A structural integrity based parametric design and optimization method for type IV hydrogen filament winding composite pressure vessel

Designing Type IV hydrogen storage composite pressure vessels (CPVs) to meet both safety and lightweight requirements remains a challenge. This study clarifies the limitations of the current widely used parametric design method for composite pressure vessels and proposes a structural integrity-based parametric design method. In the proposed method, the various helical composite layers in the advanced variable radii design are first determined based on the structural features of the dome region, followed by the determination of the hoop composite layers for the cylindrical region. The parametric design method is fast and cost-efficient, providing essential input data for finite element analysis and structural optimization. Furthermore, the Box–Behnken design (BBD) combined with a hybrid Whale Optimization Algorithm, Backpropagation Neural Network, and Genetic Algorithm (WOA-BPNN-GA) optimization procedure is proposed to optimize the structural design, achieving up to 30% reduction in composite structure mass. The designed and optimized filament winding composite pressure vessel was manufactured and tested. Good agreement is observed between the design and experimental results, with errors of 3.33% for burst pressure and 3.63% for composite structural mass. This agreement validates the proposed structural integrity-based parametric design method and optimization procedure.