Controls for space structures

Assembly and operation of large space structures (LSS) in orbit will require robot-assisted docking and berthing of partially-assembled structures. These operations require new solutions to the problems of controls. This is true because of large transient and persistent disturbances, controller-structure interaction with unmodeled modes, poorly known structure parameters, slow actuator/sensor dynamical behavior, and excitation of nonlinear structure vibrations during control and assembly. For on-orbit assembly, controllers must start with finite element models of LSS and adapt on line to the best operating points, without compromising stability. This is not easy to do, since there are often unmodeled dynamic interactions between the controller and the structure. The indirect adaptive controllers are based on parameter estimation. Due to the large number of modes in LSS, this approach leads to very high-order control schemes with consequent poor stability and performance. In contrast, direct model reference adaptive controllers operate to force the LSS to track the desirable behavior of a chosen model. These schemes produce simple control algorithms which are easy to implement on line. One problem with their use for LSS has been that the model must be the same dimension as the LSS - i.e., quite large. A control theory based on the command generator tracker (CGT) ideas of Sobel, Mabins, Kaufman and Wen, Balas to obtain very low-order models based on adaptive algorithms was developed. Closed-loop stability for both finite element models and distributed parameter models of LSS was proved. In addition, successful numerical simulations on several LSS databases were obtained. An adaptive controller based on our theory was also implemented on a flexible robotic manipulator at Martin Marietta Astronautics. Computation schemes for controller-structure interaction with unmodeled modes, the residual mode filters or RMF, were developed. The RMF theory was modified to compensate slow actuator/sensor dynamics. These new ideas are being applied to LSS simulations to demonstrate the ease with which one can incorporate slow actuator/sensor effects into our design. It was also shown that residual mode filter compensation can be modified for small nonlinearities to produce exponentially stable closed-loop control. A theory for disturbance accommodating controllers based on reduced order models of structures was developed, and stability results for these controllers in closed-loop with large-scale finite element models of structures were obtained

Numerical product design: Springback prediction, compensation and optimization

Numerical simulations are being deployed widely for product design. However, the accuracy of the numerical tools is not yet always sufficiently accurate and reliable. This article focuses on the current state and recent developments in different stages of product design: springback prediction, springback compensation and optimization by finite element (FE) analysis. To improve the springback prediction by FE analysis, guidelines regarding the mesh discretization are provided and a new through-thickness integration scheme for shell elements is launched. In the next stage of virtual product design the product is compensated for springback. Currently, deformations due to springback are manually compensated in the industry. Here, a procedure to automatically compensate the tool geometry, including the CAD description, is presented and it is successfully applied to an industrial automotive part. The last stage in virtual product design comprises optimization. This article presents an optimization scheme which is capable of designing optimal and robust metal forming processes efficiently