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Institute
- Fachbereich Elektrotechnik und Informationstechnik (47) (remove)
Highly competitive markets paired with tremendous production volumes demand particularly cost efficient products. The usage of common parts and modules across product families can potentially reduce production costs. Yet, increasing commonality typically results in overdesign of individual products. Multi domain virtual prototyping enables designers to evaluate costs and technical feasibility of different single product designs at reasonable computational effort in early design phases. However, savings by platform commonality are hard to quantify and require detailed knowledge of e.g. the production process and the supply chain. Therefore, we present and evaluate a multi-objective metamodel-based optimization algorithm which enables designers to explore the trade-off between high commonality and cost optimal design of single products.
To increase pressure to supply all floors of high buildings with water, booster stations, normally consisting of several parallel pumps in the basement, are used. In this work, we demonstrate the potential of a decentralized pump topology regarding energy savings in water supply systems of skyscrapers. We present an approach, based on Mixed-Integer Nonlinear Programming, that allows to choose an optimal network topology and optimal pumps from a predefined construction kit comprising different pump types. Using domain-specific scaling laws and Latin Hypercube Sampling, we generate different input sets of pump types and compare their impact on the efficiency and cost of the total system design. As a realistic application example, we consider a hotel building with 325 rooms, 12 floors and up to four pressure zones.
Around 60% of the paper worldwide is made from recovered paper. Especially adhesive contaminants, so called stickies, reduce paper quality. To remove stickies but at the same time keep as many valuable fibers as possible, multi-stage screening systems with several interconnected pressure screens are used. When planning such systems, suitable screens have to be selected and their interconnection as well as operational parameters have to be defined considering multiple conflicting objectives. In this contribution, we present a Mixed-Integer Nonlinear Program to optimize system layout, component selection and operation to find a suitable trade-off between output quality and yield.
Successful optimization requires an appropriate model of the system under consideration. When selecting a suitable level of detail, one has to consider solution quality as well as the computational and implementation effort. In this paper, we present a MINLP for a pumping system for the drinking water supply of high-rise buildings. We investigate the influence of the granularity of the underlying physical models on the solution quality. Therefore, we model the system with a varying level of detail regarding the friction losses, and conduct an experimental validation of our model on a modular test rig. Furthermore, we investigate the computational effort and show that it can be reduced by the integration of domain-specific knowledge.
The application of mathematical optimization methods for water supply system design and operation provides the capacity to increase the energy efficiency and to lower the investment costs considerably. We present a system approach for the optimal design and operation of pumping systems in real-world high-rise buildings that is based on the usage of mixed-integer nonlinear and mixed-integer linear modeling approaches. In addition, we consider different booster station topologies, i.e. parallel and series-parallel central booster stations as well as decentral booster stations. To confirm the validity of the underlying optimization models with real-world system behavior, we additionally present validation results based on experiments conducted on a modularly constructed pumping test rig. Within the models we consider layout and control decisions for different load scenarios, leading to a Deterministic Equivalent of a two-stage stochastic optimization program. We use a piecewise linearization as well as a piecewise relaxation of the pumps’ characteristics to derive mixed-integer linear models. Besides the solution with off-the-shelf solvers, we present a problem specific exact solving algorithm to improve the computation time. Focusing on the efficient exploration of the solution space, we divide the problem into smaller subproblems, which partly can be cut off in the solution process. Furthermore, we discuss the performance and applicability of the solution approaches for real buildings and analyze the technical aspects of the solutions from an engineer’s point of view, keeping in mind the economically important trade-off between investment and operation costs.
