Quantitative fault tolerant control design for a hydraulic actuator with a leaking piston seal

Hydraulic actuators are complex fluid power devices whose performance can be degraded in the presence of system faults. In this thesis a linear, fixed-gain, fault tolerant controller is designed that can maintain the positioning performance of an electrohydraulic actuator operating under load with a leaking piston seal and in the presence of parametric uncertainties. Developing a control system tolerant to this class of internal leakage fault is important since a leaking piston seal can be difficult to detect, unless the actuator is disassembled. The designed fault tolerant control law is of low-order, uses only the actuator position as feedback, and can: (i) accommodate nonlinearities in the hydraulic functions, (ii) maintain robustness against typical uncertainties in the hydraulic system parameters, and (iii) keep the positioning performance of the actuator within prescribed tolerances despite an internal leakage fault that can bypass up to 40% of the rated servovalve flow across the actuator piston. Experimental tests verify the functionality of the fault tolerant control under normal and faulty operating conditions.;The fault tolerant controller is synthesized based on linear time-invariant equivalent (LTIE) models of the hydraulic actuator using the quantitative feedback theory (QFT) design technique. A numerical approach for identifying LTIE frequency response functions of hydraulic actuators from acceptable input-output responses is developed so that linearizing the hydraulic functions can be avoided. The proposed approach can properly identify the features of the hydraulic actuator frequency response that are important for control system design and requires no prior knowledge about the asymptotic behavior or structure of the LTIE transfer functions. A distributed hardware-in-the-loop (HIL) simulation architecture is constructed that enables the performance of the proposed fault tolerant control law to be further substantiated, under realistic operating conditions. Using the HIL framework, the fault tolerant hydraulic actuator is operated as a flight control actuator against the real-time numerical simulation of a high-performance jet aircraft. A robust electrohydraulic loading system is also designed using QFT so that the in-flight aerodynamic load can be experimentally replicated. The results of the HIL experiments show that using the fault tolerant controller to compensate the internal leakage fault at the actuator level can benefit the flight performance of the airplane.