In dynamic analysis of constrained multibody systems (MBS), the computer simulation problem essentially reduces to finding a numerical solution to higher-index differential-algebraic equations (DAE). This paper presents a hybrid method composed of multi-input multi-output (MIMO), nonlinear, variable-structure control (VSC) theory and post-stabilization from DAE solution theory for the computer solution of constrained MBS equations. The primary contributions of this paper are: (1) explicit transformation of constrained MBS DAE into a general nonlinear MIMO control problem in canonical form; (2) development of a hybrid numerical method that incorporates benefits of both Sliding Mode Control (SMC) and DAE stabilization methods for the solution of index-2 or index-3 MBS DAE; (3) development of an acceleration-level stabilization method that draws from SMC’s boundary layer dynamics and the DAE literature’s post-stabilization; and (4) presentation of the hybrid numerical method as one way to eliminate chattering commonly found in simulation of SMC systems. The hybrid method presented can be used to simulate constrained MBS systems with either holonomic, nonholonomic, or both types of constraints. In addition, the initial conditions (ICs) may either be consistent or inconsistent. In this paper, MIMO SMC is used to find the control law that will provide two guarantees. First, if the constraints are initially not satisfied (i.e., for inconsistent ICs) the constraints will be driven to satisfaction within finite time using SMC’s stabilization method, $urobust,i=−ηisgnsi.$ Second, once the constraints have been satisfied, the control law, $ueq$ and hybrid stabilization techniques guarantee surface attractiveness and satisfaction for all time. For inconsistent ICs, Hermite-Birkhoff interpolants accurately locate when each surface reaches zero, indicating the transition time from SMC’s stabilization method to those in the DAE literature. [S0022-0434(00)02404-7]

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