Designs — Open Access Journal

A central challenge in generative design is the exploration of vast number of solutions. In this work, we extend two major density-based structural topology optimization (STO) methods based on four classes of exploration algorithms of reinforcement learning (RL) to STO problems, which approaches generative design in a new way. The four methods are: first, using $\epsilon$ -greedy policy to disturb the search direction; second, using upper confidence bound (UCB) to add a bonus on sensitivity; last, using Thompson sampling (TS) as well as information-directed sampling (IDS) to direct the search, where the posterior function of reward is fitted by Beta distribution or Gaussian distribution. Those combined methods are evaluated on some structure compliance minimization tasks from 2D to 3D, including the variable thickness design problem of an atmospheric diving suit (ADS). We show that all methods can generate various acceptable design options by varying one or two parameters simply, except that IDS fails to reach the convergence for complex structures due to the limitation of computation ability. We also show that both Beta distribution and Gaussian distribution work well to describe the posterior probability. Full article

As Digital Twins gain more traction and their adoption in industry increases, there is a need to integrate such technology with machine learning features to enhance functionality and enable decision making tasks. This has lead to the emergence of a concept known as Digital Triplet; an enhancement of Digital Twin technology through the addition of an ’intelligent activity layer’. This is a relatively new technology in Industrie 4.0 and research efforts are geared towards exploring its applicability, development and testing of means for implementation and quick adoption. This paper presents the design and implementation of a Digital Triplet for a three-floor elevator system. It demonstrates the integration of a machine learning (ML) object detection model and the system Digital Twin. This was done to introduce an additional security feature that enabled the system to make a decision, based on objects detected and take preliminary security measures. The virtual model was designed in Siemens NX and programmed via Total Integrated Automation (TIA) portal software. The corresponding physical model was fabricated and controlled using a Programmable Logic Controller (PLC) S7 1200. A control program was developed to mimic the general operations of a typical elevator system used in a commercial building setting. Communication, between the physical and virtual models, was enabled using the OPC-Unified Architecture (OPC-UA) protocol. Object recognition using “You only look once” (YOLOV3) based machine learning algorithm was incorporated. The Digital Triplet’s functionality was tested, ensuring the virtual system duplicated actual operations of the physical counterpart through the use of sensor data. Performance testing was done to determine the impact of the ML module on the real-time functionality aspect of the system. Experiment results showed the object recognition contributed an average of $1.083$ s to an overall signal travel time of $1.338$ s. Full article

Customers’ needs and wants with regard to dairy products are increasingly diverse, and companies must be able to produce a variety of products. This study aimed to obtain alternative product configurations in accordance with customer requirements and to determine the types of modules required to realize the product by synergizing conjoint analysis and the decision-making trial and evaluation laboratory (DEMATEL) method. The product configuration was based on pleasurable design consisting of three aspects, namely functionality, usability, and pleasure. Pleasurable design was chosen because it involves the human in the product design as a product user so that the product design is in accordance with customer expectations. The research used the survey method with consumers of ice cream. Descriptive analysis was used to describe the product attributes desired by consumers. Orthogonal design was used to construct alternative product configurations, while the product configuration rank was determined using conjoint analysis. Based on the results of the research, the selected attributes for the functionality aspects were taste and texture, the selected attributes for the usability aspects were shape and packaging materials, and the selected attributes for the pleasure aspects were health benefits and appearance. The orthogonal design results led to 25 alternative product configurations, followed by determination of the ranking of alternative product configurations. Then the DEMATEL method was applied to analyse the relationship between the product configuration attributes to determine the types of modules that must be provided. Full article

To remain competitive in the market, it is crucial to reduce the time and costs involved in product development. Design for manufacturing and assembly is an engineering methodology that can reduce costs without compromising reliability, performance and time to market objectives. This paper presents a case study for an in-market Table Top Chain (TTC) conveyor system used by a reputed company in Saudi Arabia. TTC conveyor systems are extensively used by major food companies around the world for transporting packaged bottles, glass and cans. There are three main types of these systems, i.e., straight running, side flexing and multiflex. This work focuses on the redesign of a side flexing TTC conveyor system. The existing design of the TTC conveyor system was analysed using the DFMA 9.3 software. The outcomes of the initial analysis were utilised to redesign the TTC conveyor system for cost and design efficiency improvements. The optimum design was selected using Pugh controlled convergence method and further tested for its structural performance using finite element analysis. The redesigned model showed substantial improvements with cost reductions of 29% and an increase in design efficiency from 1.7% to 5%. Finite element analysis has also been carried out with SolidWorks 2019 to validate the structural integrity of the new concept design. Full article

