Protoype of closed-loop actuation system
Development of a high-speed, closed-loop actuation system enabling independent and precise deployment of aerodynamic control surfaces under demanding wind tunnel conditions.
Project Overview
This project focuses on the design and implementation of a robust and high-performance actuation solution for aerodynamic control surfaces used in experimental testing environments. The objective was to replace an existing actuation system that allowed only slow and limited independent movements, thereby restricting the fidelity and scope of aerodynamic investigations.
The new system was required to operate within a highly challenging test environment characterized by high pressure, supersonic flow condition and significant mechanical loads. Consequently, robustness, accuracy and compact integration were key design drivers.
IBK Innovation developed a next-generation actuation solution based on individual actuators controlled by decentralized microcontrollers embedded directly within the model structure. This distributed control concept enables fast and fully independent movement of each control surface, reducing signal delay and increasing operational flexibility.
To achieve the demanded accuracy, a closed-loop control strategy with real-time positional feedback was implemented. This design ensured high precision and repeatability, although the integration of sensors and electronics within extremely limited installation space and thermal load on the microcontroller imposed substantial challenges during development.
Beyond hardware, IBK also developed the corresponding control and measurement software environment (full-stack). This software enables synchronized operation between actuation states and aerodynamic data acquisition, allowing real-time adaptation of the test envelope and rapid response to unexpected changes during the wind tunnel campaign.
The resulting system represents a substantial advancement in test model actuation technology. It combines high-speed deployment with robust and compact integration, designed to withstand demanding test conditions and to enable precise and repeatable aerodynamic investigations. The upcoming test phase will demonstrate the system’s performance and reliability under operational conditions.
Contributions & Deliverables
IBK deliverables & measurable outcomes
• Design and realization of independent control surface actuation system with embedded microcontrollers
• Closed-loop control implementation for high-accuracy deployment
• Full-stack measurement and control software for test operation
• Mechanical and operational integration and verification on wind tunnel model
Methods, Tools & Facilities
Methods
• Mechatronic design and control system engineering
• Embedded microcontroller programming, closed-loop control algorithms
• Test preparation for pressurized and supersonic wind tunnel operation
Tools
MATLAB, Python
Facilities
Wind tunnel
Additional Information
Duration
05.2022 – 12.2025