To address the problem that sudden structural damage during full-scale static tests of highly flexible aircraft easily induces system instability and secondary damage, the loading control simulation method for a rigid-flexible coupled system containing actuators is investigated. First, based on the physical and mechanical characteristics of the components, a full-scale rigid-flexible coupled finite element model comprising nonlinear wing elements and a linear fuselage super-element is constructed. This model achieves high-fidelity simulation of key components from buckling to fracture while balancing computational efficiency. Second, an embedded control framework based on ABAQUS user subroutines is developed. Incremental proportional-integral-derivative (PID) control laws and virtual actuator dynamic models are integrated into the implicit solver, which successfully resolves the computational convergence difficulties caused by abrupt structural changes. On this basis, the sudden fracture condition under ultimate loads is reproduced, and the mechanical response characteristics of unloading strategies, such as displacement locking and passive pressure relief, are compared. An actuator coordinated unloading control strategy based on force feedback is then proposed. The research results indicate that non-closed-loop strategies will induce severe secondary damage due to residual internal force retention or impacts. In contrast, the closed-loop force-controlled unloading strategy can self-adapt to the minimum unloading time determined by the dynamic characteristics of the damaged structure. Under the premise of not generating additional plastic damage, this strategy controls the kinetic energy ratio at 1.02 %, successfully achieving a smooth attenuation of the dynamic response and stable attitude recovery of the full aircraft after sudden damage, providing a feasible method for the control design of high-risk full-scale static tests.
WEI Hao-Tian
,
YU Zhe-Feng
. Embedded Simulation of Loading Control and Analysis on Unloading Strategies for Full-scale Aircraft Static Test[J]. ACTA AERONAUTICAET ASTRONAUTICA SINICA, 0
: 1
-0
.
DOI: 10.7527/S1000-6893.2026.33571
[1]吴宇.飞机结构试验杠杆加载系统数字化设计技术研究[D]. 南京航空航天大学, 2020.
[2]罗树东.飞机结构强度虚拟试验技术研究[J]. 中国科技纵横, 2014(18):84-85.
[3]郑晓曦, 孙国正.虚拟样机系统[J].计算机工程与应用, 2005, 41(1):117-119
[4]郑党党, 刘更, 任俊俊，等.飞机设计中仿真技术应用现状及发展趋势[J].航空制造技术, 2015, 58(2324):68-70
[5]侯同济.飞机结构强度静力试验计算机仿真系统的构架与组成[J]. 结构强度研究, 2005(2):42-49.
[6]赵谋周, 万亚锋, 刘存，等.大型飞机机翼强度设计与验证技术[J].工程与试验, 2017, 57(1):19-23
[7]陆清, 吴双.民用飞机虚拟集成试验技术研究[J]. 民用飞机设计与研究, 2017(2):1-7.
[8]Nicolaidou E, Hill T L, Neild S A.Indirect reduced-order modelling: using nonlinear manifolds to conserve kinetic energy[J]. Proceedings of the Royal Society A: Mathematical, Physical and Engineering Sciences, 2020, 476(2243).
[9]Walgren P, Hartl D.A nonlinear substructure method based on a computational plasticity framework for efficient analysis of structural assemblies[J]. International Journal of Plasticity, 2023, 169: 103728.
[10]Kim K, Khanna V, Wang X Q, et al.Nonlinear reduced order modeling of flat cantilevered structures[C]//50th AIAA/ASME/ASCE/AHS/ASC Structures, Structural Dynamics, and Materials Conference 17th AIAA/ASME/AHS Adaptive Structures Conference 11th AIAA No. 2009: 2492.
[11]Feeny B F, Kappagantu R.On the physical interpretation of proper orthogonal modes in vibrations[J].Journal of sound and vibration, 1998, 211(4):607-616
[12]Koeppe A, Bamer F, Markert B.An efficient Monte Carlo strategy for elasto-plastic structures based on recurrent neural networks: AKoeppe et al[J].Acta Mechanica, 2019, 230(9):3279-3293
[13]Mozaffar M, Bostanabad R, Chen W, et al.Deep learning predicts path-dependent plasticity[J].Proceedings of the National Academy of Sciences, 2019, 116(52):26414-26420
[14]Kohar C P, Greve L, Eller T K, et al.A machine learning framework for accelerating the design process using CAE simulations: An application to finite element analysis in structural crashworthiness[J]. Computer Methods in Applied Mechanics and Engineering, 2021, 385: 114008.
[15]An C, Meng Y, Xie C, et al.A substructure synthesis method with nonlinear ROM including geometric nonlinearities[J].Aerospace, 2021, 8(11):344-
[16]Alomar Z, Maccioni L, Concli F.Development and Implementation of Element Deletion Algorithm into an Open-Source Software Based on the Fracture Locus of Materials[J].Materials, 2022, 16(1):187-
[17]Li Y, Yuan J, Zhang X, et al.Research on Multi-point Cross-coupling Compensation Control Algorithm[C]//2024 International Conference on the Frontiers of Electronic, Electrical and Information Engineering (ICFEEIE). IEEE, 2024: 51-55.
[18]HAO Zhenyang, Zhang Qiyao, Chen Huajie, et al.Research and Design of Coordinated Control Strategy for Smart Electromechanical Actuator System[J]. Transactions of Nanjing University of Aeronautics & Astronautics, 2022, 39(5).
[19]林宸宇, 李建伟, 郭文哲, 蒋明真, 张磊安, 文永双.基于-的风电叶片静力试验多点协同加载控制算法[J].太阳能学报, 2023, 44(7):386-391
[20]梁舒雅, 徐昕炜, 杨特, 等.飞机异常动载荷快速定位的深度神经网络方法[J].振动工程学报, 2024, 37(10):1651-1659
[21]Gu J, Qin Y, Xia Y, et al.Failure analysis and prevention for tower crane as sudden unloading[J].Journal of Failure Analysis and Prevention, 2021, 21(5):1590-1595
[22]王刚, 谢文娇, 尹伟, 等.飞机结构强度试验系统控制参数自整定技术[J].工程与试验, 2025, 65(01):13-16
CJA