Optimal hardware and control co-design applied to an active car suspension setup

For complex systems, it is not easy to obtain optimal designs for the hardware architecture and control configurations. Every design aspect influences the final performance, and often the interactions of the different components cannot be clearly determined in advance. In this work, a novel co-design optimization method was applied that allows the optimal placement and selection of actuators and sensors to be performed simultaneously with the determination of the control architecture and associated controller tuning parameters. This novel co-design method was applied to a state-space model of a downscaled active car suspension laboratory setup. This setup mimics a car driving over a specific road surface while active components in the suspension have to increase the driver’s comfort by counteracting unwanted vibrations. The result of this co-design optimization methodology is a Pareto front that graphically represents the trade-off between the maximum performance and the total implementation cost; the co-design results were validated with measurements of the physical active car suspension setup. The obtained controller tuning parameters are compared herein with existing controller tuning methods to demonstrate that the co-design method is able to determine optimal controller tuning parameters

Computationalcost Reduction of Robust Controllers Foractive Magnetic Bearing Systems

This work developed strategies for reducing the computational complexity of implementing robust controllers for active magnetic bearing (AMB) systems and investigated the use of a novel add-on controller for gyroscopic effect compensation to improve achievable performance with robust controllers. AMB systems are multi-input multi-output (MIMO) systems with many interacting mechanisms that needs to fulfill conflicting performance criteria. That is why robust control techniques are a perfect application for AMB systems as they provide systematic methods to address both robustness and performance objectives. However, robust control techniques generally result in high order controllers that require high-end control hardware for implementation. Such controllers are not desirable by industrial AMB vendors since their hardware is based on embedded systems with limited bandwidths. That is why the computational cost is a major obstacle towards industry adaptation of robust controllers. Two novel strategies are developed to reduce the computational complexity of singlerate robust controllers while preserving robust performance. The first strategy identifies a dual-rate configuration of the controller for implementation. The selection of the dualrate configuration uses the worst-case plant analysis and a novel approach that identifies the largest tolerable perturbations to the controller. The second strategy aims to redesign iv the controller by identifying and removing negligible channels in the context of robust performance via the largest tolerable perturbations to the controller. The developed methods are demonstrated both in simulation and experiment using three different AMB systems, where significant computational savings are achieved without degrading the performance. To improve the achievable performance with robust controllers, a novel add-on controller is developed to compensate the gyroscopic effects in flexible rotor-AMB systems via modal feedback control. The compensation allows for relaxing the robustness requirements in the control problem formulation, potentially enabling better performance. The effectiveness of the developed add-on controller is demonstrated experimentally on two AMB systems with different rotor configurations. The effects of the presence of the add-on controller on the performance controller design is investigated for one of the AMB systems. Slight performance improvements are observed at the cost of increased power consumption and increased computational complexity

Design and verification of Guidance, Navigation and Control systems for space applications

