A roller test bench for the evaluation of automotive vehicle noise, vibration and harshness
- Authors: Raffler, Oliver
- Date: 2015
- Subjects: Motor vehicles -- Transmission devices -- Noise Mechanical engineering Automobiles -- Noise
- Language: English
- Type: Thesis , Masters , MEngineering
- Identifier: http://hdl.handle.net/10948/21646 , vital:29728
- Description: The purpose of this thesis is the construction of a test bench for the assessment of the NVH behaviour of a newly manufactured VW Polo 5. This will be done in collaboration with Volkswagen South Africa. Firstly, in order to gain a better understanding of the requirements such a test bench has to fulfill, the VW Polo, the guidelines prescribed by VW as well as the actual testing procedure implemented by VW Uitenhage will be analysed. Thereafter, the main section of the thesis will deal with the construction of the test bench. As agreed upon with Volkswagen Uitenhage, a test bench will be built during the course of the studies. This test bench will allow stimulation in low frequency as well as high frequency ranges and in addition to that, a second version of the test bench with optimised costing will be derived from the first one. The second model will only allow stimulation in high frequency ranges. During the thesis, a version of the test bench, the RTB-HC, has been developed which enables the stimulation of the high and low frequencies. In addition, a cost optimized version was developed. This version will be referred as RTB-LC. This version allows only a high frequency excitation.
- Full Text:
- Date Issued: 2015
- Authors: Raffler, Oliver
- Date: 2015
- Subjects: Motor vehicles -- Transmission devices -- Noise Mechanical engineering Automobiles -- Noise
- Language: English
- Type: Thesis , Masters , MEngineering
- Identifier: http://hdl.handle.net/10948/21646 , vital:29728
- Description: The purpose of this thesis is the construction of a test bench for the assessment of the NVH behaviour of a newly manufactured VW Polo 5. This will be done in collaboration with Volkswagen South Africa. Firstly, in order to gain a better understanding of the requirements such a test bench has to fulfill, the VW Polo, the guidelines prescribed by VW as well as the actual testing procedure implemented by VW Uitenhage will be analysed. Thereafter, the main section of the thesis will deal with the construction of the test bench. As agreed upon with Volkswagen Uitenhage, a test bench will be built during the course of the studies. This test bench will allow stimulation in low frequency as well as high frequency ranges and in addition to that, a second version of the test bench with optimised costing will be derived from the first one. The second model will only allow stimulation in high frequency ranges. During the thesis, a version of the test bench, the RTB-HC, has been developed which enables the stimulation of the high and low frequencies. In addition, a cost optimized version was developed. This version will be referred as RTB-LC. This version allows only a high frequency excitation.
- Full Text:
- Date Issued: 2015
Closed-loop temperature control of friction stir welding
- Authors: Pothier, Raymond Peter
- Date: 2015
- Subjects: Friction welding
- Language: English
- Type: Thesis , Masters , MEngineering
- Identifier: http://hdl.handle.net/10948/10362 , vital:26656
- Description: This study develops and presents a friction stir weld (FSW) quality assurance tool based on control of weld zone temperature. Apart from correct tool geometry, tool tilt angle, traverse speed and forge force during welding, one important requirement is that the weld material be sufficiently plasticised (softened). The level of plasticisation is related to weld zone temperature which is primarily dependent on spindle speed, traverse speed and forge force. When all other conditions are correct, sufficiently plasticised material flows around and consolidates behind the tool without the production of voids in the weld. Typically, weld temperature varies along the weld length which may result in variations in weld quality. Weld zone temperature control makes constant weld zone temperature possible. In this study, thermocouple sensors were embedded in the FSW tool and a weld zone temperature control algorithm was developed. Spindle speed was the actuating mechanism for controlling weld temperature. The system was modelled and controllers were designed using Matlab tools. The system was simulated and the performance was compared to the system performance during welding. The control system ensures that the weld zone temperature can be maintained irrespective of the presence of thermal disturbances. Tensile testing was conducted which confirmed a range of temperature in which the welds resulted in consistent strength.
