Engineering Design Methods Research Articles

Thermodynamics-Informed Neural Networks for the Design of Solar Collectors: An Application on Water Heating in the Highland Areas of the Andes

This study addresses the challenge of optimizing flat-plate solar collector design, traditionally reliant on trial-and-error and simplified engineering design methods. We propose using physics-informed neural networks (PINNs) to predict optimal design conditions in a range of data that not only characterized the highlands of Ecuador but also similar geographical locations. The model integrates three interconnected neural networks to predict global collector efficiency by considering atmospheric, geometric, and physical variables, including overall loss coefficient, efficiency factors, outlet fluid temperature, and useful heat gain. The PINNs model surpasses traditional simplified thermodynamic equations employed in engineering design by effectively integrating thermodynamic principles with data-driven insights, offering more accurate modeling of nonlinear phenomena. This approach enhances the precision of solar collector performance predictions, making it particularly valuable for optimizing designs in Ecuador’s highlands and similar regions with unique climatic conditions. The ANN predicted a collector overall loss coefficient of 5.199 W/(m2·K), closely matching the thermodynamic model’s 5.189 W/(m2·K), with similar accuracy in collector useful energy gain (722.85 W) and global collector efficiency (33.68%). Although the PINNs model showed minor discrepancies in certain parameters, it outperformed traditional methods in capturing the complex, nonlinear behavior of the data set, especially in predicting outlet fluid temperature (55.05 °C vs. 67.22 °C).

Early Design Stage Evaluation of All Electric Aircraft Power Systems Focusing on Long-Term Behavior

In the aircraft industry, there is a shift towards more and all-electric power systems resulting in great research efforts on single components like batteries. At the same time there is an increasing need to investigate and evaluate the long-term behavior of the whole electric power system to ensure safe and sustainable aircraft operation. Focusing on this challenge, the objective of this article is to propose a framework for electric power system assessment in the early design stages. In particular, the focus is on identifying and handling uncertainties regarding failure behavior and degradation, both on the component and system level. The evaluation of different power system topologies is based on the integration of Model-Based Systems Engineering and robust design methods. In this context, another central aspect is the definition of system and component requirements derived from the flight mission profile. SysML diagrams are used to define use cases and possible system topologies. Sensitivity of degradation effects are evaluated using robust design methods. The application of the framework and these methods is illustrated using a short-range aircraft with an all-electric power system. The results highlight the applicability of the framework to cope with the uncertainties that occur in the early design stages and point out fields of further research.

Research and Application of Key Technologies for Ultra High Pressure Grouting of Yangjiang Pumped Storage Power Station in Guangdong Province

Abstract The most effective guarantee measure for the permeability stability of reinforced concrete lined high-pressure waterways is grouting. The traditional grouting treatment techniques and specifications can not effectively adapt to construction projects with higher requirements. This paper comprehensively expounds the new theoretical research system and grouting engineering design method proposed through model test and inverse calculation, and introduces the construction technology and technical requirements of 10Mpa ultra-high pressure grouting in the engineering field in combination with the construction practice of Yangjiang Pumped Storage Power Station, so as to provide useful reference for the construction of high-pressure waterway of pumped storage power station project.

The impact of specialized software on concept generation

AbstractSoftware implementations of traditional engineering design methods can potentially enrich the original methods. A study was conducted to better understand how concept generation can be facilitated using software. Participants of the study were asked to generate concepts using either specialized software, or by using traditional means, for applying function-means modeling and morphological matrices. A concept concretization metric was used to evaluate the results, which indicated that there are both positive and negative aspects of performing concept generation using specialized software.

Innovative design of multi-contradiction systems based on the function-structure model

Innovative design of complex systems faces multi-contradiction (MC). The existing methods to solve MC are mainly based on the General Theory of Powerful Thinking (OTSM) which is independent of the classical Engineering Design Method (ED) to form the process model, they cannot inherit the accumulated knowledge and advantages of ED. This paper proposes a product innovation design process model for MC based on the function-structure model. It starts with an initial scenario of the system to build the function-structure model and MC network based on the root contradiction analysis. The network structure entropy and function importance decision methods are introduced for the trimming target confirming. The key contradiction-node is identified and solved by strategies of trimming based on internal and external resources of the system. The function-structure model in ED and trimming in TRIZ are combined to form an innovative design process for MC systems. The proposed method is evaluated in a case study of an innovative design of the girder bridge erector.

