Structural Optimization of Components in Controlled Mechanical Systems

2007 ◽  
Author(s):  
Albert Albers ◽  
Jens Ottnad ◽  
Pascal Ha¨ußler ◽  
Johannes Minx
Keyword(s):  
Control System ◽  
Topology Optimization ◽  
Product Development ◽  
Structural Optimization ◽  
Continuous Process ◽  
Research Work ◽  
Mechanical Systems ◽  
Optimization Process ◽  
Research Centre ◽  
Mechatronic System

The importance of computer aided engineering in product development processes and research has been increasing rapidly throughout the past years. Today’s software can e.g. help to optimize complex components regarding different objectives or conditions. The capability of these tools has been proved in many industrial applications. They are used in order to improve the products on the one hand and to reduce the development time, and therefore, the costs of the product development on the other hand. New studies in the field of structural optimization concentrate on dynamically loaded parts in mechanical systems. In the state-of-the-art process and methods it is assumed that there exists a set of external loads or load functions acting on the part. The fact that due to geometric modifications caused by an optimization process, changes of the system’s dynamic properties and its overall behaviour may be neglected. In order to take into account the interaction between part and system with all its consequences for the optimization process, a simulation of the complete system is integrated into the optimization process within the research work presented in this paper. Dynamic systems today very often are controlled. The control has a major influence on the dynamic characteristics of the system. Therefore the target is to take into account the aspects of the control system as well during a topology optimization process of the mechanical part in a mechatronic system. Here, a hybrid multibody system simulation, that is, a MBS containing flexible bodies, in conjunction with a Co-Simulation of the control system is integrated into the optimization process. A humanoid robot is an example for such a complex mechatronic system. The goal of the collaborative research centre 588 “learning and cooperating multimodal robots” at the University of Karlsruhe (TH) is the development of robots that can help the human fulfilling everyday tasks in a human environment. The research work presented in this paper is a contribution towards the integration of existing isolated methods into a continuous process. The benefits will be illustrated by an example. The focus is set on the design of the mechanical parts in conjunction with an automatic parameter adaption (optimization) of the control system. Finite element analysis, multibody simulation, control design tools, parameter optimization and topology optimization are tied together into one process to allow an efficient optimization of structures “within” their surrounding mechatronic system.

Topology Optimization of Multiple Parts in Dynamic Controlled Systems

2008 ◽  
Author(s):  
Albert Albers ◽  
Jens Ottnad ◽  
Pascal Ha¨ußler ◽  
Johannes Minx
Keyword(s):  
Control System ◽  
Structural Optimization ◽  
Dynamic Properties ◽  
Continuous Process ◽  
Research Work ◽  
Humanoid Robots ◽  
Optimization Process ◽  
Research Centre ◽  
Mechatronic System ◽  
Computer Aided

The importance of computer aided engineering (CAE) in product development processes and research has been increasing throughout the past years. Consequently, optimization tools gained more and more importance. In state-of-the-art processes and methods concerning structural optimization it is assumed that there exists a set of external loads or load functions acting on the part. Very often modern products represent complex mechatronic system. The fact that the system’s dynamic properties and its overall behaviour may change due to geometric modifications of a part caused by an optimization process is typically neglected. In order to take into account the interaction between the part, dynamic system, control system and the changing mechanical behaviour with all its consequences for the optimization process, a simulation of the complete mechatronic system is integrated into the optimization process within the research work presented in this paper. A hybrid multibody system (MBS) simulation, that is, a MBS containing flexible bodies, in conjunction with a cosimulation of the control system represented by tools of the Computer Aided Control Engineering (CACE) is integrated into the optimization process. The research work presented in this paper is a contribution towards the integration of existing CAE methods into a continuous process for structural optimization. The benefits will be illustrated by an example, namely a part of the humanoid robot ARMAR III of the collaborative research centre for “Humanoid Robots” [1]. Especially the optimization of two parts at a time within one optimization loop allows an efficient optimization of structures “within” their surrounding mechatronic system.