Given industrial applications, the costs for the operation and maintenance of a pump system typically far exceed its purchase price. For finding an optimal pump configuration which minimizes not only investment, but life-cycle costs, methods like Technical Operations Research which is based on Mixed-Integer Programming can be applied. However, during the planning phase, the designer is often faced with uncertain input data, e.g. future load demands can only be estimated. In this work, we deal with this uncertainty by developing a chance-constrained two-stage (CCTS) stochastic program. The design and operation of a booster station working under uncertain load demand are optimized to minimize total cost including purchase price, operation cost incurred by energy consumption and penalty cost resulting from water shortage. We find optimized system layouts using a sample average approximation (SAA) algorithm, and analyze the results for different risk levels of water shortage. By adjusting the risk level, the costs and performance range of the system can be balanced, and thus the
system’s resilience can be engineered
On obligations in the development process of resilient systems with algorithmic design methods
(2018)
Advanced computational methods are needed both for the design of large systems and to compute high accuracy solutions. Such methods are efficient in computation, but the validation of results is very complex, and highly skilled auditors are needed to verify them. We investigate legal questions concerning obligations in the development phase, especially for technical systems developed using advanced methods. In particular, we consider methods of resilient and robust optimization. With these techniques, high performance solutions can be found, despite a high variety of input parameters. However, given the novelty of these methods, it is uncertain whether legal obligations are being met. The aim of this paper is to discuss if and how the choice of a specific computational method affects the developer’s product liability. The review of legal obligations in this paper is based on German law and focuses on the requirements that must be met during the design and development process.
Cheap does not imply cost-effective -- this is rule number one of zeitgeisty system design. The initial investment accounts only for a small portion of the lifecycle costs of a technical system. In fluid systems, about ninety percent of the total costs are caused by other factors like power consumption and maintenance. With modern optimization methods, it is already possible to plan an optimal technical system considering multiple objectives. In this paper, we focus on an often neglected contribution to the lifecycle costs: downtime costs due to spontaneous failures. Consequently, availability becomes an issue.
In times of planned obsolescence the demand for sustainability keeps growing. Ideally, a technical system is highly reliable, without failures and down times due to fast wear of single components. At the same time, maintenance should preferably be limited to pre-defined time intervals. Dispersion of load between multiple components can increase a system’s reliability and thus its availability inbetween maintenance points. However, this also results in higher investment costs and additional efforts due to higher complexity. Given a specific load profile and resulting wear of components, it is often unclear which system structure is the optimal one. Technical Operations Research (TOR) finds an optimal structure balancing availability and effort. We present our approach by designing a hydrostatic transmission system.
The paper industry is the industry with the third highest energy consumption in the European Union. Using recycled paper instead of fresh fibers for papermaking is less energy consuming and saves resources. However, adhesive contaminants in recycled paper are particularly problematic since they reduce the quality of the resulting paper-product. To remove as many contaminants and at the same time obtain as many valuable fibres as possible, fine screening systems, consisting of multiple interconnected pressure screens, are used. Choosing the best configuration is a non-trivial task: The screens can be interconnected in several ways, and suitable screen designs as well as operational parameters have to be selected. Additionally, one has to face conflicting objectives. In this paper, we present an approach for the multi-criteria optimization of pressure screen systems based on Mixed-Integer Nonlinear Programming. We specifically focus on a clear representation of the trade-off between different objectives.
Nahezu 100.000 denkbare Strukturen kann ein Getriebe bei gleicher Funktion aufweisen - je nach Ganganzahl und gefordertem Freiheitsgrad. Mit dem traditionellen Ansatz bei der Entwicklung, einzelne vielversprechende Systemkonfigurationen manuell zu identifizieren und zu vergleichen, können leicht innovative und vor allem kostenminimale Lösungen übersehen werden. Im Rahmen eines Forschungsprojekts hat die TU Darmstadt spezielle Optimierungsmethoden angewendet, um auch bei großen Lösungsräumen zielsicher ein für die individuellen Zielstellungen optimales Layout zu finden.
In product development, numerous design decisions have to be made. Multi-domain virtual prototyping provides a variety of tools to assess technical feasibility of design options, however often requires substantial computational effort for just a single evaluation. A special challenge is therefore the optimal design of product families, which consist of a group of products derived from a common platform. Finding an optimal platform configuration (stating what is shared and what is individually designed for each product) and an optimal design of all products simultaneously leads to a mixed-integer nonlinear black-box optimization model. We present an optimization approach based on metamodels and a metaheuristic. To increase computational efficiency and solution quality, we compare different types of Gaussian process regression metamodels adapted from the domain of machine learning, and combine them with a genetic algorithm. We illustrate our approach on the example of a product family of electrical drives, and investigate the trade-off between solution quality and computational overhead.
