In order to meet higher performance demands on brushless motor controllers, motor feedback signals must meet correspondingly higher standards. Brushless motor controllers require angular feedback for motor commutation, and generally for one or more of the following: torque, velocity or position regulation. These feedback categories impose different requirements on the control system. In many brushless motor applications, sinusoidal encoders have significant advantages over square-wave encoders. Signal processing techniques for sinusoidal encoder feedback signals are considered in the context of a brushless motor positioning system. In particular, a method is presented for correcting gain and offset measurement errors based on ellipse-fitting techniques. / Master of Science

<p>This thesis describes how an algorithm is transferred from a digital signal processor to an embedded microprocessor in an FPGA using C to hardware program from Altera.</p><p>Saab Avitronics develops the secondary high lift control system for the Boeing 787 aircraft. The high lift system consists of electric motors controlling the trailing edge wing flaps and the leading edge wing slats. The high lift motors manage to control the Boeing 787 aircraft with full power even if half of each motor’s stators are damaged. The motor is a PMDC brushless motor which is controlled by an advanced algorithm. The algorithm needs to be calculated by a fast special digital signal processor.</p><p>In this thesis I have tested if the algorithm can be transferred to an FPGA and still manage the time and safety demands. This was done by transferring an already working algorithm from the digital signal processor to an FPGA. The idea was to put the algorithm in an embedded NIOS II microprocessor and speed up the bottlenecks with Altera’s C to hardware program.</p><p>The study shows that the C-code needs to be optimized for C to hardware to manage the up speeding part, as the tests showed that the calculation time for the algorithm actually became longer with C to hardware. This thesis also shows that it is highly probable to use an FPGA equipped with Altera’s NIOS II safety critical microprocessor instead of a digital signal processor to control the electrical high lift motors in the Boeing 787 aircraft.</p>

This dissertation addresses the design, simulation, prototype, and test of a new energy generation system, which transforms rotational motion into electricity by the use of an innovative turbine-generator. The system is divided in two assembled subsystems that interact to finally transform kinetic energy into electricity. The first subsystem is a miniaturized notched impulse turbine system, and the second one is a millimeter permanent magnet generator (PMG) assembled into the turbine. The conversion of biomechanical energy to electric energy, using clean and free energy produced by a living organism, is being increasingly researched [1]-[11]. These are all viable options, but advantages and disadvantages of each type of energy conversions should be evaluated individually to determine key factors such as efficiency as an energy harvesting method, the implementation cost, size, and the final applications where they will be used. Through this dissertation, a new option of green energy conversion is made available; focusing on the use of turbines to extract energy from microfluidics, with diverse application in biomedical, military/aerospace, and home areas. These systems have the potential of converting mechanical movement energy, and hydraulic energy into electric energy that may be sufficient for self-powering nano/micro devices and nano/micro systems. A flow, with constant pressure, a magnetic generator, and a novel impulse turbine design are combined to form a self-contained miniaturized generator system. The turbine consists of two main parts: a bearingless rotor and the enclosure or casing; while the miniaturized magnetic generator is a permanent magnet brushless machine, consisting of permanent magnets in a ring configuration and radial coils. A permanent pressure, from microfluidic pressure system, is the force used to move the blades. This rotational motion of the turbine is transformed into electricity using magnetic induction, formed by permanent magnets on the rotor and nine coils fixed in the holder of the turbine. The electricity is generated when the magnetic field rotates and moves past the conductor, which induces a current according to Faraday's Law [1-3]. The system has potential uses not only in medical equipment, but in automotive applications, home appliances, and aquatic and ventilation systems.

This thesis describes how an algorithm is transferred from a digital signal processor to an embedded microprocessor in an FPGA using C to hardware program from Altera. Saab Avitronics develops the secondary high lift control system for the Boeing 787 aircraft. The high lift system consists of electric motors controlling the trailing edge wing flaps and the leading edge wing slats. The high lift motors manage to control the Boeing 787 aircraft with full power even if half of each motor’s stators are damaged. The motor is a PMDC brushless motor which is controlled by an advanced algorithm. The algorithm needs to be calculated by a fast special digital signal processor. In this thesis I have tested if the algorithm can be transferred to an FPGA and still manage the time and safety demands. This was done by transferring an already working algorithm from the digital signal processor to an FPGA. The idea was to put the algorithm in an embedded NIOS II microprocessor and speed up the bottlenecks with Altera’s C to hardware program. The study shows that the C-code needs to be optimized for C to hardware to manage the up speeding part, as the tests showed that the calculation time for the algorithm actually became longer with C to hardware. This thesis also shows that it is highly probable to use an FPGA equipped with Altera’s NIOS II safety critical microprocessor instead of a digital signal processor to control the electrical high lift motors in the Boeing 787 aircraft.

