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NASA NTRS1995

Actively Controlled Shaft Seals for Aerospace Applications

This study experimentally investigates an actively controlled mechanical seal for aerospace applications. The seal of interest is a gas seal, which is considerably more compact than previous actively controlled mechanical seals that were developed for industrial use. In a mechanical seal, the radial convergence of the seal interface has a primary effect on the film thickness. Active control of the film thickness is established by controlling the radial convergence of the seal interface with a piezoelectric actuator. An actively controlled mechanical seal was initially designed and evaluated using a mathematical model. Based on these results, a seal was fabricated and tested under laboratory conditions. The seal was tested with both helium and air, at rotational speeds up to 3770 rad/sec, and at sealed pressures as high as 1.48 x 10(exp 6) Pa. The seal was operated with both manual control and with a closed-loop control system that used either the leakage rate or face temperature as the feedback. The output of the controller was the voltage applied to the piezoelectric actuator. The seal operated successfully for both short term tests (less than one hour) and for longer term tests (four hours) with a closed-loop control system. The leakage rates were typically 5-15 slm (standard liters per minute), and the face temperatures were generally maintained below 100C. When leakage rate was used as the feedback signal, the setpoint leakage rate was typically maintained within 1 slm. However, larger deviations occurred during sudden changes in sealed pressure. When face temperature was used as the feedback signal, the setpoint face temperature was generally maintained within 3 C, with larger deviations occurring when the sealed pressure changes suddenly. the experimental results were compared to the predictions from the mathematical model. The model was successful in predicting the trends in leakage rate that occurred as the balance ratio and sealed pressure changed, although the leakage rates were not quantitatively predicted with a high degree of accuracy. This model could be useful in providing valuable design information for future actively controlled mechanical seals.

Salant, Richard F.↗

NASA NTRS1996

Pointing and Scanning Control of Instruments Using Rotating Unbalanced Masses

Motions of telescopes, satellites, and other flight bodies have been controlled by various means in the past. For example, gimbal mounted devices can use electric motors to produce pointing and scanning motions. Reaction wheels, control moment gyros, and propellant-charged reaction jets are other technologies that have also been used. Each of these methods has its advantages, but all actuator systems used in a flight environment face the challenges of minimizing weight, reducing energy consumption, and maximizing reliability. Recently, Polites invented and patented the Rotating Unbalanced Mass (RUM) device as a means for generation scanning motion on flight experiments. RUM devices have been successfully used to generate various scanning motions. The basic principle: a RUM rotating at constant annular velocity exerts a cyclic centrifugal force on the instrument or main body, thus producing a periodic scanning motion. A system of RUM devices exerts no reaction forces on the main body, requires very little energy, and is very simple to construct and control. These are significant advantages over electric motors, reaction wheels, and control moment gyroscopes. Although the RUM device very easily produces scanning motion, an auxiliary control system may be required to maintain the proper orientation, or pointing of the main body. It has been suggested that RUM devices can be used to control pointing dynamics, as well as generate the desired periodic scanning motion. The idea is that the RUM velocity will not be constant, but will vary over the period of one RUM rotation. The thought is that the changing angular velocity produces a centrifugal force having time-varying magnitude and direction. The scope of the present research project is to further study the pointing control concept, and to implement a microcontroller program to control an experimental hardware system. This report is subdivided into three themes. The basic dynamic modeling and control principles are described first. Then, the controller implementation and preliminary test results are discussed. Finally, suggestions for future work are presented.

