Design, Modeling, and Excess Force Suppression of a Thrust Reverser Test Rig Based on Structural Invariance Principle

This study presents a systematic framework for the design, dynamic modeling, and control optimization of a thrust reverser test rig, addressing the critical challenge of excess force suppression in passive electro-hydraulic servo systems. The test rig integrates modular mechanical components, such as simulated torsion beams and reaction frames, with a distributed electro-hydraulic architecture. Finite element analysis validates the structural integrity under extreme operational loads. A decoupled transfer function model quantifies the force-displacement coupling mechanism between passive force loading and active positioning subsystems. By integrating velocity feedforward compensation based on the structural invariance principle with PID closed-loop control, the system achieves significant suppression of excess force while maintaining robust tracking accuracy under dynamic load spectra. Simulations demonstrate enhanced operational bandwidth and synchronization between subsystems, though transient impacts during startup persist due to nonlinear velocity step responses. The modular design and hierarchical control strategy provide a scalable solution for aviation component certification. Future work will focus on addressing transient nonlinearities and experimental validation to further enhance system performance and reliability.