Integrated Structural and Controller Optimization in Dynamic Mechatronic Systems

2010 ◽  
Vol 132 (4) ◽  
Author(s):  
Albert Albers ◽  
Jens Ottnad
Keyword(s):  
Control System ◽  
Research Work ◽  
Humanoid Robots ◽  
Optimization Process ◽  
Research Centre ◽  
System Control ◽  
Mechatronic System ◽  
Mechatronic Systems ◽  
Control Engineering ◽  
Optimization Loop

In order to take into account the interaction between the part, dynamic system, control system, and changing mechanical behavior with all its consequences for the optimization process, a simulation of the complete mechatronic system is integrated into the optimization process within the research work presented in this paper. A hybrid multibody system (MBS) simulation, that is a MBS containing flexible bodies, in conjunction with a cosimulation of the control system represented by tools of the computer aided control engineering, is integrated into the optimization process. By an inner optimization loop the controller parameters are adopted new in each of the iterations of the topology optimization in order to provide realistic load cases. The benefits will be illustrated by an example in conjunction with the humanoid robot ARMAR III of the Collaborative Research Centre 588 “Humanoid Robots-Learning and Cooperating Multimodal Robots” in Karlsruhe Germany. It will be shown how the new approach for the optimization of parts “within” their surrounding mechatronic system allows an efficient optimization of such structures.

Design of Robust Mechatronics Embedded Systems by Integration of Virtual Simulation and Mechatronics Platform

2015 ◽  
Author(s):  
Devdas Shetty ◽  
Naresh Poudel ◽  
Esther Ososanya
Keyword(s):  
Control System ◽  
Product Development ◽  
Complex Systems ◽  
Real Time ◽  
Machine Tools ◽  
Mechatronic System ◽  
Embedded Control ◽  
Embedded Control System ◽  
Mass Spring ◽  
Technology Demonstrator

Increasing demands on the productivity of complex systems, such as machine tools and their steadily growing technological importance will require the application of new methods in the product development process. This paper shows that the analysis of the simulation results from the simulation based mechatronic model of a complex system followed by a procedure that allows a better understanding of the dynamic behavior and interactions of the components. Mechatronics is a design philosophy, which is an integrating approach to engineering design. Through a mechanism of simulating interdisciplinary ideas and techniques, mechatronics provides ideal conditions to raise the synergy, thereby providing a catalytic effect for the new solutions to technically complex situations. This paper shows how the mechatronic products can exhibit performance characteristics that were previously difficult to achieve without the synergistic combination. The paper further examines an approach used in modeling, simulation and optimization of dynamic machine tools and adopts it for general optimized design of mechatronics instrumentation and portable products. By considering the machine tool as a complete mechatronic system, which can be broken down into subsystems, forms the fundamental basis for the procedure. Starting from this point of view it is necessary to establish appropriate simulation models, which are capable of representing the relevant properties of the subsystems and the dynamic interactions between the machine components. Many real-world systems can be modeled by the mass-spring-damper system and hence considering one such system, namely Mechatronics Technology Demonstrator (MTD) is discussed here. MTD is a portable low cost, technology demonstrator, developed and refined by the authors. It is suitable for studying the key elements of mechatronic systems including; mechanical system dynamics, sensors, actuators, computer interfacing, and application development. An important characteristic of mechatronic devices and systems is their built-in intelligence that results through a combination of precision, mechanical and electrical engineering, and real time programming integrated to the design process. The synergy can be generated by the right combination of parameters, that is, the final product can be better than just the sum of its parts. The paper highlights design optimization of several mechatronic products using the procedures derived by the use of mass spring damper based mechatronic system. The paper shows step by step development of a mechatronic product and the use of embedded software for portability of hand held equipment. A LabVIEW based platform was used as a control tool to control the MTD, perform data acquisition, post-processing, and optimization. In addition to the use of LabVIEW software, the use of embedded control system has been proposed for real-time control and optimization of the mass-spring-damper system. Integrating embedded control system with the mass-spring-damper system makes the MTD a multi-concepts Mechatronics platform. This allows interface with external sensors and actuators with closed-loop control and real-time monitoring of the physical system. This teaches students the skill set required for embedded control: design control algorithms (model-based embedded control software development, signal processing, communications), Computer Software (real-time computation, multitasking, interrupts), Computer hardware (interfacing, peripherals, memory constraints), and System Performance Optimization. This approach of deriving a mathematical model of system to be controlled, developing simulation model of the system, and using embedded control for rapid prototyping and optimization, will practically speed product development and improve productivity of complex systems.