- Full Text:
- Date Issued: 2015
- Authors: Pothier, Raymond Peter
- Date: 2015
- Subjects: Friction welding
- Language: English
- Type: Thesis , Masters , MEngineering
- Identifier: http://hdl.handle.net/10948/10362 , vital:26656
- Description: This study develops and presents a friction stir weld (FSW) quality assurance tool based on control of weld zone temperature. Apart from correct tool geometry, tool tilt angle, traverse speed and forge force during welding, one important requirement is that the weld material be sufficiently plasticised (softened). The level of plasticisation is related to weld zone temperature which is primarily dependent on spindle speed, traverse speed and forge force. When all other conditions are correct, sufficiently plasticised material flows around and consolidates behind the tool without the production of voids in the weld. Typically, weld temperature varies along the weld length which may result in variations in weld quality. Weld zone temperature control makes constant weld zone temperature possible. In this study, thermocouple sensors were embedded in the FSW tool and a weld zone temperature control algorithm was developed. Spindle speed was the actuating mechanism for controlling weld temperature. The system was modelled and controllers were designed using Matlab tools. The system was simulated and the performance was compared to the system performance during welding. The control system ensures that the weld zone temperature can be maintained irrespective of the presence of thermal disturbances. Tensile testing was conducted which confirmed a range of temperature in which the welds resulted in consistent strength.
- Full Text:
- Date Issued: 2015
Design of a low-cost autonomous guided cart for material handling
- Authors: Cawood, Gareth James
- Date: 2015
- Subjects: Automobiles -- Design and construction , Automobiles -- Automatic control , Vehicles -- Automatic control
- Language: English
- Type: Thesis , Masters , MEngineering
- Identifier: vital:9655
- Description: This dissertation covers the design and manufacture of an autonomous guided cart (AGC) for use in the material handling industry. General Motors South Africa (GMSA) requires a low-cost AGC for use in their Struandale plant. A budget of R35 000 per unit was proposed. The researcher, in collaboration with staff at GM, compiled a list of engineering requirements for the AGC. After research into the unique problems of the project, an examination of a previous design attempt by staff of GM Thailand, the researcher developed a new design, the subject of this report. Different solutions for each design problem were investigated before the design was finalised. A three-wheeled vehicle was designed making use of two motors in a differential-drive setup to control motion. Navigation is via a line-following mechanism, using an induction sensor-array in conjunction with a pre-laid metallic strip. To aid the design, the system was modelled to understand the different control elements at play. The researcher developed software for several aspects of the design: for the PLC controlling the system and motors; for a microcontroller that communicates with the PLC and a wireless module; for a computer server that communicates with a second wireless device, receiving information from the PLC; and a web interface to view this information. These form the SCADA integration of the project. The final product meets the GMSA specifications. It is a robot capable of towing a trolley of mass not exceeding 350 kg. While the robot is able to navigate a pre-laid route, it cannot reliably stop at marked locations. It is possible to monitor the system via a web-interface. The robot is capable of operating for an entire 8-hour shift before the batteries need to be recharged. The total cost of the prototype was R26 340.
- Full Text:
- Date Issued: 2015
- Authors: Cawood, Gareth James
- Date: 2015
- Subjects: Automobiles -- Design and construction , Automobiles -- Automatic control , Vehicles -- Automatic control
- Language: English
- Type: Thesis , Masters , MEngineering
- Identifier: vital:9655
- Description: This dissertation covers the design and manufacture of an autonomous guided cart (AGC) for use in the material handling industry. General Motors South Africa (GMSA) requires a low-cost AGC for use in their Struandale plant. A budget of R35 000 per unit was proposed. The researcher, in collaboration with staff at GM, compiled a list of engineering requirements for the AGC. After research into the unique problems of the project, an examination of a previous design attempt by staff of GM Thailand, the researcher developed a new design, the subject of this report. Different solutions for each design problem were investigated before the design was finalised. A three-wheeled vehicle was designed making use of two motors in a differential-drive setup to control motion. Navigation is via a line-following mechanism, using an induction sensor-array in conjunction with a pre-laid metallic strip. To aid the design, the system was modelled to understand the different control elements at play. The researcher developed software for several aspects of the design: for the PLC controlling the system and motors; for a microcontroller that communicates with the PLC and a wireless module; for a computer server that communicates with a second wireless device, receiving information from the PLC; and a web interface to view this information. These form the SCADA integration of the project. The final product meets the GMSA specifications. It is a robot capable of towing a trolley of mass not exceeding 350 kg. While the robot is able to navigate a pre-laid route, it cannot reliably stop at marked locations. It is possible to monitor the system via a web-interface. The robot is capable of operating for an entire 8-hour shift before the batteries need to be recharged. The total cost of the prototype was R26 340.