Hung, John Y.↗

NASA NTRS1959

Ground Simulator Studies of a Nonlinear Linkage in a Power Control System

An investigation was made to determine the characteristics of a nonlinear linkage installed in a power control system incorporated in a ground simulator. The nonlinear linkage provided for increased control-stick motion for relatively small simulator response at control motions near neutral. The quality of the control system was rated on the ease and precision with which various tracking tasks were performed by the pilots who operated the simulator. The results obtained with the nonlinear linkage installed in the control system were compared with those obtained by using the normal linear control system. Several combinations of nonlinearity of the linkage were tested for various dynamic characteristics of the simulator. It was found that the pilots were able to track almost as well with the nonlinear linkage installed as with the normal system. All of the pilots were of the opinion, however, that the nonlinearity was an undesirable feature in the control system because of the apparent lack of simulator response through the neutral range of the linkage where relatively large stick deflections could be made with very little simulator motion. The results showed that increased lag between the target and chair position, higher stick-force levels, and uneven stick forces due to the dynamics of the linkage were general characteristics of all the nonlinear linkage conditions tested. It was also found that for cases of low simulator damping, rapid control motions caused considerably higher overshoots when the nonlinear linkage was installed than were obtained for the normal linear control system. These characteristics were considered to be sufficiently undesirable to out-weigh the advantages to be gained from the use of a nonlinear linkage in the control system of an airplane.

Assadourian, Arthur↗

NASA NTRS1959

Trajectory Control for Vehicles Entering the Earth's Atmosphere at Small Flight Path Angles

Methods of controlling the trajectories of high-drag-low-lift vehicles entering the earth's atmosphere at angles of attack near 90 deg and at initial entry angles up to 3 deg are studied. The trajectories are calculated for vehicles whose angle of attack can be held constant at some specified value or can be perfectly controlled as a function of some measured quantity along the trajectory. The results might be applied in the design of automatic control systems or in the design of instruments which will give the human pilot sufficient information to control his trajectory properly during an atmospheric entry. Trajectory data are compared on the basis of the deceleration, range, angle of attack, and, in some cases, the rate of descent. The aerodynamic heat-transfer rate and skin temperature of a vehicle with a simple heat-sink type of structure are calculated for trajectories made with several types of control functions. For the range of entry angles considered, it is found that the angle of attack can be controlled to restrict the deceleration down to an arbitrarily chosen level of 3g. All the control functions tried are successful in reducing the maximum deceleration to the desired level. However, in order to avoid a tendency for the deceleration to reach an initial peak decrease, and then reach a second peak, some anticipation is required in the control function so that the change in angle of attack will lead the change in deceleration. When the angle of attack is controlled in the aforementioned manner, the maximum rate of aerodynamic heat transfer to the skin is reduced, the maximum skin temperature of the vehicle is virtually unaffected, and the total heat absorbed is slightly increased. The increase in total heat can be minimized, however, by maintaining the maximum desired deceleration for as much of the trajectory as possible. From an initial angle of attack of 90 deg, the angle-of-attack requirements necessary to maintain constant values of deceleration (1g to 4g) and constant values of rate of descent (450 to 1,130 ft/sec) as long as it is aerodynamically practical are calculated and are found to be moderate in both magnitude and rate. Entry trajectories made with these types of control are presented and discussed.

Eggleston, John M.↗

NASA NTRS1998

Deterministic Reconfigurable Control Design for the X-33 Vehicle

In the event of a control surface failure, the purpose of a reconfigurable control system is to redistribute the control effort among the remaining working surfaces such that satisfactory stability and performance are retained. Four reconfigurable control design methods were investigated for the X-33 vehicle: Redistributed Pseudo-Inverse, General Constrained Optimization, Automated Failure Dependent Gain Schedule, and an Off-line Nonlinear General Constrained Optimization. The Off-line Nonlinear General Constrained Optimization approach was chosen for implementation on the X-33. Two example failures are shown, a right outboard elevon jam at 25 deg. at a Mach 3 entry condition, and a left rudder jam at 30 degrees. Note however, that reconfigurable control laws have been designed for the entire flight envelope. Comparisons between responses with the nominal controller and reconfigurable controllers show the benefits of reconfiguration. Single jam aerosurface failures were considered, and failure detection and identification is considered accomplished in the actuator controller. The X-33 flight control system will incorporate reconfigurable flight control in the baseline system.

