Using optimization to optimally interface different components with many parameters.

Not infrequently, combining optimally-engineered components leads to overall suboptimal results. Such a situation was faced by this industrial good supplier when having to design the mechanical connection between two key components for many product variants of a new product family.

As the new product was a step-changer for the company, the old design rules regarding this engineering tasks were not valid anymore. Furthermore, due to less stringent overall requirements, the past rules-of-thumb embedded larger safety margins with a negative impact on product cost.

An engineering optimization strategy was developed by Isaak Tsalicoglou for this design challenge. Following initial CAD modeling to determine an appropriate parameterization, the optimization strategy relied on a fast computational model of the connection interface and aggressive targets to reduce the overall size (and therefore also the overall cost).

Thanks to the positive results in a short timeframe with very low engineer effort, this automated design loop was established productively across all product lines. The resulting Python code VdrWOpt (Verdichterrad-Welle-Optimierung) is proprietary.