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All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Accelerating Large-Format Metal Additive Manufacturing: How Controls R&D is Driving Speed, Scale, and Efficiency

This article highlights work at Oak Ridge National Laboratory’s Manufacturing Demonstration Facility to develop closed-loop, feedback control for laser-wire based Directed Energy Deposition, a form of metal Big Area Additive Manufacturing (m-BAAM), a process being developed in partnership with GKN Aerospace specifically for the production of Ti-6Al-4V pre-forms for aerospace components. A large-scale structural demonstrator component is presented as a case-study in which not just control, but the entire 3D printing workflow for m-BAAM is discussed in detail, including design principles for large-format metal AM, toolpath generation, parameter development, process control, and system operation, as well as post-print net-shape geometric analysis and finish machining. In terms of control, a multi-sensor approach has been utilized to measure both layer height and melt pool size, and multiple modes of closed-loop control have been developed to manipulate process parameters (laser power, print speed, deposition rate) to control these variables. Layer height control and melt pool size control have yielded excellent local (intralayer) and global (component-level) geometry control, and the impact of melt pool size control in particular on thermal gradients and material properties is the subject of continuing research. Further, these modes of control have allowed the process to advance to higher deposition rates (exceeding 7.5 lb/hr), larger parts (1-meter scale), shorter build times, and higher overall efficiency. The control modes are examined individually, highlighting their development, demonstration, and lessons learned, and it is shown how they operate concurrently to enable the printing of a large-scale, near net shape Ti-6Al-4V component.

Gibson, Brian↗
DOE OSTI2018

Modular Controllable Transformers (MCT)