Wagner, Elaine A.↗

NASA NTRS1998

Predictive Feedback and Feedforward Control for Systems with Unknown Disturbances

Predictive feedback control has been successfully used in the regulation of plate vibrations when no reference signal is available for feedforward control. However, if a reference signal is available it may be used to enhance regulation by incorporating a feedforward path in the feedback controller. Such a controller is known as a hybrid controller. This paper presents the theory and implementation of the hybrid controller for general linear systems, in particular for structural vibration induced by acoustic noise. The generalized predictive control is extended to include a feedforward path in the multi-input multi-output case and implemented on a single-input single-output test plant to achieve plate vibration regulation. There are cases in acoustic-induce vibration where the disturbance signal is not available to be used by the hybrid controller, but a disturbance model is available. In this case the disturbance model may be used in the feedback controller to enhance performance. In practice, however, neither the disturbance signal nor the disturbance model is available. This paper presents the theory of identifying and incorporating the noise model into the feedback controller. Implementations are performed on a test plant and regulation improvements over the case where no noise model is used are demonstrated.

Juang, Jer-Nan↗

NASA NTRS1996

An Overview of Controls and Flying Qualities Technology on the F/A-18 High Alpha Research Vehicle

The NASA F/A-18 High Alpha Research Vehicle (HARV) has been the flight test bed of a focused technology effort to significantly increase maneuvering capability at high angles of attack. Development and flight test of control law design methodologies, handling qualities metrics, performance guidelines, and flight evaluation maneuvers are described. The HARV has been modified to include two research control effectors, thrust vectoring, and actuated forebody strakes in order to provide increased control power at high angles of attack. A research flight control system has been used to provide a flexible, easily modified capability for high-angle-of-attack research controls. Different control law design techniques have been implemented and flight-tested, including eigenstructure assignment, variable gain output feedback, pseudo controls, and model-following. Extensive piloted simulation has been used to develop nonlinear performance guide-lines and handling qualities criteria for high angles of attack. This paper reviews the development and evaluation of technologies useful for high-angle-of-attack control. Design, development, and flight test of the research flight control system, control laws, flying qualities specifications, and flight test maneuvers are described. Flight test results are used to illustrate some of the lessons learned during flight test and handling qualities evaluations.

Pahle, Joseph W.↗

NASA NTRS1998

Sliding Mode Thermal Control System for Space Station Furnace Facility

The decoupled control of the nonlinear, multiinput-multioutput, and highly coupled space station furnace facility (SSFF) thermal control system is addressed. Sliding mode control theory, a subset of variable-structure control theory, is employed to increase the performance, robustness, and reliability of the SSFF's currently designed control system. This paper presents the nonlinear thermal control system description and develops the sliding mode controllers that cause the interconnected subsystems to operate in their local sliding modes, resulting in control system invariance to plant uncertainties and external and interaction disturbances. The desired decoupled flow-rate tracking is achieved by optimization of the local linear sliding mode equations. The controllers are implemented digitally and extensive simulation results are presented to show the flow-rate tracking robustness and invariance to plant uncertainties, nonlinearities, external disturbances, and variations of the system pressure supplied to the controlled subsystems.

Jackson Mark E.↗

NASA NTRS1999

Advanced Design and Implementation of a Control Architecture for Long Range Autonomous Planetary Rovers

An advanced design and implementation of a Control Architecture for Long Range Autonomous Planetary Rovers is presented using a hierarchical top-down task decomposition, and the common structure of each design is presented based on feedback control theory. Graphical programming is presented as a common intuitive language for the design when a large design team is composed of managers, architecture designers, engineers, programmers, and maintenance personnel. The whole design of the control architecture consists in the classic control concepts of cyclic data processing and event-driven reaction to achieve all the reasoning and behaviors needed. For this purpose, a commercial graphical tool is presented that includes the mentioned control capabilities. Messages queues are used for inter-communication among control functions, allowing Artificial Intelligence (AI) reasoning techniques based on queue manipulation. Experimental results show a highly autonomous control system running in real time on top the JPL micro-rover Rocky 7 controlling simultaneously several robotic devices. This paper validates the sinergy between Artificial Intelligence and classic control concepts in having in advanced Control Architecture for Long Range Autonomous Planetary Rovers.

