Taguchi Methodology to Optimize the Design of a MR-Brake With Permanent Magnet

2012 ◽  
Author(s):  
Ozan Erol ◽  
Hakan Gurocak
Keyword(s):  
Permanent Magnet ◽  
Volume Ratio ◽  
Search Space ◽  
Friction Torque ◽  
Optimization Techniques ◽  
Design Parameters ◽  
Physical Factors ◽  
Optimization Approach ◽  
Taguchi Optimization ◽  
Element Analysis

Magnetorheological (MR) brakes provide variable friction torque by electronically changing the viscosity of a magnetic fluid inside the actuator. The MR-brakes have many desirable characteristics, such as high torque-to-volume ratio, inherent stability and ease of control. However, the design process of such an actuator is complex and time consuming due to many parameters involved in the design, including geometric and physical factors and their interactions. The first contribution of this research is a new optimization approach where we combined the Taguchi optimization method with parameterized magnetic finite element analysis. Unlike other optimization techniques, this method can identify the dominant parameters of the design and investigate their interactions with the design output while reducing the search space and the design time. The second contribution is the design optimization of a novel MR-brake, which incorporates a serpentine flux path and a permanent magnet. To the best of our knowledge, this is the first such MR-brake. The new MR-brake design provides a fail-safe feature while reducing the volume by decreasing the number of coil turns required. Results showed that some of the geometric parameters and the current have the most significant effect on the torque output out of the 12 design parameters.

Design Optimization Method for MR-Brake Actuators

2011 ◽  
Author(s):  
Ozan G. Erol ◽  
Hakan Gurocak ◽  
Berk Gonenc
Keyword(s):  
Optimal Solution ◽  
Volume Ratio ◽  
Optimization Methods ◽  
Search Space ◽  
Optimization Method ◽  
Friction Torque ◽  
Element Analysis ◽  
Taguchi Design Of Experiments ◽  
Variable Friction ◽  
Electronically Controllable

MR-brakes work by varying viscosity of a magnetorheological (MR) fluid inside the brake. This electronically controllable viscosity leads to variable friction torque generated by the actuator. A properly designed MR-brake can have a high torque-to-volume ratio which is quite desirable for an actuator. However, designing an MR-brake is a complex process as there are many parameters involved in the design which can affect the size and torque output significantly. The contribution of this study is a new design approach that combines the Taguchi design of experiments method with parameterized finite element analysis for optimization. Unlike the typical multivariate optimization methods, this approach can identify the dominant parameters of the design and allows the designer to only explore their interactions during the optimization process. This unique feature reduces the size of the search space and the time it takes to find an optimal solution. It normally takes about a week to design an MR-brake manually. Our interactive method allows the designer to finish the design in about two minutes. In this paper, we first present the details of the MR-brake design problem. This is followed by the details of our new approach. Next, we show how to design an MR-brake using this method. Prototype of a new brake was fabricated. Results of experiments with the prototype brake are very encouraging and are in close agreement with the theoretical performance predictions.

Analysis of a Tubular Linear Permanent Magnet Motor for Reciprocating Compressor Applications

2013 ◽  
Vol 448-453 ◽  
pp. 2114-2119 ◽  
Author(s):  
Izzeldin Idris Abdalla ◽  
Taib Ibrahim ◽  
Nursyarizal Mohd Nor
Keyword(s):  
Permanent Magnet ◽  
Permanent Magnets ◽  
Outer Radius ◽  
Design Parameters ◽  
Reciprocating Compressor ◽  
Permanent Magnet Motors ◽  
Permanent Magnet Motor ◽  
Element Analysis ◽  
Split Ratio ◽  
Single Coil

This paper describes a design optimization to achieve optimal performance of a two novel single-phase short-stroke tubular linear permanent magnet motors (TLPMMs) with rectangular and trapezoidal permanent magnets (PMs) structures. The motors equipped with a quasi-Halbach magnetized moving-magnet armature and slotted stator with a single-slot carrying a single coil. The motors have been developed for reciprocating compressor applications such as household refrigerators. It is observed that the TLPMM efficiency can be optimized with respect to the leading design parameters (dimensional ratios). Furthermore, the influence of mover back iron is investigated and the loss of the motor is computed. Finite element analysis (FEA) is employed for the optimization, and the optimal values of the ratio of the axial length of the radially magnetized magnets to the pole pitch as well as the ratio of the PMs outer radius-to-stator outer radius (split ratio), are identified.