Nowadays, embedded systems are increasingly complex, meaning that traditional testing methods are costly to use and infeasible to directly apply due to the complex interactions between hardware and software. Modern embedded systems are also demanded to function based on low-energy computing. Hence, testing the energy usage is increasingly important. Artifacts produced during the development of embedded systems, such as architectural descriptions, are beneficial abstractions of the system’s complex structure and behavior. Electronic Architecture and Software Tools Architecture Description Language (EAST-ADL) is one such example of a domain-specific architectural language targeting the automotive industry. In this paper, we propose a method for testing design models using EAST-ADL architecture mutations. We show how fault-based testing can be used to generate, execute and select tests using energy-aware mutants—syntactic changes in the architectural description, used to mimic naturally occurring energy faults. Our goal is to improve testing of complex embedded systems by moving the testing bulk from the actual systems to models of their behaviors and non-functional requirements. We combine statistical model-checking, increasingly used in quality assurance of embedded systems, with EAST-ADL architectural models and mutation testing to drive the search for faults. We show the results of applying this method on an industrial-sized system developed by Volvo GTT. The results indicate that model testing of EAST-ADL architectural models can reduce testing complexity by bringing early and cost-effective automation. Full article

Many different product development approaches are taught and used in engineering and management disciplines. These formalized design methods, processes, and environments differ in the types of projects for which they are relevant, the project components they include, and the support they provide users. This paper details a review of sixteen well-established product development approaches, the development of a decision support system to help designers and managers navigate these approaches, and the administration of a survey to gather subjective assessments and feedback from design experts. The included approaches—design thinking, systems thinking, total quality management, agile development, waterfall process, engineering design, spiral model, vee model, axiomatic design, value-driven design, decision-based design, lean manufacturing, six sigma, theory of constraints, scrum, and extreme programming—are categorized based on six criteria: complexity, guidance, phase, hardware or software applicability, values, and users. A decision support system referred to as the Product Development Approach Advisor (PD Advisor) is developed to aid designers in navigating these approaches and selecting an appropriate approach based on specific project needs. Next, a survey is conducted with design experts to gather feedback on the support system and the categorization of approaches and criteria. The survey results are compared to the original classification of approaches by the authors to validate and provide feedback on the PD Advisor. The findings highlight the value and limitations of the PD Advisor for product development practice and education, as well as the opportunities for future work. Full article

Computational fluid dynamics (CFD) can help in understanding the nature of leakage flow phenomena inside the rotary positive displacement machines (PDMs). However, due to the lack of experimental results, the analysis of leakage flows in rotary PDMs by CFD has not yet been fully validated. Particle image velocimetry (PIV) tests with a microscopic lens and phase-lock were conducted to obtain the velocity field around the tip gap in an optical Roots blower. The three-dimensional unsteady CFD model of the Roots blower with the dynamic grids generated by Screw Compressor Rotor Grid Generation (SCORG) was established to predict the gap flow under the same operating conditions. The images obtained by the PIV tests were analyzed and some factors which compromise the quality of test results in the gap flow were identified, such as reflections and transparency of the window. The flow fields obtained by CFD have the same flow pattern and velocity magnitude as the experimental results in the majority of observed regions but overestimate the leakage flow velocity. The CFD results show a vortex induced by the leakage flow in the downstream region of the gap. The flow losses in the tip gap mainly happen at the entrance upstream of the gap. Finally, some suggestions for future work are discussed. Full article

Over the last decade, Computational Fluid Dynamics (CFD) has been increasingly applied for the design and analysis of positive displacement machines employed in vapor compression and power generation applications. Particularly, single-screw and twin-screw machines have received attention from the researchers, leading to the development and application of increasingly efficient techniques for their numerical simulation. Modeling the operation of such machines including the dynamics of the compression (or expansion) process and the deforming working chambers is particularly challenging. The relative motion of the rotors and the variation of the gaps during machine operation are a few of the major numerical challenges towards the implementation of reliable CFD models. Moreover, evaluating the thermophysical properties of real gases represents an additional challenge to be addressed. Special care must be given to defining equation of states or generating tables and computing the thermodynamic properties. Among several CFD suite available, the open-source OpenFOAM tool OpenFOAM, is regarded as a reliable and accurate software for carrying out CFD analyses. In this paper, the dynamic meshing techniques available within the software as well as new libraries implemented for expanding the functionalities of the software are presented. The simulation of both a single-screw and a twin-screw machine is described and results are discussed. Specifically, for the single-screw expander case, the geometry will be released as open-access for the entire community. Besides, the real gas modeling possibilities implemented in the software will be described and the CoolProp thermophysical library integration will be presented. Full article

