Dynamic reliability-based robust design optimization with time-variant probabilistic constraints

With the increasing complexity of engineering systems, ensuring high system reliability and system performance robustness throughout a product life cycle is of vital importance in practical engineering design. Dynamic reliability analysis, which is generally encountered due to time-variant system random inputs, becomes a primary challenge in reliability-based robust design optimization (RBRDO). This article presents a new approach to efficiently carry out dynamic reliability analysis for RBRDO. The key idea of the proposed approach is to convert time-variant probabilistic constraints to time-invariant ones by efficiently constructing a nested extreme response surface (NERS) and then carry out dynamic reliability analysis using NERS in an iterative RBRDO process. The NERS employs an efficient global optimization technique to identify the extreme time responses that correspond to the worst case scenario of system time-variant limit state functions. With these extreme time samples, a kriging-based time prediction model is built and used to estimate extreme responses for any given arbitrary design in the design space. An adaptive response prediction and model maturation mechanism is developed to guarantee the accuracy and efficiency of the proposed NERS approach. The NERS is integrated with RBRDO with time-variant probabilistic constraints to achieve optimum designs of engineered systems with desired reliability and performance robustness. Two case studies are used to demonstrate the efficacy of the proposed approach.     

Life-cycle reliability-based robust design optimization for GP model with response uncertainty

Reliability-based robust design optimization (RBRDO) is a crucial tool for life-cycle quality improvement. Gaussian process (GP) model is an effective alternative modeling technique that is widely used in robust parameter design. However, there are few studies to deal with reliability-based design problems by using GP model. This article proposes a novel life-cycle RBRDO approach concerning response uncertainty under the framework of GP modeling technique. First, the hyperparameters of GP model are estimated by using the Gibbs sampling procedure. Second, the expected partial derivative expression is derived based on GP modeling technique. Moreover, a novel failure risk cost function is constructed to assess the life-cycle reliability. Then, the quality loss function and confidence interval are constructed by simulated outputs to evaluate the robustness of optimal settings and response uncertainty, respectively. Finally, an optimization model integrating failure risk cost function, quality loss function, and confidence interval analysis approach is constructed to find reasonable optimal input settings. Two case studies are given to illustrate the performance of the proposed approach. The results show that the proposed approach can make better trade-offs between the quality characteristics and reliability requirements by considering response uncertainty.     

汽车车身耐撞性设计参数的区间稳健性优化

基于区间分析,提出了一种考虑公差的汽车车身耐撞性稳健优化设计模型,可在有效降低耐撞性能对设计参数波动敏感性的同时实现公差范围的最大化。该模型首先利用对称公差来描述汽车碰撞模型中车身关键耐撞部件的主要尺寸、位置和形状等设计参数本身的不确定性,然后将参数设计和公差设计相结合,建立了以稳健性评价指标和公差评价指标为优化目标,设计变量名义值和公差同步优化的多目标优化模型。再次,利用区间可能度处理不确定约束,将该优化模型转换为确定性多目标优化模型。最后,将该模型应用于两个汽车耐撞性优化设计问题,并通过序列二次规划法和改进的非支配排序遗传算法进行求解,结果表明该方法及稳健优化设计模型可行且实用。     

A surrogate assisted parallel multiobjective evolutionary algorithm for robust engineering design

A number of multi-objective evolutionary algorithms have been proposed in recent years and many of them have been used to solve engineering design optimization problems. However, designs need to be robust for real-life implementation, i.e. performance should not degrade substantially under expected variations in the variable values or operating conditions. Solutions of constrained robust design optimization problems should not be too close to the constraint boundaries so that they remain feasible under expected variations. A robust design optimization problem is far more computationally expensive than a design optimization problem as neighbourhood assessments of every solution are required to compute the performance variance and to ensure neighbourhood feasibility. A framework for robust design optimization using a surrogate model for neighbourhood assessments is introduced in this article. The robust design optimization problem is modelled as a multi-objective optimization problem with the aim of simultaneously maximizing performance and minimizing performance variance. A modified constraint-handling scheme is implemented to deal with neighbourhood feasibility. A radial basis function (RBF) network is used as a surrogate model and the accuracy of this model is maintained via periodic retraining. In addition to using surrogates to reduce computational time, the algorithm has been implemented on multiple processors using a master–slave topology. The preliminary results of two constrained robust design optimization problems indicate that substantial savings in the actual number of function evaluations are possible while maintaining an acceptable level of solution quality.     