Martin-Alvarez, A.↗

NASA NTRS2000

Generalized Predictive and Neural Generalized Predictive Control of Aerospace Systems

The research work presented in this thesis addresses the problem of robust control of uncertain linear and nonlinear systems using Neural network-based Generalized Predictive Control (NGPC) methodology. A brief overview of predictive control and its comparison with Linear Quadratic (LQ) control is given to emphasize advantages and drawbacks of predictive control methods. It is shown that the Generalized Predictive Control (GPC) methodology overcomes the drawbacks associated with traditional LQ control as well as conventional predictive control methods. It is shown that in spite of the model-based nature of GPC it has good robustness properties being special case of receding horizon control. The conditions for choosing tuning parameters for GPC to ensure closed-loop stability are derived. A neural network-based GPC architecture is proposed for the control of linear and nonlinear uncertain systems. A methodology to account for parametric uncertainty in the system is proposed using on-line training capability of multi-layer neural network. Several simulation examples and results from real-time experiments are given to demonstrate the effectiveness of the proposed methodology.

Kelkar, Atul G.↗

NASA NTRS1994

Toward Real Time Neural Net Flight Controllers

NASA Ames Research Center has an ongoing program in neural network control technology targeted toward real time flight demonstrations using a modified F-15 which permits direct inner loop control of actuators, rapid switching between alternative control designs, and substitutable processors. An important part of this program is the ACTIVE flight project which is examining the feasibility of using neural networks in the design, control, and system identification of new aircraft prototypes. This paper discusses two research applications initiated with this objective in mind: utilization of neural networks for wind tunnel aircraft model identification and rapid learning algorithms for on line reconfiguration and control. The first application involves the identification of aerodynamic flight characteristics from analysis of wind tunnel test data. This identification is important in the early stages of aircraft design because complete specification of control architecture's may not be possible even though concept models at varying scales are available for aerodynamic wind tunnel testing. Testing of this type is often a long and expensive process involving measurement of aircraft lift, drag, and moment of inertia at varying angles of attack and control surface configurations. This information in turn can be used in the design of the flight control systems by applying the derived lookup tables to generate piece wise linearized controllers. Thus, reduced costs in tunnel test times and the rapid transfer of wind tunnel insights into prototype controllers becomes an important factor in more efficient generation and testing of new flight systems. NASA Ames Research Center is successfully applying modular neural networks as one way of anticipating small scale aircraft model performances prior to testing, thus reducing the number of in tunnel test hours and potentially, the number of intermediate scaled models required for estimation of surface flow effects.

Jorgensen, C. C.↗

NASA NTRS2001

Reconfigurable Control Design for the Full X-33 Flight Envelope

A reconfigurable control law for the full X-33 flight envelope has been designed to accommodate a failed control surface and redistribute the control effort among the remaining working surfaces to retain satisfactory stability and performance. An offline nonlinear constrained optimization approach has been used for the X-33 reconfigurable control design method. Using a nonlinear, six-degree-of-freedom simulation, three example failures are evaluated: ascent with a left body flap jammed at maximum deflection; entry with a right inboard elevon jammed at maximum deflection; and landing with a left rudder jammed at maximum deflection. Failure detection and identification are accomplished in the actuator controller. Failure response comparisons between the nominal control mixer and the reconfigurable control subsystem (mixer) show the benefits of reconfiguration. Single aerosurface jamming failures are considered. The cases evaluated are representative of the study conducted to prove the adequate and safe performance of the reconfigurable control mixer throughout the full flight envelope. The X-33 flight control system incorporates reconfigurable flight control in the existing baseline system.

