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Abstract
Robustness optimization to enhance the reliability of an engine mounting system (EMS) is necessary in the decoupling
design of the EMS, because the stochastic factors or uncertainties will have a significant influence on the decoupling state
of the system and decrease the reliability of the system. This paper carries out the robustness optimization on the
decoupling design based on torque roll axis decoupling theory. After building the dynamic model of the EMS, the con-
straints and objective functions of the optimization are improved by the principle of Six Sigma. A complete process of
robustness is built and the examples for three different types of EMS are calculated and analyzed. The results show that
the quality levels have been enhanced by the robustness optimization, which means the design of EMS is more reliable
than deterministic design. Although the degree of the decoupling state lowers slightly, by taking all the performance of
the system into consideration, the decrease of decoupling is acceptable and the robustness design is valuable in the real
engineering.
Keywords
Robustness optimization, engine mounting system, Six Sigma, torque roll axis, decoupling
and Singh’s work by taking non-proportional damping adapted in this paper, the optimization process is also
and compliant base into consideration and made the effective for the design with other quality level.
model of NVH more authentic.5–7 Wu and Liu dis-
cussed the effect of damping and compliant base by
Six Sigma optimization method
analyzing and comparing three typical models,8 and the
decoupling condition illustrates that the TRA decou- Figure 1 shows that deterministic optimization is
pling method is effective for all these models. These always close to the constraint boundary, which leads to
studies, which are based on Geck and Patton’s early high risk of failure when the design variable gets a
research on engine mount optimization, 9 have illu- small change. The goal of the robust optimization
strated that the TRA decoupling method can obtain a design is not only to optimize the performance, but also
more thorough decoupling state and even a theoretical to desensitize the performance to the fluctuations of
complete decoupling for an EMS. the design variables.2 A robustness solution may not
However, in reality, the parameters of the mounting lead to the best performance, but it possesses both high
components are difficult to be exactly realized due to reliability and relatively good performance.
some uncertain reasons in manufacture and assembly. The Six Sigma method is one of the robustness opti-
For example, the stiffness of the mounting components mization methods, where sigma refers to standard
may fluctuate around a certain value due to the instabil- deviation s. It brings the probabilistic model into the
ity of the rubber materials, and the real location of the optimization model in the beginning of the design, and
mounting may be different from the optimal value evaluates the reliability of the system by measuring the
because of installation errors. These uncertainties may probability distribution of performance index around
have a significant influence on the decoupling state of the mean value.14–16 Generally, it can be assumed that
the system, so the fluctuation of the parameters should the parameters of the system conform to normal distri-
be taken into consideration to make the optimization bution. Thus, the probability of failure, which can
model more authentic and reliable. Obviously the reflect the reliability of the system, is related to the s
robustness optimization of the EMS is critically neces- level
sary. Studies have been done about the robustness of an As shown in Figure 2, different sigma levels repre-
EMS and some progress has been achieved. The sent different probabilities of normal distribution.
research of Sirafi and Chang on the robustness of For example, 3 s is equivalent to a probability of
mount system did a valuable analysis about the NVH 99.73%, and 6 s is equivalent to the probability of
performance on idle condition.10 The optimization 99.9999998%. So 6 s represents a very high probability
method used in their paper was well studied by Jiang that the objective function value is in feasible region
et al.,11 who did research about the programming even in a long term or massive production.
method for uncertain optimization problems, and Qiu
and Wang,12 who compared the dynamic response of
structures with uncertain non-probabilistic interval
analysis method and probabilistic approach. The
research of Vochteloo et al. about a multidisciplinary
optimization method was also a great supplement of
robustness optimization.13
This paper aims at the application of robustness
optimization on TRA decoupling. Three typical kinds
of EMS are used to validate the method. The best com-
bination of parameters of the mounting components
can be obtained by the TRA decoupling process. After
conducting the Six Sigma analysis, it is found that the
Figure 1. Process of deterministic optimization and robustness
reliability of the original system is pretty low. So the
optimization.
robustness optimization is carried out on the determi-
nistic optimized system. First, the sensitivity analysis is
made to choose the most influential parameters as the
optimization variables. Then the Six Sigma optimiza-
tion process is carried out by Isight software and new
optimum parameters are obtained. Finally, the quality
level and frequency response functions (FRFs) of the
new EMS are calculated to compare with the determi-
nistic optimized system. The results show that although
the decoupling state of EMS is slightly damaged, the
reliability of the system get enhanced, which makes the
design more feasible. Although Six Sigma principle is Figure 2. Probability of different levels of s.
