Robust Design Optimization Method for Centrifugal Impellers under Surface Roughness Uncertainties Due to Blade Fouling

Blade fouling has been proved to be a great threat to compressor performance in operating stage. The current researches on fouling-induced performance degradations of centrifugal compressors are based mainly on simplified roughness models without taking into account the realistic factors such as spatial non-uniformity and randomness of the fouling-induced surface roughness. Moreover, little attention has been paid to the robust design optimization of centrifugal compressor impellers with considerations of blade fouling. In this paper, a multi-objective robust design optimization method is developed for centrifugal impellers under surface roughness uncertainties due to blade fouling. A three-dimensional surface roughness map is proposed to describe the nonuniformity and randomness of realistic fouling accumulations on blades. To lower computational cost in robust design optimization, the support vector regression（SVR） metamodel is combined with the Monte Carlo simulation（MCS） method to conduct the uncertainty analysis of fouled impeller performance. The analyzed results show that the critical fouled region associated with impeller performance degradations lies at the leading edge of blade tip. The SVR metamodel has been proved to be an efficient and accurate means in the detection of impeller performance variations caused by roughness uncertainties. After design optimization, the robust optimal design is found to be more efficient and less sensitive to fouling uncertainties while maintaining good impeller performance in the clean condition. This research proposes a systematic design optimization method for centrifugal compressors with considerations of blade fouling, providing a practical guidance to the design of advanced centrifugal compressors.

Robust Design Optimization and Improvement by Metamodel

The robust design optimization(RDO)is an effective method to improve product performance with uncertainty factors.The robust optimal solution should be not only satisfied the probabilistic constraints but also less sensitive to the variation of design variables.There are some important issues in RDO,such as how to judge robustness,deal with multi-objective problem and black-box situation.In this paper,two criteria are proposed to judge the deterministic optimal solution whether satisfies robustness requirment.The robustness measure based on maximum entropy is proposed.Weighted sum method is improved to deal with the objective function,and the basic framework of metamodel assisted robust optimization is also provided for improving the efficiency.Finally,several engineering examples are used to verify the advantages.

Uncertainty analysis and robust design optimization for the heat-assisted bending of high-strength titanium tube

Heat-assisted rotary draw bending(HRDB)is a promising technique for manufacturing difficult-to-form tubular components comprising high-strength titanium tubes(HSTTs)with small bending radii.However,as a multidie constrained and thermomechanical coupled process with many uncertainty factors,a high risk of several defects,such as cross-section distortion,over wall thinning,or even cracking,is present.Achieving the robust design optimization(RDO)of complex forming processes remains a nontrivial and challenging scientific issue.Herein,considering a high-strength Ti-3Al-2.5V titanium alloy tube as a case material,the five significant uncertainty factors in HRDB,i.e.,temperature distribution,tube geometrical characteristics,tube material parameters,tube/tool friction,and boost velocity had been analyzed.Subsequently,considering the preheating and HRDB of HSTT,a whole-process thermomechanical three-dimensional finite element model was established and validated for virtual experiments.Further,considering the maximum section distortion Q and maximum wall-thickness thinning t as the optimization objectives and the mean and variance of material and forming parameters,an RDO model was established.Finally,the Pareto optimal solutions were obtained using the nondominated sorting genetic algorithm II,and a minimum distance selection method was employed to obtain the satisfactory solution.Results show that the optimized solutions considering the uncertainty factors reduce the maximum section distortion rate of HSTT after bending by 38.1%and the maximum wallthickness thinning rate by 27.8%.

Robust Multiobjective and Multidisciplinary Design Optimization of Electrical Drive Systems

Design and optimization of electrical drive systems often involve simultaneous consideration of multiple objectives that usually contradict to each other and multiple disciplines that normally coupled to each other.This paper aims to present efficient system-level multiobjective optimization methods for the multidisciplinary design optimization of electrical drive systems.From the perspective of quality control,deterministic and robust approaches will be investigated for the development of the optimization models for the proposed methods.Meanwhile,two approximation methods,Kriging model and Taylor expansion are employed to decrease the computation/simulation cost.To illustrate the advantages of the proposed methods,a drive system with a permanent magnet synchronous motor driven by a field oriented control system is investigated.Deterministic and robust Pareto optimal solutions are presented and compared in terms of several steady-state and dynamic performances(like average torque and speed overshoot)of the drive system.The robust multiobjective optimization method can produce optimal Pareto solutions with high manufacturing quality for the drive system.

