applied
sciences
Article
Optimization of Pile Driver Frame Based on
Sensitivity Analysis
Jinmei Wu *, Yanqing Yang * and Jiameng Hu
Citation: Wu, J.; Yang, Y.; Hu, J.
Optimization of Pile Driver Frame
Based on Sensitivity Analysis. Appl.
Sci. 2023, 13, 4774. https://doi.org/
10.3390/app13084774
Academic Editor: Yang Kuang
Received: 16 February 2023
Revised: 23 March 2023
Accepted: 31 March 2023
Published: 10 April 2023
Copyright: © 2023 by the authors.
Licensee MDPI, Basel, Switzerland.
This article is an open access article
distributed under the terms and
conditions of the Creative Commons
Attribution (CC BY) license (https://
creativecommons.org/licenses/by/
4.0/).
Appl. Sci. 2023, 13, 4774. https://doi.org/10.3390/app13084774
School of Mechanical Engineering, North China University of Water Resources and Electric Power,
Zhengzhou 450011, China; z20211040503@stu.ncwu.edu.cn
* Correspondence: wujinmei@ncwu.edu.cn (J.W.); 15638535693@163.com (Y.Y.)
Abstract: The optimization of the pile driver frame is very important to the overall performance of
the pile driver. This paper examines the large body structure of a model of a hydraulic static pile
driver as the research object. ANSYS APDL finite element software is used to perform static analysis
and sensitivity analysis on the large body structure of the pile driver. On the premise of meeting the
design requirements, according to the most dangerous working conditions of the pile driver, the size
optimization of the frame structure of the pile driver is carried out based on sensitivity analysis. The
mathematical model is established with the plate thickness as the design variable, the strength and
stiffness of the body structure as the constraints, and the minimum mass of the body structure as
the objective function. The optimization results show that the optimization design model based on
sensitivity analysis not only meets the strength and stiffness conditions of the large structure, but
also reduces the structural mass by 22.1% and greatly reduces the production cost.
Keywords: sensitivity; pile driver; frame; ANSYS; optimization design
1. Introduction
In civil engineering infrastructure, the most common form of foundation is the pile
foundation. With the development of the mechanical engineering industry, the quality of
pile pressing machinery has also developed for the better. In China’s economic construction,
pile pressing machinery plays an increasingly critical role. There are various types of
pile pressing equipment. The most common ones are as follows: barrel type diesel pile
hammer, hydraulic pile hammer, hydraulic static pile hammer, hydraulic vibratory hammer,
etc. [1–5]. Compared with other types of pile presses, hydraulic static pile presses have
numerous advantages. First, the hydraulic static pile driver does not greatly affect the
surrounding buildings or environment while working, so it does not cause damage to the
land structure [6]. Secondly, when working, the top of the pile is not easily damaged and
the whole pile body is not subject to bending. During the whole construction process, the
noise and the vibrational impact on the ground can be ignored. Since the hydraulic pile
driver is hydraulically driven, linear motion is easily achieved and the power utilization
rate of the entire device is extremely high [7]. Finally, since the hydraulic apparatus has
been kept in a relatively steady state during the operation, it is not difficult to achieve a
stepless velocity regulation during the motion or over a wide range. As the manufacturing
industry has developed, hydraulic components have also become more standardized, it
has also become a more versatile part.. Hydraulic static pile drivers gradually became
used in civil engineering, as they were more convenient for automated operation and
protection against overload [8]. The hydrostatic pile driver is a piling machine that uses
static pressure to press piles into various substrates, thus realizing the foundation for
building implementation, as shown in Figure 1.
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Figure1.1.YZY400
Figure YZY400hydraulic
hydraulicstatic
staticpile
piledriver.
driver.

