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This paper presents an approach to the automatic redesign of flight control systems for aircraft that have suffered one or more control element failures. The procedure is based on Linear Quadratic design techniques, and produces a control system that maximizes a measure of feedback system performance subject to a bandwidth constraint.
The purpose of this project was to investigate the use of optimization techniques to improve the flutter margins of the HARM AGM-88A wing. The missile has four cruciform wings, located near mid-fuselage, that are actuated in pairs symmetrically and antisymmetrically to provide pitch, yaw, and roll control. The wings have a solid stainless steel forward section and a stainless steel crushed-honeycomb aft section. The wing restraint stiffness is dependent upon wing pitch amplitude and varies from a low value near neutral pitch attitude to a much higher value at off-neutral pitch attitudes, where aerodynamic loads lock out any free play in the control system. The most critical condition for flutter is the low-stiffness condition in which the wings are moved symmetrically. Although a tendency toward limit-cycle flutter is controlled in the current design by controller logic, wing redesign to improve this situation is attractive because it can be accomplished as a retrofit. In view of the exploratory nature of the study, it was decided to apply the optimization to a wing-only model, validated by comparison with results obtained by Texas Instruments (TI). Any wing designs that looked promising were to be evaluated at TI with more complicated models, including body modes. The optimization work was performed by McIntosh Structural Dynamics, Inc. (MSD) under a contract from TI.
A computational analysis, modification, and preliminary redesign study was performed on the nozzle contour of the Langley Hypersonic CF4 Tunnel. This study showed that the existing nozzle was contoured incorrectly for the design operating condition, and this error was shown to produce the measured disturbances in the exit flow field. A modified contour was designed for the current nozzle downstream of the maximum turning point that would provide a uniform exit flow. New nozzle contours were also designed for an exit Mach number and Reynolds number combination which matches that attainable in the Langley 20-Inch Mach 6 Tunnel. Two nozzle contours were designed: one having the same exit radius but a larger mass flow rate than that of the existing CF4 Tunnel, and the other having the same mass flow rate but a smaller exit radius than that of the existing CF4 Tunnel.
The Space Shuttle Redesigned Solid Rocket Motor (RSRM) Certification Program provides confidence that the RSRM and its components/subsystems meet or exceed Mission Oriented Requirements when manufactured per design requirements and specified/approved processes. Certification is based on documented results of tests, analyses, inspections, similarity, and demonstrations. Evidencing information is provided to certify that each RSRM component/subsystem satisfies design, mission related requirements and objectives.
The effects of erosion and thermal degradation on the Space Shuttle Redesigned Solid Rocket Motor (RSRM) nozzle's structural dynamic characteristics were analytically evaluated. Also considered was stiffening of the structure due to internal pressurization. A detailed NASTRAN finite element model of the nozzle was developed and used to evaluate the influence of these effects at several discrete times during motor burn. Methods were developed for treating erosion and thermal degradation, and a procedure was developed to account for internal pressure stiffening using differential stiffness matrix techniques. Results were verified using static firing test accelerometer data. Fast Fourier Transform and Maximum Entropy Method techniques were applied to the data to generate waterfall plots which track modal frequencies with burn time. Results indicate that the lower frequency nozzle 'vectoring' modes are only slightly affected by erosion, thermal effects and internal pressurization. The higher frequency shell modes of the nozzle are, however, significantly reduced.
The Spartan Release Engage Mechanism (REM) is a system designed to restrain the Spartan spacecraft during Space Transportation System (STS) launch and landing. The mechanism is designed to allow deployment and retrieval of the Spartan free flyer spacecraft from the shuttle payload bay. Because current Spartan spacecraft payloads are much heavier than payloads intended for the original REM, an extensive redesign, analysis, and test program was necessary. Also, increased emphasis on safety in the post-Challenger era prompted a reevaluation of possible failures. Much of the design effort focused on improving the latch mechanism gearbox. Key concerns were effective gear lubrication, thermal gradients at the gearbox mounts, operation at thermal extremes, and gear-train failure contingencies. Increased concern for reliability led to the design of an Extra Vehicular Activity (EVA) backup latch system.
