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A methodology is presented for the synthesis of control augmented structures which can be modeled as an assemblage of beam, truss, and nonstructural mass elements augmented by a robust noncollocated direct output feedback control system. The control system is robust in the sense that it can tolerate manufacturing and realization errors. The robust control system is synthesized using a constraint buffering technique in conjunction with the approximation concepts approach to system synthesis. All of the design constraints on the system, including the dynamic stability, are buffered by a nonlinear quantity that is a function of acceptable tolerances on the design variables and the sensitivity of the constraints to changes in these design variables. Numerical results which illustrate the effectiveness of the method presented are given.

In engineering design practice behavior is usually predicted based on some known nominal design. However, when the design is fabricated it will differ from the nominal design because of manufacturing tolerances. In order to generate nominal designs that will still satisfy behavior constraints in the presence of manufacturing tolerances, engineers resort to the use of safety factors, over and above those introduced to account for other uncertainties (e.g., in load conditions, material properties, analysis modeling). The accurate selection of the values of these manufacturing tolerances safety factors is dependent on the capability of the engineer to determine the sensitivity of the critical constraints to changes in the design variables. This process usually leads to overly conservative designs. The task of choosing safety factors is much more difficult in structural synthesis because: (1) it is not known which constraints will be active at the final design, (2) as the design changes during the synthesis process the sensitivities of the constraints with respect to the design variables also change, and (3) the imposition of the safety factors themselves may change the set of critical constraints. These difficulties can be overcome with the approximation concepts approach to structural synthesis by buffering the approximate constraints with quantities that are related to the design variable tolerances and the accurate sensitivities of the constraints with respect to the design variable. Designs generated by this approach tend to be feasible but not overly conservative.

A methodology for control-augmented structural synthesis is presented for structure-control systems which can be modeled as an assemblage of beam, truss, and nonstructural mass elements augmented by a noncollocated direct output feedback control system. Truss areas, beam cross sectional dimensions, nonstructural masses and rotary inertias, and controller position and velocity gains are treated simultaneously as design variables. The structural mass and a control-system performance index can be minimized simultaneously, with design constraints placed on static stresses and displacements, dynamic harmonic displacements and forces, structural frequencies, and closed-loop eigenvalues and damping ratios. Intermediate design-variable and response-quantity concepts are used to generate new approximations for displacements and actuator forces under harmonic dynamic loads and for system complex eigenvalues. This improves the overall efficiency of the procedure by reducing the number of complete analyses required for convergence. Numerical results which illustrate the effectiveness of the method are given.

Dynamic stability constraints are included in a computer program that simultaneously synthesizes a structure and its control system. Two measures of stability, the real part of the system complex eigenvalues and the damping ratio, are examined. The procedure for calculating the sensitivities of the two measures of stability to changes in the structure and its control system is explained. The sensitivities are used to formulate an approximate problem that is solved at each design iteration. The effects of structural damping and noncollated controllers on the synthesis process are discussed.

Now that quantities of prepreg were made on the thermoplastic coating line, they are being formed into both textile preform structures and directly into composite samples. The textile preforms include both woven and knitted structures which will be thermoformed into a finished part. In order to determine if the matrix resin is properly adhering to the fibers or if voids are being formed in the coating process, the tensile strength and modulus of these samples will be tested. The matrix uniformity of matrix distribution in these samples is also being determined using an image analyzer.