In the last decades, systems have strongly increased their complexity in terms of number of functions that can be performed and quantity of relationships between functions and hardware as well as interactions of elements and disciplines concurring to the definition of the system. The growing complexity remarks the importance of defining methods and tools that improve the design, verification and validation of the system process: effectiveness and costs reduction without loss of confidence in the final product are the objectives that have to be pursued. Within the System Engineering context, the modern Model and Simulation based approach seems to be a promising strategy to meet the goals, because it reduces the wasted resources with respect to the traditional methods, saving money and tedious works. Model Based System Engineering (MBSE) starts from the idea that it is possible at any moment to verify, through simulation sessions and according to the phase of the life cycle, the feasibility, the capabilities and the performances of the system. Simulation is used during the engineering process and can be classified from fully numerical (i.e. all the equipment and conditions are reproduced as virtual model) to fully integrated hardware simulation (where the system is represented by real hardware and software modules in their operational environment). Within this range of simulations, a few important stages can be defined: algorithm in the loop (AIL), software in the loop (SIL), controller in the loop (CIL), hardware in the loop (HIL), and hybrid configurations among those. The research activity, in which this thesis is inserted, aims at defining and validating an iterative methodology (based on Model and Simulation approach) in support of engineering teams and devoted to improve the effectiveness of the design and verification of a space system with particular interest in Guidance Navigation and Control (GNC) subsystem. The choice of focusing on GNC derives from the common interest and background of the groups involved in this research program (ASSET at Politecnico di Torino and AvioSpace, an EADS company). Moreover, GNC system is sufficiently complex (demanding both specialist knowledge and system engineer skills) and vital for whatever spacecraft and, last but not least the verification of its behavior is difficult on ground because strong limitations on dynamics and environment reproduction arise. Considering that the verification should be performed along the entire product life cycle, a tool and a facility, a simulator, independent from the complexity level of the test and the stage of the project, is needed. This thesis deals with the design of the simulator, called StarSim, which is the real heart of the proposed methodology. It has been entirely designed and developed from the requirements definition to the software implementation and hardware construction, up to the assembly, integration and verification of the first simulator release. In addition, the development of this technology met the modern standards on software development and project management. StarSim is a unique and self-contained platform: this feature allows to mitigate the risk of incompatibility, misunderstandings and loss of information that may arise using different software, simulation tools and facilities along the various phases. Modularity, flexibility, speed, connectivity, real time operation, fidelity with real world, ease of data management, effectiveness and congruence of the outputs with respect to the inputs are the sought-after features in the StarSim design. For every iteration of the methodology, StarSim guarantees the possibility to verify the behavior of the system under test thanks to the permanent availability of virtual models, that substitute all those elements not yet available and all the non-reproducible dynamics and environmental conditions. StarSim provides a furnished and user friendly database of models and interfaces that cover different levels of detail and fidelity, and supports the updating of the database allowing the user to create custom models (following few, simple rules). Progressively, pieces of the on board software and hardware can be introduced without stopping the process of design and verification, avoiding delays and loss of resources. StarSim has been used for the first time with the CubeSats belonging to the e-st@r program. It is an educational project carried out by students and researchers of the “CubeSat Team Polito” in which StarSim has been mainly used for the payload development, an Active Attitude Determination and Control System, but StarSim’s capabilities have also been updated to evaluate functionalities, operations and performances of the entire satellite. AIL, SIL, CIL, HIL simulations have been performed along all the phases of the project, successfully verifying a great number of functional and operational requirements. In particular, attitude determination algorithms, control laws, modes of operation have been selected and verified; software has been developed step by step and the bugs-free executable files have been loaded on the micro-controller. All the interfaces and protocols as well as data and commands handling have been verified. Actuators, logic and electrical circuits have been designed, built and tested and sensors calibration has been performed. Problems such as real time and synchronization have been solved and a complete hardware in the loop simulation test campaign both for A-ADCS standalone and for the entire satellite has been performed, verifying the satisfaction of a great number of CubeSat functional and operational requirements. The case study represents the first validation of the methodology with the first release of StarSim. It has been proven that the methodology is effective in demonstrating that improving the design and verification activities is a key point to increase the confidence level in the success of a space mission

Summary of Research 1994

The views expressed in this report are those of the authors and do not reflect the official policy or position of the Department of Defense or the U.S. Government.This report contains 359 summaries of research projects which were carried out under funding of the Naval Postgraduate School Research Program. A list of recent publications is also included which consists of conference presentations and publications, books, contributions to books, published journal papers, and technical reports. The research was conducted in the areas of Aeronautics and Astronautics, Computer Science, Electrical and Computer Engineering, Mathematics, Mechanical Engineering, Meteorology, National Security Affairs, Oceanography, Operations Research, Physics, and Systems Management. This also includes research by the Command, Control and Communications (C3) Academic Group, Electronic Warfare Academic Group, Space Systems Academic Group, and the Undersea Warfare Academic Group

A Foot Placement Strategy for Robust Bipedal Gait Control

This thesis introduces a new measure of balance for bipedal robotics called the foot placement estimator (FPE). To develop this measure, stability first is defined for a simple biped. A proof of the stability of a simple biped in a controls sense is shown to exist using classical methods for nonlinear systems. With the addition of a contact model, an analytical solution is provided to define the bounds of the region of stability. This provides the basis for the FPE which estimates where the biped must step in order to be stable. By using the FPE in combination with a state machine, complete gait cycles are created without any precalculated trajectories. This includes gait initiation and termination. The bipedal model is then advanced to include more realistic mechanical and environmental models and the FPE approach is verified in a dynamic simulation. From these results, a 5-link, point-foot robot is designed and constructed to provide the final validation that the FPE can be used to provide closed-loop gait control. In addition, this approach is shown to demonstrate significant robustness to external disturbances. Finally, the FPE is shown in experimental results to be an unprecedented estimate of where humans place their feet for walking and jumping, and for stepping in response to an external disturbance

The optimal control of power electronic embedded networks in More Electric Aircraft

