Surrogate-Based Calculation Method for Robust Design Optimization Considering the Fatigue Probability for Variable Service Loads of eBike Drive Units

Designs Pub Date : 2023-12-25 DOI:10.3390/designs8010004
Marco Steck, S. Husung
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Abstract

This paper proposes a robust design-optimization approach for eBike drive units that incorporates the highly variable driver-dependent load collectives and system conditions into a fatigue calculation. In an initial step, the relevant influences and loads on the investigated system are examined and reviewed in relation to the current normative requirements. From a methodical viewpoint, this paper presents a surrogate-based simulation-based approach to assess reliability across the entire geometry according to a probabilistic fatigue calculation. The probabilistic evaluation considers the several measured load collectives of different drivers and driving scenarios to enable a robust and type-oriented bike design. In addition to methods of fatigue calculation, this approach also includes common methods of order reduction and reliability-based design optimization. To avoid additional uncertainties in the calculation, this approach considers a complex critical-plane-based multiaxial-fatigue calculation to correctly evaluate the multiaxial and non-proportional stress state across the whole geometry. A data-based surrogate model that supports the fatigue calculation by predicting the load across the given uncertainties is the key to the efficient assessment of the service life of the eBike. Lastly, the identified uncertainties in the design of eBike drive units are investigated and evaluated by this method.
基于代用计算方法的鲁棒性设计优化,考虑电动自行车驱动装置的可变服务负载的疲劳概率
本文针对电动自行车驱动装置提出了一种稳健的设计优化方法,该方法将高度可变的、取决于驾驶员的负载集合和系统条件纳入疲劳计算。首先,根据当前的规范要求,研究和审查了调查系统的相关影响因素和负载。从方法论的角度来看,本文提出了一种基于代用模拟的方法,根据概率疲劳计算来评估整个几何形状的可靠性。概率评估考虑了不同驾驶员和驾驶情况下的多个测量载荷集合,以实现稳健的、以类型为导向的自行车设计。除疲劳计算方法外,这种方法还包括常用的阶次降低和基于可靠性的设计优化方法。为避免计算中出现额外的不确定性,该方法考虑了复杂的基于临界平面的多轴疲劳计算,以正确评估整个几何体的多轴和非比例应力状态。基于数据的代用模型通过预测给定不确定性的载荷来支持疲劳计算,是高效评估电动自行车使用寿命的关键。最后,该方法对电动自行车驱动单元设计中已识别的不确定性进行了研究和评估。
本文章由计算机程序翻译,如有差异,请以英文原文为准。
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