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Manufacturing Process Simulation for the Prediction of Tool-Part-Interaction and Ply Wrinkling
(2019)
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.
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.
The optical performance of a 2-axis solar concentrator was simulated with the COMSOL Multiphysics® software. The concentrator consists of a mirror array, which was created using the application builder. The mirror facets are preconfigured to form a focal point. During tracking all mirrors are moved simultaneously in a coupled mode by 2 motors in two axes, in order to keep the system in focus with the moving sun. Optical errors on each reflecting surface were implemented in combination with the solar angular cone of ± 4.65 mrad. As a result, the intercept factor of solar radiation that is available to the receiver was calculated as a function of the transversal and longitudinal angles of incidence. In addition, the intensity distribution on the receiver plane was calculated as a function of the incidence angles.
In parallel to the evolution of the Planetary Defense Conference, the exploration of small solar system bodies has advanced from fast fly-bys on the sidelines of missions to the planets to the implementation of dedicated sample-return and in-situ analysis missions. Spacecraft of all sizes have landed, touch-and-go sampled, been gently beached, or impacted at hypervelocity on asteroid and comet surfaces. More have flown by close enough to image their surfaces in detail or sample their immediate environment, often as part of an extended or re-purposed mission. And finally, full-scale planetary defense experiment missions are in the making. Highly efficient low-thrust propulsion is increasingly applied beyond commercial use also in mainstream and flagship science missions, in combination with gravity assist propulsion. Another development in the same years is the growth of small spacecraft solutions, not in size but in numbers and individual capabilities. The on-going NASA OSIRIS-REx and JAXA HAYABUSA2 missions exemplify the trend as well as the upcoming NEA SCOUT mission or the landers MINERVA-II and MASCOT recently deployed on Ryugu. We outline likely as well as possible and efficient routes of continuation of all these developments towards a propellant-less and highly efficient class of spacecraft for small solar system body exploration: small spacecraft solar sails designed for carefree handling and equipped with carried landers and application modules, for all asteroid user communities –planetary science, planetary defence, and in-situ resource utilization. This projection builds on the experience gained in the development of deployable membrane structures leading up to the successful ground deployment test of a (20 m)² solar sail at DLR Cologne and in the 20 years since. It draws on the background of extensive trajectory optimization studies, the qualified technology of the DLR GOSSAMER-1 deployment demonstrator, and the MASCOT asteroid lander. These enable ‘now-term’ as well as near-term hardware solutions, and thus responsive fast-paced development. Mission types directly applicable to planetary defense include: single and Multiple NEA Rendezvous ((M)NR) for mitigation precursor, target monitoring and deflection follow-up tasks; sail-propelled head-on retrograde kinetic impactors (RKI) for mitigation; and deployable membrane based methods to modify the asteroid’s properties or interact with it. The DLR-ESTEC GOSSAMER Roadmap initiated studies of missions uniquely feasible with solar sails such as Displaced L1 (DL1) space weather advance warning and monitoring and Solar Polar Orbiter (SPO) delivery which demonstrate the capability of near-term solar sails to achieve NEA rendezvous in any kind of orbit, from Earth-coorbital to extremely inclined and even retrograde orbits. For those mission types using separable payloads, such as SPO, (M)NR and RKI, design concepts can be derived from the separable Boom Sail Deployment Units characteristic of DLR GOSSAMER solar sail technology, nanolanders like MASCOT, or microlanders like the JAXA-DLR Jupiter Trojan Asteroid Lander for the OKEANOS mission which can shuttle from the sail to the asteroids visited and enable multiple NEA sample-return missions. These are an ideal match for solar sails in micro-spacecraft format whose launch configurations are compatible with ESPA and ASAP secondary payload platforms.