This research effort develops a comprehensive computational framework to support the parametric optimal design of uncertain dynamical systems. Uncertainty comes from various sources, such as: system parameters, initial conditions, sensor and actuator noise, and external forcing. Treatment of uncertainty in design is of paramount practical importance because all real-life systems are affected by it; not accounting for uncertainty may result in poor robustness, sub-optimal performance and higher manufacturing costs. Contemporary methods for the quantification of uncertainty in dynamical systems are computationally intensive which, so far, have made a robust design optimization methodology prohibitive. Some existing algorithms address uncertainty in sensors and actuators during an optimal design; however, a comprehensive design framework that can treat all kinds of uncertainty with diverse distribution characteristics in a unified way is currently unavailable. The computational framework uses Generalized Polynomial Chaos methodology to quantify the effects of various sources of uncertainty found in dynamical systems; a Least-Squares Collocation Method is used to solve the corresponding uncertain differential equations. This technique is significantly faster computationally than traditional sampling methods and makes the construction of a parametric optimal design framework for uncertain systems feasible. The novel framework allows to directly treat uncertainty in the parametric optimal design process. Specifically, the following design problems are addressed: motion planning of fully-actuated and under-actuated systems; multi-objective robust design optimization; and optimal uncertainty apportionment concurrently with robust design optimization. The framework advances the state-of-the-art and enables engineers to produce more robust and optimally performing designs at an optimal manufacturing cost. / Ph. D.

Nous nous intéressons à la conception des mains mécaniques anthropomorphes destinées à manipuler des objets dans un environnement humain. Via l'analyse du mouvement de sujets humains lors d'une tâche de manipulation de référence, nous proposons une méthode pour évaluer la capacité des mains robotiques à manipuler les objets. Nous montrons comment les rapports de couplage angulaires entre les articulations et les limites articulaires, influent sur l'aptitude à manipuler dynamiquement des objets. Nous montrons également l'impact du poignet sur les tâches de manipulation rapides. Nous proposons une stratégie pour calculer les forces de manipulation en bout de doigts et dimensionner les moteurs d'un tel préhenseur. La méthode proposée est dépendante de la tâche visée et s'adapte à tout type de mouvement dès lors qu'il peut être capturé et analysé. Dans une deuxième partie, consacrée aux robots manipulateurs, nous élaborons des algorithmes de commande optimale. En considérant l'énergie cinétique du robot comme une métrique, le modèle dynamique est formulé sous forme tensorielle dans le cadre de la géométrie Riemannienne. La discrétisation temporelle est basée sur les Éléments Finis d'Hermite. Nous intégrons les équations de Lagrange du mouvement par une méthode de perturbation. Des exemples de simulation illustrent la superconvergence de la technique d'Hermite. Le critère de contrôle est choisi indépendant des paramètres de configuration. Les équations de la commande associées aux équations du mouvement se révèlent covariantes. La méthode de commande optimale proposée consiste à minimiser la fonction objective correspondant au critère invariant sélectionné. / We focus on the design of anthropomorphous mechanical hands destined to manipulate objects in a human environment. Via the motion analysis of a reference manipulation task performed by human subjects, we propose a method to evaluate a robotic hand manipulation capacities. We demonstrate how the angular coupling between the fingers joints and the angular limits affect the hands potential to manipulate objects. We also show the influence of the wrist motions on the manipulation task. We propose a strategy to calculate the fingertip manipulation forces and dimension the fingers motors. In a second part devoted to articulated robots, we elaborate optimal control algorithms. Regarding the kinetic energy of the robot as a metric, the dynamic model is formulated tensorially in the framework of Riemannian geometry. The time discretization is based on the Hermite Finite Elements.A time integration algorithm is designed by implementing a perturbation method of the Lagrange's motion equations. Simulation examples illustrate the superconvergence of the Hermite's technique. The control criterion is selected to be coordinate free. The control equations associated with the motion equations reveal to be covariant. The suggested control method consists in minimizing the objective function corresponding to the selected invariant criterion.