结构动力鲁棒优化设计方法综述

如何提高结构动力学性能的鲁棒性,以减小各种不确定性因素对设计结果的影响是当前学术界和工程界研究和关注的热点问题之一。该文阐述了结构动力鲁棒优化设计的基本概念,从基于Taguchi的方法、基于多目标优化的方法和基于响应面建模的方法三个方面对结构动力鲁棒优化设计的研究进行了综述。以双转子为例,从结构的动力响应要求出发,采用响应面建模、多目标优化的方法进行了设计并与采用Taguchi方法得到的结果进行比较。结果表明,基于响应面建模、多目标优化的方法能够获得多个具有鲁棒性的设计方案,在处理具有不确定性的结构动力学问题时有着很大的应用潜力。最后,对当前方法和后续研究内容作了简要总结和展望。     

An integration design optimization framework of robust design,axiomatic design,and reliability‐based design

Robust design, axiomatic design, and reliability‐based design provide effective approaches to deal with quality problems, and their integration will achieve better quality improvement. An integration design optimization framework of robust design, axiomatic design, and reliability‐based design is proposed in this paper. First, the fitted response model of each quality characteristic is obtained by response surface methodology and the mean square error (MSE) estimation is given by a second‐order Taylor series approximation expansion. Then the multiple quality characteristics robust design model is developed by the MSE criteria. Finally, the independence axiom constraints for decoupling and reliability constraints are integrated into the multiple quality characteristics robust design model, and the integration design optimization framework is formulated, where the weighted Tchebycheff approach is adopted to solve the multiple objective programming. An illustrative example is presented at the end, and the results show that the proposed approach can obtain better trade‐offs among conflicting quality characteristics, variability, coupling degree and reliability requirements. Copyright © 2011 John Wiley & Sons, Ltd.     

Stability analysis and regularization of uncertain linear multi-objective integer optimization problems

This article presents a systematic approach to analysing linear integer multi-objective optimization problems with uncertainty in the input data. The goal of this approach is to provide decision makers with meaningful information to facilitate the selection of a solution that meets performance expectations and is robust to input parameter uncertainty. Standard regularization techniques often deal with global stability concepts. The concept presented here is based on local quasi-stability and includes a local regularization technique that may be used to increase the robustness of any given efficient solution or to transform efficient solutions that are not robust (i.e. unstable), into robust solutions. An application to a multi-objective problem drawn from the mining industry is also presented.     

Root cause analysis strategy for robust design domain recognition

Design domain identification with desirable attributes (e.g. feasibility, robustness and reliability) provides advantages when tackling large-scale engineering optimization problems. For the purpose of dealing with feasibility robustness design problems, this article proposes a root cause analysis (RCA) strategy to identify desirable design domains by investigating the root causes of performance indicator variation for the starting sampling initiation of evolutionary algorithms. The iterative dichotomizer 3 method using a decision tree technique is applied to identify reduced feasible design domain sets. The robustness of candidate domains is then evaluated through a probabilistic principal component analysis-based criterion. The identified robust design domains enable optimal designs to be obtained that are relatively insensitive to input variations. An analytical example and an automotive structural optimization problem are demonstrated to show the validity of the proposed RCA strategy.     

DESIGN OPTIMIZATION FOR ROBUSTNESS USING QUADRATURE FACTORIAL MODELS

Abstract

This paper describes a robust optimization methodology for designs involving either complex simulations or actual experiments. The methodology adopts a new objective function that consists of the Expected Performance (EP) and the weighted Deviation Index (DI). The proposed Quadrature Factorial Model estimates the expected performance and the standard deviation of a design. This scheme greatly reduces the number of experiments and provides superior results for systems with significant interaction effects and nonlinear variations. The proposed methodology is applied to the design of helical gears with minimum transmission error. The robust optimum shows a significant reduction of the expected transmission error compared with previous studies, while maintaining the insensitivity to manufacturing errors and load variation.     

Multiresponse optimization using multivariate process capability index

Robust design is an efficient method for product and process improvement which combines experimentation with optimization to create a system that is less sensitive to uncontrollable variation. In this article, a simple and integrated modeling methodology for robust design is proposed. This methodology achieves the robustness objective function and input variables constraints simultaneously. The objective function is written in terms of the multivariate process capability vector (MC_pm) of several competing features of the system under study. The proposed methodology is applicable to general functions of the system performance with random variables. The effectiveness of the methodology is verified using two real‐world examples which are compared with those of other robust design methods. Copyright © 2010 John Wiley & Sons, Ltd.     