CcDPM: A Continuous Conditional Diffusion Probabilistic Model for Inverse Design

Engineering design methods aim to generate new designs that meet desired performance requirements. Past work has directly introduced conditional Generative Adversarial Networks (cGANs) into this field and achieved promising results in single-point design problems(one performance requirement under one working condition). However, these methods assume that the performance requirements are distributed in categorical space, which is not reasonable in these scenarios. Although Continuous conditional GANs (CcGANs) introduce Vicinal Risk Minimization (VRM) to reduce the performance loss caused by this assumption, they still face the following challenges: 1) CcGANs can not handle multi-point design problems (multiple performance requirements under multiple working conditions). 2) Their training process is time-consuming due to the high computational complexity of the vicinal loss. To address these issues, A Continuous conditional Diffusion Probabilistic Model (CcDPM) is proposed, which the first time introduces the diffusion model into the engineering design area and VRM into the diffusion model. CcDPM adopts a novel sampling method called multi-point design sampling to deal with multi-point design problems. Moreover, the k-d tree is used in the training process of CcDPM to shorten the calculation time of vicinal loss and speed up the training process by 2-300 times in our experiments. Experiments on a synthetic problem and three real-world design problems demonstrate that CcDPM outperforms the state-of-the-art GAN models.

Analysis of strength, durability, stability, and fatigue parameters of furniture doors and drawers using engineering design method

Mechanical behavior properties were investigated for cabinet-type cabinet doors in kitchen furniture and drawer bottoms and joints used as storage areas under load in accordance with relevant standards (BS EN 16122). In the first stage, values physical and mechanical for particle board (PB) and medium-density fiberboard (MDF) were determined. According to the test results in the second stage, it was determined that the doors assembled using a torque of 1.3 N/m in the door tests were less deformed than those assembled with 0.63 N/m. According to the finite element analysis and real test results carried out in the final stage, it has been determined that the vertical loading analysis applied on the doors coincides with the real experiments by 85%, horizontal loading by 84%, and slam shut by 50%. The doors didn’t pass the final stage durability test in real experiments, and the analysis results revealed that the deformation areas were the same as for real experiment. In the drawers; strength 85%, displacement 84%, and slam shut 94% overlap are represented. The drawers completed the durability test in real experiments, and in the analysis, it was determined that the deformation that occurred under high stresses was in the same areas.

Theoretical study of bearing capacity calculation model for multi-segment confined concrete arch and design method in underground engineering

Theoretical study of bearing capacity calculation model for multi-segment confined concrete arch and design method in underground engineering

Fundamental drying and agglomeration experiments with bio-fraction and refuse derived fuel for the development of pyrolysis reactor feed.

The EU's circular economy concept necessitates increasing the recycling ratio of municipal solid wastes. There are many existing mechanical-biological processing plants in Hungary for the preparation of residual municipal solid wastes (RMSWs). The two most important products of these plants are the bio-fraction and the refuse derived fuel (RDF). Currently, there are problems with both of these material streams in Hungary, since most of the bio-fraction is still landfilled, and the local thermal utilisation of the RDF has not been implemented yet. The high moisture content of the produced bio-fraction and RDF causes difficulties for the downstream operations; therefore, there is recent engineering interest in drying and agglomeration of these materials. The authors have carried out systematic and parallel drying and briquetting experimental series to study the effect of the material, material composition, mass (volume or surface) of the material, particle size distribution and pre-treatment with a cutting mill on drying intensity in a 1 m3 oven and their effect on briquettability by a laboratory briquette press. The initial slope of the relative moisture loss as function of time was determined. Process engineering design methods of convective hot air-drying can be further developed taking into account the research results. Results can be used for the design of the feed of a pyrolysis reactor once reactor experiments have provided the optimal feed requirements.

