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Design
What is the relationship between analysis
and design?
Engineering Analysis
Engineering Design
The design process is iterative.
Desired System
Performance Design Specification
The design process is iterative.
Physical
Computer
Analysis
Testing
Simulation
Desired System
Performance Candidate Check Specification
Design Performance
Specification
Manual
Designed
Update
Optimization
Experiments
Design
Tuning
Algorithm
What is engineering design
optimization?
Engineering Design Optimization
Framed engineering Mathematical optimization problem
design problem: formulation:
• Scope • Well-posed, solvable
• Assumptions • Models (approximates) original
• Goals target problem well
• Enhances design
Model/Simulation-Based Design capabilities (speed,
Design Optimization
performance,
• Simulate results system
rapidly (often faster/less
expensive than physical experiments)
complexity)
• Explore design space efficiently (find best
design without having to test them all)
• effects
• Predict Requires additional investment
of design decisions (time,
• Go beyond meeting expertise,
requirements (RDD)
• Gain intuition through model development • Make new things possible, create and
resources)
• Discover what physical mechanisms are understand unprecedented systems
influential with respect to design problem • Automate parts of the design process
• Increased design flexibility and complexity
Analytical Design (Design With Analysis)
Design Flexibility
Three questions:
• How can we describe design alternatives?
– Design representation
• How can we quantitatively compare design alternatives?
– Comparative Metrics (objectives and constraints)
• Given a design, how can we predict its performance?
– Predictive mathematical models
– Important for exploring what is physically realizable
f 1 (x )
Concept 2
Attainable Set
Concept 3
Attainable Set
Target Point
Utopia Point
f 2 (x )
Optimization: Beyond Requirements-driven design:
• Solution is non-obvious:
– With some trivial problems, we can use intuition to reason through
what the optimal result will be.
– Monotonicity is often present in engineering design. Often one or
more constraints are active. (min mass, st stress)
– Active failure mode constraints are usually fine, but active arbitrary
bounds usually indicate something was overlooked in the formulation
(oversimplified model, improper design representation).
• Competing phenomena or other tradeoffs create design conditions where
a ‘sweet spot’ exists, and optimization helps us find this sweet spot
• Optimization formulation, modeling, and solution provide new design
insights
– Results provide new intuition for how certain types of systems should
be designed
Example: Simple, Non-Trivial Problem
Sweet Spot Example: Simple Structural Design
Large r non-optimal
designs
Substantive
rationality
solution
Modeling for Design
Modeling for Design
Requires a deeper understanding of the relationship
between engineering analysis and design.
• Design is the ‘inverse problem’
• Design optimization helps to focus modeling activities,
reveals model shortcomings
• Development of adequate models: perhaps the most
significant barrier to adoption of design optimization in
industry.
• Why might existing models be inadequate?
• Engineers who develop models often are not the ones
using them for design.
Product Concept Systems-Level Detail Testing and Production
Planning Development Design Design Refinement Ramp-up
Steady-state
Lumped-parameter simulations
Error
Distributed-parameter simulations
Computational Expense
Two fundamental types of system interaction/coupling:
Resistor 1D ODE
1. 2. Network 3. 2D PDE 4. 3D PDE
Network
Low Fidelity
• Inaccuracy has low impact on design Model
solution (robustness)
High Fidelity
• Allows for design flexibility
Model
• Support adjustment of independent
design variables
• Often must include important
physics couplings How far apart are the optima?
How do we measure model suitability for a
design problem?
• Model validation: how closely do predicted
results match actual system behavior?
versus
• Assessing model suitability for design: Will using
the model get us to the right design solution?
Optimization Algorithms:
• Understand them well enough to choose the right algorithm for a problem
• Know what to do when things go wrong
• Algorithm, formulation, model
• Write your own basic optimization algorithms
• Explore design alternatives efficiently
Modeling:
• Learn how to develop engineering analysis models that work well for design
optimization
• Understand how to use the right model fidelity and complexity for a problem
Other Relevant Courses:
• IE 513: Optimal System Design
• ECE 490: Introduction to Optimization
• AE 498: Topology Optimization
• GE 598: Dynamic System Design
• AE 502: Optimal Control
See: tinyurl.com/esdl-info
Appendix
Integrated System Design
System Design Paradigm:
The whole is greater than the sum of the parts
• Base design decisions on what is best for the overall system, not individual parts
system-level
3: Inverter 4: Battery
design
2: Generator
1: Engine 5: Motor
material-level
design
6: Gears
7: Vehicle