Applied Mechanics and Materials Vol. 805

Abstract: Model based predictive control is a new promising control method in the field of powerelectronics and electrical drives. The main advantages of MPC are simplicity and intuitiveness of thecontrol method. Constraints and nonlinearities of the system can easily be included, which makes thelinearisation of the system unnecessary. By using MPC it is possible to avoid the cascaded structureof common linear control methods and to gain a fast dynamic performance. A disadvantage is theneed to calculate the optimal actuating variable multiple times in every single sampling cycle leadsto a huge requirement of computational power. So far the computational requirement was the greatestbarrier for the practical application of model based predictive control in the field of power electronicsand electrical drive systems. In addition the small time constants of fractional horse power drivescomplicate the application of predictive control algorithms. In this paper, the feasibility of hardwareimplementation of a cost function based Finite Control Set MPC (FCS-MPC) algorithm for directspeed control of fractional horse power drives is explored. The cost function allows to address variouscontrol goals like dynamics of transitions and energy efficiency – an advantage linear conventionalcontrol methods cannot offer. Hitherto there are very few publications for direct predictive speed. Thepresented approach for direct predictive speed control includes a finite number of possible switchingstates of the converter. This considers the discrete nature of power converters and avoids the need formodulation. The basic principle of the control method is presented and the performance is demonstratedby simulations and experimental results for an industrial brushed type DC-motor.

Abstract: This paper presents a simulation model, which enables the energetic simulation of complex mechatronic powertrains over complete drive cycles. One focus of this work is on reducing the simulation duration to enable the simulation of extended drive cycles on the one hand, and the possibility to optimize drive cycles on the other hand. Furthermore, the program allows the user to assemble an energetically optimized selection of propulsion components.

Abstract: Owing to a high cost pressure and the need for a reduction of carbon dioxide emissions for manufacturing calcium silicate masonry units (CS), the CS-industry strives to cut the energy consumption. The most energy consuming process step is the autoclaving. About 87% of the energy is required for this particular process step, where the green bodies are steam-hardened at 200°C.For reducing the energy consumption, most of the alternatives aim at optimizing the complete manufacturing process. In this paper, the focus is put on an optimized loading process for the autoclaves, in consideration of preceding and subsequent process steps. For this purpose, a simulation model is developed, where different strategies of loading are implemented and tested. This model can be used to find optimally scheduled assignments of production orders to the available autoclaves, based on the volume of each manufactured product.The analysis of the tested strategies shows, that it is possible to save up to almost 9 % of the required energy for autoclaving by an optimized assignment of the available autoclaves.

Abstract: Manufacturers and users of packaging machines are facing two significant challenges: the improvement of the sustainability and the enhancement of the format flexibility. The sustainability of products is becoming a more important influencing factor for the consumer buying behavior. Therefore, the increase of the energy and resource efficiency of packaging machines is a very promising strategy to achieve this goal. At first glance no correlation between format flexibility and sustainability seems to exist. But in fact, both topics partly depend on each other. These connections are the focus of this paper. Exemplary for sustainability, the resource and energy efficiency in the context of packaging machines will be considered. As a further detailing, this paper also contains an experimental investigation of a more format flexible and sustainable processing technology for sealing. Therefore, the heat-impulse technology was investigated.

Abstract: Advanced cleanliness requirements in production are forcing industrial companies to include new cleaning processes into their manufacturing process. Complex cleaning operation procedures can lower process productivity and at the same time are responsible for substantial parts of the overall energy consumption. An optimization of cleaning processes with respect to cleaning duration, energy consumption and efficiency can therefore contribute to cost reduction significantly. This article presents a procedure for real data based assessment of industrial cleaning equipment. Based upon the resulting information of the procedure, productivity ratios and energy consumptions can be determined up to individual cleaning components. This creates the required transparency to derive customized production and energy efficiency optimization measures.