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Yes / Here the design and functional optimisation of thermoformed thin-walled structures made from plastics is considered. Such objects are created in great numbers especially in the food packaging industry. In fact these objects are produced in such vast numbers each year, that one important task in the design of these objects is the minimisation of the amount of plastic used, subject to functional constraints. In this paper a procedure for achieving this is described, which involves the automatic optimisation of the mold shape taking into account the strength of the final object and its thickness distribution, thus reducing the need to perform inefficient and expensive `trial and error¿ experimentation using physical prototypes. An efficient technique for parameterising geometry is utilised here, enabling to create a wide variety of possible mold shapes on which appropriate analysis can be performed. The results of the analysis are used within an automatic optimisation routine enabling to find a design which satisfies user requirements. Thus, the paper describes a rational means for the automatic optimal design of composite thermoformed thin-walled structures.

Wireless Sensor Networks(WSNs) have gained a lot of attention because of their potential to immerse deeper into people' lives. The applications of WSNs range from small home environment networks to large habitat monitoring. These highly diverse scenarios impose different requirements on WSNs and lead to distinct design and implementation decisions. This thesis presents an optimization framework for WSN design which selects a proper set of protocols and number of nodes before a practical network deployment. A Genetic Algorithm(GA)-based Sensor Network Design Tool(SNDT) is proposed in this work for wireless sensor network design in terms of performance, considering application-specific requirements, deployment constrains and energy characteristics. SNDT relies on offine simulation analysis to help resolve design decisions. A GA is used as the optimization tool of the proposed system and an appropriate fitness function is derived to incorporate many aspects of network performance. The configuration attributes optimized by SNDT comprise the communication protocol selection and the number of nodes deployed in a fixed area. Three specific cases : a periodic-measuring application, an event detection type of application and a tracking-based application are considered to demonstrate and assess how the proposed framework performs. Considering the initial requirements of each case, the solutions provided by SNDT were proven to be favourable in terms of energy consumption, end-to-end delay and loss. The user-defined application requirements were successfully achieved.

Automotive engines are becoming increasingly technically complex and associated legal emissions standards more restrictive, making the task of identifying optimum actuator settings to use significantly more difficult. Given these challenges, this research aims to develop a process for engine calibration optimisation by exploiting advanced mathematical methods. Validation of this work is based upon a case study describing a steady-state Diesel engine calibration problem. The calibration optimisation problem seeks an optimal combination of actuator settings that minimises fuel consumption, while simultaneously meeting or exceeding the legal emissions constraints over a specified drive cycle. As another engineering target, the engine control maps are required as smooth as possible. The Multidisciplinary Design Optimisation (MDO) Frameworks have been studied to develop the optimisation process for the steady state Diesel engine calibration optimisation problem. Two MDO strategies are proposed for formulating and addressing this optimisation problem, which are All At Once (AAO), Collaborative Optimisation. An innovative MDO formulation has been developed based on the Collaborative Optimisation application for Diesel engine calibration. Form the MDO implementations, the fuel consumption have been significantly improved, while keep the emission at same level compare with the bench mark solution provided by sponsoring company. More importantly, this research has shown the ability of MDO methodologies that manage and organize the Diesel engine calibration optimisation problem more effectively.

