Shape optimization of energy storage flywheel rotor

A flywheel plays an important role in storing energy in modern machine systems. Flywheels can store rotational energy at a high rotating speed and have the ability to deliver a high output power if the system needs a stored energy to overcome a sudden loading or keep rotating for an expected long time. The energy density (stored energy per unit mass) and the amount of rotational energy are the two essential parameters to evaluate the performance of energy storage flywheels. In order to improve the energy storage capability of flywheels, parametric geometry modeling and shape optimization method for optimizing the flywheel rotor geometry is proposed in the present paper. We first build the shape optimization model of flywheel by parametric geometry modeling method with the objective to maximize the energy density of a flywheel rotor. Then the downhill simplex method is adopted to solve the nonlinear optimization problem in multidimensional space. Finally, we obtain the optimized shapes of flywheel rotor which could significantly improve the energy storage capability and working safety performance compared with the traditional design flywheel of constant thickness rotor. It is found that the maximum structural stress constraint applied in the designed region has a remarkable effect on the shape optimization.

     

Determination of the Pull-Off Forces and Pull-Off Dynamics of an Electrostatically Actuated Silicon Disk

To increase the mechanical sensitivity of micromachined yaw rate sensors, the proof mass can be designed as an electrostatically levitated flywheel. Therefore, the flywheel is kept in its levitated position by an electrostatic field exerted by an array of electrodes above and underneath the flywheel. Once the flywheel is in contact with either the bottom electrodes or the top electrodes, adhesion forces arise which might prohibit the flywheel from being lifted back to its levitated operation position. The subject of this paper is the investigation of the pull-off forces emerging during the start-up phase of an electrostatically actuated silicon disk, which is a test structure for such a levitated flywheel gyroscope. For the experimental determination of the pull-off forces, a test device based on a levitated flywheel gyroscope design is fabricated featuring soft polymeric and thus insulating springs for the inhibition of the lateral movement of the disk. Furthermore, the surfaces of the silicon disk and the electrode contact areas are modified to reduce the amount of the adhesion forces. For such textured surfaces, a pull-off force of 0.25 plusmn 0.05 mN is measured for a circular disk with a diameter of 3 mm. This corresponds to an adhesion energy per area of 3.5 ldr 10^-6 mJ/m². Thus, a repeatable pull-off of the flywheel at moderate actuation voltages is achieved.     

Optimization of cylindrical composite flywheel rotors for energy storage

The use of flywheel rotors for energy storage presents several advantages, including fast response time, high efficiency and long cycle lifetime. Also, the fact that the technology poses few environmental risks makes it an attractive solution for energy storage. However, widespread application of tailorable circumferentially wound composite flywheel rotors is hampered by the relatively low energy density that these rotors have been able to achieve. This contributes to high capital cost, which currently makes the flywheels prohibitively expensive for many applications. With the materials that are currently available, there seems to be ample room for improvement in the energy density achieved by composite flywheel rotors. To this aim, some of the design methods that have previously been proposed are herein studied, and our findings suggest that the manner in which the optimization problem is formulated is crucial to the design of high energy density flywheels. A new problem formulation is proposed, which is shown to lead to notable improvements in certain cases. By making use of the proposed problem formulation, flywheel rotors can be designed to consistently achieve high energy density relative to the materials that are made available. This can contribute towards lowering the cost of flywheel systems, and making flywheel energy storage viable for a wider range of applications.     

多层异构式复合材料飞轮的虚拟设计

随着电子计算机技术的不断发展，虚拟设计与虚拟制造在机械制造业中所起的作用不断加重。该文基于美国ANSYS有限元处理软件，对复合材料飞轮转子进行虚拟设计。复合材料飞轮转子在高速旋转时，由于惯性力的作用，会产生较大的径向应力和环向应力。若飞轮转子的形状参数、材料参数给定，则飞轮在工作时发生断裂破坏只取决于其工作转速的大小(不考虑环境因素及其它意外情况)。为了有效地避免飞轮转子因超过其极限转速而发生材料断裂破坏，本文通过利用ANSYS有限元处理软件的优化设计模块，对复合材料飞轮转子的极限转速做初步的预测，并给出飞轮转子在该极限转速下的应力分布情况，同时计算出此种结构的飞轮储能系统的最大储能量。     

Cost optimization of hybrid composite flywheel rotors for energy storage

A novel approach to composite flywheel rotor design is proposed. Flywheel development has been dominated by mobile applications where minimizing mass is critical. This technology is also attractive for various industrial applications. For these stationary applications, the design is considerably cost-driven. Hence, the energy-per-cost ratio was used as the objective function. Based on an analytical approach for calculating stresses in multi-rim hybrid composite rotors, the nonlinear optimization problem was solved using a multi-strategy optimization scheme that combines an evolutionary algorithm with a nonlinear interior-point method. The problem was solved for a sample rotor with varying cost ratio of the rim materials. Instead of an optimal solution per cost ratio, only four optimal designs were obtained with a sharp transition between designs at specific cost ratios. This sharp transition is explained by the intricate interplay that exists between the objective function and the nonlinear constraints imposed by the applied failure criteria.     

