FAST OPTIMIZATION OF A LINEAR ACTUATOR BY SPACE MAPPING USING UNIQUE FINITE ELEMENT MODEL Stphane VIVIER, Didier LEMOINE,

Guy FRIEDRICH Senior member

Laboratoire dElectromcanique de Compigne (LEC) Universit de Technologie de Compigne (UTC) Centre de Recherche de Royallieu B.P. 20529 Rue Personne de Roberval 60205 Compigne - FRANCE stephane.vivier@utc.fr
Abstract This paper focuses on the optimization technique of a linear actuator by computer means. The authors sought to minimize the time required for this optimal design. In addition to the sole efficiency of optimization methods, strictly speaking, the time development of the models was taken into account. This approach leads to an original and effective methodology. Index Terms Optimization method, Finite Element method, Actuators, Numerical models

I.

INTRODUCTION

This article presents the methodology used for the optimization of the main characteristics of a resonant linear actuator. Firstly, a general presentation of the machine its geometrical aspects and expected performances is achieved. In order to improve the output characteristics of this actuator, the optimization method, called Space mapping, is then applied. This algorithm uses two models of the same machine, which are different by the precision of their results. The innovation brought by this work, lies in the exclusive and intensive use of a single finite element modeling, for which it is possible to adjust the precision of its results. This approach, coupled with the efficiency of the optimization method itself, demonstrates many advantages, such as, mainly, the important reduction of the overall time for the optimization process. II. PRESENTATION OF THE ACTUATOR

The geometry of the actuator is sketched in Figure 1. The actuator has an axisymmetric configuration. It is composed of two coils (lower and upper ones), fed separately. The cross section of the fixed part adopts an E shape, symmetrical with the horizontal median plane. The mobile part is a ring with a trapezoidal cross section. It is free to move linearly and vertically. It is linked to the diaphragm and to one or two springs. The geometry can be entirely defined by eight parameters. Table I gives their variation bounds. From these limits, it becomes possible to deduce (arbitrarily) a set of reference values, used for the definition of the first not-yet-optimized configuration of the actuator. The corresponding principal characteristics are given in Table II.
TABLE I DEFINITION PARAMETERS FOR THE ACTUATOR GEOMETRY Lo. Up. Ref. Name Unit Description bd bd val. h 50 150 80 mm Total height lmi 0.5 30 10 mm Width of internal branch lme 0.5 30 10 mm Width of external branch Height of peripheral hmi 0.5 30 10 mm branches lmc 0.5 30 20 mm Width of central branch hmc 0.5 30 20 mm Height of central branch Height of inner side of ha 0.5 30 20 mm ring Angle of displacement 0 75 45 deg airgaps TABLE II REFERENCE CHARACTERISTICS OF THE ACTUATOR Name Value Unit Description Mring 0.430 kg Mass of the ring Mtot 7.1 kg Total mass of actuator Ftot 320 N Electromagnetic force Pmoy 904 W Average power Pmoy/Vtot 0.74 kW/l Ratio mean power / volume TABLE III MAIN REQUIRED SPECIFICATIONS +/- 4 mm Movement amplitude Frequency f0 200 Hz Maximal force (median position) 360 N Diaphragm (membrane) mass 28 g

In order to illustrate the originality of the optimization process presented in this paper, one will consider the application example of a resonant linear actuator, typically used in diaphragm pumps [1]. This linear configuration was chosen to suppress the main drawbacks of classical rotating motors coupled with movement transformation systems like cams [2-3]. The installation of this actuator is envisaged inside an embedded system (a car for example); hence, this machine should present small overall dimensions, while keeping good motive performances. The typical expected specifications are gathered together in Table III. The optimization process will seek to find the best geometrical dimensions, to obtain these performances.

If the actuator is used within an embedded automotive application, it appears clearly that its mass is too important

978-1-4244-5287-3/10/$26.00 2010 IEEE

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(7.1 kg). Moreover, the mass of the mobile ring is also big, and may limit the dynamic performances expected. For the use by an optimization algorithm, such as Space Mapping methods, the actuator presented previously is now considered from the mathematical point of view. This is the modeling stage. This paper presents results coming from models based on magnetostatic relations coupled with electrical and mechanical equations.

