Optimization Studies

You know what you need to achieve for your design to succeed. Slightly lighter, stronger, lower cost, more efficient design isn't good enough. Your product design needs to be just right. That used to be a pretty arbitrary statement, but through the use of behavioral modeling algorithms built into Pro Engineer and SolidWorks design optimization has become the new standard.

Our team made great use of design optimization studies while designing a peripheral video game controller for the Wii console. Game controllers need to be as light as possible since they are used for sometimes extended periods of time by people of all ages. And the design needs to be optimized for cost. The issue with this particular device design was that it could measure how hard you pushed or pulled on the handles up to 250 lbs. This combined with the fact that the handles had to move when you pulled on them guaranteed the need for some kind of metal structure inside the controller to carry the load. This is a classic technical contradiction, the product needs to be very strong and yet as light as possible and optimized for cost.

We began by brainstorming three different conceptual design directions for the load supporting frame. A combination of hand calculations and finite element analysis helped us narrow in on the most promising design. We then set up optimization studies where the computer was allowed to change certain key dimensions of the structure, evaluate the strength, stiffness and weight and then iterate. All the while we were weighing design optimization cost of goods implications. For this particular model the software could run through thousands of combinations of dimensions to find the optimum design over night. When we returned in the morning we had a sheet metal frame that was as light as it could possibly be while maintaining strength and rigidity. This also turned out to be doable at an acceptable cost.

In another recent project we did design optimization cost and performance analysis for the City of Philadelphia. The city recently set out to make the visitors experience the best it can be by creating a new series of transit portals to identify the many entrances to the underground subway system. These new portals must be optimized to meet safety standards to protect against storm damage, while still providing the visual access to be effective landmarks for tourists. Using the tools of Pro/E, a design optimization model was developed to maximize sign visibility, reduce excess material, and meet all required standards.

There are many types of design optimization studies that may be required for a new product, but in general they fall under the heading of design optimization cost reduction. The reason that you might want to optimize the strength to weight ratio is ultimately to provide the greatest function for the lowest cost.

Alternatively you may want to perform a size optimization; perhaps slightly higher cost is acceptable if the user enjoys a smaller product. Each of these variables can either be optimized individually or they can be combined into multi-objective design optimization studies using state of the art Monte Carlo methods. At the end of the day you truly get the best design possible.

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