Les systèmes d'entraînement de bandes flexibles sont utilisés dans la production d'une très grande variété de produits du quotidien mais également dans la métallurgie et dorénavant pour la production des nouvelles technologies. L'amélioration des systèmes industriels d'entraînement de bandes est un problème difficile car ils sont de grande dimension, non-linéaires, à paramètres variant et incertains. Ils possèdent un fort couplage entre les différentes parties (mécanique et commande) à cause de la bande qui relie les éléments. Il faut donc améliorer la chaîne de production par une approche pluridisciplinaire. Les objectifs sont de maîtriser les paramètres clés de ces systèmes afin de garantir les cadences de production et les précisions demandées de plus en plus importantes. Il faut également réduire les défauts les plus récurrents, notamment les plis de bande. Or jusqu'à présent seuls des modèles 1D étaient utilisés. Ils sont indispensables pour la synthèse de commande et les études fréquentielles mais ne permettent pas d'étudier des phénomènes complexes tels que les plis de bande. Une nouvelle approche d'étude de ces systèmes est développée. Dans un premier temps, des améliorations de structures de commandes sont proposées. Dans un second temps un modèle 3D par éléments finis utilisant un algorithme de dynamique multicorps flexibles est développé et utilisé pour étudier les plis de bande par comparaison à la théorie classique de prédiction de ces défauts. Dans un troisième temps un simulateur complet est développé comprenant le modèle 3D mécanique par élément finis couplé à la partie commande (co-simulation). / Roll-to-Roll systems are used in the manufacturing of a wide variety of everyday products as well as in metallurgy and for the manufacturing of new technologies. The improvement of Roll-to-Roll systems is a difficult problem because they are large, non-linear, with varying and uncertain parameters. They have a coupling between the different parts (mechanical and control) with the help of the web connecting the elements. It is therefore necessary to improve the process line through a multidisciplinary approach. The objectives are to master the key parameters of these systems in order to guarantee the manufacturing rates and the more important accuracies requested. It is also necessary to reduce or remove the most recurring defects such as web wrinkles. Until now, only 1D models were used. They are essential for control synthesis and frequency studies but they do not allow to study complex phenomena such as web wrinkles. A new approach for studying these systems is developed. First, improvements of control structures are proposed. Secondly, a 3D finite element model using a flexible multibody dynamics algorithm is developed, used in this work to study web wrinkles and compared to the classical prediction theory of these defects. Finally, a complete simulator is developed including the mechanical 3D model by finite element coupled to the control part (co-simulation).

Indiana University-Purdue University Indianapolis (IUPUI) / In this thesis, an explicit time integration code which integrates multibody dynamics and the discrete element method is used for modelling the excavation and moving operation of cohesive soft soil (such as mud and snow) by bulldozers. A soft cohesive soil material model (that includes normal and tangential inter-particle force models) is used that can account for soil compressibility, plasticity, fracture, friction, viscosity and gain in cohesive strength due to compression. In addition, a time relaxation sub-model for the soil plastic deformation and cohesive strength is added in order to account for loss in soil cohesive strength and reduced bulk density due to tension or removal of the compression. This is essential in earth moving applications since the soil that is dug typically becomes loose soil that has lower shear strength and lower bulk density (larger volume) than compacted soil. If the model does not account for loss of soil shear strength then the dug soil pile in front of the blade of a bulldozer will have an artificially high shear strength. A penalty technique is used to impose joint and normal contact constraints. An asperity-based friction model is used to model contact and joint friction. A Cartesian Eulerian grid contact search algorithm is used to allow fast contact detection between particles. A recursive bounding box contact search algorithm is used to allow fast contact detection between the particles and polygonal contact surfaces. A multibody dynamics bulldozer model is created which includes the chassis/body, C-frame, blade, wheels and hydraulic actuators. The components are modelled as rigid bodies and are connected using revolute and prismatic joints. Rotary actuators along with PD (Proportional-Derivative) controllers are used to drive the wheels. Linear actuators along with PD controllers are used to drive the hydraulic actuators. Polygonal contact surfaces are defined for the tires and blade to model the interaction between the soil and the bulldozer. Simulations of a bulldozer performing typical shallow digging operations in a cohesive soil are presented. The simulation of a rear wheel drive bulldozer shows that, it has a limited digging capacity compared to the 4-wheel drive bulldozer. The effect of the relaxation parameter can be easily observed from the variation in the Bulldozer's velocity. The higher the relaxation parameter, the higher is the bulldozer's velocity while it is crossing over the soil patch. For the low penetration depth run the bulldozer takes less time compared to high penetration depth. Also higher magnitudes of torques at front and rear wheels can be observed in case of high penetration depth. The model is used to predict the wheel torque, wheel speed, vehicle speed and actuator forces during shallow digging operations on three types of soils and at two blade penetration depths. The model presented can be used to predict the motion, loads and required actuators forces and to improve the design of the various bulldozer components such as the blade, tires, engine and hydraulic actuators.

