A generalized framework using hardware-in-evaluation-loop for design optimization

This paper presents a generalized framework using sensing, actuation and control hardware in an evaluation loop (HEL) for optimizing product/equipment designs where intervention utilizing human experience (and/or knowledge) is desired. Formulated using power variables, two practical applications covering multi physic (mechanical, electrical, magnetic and fluid) domains are demonstrated. The first illustrates a HEL with a ball-joint-like permanent-magnet spherical motor (PMSM) as a haptic device enabling a designer to realistically feel engaging forces/torques of a virtually simulated snap-fit disassembly. As a media for converting electrical to mechanical energy, measured magnetic fields in the PMSM is utilized enabling the designer to simultaneously sense the motion and torque feedback in real-time without additional dedicated sensors to derive a good evaluation. The second example extends the HEL application to optimize a fluid system design, where the interest is to minimize hydraulic energy losses. Along with an experimental prototype in the evaluation loop, algebraic solutions are used to calculate losses (against which the experimental measured data are compared) providing a basis for minimizing hydraulic energy consumption.