Large Power Transformers (LPTs) are at the heart of the electricity infrastructure and are critical pieces in today’s grid. Aging assets, long turn-around times, transportation delays and dependence on foreign manufacturing for these components have created conditions for points of failure across the system. Moreover, there is no available dynamic control on these passive sections of the grid. For all the automation embedded on the low voltage side of the low voltage side of the system there is absolutely no flexibility on the high voltage side. Changes in power flow patterns are brought about by altering dispatch patterns for generators which requires a coordinated effort and is often time consuming. Traditional FACTS based approaches such as UPFC or HVDC light involve massive modifications to the existing infrastructure. Recent instances of physical attacks on LPTs and the slow recovery process associated with fixing or replacing these damaged units has created an increased awareness for this issue. LPT designs are highly customized owing to specific field requirements. Long lead times coupled with transportation delays make procuring and installing LPTs a lengthy process. In an attempt to minimize the recovery time following an LPT failure, transformer manufacturers have developed mobile transformer units. These units typically consist of either a single-phase or three-phase transformer mounted on a truck and characterized by compact form factors. By reducing the assembly time and transport time these units offer a fast and temporary solution to LPT failures. Several efforts led by DOE, Edison Electric Company (EEI) and North American Electric Reliability Corporation (NERC) have led to the RecX program. RecX transformers consist of single phase transformers transported on specialized assemblies to enable fast restoration and minimal installation time. NERC and EEI have instituted transformer sharing programs like Spare Equipment Database (SED) as well as Spare Transformer Equipment Database (STEP) which encourage utilities to maintain and share a fleet of LPTs. Mobile transformers are typically limited to less than 100 MVA to enable transportation on a trailer. Also, the efficiency of mobile transformer units and RecX transformers is lower since they are temporary solutions. The ideal replacement solution would be one that could utilize a set of standardized transformers while incorporating flexibility to influence metrics like power flow, apparent impedance and voltage profiles. In view of these issues the team at Georgia Tech proposed a concept called Modular Controllable Transformers (MCTs). This project was commissioned as a part of DOE’s Transformer Resiliency and Advance Component (TRAC) program. The approach consists of splitting one large unit rated upwards of 100 MVA with smaller modular, standardized units. Each of these smaller units are augmented with a converter to add power flow, voltage and impedance control. Splitting the power level into multiple units has two important implications. By making smaller units, the transportation times can be reduced drastically. Moreover, even though these units have very specific impedance and other parameters, the augmented converters can make it emulate the unit being replaced. Thus, faster replacement times and added controls are achieved making this an extremely resilient approach. In the event of one modular units failure, the other two controllable units can operate in the most resilient fashion keeping the net system overloads to a minimum. Moreover, for the same probability of failure only a fraction of the system capacity is lost. The converter is augmented on to the tertiary winding of the transformer making it retrofittable in the field without massive modifications to the system. The material proposed in this report highlights design considerations to minimize recovery time as well as results displaying overall improvement in resiliency. The cost analysis of this approach shows significant savings compared to UPFC and HVDC lite based approaches. Extensive analysis was conducted on numerous aspects of this project over the course of this project. Simulation studies were conducted to prove the 5MVA converter design. Challenging BIL constraints and transient issues were addressed over the course of this project. Simulations on EMTP platform presented in consequent sections were used to finely tune the control for the same. A final design for a back-to-back 5MVA neutral-point-clamped (NPC) converter was completed in this project. Furthermore, switching components like high power IGBTs from IXYS Westcode Press-Pack series and ABB Stackpack series were identified for this application. These devices exhibit a blocking voltage of 6.5 kV and a nominal collector current of 900 A. Potential housing options as well as existing commercial option were identified for this converter design. A 56 MVA modular transformer unit was designed with Delta Star Inc. with consultation and inputs from all project members. The transformer cooling systems were chosen to be Oil Natural Air Forced (ONAF) to optimize ease of transport. A full Product Requirement Document (PRD) for the converter and the transformer was generated. The team also investigated key aspects of resiliency and how to quantify the same. A metric was developed to analyze resiliency and numerous simulation cases were presented. Increased (N-1) resiliency and outage resistance was showcased through simulation on the Texas Large scale power system. Dynamic control capabilities were also showcased on numerous system level simulations. An IEEE 30 bus system was used to show the ability of the MCT approach to reduce line congestion. Power flow control; a part of the MCTs abilities, showcased a 29% reduction in transformer loading on the same system. Full control over tie line flows was demonstrated on a modified IEEE 13 bus system. Dynamic LTC capabilities were shown through simulation and were compared to traditional LTCs. Furthermore, the ability of the MCTs to alter apparent transformer impedance was simulated to promote standardization of modular transformer units while retaining the ability to emulate a varied range of impedance characteristics. Thus granular control over power flow, voltages, impedances and was presented. Regulatory analysis conducted by Oak Ridge National Laboratory (ORNL) further bolstered the efficacy of the MCT approach and verified the added resiliency achieved due to this approach. As a conclusion, it was proved that the resilience improvement obtained from using the MCT approach is justified by just one failure in a 30-year period. This means that the benefits obtained from using the MCT approach far outweigh the cost of setting this approach up. As a part of the future efforts, the team is proposing building a (12.47-24) kV/400 kVA scaled down unit to control 5MVA of power flows. Emphasis would be laid on using commercial components to speed up the build of these units. Further the actual transport of the modular transformer unit would be a part of this operation and would provide insight into transportation issues. The approach shows much promise and adds key dynamic control on passive sub transmission and transmission sectors.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2022

Hierarchical Model-Free Transactive Control of Building Loads to Support Grid Services

