Real-Time Structural Deflection Estimation in Hydraulically Actuated Systems Using 3D Flexible Multibody Simulation and DNNs

The precision, stability, and performance of lightweight high-strength steel structures in heavy machinery is affected by their highly nonlinear dynamics. This, in turn, makes control more difficult, simulation more computationally intensive, and achieving real-time autonomy, using standard approaches, impossible. Machine learning through data-driven, physics-informed and physics-inspired networks, however, promises more computationally efficient and accurate solutions to nonlinear dynamic problems. This study proposes a novel framework that has been developed to estimate real-time structural deflection in hydraulically actuated three-dimensional systems. It is based on SLIDE, a machine-learning-based method to estimate dynamic responses of mechanical systems subjected to forced excitations.~Further, an algorithm is introduced for the data acquisition from a hydraulically actuated system using randomized initial configurations and hydraulic pressures.~The new framework was tested on a hydraulically actuated flexible boom with various sensor combinations and lifting various payloads. The neural network was successfully trained in less time using standard parameters from PyTorch, ADAM optimizer, the various sensor inputs, and minimal output data. The SLIDE-trained neural network accelerated deflection estimation solutions by a factor of $10^7$ in reference to flexible multibody simulation batches and provided reasonable accuracy. These results support the studies goal of providing robust, real-time solutions for control, robotic manipulators, structural health monitoring, and automation problems.

SLIDE: A machine-learning based method for forced dynamic response estimation of multibody systems

In computational engineering, enhancing the simulation speed and efficiency is a perpetual goal. To fully take advantage of neural network techniques and hardware, we present the SLiding-window Initially-truncated Dynamic-response Estimator (SLIDE), a deep learning-based method designed to estimate output sequences of mechanical or multibody systems with primarily, but not exclusively, forced excitation. A key advantage of SLIDE is its ability to estimate the dynamic response of damped systems without requiring the full system state, making it particularly effective for flexible multibody systems. The method truncates the output window based on the decay of initial effects, such as damping, which is approximated by the complex eigenvalues of the systems linearized equations. In addition, a second neural network is trained to provide an error estimation, further enhancing the methods applicability. The method is applied to a diverse selection of systems, including the Duffing oscillator, a flexible slider-crank system, and an industrial 6R manipulator, mounted on a flexible socket. Our results demonstrate significant speedups from the simulation up to several millions, exceeding real-time performance substantially.