Inrecent
In recentyears,
years, with
with thethe development
development of piling
of piling technology,
technology, hydraulichydraulic
static pilestatic
pressespile
presses
have have
taken taken arole
a pivotal pivotal
in therole in the construction
construction of pile foundations.
of pile foundations. However,However,
with the mod- with
the demands
ern modern demands
of green of green development,
development, energyand
energy saving saving and emission
emission reduction,reduction, light-
lightweight
weight vehicles
vehicles have become have become
a new trend a newintrend in the development
the development of the manufacturing
of the manufacturing industry. in-
dustry. Product
Product “weight “weight
loss” hasloss”become has become the top priority
the top priority for product
for product design anddesign and devel-
development
opment
in in this industry.
this industry. The lightweight
The lightweight design design
not only notenables
only enables efficient
efficient product product
qualityquality
and
and material
material saving saving development
development concepts,concepts,
but also but also guarantees
guarantees productproduct performance.
performance. It is alsoIt
beneficial to enhance
is also beneficial the company’s
to enhance key competitive
the company’s advantages
key competitive and major
advantages anddevelopment
major devel-
policies. In order In
opment policies. to order
occupy to aoccupy
favorable positionposition
a favorable in the international trend oftrend
in the international industrial
of in-
change,
dustrialChina
change, has proposed
China the “Made
has proposed thein“Made
Chinain 2025”
China strategy in the new
2025” strategy international
in the new inter-
environment. “Made in“Made
national environment. China in 2025”
China is dedicated to breaking
2025” is dedicated the situation
to breaking of China’s
the situation of
manufacturing industry being big but not strong, and vigorously
China’s manufacturing industry being big but not strong, and vigorously carrying out carrying out independent
research
independentand development. Domestic scholars
research and development. are working
Domestic scholarshard to achieve
are working andtocatch
hard up
achieve
with the advanced
and catch up with level of the international
the advanced level of themachinery
internationalindustry as soon
machinery as possible.
industry as soon The as
pile driverThe
possible. is an integral
pile driver partis anofintegral
China’spart manufacturing [9]. With the improvement
of China’s manufacturing [9]. With the im- of
computer
provement technologies,
of computermany researchers
technologies, manyhave graduallyhave
researchers mastered somemastered
gradually of the advanced
some of
software programs such as ANSYS, ABAQUS, MATLAB,
the advanced software programs such as ANSYS, ABAQUS, MATLAB, and so on. All ofand so on. All of these programs
can be programs
these used for the optimization
can be used fordesign of mechanical
the optimization equipment.
design The level
of mechanical of mechanical
equipment. The
optimization
level of mechanical optimization in China has started to improve. By usingmethods,
in China has started to improve. By using specific optimization it is
specific opti-
possible
mizationtomethods,
optimizeitmultiple
is possible objectives
to optimizewithmultiple
complexobjectives
linkages at thecomplex
with same time. In this
linkages at
context,
the same the design
time. of pile
In this driving
context, themachines
design ofispile no driving
longer just about achieving
machines is no longer thejust
required
about
strength
achieving and thestiffness
requiredof the structure.
strength and The aim isofalso
stiffness thetostructure.
design mechanical
The aim isequipment
also to designthat
combines safety and economy. Optimal design methods based
mechanical equipment that combines safety and economy. Optimal design methods based on sensitivity analysis have
found applications
on sensitivity in numerous
analysis have found fields [10] such asinautomotive,
applications numerous fieldsaerospace
[10] design,
such asand agri-
automo-
cultural machinery. Tang Jing et al. used the structural parameters
tive, aerospace design, and agricultural machinery. Tang Jing et al. used the structural of commercial vehicle
cabs, using thickness
parameters as design
of commercial vehiclevariables, and applied
cabs, using thickness theassensitivity analysisand
design variables, method
applied to
filter out the best variables to achieve the lightweight goal [11]. Wang Li proposed and
the sensitivity analysis method to filter out the best variables to achieve the lightweight
evaluated a multidisciplinary sensitivity analysis for rotorcraft simulation and applied it to
goal [11]. Wang Li proposed and evaluated a multidisciplinary sensitivity analysis for ro-
the constrained optimization of rotorcraft configuration [12]. Yu Tongtong et al. proposed a
torcraft simulation and applied it to the constrained optimization of rotorcraft configura-
parametric sensitivity analysis of the composite prepreg tape winding process and applied
tion [12]. Yu Tongtong et al. proposed a parametric sensitivity analysis of the composite
it to the establishment of an optimization method for winding process parameters [13].
prepreg tape winding process and applied it to the establishment of an optimization
Liu Qimao proposed to solve the sensitivity by gradient method and applied it to the
method for winding process parameters [13]. Liu Qimao proposed to solve the sensitivity
lightweight design of combined beams [14]. Kiendl, J. et al. proposed a method for the
by gradient method and applied it to the lightweight design of combined beams [14].
geometry optimization of shell structures by applying sensitivity weighting [15]. From
Kiendl, J. et al. proposed a method for the geometry optimization of shell structures by
the literature, it can be seen that the application based on the sensitivity analysis method
applying sensitivity weighting [15]. From the literature, it can be seen that the application
solves the problem of the optimal design of metal structures such as commercial vehicles
based on the sensitivity analysis method solves the problem of the optimal design of metal
and rotorcraft. The optimization of the sensitivity calculation method is also proposed to
structures
increase thesuch as commercial
efficiency vehicles and rotorcraft.
of model optimization. However, thereThe optimization
has been littleofresearch
the sensitivity
for the
calculation method is also proposed to increase the efficiency of model optimization.
Appl. Sci. 2023, 13, 4774 3 of 14