Multi-objective robust design optimization of a novel negative Poisson's ratio bumper system

Negative Poisson's ratio(NPR) structure has outstanding performances in lightweight and energy absorption, and it can be widely applied in automotive industries. By combining the front anti-collision beam, crash box and NPR structure, a novel NPR bumper system for improving the crashworthiness is first proposed in the work. The performances of the NPR bumper system are detailed studied by comparing to traditional bumper system and aluminum foam filled bumper system. To achieve the rapid design while considering perturbation induced by parameter uncertainties, a multi-objective robust design optimization method of the NPR bumper system is also proposed. The parametric model of the bumper system is constructed by combining the full parametric model of the traditional bumper system and the parametric model of the NPR structure. Optimal Latin hypercube sampling technique and dual response surface method are combined to construct the surrogate models. The multi-objective robust optimization results of the NPR bumper system are then obtained by applying the multi-objective particle swarm optimization algorithm and six sigma criteria. The results yielded from the optimizations indicate that the energy absorption capacity is improved significantly by the NPR bumper system and its performances are further optimized efficiently by the multi-objective robust design optimization method.

Multi-parameter Sensitivity Analysis and Application Research in the Robust Optimization Design for Complex Nonlinear System

The current research of complex nonlinear system robust optimization mainly focuses on the features of design parameters, such as probability density functions, boundary conditions, etc. After parameters study, high-dimensional curve or robust control design is used to find an accurate robust solution. However, there may exist complex interaction between parameters and practical engineering system. With the increase of the number of parameters, it is getting hard to determine high-dimensional curves and robust control methods, thus it＇s difficult to get the robust design solutions. In this paper, a method of global sensitivity analysis based on divided variables in groups is proposed. By making relevant variables in one group and keeping each other independent among sets of variables, global sensitivity analysis is conducted in grouped variables and the importance of parameters is evaluated by calculating the contribution value of each parameter to the total variance of system response. By ranking the importance of input parameters, relatively important parameters are chosen to conduct robust design analysis of the system. By applying this method to the robust optimization design of a real complex nonlinear system-a vehicle occupant restraint system with multi-parameter, good solution is gained and the response variance of the objective function is reduced to 0.01, which indicates that the robustness of the occupant restraint system is improved in a great degree and the method is effective and valuable for the robust design of complex nonlinear system. This research proposes a new method which can be used to obtain solutions for complex nonlinear system robust design.

Robustness optimization for rapid prototyping of functional artifacts based on visualized computing digital twins

This study presents a robustness optimization method for rapid prototyping(RP)of functional artifacts based on visualized computing digital twins(VCDT).A generalized multiobjective robustness optimization model for RP of scheme design prototype was first built,where thermal,structural,and multidisciplinary knowledge could be integrated for visualization.To implement visualized computing,the membership function of fuzzy decision-making was optimized using a genetic algorithm.Transient thermodynamic,structural statics,and flow field analyses were conducted,especially for glass fiber composite materials,which have the characteristics of high strength,corrosion resistance,temperature resistance,dimensional stability,and electrical insulation.An electrothermal experiment was performed by measuring the temperature and changes in temperature during RP.Infrared thermographs were obtained using thermal field measurements to determine the temperature distribution.A numerical analysis of a lightweight ribbed ergonomic artifact is presented to illustrate the VCDT.Moreover,manufacturability was verified based on a thermal-solid coupled finite element analysis.The physical experiment and practice proved that the proposed VCDT provided a robust design paradigm for a layered RP between the steady balance of electrothermal regulation and manufacturing efficacy under hybrid uncertainties.

Influence of the Hook Position on the Vertical Vibrations of an Automobile Exhaust System:Application of the Robust Optimization Design

A robust optimization design method is proposed to investigate the influence of the hook position on the vertical vibration(bending)of an automobile exhaust system.A block diagram for the robustness analysis of the exhaust system is initially constructed from the major affecting factors.Secondly,the second-order inertia force is set as the vibration excitation source of the exhaust system and the displacement of four hooks of the exhaust system is selected as the variable factor.Then tests are carried out to investigate the resulting vertical bending considering four influencing factors and three levels of analysis.Finally,a variance analysis of the vertical bending is performed.The present study provides a set of guidelines to control the key factors affecting the vibration of vehicle exhaust systems while proposing an effective method to reduce vehicle vibration and improve noise analysis。

Development of a deviation package method for low-cost robust optimization in compressor blade design

Manufacture variations can greatly increase the performance variability of compressor blades. Current robust design optimization methods have a critical role in reducing the adverse impact of the variations, but can be affected by errors if the assumptions of the deviation models and distribution parameters are inaccurate. A new approach for robust design optimization without the employment of the deviation models is proposed. The deviation package method and the interval estimation method are exploited in this new approach. Simultaneously, a stratified strategy is used to reduce the computational cost and assure the optimization accuracy. The test case employed for this study is a typical transonic compressor blade profile, which resembles most of the manufacture features of modern compressor blades. A set of 96 newly manufactured blades was measured using a coordinate measurement machine to obtain the manufacture variations and produce a deviation package. The optimization results show that the scatter of the aerodynamic performance for the optimal robust design is 20% less than the baseline value. By comparing the optimization results obtained from the deviation package method with those obtained from widely-used methods employing the deviation model, the efficiency and accuracy of the deviation package method are demonstrated. Finally, the physical mechanisms that control the robustness of different designs were further investigated, and some statistical laws of robust design were extracted.