Cotting, M. Christopher↗

NASA NTRS2001

Intelligent Control Approaches for Aircraft Applications

This paper presents an overview of various intelligent control technologies currently being developed and studied under the Intelligent Flight Control (IFC) program at the NASA Ames Research Center. The main objective of the intelligent flight control program is to develop the next generation of flight controllers for the purpose of automatically compensating for a broad spectrum of damaged or malfunctioning aircraft components and to reduce control law development cost and time. The approaches being examined include: (a) direct adaptive dynamic inverse controller and (b) an adaptive critic-based dynamic inverse controller. These approaches can utilize, but do not require, fault detection and isolation information. Piloted simulation studies are performed to examine if the intelligent flight control techniques adequately: 1) Match flying qualities of modern fly-by-wire flight controllers under nominal conditions; 2) Improve performance under failure conditions when sufficient control authority is available; and 3) Achieve consistent handling qualities across the flight envelope and for different aircraft configurations. Results obtained so far demonstrate the potential for improving handling qualities and significantly increasing survivability rates under various simulated failure conditions.

Gundy-Burlet, Karen↗

NASA NTRS2002

Test Platform for Advanced Digital Control of Brushless DC Motors (MSFC Center Director's Discretionary Fund)

A FY 2001 Center Director's Discretionary Fund task to develop a test platform for the development, implementation. and evaluation of adaptive and other advanced control techniques for brushless DC (BLDC) motor-driven mechanisms is described. Important applications for BLDC motor-driven mechanisms are the translation of specimens in microgravity experiments and electromechanical actuation of nozzle and fuel valves in propulsion systems. Motor-driven aerocontrol surfaces are also being utilized in developmental X vehicles. The experimental test platform employs a linear translation stage that is mounted vertically and driven by a BLDC motor. Control approaches are implemented on a digital signal processor-based controller for real-time, closed-loop control of the stage carriage position. The goal of the effort is to explore the application of advanced control approaches that can enhance the performance of a motor-driven actuator over the performance obtained using linear control approaches with fixed gains. Adaptive controllers utilizing an exact model knowledge controller and a self-tuning controller are implemented and the control system performance is illustrated through the presentation of experimental results.

Gwaltney, D. A.↗

NASA NTRS2002

Implementation of Adaptive Digital Controllers on Programmable Logic Devices

Much has been made of the capabilities of FPGA's (Field Programmable Gate Arrays) in the hardware implementation of fast digital signal processing (DSP) functions. Such capability also makes and FPGA a suitable platform for the digital implementation of closed loop controllers. There are myriad advantages to utilizing an FPGA for discrete-time control functions which include the capability for reconfiguration when SRAM- based FPGA's are employed, fast parallel implementation of multiple control loops and implementations that can meet space level radiation tolerance in a compact form-factor. Other researchers have presented the notion that a second order digital filter with proportional-integral-derivative (PID) control functionality can be implemented in an FPGA. At Marshall Space Flight Center, the Control Electronics Group has been studying adaptive discrete-time control of motor driven actuator systems using digital signal processor (DSF) devices. Our goal is to create a fully digital, flight ready controller design that utilizes an FPGA for implementation of signal conditioning for control feedback signals, generation of commands to the controlled system, and hardware insertion of adaptive control algorithm approaches. While small form factor, commercial DSP devices are now available with event capture, data conversion, pulse width modulated outputs and communication peripherals, these devices are not currently available in designs and packages which meet space level radiation requirements. Meeting our goals requires alternative compact implementation of such functionality to withstand the harsh environment encountered on spacecraft. Radiation tolerant FPGA's are a feasible option for reaching these goals.