Ultimate Load-Bearing Capacity and Sustainable Performance of Pile Foundations of Yanji Suspension Bridge in Fault Zone Based on Refined Geological Model

Pile foundation is the most important foundation type of long-span bridges, of which the ultimate load-bearing capacity affects the safety and sustainable performance of bridges. When constructing large-span bridges, the bridge site may be close to the adjacent fault zones, which seriously affects the safety and long-term performance of pile foundations, causing the failure and unsustainability of long-span bridges in their life-cycle service life. At present, there are no engineering design rules or methods for assessing the load-bearing capacity of the pile foundation near the fault zones. To study the influence of the fault zone on the loading-bearing capacity and sustainable performance of pile foundations, triaxial compression tests were carried out on the mylonite at the Yanji suspension bridge site near the Xiangfan–Guangji fault zone in Hubei Province. The mechanical properties of mylonite were reflected by the Mohr–Coulomb yield criterion, and a topographic and geological modeling method based on the multi-platform was established. Then, the ABAQUS finite element software was used to study the deformation, stress, failure modes, and sustainable performance of the pile foundation under different bridge load levels, analyze the safety of the pile foundation in the fracture zone, and summarize the ultimate bearing characteristics of the pile foundation. The results show that the whole pile and surrounding rock are basically elastic under the pressure of the designed load, the plastic zone of the pile foundation is mainly concentrated at the pile bottom, and the shear stress concentration zone of the pile is mainly manifested in the joint of the cap and pile and the interface between soft and hard rock. When the load is increased to 4 times the designed load, the stress concentration area of the pile body gradually shifts upward from the pile bottom, and the surrounding rock at the bottom forms an “X-shaped” shear failure zone. After 100 years of operation, the maximum compressive stress of piles reaches 28.6 MPa, which is 120% higher than that at the beginning of the bridge construction, indicating that the sustainable performance of the piles can withstand the effect of the fault zone over the designed service years.

Heating, Ventilation, and Air Conditioning (HVAC) Engineering Design Methods and System Analysis

Heating, Ventilation, and Air Conditioning (HVAC) Engineering Design Methods and System Analysis

Design of Power Supply for Distributed Aero-engine Intelligent Control System

Compared with centralized power supply system architecture, distributed power supply architecture can better meet the requirements of distributed aero-engine intelligent control systems. The design of distributed power supply topology plays a vitally important role in the distributed power supply system. The paper presents an engineering design method of distributed power supply for the distributed control system in a certain aero-engine. The distributed power supply topology is developed. Based on this topology, the bus voltage level and the current of the distributed intelligent nodes are designed. The optimal selection method of transmission cable types between intelligent nodes is also provided based on the equivalent circuit of a distributed power supply system. The results show that the cable transmission loss and voltage drop meet the design specifications of electrical cable. The proposed distributed power scheme for the distributed engine control system results in minimal modifications, smaller transmission current, and lighter cables.

Towards Robust and Effective Passive Compliance Design of End-Effectors for Robotic Train Fluid Servicing

Without mechanical compliance robots rely on controlled environments and precision equipment to avoid clashes and large contact forces when interacting with an external workpiece, e.g., a peg-in-hole (PiH) task. In such cases, passive compliance devices are used to reduce the insertion force (and in turn the robot payload) while guiding corrective motions. Previous studies in this field are limited to small misalignments and basic PiH geometries inapplicable to prevalent robotic and autonomous systems (RASs). In addition to these issues, our work argues that there is a lack of a unified approach to the development of passive compliance systems. To this end, we propose a higher-level design approach using robust engineering design (RED) methods. In a case study, we demonstrated this general approach with a Taguchi design framework, developing a remote centre compliant (RCC) end-effector for robotic train fluid servicing. For this specific problem, a pseudo-rigid-body model (PRBM) is suggested in order to save enormous computation time in design, modelling, and optimisation. Our results show that the compliant end-effector is capable of significantly reducing the insertion force for large misalignments up to 15 mm and 6 degrees.

Challenges of high-fidelity virtual reactor for exascale computing and research progress of China Virtual Reactor

The virtual reactor is a sophisticated software system deployed on supercomputers to simulate physics process or predict component behaviors inside real reactors. It highly relies on advanced modeling and coupling methods, high performance computing and advanced verification and validation (V&V) techniques, which is another important method for reactor engineering design and mechanism research besides experiment. With the advent of exascale computer, it becomes mainstream trend to develop full-core high-fidelity simulation research under the help of exascale computing technology. This paper first summarizes the challenges of developing high-fidelity virtual reactor simulation in exascale computing. The challenges of high-fidelity virtual reactor simulation are introduced from four aspects: science-based modeling methods, high-resolution mesh model, scientific numerical methods , and multiphysics and multiscale coupling. Based on the architecture of exascale computer, the challenges of parallel optimization of virtual reactor for exascale computing are introduced. Furthermore, this paper introduces the recent research progress of China Virtual Reactor (CVR), which is about the parallel optimization for Chinese exascale computers and the functional extensions for achieving full-core high-fidelity simulation. The recent research progress of CVR includes multiscale simulation software of materials, fuel performance simulation software, thermal-hydraulic simulation software, full-core high-resolution meshing tool, and optimization of basic sparse operators.

