Abstract

This paper investigates the identification and control of unstable, under-actuated systems with nonlinear dynamic behaviour. Due to their instability and non-linear responses to conventional control techniques, these systems pose a particular challenge for precise modelling and effective control. To address these problems, we developed a methodical, model-based approach using rapid control prototyping (RCP), which is based on physical models and integrates model-in-theloop (MiL), software-in-the-loop (SiL) and hardware-in-the-loop (HiL) testing. The methodological framework includes the identification of system dynamics using measurement data-based approaches and the verification of the models to ensure their accuracy. By applying these models to the specific example of the S-Mobile, a highly dynamic intralogistics system with a spherical electric drive, we demonstrate the effectiveness of the approach. The results show improved model accuracy and robust control of the system, emphasising its potential applicability in similarly complex technical systems.