With the advancement of power electronic technologies over recent decades, there has been an overall increase in the utilisation of distributed generation and power electronic embedded networks in a large sphere of applications. Probably one of the most prominent areas of utilisation of new power electronics embedded systems is the use in power networks onboard military and civilian aircraft. With environmental concerns and increased competition in the civil aviation sector, more aircraft manufactures are replacing and interfacing electrical alternatives over heavier, less efficient and costly pneumatic, hydraulic and mechanical systems. In these modern power systems, the increased proliferation of power electronic converters and distributed generation raises important issues in regards to the performance, stability and robustness between interfaced switching units. These phenomena, such as power electronic sub-system interactions, become even more prominent in micro-grid applications or other low voltage distribution systems where interfaced converters are in close proximity to one another. In More Electric Aircraft (MEA), these interfaced power electronic converters are connected to the same non-stiff low power AC grid, which further increases the interactive effects between converter sub-systems. If these effects are not properly taken into account, then external disturbances to the system at given operating conditions can result in degradation of the system performance, failure in meeting the operating requirements of the grid, or in the worst case, instability of the whole grid. With much research in the area of decreasing the size and weight of systems, there is much literature proposing optimisation methods which decrease the size of filters between interfacing converters. Whilst effectively decreasing the size of these systems, interactions between interfaced converters gets worse, and is often improperly accounted for. The work presented in this thesis proposes a novel approach to the decentralisation and optimisation of converter controls on a power electronics embedded power network. In order to account for the interactive dynamics between sub-systems in the environment of reduced passive filter networks, all the system dynamics including the interactive terms are modelled globally. An optimal controller design approach based on the H2 optimisation is proposed to synthesise and generate automatically the controller gains for each power electronic sub-system. H2 optimisation is a powerful tool, which not only allows the submission, optimisation and development of closed loop controls for large dynamic systems, but offers the ability to the user to construct the controller for given structures. This enables the development of decentralised controllers for every sub-system with intrinsic knowledge of the closed loop dynamics of every other interconnect sub-system. It is shown through simulation and by experimental validation that this novel approach to grid control optimisation not only can improve overall dynamic performance of all sub-systems over 15traditional methods of design, but can also intrinsically reduce or better yet mitigate against the interactive effects between all converters. In addition, this method of controller design will be shown to not only be scalable to expanding sizes of grids, but the Phase-locked loops (PLLs) integrated to grid connected devices can also be considered in the optimisation procedure. PLLs are widely known to further cause interactive behaviours between grid interfaced devices. Including this into the optimisation also has been validated experimentally to prevent interactions on the grid, and improve performance over traditional design methods. Adaptations to the controller are performed to ensure operation in variable frequency environments (as is common in MEA), as well as methods of single converter optimisation when interfacing to an unknown grid. Additionally some initial research towards an adaption of the H2 controller to incorporate robustness as well as performance into the optimisation procedure is presented with mathematical concepts shown through simulation

The optimal control of power electronic embedded networks in More Electric Aircraft

With the advancement of power electronic technologies over recent decades, there has been an overall increase in the utilisation of distributed generation and power electronic embedded networks in a large sphere of applications. Probably one of the most prominent areas of utilisation of new power electronics embedded systems is the use in power networks onboard military and civilian aircraft. With environmental concerns and increased competition in the civil aviation sector, more aircraft manufactures are replacing and interfacing electrical alternatives over heavier, less efficient and costly pneumatic, hydraulic and mechanical systems. In these modern power systems, the increased proliferation of power electronic converters and distributed generation raises important issues in regards to the performance, stability and robustness between interfaced switching units. These phenomena, such as power electronic sub-system interactions, become even more prominent in micro-grid applications or other low voltage distribution systems where interfaced converters are in close proximity to one another. In More Electric Aircraft (MEA), these interfaced power electronic converters are connected to the same non-stiff low power AC grid, which further increases the interactive effects between converter sub-systems. If these effects are not properly taken into account, then external disturbances to the system at given operating conditions can result in degradation of the system performance, failure in meeting the operating requirements of the grid, or in the worst case, instability of the whole grid. With much research in the area of decreasing the size and weight of systems, there is much literature proposing optimisation methods which decrease the size of filters between interfacing converters. Whilst effectively decreasing the size of these systems, interactions between interfaced converters gets worse, and is often improperly accounted for. The work presented in this thesis proposes a novel approach to the decentralisation and optimisation of converter controls on a power electronics embedded power network. In order to account for the interactive dynamics between sub-systems in the environment of reduced passive filter networks, all the system dynamics including the interactive terms are modelled globally. An optimal controller design approach based on the H2 optimisation is proposed to synthesise and generate automatically the controller gains for each power electronic sub-system. H2 optimisation is a powerful tool, which not only allows the submission, optimisation and development of closed loop controls for large dynamic systems, but offers the ability to the user to construct the controller for given structures. This enables the development of decentralised controllers for every sub-system with intrinsic knowledge of the closed loop dynamics of every other interconnect sub-system. It is shown through simulation and by experimental validation that this novel approach to grid control optimisation not only can improve overall dynamic performance of all sub-systems over 15traditional methods of design, but can also intrinsically reduce or better yet mitigate against the interactive effects between all converters. In addition, this method of controller design will be shown to not only be scalable to expanding sizes of grids, but the Phase-locked loops (PLLs) integrated to grid connected devices can also be considered in the optimisation procedure. PLLs are widely known to further cause interactive behaviours between grid interfaced devices. Including this into the optimisation also has been validated experimentally to prevent interactions on the grid, and improve performance over traditional design methods. Adaptations to the controller are performed to ensure operation in variable frequency environments (as is common in MEA), as well as methods of single converter optimisation when interfacing to an unknown grid. Additionally some initial research towards an adaption of the H2 controller to incorporate robustness as well as performance into the optimisation procedure is presented with mathematical concepts shown through simulation