Residential buildings consume 4.4 quads of electricity annually, approximately 37% of the total electricity consumption in the United States. This represents a vast resource that can be used for demand management and other ancillary services. This project aims to develop a robust, scalable hierarchical transactional control mechanism incorporating elements of model-free control (MFC) and game theory to harness buildings to provide ancillary services to the grid. This approach is being taken to address the challenges of incorporating traditional transactional control schemes into existing buildings. The challenges include small individual building sizes requiring aggregation of many buildings, unpredictable energy usage that makes model identification difficult, and satisfying the sensitive occupant comfort constraints. In the proposed approach, by separating the control mechanism into two layers above and below the load aggregator, MFC can be used below the aggregator to modulate flexible building loads in response to pricing signals with guaranteed performance. This allows the burden of identifying an accurate model of the system to be shifted to the above-aggregator layer, where fluctuations in individual building usage have less impact on predicted building system behavior. Game theory concepts can then be used to determine pricing curves and control signals among regional aggregators. Managing this control in a game-theoretic approach will allow us to build in financial incentives that increase customer engagement. Additionally, the usage of MFC necessitates less burdensome computational and communication requirements, thus, it is easily deployable on small, embedded devices. In a broader sense, developing a strategy capable of effectively incorporating residential and small commercial buildings will allow greater throughput of existing and emerging grid services in addition to future transactive energy grid management methods. Using MFC within a hierarchical control architecture will allow the shifting of existing forecasting challenges to an aggregate level, where dynamics are slower and more predictable. This will enable a smooth interface between the grid services requests of utilities and the reliable control required by participating buildings. MFC, which supports distributed control architecture, permits a scalable solution that can be deployed to neighborhood-size systems as well as individual buildings. This project focuses on three objectives: (1) developing the mathematical framework, algorithm toolkit, and software toolset of the two-layer transactive control testbed; (2) developing a scalable solution for application over many residential and small-size commercial buildings with sparse distributed communication; and (3) field testing and implementation on hardware of the control strategies developed in the previous two objectives. The research and development activities are focused and designed to be impactful within the relevant 2025 targets timeframe. An open-source control framework for exploiting variability and dispatchability of building loads will be delivered as the outcome of the project. This capability enables greater participation of loads in electricity markets and ancillary services that are both useful for the utility and financially beneficial for building owners.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2022

Improved Moisture Management Technology for Eco-N-Control Fertilizer

Three fertilizer technologies to manage nitrogen (N) release rates in soil dominate the market today: 1) bulk controlled-release technologies, which use the intrinsic solubility properties of a N-organic co-polymer to control N release; 2) barrier-based controlled-release technologies, which use porous polymer or sulfur coatings as a physical barrier to control N release from encapsulated N nutrients; and 3) slow-release technologies, which use enzyme inhibitors to chemically slow down the transformation of N nutrients into ammonia (NH 3 ) or to temporarily reduce populations of bacteria in the soil that are responsible for converting ammonium (NH 4 + ) to highly soluble nitrates. These technologies are expensive and provide only limited control of N-release rates. Also, from another environmental perspective, synthetic polymer coatings do not decompose easily and will accumulate over time with continuous application of fertilizer. For most of the past two decades we have been developing the Eco-N-Control solid-nitride fertilizer technology, a type of bulk controlled-release technology. With Eco-N-Control, solid-nitride compounds weather like a mineral, slowly releasing N at a rate determined by their composition. Testing by an industrial collaborator, however, showed that earlier versions of Eco-N-Control released at 25% of the desired rate when deployed in unsaturated soils. The overall goal of the current project, therefore, was to strengthen our IP position and the potential for licensing of Eco-N-Control solid-nitride fertilizer technology by developing new ways to manage the level of moisture in contact with the fertilizer when applied to soil thereby ensuring the desired N-release rate. We achieved this goal by developing a biodegradable polymer cross-linking approach that substantially improved performance of our patented solid-nitride fertilizer. We found that cross-linking an environmentally friendly and biodegradable polymer with a mixture of solid nitrides, other N-nutrient compounds and other additives offers several advantages: 1) mechanical robustness of fertilizer beads, 2) chemical stability during storage, 3) maintenance of sufficient water content in the vicinity of the nitride, and 4) control of N-release rates. We also updated our N-release testing protocol to more realistically simulate the conditions found in soil. Finally, we filed an invention disclosure record to protect these new aspects of Eco-N-Control technology, which offers a potential way to lower both agricultural and industrial pollution by providing an efficient N-delivery mechanism to plants.