Randomized Algorithms for Probabilistic Optimal Robust Performance Controller Design

Polynomial-time randomized algorithms were constructed to approximately solve optimal robust performance controller design problems in probabilistic sense and the rigorous mathematical justification of the approach was given. The randomized algorithms here were based on a property from statistical learning theory known as (uniform) convergence of empirical means (UCEM). It is argued that in order to assess the performance of a controller as the plant varies over a pre-specified family, it is better to use the average performance of the controller as the objective function to be optimized, rather than its worst-case performance. The approach is illustrated to be efficient through an example.

APPLICATION OF MODERN ROBUST OPTIMAL DESIGN METHOD TO THE SHOCK ABSORBER IN A CAR*

To reduce the variation of velocity characteristic of the shock absorber in acar, a modern robust optimal design method is applied to its structural parameters design. Firstly,the method is used to obtain the robust values which have low sensitivity to velocitycharacteristic and analyze the influences of the parameters on velocity characteristic. Secondly,the method is used to obtain their maximum tolerances under the condition of ensuring productquality. The results obviously improve the velocity characteristic.

Design optimization of a torpedo shell structure

An optimized methodology to design a more robust torpedo shell is proposed. The method has taken into account reliability requirements and controllable and uncontrollable factors such as geometry, load, material properties, manufacturing processes, installation, etc. as well as human and environmental factors. The result is a more realistic shell design. Our reliability optimization design model was developed based on sensitivity analysis. Details of the design model are given in this paper. An example of a torpedo shell design based on this model is given and demonstrates that the method produces designs that are more effective and reliable than traditional torpedo shell designs. This method can be used for other torpedo system designs.

A gradient-based method assisted by surrogate model for robust optimization of turbomachinery blades

The design optimization taking into account the impact of uncertainties favors improving the robustness of the design.A Surrogate-Assisted Gradient-Based(SAGB)method for the robust aerodynamic design optimization of turbomachinery blades considering large-scale uncertainty is introduced,verified and validated in the study.The gradient-based method is employed due to its high optimization efficiency and any one surrogate model with sufficient response accuracy can be employed to quantify the nonlinear performance changes.The gradients of objective performance function to the design parameters are calculated first for all the training samples,from which the gradients of cost function can be fast determined.To reveal the high efficiency and high accuracy of SAGB on gradient calculation,the number of flow computations needed is evaluated and compared with three other methods.Through the aerodynamic design optimization of a transonic turbine cascade minimizing total pressure loss at the outlet,the SAGB-based gradients of the base and optimized blades are compared with those obtained by the Monte Carlo-assisted finite difference method.Moreover,the results of both the robust and deterministic aerodynamic design optimizations are presented and compared to demonstrate the practicability of SAGB on improving the aerodynamic robustness of turbomachinery blades.

New Synchronization Algorithm and Analysis of Its Convergence Rate for Clock Oscillators in Dynamical Network with Time-Delays

New synchronization algorithm and analysis of its convergence rate for clock oscillators in dynamical network with time-delays are presented.A network of nodes equipped with hardware clock oscillators with bounded drift is considered.Firstly,a dynamic synchronization algorithm based on consensus control strategy,namely fast averaging synchronization algorithm （FASA）,is presented to find the solutions to the synchronization problem.By FASA,each node computes the logical clock value based on its value of hardware clock and message exchange.The goal is to synchronize all the nodes＇ logical clocks as closely as possible.Secondly,the convergence rate of FASA is analyzed that proves it is related to the bound by a nondecreasing function of the uncertainty in message delay and network parameters.Then,FASA＇s convergence rate is proven by means of the robust optimal design.Meanwhile,several practical applications for FASA,especially the application to inverse global positioning system （IGPS） base station network are discussed.Finally,numerical simulation results demonstrate the correctness and efficiency of the proposed FASA.Compared FASA with traditional clock synchronization algorithms （CSAs）,the convergence rate of the proposed algorithm converges faster than that of the CSAs evidently.

Rotorcraft flight endurance estimation based on a new battery discharge model

To avoid the numerical complexities of the battery discharge law of electric-powered rotorcrafts,this study uses the Kriging method to model the discharge characteristics of Li-Po batteries under standard conditions.A linear current compensation term and an ambient temperature compensation term based on radial basis functions are then applied to the trained Kriging model,leading to the complete discharged capacity-terminal voltage model.Using an orthogonal experimental design and a sequential method,the coefficients of the current and ambient temperature compensation terms are determined through robust optimization.An endurance calculation model for electric-powered rotorcrafts is then established,based on the battery discharge model,through numerical integration.Laboratory tests show that the maximum relative error of the proposed discharged capacity-terminal voltage model at detection points is 0.0086,and that of the rotorcraft endurance calculation model is 0.0195,thus verifying their accuracy.A flight test further demonstrates the applicability of the proposed endurance model to general electric-powered rotorcrafts.