application of pile machinery, especially the metal structure of pile machinery. Therefore,
the use of an optimal design method for the large body structure of the pile press not only
reduces materials waste, but is important to accelerate the realization of the “Made in China
2025” strategy in China.
In this paper, the three-dimensional model of the large body structure of the pile press
is established by using the finite element analysis method. Sensitivity analysis was used
to optimize the design of the large body structure of the pile press, which minimizes the
weight of the large body skeleton structure to meet the strength and stiffness constraints,
thereby reducing the production cost [16].

2. Body Model Structure and Analysis

The large body skeleton structure is a key component of the hydraulic static pile
driver. Specifically, it is the main load-bearing part of the pile driver. Except for the lower
support structure of the pile driver and the walking mechanism, the weight of the rest of
the machine is supported by the large body of the pile driver. It enables the pile driver and
crane to work properly. In this way, it plays a role in the entire structure of the pile driver.
With a large body structure, the motion of the walking and traversing mechanisms will
drive the upper parts that cannot move together. Therefore, the design of the large-body
skeleton structure plays a crucial role in the working performance and operation of the pile
driver.

2.1. Finite Element Model (FEM)

The rapid development of computer technologies has made it possible to use simula-
tion techniques to complete the design and analysis of complex product structures. The
finite element method is based on the principle of variability, and is essentially a numerical
approximation method. It helps to solve complex engineering problems by approximating
the structure as a whole, using a finite number of organic combinations of discrete units.
Since the finite element method has a very clear physical concept, this method is also
highly suitable for more complex structures. At the same time, the calculations of the finite
element method can be implemented by computer and are highly efficient. Currently, the
finite element method is widely used in the study of static structural dynamics, fluid analy-
sis, thermal analysis, electromagnetic field analysis and other problem areas. The use of
parametric finite element modeling techniques for the modeling, analysis, and optimization
of product design is one of the commonly used approaches in engineering practice. A
high-precision model construction based on the finite element analysis method is able to
recover the true model with relative accuracy. The analysis and design of product batches
through parameters considerably improves design efficiency and saves design costs. In
this paper, the ANSYS parametric design language provided by the ANSYS finite element
analysis software is used to perform computer-aided modeling. The finite element model
of the large body structure of the YZY400 hydraulic pile driver is used as the object of study,
and all the performance parameters of the pile driver are shown in Table 1.

Table 1. YZY400 pile driver performance table.

Numerical
Parameter Parameter Numerical Value
Value
Total mass 140 t Crane rated lifting 16 t
Piling capacity 400 t Whole machine size 12.9 × 10.0 × 7.38 m3
Grounding Longship 0.119 MPa Line Longship 3.3 m
specific voltage Shortship 0.127 MPa Size Shortship 0.8 m
Pressing piles Maximum speed 4.7 m/min Stake Square pile 250, 300, 400 mm
Speed Minimum speed 1.3 m/min size Round pile 300, 400, 500 mm

The large body structure of this model of the static pile driver is welded by steel plates
and is a complex space box system structure. In order to ensure that the finite element anal-
ysis is carried out properly and effectively, the original model is simplified appropriately.
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Appl. Sci. 2023, 13, 4774 The large body structure of this model of the static pile driver is welded by steel plates 4 of 14