电动汽车用飞轮电池充放电控制系统研究

针对现有电池技术还不能满足电动汽车对电池系统能量密度和功率密度还有寿命的要求,本文结合蓄电池的高比能量和飞轮电池的高比功率,提出了基于蓄电池和飞轮电池的复合电源。建立了飞轮电池的充放电的数学模型,并提出了飞轮电池充放电的控制策略。飞轮充电过程中采用模糊-PI复合控制策略,放电过程中根据驱动电机需要的瞬时电流值来控制斩波器开关的通断。结果表明系统具有较好的动态特性。     

Research on simulation of ship electric propulsion system with flywheel energy storage system

Flywheel energy storage has been widely used to improve the ground electric power quality. This paper designed a flywheel energy storage device to improve ship electric propulsion system power grid quality. The practical mathematical models of flywheel energy storage and ship electric propulsion system were established. Simulation research on the effect of ship electric propulsion system power quality, made by flywheel energy storage, was completed by using the software Matlab/simulink. We have done a lot of simulation experiments on sudden load of ship integrated electric propulsion system, one system is with flywheel energy storage, another one is not with. Comparing with these simulation results, we can see that the flywheel energy storage designed in this paper has improved ship electric propulsion system network power quality as well as increases the reliability of the ship power grid. The conclusions can provide a theoretical guidance for the design of flywheel energy storage applied in ship integrated electric propulsion system.     

Design optimization of laminated composites using a new variant of simulated annealing

The aim of this study is to minimize the thickness (or weight) of laminated composite plates subject to both in-plane and out-of-plane loading. A new variant of the simulated annealing algorithm is proposed to optimize the lay-up design. Fiber orientation angle and number of plies in each lamina are used as design variables. Considering static failure as the critical failure mode, the maximum stress and Tsai–Wu criteria are used together to predict failure. Numerical results show that the optimization methodology proposed in this study can find the globally optimum laminate designs even with a high number of design variables.     

Design objectives with non-zero prescribed support displacements

When non-zero prescribed support displacements are involved in addition to design independent loads for a continuum/structure, then the objectives of minimum compliance (total elastic energy) and of maximum strength lead to different designs. This is verified by the presented sensitivities. Designs from neither of the two objectives are characterized by uniformly distributed energy density. However, simple iterations with the goal of obtaining uniform energy density show that the strength is favored by this approach. These observations leads to a rejection of the objectives of compliance minimization as well as that of direct strength maximization; we choose the objective of obtaining uniform energy density and show by examples that the obtained solutions are close to fulfilling also strength maximization, with the price of increased compliance. Optimal design examples are presented and discussed in detail for different combinations of non-zero prescribed support displacements and design independent loads.     

Optimum design of composite laminates for minimum thickness

In this study, an optimization procedure is proposed to minimize thickness (or weight) of laminated composite plates subject to in-plane loading. Fiber orientation angles and layer thickness are chosen as design variables. Direct search simulated annealing (DSA), which is a reliable global search algorithm, is used to search the optimal design. Static failure criteria are used to determine whether load bearing capacity is exceeded for a configuration generated during the optimization process. In order to avoid spurious optimal designs, both the Tsai–Wu and the maximum stress criteria are employed to check static failure. Numerical results are obtained and presented for different loading cases.     

Numerical simulation of slider air bearings based on a mesh-free method for HDD applications

This paper focuses on the development of a computational method to be used as a tool for air bearing simulation and design in modern hard disk drive. A data density of 100 Gb/in.² has already been achieved in today’s production. The hard disk drive industry’s next goal is to increase the data density to 1 Tb/in.² . New features in air bearing designs include shaped rails, multiple etching depths and negative pressure pockets. Thus, mesh generation is a difficult task in the air bearing simulation. This, in turn, demands the development of an accurate and easy-to-use computational method to solve Reynolds equations based on various flow models. Least square finite difference scheme, one of mesh-less methods, is presented to solve the slider air bearing problems of hard disk drives. For each specified attitude, the air bearing pressure is obtained by solving the Reynolds equation using the mesh-free method. The discretized nonlinear systems of equations are solved by successive over-relaxation (SOR) implementation, and the results of the numerical solutions are compared with other numerical and experimental data.     