An Agent Based Optimization Approach to Manufacturing Process Planning

2001 ◽  
Author(s):  
Saurabh Deshpande ◽  
Jonathan Cagan
Keyword(s):  
Stochastic Optimization ◽  
Process Planning ◽  
Manufacturing Process ◽  
Optimization Problems ◽  
Search Space ◽  
Optimization Techniques ◽  
Process Models ◽  
Optimization Approach ◽  
Agent Based ◽  
Manufacturing Process Planning

Abstract Many optimization problems, such as manufacturing process planning optimization, are difficult problems due to the large number of potential configurations (process sequences) and associated (process) parameters. In addition, the search space is highly discontinuous and multi-modal. This paper introduces an agent based optimization algorithm that combines stochastic optimization techniques with knowledge based search. The motivation is that such a merging takes advantage of the benefits of stochastic optimization and accelerates the search process using domain knowledge. The result of applying this algorithm to computerized manufacturing process models is presented.

Shape Optimal Design of Contact Springs of Electronic Connectors

2002 ◽  
Vol 124 (3) ◽  
pp. 178-183 ◽  
Author(s):  
Yeh-Liang Hsu ◽  
Yuan-Chan Hsu ◽  
Ming-Sho Hsu
Keyword(s):  
Contact Force ◽  
Printed Circuit Boards ◽  
Normal Force ◽  
Optimization Techniques ◽  
Contact Forces ◽  
Design Parameters ◽  
Original Design ◽  
Insertion Force ◽  
Element Analysis ◽  
Normal Contact

An electronic connector provides a separable interface between two subsystems of an electronic system. The contact spring is probably the most critical component in an electronic connector. Mechanically, the contact spring provides the contact normal force, which establishes the contact interface as the connector is mated. However, connector manufacturers have a basic struggle between the need for high normal contact forces and low insertion forces. Designing connectors with large numbers of pins that are used with today’s integrated circuits and printed circuit boards often results in an associated rise in connector insertion force. It is possible to lower the insertion force of a connector by redesigning the geometry of the contact spring, but this also means a decrease in contact normal force. In this paper, structural shape optimization techniques are used to find the optimal shape of the contact springs of an electronic connector. The process of the insertion of a PCB into the contact springs of a connector is modeled by finite element analysis. The maximum insertion force and the contact normal force are calculated. The effects of several design parameters are discussed. The geometry of the contact springs is then parameterized and optimized. The required insertion force is minimized while the normal contact force and the resulting stress are maintained within specified values. In our example, the insertion force of the final contact spring design is reduced to 68.3% of that of the original design, while the contact force and the maximum stress are maintained within specified values.

Optimum Design of Tractor Clutch PTO Finger by Using Topology and Shape Optimization

2015 ◽  
Author(s):  
O. Dogan ◽  
F. Karpat ◽  
N. Kaya ◽  
C. Yuce ◽  
M. O. Genc ◽  
...  
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Topology Optimization ◽  
Shape Optimization ◽  
Optimization Techniques ◽  
Design Parameters ◽  
Agricultural Activities ◽  
Element Analysis ◽  
Design Life ◽  
Topology And Shape Optimization

Tractors are one of the most important agricultural machinery in the world. They provide agricultural activities in challenging conditions by using various agricultural machineries which are added on them. Therefore, there has been a rising demand for tractor use for agricultural activities. During the power transmission, tractor clutches are exposed to high static and cyclic loading directly. Thus, most of clutch parts fail before completing their design life which is under 106 cycles. Especially, because of the high stress, there are a number of fractures and breakages are observed around the pin area of the finger mechanisms. Due to these reasons, it is necessary to re-design these fingers by using modern optimization techniques and finite element analysis. This paper presents an approach for analysis and re-designs process of tractor clutch PTO finger. Firstly, the original designs of the PTO fingers are analyzed by using finite element analysis. Static structural analyses are applied on these fingers by using ANSYS static structural module. The boundary conditions are determined according to the data from the axial fatigue test bench. Afterwards, the stress-life based fatigue analyses are performed with respect to Goodman criterion. It is seem that the original design of the PTO finger, failed before the design life. Hence, the PTO finger is completely re-designed by using topology and shape optimization methods. Topology optimization is used to find the optimum material distribution of the PTO fingers. Topology optimization is performed in solidThinking Inspire software. The precise dimensions of the PTO fingers are determined by using shape optimization and response surface methodology. Two different design parameters, which are finger thickness and height, are selected for design of experiment and 15 various cases are analyzed. By using DOE method three different equations are obtained which are maximum stresses, mass, and displacement depending on the selected design parameters. These equations are used in the optimization as objective and constraint equations in MATLAB. The results indicate that the proposed models predict the responses adequately within the limits of the parameters being used. The final dimensions of the fingers are determined after shape optimization. The new designs of the PTO fingers are re-analyzed in terms of static and fatigue analysis. The new design of the PTO finger passed the analysis successfully. As a result of the study, the finger mass is increased 7% but it is quite small. Maximum Equivalent Von-Misses stress reduction of 25.3% is achieved. Fatigue durability of the PTO finger is improved 53.2%. The rigidity is improved up to 27.9% compared to the initial design. The optimal results show that the developed method can be used to design a durable, low manufacturing cost and lightweight clutch parts.