they must remain representative of the general characteristics and physical behavior of the actuator. The second model, generally called fine model, must be designed in order to give reference results. These results give the possibility to automatically correct, at regular intervals, the output values of the traditional optimizations carried out using the coarse model, introduced previously. Hence, the Space Mapping approach corresponds to an automation of the optimization-correction procedures, which are generally hand-made. Moreover, an important aspect concerns the judicious use of the resources: fast models are used for optimizations only, whereas fine models are used to readjust the previously obtained optimization results. It should be noted that no proof of convergence has been established for this algorithm. However, its (easy) application has proved its effectiveness and reliability. The additional effort initially required for the development of the two models is recovered in a certain way, by the increase of the research efficiency for the optimal conditions. The operating procedure of the optimization algorithm by Space Mapping being well defined, the nature of the (coarse and fine) models remains to be specified.
2- Determination of reference xi

Fig. 1. General building configuration of actuator

1- Optimization x0 Coarse model i=argmin(i) xi, ci

Fine model

III. SPACE MAPPING METHODS The method used for the research of the best building characteristics of the actuator, belongs to the Space Mapping method family. These techniques have in common their principle of functioning: the simultaneous and coordinated use of two models of the same system. These 2 models differ by the precision of their results. Output Space Mapping Method The algorithm retained in this study is often called Output Space Mapping. Its operating mode is summarized by Figure 2. From initial values (x0), an optimization is carried out by using a first model (any good optimization algorithm can suit). The result of this optimization (ci) is then checked, and possibly corrected, by that (fi) obtained thanks to the evaluation of a second reference model, for the solution configuration (xi) found previously. This readjustment consists in weighting (i) the outputs of the first model so that they agree with the corresponding outputs of the second model. This general procedure is repeated as long as it is possible to improve these values, with regard to fixed objectives. The first model, described as a coarse model, must be built in order to quickly give the calculated performances of the actuator. This model is used in an intensive way by a traditional optimization algorithm, based for example on the SQP (Sequential Quadratic Programming) algorithm. The results given by this model do not have to be precise, but A.

fi

xi, ci

i=fi-ci 3- Correction of coarse model with reference value

Fig. 2. General diagram of the Output Space Mapping algorithm

B.

Usual modeling approaches The choice of the types of models must conform to the requirements presented in the preceding paragraph; to summarize, one needs: a (very) fast coarse model, representative of the operating behavior of the actuator; a fine model giving reference results. Typically, in the context of design and optimization of actuators by computer means, and within the framework of magnetic modeling, the fast model corresponds to a reluctance network (more seldom to explicit and purely analytical relations), whereas the reference model consists of a finite element (FE) modeling. This approach suffers from the major disadvantage to require the construction of two models of two different types, which must be evaluated thanks to two different dedicated programs. Thus, in addition to the doubling of the adjustment time of the models, this solution demands a greater diversity of resources. One can partly correct this drawback, by exploiting two reluctance networks (of the same actuator) [4], the difference

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between them being characterized for instance by the number of flux paths taken into account (typically concerning leakage flux), and by the accuracy of the reluctance formula implemented. Within this framework, a model can be deduced from the building of the other one; hence, the doubling of time is partially cancelled. Moreover, the same circuit analysis computer program can be used for the solving of the two networks. This approach still has weaknesses, whose main ones are: the lack of accuracy of the results given by the methods using lumped parameters (components), such as that of the magnetic equivalent circuits (MEC); the non-negligible time for the construction of the two reluctance networks. For these reasons, another solution was used to suppress these drawbacks, as well as possible. New approach for model construction Within the framework of the study presented by this paper, it was made the choice to use only one finite element modeling of the actuator. From this single numerical object, it is then necessary to deduce two derived models with different output precisions, as recommended by the Space Mapping method. Hence, the definition of the finite element model is parameterized, in order to be able to adjust the modeling fineness, and thus the precision of the results. The fineness adjustment can be ensured, for instance, by: a more or less fine consideration of the actuator geometry (simplified curves, etc.); the use of more or less precise techniques for the consideration of special boundary conditions (typically, in the case of open spaces for the consideration of infinity); the precision value requested, for the solution computed by finite element solvers; the definition of the mesh. This last point, in particular, allows tuning the precision of the finite element model, and acts in the same time on the evaluation speed of this model. Indeed, changing the mesh modifies the number of nodes (and elements) and thus modifies the mathematical size of the problem. Logically, one defines the fine model at first; it corresponds to a finite element model using a mesh with a good quality (with a significant number of nodes, with high order finite elements, etc.). The (per length and/or surface unit) node density of the mesh must be parameterized. Thus, a simple change of these parameter values makes it possible to modify the mesh and obtain a simplified and faster model. One will note that, from the point of view of the mesh, this technique allows a quasi-continuous adjustment of fineness (and not only discrete as used in the present study). Figures 3 and 4 represent the two models used in this study. Table IV summarizes their characteristics. C.