Variation-aware clock network buffer sizing using robust multi-objective optimization

Many engineering optimization problems include unavoidable uncertainties in parameters or variables. Ignoring such uncertainties when solving the optimization problems may lead to inferior solutions that may even violate problem constraints. Another challenge in most engineering optimization problems is having different conflicting objectives that cannot be minimized simultaneously. Finding a balanced trade-off between these objectives is a complex and time-consuming task. In this paper, an optimization framework is proposed to address both of these challenges. First, we exploit a self-calibrating multi-objective framework to achieve a balanced trade-off between the conflicting objectives. Then, we develop the robust counterpart of the uncertainty-aware self-calibrating multi-objective optimization framework. The significance of this framework is that it does not need any manual tuning by the designer. We also develop a mathematical demonstration of the objective scale invariance property of the proposed framework. The engineering problem considered in this paper to illustrate the effectiveness of the proposed framework is a popular sizing problem in digital integrated circuit design. However, the proposed framework can be applied to any uncertain multi-objective optimization problem that can be formulated in the geometric programming format. We propose to consider variations in the sizes of circuit elements during the optimization process by employing ellipsoidal uncertainty model. For validation, several industrial clock networks are sized by the proposed framework. The results show a significant reduction in one objective (power, on average 38 %) as well as significant increase in the robustness of solutions to the variations. This is achieved with no significant degradation in the other objective (timing metrics of the circuit) or reduction in its standard deviation which demonstrates a more robust solution.     

An uncertain multidisciplinary design optimization method using interval convex models

This article proposes an uncertain multi-objective multidisciplinary design optimization methodology, which employs the interval model to represent the uncertainties of uncertain-but-bounded parameters. The interval number programming method is applied to transform each uncertain objective function into two deterministic objective functions, and a satisfaction degree of intervals is used to convert both the uncertain inequality and equality constraints to deterministic inequality constraints. In doing so, an unconstrained deterministic optimization problem will be constructed in association with the penalty function method. The design will be finally formulated as a nested three-loop optimization, a class of highly challenging problems in the area of engineering design optimization. An advanced hierarchical optimization scheme is developed to solve the proposed optimization problem based on the multidisciplinary feasible strategy, which is a well-studied method able to reduce the dimensions of multidisciplinary design optimization problems by using the design variables as independent optimization variables. In the hierarchical optimization system, the non-dominated sorting genetic algorithm II, sequential quadratic programming method and Gauss–Seidel iterative approach are applied to the outer, middle and inner loops of the optimization problem, respectively. Typical numerical examples are used to demonstrate the effectiveness of the proposed methodology.     

Multi-objective hierarchical genetic algorithms for multilevel redundancy allocation optimization

Multilevel redundancy allocation optimization problems (MRAOPs) occur frequently when attempting to maximize the system reliability of a hierarchical system, and almost all complex engineering systems are hierarchical. Despite their practical significance, limited research has been done concerning the solving of simple MRAOPs. These problems are not only NP hard but also involve hierarchical design variables. Genetic algorithms (GAs) have been applied in solving MRAOPs, since they are computationally efficient in solving such problems, unlike exact methods, but their applications has been confined to single-objective formulation of MRAOPs. This paper proposes a multi-objective formulation of MRAOPs and a methodology for solving such problems. In this methodology, a hierarchical GA framework for multi-objective optimization is proposed by introducing hierarchical genotype encoding for design variables. In addition, we implement the proposed approach by integrating the hierarchical genotype encoding scheme with two popular multi-objective genetic algorithms (MOGAs)—the strength Pareto evolutionary genetic algorithm (SPEA2) and the non-dominated sorting genetic algorithm (NSGA-II). In the provided numerical examples, the proposed multi-objective hierarchical approach is applied to solve two hierarchical MRAOPs, a 4- and a 3-level problems. The proposed method is compared with a single-objective optimization method that uses a hierarchical genetic algorithm (HGA), also applied to solve the 3- and 4-level problems. The results show that a multi-objective hierarchical GA (MOHGA) that includes elitism and mechanism for diversity preserving performed better than a single-objective GA that only uses elitism, when solving large-scale MRAOPs. Additionally, the experimental results show that the proposed method with NSGA-II outperformed the proposed method with SPEA2 in finding useful Pareto optimal solution sets.     

