Click here to load reader

Optimization Driven Design of Compressor logo here 10 Presentation at the ATC2013. • Topology Optimization by using OptiStruct® Optimization Driven Design of Compressor Mounting

  • View
    213

  • Download
    1

Embed Size (px)

Text of Optimization Driven Design of Compressor logo here 10 Presentation at the ATC2013. • Topology...

  • KS. Kong

    Optimization Driven Design of

    Compressor Mounting Bracket

    27 August, 2013

  • Customer

    logo

    here 2 Presentation at the ATC2013.

    Background of APM Engineering & Research

    APM Engineering & Research Sdn Bhd

    Suspension System

    Range of coil, leaf and parabolic

    spring, air bellow.

    Shock absorber.

    Corner Module.

    Complete leaf spring suspension

    Module.

    Gas spring

    Climate Control

    Radiator, Condenser core and

    assembly.

    Blower fan and shroud.

    Complete A/C Cooling module.

    Seating Systems

    Complete Seating System.

    New seating mechanisms (Track,

    Recliner, Height adjustment,

    Lumbar support)

    Interiors and Plastics

    Door Panel and Interior trims &

    head liners.

    Instrument Panel, Bumper System

  • Customer

    logo

    here 3 Presentation at the ATC2013.

    Introduction

    The compressor plays a very important role in the automotive air conditioning system. It

    is attached to the engine via a compressor bracket and tightened by bolts. The

    compressor bracket is exposed to the heaviest vibration conditions among the air

    conditioning parts.

    Present work deals with FEA analysis and topology optimization of compressor bracket

    using Altair HyperWorks.

    Optimization Driven Design of Compressor Mounting Bracket

    APM Engineering & Research Sdn Bhd

    A/C

    Compressor

    Compressor

    bracket

  • Customer

    logo

    here 4 Presentation at the ATC2013.

    Objective of Paper

    To determine the natural frequency of the compressor mounting bracket using modal

    analysis.

    Topology optimization on the compressor bracket to get a new bracket design to

    improve its stiffness.

    To determine the axial and shear loads on the mounting bolts for initial and new bracket

    design by dynamic load analysis.

    Optimization Driven Design of Compressor Mounting Bracket

    APM Engineering & Research Sdn Bhd

  • Customer

    logo

    here 5 Presentation at the ATC2013.

    Statement of Problem

    To evaluate bolt failure at the engine mounting locations.

    To design a compressor bracket with higher natural frequency.

    Optimization Driven Design of Compressor Mounting Bracket

    APM Engineering & Research Sdn Bhd

    Engine

    block

    Bolt breakage area

    Compressor

    bracket

    Bolt M10

    Bolt M8

    Compressor

    bracket

    A/C

    Compressor

    Side view Rear view

  • Customer

    logo

    here 6 Presentation at the ATC2013.

    Methodology

    Optimization Driven Design of Compressor Mounting Bracket

    APM Engineering & Research Sdn Bhd

    Preprocessing Phase

    HyperMesh for

    meshing

    Solution Phase

    RADIOSS solver

    for modal analysis

    and dynamic

    analysis

    Postprocessing Phase

    HyperView for

    results

    visualization

    Optistruct for

    topology

    optimization

  • Customer

    logo

    here 7 Presentation at the ATC2013.

    FE Model

    The compressor bracket is appropriately constrained in its engine mounting position and locations.

    The bolts are modeled with 1D beam element.

    The compressor mass is modeled at its C.G and is distributed to its mounting points.

    A load excitation of 30G is applied in the lateral direction at the engine mounting locations.

    Optimization Driven Design of Compressor Mounting Bracket

    APM Engineering & Research Sdn Bhd

    C.G. of A/C

    Compressor

    mass 6.8kg

    30G

    excitation

    loading

    Belt load

  • Customer

    logo

    here 8 Presentation at the ATC2013.

    Modal Analysis (Baseline bracket)

    Optimization Driven Design of Compressor Mounting Bracket

    APM Engineering & Research Sdn Bhd

    First mode natural frequency: 231Hz

  • Customer

    logo

    here 9 Presentation at the ATC2013.

    30 G Dynamic Excitation on Bolts (Baseline bracket)

    Optimization Driven Design of Compressor Mounting Bracket

    APM Engineering & Research Sdn Bhd

    Consider the operating vibration frequency is 300Hz, the result shows response peak for

    both M8 and M10 bolts are above the failure criteria at frequency 231Hz.

  • Customer

    logo

    here 10 Presentation at the ATC2013.

    Topology Optimization by using OptiStruct

    Optimization Driven Design of Compressor Mounting Bracket

    APM Engineering & Research Sdn Bhd

    Non

    Design

    Space

    Design

    Space Design Space is the space or areas identified by

    the designer which could be modified. Non-

    Design Space are the areas which cannot be

    modified.

    Design objective: Natural frequency min 300Hz

    Natural frequency: 39%

    Baseline Optimized

    231Hz 332Hz

  • Customer

    logo

    here 11 Presentation at the ATC2013.

    Modal Analysis (Optimized bracket)

    Optimization Driven Design of Compressor Mounting Bracket

    APM Engineering & Research Sdn Bhd

    First mode natural frequency: 332Hz

  • Customer

    logo

    here 12 Presentation at the ATC2013.

    30 G Dynamic Excitation on Bolts (Optimized bracket)

    Optimization Driven Design of Compressor Mounting Bracket

    APM Engineering & Research Sdn Bhd

    For the optimized bracket design, the response peak for both M8 and M10 bolts are shifted out of the operating

    vibration frequency (300Hz), and the design is considered safe.

    Non-operating zone

    Non-operating zone

    Operating zone

    Operating zone

  • Customer

    logo

    here 13 Presentation at the ATC2013.

    In-depth understanding of problem by analysis result.

    Optimized design in terms of performance and packaging.

    High design confidence level with minimum prototypes.

    Less turn around time for new design of bracket.

    Higher productivity through HyperWorks integration.

    Benefits summary

    APM Engineering & Research Sdn Bhd

  • Customer

    logo

    here 14 Presentation at the ATC2013.

    High vibration level plays a major role in engine mounted component design, especially

    in the compressor supporting bracket.

    To avoid resonance, bracket natural frequency must be more than vibration frequency

    operating range. The baseline design of the compressor bracket shows natural

    frequency was below 300 Hz which is under operating vibration frequency.

    Optimization method was applied to give the right design direction at the stage of

    designing a new bracket which is stiffer, with natural frequency higher than operating

    vibration frequency.

    Conclusion

    APM Engineering & Research Sdn Bhd

  • Customer

    logo

    here 15 Presentation at the ATC2013.

    I would like to express my greatest gratitude to Mr. Dipak

    Chandwani, Mr. Ravi Kodwani and Mr. Srikanth R. from Altair for

    their continuous support during the project & presentation.

    THANK YOU!

    Acknowledgements/Credits

    APM Engineering & Research Sdn Bhd

Search related