Integrated control and health management. Orbit transfer rocket engine technology program

To insure controllability of the baseline design for a 7500 pound thrust, 10:1 throttleable, dual expanded cycle, Hydrogen-Oxygen, orbit transfer rocket engine, an Integrated Controls and Health Monitoring concept was developed. This included: (1) Dynamic engine simulations using a TUTSIM derived computer code; (2) analysis of various control methods; (3) Failure Modes Analysis to identify critical sensors; (4) Survey of applicable sensors technology; and, (5) Study of Health Monitoring philosophies. The engine design was found to be controllable over the full throttling range by using 13 valves, including an oxygen turbine bypass valve to control mixture ratio, and a hydrogen turbine bypass valve, used in conjunction with the oxygen bypass to control thrust. Classic feedback control methods are proposed along with specific requirements for valves, sensors, and the controller. Expanding on the control system, a Health Monitoring system is proposed including suggested computing methods and the following recommended sensors: (1) Fiber optic and silicon bearing deflectometers; (2) Capacitive shaft displacement sensors; and (3) Hot spot thermocouple arrays. Further work is needed to refine and verify the dynamic simulations and control algorithms, to advance sensor capabilities, and to develop the Health Monitoring computational methods

The annulling of the sudden appearance of an unbalance in rotary machines by using active magnetic bearings

The application of magnetic bearings has become more frequent during the last 20 years and represents a significant aspect of improvements in the construction of machines with rotary motion. With the advancement of technology, the number of applications in which magnetic bearings have found their application is increasing. In this paper, it is shown how the effect of magnetic forces can annul the negative influence of unbalance, which suddenly appeared in a rotor supported in active magnetic bearings. Such cases may occur in operation due to breakage and rotor parts falling off (e.g., fan blades), which will lead to a sudden change in the mass balance of the rotor system and dislocation of the centre of mass in relation to the geometric centre of the rotor. In the paper, a mathematical model of the dynamic behaviour of a rigid rotor in active magnetic bearings was developed. The model is nonlinear and has five degrees of freedom and can only be solved numerically. The Newmark beta method and the Newton-Raphson method were used to solve the system of nonlinear differential equations. The results of the simulation showed the advantages of using active magnetic bearings for annulling sudden occurrences of unbalance in rotary machines

Real-time sensor data development for smart truck drivetrains

Heavy articulated transport vehicles have a poor reputation associated with dramatic road accidents with frequent fatalities for those in automobiles. The result of this work is a formal data flow structure to enhance real-time decision-making in complex mechanical systems to increase performance capability and responsiveness to human commands. This structure recognizes the multiple layers of highly non-linear mechanical components (actuators, wheel tire & ground surfaces, controllers, power supplies, human/machine interfaces, etc.) that must operate in unison (i.e., reduce conflicts) in real-time (in milli-seconds) to enhance operator (driver) control to maximize human choice. This work contains a discussion on dependable sensor data is vital in complex systems that rely on a suite of sensors for both control as well as condition monitoring purposes as well as discussion on real-time energy distribution analysis in high momentum mechanical systems. The focus will be on tractor trucks of class 7 & 8 that are outfitted with an array of low-cost redundant sensors leveraging advances in intelligent robotic systems. This work details many topics including: Most relevant sensor types and their technologies, Designing, implementing, and maintaining a multi-sensor system using feasible industry standards, Sensor signal integrity and data flow processing for decision making, Asynchronous data flow methods for operating decision making schemes in real-time, Multiple applications to enhance tractor trucks systems with multi-sensor systems for real-time decision making.Mechanical Engineerin