scholarly journals A DIFFERENT APPROACH IN OPTIMUM DESIGN PROCESS AND FEA VALIDATION OF LOW-SPEED MULTI-PHASE IPMSMS

2017 ◽  
Vol 18 (1) ◽  
pp. 133-145
Author(s):  
Seyed Asghar Gholamian ◽  
Hamid Reza Gholinejad
Keyword(s):  
Permanent Magnet ◽  
Ant Colony Algorithm ◽  
Permanent Magnet Synchronous Motor ◽  
Design Procedure ◽  
Volume Ratio ◽  
Magnetic Flux Density ◽  
Permanent Magnet Motors ◽  
Element Analysis ◽  
Interior Permanent Magnet ◽  
Dimensional Finite Element

Magnets placement effects on permanent magnet motors performance, because of its different magnetic flux density distribution. Therefore, different types of magnet placement should be examined experimentally or by valid simulations. In this paper, first, an interior permanent magnet synchronous motor (IPMSM) called spoke type with specifications related to the propulsion of ships is designed and then optimized by ant colony algorithm to increase the torque-to-volume ratio. The design procedure and its formulas presented as simple as possible. Then, to verify the optimization results of the optimized motor, a Two-dimensional finite element analysis (FEA) is done. Also in this analyze the core and the slot saturation was studied.

Application of the corrected response surface methodology for the optimization of a permanent magnet synchronous machine

2018 ◽  
Vol 37 (2) ◽  
pp. 740-754 ◽  
Author(s):  
Stéphane Vivier
Keyword(s):  
Optimal Design ◽  
Permanent Magnet ◽  
Response Surface ◽  
Synchronous Machine ◽  
Optimization Techniques ◽  
Permanent Magnet Synchronous Machine ◽  
Optimization Approach ◽  
Content Type ◽  
Coarse Model ◽  
Conventional Optimization

PurposeThis paper aims to introduce an original application of the corrected response surface method (CRSM) in the context of the optimal design of a permanent magnet synchronous machine used as an integrated starter generator. This method makes it possible to carry out this design in a very efficient manner, in comparison with conventional optimization approaches. Design/methodology/approachThe search for optimal conditions is achieved by the joint use of two multi-physics models of the machine to be optimized. The former models most finely the physical functioning of the machine; it is called “fine model”. The second model describes the same physical phenomena as the fine model but must be much quicker to evaluate. Thus, to minimize its evaluation time, it is necessary to simplify it considerably. It is called “coarse model”. The lightness of the coarse model allows it to be used intensively by conventional optimization algorithms. On the other hand, the fine reference model makes it possible to recalibrate the results obtained from the coarse model at any instant, and mainly at the end of each classical optimization. The difference in definition between fine and coarse models implies that these two models do not give the same output values for the same input configuration. The approach described in this study proposes to correct the values of the coarse model outputs by constructing an adjustment (correcting) response surface. This gives the name to this method. It then becomes possible to have the entire load of the optimization carried over to the coarse model adjusted by the addition of this correction response surface. FindingsThe application of this method shows satisfactory results, in particular in comparison with those obtained with a traditional optimization approach based on a single (fine) model. It thus appears that the approach by CRSM makes it possible to converge much more quickly toward the optimal configurations. Also, the use of response surfaces for optimization makes it possible to capitalize the modeling data, thus making it possible to reuse them, if necessary, for subsequent optimal design studies. Numerous tests show that this approach is relatively robust to the variations of many important functioning parameters. Originality/valueThe CRSM technique is an indirect multi-model optimization method. This paper presents the application of this relatively undeveloped optimization approach, combining the features and benefits of (Indirect) efficient global optimization techniques and (multi-model) space mapping methods.