Growing demands for energy are motivating researchers to conduct in-depth analysis of positive displacement machines such as oil-injected screw compressors which are frequently used in industrial applications like refrigeration, oil and gas and air compression. The performance of these machines is strongly dependent on the oil injection. Optimisation of oil has a great energy saving potential by both increasing efficiency and reducing other impacts on the environment. Therefore, a three-dimensional, transient computational fluid dynamics study of oil injection in a twin-screw compressor is conducted in this research. This study explores pseudo single-fluid multiphase (SFM) models of VOF (Volume of Fluid) and a mixture for their capability to predict the performance of the oil-injected twin screw compressor and compare this with the experimental values. SCORG^TM (Screw Compressor Rotor Grid Generator) is used to generate numerical grids for unstructured solver Fluent with the special interface developed to facilitate user defined nodal displacement (UDND). The performance predictions with both VOF and mixture models provide accurate values for power consumption and flow rates with low deviation between computational fluid dynamics (CFD) and the experiment at 6000 RPM and 7.0 bar discharge pressure. In addition, the study reflects on differences in predicting oil distribution with VOF, mixture and Eulerian-Eulerian two-fluid models. Overall, this study provides an insight into multiphase flow-modelling techniques available for oil-injected twin-screw compressors comprehensively accounting for the details of oil distribution in the compression chamber and integral compressor performance. Full article

Trying virtual garments on a virtual body has become widespread in the design industry as a result of 3D computer-aided design (CAD) system and progress in body measurement systems. Spending less time and cost compared to traditional methods of garment design is the main benefit of design software development. Moreover, it leads to improved garment fitting on the body which fulfills customer desires. In the present study, a parametric graphical method was utilized to develop a 3D virtual mannequin for the pregnancy period. The former, the 3D adaptive mannequin model was predicted based on a woman’s weight by analyzing body morphology evolution of a pregnant woman. The mannequin was verified by the results of another pregnant body. Then, the developed mannequin based on weight gain during maternity was applied to design a garment block pattern. The virtual try-on of the developed garment block pattern suggested that it was well-fitted on the 3D virtual mannequin while two armpit darts and two elastic seams were allocated. Hence, the developed garment block pattern will be used to make a personalized protective garment in our future work using an electromagnetic shielding woven fabric formerly manufactured by our group. Full article

The market for dry vacuum pumps is expected to increase in the coming years. Improving the efficiency of these machines requires comprehensive understanding of the flow dynamics within the working chambers. For this purpose, Computational Fluid Dynamics (CFD) is used as it offers better insight of the working process of a screw machine. In this study, a twin-screw vacuum pump with a large helix angle was analysed. This is a challenging case for CFD due to the limitations of grid generation in the transverse plane on the mesh quality. Two types of transverse meshes were generated using the software SCORG^TM: casing to rotor non-conformal mesh and casing to rotor conformal mesh. The quality of the mesh in terms of aspect ratio and orthogonality were compared. The casing to rotor conformal mesh was used with ANSYS Fluent in order to obtain performance characteristics of the vacuum pump with the moderate helix angle of 62° such as the mass flow rate, rotor torque, and indicated power. The performance prediction results were satisfactory but the grid quality was relatively low with orthogonality reaching 40° and aspect ratio over 250 in some cases. As the helix angle increases the quality of mesh decreases. This paper presents the new development of a grid generation algorithm which uses the normal rack to map the fluid domain in the normal plane instead of the transverse plane. This new mesh generation method is expected to better align the computational grid with the main and leakage flows in order to significantly improve grid quality and reduce the numerical diffusion in case of screw machines with large helix angles. Full article

We present design guidelines on light emitting diode (LED) costumes for dance performances assuming repetitive use during concerts. We used LED costumes more than 120 times for large concerts of well-known artists at venues of approximately 50,000 capacity that were commercially successesful and we updated the LED costume design twice based on our experiences during these concerts. Through analyzing the position of broken LEDs and the types of breakage and the problems that occurred during actual performances, we devised 17 design guidelines on LED costumes for dance performances. Thanks to these design guidelines, the LEDs on the costume are more difficult to break and we can prepare for any contingencies that may occur during a performance. We fabricated an improved LED costume based on our design guidelines and conducted endurance tests involving dancing. Throughout the endurance tests, the LEDs did not break, and other factors that cause LED breakage were found. We participated in two exhibitions to conduct special LED dance performances. Full article