42 ENGINEERING↗
DOE OSTI2023

Demonstrating Load-Shaping Capabilities of Cost Minimizing Heat Pump Water Heater Controls with Varying Price Profiles

Increased penetration of photovoltaics and electrification of traditionally gas appliances are exacerbating existing challenges in cost-effectively balancing electricity grid supply and demand. Decarbonization without incurring expensive transmission and distribution system capacity increases requires shifting building loads from peak demand times to peak renewable production times. Grid operators are evaluating new ways of encouraging load shifting, including using time-varying price structures to provide a financial incentive. If devices incorporate price-responsive controls, a price profile could be designed to yield a wide variety of load curves as needed to optimize grid functionality. Heat pump water heaters (HPWHs) are an ideal device for price-responsive controls because the storage tank enables them to optimize the timing of electricity consumption without impacting hot water delivery service. This paper presents work demonstrating how price-responsive controls for HPWHs can provide different load profiles, as needed to stabilize the grid, in response to different price profiles. HPWH manufacturers now include web API and CTA-2045 communication capabilities which enable sending load shaping control signals. Pilot studies and preliminary programs have utilized these capabilities with uniform control strategies to reduce 4-9 PM electricity consumption. However, no studies have developed flexible controls capable of both a) responding to constantly varying price profiles and b) customizing logic to match the needs of each HPWH. Berkeley Lab's CalFlexHub project is pioneering price-driven load flexibility by developing and deploying cost-minimizing controls utilizing setpoint setting signals for fleets of HPWHs in response to varying price profiles. Control development is based on simulations using the Flexible Heat Pump Water Heater Performance Predictor which captures the control decisions of a residential, integrated HPWH manufacturer’s on-board controller. The proposed cost-reducing controls respond to constantly changing price profiles, providing the ability to change the price profile to generate load curves as needed to maintain grid stability. Preliminary simulations studying the load shaping capabilities of price-responsive controls on a fleet of 60 HPWHs have demonstrated an average of a) 135.4% increases in load during low-price periods, b) >36.8% reductions in electricity peak-price period, and c) 6.2% electricity cost savings.

24 POWER TRANSMISSION AND DISTRIBUTION↗
NASA NTRS1978

Wind tunnel evaluation of YF-12 inlet response to internal airflow disturbances with and without control

The response of terminal-shock position and static pressures in the subsonic duct of a YF-12 aircraft flight-hardware inlet to perturbations in simulated engine corrected airflow were obtained with and without inlet control. Frequency response data, obtained with inlet controls inactive, indicated the general nature of the inherent inlet dynamics, assisted in the design of controls, and provided a baseline reference for responses with active controls. All the control laws were implemented by means of a digital computer that could be programmed to behave like the flight inlet's existing analog control. The experimental controls were designed using an analytical optimization technique. The capabilities of the controls were limited primarily by the actuation hardware. The experimental controls provided somewhat better attenuation of terminal shock excursions than did the YF-13 inlet control. Controls using both the forward and aft bypass systems also provided somewhat better attenuation than those using just the forward bypass. The main advantage of using both bypasses is in the greater control flexibility that is achieved.

Cole, G. L.↗
NASA NTRS1983

A study of helicopter gust response alleviation by automatic control

Two control schemes designed to alleviate gust-induced vibration are analytically investigated for a helicopter with four articulated blades. One is an individual blade pitch control scheme. The other is an adaptive blade pitch control algorithm based on linear optimal control theory. In both controllers, control inputs to alleviate gust response are superimposed on the conventional control inputs required to maintain the trim condition. A sinusoidal vertical gust model and a step gust model are used. The individual blade pitch control, in this research, is composed of sensors and a pitch control actuator for each blade. Each sensor can detect flapwise (or lead-lag or torsionwise) deflection of the respective blade. The acturator controls the blade pitch angle for gust alleviation. Theoretical calculations to predict the performance of this feedback system have been conducted by means of the harmonic method. The adaptive blade pitch control system is composed of a set of measurements (oscillatory hub forces and moments), an identification system using a Kalman filter, and a control system based on the minimization of the quadratic performance function.

Saito, S.↗
NASA NTRS1987

Design of force/position controllers for manipulators

The paper presents simple methods for the design of adaptive force and position controllers for robot manipulators within the hybrid control architecture. The force controller is composed of an adaptive PID feedback controller, an auxiliary signal and a force feedforward term, and achieves tracking of desired force setpoints in the constraint directions. The position controller consists of adaptive feedback and feedforward controllers and an auxiliary signal; and accomplishes tracking of desired position trajectories in the free directions. The controllers are capable of compensating for dynamic cross-couplings that exist between the position and force control loops in the hybrid control architecture. The adaptive controllers do not require knowledge of the complex dynamic model or parameter values of the manipulator or the environment. The proposed control schemes are computationally fast and suitable for implementation in on-line control with high sampling rates.