scholarly journals Application of Taguchi Optimization Techniques to the Combustor Design Process

1995 ◽  
Author(s):  
M. L. Cooner ◽  
R. S. Reynolds ◽  
R. Srinivasan
Keyword(s):  
Optimization Techniques ◽  
Operating Conditions ◽  
Design Parameters ◽  
Surface Cooling ◽  
Taguchi Optimization ◽  
Initial Development ◽  
Taguchi Design Of Experiments ◽  
Primary Zone ◽  
Improved Design ◽  
Characteristics Development

This paper describes the application of Taguchi design of experiments (DOE) methods to the initial development of the T800-LHT-801 growth engine combustor design. The performance of a gas turbine combustor is strongly influenced by the primary zone aerodynamics and stoichiometry. The interactions between fuel spray and airflows through swirlers, primary jets, and dome surface cooling dominate the primary zone characteristics. Development of a robust combustor design requires a good knowledge of the relative sensitivities of these interactions. In this application, the Taguchi DOE method was used to efficiently determine the design parameters driving the combustor performance, while minimizing the number of tests. The improved design configuration resulted in 60 percent reduction in Lean Blow Out (LBO), 140°C reduction in peak wall temperature, and elimination of carbon formation potential at severe operating conditions.

Novel linear switched-flux PM machine with 9/10 primary/secondary pole number combination

2015 ◽  
Vol 34 (6) ◽  
pp. 1656-1672 ◽  
Author(s):  
Qinfen Lu ◽  
Yanxin Li ◽  
Yunyue Ye ◽  
J.T. Chen ◽  
Z.Q. Zhu
Keyword(s):  
Permanent Magnet ◽  
Thrust Force ◽  
Load Condition ◽  
Design Parameters ◽  
Force Density ◽  
Direct Drive ◽  
Low Thrust ◽  
Element Analysis ◽  
Content Type ◽  
Force Ripple

Purpose – Due to linear structure, linear switched flux permanent magnet machines (LSFPMMs) also may have odd pole primary, such as 9, 15, 21, etc., without unbalanced magnetic force in equivalent rotary machines. The paper aims to discuss these issues. Design/methodology/approach – In order to increase the thrust force density, the influence of some major design parameters, including split ratio, PM thickness, primary slot width and secondary pole width, are investigated by finite element analysis. For reducing the thrust force ripple under on-load condition, the end auxiliary teeth are adopted and their positions are also optimized. Findings – This novel 9/10 primary/secondary poles LSFPMM has high average thrust force and low thrust force ripple by optimization. The results demonstrate that the odd pole primary may be a good candidate for long-stroke linear direct drive application. Originality/value – A novel 9/10 primary/secondary poles linear switched flux permanent magnet machine is developed in this paper. The similar conclusions could be obtained for other LSFPMMs with odd pole primary.

Flow Uniformity Characterization and Its Application in Extruder Flow Channel Design Optimization

2009 ◽  
Author(s):  
Minwu Yao ◽  
Ching-Chih Lee
Keyword(s):  
Design Optimization ◽  
Cross Section ◽  
Search Space ◽  
Flow Channel ◽  
Channel Cross Section ◽  
Optimization Approach ◽  
Flow Uniformity ◽  
Element Analysis ◽  
Automated Optimization ◽  
Optimization Loop

We are interested in developing a general design optimization loop for extruder flow channel inserts based on 3-D finite element analysis (FEA). A key step of the computational procedure is the automated flow uniformity assessment which requires a quantitative characterization of the flow uniformity at the exit opening. To this end, a non-dimensional flow uniformity parameter is proposed, which is independent of flow rate & geometric dimensions and applicable to any shape of the flow channel cross-section. For a rectangular exit opening, two additional flow uniformity parameters are used to characterize the flow distribution in the two principal directions of the exit cross-section. The proposed flow uniformity parameter was successfully used as the objective function in an automated optimization loop for geometric design of flow channel inserts. The automated optimization loop allowed us to explore the design space in a broad range. Simulation results show that flow balance is consistently improved with the expansion of the design search space. It was also found that the automated optimization loop provides a better optimal solution than those obtained from the manual optimization approach under the same pressure-drop constraint.

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