RAID控制器中磁盘接口控制器流水线设计与实现

在研究磁盘接口功能和现有磁盘接口设计的基础上,提出了一种带四级流水的磁盘接口设计模型,并对该模型实现过程中的模块间通信问题和模块间缓冲管理问题进行了相应的分析和设计。通过FPGA仿真与实验结果表明,在各种情况下,磁盘接口的吞吐率都有提高,在高写请求率和重负载两种情况下尤为显著。     

Optimization of axisymmetric elastic modulus distributions around a hole for increased strength

Holes in engineering structures cause stress concentrations that often lead to failure. In nature, however, blood vessel holes (foramina) in load-bearing bones are not normally involved in structural failures. It has been found that this behavior is linked to the material distribution near the hole. In the present paper, we have investigated the effectiveness of optimizing the radial distribution of the isotropic elastic modulus around a circular hole to increase load-carrying capacity. Bezier curves were used to describe the radial distribution of the elastic modulus. Since changing the elastic modulus usually affects the strength, the ratio of maximum principal stress to strength was chosen as the objective function for optimization. Using non-dimensional analysis of the 2-D elasticity equations, we identified three parameters that govern the optimum design and are applicable to a wide range of materials, loading, and geometries. The first is a material parameter that describes the relationship between the strength and elastic modulus, the second is the geometric parameter given by the ratio of the optimized field to the hole radius, and the third is the biaxial load ratio. The effect of failure criterion choice on the optimum elastic modulus distribution is also investigated. Optimum elastic modulus distributions for materials whose strength increases faster than the stiffness, as density and/or composition is varied, completely eliminated the effect of the hole by locally stiffening areas that experience high stresses. When the strength lagged behind the stiffness, optimum designs were similar to those found in bones, and relied on modulus distributions that direct the loads away from the hole.     

Interpolation/penalization applied for strength design of 3D thermoelastic structures

With design independent loads and only a constrained volume (no local bounds), the same optimal design leads simultaneously to minimum compliance and maximum strength. However, for thermoelastic structures this is not the case and a maximum volume may not be an active constraint for minimum compliance. This is proved for thermoelastic structures by sensitivity analysis of compliance that facilitates localized determination of sensitivities, and the compliance is not identical to the total elastic energy (twice strain energy). An explicit formula for the difference is derived and numerically illustrated with examples. In compliance minimization for thermoelastic structures it may be advantageous to decrease the total volume, but for strength maximization it is argued to keep the total permissible volume. Linear interpolation (no penalization) may to a certain extent be argued for 2D thickness optimized designs, but for 3D design problems interpolation must be included and not only from the penalization point of view to obtain 0–1 designs. Three interpolation types are presented in a uniform manner, including the well known one parameter penalizations, named SIMP and RAMP. An alternative two parameter interpolation in explicit form is preferred, and the influence of interpolation on compliance sensitivity analysis is included. For direct strength maximization the sensitivity analysis of local von Mises stresses is demanding. An applied recursive procedure to obtain uniform energy density is presented in details, and it is shown by examples that the obtained designs are close to fulfilling also strength maximization. Explicit formulas for equivalent thermoelastic loads in 2D and 3D finite element analysis are derived and applied, including the sensitivity analysis.     

Multi-extremum-modified response basis model for nonlinear response prediction of dynamic turbine blisk

For the nonlinear dynamic analyses of complex mechanical components, it is necessary to apply efficient modeling framework to reduce computational burden. The accurate surrogate model for approximating the nonlinear responses of several failures is a vital issue to provide robust and safe design conditions in complex engineering applications. In this paper, two different Modified multi-extremum Response Surface basis Models (MRSM) are proposed for dynamic nonlinear responses of failure capacities for turbine blisk responses. The proposed MRSM is established using two regression processes including regressed the input variables by linear or exponential basis functions in first calibrating phase and regressed the second-order polynomial basis function using inputs data provided by first stage in second calibrating procedure. A sensitivity analysis using MRSM is proposed to consider the variation of input variables on the nonlinear responses. In the sensitivity analysis procedure, the effects of input variables are evaluated using the calibrating results given from the first regressed process. To evaluate the performance of the proposed MRSM, three multi-extremum failure modes including radial deformation of compressor blisk, maximum strain, and stress of compressor blade and disk are considered. the prediction of MRSM of nonlinear responses for Thermal-fluid–structure system with dynamical nonlinear finite-element analyses is compared with response surface method (RSM) and artificial neural network (ANN). The predicted results of modeling approaches showed that the sensitivity analysis based on MRSM accurately provided the effective degree for input variables. The gas temperature has the highest effects on nonlinear responses of turbine blisk which is followed by angular speed and material density. The MRSM combined with basic exponential function performs better than other models, while the MRSM coupled with linear function is more accurate than ANN and RSM. The proposed MRSM models have illustrated the accurate and efficient framework for approximating dynamic structural analysis of complex components.