A transient, semi-coupled, multi-dimensional thermal and flow analysis methodology was developed to predict the thermal/gas dynamic conditions in the field joint region of the Redesigned Solid Rocket Motor (RSRM). Transient temperature response, pressure history, and combustion gas flow rate (within the field joint region), were of principle interest, in the course of this study. The thermal environment in the field joint was modeled using SINDA, a finite difference based thermal network analyzer. The combustion gas flow boundary condition was generated using the FLAP code; this code performs a transient, lumped-parameter, control volume analysis to solve the mass, momentum, and energy conservation equations. The FLAP computer code was modified to account for erosion of the NBR insulation material, following ignition. An independent grid sensitivity study was conducted to determine an appropriate grid distribution near the wall. The predicted results, obtained using an optimum grid distribution and computer generated flow boundary condition, were compared with subscale test data.
The mixed-mode bending (MMB) test uses a lever to apply simultaneously mode I and mode II loading to a split-beam specimen. An iterative analysis that accounts for the geometric nonlinearity of the MMB test was developed. The analysis accurately predicted the measured load-displacement response and the strain energy release rate, G, of an MMB test specimen made of AS4/PEEK. The errors in G when calculated using linear theory were found to be as large as 30 percent in some cases. Because it would be inconvenient to use a nonlinear analysis to analyze MMB data, the MMB apparatus was redesigned to minimize the nonlinearity. With the improved apparatus, loads are applied just above the midplane of the test specimen through a roller attached to the lever. This apparatus was demonstrated by measuring the mixed-mode delamination fracture toughhess of the test specimen. The nonlinearity errors associated with testing this tough composite material were less than +/- 3 percent. The data from the improved MMB apparatus analyzed with a linear analysis were similar to those found with the original apparatus and the nonlinear analysis.
The concepts of multivariable control design are used to redesign structures represented by lumped parameter models. When the mass is held constant, the changing of passive structural members is mathematically equivalent to an output feedback decentralized control problem. When the mass is also allowed to change, a generalization of the output feedback formulation is required. The design objective is to minimize the changes in the structure required to simultaneously satisfy inequality constraints on both the root-mean-square and absolute value of the dynamic response of each output. An alternative objective treated is to minimize the root-mean-square of the dynamic response subject to inequality constraints on the changes allowed in each structural member. Examples illustrate both procedures.
A control redesign problem of the Hubble Space Telescope for reducing the effects of solar array vibrations on telescope pointing jitter is investigated. Both classical and H(infinity) control design methodologies are employed for such a control problem with a non-colocated actuator and sensor pair. This paper successfully demonstrates the effectiveness of a dipole concept for precision line-of-sight pointing control in the presence of significant structural vibrations. Proposed controllers with two dipoles effectively reduce the effects of the solar array induced disturbances at 0.12 Hz and 0.66 Hz on pointing jitter.
A one-dimensional analytical tool, TOPAZ (Transient One-dimensional Pipe flow AnalyZer), was used to model the flow characteristics of hot combustion gases through Redesigned Solid Rocket Motor (RSRM) joints and to compute the resultant material surface temperatures and o-ring seal erosion of the joints. The capabilities of the analytical tool were validated with test data during the Seventy Pound Charge (SPC) motor test program. The predicted RSRM joint thermal response to ignition transients was compared with test data for full-scale motor tests. The one-dimensional analyzer is found to be an effective tool for simulating combustion gas flows in RSRM joints and for predicting flow and thermal properties.
An elastomeric O-ring material is used in the joints of the redesigned solid motors (RSRM's) of the National Space Transportation System (NSTS). The selection of the O-ring material used in the RSRM's was a very thorough process that included efforts by NASA's Marshall Space Flight Center and the Langley Research Center, and the Thiokol Corporation. One of the efforts performed at MSFC was an extensive in-house laboratory test regime to screen potential O-ring materials and ultimately to characterize the elastomeric material that was chosen to be used in the RSRM's. The laboratory tests performed at MSFC are summarized.