and is a complex space box system structure. In order to ensure that the finite element
analysis is carried out properly and effectively, the original model is simplified appropri-
ately. Members
Members withoutwithout load-bearing
load-bearing effects
effects were were removed,
removed, details suchdetails such as unnecessary
as unnecessary holes and
rounded
holes andcorners
rounded were simplified,
corners and legs attached
were simplified, and legs to attached
the bulk to structure
the bulk were simplified.
structure were
In this paper,
simplified. Ininthis
order to facilitate
paper, in orderthe optimization
to facilitate analysis of the
the optimization bulk structure
analysis based
of the bulk on
struc-
its properties,
ture based onwe its parametrically
properties, we model it using the
parametrically modelANSYS APDL
it using thepc-software(Mechanical
ANSYS APDL pc-soft-
APDL 2020 R1, ANSYS,
ware(Mechanical APDLUSA).2020 Since the bulk
R1, ANSYS, structure
USA). Sincebelongs
the bulk tostructure
a large thin plate structure,
belongs to a large
with a large difference between the thickness and the rest
thin plate structure, with a large difference between the thickness and the restof the dimensions, the plate
of theand
di-
shell units are
mensions, the chosen
plate andto shell
simulate
unitsactual steel plates
are chosen whenactual
to simulate modeling.
steel The specific
plates when type
model- is
chosen
ing. The from the shell
specific type63is in APDLfrom
chosen [17]. the
During
shellthe
63 finite
in APDL element
[17]. analysis,
During thethefinite
transmission
element
of forces relies
analysis, on the nodesofbetween
the transmission the units.
forces relies on theInnodes
orderbetween
to ensure that
the the In
units. finite element
order to en-
analysis is performed correctly, a proper meshing is particularly important.
sure that the finite element analysis is performed correctly, a proper meshing is particu- Therefore, in
this paper, the model is meshed in the form of free triangles. The meshing
larly important. Therefore, in this paper, the model is meshed in the form of free triangles. of local locations
in
Thethemeshing
model isofshown in Figurein
local locations 2. the model is shown in Figure 2.

Figure2.2.Large
Figure Largebody
bodystructure
structurefinite
finiteelement
elementmodel.
model.

After the
After the establishment
establishment of
of the
the finite
finite element
element model
model ofof the
the large
large body
body structure,
structure, the
the
boundaryconditions
boundary conditionsare areapplied
appliedto tothe
themodel,
model,and
andthe
thestatic
staticanalysis
analysisisiscarried
carriedout
outbased
based
onthe
on theloads
loadsthat
thatthe
thelarge
largebody
bodyskeleton
skeletonisissubjected
subjectedto
toin
inthe
theactual
actualwork.
work.

2.2.
2.2. Static
Static Analysis
Analysis
2.2.1.
2.2.1. Typical
TypicalWorking
WorkingCondition
ConditionSelection
Selection
As
Asshown
shownininFigure
Figure3,3,aahydraulic
hydraulicoil
oiltank
tankand
andcab,
cab,used
usedtotopower
powerthe
thepile
piledriver
driver for
for
pile extraction and pile pressing, are also mounted on the large body skeleton. The
pile extraction and pile pressing, are also mounted on the large body skeleton. The staticstatic
pile
piledriver
driverworks
worksononthe
thepile
pileby
bymeans
meansof ofaapile
pilepressing
pressingmechanism.
mechanism.Hydraulic
Hydrauliccylinders
cylinders
in
in the chassis platform provide the power for the pile pressing and pilepulling
the chassis platform provide the power for the pile pressing and pile pullingaction.
action.

Figure 3. Hydraulic pile driving mechanism and cab.

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Appl. Sci. 2023, 13, 4774 5 of 14

Figure 3. Hydraulic pile driving mechanism and cab.

The static pile driver operates on the pile through a pile pressing mechanism, pow-
ered byThehydraulic
static pilecylinders
driver operates on the pile
in the chassis through
platform a pile pressing
to enable mechanism,
a pile pressing powered
and pile pull-
by hydraulic cylinders in the chassis platform to enable a pile pressing and pile pulling
ing action. The pile pressing mechanism is connected to the large body in the upper part
action. The pile pressing mechanism is connected to the large body in the upper part of
of the massive body skeleton structure. The entire pile driver travels and moves through
the massive body skeleton structure. The entire pile driver travels and moves through a
a travel mechanism and a traverse mechanism in the lower part of the large body platform.
travel mechanism and a traverse mechanism in the lower part of the large body platform.
The outriggers are bolted to the bulkhead structure, and the outriggers have hydraulic
The outriggers are bolted to the bulkhead structure, and the outriggers have hydraulic
cylinders attached to the long boat by hinges. The ball head of the ball hinge is attached to
cylinders attached to the long boat by hinges. The ball head of the ball hinge is attached to
the slewing mechanism and the short boat. The large body platform structure will link the
the slewing mechanism and the short boat. The large body platform structure will link the
static pile drivers into a single unit that will directly bear the reaction force when the pile
static pile drivers into a single unit that will directly bear the reaction force when the pile is
is pressed. The maximum deformation of the bulk structure occurs when the static pile
pressed. The maximum deformation of the bulk structure occurs when the static pile driver
driver implements the pile pressing action. In this paper, we present a hydrostatic analysis
implements the pile pressing action. In this paper, we present a hydrostatic analysis of the
of the pile pressing operation and its hydrostatic properties under the most dangerous
pile pressing operation and its hydrostatic properties under the most dangerous operating
operating
conditions.conditions.

