Controller Design for Active Vibration Damping with Inertial Actuators

In the machining industry, there is a constant need to improve productivity while maintaining required dimensional tolerances and surface quality. The self-excited vibration called chatter is one of the main factors limiting machining productivity. Chatter produces unstable cutting conditions during machining and unstable forces will damage and shorten the life of the machine tool. It can also damage the cutting tool, machining components as well as produce a poor surface finish on the workpiece. Researchers have developed various chatter suppression techniques such as changing process parameters, spindle speeds, and using passive dampers. However, many of these methods are not very robust to changing dynamics in the machine tool due to changing machine positioning, cutting setups, etc. Active vibration damping with a force actuator is a robust method of adding damping by due to its bandwidth and variable controller gains. However, the commissioning of the controller design for the actuators is not trivial and requires significant manual tuning to reach optimal productivity. The research presented in this thesis aims to simplify and automate the controller design process for force actuators. A frequency domain, sensitivity based automatic controller tuning method for force actuators has been developed. This method uses the measured actuator dynamics and open-loop system dynamics to develop a prediction tool for closed-loop responses without needing to have the complete system model (model free). By monitoring the predicted closed-loop response of various virtually designed controllers, an optimal controller is found amongst the candidate parameter values. The stability of the system and actuator is monitored during the search to ensure that the system is stable throughout its bandwidth that the actuator does not become saturated. The controller is then experimentally tested to ensure that the predicted output is the same as the real output. In cases where the system has several vibration modes that are in counter-phase and close in frequency, the model-free approach does not perform well. A more complex model-based control law has also been developed and implemented. The method automatically identifies a transfer function model for the measured open-loop system dynamics and synthesizes mixed-sensitivity optimization based controller to damp out the modes in counter-phase. In order to verify that the model-based controllers can reduce vibration modes in counter-phase, a small-scale experimental setup was developed to mimic machine tools with vibration modes in counter-phase. A flexure was designed and fabricated. A shaker from Modal Shop is used as an active damping actuator to reduce the flexure’s vibration modes. It was concluded that while the model-based controller synthesis techniques were able to damp the vibration modes in counter phase, the flexure was too simplistic and the model-free controller was able to achieve similar results

A Comprehensive Review of Digital Twin -- Part 1: Modeling and Twinning Enabling Technologies

As an emerging technology in the era of Industry 4.0, digital twin is gaining unprecedented attention because of its promise to further optimize process design, quality control, health monitoring, decision and policy making, and more, by comprehensively modeling the physical world as a group of interconnected digital models. In a two-part series of papers, we examine the fundamental role of different modeling techniques, twinning enabling technologies, and uncertainty quantification and optimization methods commonly used in digital twins. This first paper presents a thorough literature review of digital twin trends across many disciplines currently pursuing this area of research. Then, digital twin modeling and twinning enabling technologies are further analyzed by classifying them into two main categories: physical-to-virtual, and virtual-to-physical, based on the direction in which data flows. Finally, this paper provides perspectives on the trajectory of digital twin technology over the next decade, and introduces a few emerging areas of research which will likely be of great use in future digital twin research. In part two of this review, the role of uncertainty quantification and optimization are discussed, a battery digital twin is demonstrated, and more perspectives on the future of digital twin are shared

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

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

Six Decades of Flight Research: An Annotated Bibliography of Technical Publications of NASA Dryden Flight Research Center, 1946-2006

Titles, authors, report numbers, and abstracts are given for nearly 2900 unclassified and unrestricted technical reports and papers published from September 1946 to December 2006 by the NASA Dryden Flight Research Center and its predecessor organizations. These technical reports and papers describe and give the results of 60 years of flight research performed by the NACA and NASA, from the X-1 and other early X-airplanes, to the X-15, Space Shuttle, X-29 Forward Swept Wing, X-31, and X-43 aircraft. Some of the other research airplanes tested were the D-558, phase 1 and 2; M-2, HL-10 and X-24 lifting bodies; Digital Fly-By-Wire and Supercritical Wing F-8; XB-70; YF-12; AFTI F-111 TACT and MAW; F-15 HiDEC; F-18 High Alpha Research Vehicle, F-18 Systems Research Aircraft and the NASA Landing Systems Research aircraft. The citations of reports and papers are listed in chronological order, with author and aircraft indices. In addition, in the appendices, citations of 270 contractor reports, more than 200 UCLA Flight System Research Center reports, nearly 200 Tech Briefs, 30 Dryden Historical Publications, and over 30 videotapes are included