- Full Text:
- Date Issued: 2015
Single event upset testing of flash based field programmable gate arrays
- Authors: Potgieter, Juan-Pierre
- Date: 2015
- Subjects: Field programmable gate arrays
- Language: English
- Type: Thesis , Masters , MEngineering
- Identifier: http://hdl.handle.net/10948/12520 , vital:27083
- Description: In the last 50 years microelectronics have advanced at an exponential rate, causing microelectronic devices to shrink, have very low operating voltages and increased complexities; all this has made circuits more sensitive to various kinds of failures. These trends allowed soft errors, which up until recently was just a concern for space application, to become a major source of system failures of electronic products. The aim of this research paper was to investigate different mitigation techniques that prevent these soft errors in a Video Graphics Array (VGA) controller which is commonly used in projecting images captured by cameras. This controller was implemented on a Flash Based Field Programmable Gate array (FPGA). A test set-up was designed and implemented at NRF iThemba LABS, which was used to conduct the experiments necessary to evaluate the effectiveness of different mitigation techniques. The set-up was capable of handling multiple Device Under Tests (DUT) and had the ability to change the angle of incidence of each DUT. The DUTs were radiated with a 66MeV proton beam while the monitoring equipment observed any errors that had occurred. The results obtained indicated that all the implemented mitigation techniques tested on the VGA system improved the system’s capability of mitigating Single Event Upsets (SEU). The most effective mitigation technique was the OR-AND Multiplexer Single Event Transient (SET) filter technique. It was thus shown that mitigation techniques are viable options to prevent SEU in a VGA controller. The permanent SEU testing set-up which was designed and manufactured and was used to conduct the experiments, proved to be a practical option for further microelectronics testing at iThemba LABS.
- Full Text:
- Date Issued: 2015
- Authors: Potgieter, Juan-Pierre
- Date: 2015
- Subjects: Field programmable gate arrays
- Language: English
- Type: Thesis , Masters , MEngineering
- Identifier: http://hdl.handle.net/10948/12520 , vital:27083
- Description: In the last 50 years microelectronics have advanced at an exponential rate, causing microelectronic devices to shrink, have very low operating voltages and increased complexities; all this has made circuits more sensitive to various kinds of failures. These trends allowed soft errors, which up until recently was just a concern for space application, to become a major source of system failures of electronic products. The aim of this research paper was to investigate different mitigation techniques that prevent these soft errors in a Video Graphics Array (VGA) controller which is commonly used in projecting images captured by cameras. This controller was implemented on a Flash Based Field Programmable Gate array (FPGA). A test set-up was designed and implemented at NRF iThemba LABS, which was used to conduct the experiments necessary to evaluate the effectiveness of different mitigation techniques. The set-up was capable of handling multiple Device Under Tests (DUT) and had the ability to change the angle of incidence of each DUT. The DUTs were radiated with a 66MeV proton beam while the monitoring equipment observed any errors that had occurred. The results obtained indicated that all the implemented mitigation techniques tested on the VGA system improved the system’s capability of mitigating Single Event Upsets (SEU). The most effective mitigation technique was the OR-AND Multiplexer Single Event Transient (SET) filter technique. It was thus shown that mitigation techniques are viable options to prevent SEU in a VGA controller. The permanent SEU testing set-up which was designed and manufactured and was used to conduct the experiments, proved to be a practical option for further microelectronics testing at iThemba LABS.