Study on the Optimization of Pile Length of Micropiles in Soil Landslides

This study summarizes the engineering design and calculation methods of micropiles and proposes a pile length optimization model based on numerical simulation software. Based on the proposed micropile calculation method and optimization method, a specific analysis of a project example was carried out, and a series of calculations, such as micropile design calculation and pile length optimization for the project, was completed. The results show that the miniature pile length optimization model based on numerical simulation finite difference method improves the previous method by automating the optimization process through fast modeling, automatic creation of optimization commands, and output and analysis of optimization results, and realizes the optimization of pile length using numerical simulation, which improves the efficiency of the optimization of the pile length under the premise of guaranteeing accuracy, and achieves the unity of both efficiency and accuracy. The feasibility of this optimization process is proved by engineering examples. The engineering practicability of the micropile design calculation method and optimization method proposed in this study is proved through practice. It provides a reference value for the initial fast and flexible management of small landslides.

Early Design Phase Method for Characterizing and Comparing Wave Energy Converter Archetypes

The ocean is both a precious resource for coastal communities and a vast source of largely untapped renewable energy that can help combat climate change. This presents a unique opportunity for wave energy converters (WEC) to provide both utility-scale and small-scale electricity for resilient, energy-efficient communities that can better withstand the effects of climate change. Designing a WEC is not straightforward as the ocean supports a wide range of uses and the highly energetic environment can threaten survival. This requires WEC designers to deconflict their use area and select deployment locations that minimize risk. Subsurface WEC designs provide a potential solution for these challenges as their deployment depth can mitigate area-use conflicts with other ocean users. A fully submerged WEC also has increased survivability due to being in a less energetic environment and at a depth that they are less likely to collide with ocean vessels. However, a submerged WEC may also suffer from the less energetic environment as it decreases the amount of electricity the WEC can generate. These tradeoffs make it unclear when subsurface WECs are beneficial to deploy. There is little research to date that offers comprehensive understanding of this field of WECs in regard to their capabilities or constraints. This paper presents a method for characterizing and understanding the functions of WEC archetypes by leveraging functional decomposition to examine high level overlaps between archetypes. Functional decomposition is a well-established engineering design method for breaking down complex systems into constituent parts to track flows of energy, information, and materials. The method enables engineers understand how each component contributes to the overall functionality of the system and enables us to analyze functional performance overlaps between WEC archetypes. We apply this method to submerged WECs and present an analysis of the high level functions. The findings of this case study shed light on the functional uniqueness of submerged WEC archetypes and can be used to guide future development in subsurface WEC technology. Better identifying functional overlaps between WEC archetypes will help researchers and developers generate effective designs that build resilient coastal communities.

APPLICATION OF A GAS-SOLID FLUIDISED BED SEPARATOR FOR ALUMINIUM-COPPER SCRAP RECYCLING

The EUbs circular economy concept necessitates the recycling of material streams used once or multiple times into the productionb consumption cycle again and again. The commonly known problem b that the number of recycling cycles of plastics is limited drives the economy towards metal usage again, because metal recycling cycles are limitless. Therefore, the efficient and economic separation of mixed aluminium and copper scraps in the 30b100 mm particle size range is an important issue for our society. In this study fundamental and applied research was carried out for the application of a gas-solid fluidised bed separator for aluminium-copper scrap recycling. A laboratory scale aero-suspension dense media separator was developed. Fundamental fluidisation experiments were carried out with this device and a powder rheometer. Afterwards pilot-scale and later industrial-scale separators were designed and built. The results indicate that the well-known Ergun fluidisation model can be the basis of a new process engineering design method for sizing dry fluidised bed separators.