Seraji, H.↗
NASA NTRS1988

Dual adaptive control: Design principles and applications

The design of an actively adaptive dual controller based on an approximation of the stochastic dynamic programming equation for a multi-step horizon is presented. A dual controller that can enhance identification of the system while controlling it at the same time is derived for multi-dimensional problems. This dual controller uses sensitivity functions of the expected future cost with respect to the parameter uncertainties. A passively adaptive cautious controller and the actively adaptive dual controller are examined. In many instances, the cautious controller is seen to turn off while the latter avoids the turn-off of the control and the slow convergence of the parameter estimates, characteristic of the cautious controller. The algorithms have been applied to a multi-variable static model which represents a simplified linear version of the relationship between the vibration output and the higher harmonic control input for a helicopter. Monte Carlo comparisons based on parametric and nonparametric statistical analysis indicate the superiority of the dual controller over the baseline controller.

Mookerjee, Purusottam↗
NASA NTRS1988

Robust control with structured perturbations

Two important problems in the area of control systems design and analysis are discussed. The first is the robust stability using characteristic polynomial, which is treated first in characteristic polynomial coefficient space with respect to perturbations in the coefficients of the characteristic polynomial, and then for a control system containing perturbed parameters in the transfer function description of the plant. In coefficient space, a simple expression is first given for the l(sup 2) stability margin for both monic and non-monic cases. Following this, a method is extended to reveal much larger stability region. This result has been extended to the parameter space so that one can determine the stability margin, in terms of ranges of parameter variations, of the closed loop system when the nominal stabilizing controller is given. The stability margin can be enlarged by a choice of better stabilizing controller. The second problem describes the lower order stabilization problem, the motivation of the problem is as follows. Even though the wide range of stabilizing controller design methodologies is available in both the state space and transfer function domains, all of these methods produce unnecessarily high order controllers. In practice, the stabilization is only one of many requirements to be satisfied. Therefore, if the order of a stabilizing controller is excessively high, one can normally expect to have a even higher order controller on the completion of design such as inclusion of dynamic response requirements, etc. Therefore, it is reasonable to have a lowest possible order stabilizing controller first and then adjust the controller to meet additional requirements. The algorithm for designing a lower order stabilizing controller is given. The algorithm does not necessarily produce the minimum order controller; however, the algorithm is theoretically logical and some simulation results show that the algorithm works in general.

Keel, Leehyun↗
NASA NTRS1987

Adaptive hybrid control of manipulators

Simple methods for the design of adaptive force and position controllers for robot manipulators within the hybrid control architecuture is presented. The force controller is composed of an adaptive PID feedback controller, an auxiliary signal and a force feedforward term, and it achieves tracking of desired force setpoints in the constraint directions. The position controller consists of adaptive feedback and feedforward controllers and an auxiliary signal, and it accomplishes tracking of desired position trajectories in the free directions. The controllers are capable of compensating for dynamic cross-couplings that exist between the position and force control loops in the hybrid control architecture. The adaptive controllers do not require knowledge of the complex dynamic model or parameter values of the manipulator or the environment. The proposed control schemes are computationally fast and suitable for implementation in on-line control with high sampling rates.

Seraji, H.↗
NASA NTRS1989

Robust high-performance control for robotic manipulators

Model-based and performance-based control techniques are combined for an electrical robotic control system. Thus, two distinct and separate design philosophies were merged into a single control system having a control law formulation including two distinct and separate components, each of which yields a respective signal componet that is combined into a total command signal for the system. Those two separate system components include a feedforward controller and feedback controller. The feedforward controller is model-based and contains any known part of the manipulator dynamics that can be used for on-line control to produce a nominal feedforward component of the system's control signal. The feedback controller is performance-based and consists of a simple adaptive PID controller which generates an adaptive control signal to complement the nomical feedforward signal.