     

高端磁盘阵列可靠性测试建模方法研究

阐述了衡量高端磁盘阵列可靠性的重要指标MTTDL,通过分析两种造成磁盘错误的原因,建模计算了各种RAID级别的MTTDL,设计了磁盘读出错率的测试方案,实现了基于分布式的磁盘读出错率测试程序。     

Experiments on slider lubricant interactions and lubricant transfer using TFC sliders

Future magnetic storage density targets (>4 Tb/in. ²) require subnanometer physical clearances that pose a tremendous challenge to the head disk interface (HDI) design. A detailed understanding of slider-lubricant interactions at small clearances and contact is important to not only address magnetic spacing calibration and long term HDI reliability but also to meet additional challenges imposed by future recording architectures such as heat assisted magnetic recording (HAMR). In this work, the behavior of the disk lubricant is investigated through controlled tests using TFC sliders which are actuated to proximity (i.e. backoff) and into contact (i.e. overpush) on one specific half of the disk per rotation by synchronization with the spindle index. Observations for lubricant distribution in contact tests (i.e. overpush) reveal an accumulation of lubricant on the disk near the onset of contact suggesting a migration of lubricant from the slider to the disk as the slider approaches the disk. Experiments also reveal that there is a similar deposition of lubricant even in the absence of contact for backoff tests. Furthermore, light contact tests result in significant lubricant rippling and depletion with associated slider dynamics. The lubricant rippling frequencies correlate well with the slider’s vibration frequencies. Interestingly, strong overpush may lead to stable slider dynamics (for certain air bearing designs) that is also associated with noticeably lower lubricant distribution (compared to the light contact case), and the greatest lubricant changes are observed only at the onset and the end of contact. This paper reveals the complex nature of slider-lubricant interactions under near-contact and contact conditions, and it highlights the need for further studies on the topic to help design a HDI for recording architectures of the future.     

Test adequacy criteria for UML design models

Systematic design testing, in which executable models of behaviours are tested using inputs that exercise scenarios, can help reveal flaws in designs before they are implemented in code. In this paper a technique for testing executable forms of UML (Unified Modelling Language) models is described and test adequacy criteria based on UML model elements are proposed. The criteria can be used to define test objectives for UML designs. The UML design test criteria are based on the same premise underlying code test criteria: coverage of relevant building blocks of models is highly likely to uncover faults. The test adequacy criteria proposed in this paper are based on building blocks for UML class and interaction diagrams. Class diagram criteria are used to determine the object configurations on which tests are run, while interaction diagram criteria are used to determine the sequences of messages that should be tested. Copyright © 2003 John Wiley & Sons, Ltd.     

Design and testing of track-following controllers for dual-stage servo systems with PZT actuated suspensions

 This paper discusses the design and testing of two track-following controllers for dual-stage servo systems in hard disk drives. The first controller is designed using the μ-synthesis multivariable robust optimal controller design methodology. The second is designed using classical single-input-single-output (SISO) frequency shaping design techniques, based on sensitivity transfer functions decoupling of the dual-stage actuator. The controllers were implemented and tested on a disk drive with a PZT actuated suspension based dual-stage servo system. The position error signal (PES) for the servo system was obtained by measuring the slider displacement using an LDV and injecting simulated track runout. In the experiment, both designs achieved a track-mis-registration (TMR) less than 10 nm. Received: 25 July 2001/Accepted: 1 November 2001     

Minimum cost design of reinforced concrete beams using continuum-type optimality criteria

This paper outlines a general procedure for obtaining, on the basis of continuum-type optimality criteria (COC), economic designs for reinforced concrete beams under various design constraints. The costs to be minimized include those of concrete, reinforcing steel and formwork. The constraints consist of limits on the maximum deflection, and on the bending and shear strengths. However, the formulation can easily cater for other types of constraints such as those on axial strength. Conditions of cost minimality are derived using calculus of variation on an augmented Lagrangian. An iterative procedure based on optimality criteria is applied to a test example involving a reinforced concrete propped cantilever beam whose cross-section varies continuously. Numerical examples are presented in which the design variables are both the width and the depth or the depth alone, and the optimal costs are compared. The solution of the test example with depth alone as the design variable is confirmed by an alternative approach using discretized continuum-type optimality criteria (DCOC).