Cost Minimization for the Planet Carrier by Optimizing the Topology

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Cost Minimization for the Planet Carrier by Optimizing the Topology

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27 Oct 2009 ... Cost Check. Job Definition. Gear box. Gear box. Flender catalog for planetary gear boxes. Two planetary stages and one spur wheel stage.

Cost Minimization for the Planet Carrier by Optimizing the Topology 3rd European HyperWorks Technology Conference Ludwigsburg, 03. Nov. 2009 © Siemens AG 2009. All Rights Reserved.

Gear box Gear box

Flender catalog for planetary gear boxes

Job Definition Cost Check

Introduction of a new optimization software

Optimization Model

Two planetary stages and one spur wheel stage

Result Benefit

Page 2

2009-10-27

© Siemens AG 2009. All Rights Reserved. Industry Sector

Job Definition Gear box

What do we know about the optimization potential ?

Job Definition Cost Check Optimization Model

Past:

Experience

Present: Experience, simulation, computer-assisted optimization (OptiStruct)

Result Benefit

Cutting treatment

Source: Flender Page 3

2009-10-27

Casting technology

© Siemens AG 2009. All Rights Reserved. Industry Sector

Cost Check Gear box

Total cost of the gearbox

Job Definition Cost Check Optimization Model Result Benefit

Raw material represents 1.5% of the whole gearbox Cost reduction by reducing the amount of raw material is unimportant However – we may be able to optimize Æ weight Æ stiffness Page 4

2009-10-27

© Siemens AG 2009. All Rights Reserved. Industry Sector

Topology Optimization – What is it? Gear box Job Definition

“A CAE tool to create ideas in the development process” Used: OptiStruct software

Cost Check Optimization Model Result Benefit

Source: Altair Engineering

Method: change finite elements by density 100 % density solid material (red) Page 5

2009-10-27

0 % density no material (blue) © Siemens AG 2009. All Rights Reserved. Industry Sector

Model Gear box

Main problem: Misalignment of the planet axis

Job Definition

Æ worsens the teeth contact

Cost Check

Æ reduces the lifetime of bearings and teeth

Optimization Model Result Benefit

Page 6

2009-10-27

© Siemens AG 2009. All Rights Reserved. Industry Sector

Model Gear box

Designed space consists of finite elements

Job Definition

Designed space (blue)

Cost Check

Non-designed space (red) Æ not changeable

Æ changeable

Optimization Model

Cyclic symmetry

Result

Linear computation model

Benefit

Page 7

2009-10-27

© Siemens AG 2009. All Rights Reserved. Industry Sector

Model Gear box

Boundary conditions:

Job Definition

Specified force & torque

Cost Check Optimization Model

Results:

Result

Misalignment of planet axis

Benefit

Volume

3 different kinds of optimization: Minimize volume by specific misalignment of planet axis Minimize misalignment of planet axis by specific volume (30%) Minimize misalignment of planet axis by specific volume (50%)

Page 8

2009-10-27

© Siemens AG 2009. All Rights Reserved. Industry Sector

Results Gear box Job Definition Cost Check

The results are not digital - one or zero! It’s all about density distribution 0.0

0.1

0.3

0.9

Optimization Model Result Benefit

Page 9

2009-10-27

© Siemens AG 2009. All Rights Reserved. Industry Sector

Layout A Gear box

Target: minimize volume by a specific misalignment of planet axis

Job Definition

Weight (raw material): -12%

Cost Check

Misalignment of planet axis +30%

Optimization Model Result Benefit

Page 10

2009-10-27

© Siemens AG 2009. All Rights Reserved. Industry Sector

Layout B Gear box

Target: minimize misalignment of axis by specific volume (30%)

Job Definition

Weight (raw material): +3%

Cost Check

Misalignment of planet axis: -5%

Optimization Model Result Benefit

Page 11

2009-10-27

© Siemens AG 2009. All Rights Reserved. Industry Sector

Layout C Gear box

Target: minimize misalignment of axis by specific volume (50%)

Job Definition

Weight (raw material): +26%

Cost Check

Misalignment of planet axis: -36%

Optimization Model Result Benefit

Page 12

2009-10-27

© Siemens AG 2009. All Rights Reserved. Industry Sector

Comparison Gear box Job Definition Cost Check Optimization Model Result Benefit

Page 13

2009-10-27

© Siemens AG 2009. All Rights Reserved. Industry Sector

Benefit Gear box Job Definition Cost Check

Benefit of this analysis:

Optimization

The carrier in our current products is in excellent shape

Model

Rules for design

Result

First experience gained in Siemens MD

Benefit

Page 14

Future: apply in other areas - (gearbox housing…)

2009-10-27

© Siemens AG 2009. All Rights Reserved. Industry Sector

Dr. Torsten Bunge Siemens AG, Mechanical Drives Research and Developement Department Alfred-Flender-Straße 77 46395 Bocholt, Germany Phone: 02871/92-2046 Fax: 02871/92-1500 E-Mail: [email protected]

© Siemens AG 2009. All Rights Reserved.