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This thesis presents the design, simulation and real time implementation of control strategies of a subsea multiphase electric pump system, which consists of a pair of piston type pumps, a permanent magnet linear synchronous motor (PLSM) , a voltage source inverter and a control unit. The pump is required to operate efficiently and effectively for pure oil, pure gas, and for a mixture of the two.

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This study focuses on the evolving microstructure and its associated mechanical properties during each step of a seven step manufacturing process for 1010 steel tubing. For the microstructural analysis, we employed optical microscopy to quantify the ferrite grain size and pearlite grain size at each material step. To determine the mechanical properties, we used a Vickers hardness indenter and performed both tension and compression tests at varying strain rates and temperatures. Mechanical tests results indicate decreasing strength with increasing grain size, agreeing with the Hall-Petch relation and were used to correlate hardness and yield strength with grain size. Additionally, tensile and compression tests were performed at different strain rates to examine the effect of microstructural features on the mechanical properties of the steel tubing. Understanding the structure/property relationships of 1010 steel tubing during different processing conditions allows tubing to be manufactured more efficiently with desirable mechanical properties.

Heat shrink tubing is used to insulate wire conductors, protect wires, and to create cable entry seals in wire harnessing industries. Performing this sensitive process manually is time consuming, the results are strongly dependent on the operator’s expertise, and the process presents safety concerns. Alternatively, automating the process minimizes the operators’ direct interaction, decreases the production cost over the long term, and improves quantitative and qualitative production indicators dramatically. This thesis introduces the automation of a heat shrink tubing prototype machine that benefits the wire harnessing industry. The prototype consists of an instrumented heat chamber on a linear positioning system, and is fitted with two heat guns. The chamber design allows for the directing of hot air from the heat guns onto the wire harness uniformly through radially-distributed channels. The linear positioning system is designed to move the heat chamber along the wire harness as the proper shrinkage temperature level is reached. Heat exposure time as a major factor in the heat shrink tubing process can be governed by controlling the linear speed of the heat chamber. A control unit manages the actuator position continuously by measuring the chamber’s speed and temperature. A model-based design approach is followed to design and test the controller, and MATLAB/Simulink is used as the simulation environment. A programmable logic controller is selected as the controller implementation platform. The control unit performance is examined and its responses follow the simulation results with adequate accuracy.