The design of this thesis intends to present that 120¢X Communication and Flux-Weakening Control techniques can be successfully applied to a Digital Signal Processor (DSP) together with the hardware structure of an inverter. Experimental results are shown that utilizing IPM Motor as Drive Motor of Electric Vehicle, 120¢X Communication techniques can reduce ripple torque and maintain the stability of output torque. Furthermore, through Phase advanced control motor, it enables a higher output torque during the mid-lower speed. Using Flux-Weakening Control helps motor from higher output speed to the highest output speed. Moreover, the security of motor driver can be enhanced by designing circuit, which prevents over voltage. The function of motor driver will be better due to the decreased hardware size and increased accuracy that are the advantage of writing DSP scripts to analyze rotor speed.

Gato del Sol III, was powered by a solar array of 480 Silicon mono-crystalline photovoltaic cells. Maximum Power Point trackers efficiently made use of these cells and tracked the optimal load. The cells were mounted on a fiber glass and foam core composite shell. The shell rides on a lightweight aluminum space frame chassis, which is powered by a 95% efficient brushless DC motor. Gato del Sol IV was the University of Kentucky Solar Car Team’s (UKSCT) entry into the American Solar Car Challenge (ASC) 2010 event. The car makes use of 310 high density lithium-polymer batteries to account for a 5 kWh pack, enough to travel over 75 miles at 40 mph without power generated by the array. An in-house battery protection system and charge balancing system ensure safe and efficient use of the batteries. Various electrical sub-systems on the car communicate among each other via Controller Area Network (CAN). This real time data is then transmitted to an external computer via RF communication for data collection.

Visando uma opção de substituição, onde for possível e aplicável, do motor de indução monofásico, este trabalho relata o estudo teórico, a construção, o acionamento e os ensaios de um motor bifásico com ímã permanente no rotor, de baixa potência, utilizando imãs de ferrita na confecção do rotor. / This work shows the theoretical studies, building, driving systems and tests of a small-power double-phase motor with ferrite permanent-magnet in the rotor, based on the original structure of a single-phase induction motor. The objective is to create an option to replace the single-phase induction motor where it is possible and applicable.

Visando uma opção de substituição, onde for possível e aplicável, do motor de indução monofásico, este trabalho relata o estudo teórico, a construção, o acionamento e os ensaios de um motor bifásico com ímã permanente no rotor, de baixa potência, utilizando imãs de ferrita na confecção do rotor. / This work shows the theoretical studies, building, driving systems and tests of a small-power double-phase motor with ferrite permanent-magnet in the rotor, based on the original structure of a single-phase induction motor. The objective is to create an option to replace the single-phase induction motor where it is possible and applicable.

Intralogistics, or material handling, traditionally use roller or chain conveyors to moveo bjects and goods in factories and warehouses. One negative aspect of the traditional types of conveyors is that they are expensive, as they are comprised of many moving parts. This thesis proposes a novel type of conveyor solution in which a transportation fixture with an integrated open thread slides on L­-shaped profiles and is propelled forward by a screw. A potential obstacle to the usefulness of such a conveyor is that a screw has innately low efficiency due to the mechanics of screws compared to the principle of rolling that is employed in a roller or chain conveyor. This thesis investigates the functionality and efficiency of the proposed conveyor, or more particularly the core functionality, which is the screw and thread mechanism. A test rig was designed and built, in which experiments were carried out. In the experiments, the material, manufacturing technology, and helix angle of the screw and thread, and the speed were varied. The influence on torque, power demand, and efficiency among other parameters were measured and evaluated. Additionally, a method for automatic thread meshing is presented and testing of it was carried out, which showed reliability with and without positional feedback, which gives the conveyor more use cases. It was found that the efficiency of the screw and thread mechanism was higher for screws with a higher lead, steel screws with a diameter of 50 mm exhibited an efficiency of 31% ± 4.5 % with a lead of 32 mm but only 8.7% ± 1.6 % with a lead of 8 mm. 3D printed plastic screws had slightly lower but similar early life efficiency as steel screws, but seized or wore down when tested in an accelerated lifetime experiment. Because a high screw lead is favorable, and because of the size and geometry constraints of such a conveyor (discussed in the conclusion of the report), a direct drive motoris not suitable, and instead a motor and gearbox combination is recommended. The conveyor shows promise as an alternative solution to traditional conveyors in low load applications. / Intralogistik, eller materialhantering, använder traditionellt rull-­ eller kedjetransportörer för att flytta gods i fabriker och lager. En negativ aspekt med dessa traditionella transportörer är att de är dyra, då de består av ett stort antal rörliga delar. Detta examensarbete föreslår en ny typ av transportör i vilken en transportfixtur med en inbyggd kuggstång glider på L­-formade profiler and drivs framåt av en skruv. Ett potentiellt hinder för denna typ av transportörs användbarhet är att en skruv naturligt har låg verkningsgrad på grund av skruvens mekanik i jämförelse med principen av rullning som används av rull- och kedjetransportörer. Detta examensarbete undersöker funktionaliteten och verkningsgraden av den föreslagna transportören, mer specifikt kärnfunktionaliten som är en skruv-­ och gängmekanism. En testrigg designades och byggdes, i vilken experiment utfördes. I experimenten varierades materialet och spiralvinkeln av skruven och gängan, samt hastigheten. Vridmomentet, effekten, verkningsgraden och andra parametrar mättes och utvärderades. Dessutom presenteras en metod för automatiskt gängingrepp som även testades, som visade sig vara tillförlitligt både med och utan positionsåterkoppling, vilket ger skruvtransportören fler användningsområden. Resultaten visade att verkningsgraden av skruv­ och gängmekanismen var högre för skruvar med högre spiralvinkel. Stålskruvar med en diameter på 50 mm visade på en verkningsgrad om 31% ± 4.5 % med en stigning på 32 mm men endast 8.7% ± 1.6 % med en stigning på 8 mm. 3D­-Printade plastskruvar hade något lägre men liknande verkningsgrad som stålskruvar i början av sin livslängd, men skar fast eller nöttes ned när de testades i ett långtidsexperiment. Eftersom hög stigning på skruven är fördelaktigt och på grund av de geometriska begränsningar av en sådan transportör (diskuteras i slutsatsen av rapporten), är det inte lämpligt att driva skruven direkt från en elmotor, utan istället rekommenderas en motorväxellådekombination. Transportören verkar lovande som ett alternativ till traditionella transportörer i applikationer med låg last.