The Control of Vibration Transmissibility Using an Electrodynamic Actuator –Close-Loop Solution

2013 ◽  
Vol 436 ◽  
pp. 166-173
Author(s):  
A. Mihaela Mîţiu ◽  
Daniel Constantin Comeagă ◽  
Octavian G. Donţu
Keyword(s):  
Mathematical Model ◽  
Control System ◽  
Mechanical System ◽  
Closed Loop ◽  
Mechanical Systems ◽  
Vibration Transmissibility ◽  
Technical Solutions ◽  
The Mathematical Model

In this paper are presented some aspects of transmissibility control of mechanical systems with 1 DOF so that the effects of vibration on their action to be minimized. Some technical solutions that can be used for this purpose is analyzed. Starting from the mathematical model of an electro-mechanical system with 1 DOF, are identified the parameters which influence the effectiveness of the transmissibility control system using an electrodynamic actuator who work in "closed loop".

Innovative Design, Structural Optimization and Additive Manufacturing of New-Generation Turbine Blades

2021 ◽  
pp. 1-31
Author(s):  
Lorenzo Pinelli ◽  
Andrea Amedei ◽  
Enrico Meli ◽  
Federico Vanti ◽  
Benedetta Romani ◽  
...  
Keyword(s):  
Topology Optimization ◽  
Additive Manufacturing ◽  
Structural Optimization ◽  
Turbine Blade ◽  
Turbine Blades ◽  
Topological Optimization ◽  
Mode Shapes ◽  
Structural Topology Optimization ◽  
Structural Topology ◽  
New Generation

Abstract The need for high performances is pushing the complexity of mechanical design at very high levels, especially for turbomachinery components. Structural topology optimization methods together with additive manufacturing techniques for high resistant alloys are considered very promising tools, but their potentialities have not been deeply investigated yet for critical rotating components like new-generation turbine blades. This research work proposes a methodology for the design, the optimization and the additive manufacturing of extremely stressed turbomachinery components like turbine blade-rows. The presented procedure pays particular attention to important aspects of the problems as fluid-structure interactions and fatigue of materials, going beyond the standard structural optimization approaches found in the literature. The numerical procedure shows robustness and efficiency, making the proposed methodology a good tool for rapid design and prototyping, and for reducing the design costs and the time-to-market typical of these mechanical elements. The procedure has been applied to a low-pressure turbine rotor to improve the aeromechanical behavior while keeping the aerodynamic performance. From the original geometry, mode-shapes, forcing functions and aerodynamic damping have been numerically evaluated and are used as input data for the following topological optimization. Finally, the optimized geometry has been verified in order to confirm the improved aeromechanical design. After the structural topology optimization, the final geometries provided by the procedure have been then properly rendered to make them suitable for additive manufacturing. Some prototypes of the new optimized turbine blade have been manufactured to be tested in terms of fatigue.

Stiffened CFRP-Panels Under Buckling Loads: Modeling, Analysis, Optimization

1995 ◽  
Author(s):  
Hans A. Eschenauer ◽  
Christof M. Weber
Keyword(s):  
Structural Analysis ◽  
Structural Optimization ◽  
Fiber Composite ◽  
Composite Plates ◽  
Optimization Process ◽  
Optimal Layout ◽  
Buckling Loads ◽  
Whole Process ◽  
Modeling Analysis ◽  
Complete Optimization

Abstract The present paper addresses the optimal layout of stiffened fiber composite plates (Fig. 1) considering buckling constraints; these plates are increasingly applied in many fields of engineering (air- and spacecraft technology, automotive industries, boatbuilding etc.). This particular area of structural optimization still requires substantial investigations into its fundamentals. The structural analysis alone for the treatment of this type of problems may increase to such a degree that the complete optimization process requires extremely long computation times due to the processing of a high amount of data, a fact that calls for the development of “intelligent” procedures in order to reduce the computation effort to a tolerable measure and to maintain reduplicability of the whole process. For this purpose, a so-called “constructive design model” is introduced.