Seraji, Homayoun↗
NASA NTRS1989

Automatic control of cryogenic wind tunnels

Inadequate Reynolds number similarity in testing of scaled models affects the quality of aerodynamic data from wind tunnels. This is due to scale effects of boundary-layer shock wave interaction which is likely to be severe at transonic speeds. The idea of operation of wind tunnels using test gas cooled to cryogenic temperatures has yielded a quantrum jump in the ability to realize full scale Reynolds number flow similarity in small transonic tunnels. In such tunnels, the basic flow control problem consists of obtaining and maintaining the desired test section flow parameters. Mach number, Reynolds number, and dynamic pressure are the three flow parameters that are usually required to be kept constant during the period of model aerodynamic data acquisition. The series of activity involved in modeling, control law development, mechanization of the control laws on a microcomputer, and the performance of a globally stable automatic control system for the 0.3-m Transonic Cryogenic Tunnel (TCT) are discussed. A lumped multi-variable nonlinear dynamic model of the cryogenic tunnel, generation of a set of linear control laws for small perturbation, and nonlinear control strategy for large set point changes including tunnel trajectory control are described. The details of mechanization of the control laws on a 16 bit microcomputer system, the software features, operator interface, the display and safety are discussed. The controller is shown to provide globally stable and reliable temperature control to + or - 0.2 K, pressure to + or - 0.07 psi and Mach number to + or - 0.002 of the set point value. This performance is obtained both during large set point commands as for a tunnel cooldown, and during aerodynamic data acquisition with intrusive activity like geometrical changes in the test section such as angle of attack changes, drag rake movements, wall adaptation and sidewall boundary-layer removal. Feasibility of the use of an automatic Reynolds number control mode with fixed Mach number control is demonstrated.

Balakrishna, S.↗
NASA NTRS1990

Electromechanical actuation for thrust vector control applications

At present, actuation systems for the Thrust Vector Control (TVC) for launch vehicles are hydraulic systems. The Advanced Launch System (ALS), a joint initiative between NASA and the Air Force, is a launch vehicle that is designed to be cost effective, highly reliable and operationally efficient with a goal of reducing the cost per pound to orbit. As part of this initiative, an electromechanical actuation system is being developed as an attractive alternative to the hydraulic systems used today. NASA-Lewis is developing and demonstrating an Induction Motor Controller Actuation System with a 40 hp peak rating. The controller will integrate 20 kHz resonant link Power Management and Distribution (PMAD) technology and Pulse Population Modulation (PPM) techniques to implement Field Oriented Vector Control (FOVC) of a new advanced induction motor. Through PPM, multiphase variable frequency, variable voltage waveforms can be synthesized from the 20 kHz source. FOVC shows that varying both the voltage and frequency and their ratio (V/F), permits independent control of both torque and speed while operating at maximum efficiency at any point on the torque-speed curve. The driver and the FOVC will be microprocessor controlled. For increased system reliability, a Built-in Test (BITE) capability will be included. This involves introducing testability into the design of a system such that testing is calibrated and exercised during the design, manufacturing, maintenance and prelaunch activities. An actuator will be integrated with the motor controller for performance testing of the EMA TVC system. The design and fabrication of the motor controller is being done by General Dynamics Space Systems Division. The University of Wisconsin-Madison will assist in the design of the advanced induction motor and in the implementation of the FOVC theory. A 75 hp electronically controlled dynamometer will be used to test the motor controller in all four quadrants of operation using flight type control algorithms. Integrated testing of the controller and actuator will be conducted at a facility yet to be named. The EMA system described above is discussed in detail.

Roth, Mary Ellen↗
NASA NTRS1989

Control strategies for a telerobot

One of the major issues impacting the utility of telerobotic systems for space is the development of effective control strategies. For near-term applications, telerobot control is likely to utilize teleoperation methodologies with integrated supervisory control capabilities to assist the operator. Two different approaches to telerobotic control are evaluated: bilateral force reflecting master controllers and proportional rate six degrees-of-freedom hand controllers. The controllers' performance of single manipulator arm tasks is compared. Simultaneous operation of both manipulator arms and complex multiaxis slave arm movements is investigated. Task times are significantly longer and fewer errors are committed with the hand controllers. The hand controllers are also rated significantly higher in cognitive and manual control workload on the two-arm task. The master controllers are rated significantly higher in physical workload. The implications of these findings for space teleoperations and higher levels of control are discussed.