Verfügbarkeit und Nachhaltigkeit sind wichtige Anforderungen bei der Planung langlebiger technischer Systeme. Meist werden bei Lebensdaueroptimierungen lediglich einzelne Komponenten vordefinierter Systeme untersucht. Ob eine optimale Lebensdauer eine gänzlich andere Systemvariante bedingt, wird nur selten hinterfragt. Technical Operations Research (TOR) erlaubt es, aus Obermengen technischer Systeme automatisiert die lebensdaueroptimale Systemstruktur auszuwählen. Der Artikel zeigt dies am Beispiel eines hydrostatischen Getriebes.
The chemical industry is one of the most important industrial sectors in Germany in terms of manufacturing revenue. While thermodynamic boundary conditions often restrict the scope for reducing the energy consumption of core processes, secondary processes such as cooling offer scope for energy optimisation. In this contribution, we therefore model and optimise an existing cooling system. The technical boundary conditions of the model are provided by the operators, the German chemical company BASF SE. In order to systematically evaluate different degrees of freedom in topology and operation, we formulate and solve a Mixed-Integer Nonlinear Program (MINLP), and compare our optimisation results with the existing system.
Water suppliers are faced with the great challenge of achieving high-quality and, at the same time, low-cost water supply. In practice, the focus is set on the most beneficial maintenance measures and/or capacity adaptations of existing water distribution systems (WDS). Since climatic and demographic influences will pose further challenges in the future, the resilience enhancement of WDS, i.e. the enhancement of their capability to withstand and recover from disturbances, has been in particular focus recently. To assess the resilience of WDS, metrics based on graph theory have been proposed. In this study, a promising approach is applied to assess the resilience of the WDS for a district in a major German City. The conducted analysis provides insight into the process of actively influencing the
resilience of WDS
In order to maximize the possible travel distance of battery electric vehicles with one battery charge, it is mandatory to adjust all components of the powertrain carefully to each other. While current vehicle designs mostly simplify the powertrain rigorously and use an electric motor in combination with a gearbox with only one fixed transmission ratio, the use of multi-gear systems has great potential. First, a multi-speed system is able to improve the overall energy efficiency. Secondly, it is able to reduce the maximum momentum and therefore to reduce the maximum current provided by the traction battery, which results in a longer battery lifetime. In this paper, we present a systematic way to generate multi-gear gearbox designs that—combined with a certain electric motor—lead to the most efficient fulfillment of predefined load scenarios and are at the same time robust to uncertainties in the load. Therefore, we model the electric motor and the gearbox within a Mixed-Integer Nonlinear Program, and optimize the efficiency of the mechanical parts of the powertrain. By combining this mathematical optimization program with an unsupervised machine learning algorithm, we are able to derive global-optimal gearbox designs for practically relevant momentum and speed requirements.
Planning the layout and operation of a technical system is a common task
for an engineer. Typically, the workflow is divided into consecutive stages: First,
the engineer designs the layout of the system, with the help of his experience or of
heuristic methods. Secondly, he finds a control strategy which is often optimized
by simulation. This usually results in a good operating of an unquestioned sys-
tem topology. In contrast, we apply Operations Research (OR) methods to find a
cost-optimal solution for both stages simultaneously via mixed integer program-
ming (MILP). Technical Operations Research (TOR) allows one to find a provable
global optimal solution within the model formulation. However, the modeling error
due to the abstraction of physical reality remains unknown. We address this ubiq-
uitous problem of OR methods by comparing our computational results with mea-
surements in a test rig. For a practical test case we compute a topology and control
strategy via MILP and verify that the objectives are met up to a deviation of 8.7%.