Wu et al. 3
Undamped EMS with rigid base model However, after carrying out Six Sigma analysis on
First, for the example of undamped EMS with rigid the deterministic optimized system, it is found that the
base denoted as Model A, the mass matrix is4 quality level (Figure 8) of the system is only 1.683s,
which is much smaller than 6s, indicating that the sys-
2 3
73:2 0 0 0 0 0 tem has low reliability.
6 0 73:2 0 0 0 0 7 Therefore, it is necessary to apply the robustness
6 7
6 0 0 73:2 0 0 0 7 optimization to the system to enhance the reliability of
M=6 6 7
6 0 0 0 1:94 0:129 0:415 77 the design. Before the optimization, a Mont Carlo anal-
4 0 0 0 0:129 3:43 0:073 5 ysis is applied to the system to test the sensitivity of the
0 0 0 0:415 0:073 3:39 parameters. The result is shown in Figure 9, and in this
ð9Þ model the most sensitive parameters x, y1, y2, y3, y4, kx,
and kz are chosen as the design variables of the robust-
Based on TRA decoupling theory, the deterministic ness optimization. Here, x is the X coordinate of the
optimization is carried out on Model A, the optimized mounting component, y1, y2, y3, and y4 are the Y coor-
values of the stiffness and coordinates of the mounting dinates of the first, second, third, and fourth mounting
components are obtained and listed in Table 1. components, and kx and kz are the stiffnesses of the
With the deterministic design of the EMS, the FRF mounting components in the X and Z directions.4–6
(Figure 7) can be calculated and the results show that In the Isight software, the Six Sigma optimization is
the responses in other directions are much smaller than carried out on the system with the constraint of 6 s
the response in ux direction, which means that the sys- quality level. The result is shown in Figure 10 and a
tem is well decoupled. comparison of the parameters with those from the
6 Proc IMechE Part D: J Automobile Engineering 00(0)
x 0.2518 0.4378
y1 0.1713 0.1772
y2 0.1824 0.1180
y3 0.1491 0.1008
y4 0.1446 0.1726
kx (3106) 9.3499 10.5318
kz (3106) 3.6774 3.6505
Table 5. (a) Stiffness and damping of components in Model C. (b) Coordinates of components in Model C.
(a).
(b)
Direction X Y Z
After robustness optimization and recalculating FRFs the robustness of the system has been enhanced a lot.
of the system, a comparison of the parameters with the The 6s constraint is satisfied for each objective function
deterministic optimization is listed in Table 6, and con- and the FRFs are very close to Figure 17. The result is
clusions can be obtained from Figures 20 to 21 that the even better than both Model A and Model B, which
decouple state of the system remains good enough while means this design is also effective in a real situation.
Wu et al. 11
The three examples above take different factors into Declaration of conflicting interests
consideration for the EMS models, such as non- The author(s) declared no potential conflicts of interest
proportional damping and compliant base, and the with respect to the research, authorship, and/or publi-
similar optimization process is carried out. From above cation of this article.
results, some conclusions about the robustness optimi-
zation can be obtained, which may provide an impor-
tant guidance to the engineering design. Funding
The author(s) received no financial support for the
research, authorship, and/or publication of this article.
Conclusions
In this paper, the robustness optimization is combined ORCID iD
with TRA decoupling method to enhance the reliability Xiandong Liu https://orcid.org/0000-0002-0111-3221
of the decoupling design of EMS. Firstly, on the basis
of TRA decoupling theory, some improvements are
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