Robust Nonlinear Model Predictive Control using Polynomial Chaos Expansions

The performance of model predictive controllers (MPCs) is largely dependent on the accuracy of the model predictions as compared to the actual plant outputs. Irrespective of the model used, first-principles (FP) or empirical, plant-model mismatch is unavoidable. Consequently, model based controllers must be robust to mismatch between the model predictions and the actual process behavior. Controllers that are not robust may result in poor closed loop response and even instability. Model uncertainty can generally be formulated into two broader forms, parametric uncertainty and unstructured uncertainty. Most of the current robust nonlinear MPC have been based on FP-model where only robustness to bounded disturbances rather than parametric uncertainty has been addressed. Systematically accounting for parametric uncertainty in the robust design has been difficult in FP-models due to varying forms in which uncertain parameters occur in the models. To address parametric uncertainty robustness tests based on Structured Singular Value (SSV) and Linear Matrix Inequalities (LMI) have been proposed previously, however these algorithms tend to be conservative because they consider worst-case scenarios and they are also computationally expensive. For instance the SSV calculation is NP-hard and as a result it is not suitable for fast computations. This provides motivation to work on robust control algorithms addressing both parametric and unstructured uncertainty with fast computation times. To facilitate the design of robust controllers which can be computed fast, empirical models are used in which parametric uncertainty is propagated using Polynomial Chaos Expansion (PCE) of parameters. PCE assists in speeding up the computations by providing an analytical expression for the L^2-norm of model predictions while also eliminating the need to design for the worst-case scenario which results in conservatism. Another way of speeding up computations in MPC algorithms is by grouping subsets of available the inputs and outputs into subsystems and by controlling each of the subsystems by MPC controllers of lower dimensions. This latter approach, referred in the literature as Distributed MPC, has been tackled by different strategies involving different degrees of coordination between subsystems but it has not been studied in terms of robustness to model error. Based on the above considerations the current work investigates different robustness aspects of predictive control algorithms for nonlinear processes with special emphasis on the following three situations, i) a nonlinear predictive control based on a Volterra series model where the uncertain parameters are formulated as PCE’s, ii) The application of a PCE-based approach to control and optimization of bioreactors where the model is based on dynamic flux metabolic models, and iii) A Robust Distributed MPC with a robust estimator that is needed to account for the interactions between sub-systems in distributed control

Improved autogyro flying qualities using automatic control methods

An autogyro or Autogiro is a unique type of rotary-wing aircraft that was successfully flown in the 1920s, many years before the first helicopter came to service. As far as the rotorcraft technology is concerned, the technical issues addressed by autogyros were eventually rectified and paved the way for the success of helicopter development. When helicopter became more popular and accepted in the civil aviation industry in the 1940s, autogyros were nearly forgotten and the popularity slowly diminished. The re-emergence of autogyros in the last two decades in hobby and sports flight activities, however, coincides with bad safety records due to stability issues. At the time of this writing, there are no specific flying qualities standards to be em- ployed as guidelines to design a light autogyro with good stability attributes. The only requirements available are addressed in the BCAR Section T airworthiness standard for light autogyros which only prescribes some basic dynamic stability requirements for the vehicle. For existing conventional light autogyros which mostly of ‘home-built’ type, complying with the airworthiness standards would be an issue as most of them were built beforehand. From these concerns, this Thesis aims to improve the flying qualities performance of existing light autogyros through automatic flight control methods, as one of the ways to practically achieve the required performance. Consequently, specific flying qualities requirements for light autogyros must first be proposed as preliminary guidelines for design and flying qualities improvement. A generic mathematical model of light autogyros named ARDiS is developed based on the ‘multiblade’ simulation ap- proach which is computationally cost-effective. This model was successfully validated against real autogyro flight data and later implemented in the control enhancement of the vehicle. The control enhancement was developed using classical approaches with limitation in size and simplicity of the vehicle as a light aircraft. Proper actuation control hard- ware was separately modelled and deployed into the autogyro to demonstrate a higher dynamics in the control mechanism so that a more realistic attitude behaviour of the vehicle is presented. This control enhancement was successfully evaluated with both, linear and nonlinear simulations according to the proposed autogyro flying qualities attributes. All presented results signify a higher possibility of improving the flying qualities of currently used and future built light autogyros through control enhance- ment