2.2.2.
2.2.2. Analysis
Analysisof of Stress
Stress Results
Results inin Typical
Typical Working Conditions
Working Conditions
The
The maximum
maximumpile-uppile-upforce
forceofofthe
thepile-up
pile-updriver
driveris 400 t. The
is 400 combined
t. The combinedeffect of the
effect of
maximum
the maximum pile-up reaction
pile-up force,force,
reaction and the gravity
and of the pile-up
the gravity table itself,
of the pile-up tablehas an upward
itself, has an
effect
upward oneffect
the pile-up driver’sdriver’s
on the pile-up bulk structure. The longitudinal
bulk structure. meander
The longitudinal mechanism
meander sup-
mechanism
ports
supportsthe the
entire structure,
entire andand
structure, thethe
combined
combined force acts
force actsononthe
theconnecting
connectingsurfaces
surfacesofof the
the
cylinder
cylinder andand column
column in in the
the form
form of
of aa uniform
uniform load
load q.q. The
Thecalculated
calculatedload
loadqqisis3.061
3.061Mpa,
Mpa,
and
and aa diagram
diagram ofof the
the bulk
bulk structure
structure is shown in Figure 4.

Figure 4.
Figure Large structure
4. Large structure component
component drawing.
drawing.

In the
In the finite
finite element,
element, the
the transmission
transmissionofof force
force is
is carried
carried out
out with
with the
the help
help of
of nodes,
nodes,
so the
so the load
load can
can be
be applied
applied either
either centrally
centrally on
on the
the nodes
nodes or or uniformly
uniformly on
on the
the surface.
surface. This
This
calculation applies the load q on the connection surface of the column with
calculation applies the load q on the connection surface of the column with the uniform the uniform
load applied.
load applied. The
The large
large body
body structure
structurecross-sectional
cross-sectionaldimension
dimensionparameters
parameters are shown
are shownin
Figure 5.
in Figure 5.
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Figure
Figure
Figure 5.
5.5. Section
Section
Section size
size
size of
ofof large
large
large structure.
structure.
structure.

InIn the
Inthe above
theabove figure,
abovefigure,figure,RR1R1is1 is the
isthe thickness
thicknessofof
thethickness ofthethe crane
thecrane support
cranesupport
supportplate.plate.
plate.RR 2R22 is
is the
isthe thickness
thethickness
thickness
of the side seal cover plate. R3 3is the thickness of the inner longitudinal plate. RR
of
of the
the side
side seal
seal cover
cover plate.
plate. R R 3 is
is the
the thickness
thickness of
of the
the inner
inner longitudinal
longitudinal plate.
plate. 4 is
4R4is
the
isthe
the
thickness of
thicknessofofthe
thickness the side
theside sealing
sidesealing plate.
sealingplate. R
plate.R5R5and
5 and R
R6Rare
66 are the thickness
thicknessofofthe
the thickness of the pile
thepile mouth
pilemouth sealing
mouthsealing
sealing
plate
plateand
plate and
andthethe middle
themiddle longitudinal
middlelongitudinal
longitudinalplate, plate, respectively.
plate,respectively.
respectively.
InIn actual
Inactual operation,
actualoperation,
operation,the thebigbig body
bigbody structure
structureisislifted
bodystructure lifted
liftedononthe theground
ground
groundbybyfour four cylinders,
fourcylinders,
cylinders,
and the pile is pulled or pressed along the cylinder legs in an up and down direction toto
and
and the
the pile
pile is
is pulled
pulled or
or pressed
pressed along
along the
the cylinder
cylinder legs
legs in
in an
an up
up and
and down
down direction
direction to
complete
complete the
the working
working condition.
condition. The
The degrees
degrees of of freedom
freedom
complete the working condition. The degrees of freedom of the cylinder legs in other di- of of
the the cylinder
cylinder legs legs
in in
otherotherdi-
directions
rectionsare
rections areare limited,
limited,
limited, so
sosothe the
thebig big
bigbodybodybody structure
structure
structure has has
hasonly
onlyonly
one one
onedegree degree
degree of freedom.
ofoffreedom.
freedom. When
When When the
the
the constraints
constraintsare aresetare
setfor set
forthe for the
thelarge large
largebody body
bodystructure structure
structuremodel, model,
model,the the
thedegrees degrees
degreesofoffreedom of freedom
freedomininallalldirec- in all
direc-
constraints
directions
tionsofofthe oflarge
thelarge the large body
bodystructure
structure structure are restricted,
arerestricted,
restricted, exceptforexcept
forthe for
therelease the release
release of thedegrees
Z-axis
tions body are except ofofthe theZ-axis
Z-axis degrees
degrees of freedom. Therefore, the pile driver is restrained at the connection between
ofoffreedom.
freedom.Therefore,
Therefore,the thepile
piledriver
driverisisrestrained
restrainedatatthe theconnection
connectionbetween betweenthe thelarge
large
the
body large body structure
structure and the and There
legs. the legs. are There
2 degreesare 2of degrees
freedom of in
freedom
the in the translation
translation direction
body structure and the legs. There are 2 degrees of freedom in the translation direction
direction
and3 3degrees and 3ofdegrees
degrees freedom of in
freedom in thedirection
therotation
rotation rotation direction
(ROTX,ROTY, (ROTX,
ROTY, ROTY,asROTZ),
ROTZ), showninas in
and of freedom in the direction (ROTX, ROTZ), as shown
shown
Figure6.6.in Figure 6.
Figure

