Search Results (11)

With the rapid development of Computerized Numerical Control (CNC) systems, traditional industrial communication protocols fail to meet the requirements for high real-time performance and reliability. To address these challenges, an open five-axis CNC system is designed and implemented based on the gLink-II bus protocol. This system features a layered architecture that integrates the Windows operating system with a Real-Time Operating System (RTOS) kernel, along with a multithreaded data interaction structure based on a circular buffer to enhance real-time data transmission performance and improve system responsiveness. In the direct linear interpolation control for five-axis machining, an acceleration and deceleration planning method is introduced, taking into account the kinematic constraints of the rotary axes. This method optimizes velocity and acceleration control. The experimental results show that the system achieves a maximum response error of less than 0.2 milliseconds and an interpolation period of less than 0.5 milliseconds in five-axis coordinated control. The system is capable of efficiently performing data processing and task scheduling, ensuring the stability of the CNC machining process. Full article

In a conventional automotive manufacturing plant, the paint shop alone can represent 36% of the total energy consumption, making it the most demanding area in terms of electricity and fossil fuel energy consumption. This study explores the possibility of decentralizing the production of electrical power and heat simultaneously, using an Organic Rankine Cycle (ORC) system integrated with a Parabolic Trough Collector (PTC) in a paint shop. To date, no similar system has been explored or implemented by the automotive industry. To increase the efficiency of the integrated system, wasted heat generated during the paint manufacturing process is recovered and used to pre-heat the organic fluid in the ORC system. A 4E analysis (Energy, Exergy, Economic, and Environmental) is conducted to determine the practical viability of the proposed system. When applied to the southern region of the USA, this system’s installed capacity is projected to be 11 times higher than the two unique SORC pieces of equipment currently running in Louisiana and Florida. The goals are to reduce the reliance on external primary energy sources and decrease the carbon emission footprint from production activity. The system is evaluated for a location in Alabama, USA. The designed SORC, using toluene, can produce 712.2 kW_el net and 13,132 kg/h of hot water, with an overall energy efficiency of 31.02%; exergy efficiency of 34.23; and ORC efficiency of 27.70%. This leads to an electrical energy saving of 5.9% for the manufacturing plant. The regenerative thermal oxidizer (RTO) heat exchanger, the secondary heat source of the system, has the highest exergy destruction—3583 kW. The system avoids the emission of 4521 tCO₂ per year. A payback period of 10.16 years for the proposed system is estimated. Considering a planning horizon of 10 years, the investment in the system is also justified by a benefit–cost analysis. Full article

Embedded computers are ubiquitous in products across various industries, including the automotive and medical industries, and in consumer goods such as appliances and entertainment devices. These specialized computing systems utilize Systems on Chips (SoCs), devices that are made up of one or more main microprocessor cores. SoCs are augmented with sub-blocks that perform dedicated tasks to support the system. Sub-blocks contain custom logic or small-footprint microprocessors, depending upon their complexity, and perform support functions such as clock generation, device testing, phase-locked loop synchronization and peripheral management for interfaces such as a Universal Serial Bus (USB) or Serial Peripheral Interface (SPI). SoC designers have traditionally obtained sub-blocks from commercial vendors. While these sub-blocks have well-defined interfaces, their internal implementations are opaque. Without visibility of the specifics of the implementation, SoC designers are limited to the degree to which they can optimize these off-the-shelf sub-blocks. The result is that power and area constraints are dictated by the design of a third-party vendor. This work introduces a novel idea: using an open-source, small, multitasking, real-time operating system inside an SoC sub-block to manage multiple processes, thereby conserving code space. This OS is TurbOS, a new operating system whose primary goal is to provide the highest performance using the least amount of space. It is written in the assembly language of a new pipelined 16-bit microprocessor developed at the University of Florida, the Turbo9. TurbOS is derived from and incorporates the design benefits of an existing operating system called NitrOS-9, and reduces the code size from its progenitor by nearly 20%. Furthermore, it is over 80% smaller than the popular FreeRTOS operating system. TurbOS delivers a rich feature set for managing memory and process resources that are useful in SoC sub-block applications in an extremely small footprint of only 3 kilobytes. Full article