Ohara, John↗
NASA NTRS1991

Robust and real-time control of magnetic bearings for space engines

Currently, NASA Lewis Research Center is developing magnetic bearings for Space Shuttle Main Engine (SSME) turbopumps. The control algorithms which have been used are based on either the proportional-intergral-derivative control (PID) approach or the linear quadratic (LQ) state space approach. These approaches lead to an acceptable performance only when the system model is accurately known, which is seldom true in practice. For example, the rotor eccentricity, which is a major source of vibration at high speeds, cannot be predicted accurately. Furthermore, the dynamics of a rotor shaft, which must be treated as a flexible system to model the elastic rotor shaft, is infinite dimensional in theory and the controller can only be developed on the basis of a finite number of modes. Therefore, the development of the control system is further complicated by the possibility of closed loop system instability because of residual or uncontrolled modes, the so called spillover problem. Consequently, novel control algorithms for magnetic bearings are being developed to be robust to inevitable parametric uncertainties, external disturbances, spillover phenomenon and noise. Also, as pointed out earlier, magnetic bearings must exhibit good performance at a speed over 30,000 rpm. This implies that the sampling period available for the design of a digital control system has to be of the order of 0.5 milli-seconds. Therefore, feedback coefficients and other required controller parameters have to be computed off-line so that the on-line computational burden is extremely small. The development of the robust and real-time control algorithms is based on the sliding mode control theory. In this method, a dynamic system is made to move along a manifold of sliding hyperplanes to the origin of the state space. The number of sliding hyperplanes equals that of actuators. The sliding mode controller has two parts; linear state feedback and nonlinear terms. The nonlinear terms guarantee that the systems would reach the intersection of all sliding hyperplanes and remain on it when bounds on the errors in the system parameters and external disturbances are known. The linear part of the control drives the system to the origin of state space. Another important feature is that the controller parameter can be computed off-line. Consequently, on-line computational burden is small.

Sinha, Alok↗
NASA NTRS1992

Computer optimization techniques for NASA Langley's CSI evolutionary model's real-time control system

The evolution and optimization of a real-time digital control system is presented. The control system is part of a testbed used to perform focused technology research on the interactions of spacecraft platform and instrument controllers with the flexible-body dynamics of the platform and platform appendages. The control system consists of Computer Automated Measurement and Control (CAMAC) standard data acquisition equipment interfaced to a workstation computer. The goal of this work is to optimize the control system's performance to support controls research using controllers with up to 50 states and frame rates above 200 Hz. The original system could support a 16-state controller operating at a rate of 150 Hz. By using simple yet effective software improvements, Input/Output (I/O) latencies and contention problems are reduced or eliminated in the control system. The final configuration can support a 16-state controller operating at 475 Hz. Effectively the control system's performance was increased by a factor of 3.

Elliott, Kenny B.↗
NASA NTRS1991

Centralized, decentralized, and independent control of a flexible manipulator on a flexible base

The dynamics and control of a flexible manipulator arm with payload mass on a flexible base in space are considered. The controllers are provided by one torquer at the center of the base and one torquer at the connection joint of the robot and the base. The nonlinear dynamics of the system is modeled by applying the finite element method and Lagrangian formula. Three control strategies are considered and compared, i.e., centralized control, decentralized control, and independent control. All these control designs are based on the linear quadratic regulator theory. A mathematical decomposition is used in the decentralization process so that the coupling between the subsystems is weak, while a physical decomposition is used in the independent control design process. For both the decentralized and the independent controls, the stability of the overall linear system is checked before a numerical simulations is initiated. Two numerical examples show that the response of the independent control system are close to those of the centralized control system, while the responses of the decentralized control system are not.

Li, Feiyue↗