APRIL 9 TH 2016 COLOMBO, SRI LANKA. M A H E S H S H I N D E (FELLOW IMechE & CEng) Tata Motors Limited, Pune (INDIA)

Transcription

1 M A H E S H S H I N D E (FELLOW IMechE & CEng) Tata Motors Limited, Pune (INDIA)

2 Agenda Scope NEED OVERVIEW CONFLUENCE Engineering / Technologies INDUSTRY SECTORS Structural, Manufacturing, Automotive APPLICATIONS FUTURE Q&A

3 GTODAY G YESTER-YEARS!

4 Requisites BASIC PREMISE AGGREGATES CONTROLS NEED OF CONTROL Design/Process Optimization Power to weight Performance Regulation Cost effective Longevity, Reliability Abuses Multiple Environment Variable conditions Safety Specialization Time Response STRUCTURAL MECHANICAL ELECTRICAL ELECTRONIC LOADS VIBRATION TEMPERATURE HUMIDITY ELECTRICAL I/O DUTY CYCLE / USAGE PATTERN USER HABITS ABUSE

5 THE SYSTEM ELEMENTS : Synergy Wheel E N G I N E E R I N G C O N F L U E N C E COMPUTERS Hardware design Software Algorithms MECHANICAL Systems Mechanisms Automation MECH-A- TRONICS µ-processor CONTROL S/W INTERFACE ELECTRONICS Circuits I/O signals Circuits

6 System Elements Motors Pneumatic Hydraulic Electrical (Magnetic) Piezoelectric (Electrostatic) Chemical (Fuel motors) MECHANICAL SYSTEM System model Dynamic response SENSORS SWITCHESS ENCODERS, MEMs ACCELEROMETERS STRAIN GAGES THERMOCOUPLES ACTUATORS SOLENOIDS VOICE COILS SERVO MOTORS HYDRAULIC PNEUMATIC I/P Signal Conditioning & INTERFACE AMPLIFIERS FILTERS A D, D D Actuators Sequence Loading Volume Surrounding Construction Costs Efficiency Magnetic Electrical Mechanical Thermal DISPLAYS LED / LCD DIGI. SCREENS CRT HMI / MMI VMM O/P Signal Conditioning & INTERFACE AMPLIFIERS PWM Power TRANSISTORS A D, D D CONTROLLERS / DRIVE MICROCONTROLLER PLC, ALGORITHMS LOGIC, SEQUENCE TIME, ARITHMETIC COMMUNICATION ASD, VFD, VVVF, VFI, VVI Real Time Operating System (RTOS)

7 Control System Motoring Torque Rated Torque Modern VVVF Drive Asynchronous/Induction Motor (Synchronous/PM Motor) INVERTOR DRIVES Adjustable Speed Drive (ASD) Adjustable Frequency Drive (AFD) Variable Speed Drive (VSD) Variable Frequency Drive (VFD) Variable Frequency Variable Voltage (VVVF) Variable Frequency Input (VFI) Current Source Input (CSI) Pulse Width Modulation (PWM) AC DC FILTERING Slow Rotor Rotation (Lagging Rotor Position) Motoring Slip (Motoring Angle) DIGITAL O/P PULSE TRAIN Rated Slip RPM (Power Angle) Synchronous Speed (& Electrical Position) VARY Hz / V to STATOR Faster Rotor Rotation (Leading Rotor Position) Regenerative Slip (Regenerative Angle) VECTOR CONTROL OPEN LOOP CLOSE LOOP CONTROL / DRIVES - METRICS Energy Saving Low Mech./Thermal stresses Simple Installation Stator frequency control Current LIMITER (not controller) High application η% Better control Speed/torque/force Speed inverse to load Wide Speed Range Low inertia requirement Distortion Heating

8 Piping & Structures Control system application (linked to Mechanical, Electronic, Information Groups) Structural Piping systems : Power/Individual/Bilge pumping Pumps Compressors, Motors Piping Valves (Actuators) Filters Separators Drives/Controller Software (Control algorithm) Control parameters : Volume, Force, Rate, Speed, Response time, Accuracy, Displacement Blending / Mixing / Metering Loss : Efficiency Physical Characters Function / Operation Environment : External & Internal Safety, Security, HAZMAT Software & Hardware constraints Hygiene, Contamination, Non contact requirements Safety, Regulations Usage pattern & learn/teach requirements Interfaces Continuous Operation, Low maintenance Low energy, High efficiency ECONOMY BIM (Software) HVAC,WATER,SECURITY