<p dir="ltr">Positive displacement machines are used in various industries spanning the power spectrum, from industrial robotics to heavy construction equipment to aviation. These machines should be highly efficient, compact, and reliable. It is very advantageous for designers to use virtual simulations to design and improve the performance of these units as they significantly reduce cost and downtime. The recent trends of electrification and the goal to increase power density force these units to work at higher pressures and higher rotational speeds while maintaining their efficiencies and reliability. This push means that the simulation models need to advance to account for various aspects during the operation of these machines. </p><p dir="ltr">These machines typically have several bodies in relative motion with each other. Quantifying these motions and solving for their effect on the fluid enclosed are vital as they influence the machine's performance. The push towards higher rotational speeds introduces unwanted cavitation and aeration in these units. To model these effects, keeping the design evaluation time low is key for a designer. The lumped parameter approach offers the benefit of computational speed, but a major drawback that comes along with it is that it typically assumes fluid inertia to be negligible. These effects cannot be ignored, as quantifying and making design considerations to negate these effects can be beneficial. Therefore, this thesis addresses these key challenges of cavitation dynamics, body dynamics, and accounting for fluid inertia effects using a lumped parameter formulation.</p><p dir="ltr">To account for dynamics features related to cavitation, this thesis proposes a novel approach combining the two types of cavitation, i.e., gaseous and vaporous, by considering that both vapor and undissolved gas co-occupy a spherical bubble. The size of the spherical bubble is solved using the Rayleigh-Plesset equation, and the transfer of gas through the bubble interface is solved using Henry's Law and diffusion of the dissolved gas in the liquid. These equations are coupled with a novel pressure derivative equation. To account for body dynamics, this thesis introduces a novel approach for solving the positions of the bodies of a hydraulic machine while introducing new methods to solve contact dynamics and the application of Elasto Hydrodynamic Lubrication (EHL) friction at those contact locations. This thesis also proposes strategies to account for fluid inertia effects in a lumped parameter-based approach, taking as a reference an External Gear Machine. This thesis proposes a method to study the effects of fluid inertia on the pressurization and depressurization of the tooth space volumes of these units. The approach is based on considering the fluid inertia in the pressurization grooves and inside the control volumes with a peculiar sub-division. Further, frequency-dependent friction is also modeled to provide realistic damping of the fluid inside these channels.</p><p dir="ltr">To show the validity of the proposed dynamic cavitation model, the instantaneous pressure of a closed fluid volume undergoing expansion/compression is compared with multiple experimental sources, showing an improvement in accuracy compared to existing models. This modeling is then further applied to a gerotor machine and validated with experiments. Integrating this modeling technique with current displacement chamber simulation can further improve the understanding of cavitation in hydraulic systems. Formulations for body dynamics are tested on a prototype Gerotor and Vane unit. For both gerotor and vane units, comparisons of simulation results to experimental results for various dynamic quantities, such as pressure ripple, volumetric, and hydromechanical efficiency for multiple operating conditions, have been done. Extensive validation is performed for the case of gerotors where shaft torque ripple and the motion of the outer gear is experimentally validated. The thesis also comments on the distribution of the different torque loss contributions. The model for fluid inertia effects has been validated by comparing the lumped parameter model with a full three-dimensional Navier Stokes solver. The quantities compared, such as tooth space volume pressures and outlet volumetric flow rate, show a good match between the two approaches for varying operating speeds. A comparison with the experiments supports the modeling approach as well. The thesis also discusses which operating conditions and geometries play a significant role that governs the necessity to model such fluid inertia effects in the first place.</p>