- Full Text:
- Date Issued: 2015
Total ionizing dose and single event upset testing of flash based field programmable gate arrays
- Authors: Van Aardt, Stefan
- Date: 2015
- Subjects: Field programmable gate arrays Application-specific integrated circuits
- Language: English
- Type: Thesis , Masters , MEngineering
- Identifier: http://hdl.handle.net/10948/12548 , vital:27090
- Description: The effectiveness of implementing field programmable gate arrays (FPGAs) in communication, military, space and high radiation environment applications, coupled with the increased accessibility of private individuals and researchers to launch satellites, has led to an increased interest in commercial off the shelf components. The metal oxide semiconductor (MOS) structures of FPGAs however, are sensitive to radiation effects which can lead to decreased reliability of the device. In order to successfully implement a FPGA based system in a radiation environment, such as on-board a satellite, the single event upset (SEU) and total ionizing dose (TID) characteristics of the device must first be established. This research experimentally determines a research procedure which could accurately determine the SEU cross sections and TID characteristics of various mitigation techniques as well as control circuits implemented in a ProASIC3 A3P1000 FPGA. To gain an understanding of the SEU effects of the implemented circuits, the test FPGA was irradiated by a 66MeV proton beam at the iTemba LABS facility. Through means of irradiation, the SEU cross section of various communication, motor control and mitigation schemes circuits, induced by high energy proton strikes was investigated. The implementation of a full global triple modular redundancy (TMR) and a combination of TMR and a AND-OR multiplexer filter was found to most effectively mitigate SEUs in comparison to the other techniques. When comparing the communication and motor control circuits, the high frequency I2C and SPI circuits experienced a higher number of upsets when compared to a low frequency servo motor control circuit. To gain a better understanding of the absorbed dose effects, experimental TID testing was conducted by irradiating the test FPGA with a cobalt-60 (Co-60) source. An accumulated absorbed dose resulted in the fluctuation of the device supply current and operating voltages as well as resulted in output errors. The TMR and TMR filtering combination mitigation techniques again were found to be the most effective methods of mitigation.
- Full Text:
- Date Issued: 2015
- Authors: Van Aardt, Stefan
- Date: 2015
- Subjects: Field programmable gate arrays Application-specific integrated circuits
- Language: English
- Type: Thesis , Masters , MEngineering
- Identifier: http://hdl.handle.net/10948/12548 , vital:27090
- Description: The effectiveness of implementing field programmable gate arrays (FPGAs) in communication, military, space and high radiation environment applications, coupled with the increased accessibility of private individuals and researchers to launch satellites, has led to an increased interest in commercial off the shelf components. The metal oxide semiconductor (MOS) structures of FPGAs however, are sensitive to radiation effects which can lead to decreased reliability of the device. In order to successfully implement a FPGA based system in a radiation environment, such as on-board a satellite, the single event upset (SEU) and total ionizing dose (TID) characteristics of the device must first be established. This research experimentally determines a research procedure which could accurately determine the SEU cross sections and TID characteristics of various mitigation techniques as well as control circuits implemented in a ProASIC3 A3P1000 FPGA. To gain an understanding of the SEU effects of the implemented circuits, the test FPGA was irradiated by a 66MeV proton beam at the iTemba LABS facility. Through means of irradiation, the SEU cross section of various communication, motor control and mitigation schemes circuits, induced by high energy proton strikes was investigated. The implementation of a full global triple modular redundancy (TMR) and a combination of TMR and a AND-OR multiplexer filter was found to most effectively mitigate SEUs in comparison to the other techniques. When comparing the communication and motor control circuits, the high frequency I2C and SPI circuits experienced a higher number of upsets when compared to a low frequency servo motor control circuit. To gain a better understanding of the absorbed dose effects, experimental TID testing was conducted by irradiating the test FPGA with a cobalt-60 (Co-60) source. An accumulated absorbed dose resulted in the fluctuation of the device supply current and operating voltages as well as resulted in output errors. The TMR and TMR filtering combination mitigation techniques again were found to be the most effective methods of mitigation.
- Full Text:
- Date Issued: 2015
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