Following the Space Shuttle STS-51L disaster on January 28, 1986, a considerable redesign effort was launched on the Solid Rocket Booster. This effort culminated in three instrumented flights, STS-26R, 27R, and 29R, beginning in September of 1989. Aeroheating data were obtained on these flights in the form of pressure, heat flux, and gas temperature probe measurements. These data were analyzed from an ascent and reentry heating point of view. The flight data were verified, compared with historic and theoretical results, and scaled to design. Impact of these results on the current design environment set was assessed and recommendations made. This report documents this effort.
This paper proposes a new optimal digital redesign technique for finding a dynamic digital control law from the available analog counterpart and simultaneously minimizing a quadratic performance index. The proposed technique can be applied to a system with a more general class of reference inputs, and the developed digital regulator can be implemented using low cost microcomputers.
This paper presents a new, optimal digital redesign technique for finding an optimal cascaded digital controller from the given continuous-time counterpart by minimizing a quadratic performance index. The control gains can be obtained by solving a set of Liapunov equations. The developed optimal cascaded digital controller enables the state and/or outputs of the digitally controlled closed-loop sampled-data system to optimally match those of the original continuous-time closed-loop system at any instant between sampling periods. The developed control law can be implemented using inexpensive and reliable digital electronics with a relatively long sampling period.
MSFC's quick response to the Space Station redesign effort last year required the development of a computer simulation to model the attitude and station-keeping dynamics of a complex body with rotating solar arrays in orbit around the Earth. The simulation was written using a rapid-prototyping graphical simulation and design tool called MATRIX(x) and provided the capability to quickly remodel complex configuration changes by icon manipulation using a mouse. The simulation determines time-dependent inertia properties, and models forces and torques from gravity-gradient, solar radiation, and aerodynamic disturbances. Surface models are easily built from a selection of beams, plates, tetrahedrons, and cylinders. An optimization scheme was written to determine the torque equilibrium attitudes that balance gravity-gradient and aerodynamic torques over an orbit, and propellant-usage estimates were determined. The simulation has been adapted to model the attitude dynamics for small spacecraft.
Verification of proposed turbopump blading performance will involve evaluation of candidate blades in cascade test facilities. It is necessary to be able to predict the flow fields within these cascades for the results to be applicable to actual engine environments. This work presents the results of a study to predict the flow field for the NASA Lewis Transonic Turbine Blade Cascade Facility, which is similar to those used to evaluate rocket propulsion turbines. A pitchwise nonuniform total pressure distribution was observed at the blade row leading edge plane. A CFD analysis was used to show that the cause of the flow nonuniformity was a pair of vortices that originated in an embedded bellmouth inlet. Further CFD analysis was used to verify that a redesigned inlet section resulted in a flow with acceptable uniformity. A computational analysis was chosen because physical accessibility to the inlet section was limited, and because a computational approach also allows one to examine design changes cheaper and more quickly than an experimental approach would. The PARC code, a general purpose, three-dimensional, Navier-Stokes code with multiblock solution capability, was chosen for the present study. Results are presented detailing the computational requirements needed to accurately predict flows of this nature. Calculations of the original geometry showed total pressure loss regions consistent in strength and in location to experimental measurements. An examination of the results shows that the distortions are caused by a pair of vortices that originate as a result of the interaction of the flow with the imbedded bellmouth. Computations were performed for an inlet geometry which eliminated the imbedded bellmouth by bridging the region between it and the upstream wall. This analysis indicated that eliminating the imbedded bellmouth eliminates the troublesome pair of vortices, resulting in a flow with much greater pitchwise uniformity.
A control redesign problem of the Hubble Space Telescope (HST) for reducing the effects of solar array vibrations on telescope pointing jitter is investigated. Both classical and H infinity control design methodologies are employed for such a control problem with a non-colocated actuator and sensor pair. This pair successfully demonstrates the effectiveness of a dipole concept for precision line-of-sight pointing control in the presence of significant stuctural vibrations. Proposed controllers with two dipoles effectively reduce the effects of the solar array induced disturbances at 0.12 Hz and 0.66 Hz on pointing jitter.