飞机总体设计中的一种多目标鲁棒优化方法

 提出一种基于灵敏度的多目标鲁棒优化方法。针对各维设计变量存在扰动的情况,在原约束多目标优化模型上,附加偏差目标函数,并采用最差估计法对约束条件进行鲁棒可行性调整。采用全局敏度方程方法来计算目标函数和约束函数对设计变量的敏度,进而采用Pareto遗传算法搜索约束多目标优化问题的非劣解集,设计者可以根据不同的设计准则从中选择合适的设计点。将上述方法用于飞机总体参数优化设计,并与采用常规优化方法所得的优化结果进行了分析和比较。     

汽车零部件的可靠性稳健优化设计——理论部分*

将可靠性优化设计理论与可靠性灵敏度分析方法相结合，讨论了汽车零部件的可靠性稳健优化设计问题，提出了可靠性稳健优化设计的计算方法。把可靠性灵敏度融入可靠性优化设计模型之中，将可靠性稳健优化设计归结为满足可靠性要求的多目标优化问题。     

概率及非概率不确定性条件下结构鲁棒设计方法

提出了在概率不确定性和非概率不确定性同时存在时的约束函数鲁棒性和目标函数鲁棒性的实现策略及结构鲁棒设计方法。将传统优化设计问题的约束条件改造成为能同时反映两类不确定性量波动变化影响的约束条件,以实现约束函数的鲁棒性;在传统优化设计问题目标函数中增加若干个关于目标函数灵敏度的新目标函数,构成一个多目标函数设计问题,以实现目标函数的鲁棒性。所提方法应用于一个10杆桁架结构设计,采用宽容排序法求解。计算结果表明,在相同的结构总质量限制条件下,目标函数鲁棒性程度随着变量不确定性程度的增加而降低;在相同的变量不确定性程度条件下,增加结构总质量能提高目标函数鲁棒性的程度。     

Decomposition of multidisciplinary optimization problems: formulations and application to a simplified wing design

Several formulations for solving multidisciplinary design optimization (MDO) problems are presented and applied to a test case. Two bi-level hierarchical decomposition approaches are compared with two classical single-level approaches without decomposition of the optimization problem. A methodology to decompose MDO problems and a new formulation based on this decomposition are proposed. The problem considered here for validation of the different formulations involves the shape and structural optimization of a conceptual wing model. The efficiency of the design strategies are compared on the basis of optimization results.     

An uncertain optimization method for overall ballistics based on stochastic programming and a neural network surrogate model

A nonlinear stochastic programming method is proposed in this article to deal with the uncertain optimization problems of overall ballistics. First, a general overall ballistic dynamics model is achieved based on classical interior ballistics, projectile initial disturbance calculation model, exterior ballistics and firing dispersion calculation model. Secondly, the random characteristics of uncertainties are simulated using a hybrid probabilistic and interval model. Then, a nonlinear stochastic programming method is put forward by integrating a back-propagation neural network with the Monte Carlo method. Thus, the uncertain optimization problem is transformed into a deterministic multi-objective optimization problem by employing the mean value, the standard deviation, the probability and the expected loss function, and then the sorting and optimizing of design vectors are realized by the non-dominated sorting genetic algorithm-II. Finally, two numerical examples in practical engineering are presented to demonstrate the effectiveness and robustness of the proposed method.     

基于满意度函数的新型逃生管道多目标稳健性设计

新型逃生管道参数具有不确定性且单目标优化存在局限性，为了实现新型逃生管道多目标稳健性设计，结合田口稳健性设计方法与满意度函数，提出了一种基于满意度函数的多目标稳健性设计方法。该方法将产品质量特性的信噪比转换为具有田口稳健性设计的望大特性的满意度，然后通过加权几何均值实现结构的多目标稳健性设计。通过使用Hypermesh和LS-DYNA建立新型逃生管道的有限元模型，并对该有限元模型进行验证，然后运用所提出的方法对新型逃生管道进行多目标稳健性设计。结果表明，稳健性设计后新型逃生管道的信噪比提升了5.3%，说明管道抵抗噪声因子的干扰能力增强，结构更稳健；新型逃生管道质量降低了9.6%，实现了管道轻量化的目的。研究结果对提高新型逃生管道的稳健性具有一定的理论和工程意义。     

ROBUST TOLERANCE ALLOCATION USING STOCHASTIC PROGRAMMING

Abstract

Tolerance allocation in manufacturing is a prominent industrial task for enhancing productivity and reducing manufacturing costs. The classical tolerance allocation problem can be formulated as a stochastic program to determine the assignment of component tolerances such that the manufacturing cost is minimized. However, tolerance design is a prerequisite to the overall quality and cost of a product; robust tolerance design is particularly important and should be considered. In this paper, robustness is considered in formulating the tolerance allocation problem by minimizing the manufacturing cost's sensitivity. Moreover, from a practical perspective, the process capability index for each component and the upper bound of the manufacturing cost are also considered. To effectively and efficiently resolve the robust tolerance allocation problem, a sequential quadratic programming algorithm embedded with a Monte Carlo simulation is developed. To demonstrate this design method's robustness, two commonly used test problems are solved. The designs devised in this paper have lower manufacturing costs and smaller variations in manufacturing costs than those in previous studies, indicating that the proposed method is highly promising in the robust tolerance design.