9 Engineering CONVERTOR ACTUATOR TRANSMITER LOAD CONTROLS Power Energy Distributed Control Systems Microprocessor / PLCs I/O Engineering Industries Processes Chemical Refining Food / Beverage Pulp/Paper CONTROLLER / PROTECTION UNIT SAFETY / ADJUST. VALUE ON/OUT CURRENT SENSOR VELOCITY SENSOR NC / CNC Embedded Circuits (board) Sensors / Measurement Motor control Motion control Machine / process vision Manufacturing FMCG/Consumables Pharma/Bio-Medicine Material Handling Structiural Automotive HMI S M GPS Time Industrial Camera Pick and place S S S Controller Motion Bad product Good product Drive Controller Distributed I/O Motion Controller Ethernet Switch

10 Engineering Typical Case Electro-Pneumatic layout Fixed & variable speed Pressure boosting Microprocessor Optimum efficiency Low installation Robust Reliable Chassis Module Weld Fixture

11 Automotive Systems Photo source Credit: Internet

12 TYPICAL CAR ELECTRONICS ARCHITECTURE

13 HIL Simulator IPG-ROAD IPG-DRIVER IPG-TIRE IPG-CAR Brake Torques Pressure Master cylinder ESP - Hydraulic Brake System Throttle position.. ESP Torque Request Engine throttle position engine speed engine torque. Engine speed & torque Powertrain Wheel speed Wheel torque Magnetic Valve Positions - Pressure master cylinder - Lateral acceleration - Yaw rate - Steering angle - Wheel speed CAN Gate I/O Fail SafeTester CAN-Stress CAN-Bus 1 K-line* Power Supply TEST RIG ABS/ESP ECU CAN-Bus 2 * bi-direction, 1 wire interface for data transfer/diagnostics

14 Automotive Engineering Functional Testing Events Simulation and Monitoring Electrical/Electronic Load simulation (Lab-Car) Diagnostics testing Communication testing Sub-System integration Feedback for close loop test setup control Drive control : Lab-view GUI Control and Monitor : MATLAB PXI 1031 Air bag systems and satellite crash sensors Anti-lock braking systems Electronic Power Assisted Steering (EPAS) Electronic Stability Control (ESC) Near Object Detection Systems (NODS) Collision avoidance systems Head Up Displays (HUD) Advanced Driver Assistance Systems (ADAS) Tire Pressure Monitoring Systems (TPMS) Parking Assist Blind Spot Detection, Advanced Cruise Control Lighting System Wiping System Remote Key Entry (RKE) Diagnostic implementation check IVN Networking - Remote Location control : Robot - Control through portable devices - Networking : Machine to Machine (M2M) - Multiple &/or concurrent operations - Connectivity & Dependency - Real Time computation Mobile - Diagnostic & Maintain (FTP) server - Learning & course correction - Building blocks : HMI, MMI, VMM - Close loop control - Disaster/Emergency Management

15 Automotive Systems : Internet of things (IoT) Photo source Credit: Internet

16 SPECULATIVE..? Internet of Things... AUTONOMOUS..? Pre-collision / Adaptive control Uplinked (FTP) Corrections Central Server Intervention ADAPTIVE..? i-steering..? Emergency Alerts Service / Authorities / Hospital Dynamic 3-D maps SbW / X-by-Wire Driver Alerts Driving Environment Block abuse Images source credit : Internet

17 SUMMARY Extract Fission of basic engineering into specialized technologies. Two or multiple technologies Synergistically evolves Co-creation. Results are always better, (most of the times) exponentially. Control parameters/requirements effects the configuration of devices. The future is in better advancements & remote operations through Internet. Emphasis will be on efficient, smart and safest operations (Machines/cars!)

18 Q & A Q uestions? Contact mahesh.shinde@tatamotors.com Cell : No part of this work may be copied, reproduced and distributed in any form or by any means without expressed written consent from Tata Motors Limited, India. Image source credit : Internet