Thesis (MSc (Electrical and Electronic Engineering))--University of Stellenbosch, 2011. / ENGLISH ABSTRACT: Knowledge of the magnetic fields in the domain of electrical machines is required in order to model machines accurately. It is difficult to solve these fields analytically because of the complex geometries of electrical machines and the non-linear characteristics of the materials used to build them. Thus, finite element analysis, which can be used to solve the magnetic field accurately, plays an important part in the design of electrical machines. When designing electrical machines, the task of finding an optimal design is not simple because the performance of the machine has a non-linear dependence on many variables. In these circumstances, numerical optimisation using finite element analysis is the most powerful method of finding optimal designs. In this thesis, the work of improving an existing finite element simulation package, formerly known as the Cambridge package among its users, and the use of this package in the optimisation of electrical machine designs, is presented. The work involved restructuring the original package, expanding its capabilities and coupling it to numerical optimisers. The developed finite element package has been dubbed SEMFEM: the Stellenbosch Electrical Machines Finite Element Method. The Cambridge package employed the air-gap element method, first proposed by Razek et. al. [2], to solve the magnetic field for different positions of the moving component in a time-stepped finite element simulation. Because many new machine topologies have more than one air-gap, the ability to model machines with multiple air-gaps is important. The Cambridge package was not capable of this, but during the course of this work, the ability to model machines with multiple air-gaps using the air-gap element method was implemented. Many linear electrical machines have tubular, axisymmetric topologies. The functionality to simulate these machines was newly implemented because the original program was not capable of analysing these machines. Amongst other things, this involved the derivation of the coefficients of an axisymmetric air-gap element’s stiffness matrix. This derivation, along with the original air-gap element derived by Razek et. al. [2] and the extension of the method to the Cartesian coordinate system by Wang et. al. [29, 30], completes the derivation of all two-dimensional air-gap elements. In order to speed the numerical optimisation process, which is computationally expensive, parallelisation was introduced in two areas: at the level of the finite element simulation and at the level of the optimisation program. The final product is a more powerful, more usable package, geared for the optimisation of electrical machines. / AFRIKAANSE OPSOMMING: Kennis van die magnetiese velde in die gebied van elektriese masjiene word benodig om masjiene akkuraat te modelleer. Dit is moeilik om hierdie velde analities op te los as gevolg die komplekse geometrieë van elektriese masjiene en die nie-lineêre karakteristieke van die materiale wat gebruik word om hulle te bou. Dus speel eindige element analise ’n belangrike rol in die ontwerp van elektriese masjiene omdat dit gebruik kan word om die magnetiese veld akkuraat te bepaal. Wanneer elektriese masjiene ontwerp word, is dit nie ’n eenvoudige taak om ’n optimale ontwerp te vind nie omdat die werkverrigting van die masjien nie-lineêr afhanklik is van baie veranderlikes. Onder hierdie omstandighede is numeriese optimering, tesame met eindige element analise, die kragtigste metode om optimale ontwerpe te vind. In hierdie tesis word die verbetering van ’n bestaande eindige element simulasie pakket, wat onder gebruikers van die pakket as die Cambridge pakket bekend staan, en die gebruik van hierdie pakket vir die optimering van elektriese masjiene, voorgelê. Die werk het die herstrukturering van die oorspronklike pakket, die uitbreiding van die pakket se vermoëns en die koppeling van die pakket aan numeriese optimeerders behels. Die ontwikkelde eindige element pakket word SEMFEM genoem: die Stellenbosch Elektriese Masjiene Finite Element Method. Die Cambridge pakket het van die lugspleet element metode, soos oorspronlik deur Razek et. al. [2] voorgestel, gebruik gemaak om die magnetiese veld vir verskillende posisies van die bewegende komponent in ’n tyd-stapsgewyse eindige element simulasie op te los. Omdat baie nuwe masjien topologieë meer as een lugspleet het, is die vermoë om masjiene met meer as een lugspleet te kan modelleer belangrik. Die Cambridge pakket was nie hier toe in staat nie, maar die vermoë om masjiene met meervoudige lugsplete te modelleer is gedurende hierdie werk geïmplementeer. Baie lineêre masjiene het tubulêre, assimmetriese topologieë. Die funksionaliteit om hierdie masjiene te simuleer is nuut geïmplementeer omdat die oorspronlike program nie in staat was om hierdie masjiene te analiseer nie. Dit het onder andere behels dat die koeffisiënte van ’n assimmetriese lugspleetelement se styfheidsmatriks afgelei moes word. Hierdie afleiding, tesame met die oorspronlike lugspleetelement afgelei deur Razek et. al. [2] en die uitbreiding na die Cartesiese koördinaatstelsel deur Wang et. al. [29, 30], voltooi die afleiding van alle twee-dimensionele lugspleet elemente. Om die numeriese optimeringsproses, wat tipies tydsgewys duur is, te versnel, is parallellisering op twee vlakke ingebring: op die vlak van die eindige element simulasie en op die vlak van die optimeringsprogram. Die finale produk is ’n kragtiger, meer bruikbare pakket, goed aangepas vir die optimering van elektriese masjiene.