Fused filament fabrication (FFF) is a well-known and greatly accessible additive manufacturing technology, that has found great use in the prototyping and manufacture of radiofrequency componentry, by using a range of composite thermoplastic materials that possess superior properties, when compared to standard materials for 3D printing. However, due to their nature and synthesis, they are often a great challenge to print successfully which in turn affects their microwave properties. Hence, determining the optimum printing strategy and settings is important to advance this area. The manufacturing study presented in this paper shows the impact of the main process parameters: printing speed, hatch spacing, layer height and material infill, during 3D printing on the relative permittivity (ε_r), and loss tangent (tanδ) of the resultant additively manufactured test samples. A combination of process parameters arising from this study, allowed successful 3D printing of test samples, that marked a relative permittivity of 9.06 ± 0.09 and dielectric loss of 0.032 ± 0.003. Full article

Existing studies on infill patterns have tended to focus on pattern design rather than on geometric parameters. During this study, we propose a new controlling method focused specifically on the geometric parameters of infill patterns. The input parameters of this method can be used to create 3D printed objects with more lightweight interiors. The presented approach partitions a region of an object with user-specified distance inputs that are used to create infill pattern elements. Moreover, the proposed method will enable the generation of new design variations derived from a single pattern type with similar topologies and varying geometric parameters. The hexagonal pattern variations comprising regular and irregular elements have been presented. The variations of infill pattern design are useful for creating more lightweight and stronger 3D fabrications. The proposed approach is applicable for many different patterns, including linear pattern designs. The goal of this study is to devise a more cost-effective method of creating 3D-printed objects through the application of customizable infill patterns. Full article

The resilient modulus represents the subgrade soil stiffness, and it is considered one of the key material inputs in the Mechanistic Empirical Pavement Design Guide (MEPDG). The resilient modulus is typically estimated in the laboratory using a repeated load cyclic triaxial test, which is complex and time consuming to perform. Technical ability is also required to prepare the test specimens, particularly for coarse-grained soils. Therefore, there is a need to estimate the resilient modulus of coarse-grained soils from other simpler tests. In this study, correlations of resilient modulus with soil index properties and quick shear (QS) test results (quick shear strength, stress at 1% strain and tangent modulus) were developed for remolded coarse-grained soils, collected from different geographic regions in South Carolina. The developed models showed good correlations of resilient modulus to tangent modulus and soil index properties. The average tangent, modulus obtained from 30% and 50% of maximum stress of the QS tests, moisture content, optimum moisture content, dry unit weight, and maximum dry unit weight showed a statistically significant effect on estimating the resilient modulus for coarse-grained subgrade soils. The validation study confirms that the developed models can be used for predicting the resilient modulus for South Carolina coarse-grained soils. Full article

Additive manufacturing (AM) has become more important and common in recent years. Advantages of AM include the ability to rapidly design and fabricate samples much faster than traditional manufacturing processes and to create complex internal geometries. Materials are crucial components of microwave systems and proper and accurate measurement of their dielectric properties is important to aid a high level of accuracy in design. There are numerous measurement techniques and finding the most appropriate method is important and requires consideration of all different factors and limitations. One limitation of sample preparation is that the sample size needs to fit in the measurement method. By utilizing the advantage of additive manufacturing, the material can be characterized using different measurement methods. In this paper, the additive manufacturing process and dielectric measurement methods have been critically reviewed. The test specimens for measuring dielectric properties were fabricated using fused filament fabrication (FFF)-based additive manufacturing and were measured using four different commercial dielectric properties measurement instruments including split post dielectric resonator (SPDR), rectangular waveguide, TE_01δ cavity resonator, and open resonator. The measured results from the four techniques have been compared and have shown reasonable agreement with measurements within a 10 percent range. Full article

We demonstrate a 3D printed holographic metasurface antenna for beam-focusing applications at 10 GHz within the X-band frequency regime. The metasurface antenna is printed using a dual-material 3D printer leveraging a biodegradable conductive polymer material (Electrifi) to print the conductive parts and polylactic acid (PLA) to print the dielectric substrate. The entire metasurface antenna is 3D printed at once; no additional techniques, such as metal-plating and laser etching, are required. It is demonstrated that using the 3D printed conductive polymer metasurface, high-fidelity beam focusing can be achieved within the Fresnel region of the antenna. It is also shown that the material conductivity for 3D printing has a substantial effect on the radiation characteristics of the metasurface antenna. Full article