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Item Model based test equipment design and controller tuning for elevator endurance test rig(Institute of Electrical and Electronics Engineers Inc., 2017) Prasad, M.; Gangadharan, K.Servo-controlled elevator is one of the primary flight control actuators which controls pitch of the aircraft. To prove out its design, a qualification test equipment or endurance test rig is needed. Using endurance test rig, aerodynamic load is simulated by a double-Acting servo-controlled linear hydraulic cylinder to the elevator actuator. The design of the endurance test rig primarily depends on load and velocity requirements. The main aim of this work is to design the endurance test rig and tune the load controller based on simulation results and analysis. A high fidelity, non-linear mathematical model of elevator endurance test rig is developed and validated against experimental data. Critical parameters of test equipment were identified based on mathematical modeling and simulation. An appropriate load cylinder and its electro-hydraulic servo valve are chosen to meet load and velocity requirements. The rig structure stiffness has also been determined by iterative simulations. The performance and stability of the test system areas certained through dynamic analysis of the model for every flight case. Finally, a model based load controller is designed and deployed to the experimental setup with simple proportional-integral (PI) and velocity feed-forward control to meet the load control performance satisfactorily. © 2015 IEEE.Item Aileron endurance test rig design based on high fidelity mathematical modeling(Springer-Verlag Wien michaela.bolli@springer.at, 2017) Prasad, M.; Gangadharan, K.V.This paper presents a model-based approach to design aileron endurance test rig (ETR). ETR is a dynamic load simulator which simulates aerodynamic load on-ground for verifying and validating the design, performance and stability of aileron actuator. Aileron actuator is a servo-controlled linear hydraulic actuator used to control the movement of ailerons in aircraft. Aileron is one of the primary flight control surfaces which controls roll of the aircraft. In ETR, Aileron actuator acts as unit under test (UUT) while a double-acting linear hydraulic actuator produces a dynamic load with the help of high pressure fluid source and electro-hydraulic servo valve (EHSV). The design of the test rig depends on load and velocity requirements which vary widely over the whole flight envelop and depends on deflection of surface, angle of attack, aircraft speed and altitude. One of the critical factor in designing ETR is to accurately model the interaction between the UUT and load system. This paper presents a simple yet powerful approach of free body diagram to account the power flow between the two systems. Model-based approach allowed to simulate the complete test rig behavior identifying the values of the critical parameters prior to building it. A high fidelity, non-linear mathematical model of aileron ETR is developed, simulated and verified. An appropriate load actuator and its electro-hydraulic servo valve are chosen to meet load and velocity requirements. The minimum rig structure stiffness is determined to ensure the stability of the load control system. A velocity feed-forward-based load controller along with proportional-integral control is implemented and tuned to meet the load control performance satisfactorily. Finally, the developed model is validated against the experimental data from actual test rig. © 2017, Deutsches Zentrum für Luft- und Raumfahrt e.V.