Some reports on real optimization projects are given below. To view these projects, please click on the "Read more".
We tried to describe the key steps of optimization process in every project description.
There are three examples of optimization based on real projects:

1. Tower optimization

Read more
Customer: Italian company Drillmec S.p.A.Object of optimization: The tower of mobile unit (see Fig. 1).The unit is intended for carrying out of technological operations during drilling, well development, repair, running and pullingout of tubing strings and drill strings.Fig.1 – Object of optimizationGoals of optimization: It is necessary to reduce the tower weight and preserve its strength.Parameters of optimization: Geometrical structure of tower, parametres of beams (14 parametres in total). It means that to reduce the weight of the tower we can modify its structure and beams parameters.Process of simulation:a. We created the 3D parametric model of the tower with the famous finite element analysis software ANSYS (Fig. 2);Fig.2 – 3D model of tower in the ANSYS systemb. Every type of beam has its identification number. Besides, every type of beam has a set of geometrical parametres according to its ID number (Fig. 3 and 4);Fig.3 – Types of beams their identification numbersFig.4 – Types of beams with their geometrical parametres and ID numbersc. We created two configuration parametres of tower. These parametres change the number of sections in the tower structure (Fig. 5 and 6);Fig.5 – The configuration parameter n1Fig.6 – The configuration parameter n2Now, to get any configuration of the tower in ANSYS software the user must modify the tower parametres. We calculated the number of possible alternate designs of the tower construction – it is 210000000000000000000000.d. We created four calculations models according to various loading conditions (Fig. 7,8,9,10).Fig.7 – The wind pressure (frontal direction)Fig.8 – The wind pressure (lateral direction)Fig.9 – Pulling out modeFig.10 – Installation modeIntegration with optimization technology:We performed integration of four calculation models (Fig. 7,8,9,10) with the optimization software – IOSO NM (Fig. 11).Fig.11 – The optimization schemeEach model has an input file with geometrical parametres of the tower and an output file with the results of simulation. During the first stage the IOSO NM starts calculation for all models; the models perform necessary simulation and create output files with results. During the second stage the IOSO NM performs analyses of output files and modifies parameters (change 3D model of the tower) in input files. Then this cycle repeats many times until optimal solutions are found.The best solution was found for 380 iteration (Fig. 12)  but we cannot show you the 3D image of the best solution because we have no rights:Fig.12 – Weight reduction graphAs a result, we reduced the tower weight by more than 27%!Interesting facts of this optimization: 14 independent parametres
 10 restriction (constrains)
 210000000000000000000000 possible alternate designs of the tower construction
The best solution of tower construction was found for 380 iteration – but just imagine, how much time it iakes the designer of the tower to find the best solution out of 210000000000000000000000 possible alternate designs without our help? – we can say thousands of years......this is the reason why you should think about our services!

2. Heat exchanger optimization

Read more
Customer: The «Amkodor» holding (is one of the leading companies for the production of special type of machinery in CIS countries).
Object of optimization: The Heat exchanger is used in grain cleaning and drying complex. Heat exchanger transfers heat from the hot gas (which comes from the burner – red lines) to the cold gas (which comes from the atmosphere – blue lines). The hot gas flows through a set of pipes. The cold gas flows around these pipes (Fig. 1):Fig.1 – Object of optimizationGoals of optimization: Number, arrangement and diameter of pipes affect the power and the efficiency of the heat exchanger. It is necessary to find optimal solutions.Parameters of optimization: Number, arrangement, pipe diameter.Process of simulation:a. We performed analysis (of heat transfer process) of the basic construction in FlowVision software (Fig. 2,3,4);Fig.2 – Temperature diagram (3D view)Fig.3 – Temperature diagram (central plane)Fig.4 – Temperature diagram (transversel plane)b. We created 3D parametrical model of the heat exchanger with Autodesk Inventor software (Fig. 5);Pict.5 – Sketch of transverse plane with names of parametres (Autodesk Inventor software)We created identifier names (parametres) for all dimensions and made a table of these parametres  some of them have equations (Fig. 6).Fig.6 – Table of parametres in Autodesk Inventor softwareNow, the user can change a nominal value of parametres in the table, and the heat exchanger configuration is modified as well (Fig. 7).Fig.7 – How the use can modify the configuration of the heat exchanger in the Autodesk Inventor software using the table of parametres (the modified parameters are shown in blue)Integration with optimization technology:Fig.8 – Optimization diagramDuring the first stage the IOSO NM launches the AutoDesk Inventor software, and a 3D model of the heat exchanger is created. During the second stage the FlowVision software performs necessary simulation of the heat transfer process. During the third stage the IOSO NM performs analysis of the simulation results and modifies a 3D model of the heat exchanger. Then this cycle repeats many times until optimal solutions are found.The examples of the heat exchanger configuration created during the optimization process are given below  you can see results of some iterations of optimization (Fig. 9,10,11,12,13).Fig.9Fig.10Fig.11Fig.12Fig.13As a result, we increased the power of the heat exchanger by more than 71%! – but we cannot show you the 3D view of the best solution because we have no rights.

3. Gear optimization

Read more
Customer: OJSC "Minsk Tractor Works" (about 810 % of the world market of wheel tractors)Object of optimization: Spur gears from gear box.Goals of optimization: It is necessary to increase contact ratio and reduce specific sliding of the gear pair. These goals will make it possible to reduce noise in the gear and increase its durability.Parameters of optimization: Coefficient of displacement, module, number of teeth, addendum factor.Constrains of optimization: It is necessary to preserve center distance, strength, gear ratio.Process of simulation: We used the Autodesk Inventor software to calculate the gear pair (see Fig. 1,2).Fig.1 – Calculation of the gear basic design in the Autodesk Inventor softwareFig.2 – Basic design meshIntegration with optimization technology: we integrated the calculation model (Autodesk Inventor software) with the IOSO software.Fig.3 – The diagram of optimizationThe best solution was found for 725 iteration (Fig. 4) – you can see the difference between basic and optimal designs – Fig. 5.Fig.4 – Contact ratio (e_alfa) increase graph during optimization iterations
Fig.5 – Difference between basic and optimal designs
As a result, we increased the contact ratio of the gear by more than 50%! – in means that a large number of teeth are engaged, the noise is reduced and the durability is increased.
Thus it is an algorithm of optimization that we use in any optimization project:
 Determination of goals and criteria of optimization – i.e. what object characteristics must be improved?
 Determination of parametres (variables) of optimization and constrains – i.e. what can be changed in your object?
 Simulation of real physical process in the object or system with mathematical models or engineering applications (for example, 3D CAD, CFD or FEA software) – i.e. we perform analysis of the object functional purpose.
 Integration of mathematical models or engineering applications with optimization technology – i.e. we customize the optimization process.
 Control of the optimization process.