As a major coal country, China faces the issue of significant gas emissions during the coal mining process. This study aims to improve the utilization efficiency of mine gas, reduce greenhouse gas emissions, and promote the low-carbon and green transformation of the coal industry. A 10 kW gas regenerative thermal oxidizer (RTO) experimental system was constructed. The effects of initial methane concentration, low-temperature flue gas proportion, and operating load on combustion temperature, methane oxidation rate, high-temperature flue gas energy, and system thermal efficiency were studied. The results show that when the combustion temperature is below 600 °C, the CH₄ combustion reaction cannot proceed effectively, and the system temperature continuously decreases and cannot be maintained stably. The experiment determines the stable operating methane concentration range of the RTO. In this experimental system, the lower limit of the initial methane concentration is 0.28%, corresponding to an 86% methane oxidation rate. As the initial methane concentration decreases, the combustion temperature also decreases, and the methane oxidation rate follows suit. The higher the low-temperature flue gas proportion, the higher the combustion temperature, and the system’s thermal efficiency and output heat decrease with the increase in the low-temperature flue gas proportion. This experiment explores multiple factors affecting regenerative thermal oxidation, providing a basis for ensuring the safe and stable operation of the system and its optimization. Improving the thermal insulation and heat exchange performance of the storage body can expand the lower limit of the initial methane concentration, thereby increasing the stability and thermal efficiency of the system. Full article

As a subclass of nanosatellites, CubeSats have changed the game’s rules in the scientific research industry and the development of new space technologies. The main success factors are their cost effectiveness, relative ease of production, and predictable life cycle. CubeSats are very important for training future engineers: bachelor’s and master’s students of universities. At the same time, using CubeSats is a cost-effective method of nearest space exploration and scientific work. However, many issues are related to efficient time-limited development, software and system-level quality assurance, maintenance, and software reuse. In order to increase the flexibility and reduce the complexity of CubeSat projects, this article proposes a “hybrid” development model that combines the strengths of two approaches: the agile-a-like model for software and the waterfall model for hardware. The paper proposes a new computing platform solution, “Falco SBC/CDHM”, based on Microchip (Atmel) ATSAMV71Q21 with improved performance. This type of platform emphasizes low-cost space hardware that can compete with space-grade platforms. The paper substantiates the architecture of onboard software based on microservices and containerization to break down complex software into relatively simple components that undergraduates and graduates can handle within their Master’s studies, and postgraduates can use for scientific space projects. The checking of the effectiveness of the microservice architecture and the new proposed platform was carried out experimentally, involving the time spent on executing three typical algorithms of different algorithmic complexities. Algorithms were implemented using native C (Bare-metal) and WASM3 on FreeRTOS containers on two platforms, and performance was measured on both “Falco” and “Pi Pico” by Raspberry. The experiment confirmed the feasibility of the complex application of the “hybrid” development model and microservices and container-based architecture. The proposed approach makes it possible to develop complex software in teams of inexperienced students, minimize risks, provide reusability, and thus increase the attractiveness of CubeSat student projects. Full article

Consolidating tasks to a smaller number of electronic control units (ECUs) is an important strategy for optimizing costs and resources in the automotive industry. In our research, we aim to enable ECU consolidation by migrating tasks at runtime between different ECUs, which adds redundancy and fail-safety capabilities to the system. In this paper, we present a setup with a generalistic and modular architecture that allows for integrating and testing different ECU architectures and machine learning (ML) models. As part of a holistic testbed, we introduce a collection of reproducible tasks, as well as a toolchain that controls the dynamic migration of tasks depending on ECU status and load. The migration is aided by the machine learning predictions on the schedulability analysis of possible future task distributions. To demonstrate the capabilities of the setup, we show its integration with FreeRTOS-based ECUs and two ML models—a long short-term memory (LSTM) network and a spiking neural network—along with a collection of tasks to distribute among the ECUs. Our approach shows a promising potential for machine-learning-based schedulability analysis and enables a comparison between different ML models. Full article

This work discusses what should be the desirable path and correct tools for the optimal re-design and operation of processes in the Industry 4.0 framework, as illustrated in a challenging case study corresponding to a complex network of evaporation plants in a viscose-fiber factory. The goal is to integrate optimal design, to improve the existing cooling systems, together with the optimal operation of the whole network, balancing the initial investment with the potentially achievable savings. A rigorous mathematical model for such optimization purpose has been built. The model explicitly considers different structural alternatives as a superstructure for the incorporation of new equipment into the network. The uncertainty associated to future operating conditions is also considered by using a two-stage stochastic formulation. Furthermore, the model is also the base from which a deterministic real-time optimization (RTO) builds upon to support the daily management of the future network operation. The RTO tool suggests the allocation of different products to evaporation plants, the distribution of the cooling water and the suitable number of heat pumps to switch on for optimal economic operation. Design and operation problems are formulated and solved via mixed-integer non-linear programming and the results have been tested with historical plant data. Full article