Figure
Figure
Figure 6.
6.6. Large
Large body
body
Large structure
structure
body constraint
constraint
structure diagram.
diagram.
constraint diagram.

Thestructure
The
The structurewas
structure wasanalyzed
was analyzedinin
analyzed in ANSYS
ANSYS
ANSYS APDL,and
APDL,
APDL, andthe
and thestress
the stresscloud
stress cloudand
cloud anddisplacement
and displacement
displacement
cloud
cloud of
of the
the large
large body
body skeleton
skeleton under
under the
the compression
compression pile
pile condition
condition were
were
cloud of the large body skeleton under the compression pile condition were obtained, obtained,asas
obtained, as
shown
shown in
in Figure
Figure
shown in Figure 7. 7.
7.
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(a) (b)
Figure
Figure 7.
7. Large
Large body
body skeleton
skeleton stress
stress cloud
cloud and
and skeleton
skeleton displacement
displacement cloud.
cloud. (a)
(a) Large
Large body
body skeleton
skeleton
stress cloud; (b) large body skeleton displacement cloud.
stress cloud; (b) large body skeleton displacement cloud.

From
From Figure
Figure 7a,
7a, itit can
canbe
beseen
seenthat
thatthe
themaximum
maximumstress
stressofofthe
thebig
bigbody
body skeleton
skeletonis
110 MPa. The maximum stress appears at the connection of the legs of
is 110 MPa. The maximum stress appears at the connection of the legs of the big body the big body struc-
ture, which
structure, is consistent
which is consistentwith with
the actual working
the actual condition.
working According
condition. to thetocrane
According Chi-
the crane
nese standard
Chinese GBT3811-2008,
standard GBT3811-2008, taking 1.34
taking asas
1.34 the safety
the safetyfactor,
factor,the
theallowable
allowablestress
stress of
of the
the
material is 175 MPa, which meets the design requirements.
As can be seen from Figure 7b, the maximum displacement is 2.01 mm under the pile
pressing condition, which meets the requirements. The maximum deformation near the
hydraulic cylinder cover plate is also in line with the actual situation.

