of system instability or damage. On-site debugging and modification are not only extremely expensive but can be highly risky, cumulate expenditure and reduce productivity. This concerns all major industrial applications, Oil & Gas installations and Marine applications. Working conditions are difficult and the amount of tests that can be done is strictly limited to the mandatory ones. This thesis proposes two levels of industrial controller validation which can be done in experimental test platform : an algorithm validation level called Software In the Loop (SIL) treated in the second chapter ; a physical hardware validation called Hardware In the Loop (HIL) treated in the third chapter. The SIL validates only the control algorithm, the control law and the computed references without taking into account neither the actual physical commands nor the physical input feedbacks managed by the Input/Output boards. SIL validation of the system where industrial asynchronous motor is fed and regulated by a three level Variable Speed Drive with a three level voltage source converter is treated in the second chapter with a particular modeling approach adapted to such validation. The last chapter presents the HIL validation with various hardware implementations (Field Programmable Gate Array (FPGA), processors). Such validation checks both the control algorithm and the actual physical Input/Output signals generated by the dedicated boards. Each time, the modeling approach is chosen according to the hardware implementation. Currently this work has contributed to the system validation used by General Electric - Power Conversion © (GE-PC) as part of their validation phase that is mandatory for Oil & Gas projects and Marine applications

Over the last few decades, the complexity and variety of automation systems have increased dramatically. Commissioning has grown more and more critical for the entire industry. Conventional commissioning is time-consuming and expensive. It's always been a challenge in manufacturing to put new designs into production or implement new technologies, control codes, or tactics. In Virtual Commissioning (VC), control programs of the physical system's Digital Twin (DT) can be validated in Software-in-the-Loop (SIL) before the actual commissioning. The emergence of new VC tools and methods has become a tremendous advantage, bringing the values of shorter duration, flexibility, and lower risks to the commissioning process. In this thesis, advanced process control was developed using the software Matlab and Simulink in conjunction with the engineering tools S7-PLCSIM Advanced and STEP 7 TIA Portal to conduct VC. A VC approach with four key steps is taken to evaluate the possibility of validating advanced process control. The steps are modeling DT of a rolling mill, model-based control design, simulation model development in Simulink, communication between the simulation model and the PLC program using S-7 TIA Portal, and PLCSIM Advanced. Also, a simulated Human-Machine Interface was designed to operate and visualize the process. VC of the rolling mill process was verified and validated by Model-in-the-Loop (MIL) and SIL simulation. The simulation gives satisfactory results as both MIL and SIL show identical outputs of the process.

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Electric and hybrid-electric vehicles lean heavily on intricate control algorithms to provide smooth, reliable, and secure operations under any driving conditions. Three distinct supervisory control strategies have been developed, each aiming to improve reliability and vehicle performance of a dual-motor electric vehicle equipped with an all-wheel-drive, fully electric powertrain. These algorithms are adept at dynamically modulating and constraining the torque provided to the wheels, leveraging two autonomous permanent magnet electric drive units. This study utilizes a vehicle model jointly provided by MathWorks and General Motors in partnership with industry sponsors. The these strategies were implemented in the model and enhanced the performance, vehicle range, energy consumption, regenerated energy using specific EDUs provided by sponsors. Adhering to a systematic engineering iterative method, the emphasis was heavily placed on simulation and modeling during the development and validation of these strategies. Simulations ensured robust testing before field implementation, emphasizing software modeling's vital role.

Electric drives are crucial components of powertrain of modern vehicles. They need to be controlled effectively to deliver a comfortable and efficient driving experience. The control unit needs to be robust to handle extreme operating conditions and faults in a safe manner. Hardware in Loop (HIL) setups can be used to develop such control units for majority of real-life test cases, without involving physical drives. Typical HIL setup includes the controller (hardware) under test connected to a high fidelity computer model of the controlled system (plant). Thanks to the efficient, inexpensive, consistent and nondestructive nature of HIL setups, they are widely used for research and development in the automotive industry. This thesis focuses on developing such a HIL setup for latest electric drive architecture at Scania CV AB. In this thesis, the plant models are programmed onto a field programmable gate array (FPGA). The HIL setup, plant models and the controller are continuously improved throughout the thesis to achieve higher fidelity and real time replication of the internal permanent magnet synchronous machine under consideration. Software in Loop (SIL) strategy, wherein all components are represented by computer models, is also applied for rapid developments. Several aspects like flux linkage-based and inductance-based machine models, choice of arithmetic, discretization methods, noise, delays, etc. are studied and optimised during the thesis. Validation is conducted for both SIL and HIL setups and above 95% correlation with physical drive’s performance is reported. Stable operation and repeatability of the developed HIL setup ensure that the framework is scalable to be applied to other drives and control units. / Elektriska drivenheter är centrala komponenter i drivlinan hos moderna elektriska fordon. Drivenheterna måste regleras effektivt för att ge en bekväm och effektiv körupplevelse. Regulatorn måste vara robust för att säkert hantera extrema driftsförhållanden och fel. Hardware in Loop (HIL) simuleringar kan användas för att utveckla sådana regulatorer för de flesta verkliga testfall, utan att involvera de fysiska komponenterna. En typisk HIL-installation inkluderar styrenheten (hårdvaran) som testas ansluten till en datormodell av det kontrollerade systemet (anläggningen). På grund av den effektiva, billiga, konsekventa och oförstörande naturen hos HIL simuleringar används de i stor utsträckning för FoU inom fordonsindustrin. Detta examensarbete fokuserar på att utveckla en sådan HIL-modell för en elektrisk drivlina hos Scania CV AB. I detta examensarbete är anläggningsmodellerna programmerade på en programmerbar integrerad krets. HIL-inställningen, anläggningsmodellerna och styrenheten förbättras kontinuerligt under hela examensarbetet för att uppnå högre kvalitet och realtidsreplikering av den permanentmagnetiserade synkronmaskin som övervägs. En Software in Loop (SIL) strategi, där alla komponenter representeras av datormodeller, tillämpas också för snabb utveckling. Flera aspekter såsom flödesbaserade och induktansbaserade maskinmodeller, val av aritmetik, diskretiserings metoder, brus, fördröjningar etc. studeras och optimeras. Validering utförs för både SIL- och HIL-inställningar och över 95% korrelation med fysiska enhetsprestanda erhålls. Stabil drift och repeterbarhet av den utvecklade HIL-kretsen säkerställer att ramverket är skalbart för att kunna appliceras på andra enheter och regulatorer.