Safety Issues in the Development of an Innovative Medical Parallel Robot Used in Renal Single-Incision Laparoscopic Surgery.

Robotic-assisted single-incision laparoscopic surgery (SILS) is becoming an increasingly widespread field worldwide due to the benefits it brings to both the patient and the surgeon. The goal of this study is to develop a secure robotic solution for SILS, focusing specifically on urology, by identifying and addressing various safety concerns from an early design stage. Starting with the medical tasks and protocols, the technical specifications of the robotic system as well as potential; hazards have been identified. By employing competitive engineering design methods such as Analytic Hierarchy Process (AHP), Risk assessment, and Failure Mode and Effects Analysis (FMEA), a safe design solution is proposed. A set of experiments is conducted to validate the proposed concept, and the results strongly support the development of the experimental model. The Finite Element Analysis (FEA) method is applied to validate the mechanical architecture within a set of simulations, demonstrating the compliance of the robotic system with the proposed technical specifications and its capability to safely perform SILS procedures.

Method for designing and developing space mechanisms with specified dependability

Aim. According to the established concept of space launch, practically each of the spacecraft in a near-Earth orbit needs to separate from the launch vehicle and deploy its folded structures (solar panels, antennas, reflectors, rods, etc.) in the operational position and only then is able to become fully functional for its intended purpose. The reliability requirements for single-operation mechanisms are so high, that any unidentified potential threat of critical failure in the course of design, development, manufacture and operation may make the creation of such spacecraft pointless, which is confirmed by the fatal results of the missions of the Sinosat- 2, Ekspress-АМ4, Kanopus-ST, Zuma, Chinasat-18 and many other satellites and space objects. The design of space mechanisms with a specified dependability is complicated by the fact that practically all of them are unique, highly critical systems that are supposed to be as reliable as possible, are unique or rare in terms of their design, are manufactured at most in small series and operate in unique environments. Statistical data on the dependability of components and elements of mechanisms that operate in the open space environment is at best insufficient for obtaining reliable dependability calculation results using the statistical methods of the modern dependability theory, while at worst they do not exist at all. In the context of constantly growing complexity of space technology and increasing costs of any in-orbit failure there is an objective necessity for developing a method for designing space mechanisms based on the evaluation of the specified dependability using the engineering solutions (without involving statistical methods of dependability) and early failure prevention procedures. Methods. The paper presents a method for designing and developing space mechanisms based on the design engineering analysis of dependability. Results. The method proposed in the paper allows modifying the analytical verification toolkit, thus migrating from design and expert methods (e.g., Stage-Gate or FMEA) of product design to purely engineering ones that are based on engineering disciplines and design engineering methods of ensuring quality and dependability. The use of design engineering analysis of dependability as part of the design and development enables dependability assurance as a natural and integral part of a designer’s work that enables engineering decision-making in accordance with the specified dependability requirements (rather than in an isolated manner).

Study on Fundamental Force of Extreme Wave on Complex Deepwater Jacket

With the development of offshore wind power to the far-reaching sea, jacket foundation suitable for 10 ~ 60m water depth has become a development trend. The maximum waves in the far-reaching sea are generated by typhoons. The South China Sea spans the tropics and subtropics. Tropical cyclones therein are extremely active due to the features of its marine environment, like wide water-depth profile, complex topography and hydrology. Especially in recent years, under the development situation of global warming, extreme weather events have increased significantly, and strong and super typhoons have become more frequent. The extreme waves generated by them have a huge force on the jacket, affecting the safety of the project. In this paper, the relevant parameters of PMTC are calculated with the statistical method, the verified SWAN model is used to calculate the probable maximum typhoon wave, and the P-III frequency analysis on the extrapolated results of all typhoon waves are carried out by direction to obtain the design wave elements of each return period, and various extreme typhoon wave characteristic parameters were counted. Secondly, the Morison formula is used to calculate the wave force acting on the offshore fan jacket. This wave force based on different water depth and different directions is tested by physical model test. Finally, the results of model test and theoretical calculation are compared and analyzed to confirm that there is a certain correlation between the two wave forces. This empirical formula can be used to correct the calculated value of Morison formula in practical engineering design, which not only provides a simple and convenient calculation method for practical engineering design, but also provides a reference for the calculation model of the total force generalization of deep-sea complex structure foundation, which has certain theoretical value and practical significance.