Deployable structures made from ultra-thin composite materials can be folded elastically and are able to self-deploy by releasing the stored strain energy. Their lightness, low cost due to smaller number of components, and friction insensitive behaviour are key attractions for space applications. This dissertation presents a design methodology for lightweight composite booms with multiple tape-spring hinges. The whole process of folding and deployment of the tape-spring hinges under both quasi-static and dynamic loading has been captured in detail through finite element simulations, starting from a micro-mechanical model of the laminate based on the measured geometry and elastic properties of the woven tows. A stress-resultant based six-dimensional failure criterion has been developed for checking if the structure would be damaged. A detailed study of the quasi-static folding and deployment of a tape-spring hinge made from a two-ply plain-weave laminate of carbon-fibre reinforced plastic has been carried out. A particular version of this hinge was constructed and its moment-rotation profile during quasi-static deployment was measured. Folding and deployment simulations of the tape-spring hinge were carried out with the commercial finite element package Abaqus/Explicit, starting from the as-built, unstrained structure. The folding simulation includes the effects of pinching the hinge in the middle to reduce the peak moment required to fold it. The deployment simulation fully captures both the steady-state moment part of the deployment and the final snap back to the deployed configuration. An alternative simulation without pinching the hinge provides an estimate of the maximum moment that could be carried by the hinge during operation. This moment is about double the snap-back moment for the particular hinge design that was considered. The dynamic deployment of a tape-spring hinge boom has been studied both experimentally and by means of detailed finite-element simulations. It has been shown that the deployment of the boom can be divided into three phases: deployment; latching, which may involve buckling of the tape springs and large rotations of the boom; and vibration of the boom in the latched configuration. The second phase is the most critical as the boom can fold backwards and hence interfere with other spacecraft components. A geometric optimisation study was carried out by parameterising the slot geometry in terms of slot length, width and end circle diameter. The stress-resultant based failure criterion was then used to analyse the safety of the structure. The optimisation study was focused on finding a hinge design that can be folded 180 degrees with the shortest possible slot length. Simulations have shown that the strains can be significantly reduced by allowing the end cross-sections to deform freely. Based on the simulations a failure-critical design and a failure-safe design were selected and experimentally verified. The failure-safe optimised design is six times stiffer in torsion, twice stiffer axially and stores two and a half times more strain energy than the previously considered design. Finally, an example of designing a 1 m long self-deployable boom that could be folded around a spacecraft has been presented. The safety of this two-hinge boom has been evaluated during both stowage and dynamic deployment. A safe design that latches without any overshoot was selected and validated by a dynamic deployment experiment.

Automotive engines are becoming increasingly technically complex and associated legal emissions standards more restrictive, making the task of identifying optimum actuator settings to use significantly more difficult. Given these challenges, this research aims to develop a process for engine calibration optimisation by exploiting advanced mathematical methods. Validation of this work is based upon a case study describing a steady-state Diesel engine calibration problem. The calibration optimisation problem seeks an optimal combination of actuator settings that minimises fuel consumption, while simultaneously meeting or exceeding the legal emissions constraints over a specified drive cycle. As another engineering target, the engine control maps are required as smooth as possible. The Multidisciplinary Design Optimisation (MDO) Frameworks have been studied to develop the optimisation process for the steady state Diesel engine calibration optimisation problem. Two MDO strategies are proposed for formulating and addressing this optimisation problem, which are All At Once (AAO), Collaborative Optimisation. An innovative MDO formulation has been developed based on the Collaborative Optimisation application for Diesel engine calibration. Form the MDO implementations, the fuel consumption have been significantly improved, while keep the emission at same level compare with the bench mark solution provided by sponsoring company. More importantly, this research has shown the ability of MDO methodologies that manage and organize the Diesel engine calibration optimisation problem more effectively. / Jaguar Land Rover

Thesis (MScEng (Mechanical and Mechatronic Engineering))--University of Stellenbosch, 2009. / Although mass minimisation is an important application within structural optimisation, other applications include: (1) concept generation, (2) concept evaluation, (3) design for structural feasibility and (4) data matching. These applications, except data matching, are discussed and illustrated on a prototype design of the Karoo Array Telescope (KAT) antenna. The KAT passed through the design process and a full scale prototype was built, but was found to be too expensive. A detailed finite element model of the finalised design was considered as a test bed for reducing costs. Size-, shape- and topology optimisation are applied to three KAT components, while considering wind, temperature and gravity loads. Structural- and nonstructural constraints are introduced. Coupling of the structural optimisation code with an external analysis program to include non-structural responses and the parallelisation of the sensitivity calculations are presented. It is shown that if a finite element model is available, it is generally possible to apply structural optimisation to improve an existing design. A reduction of 2673 kg steel was accomplished for the existing KAT components. The total cost saving for the project will be significant, when considering that a large amount of antennas will be manufactured.