Control of a magnetically levitated ventricular assist device

This work presents theoretical and experimental means for achieving impeller stability in a magnetically levitated left ventricular assist device (LVAD). These types of medical devices are designed to boost the native heart`s ability to pump blood by means of mechanical energy transfer using a rotating impeller. Magnetic suspension of the impeller eliminates bearing friction and reduces blood damage, but it requires active controls that monitor the impeller`s position and speed in order to generate the forces and torques required to regulate its dynamic behavior. To accomplish this goal, this work includes: 1) a dynamic system model derived using energy and momentum conservation 2) dynamic analysis including stability, controllability and observability, and 3) development of two control algorithms: proportional integral derivative and sliding mode control. Experimental validation included component behavior, model accuracy, and the characterization of controller performance using a physiological simulator. The system model proved to be an adequate representation of the system while levitating in air, but additional research is needed to model hydrodynamic and gyroscopic effects. After the prototype`s subcomponents were tested, calibrated and/or modified to fit the control requirements, both control strategies were successful in controlling the rotor as it spun at 6000 rpm pumping 6L/min of water at 80mmHg. A maximum speed of 6500 rpm was achieved with speed control within 5% over most of the operating range. The control platform and many of the methods presented here are continually being used and improved towards the implantation of the device in a human subject in the future

Electromagnetic Levitation System for Active Magnetic Bearing Wheels

In this chapter, the author presents an electromagnetic levitation system for active magnetic bearing wheels. This system consists of a rotor, a shaft, a cover, and a base. The author derives a meaningful electromagnetic force by using the singular value decomposition. The author develops a control system using the proportional‐integral‐derivative controller to control the position of the rotor and regulate the two gimbal angles of the rotor. The author gives the numerical simulation and experimental results on the control of the electromagnetic levitation system

Nonlinear observers for predicting state-of-charge and state-of-health of lead-acid batteries for hybrid-electric vehicles

Abstract—This paper describes the application of state-estimation techniques for the real-time prediction of the state-of-charge (SoC) and state-of-health (SoH) of lead-acid cells. Specifically, approaches based on the well-known Kalman Filter (KF) and Extended Kalman Filter (EKF), are presented, using a generic cell model, to provide correction for offset, drift, and long-term state divergence—an unfortunate feature of more traditional coulomb-counting techniques. The underlying dynamic behavior of each cell is modeled using two capacitors (bulk and surface) and three resistors (terminal, surface, and end), from which the SoC is determined from the voltage present on the bulk capacitor. Although the structure of the model has been previously reported for describing the characteristics of lithium-ion cells, here it is shown to also provide an alternative to commonly employed models of lead-acid cells when used in conjunction with a KF to estimate SoC and an EKF to predict state-of-health (SoH). Measurements using real-time road data are used to compare the performance of conventional integration-based methods for estimating SoC with those predicted from the presented state estimation schemes. Results show that the proposed methodologies are superior to more traditional techniques, with accuracy in determining the SoC within 2% being demonstrated. Moreover, by accounting for the nonlinearities present within the dynamic cell model, the application of an EKF is shown to provide verifiable indications of SoH of the cell pack

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

Characterization and Modeling of a Control Moment Gyroscope

The Air Force Research Laboratory (AFRL) is developing a spacecraft simulator that uses Control Moment Gyroscopes (CMGs). Prior to the research herein, the Air Force Institute of Technology (AFIT) designed and built six laboratory-rated CMGs for use on the AFRL spacecraft simulator. The main contributions of this research are in the testing and modeling of a single CMG. Designing, building, and operating spacecraft simulators is time consuming and expensive, but less so than tests with on-orbit spacecraft. Reductions in cost and schedule can be realized by investing in modeling the spacecraft simulator and payload before testing. A model of the spacecraft simulator was created in previous research efforts, but was an ideal model; it did not include dynamics based on real CMGs. The objective of this research is to characterize and model a single CMG to determine the effects the real CMG\u27s performance will have on the performance of the AFRL spacecraft simulator. The gimbal motor utilizes a planetary gearbox, which has gear lash of 5 deg . Gear lash makes the existence of gravitational disturbance torques noticeable in the gimbal angular position measurements. An analytical model of the CMG gimbal was created in MATLAB. The model predicts the nonlinear dynamic behavior of the real CMG. A model of the spacecraft simulator was run through a sequence of pointing commands to generate gimbal angle commands which were then used to command the CMG to evaluate the system\u27s performance under realistic conditions. Gear slack has a cumulative time delay effect on vehicle slew responses of approximately one second over five maneuvers. The results of the tests performed in this thesis can be used to predict performance of CMG and spacecraft simulator behavior