Les travaux de thèse présentent une étude comparative d'actionneurs électromécaniques à course limitée régulant la position d'un obturateur dans une boucle d'air d'un moteur thermique. Les normes européennes sur la limitation des rejets polluants imposent de nouveaux besoins sur les performances dynamiques et mécaniques des actionneurs. Un état de l’art sur la boucle d’air des moteurs thermiques montre que deux topologies d'actionnements sont devenus majoritaires : l’une se compose d’un moteur à courant continu (MCC) à balais et d’une transmission de puissance par engrenage, l’autre est une machine sans balais à entraînement direct sur l’obturateur. La description de ces topologies montre une approche multiphysique utilisant la mécanique, l’électricité, le magnétisme, la thermique et l’automatique. À l'aide d'un cahier des charges, quatre architectures magnétiques de machines à entraînement direct ont été modélisées et optimisées en régime linéaire. Chaque machine est constituée d’aimants permanents au rotor et d’un circuit magnétique à dents polaires bobinées. De ces quatre machines, une d'entre elles est choisie sur le critère de la performance de couple par unité de volume en vu d'être optimiser sur le critère de la consommation minimale de l'énergie électrique. Pour jauger des résultats obtenus, la topologie MCC avec un réducteur à engrenage à deux étages de réduction est paramétrée et optimisée avec les mêmes contraintes et le même objectif. Les méthodes présentées associent les contraintes physiques et dynamiques sur le dimensionnement de l'actionneur et évoluent vers une optimisation de l'ensemble actionneur, électronique de puissance et loi de commande. / The present work deals with the development of limited motion actuators dedicated to the air flow regulation of internal combustion engines. Because of the recent European Standard applied to car manufacturers, new conceptions of internal combustion engines need a new air flow management such as the low pressure exhaust gas recirculation. According to a state of art on electromechanical actuators that manage the combustive flow, there are mainly two electric topologies for rotary movements: the first one is an indirect drive which is composed of a brushed DC motor associated with a reduction spur gear set, the second one is a direct drive with a brushless DC motor. The topologic analysis carried out in order to design these actuators is based on a multi-physics approach involving mechanical, electrical, magnetic, thermal behaviours and control laws. With requirements, four magnetic topologies have been modelized in linear behaviour and optimized to minimize the external volume. Each actuator is composed of two bipolar permanent magnets on the rotor and two polar teeth on the magnetic core. With an attractive criteria per volume unit torque for a limited stroke application, one of them is chosen to minimize the electrical energy consumption. In order to compare the results of this optimized actuator, a brushed motor and a two reduction stage gear set are modelized and optimized with the aim of minimizing the energy consumption with the same required performances. This approach associates physical and dynamical constraints on actuator designs and contributes to realize a global optimization of machine, power electronics and control law.