Thesis (PhD (Electrical and Electronic Engineering))--University of Stellenbosch, 2011. / ENGLISH ABSTRACT: The focus of this thesis is on the optimal design, control and evaluation of 3-phase permanent magnet radial flux synchronous machines with non-overlapping, concentrated-coil, double layer stator windings for EV hub drive applications. A simple analytical method is developed that can be used as a first design tool. The method uses and predicts the MMF harmonic content for a certain pole-slot combination as well as the harmonic content for the air gap permeance function. These harmonics are then used to calculate the torque and torque ripple of machines with large stator slot openings and surface mounted permanent magnets. A different approach to calculate the iron, stator copper eddy current and magnet losses is presented. This method specifically looks at the machine during field weakening operation when the flux paths are changing in the machine. Flux density information throughout the machine is extracted from a series of static FE solutions, to calculate the losses and to combine this with an empirical formula. Some machine topology choices are compared for use as hub drives in small electric ve- hicles. The parameters that influence the machine design are discussed and evaluated after a multidimensional design optimization is done and an efficient control algorithm is imple- mented. The algorithm works through the entire operating speed range and make use of, automatically generated, 2D look up tables to determine the correct current reference. A stator lamination design is proposed, that combines the use of rectangular preformed coils and semi-closed stator slots. Two prototype machines, one with a good winding factor and the other with a low winding factor, are built and compared. The manufacturing and testing of the two prototype machines are described and shown in detail. / AFRIKAANSE OPSOMMING: Die fokus van hierdie tesis is op die optimale ontwerp, beheer en evaluasie van 3-fase per- manent magneet radiale vloed sinchroon masjiene met nie-oorvleuelende, gekonsentreerde, dubbel laag stator wikkelinge vir EV hub motor toepassings. ’n Eenvoudige analitiese metode is ontwikkel wat as ’n eerste ontwerp gereedskap stuk gebruik kan word. Die metode gebruik en voorspel die MMF se frekwensie inhoud vir ’n sekere pool-gleuf kombinasie sowel as die frekwensie inhoud vir die lug spleet permeansie funksie. Hierdie frekwensie inhoud word dan gebruik om die draaimoment en draaimoment riffel van masjiene met groot stator gleuf openinge en oppervlak magnete te voorspel. ’n Ander benadering om yster, stator koper werwel stroom en magneet verliese te bepaal word voorgestel. Hierdie metode kyk spesifiek na masjiene onder veld verswakking beheer wanneer die vloed paaie verander vanaf die normale. Die vloeddigtheid, regdeur die masjien, word verkry deur om van ’n reeks statiese eindige element oplossings gebruik te maak en dit te kombineer met ’n empiriese verliesberekening. Die parameters wat die masjienontwerp beïnvloed, word bespreek en geëvalueer na ’n mul- tidimensionele ontwerp optimering gedoen is en ’n effektiewe beheer algoritme geïmplimen- teer is. Die algoritme werk vir enige spoed en is gebaseer op die outomaties gegenereerde 2D opsoek tabelle wat die korrekte stroomverwysing gee. ’n Stator laminasie ontwerp word voorgestel wat die gebruik van vooraf vervaardigde spoele en gedeeltelik toe stator gleuwe moontlik maak. Twee prototipe masjiene, een met ’n goeie windingsfaktor en een met ’n swakker windingsfaktor is gebou en vergelyk. Die ver- vaardiging en toetsing van die twee prototipe masjiene word in detail beskryf en gewys.

Strukturoptimierung ist momentan stark auf Diskretisierungsmethoden angewiesen. In einfachen Fällen, wie die Simulation von Rahmen und Stabwerke, wo eine Diskretisierung nicht notwendig ist, werden nur die Dehnung oder die Stauchung der Stäbe betrachtet, und die Verbindungen sind frei, wie Kugelgelenke, um die Biegungen der Stäbe zu vermeiden. In dieser Dissertation wird eine diskretisierungsfreie Methode zur Modellierung und Optimierung eines Rahmens entwickelt, die die Biegung der Balken sowie die Dehnung oder Stauchung zusammen betrachtet, wobei starre Verbindungen angenommen werden. Starre Verbindungen entstehen, wenn die Balken zusammen geschweißt oder mit mehrere Nieten verbunden sind. Die Optimierungsprobleme, sowohl das Zustands- und als auch das Entwurfsproblem, sind durch die gesamte elastische Energie und die Arbeit der äußeren Kräfte gegeben. Für das Problem der optimalen Größeneinteilung wird darüber hinaus eine topologische Sensitivität zur Einführung neuer Balken zwischen zwei beliebigen Punkten auf dem Rahmen diskutiert. / Structural optimisation currently relies heavily on methods based on discretisation. In simpler cases like the simulation of frames and trusses, where discretisation is not necessary, only the elongation or compression is considered and the joints are free, like ball and socket joints, in order to avoid bending the trusses. In this dissertation a discretisation free method for the modelling and optimisation of frames is developed which considers bending of the beams along with compression or elongation with joints between the beams being rigid. Rigid joints are commonly the result of welding two beams together or connecting them using mutiple rivets. The optimisation problems, both state and design optimisation, are formulated via the total elastic energy and the work done by external forces. Moreover, for the optimal sizing problem a topological sensitivity for introduction of new beams between any two arbitrary positions in the frame is discussed.