In automatic systems used in the control and monitoring of industrial processes, fieldbuses with specific real-time requirements are used. Often, the sensors are connected to these fieldbuses through embedded systems, which also have real-time features specific to the industrial environment in which it operates. The embedded operating systems are very important in the design and development of embedded systems. A distinct class of these operating systems is real-time operating systems (RTOSs) that can be used to develop embedded systems, which have hard and/or soft real-time requirements on small microcontrollers (MCUs). RTOSs offer the basic support for developing embedded systems with applicability in a wide range of fields such as data acquisition, internet of things, data compression, pattern recognition, diversity, similarity, symmetry, and so on. The RTOSs provide basic services for multitasking applications with deterministic behavior on MCUs. The services provided by the RTOSs are task management and inter-task synchronization and communication. The selection of the RTOS is very important in the development of the embedded system with real-time requirements and it must be based on the latency in the handling of the critical operations triggered by internal or external events, predictability/determinism in the execution of the RTOS primitives, license costs, and memory footprint. In this paper, we measured and compared the timing performance for synchronization throughout an event, semaphore, and mailbox for the following RTOSs: FreeRTOS 9.0.0, FreeRTOS 10.2.0, rt-thread, Keil RTX, uC/OS-II, and uC/OS-III. For the experimental tests, we developed test applications for two MCUs: ARM Cortex™-M4 and ARM Cortex™-M0+ based MCUs. Full article

Research and development organisations (RTOs) are at the heart of innovation systems. They help to connect innovation system actors to foster industrial innovation. Due to this intermediary role, they act as paradigmatic open innovation (OI) actors. In this context, RTOs need to balance their knowledge stocks and flows, while assuring their own innovation capabilities and positively impacting the innovation system they influence. Thus, RTOs need to develop collaboration approaches that support their own performance while increasing their capabilities and not threatening their competitive advantages derived from their knowledge stock. In this study we extend the OI research to research organisations analysing their OI approach and the impact on its own performance, developing a new framework for OI study in RTOs using a partial least squares structural equation modelling (PLS-SEM) approach. The research, based on a sample of Spanish RTOs, arises two substantive conclusions. First, an increased number of collaboration partners (collaboration breadth) and the use of a variety of OI practices have a strong impact on RTOs’ overall performance (scientific, transference, and economic results). Second, RTOs need to foster their aperture and promote an active management to benefit from collaborating partners, whereas managers should pay special attention to questions related to the protection and management of intellectual property when promoting the use of different OI practices. Both results also emphasise the importance of managing firms’ knowledge flows in the implementation of OI in RTOs. Full article

DSCBlocks is an open-source platform in hardware and software developed in JavaFX, which is focused on learning embedded systems through Digital Signal Controllers (DSCs). These devices are employed in industrial and educational sectors due to their robustness, number of peripherals, processing speed, scalability and versatility. The platform uses graphical blocks designed in Google’s tool Blockly that can be used to build different Algorithm Visualizations (AVs). Afterwards, the algorithms are converted in real-time to C language, according to the specifications of the compiler for the DSCs (XC16) and they can be downloaded in one of the two models of development board for the dsPIC 33FJ128GP804 and dsPIC 33FJ128MC802. The main aim of the platform is to provide a flexible environment, drawing on the educational advantages of the AVs with different aspects concerning the embedded systems, such as declaration of variables and functions, configuration of ports and peripherals, handling of Real-Time Operating System (RTOS), interrupts, among others, that are employed in several fields such as robotics, control, instrumentation, etc. In addition, some experiments that were designed in the platform are presented in the manuscript. The educational methodology and the assessment provided by the students (n = 30) suggest that the platform is suitable and reliable to learn concepts relating to embedded systems. Full article

The proper design of RTO systems’ structure and critical diagnosis tools is neglected in commercial RTO software and poorly discussed in the literature. In a previous article, Quelhas et al. (Can J Chem Eng., 2013, 91, 652–668) have reviewed the concepts behind the two-step RTO approach and discussed the vulnerabilities of intuitive, experience-based RTO design choices. This work evaluates and analyzes the performance of industrial RTO implementations in the face of real settings regarding the choice of steady-state detection methods and parameters, the choice of adjustable model parameters and selected variables in the model adaptation problem, the convergence determination of optimization techniques, among other aspects, in the presence of real noisy data. Results clearly show the importance of a robust and careful consideration of all aspects of a two-step RTO structure, as well as of the performance evaluation, in order to have a real and undoubted improvement of process operation. Full article