Fig. 3. Fine model (up) - Fig. 4. Coarse model (down) TABLE IV COMPARISON BETWEEN THE 2 FE MODEL CHARACTERISTICS Characteristics Fine model Coarse model Number of nodes 6830 77 in mesh Number of elements 3366 142 in mesh Type of element Triangular 6 nodes Triangular 3 in mesh (T6) nodes (T3) Technique used for Kelvins Asymptotic infinity consideration transformation conditions FE solving time 3.1 s 0.033 s Building time 4.3 s 0.068 s + solving Example : Generated force on the ring in median position 5364 N 5449 N

Ratio 1/89 1/24 1/94 1/63

One can see that the simplification of the fine model in order to obtain the coarse one is very important. However, it is such a way that the representativeness of the model is preserved with respect to the vertical thrust force. With respect to this goal, the mesh was lightened everywhere, except inside the airgaps (principal location of magnetic energy). It appears also clearly that the evaluation time of the coarse model is very small: it is possible to compute 15 finite

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element simulations per second, on average. Clearly, this model can be used in intensive optimization processes. IV. ACTUATOR OPTIMIZATION Characteristics expected One seeks to improve all the output characteristics of the actuator, i.e. to increase the generated force (Ftot) and the power/total volume ratio (Pmoy/Vtot), as well as to decrease the main masses (Mtot and Mring). More precisely, one wishes to converge towards the four goals given in Table V. These characteristics must be obtained when the upper coil of the actuator is fed with a constant current density equal to 4 A/mm. This small current feeding allows neglecting, in this paper, all thermal considerations.
GOAL CHARACTERISTICS FOR THE ACTUATOR Pmoy/Vtot Output variable Mring Mtot Ftot Value 0.28 5.1 360 1.2 Unit kg kg N kW/l This value or lower lower upper upper TABLE V

Initial (x0) 0.04 0.03 0.02 0.01 0

A.

-0.01 -0.02 -0.03 -0.04 -0.06 -0.04 -0.02 0 Final (xsol) 0.04 0.03 0.02 0.01 0 -0.01 -0.02 -0.03 -0.04 -0.06 -0.04 -0.02 0 0.02 0.04 0.06 0.02 0.04 0.06

Figure 6. Initial geometry of actuator (up) Figure 7. Final (optimized) geometry of actuator (down)

Optimization results The whole optimization process has been implemented under Matlab by the author: it is an automatic program that encompasses the building of the (unique) FE model according to the eight characteristic dimensions, the creation of the mesh, the solving of the FE model and the calculation of the output values (thrust force, mean power, masses, volumes, etc.). Table VI gives the characteristics of the actuator, given by the optimization method. 5 evaluations of the fine model and 7534 evaluations of the coarse model were necessary to obtain this result (Figure 5). This optimization required 8min 19s. The four goals are fulfilled all together in iteration 5, forcing the algorithm to stop. The optimized configuration is given by Figure 7.
TABLE VI OPTIMIZED CHARACTERISTICS OF ACTUATOR Pmoy/Vtot Output variable Mring Mtot Ftot Value 0.25 5.03 382 1.22 Unit kg kg N W/l

B.

V. CONCLUSION This article concentrated on the description of the concrete application of an optimization technique, called Output Space Mapping, in order to find better dimensions aiming at improving the performances of a resonant electromagnetic actuator. The efficiency of this method is mainly due to the coordinated use of two different models of the same actuator. However, the use of two different models usually implies the doubling of the time necessary for their creation and adjustment. In order to remedy this negative aspect, this article presented a new solution, based on the use of a unique finite element model, whose fineness and therefore the precision of its results is adjustable. This solution has the advantage of strongly shortening the delay between the beginning of the study (creation and correction of the single finite element model of the machine) and the obtaining of the optimization results. VI. REFERENCES [1] Lin, Wang, Howe, A resonant frequency tracking for linear vapor compressors, IEMDC07 Conference, 2007 [2] M. Craven, P. Ramphal, Design of an electromagnetic pump system for training heart cardiac surgery, Proceedings IEEE Southeast Conf, Kingston, pp. 192196, 5-7 Apr 2002. [3] J. A. Hoffmeister, Reliability analysis of pumps for uranium solutions, IEEE Trans. on Reliability, vol. 37, no. 2, pp. 144-148, Jun 1988. [4] S. Vivier, D. Lemoine, G. Friedrich, "Optimal design a high dynamic actuator for diaphragm pumps", IEMDC 2009.

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Fig. 5. Convergence evolution

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