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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.
Phase Repeatable Synthesizers as a New Harmonic Phase Standard for Nonlinear Network Analysis
(2018)
Motivation-based Learning: Teaching Fundamentals of Electrical Engineering with an LED Spinning Top
(2018)
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.
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
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.
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.
Resilience as a concept has found its way into different disciplines to describe the ability of an individual or system to withstand and adapt to changes in its environment. In this paper, we provide an overview of the concept in different communities and extend it to the area of mechanical engineering. Furthermore, we present metrics to measure resilience in technical systems and illustrate them by applying them to load-carrying structures. By giving application examples from the Collaborative Research Centre (CRC) 805, we show how the concept of resilience can be used to control uncertainty during different stages of product life.
The overall energy efficiency of ventilation systems can be improved by considering not only single components, but by considering as well the interplay between every part of the system. With the help of the method "TOR" ("Technical Operations Research"), which was developed at the Chair of Fluid Systems at TU Darmstadt, it is possible to improve the energy efficiency of the whole system by considering all possible design choices programmatically. We show the ability of this systematic design approach with a ventilation system for buildings as a use case example.
Based on a Mixed-Integer Nonlinear Program (MINLP) we model the ventilation system. We use binary variables to model the selection of different pipe diameters. Multiple fans are model with the help of scaling laws. The whole system is represented by a graph, where the edges represent the pipes and fans and the nodes represents the source of air for cooling and the sinks, that have to be cooled. At the beginning, the human designer chooses a construction kit of different suitable fans and pipes of different diameters and different load cases. These boundary conditions define a variety of different possible system topologies. It is not possible to consider all topologies by hand. With the help of state of the art solvers, on the other side, it is possible to solve this MINLP.
Next to this, we also consider the effects of malfunctions in different components. Therefore, we show a first approach to measure the resilience of the shown example use case. Further, we compare the conventional approach with designs that are more resilient. These more resilient designs are derived by extending the before mentioned model with further constraints, that consider explicitly the resilience of the overall system. We show that it is possible to design resilient systems with this method already in the early design stage and compare the energy efficiency and resilience of these different system designs.