Gwaltney, David A.↗

NASA NTRS2002

Direct Fault Tolerant RLV Altitude Control: A Singular Perturbation Approach

In this paper, we present a direct fault tolerant control (DFTC) technique, where by "direct" we mean that no explicit fault identification is used. The technique will be presented for the attitude controller (autopilot) for a reusable launch vehicle (RLV), although in principle it can be applied to many other applications. Any partial or complete failure of control actuators and effectors will be inferred from saturation of one or more commanded control signals generated by the controller. The saturation causes a reduction in the effective gain, or bandwidth of the feedback loop, which can be modeled as an increase in singular perturbation in the loop. In order to maintain stability, the bandwidth of the nominal (reduced-order) system will be reduced proportionally according to the singular perturbation theory. The presented DFTC technique automatically handles momentary saturations and integrator windup caused by excessive disturbances, guidance command or dispersions under normal vehicle conditions. For multi-input, multi-output (MIMO) systems with redundant control effectors, such as the RLV attitude control system, an algorithm is presented for determining the direction of bandwidth cutback using the method of minimum-time optimal control with constrained control in order to maintain the best performance that is possible with the reduced control authority. Other bandwidth cutback logic, such as one that preserves the commanded direction of the bandwidth or favors a preferred direction when the commanded direction cannot be achieved, is also discussed. In this extended abstract, a simplistic example is proved to demonstrate the idea. In the final paper, test results on the high fidelity 6-DOF X-33 model with severe dispersions will be presented.

Zhu, J. J.↗

NASA NTRS2003

Neural Flight Control System

The Neural Flight Control System (NFCS) was developed to address the need for control systems that can be produced and tested at lower cost, easily adapted to prototype vehicles and for flight systems that can accommodate damaged control surfaces or changes to aircraft stability and control characteristics resulting from failures or accidents. NFCS utilizes on a neural network-based flight control algorithm which automatically compensates for a broad spectrum of unanticipated damage or failures of an aircraft in flight. Pilot stick and rudder pedal inputs are fed into a reference model which produces pitch, roll and yaw rate commands. The reference model frequencies and gains can be set to provide handling quality characteristics suitable for the aircraft of interest. The rate commands are used in conjunction with estimates of the aircraft s stability and control (S&C) derivatives by a simplified Dynamic Inverse controller to produce virtual elevator, aileron and rudder commands. These virtual surface deflection commands are optimally distributed across the aircraft s available control surfaces using linear programming theory. Sensor data is compared with the reference model rate commands to produce an error signal. A Proportional/Integral (PI) error controller "winds up" on the error signal and adds an augmented command to the reference model output with the effect of zeroing the error signal. In order to provide more consistent handling qualities for the pilot, neural networks learn the behavior of the error controller and add in the augmented command before the integrator winds up. In the case of damage sufficient to affect the handling qualities of the aircraft, an Adaptive Critic is utilized to reduce the reference model frequencies and gains to stay within a flyable envelope of the aircraft.

Gundy-Burlet, Karen↗

NASA NTRS2003

Modeling, Simulation and Control of a Propellant Mixer

This paper addresses some modeling and control issues for a mixing chamber used in rocket engine testing at NASA Stennis Space Center. The mixer must combine high pressure liquid hydrogen (LH2) and gaseous hydrogen (GH2) to produce and output flow that meets certain thermodynamic properties before it is fed into a test article. More precisely, this paper considers that the quantities to be tracked and/or regulated are mixer internal pressure, exit mass flow, and exit temperature. The available control inputs are given by three value positions, namely those of the GH2, LH2 and exit valves. The mixer is modelled by a system of two nonlinear ordinary differential equations having density and internal energy as states. The model must be simple enough to lend itself to subsequent feedback controller design, yet its accuracy must be tested against real data. For this reason, the model includes function calls to thermodynamic property data. Some structural properties of the resulting model that pertain to controller design, such as controllability and uniqueness of the equilibrium point are shown to hold. Validation of the model against real data is also provided. As a first control approach, a small-signal (linear) model is developed based on the nonlinear model and simulated as well. Pulse disturbances are introduced to the valve positions and the quality of the linear model is ascertained by comparing its behavior against the nonlinear model simulations. Valve control strategies that simulate an operator-in-the-loop scenario are then explored demonstrating the need for automatic feedback control. Classical optimal single-output and multi-output Proportional/Integral controllers are designed based on the linear model and applied to the nonlinear model with excellent results to track simultaneous, constant setpoint changes in desired exit flow, exit temperature, and mixer pressure, as well as to reject unmeasurable but bounded additive step perturbations in the valve positions. A feedback linearization controller is designed and used to achieve tracking and regulation of the outputs over an extended range of the variables of interest.

Richter, Hanz↗