Potentials of Structural Optimization Systems in Product Development

CIRP Annals ◽  
1996 ◽  
Vol 45 (1) ◽  
pp. 165-168 ◽  
Author(s):  
M. Week ◽  
J. Asbeck ◽  
A. Büssenschütt
Keyword(s):  
Product Development ◽  
Structural Optimization

scholarly journals Structural optimization in ESAC: annals 2011

2014 ◽  
Vol 5 ◽  
pp. A09
Author(s):  
Ji-Hong Zhu ◽  
Wei-Hong Zhang
Keyword(s):  
Topology Optimization ◽  
Structural Optimization ◽  
Material Properties ◽  
Numerical Results ◽  
Multiphase Materials ◽  
And Topology ◽  
Effective Material Properties

The purpose of this paper is to give an overall introduction of the structural optimization research works in ESAC group in 2011. Four main topics are involved, i.e. 1) topology optimization with multiphase materials, 2) integrated layout and topology optimization, 3) prediction of effective material properties and 4) composite design. More detailed techniques and some numerical results are also presented and discussed here.

scholarly journals Degrading systems availability analysis: analytical semi-Markov approach

2021 ◽  
Vol 23 (1) ◽  
pp. 195-208
Author(s):  
Varun Kumar ◽  
Girish Kumar ◽  
Rajesh Kumar Singh ◽  
Umang Soni
Keyword(s):  
Steady State ◽  
Degradation Mechanism ◽  
Continuous Process ◽  
Mechanical Systems ◽  
Embedded Markov Chain ◽  
Steady State Probability ◽  
Opportunistic Maintenance ◽  
System Availability ◽  
Availability Analysis ◽  
Complex Mechanical Systems

This paper deals with modeling and analysis of complex mechanical systems that deteriorate with age. As systems age, the questions on their availability and reliability start to surface. The system is believed to suffer from internal stochastic degradation mechanism that is described as a gradual and continuous process of performance deterioration. Therefore, it becomes difficult for maintenance engineer to model such system. Semi-Markov approach is proposed to analyze the degradation of complex mechanical systems. It involves constructing states corresponding to the system functionality status and constructing kernel matrix between the states. The construction of the transition matrix takes the failure rate and repair rate into account. Once the steady-state probability of the embedded Markov chain is computed, one can compute the steady-state solution and finally, the system availability. System models based on perfect repair without opportunistic and with opportunistic maintenance have been developed and the benefits of opportunistic maintenance are quantified in terms of increased system availability. The proposed methodology is demonstrated for a two-stage reciprocating air compressor with intercooler in between, system in series configuration.

scholarly journals Topology Optimization of Vehicle B-Pillar

2021 ◽  
Vol 9 (11) ◽  
pp. 384-392
Author(s):  
Manas Metar
Keyword(s):  
Topology Optimization ◽  
Structural Optimization ◽  
Weight Reduction ◽  
Optimization Techniques ◽  
Vehicle Body ◽  
Element Analysis ◽  
Reduction Techniques ◽  
Roof Structure ◽  
Original Weight ◽  
3D Software

Abstract: Weight reduction techniques have been practiced by automobile manufacturers for the purpose of long range, less fuel consumption and achieving higher speeds. Due to the numerous set objectives that must be met, especially with respect to of car safety, automotive chassis design for vehicle weight reduction is a difficult task. In passenger classed vehicles using a monocoque chassis for vehicle construction has been a great solution for reducing overall wight of the vehicle body yet the structure is more stiffened and sturdier. However, some parts such as A-pillar, B-pillar, roof structure, floor pan can be further optimized to reduce more weight without affecting the strength needed for respective purposes. In this paper, the main focus is on reducing weight of the B-pillar. The B-pillar of a passenger car has been optimized using topology optimization and optimum weight reduction has been done. The modelling and simulation are done using SOLIDWORKS 3D software. The B-pillar in this study has been subjected to a static load of 140 KN. Further by providing goals and constraints the optimization was caried out. The results of Finite Element Analysis (FEA) of the original model are explained. The Topology Optimization resulted in reducing 53% of the original weight of the B-pillar. Keywords: Structural optimization techniques, weight reduction techniques, weight reduction technologies, need for weight reduction, Topology optimization, B-pillar design, structural optimization of B-pillar, Topology optimization of B-pillar.

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