3. Theoretical Foundations of Sensitivity Analysis

We refer to the gradient of variation of the structural or product performance values
with
with respect
respect toto the
the design
design variables
variables as
as sensitivity.
sensitivity. TheThe design
design variables in this
variables in this paper
paper are
are
the thickness of each plate among the large body structure mentioned
the thickness of each plate among the large body structure mentioned above. Changes in above. Changes in
the design
the design variables
variables cause
cause changes
changes inin the
the product
product performance
performance values,
values, such
such as
as the
the mass,
mass,
strength, and
strength, and stiffness
stiffnessof ofthe
thestructure.
structure.When
Whenanalyzing
analyzingthe thestructural stiffness,
structural stiffness,thethegradient
gradi-
of the
ent stiffness
of the variation
stiffness to to
variation thethe
value
valueofofthe
thethickness
thickness(d) (d)ofofeach
eachplate
plateof
of the
the large body
large body
is the sensitivity [18]. Mathematically, if F(d) is continuous and derivable,
is the sensitivity [18]. Mathematically, if F(d) is continuous and derivable, the first-order the first-order
sensitivity S
sensitivity S of
of this
this function
function when
when Equation
Equation (1)(1) exists
exists is:
is:
𝜕𝐹(𝑑)
∂F (d)
(1)
∂d𝜕𝑑
j

where: F𝐹(𝑑)
where: (d) isisthe
theperformance
performancevaluevalueofofthe
thelarge
largebody structure,d 𝑑is the
bodystructure, is the design
design varia-
variable
j
ble of the large body structure.
of the large body structure.
Finite
Finite element
elementanalysis
analysistheory
theoryemphasizes
emphasizes that thethe
that general structural
general static
structural finitefinite
static ele-
ment analysis has:
element analysis has:
×n { u }{𝑢}
[K ]n[𝐾]
× n×1 { F{𝐹}
×
}n×1 =={ {𝐹}
×
F } n ×1
×
(2)
(2)
where: {{𝐹}
where: F }n×1 denotes the external load vector of the structure, {u}n×1 is the
× denotes the external load vector of the structure, {𝑢}
displacement
× is the displace-
vector of the structure.
ment vector of the structure.[ K ] is the total stiffness matrix of the finite element
n×n [𝐾] × is the total stiffness matrix of the finite model; n is
element
the degrees of freedom of the structure.
model; n is the degrees of freedom of the structure.
[ F,d ]]n×1 is
[𝐹, the partial derivative of { F }n×1 with respect to the design variables d.
× is the partial derivative of {𝐹} × with respect to the design variables d.
[u, ] 1 isisthe partial derivative of {u} ×1 with respect to the design variables d. [K,d ]n×n
[𝑢,d ]n×× the partial derivative of n{𝑢} × with respect to the design variables d.
is the derivative matrix of [K ]n×n to d, and the derivative of (2) with respect to d is obtained:
[𝐾, ] × is the derivative matrix of [𝐾] × to d, and the derivative of (2) with respect to
d is obtained:  
[K,d ]n×n {u}n×1 + {K }n×n u,d n×1 = F,d n×1 (3)
[𝐾, ] × {𝑢} × + {𝐾} × 𝑢, × = 𝐹, × (3)
If the vector {𝐹} × is equal to 0, then there is:
Appl. Sci. 2023, 13, 4774 8 of 14

If the vector { F }n×1 is equal to 0, then there is:

[ F,d ]n×1 = {0}n×1 (4)

[u,d ]n×1 = {K }− 1 
n×n K,d n×n { u }n×1 (5)

where: [K ]− 1
n×n is the inverse matrix of the total stiffness matrix of the structural finite
element model. The total stiffness matrix of the structural finite element model is obtained
after summing the corresponding matrices of each cell, which is:
h i
[K ]n×n = ∑ K,d i
(6)
n×n

where: i is the cell number; [K i ]n×n is the expanded cell stiffness matrix. The derivative of
the formula of (6) to d is obtained:
h i
[K,d ]n×n = ∑ i K i ,d (7)
n×n

Equation (5) can be replaced by:

h i
[u,d ]n×1 = −[ K ]− 1
n×n ∑ K i
,d
ni ×ni
{u0}ni×1 (8)

where: [K i ,d ]ni×ni is the cell stiffness derivative matrix without order expansion, ni is
the cell degrees of freedom. {u0}ni×1 is the component of the corresponding unit i in
{u}n×1 , which is the vector of the individual unit displacements. Then, the formula of (8)
is required to calculate the sensitivity of the structural displacement vector {u}n×1 to the
design variable d. In the optimization analysis of the large body skeleton structure, the
large body finite element model is composed of plate and shell units. Therefore, the unit
stiffness matrix before the expansion of the plate and shell units is:
h h
K i ]ni×ni =[ Km
i
]ni×ni + Kbi ]ni×ni = Ed[ K1i ]ni×ni + Ed3 [K2i ]ni×ni (9)

where: E is the modulus of elasticity of the material, d is the real constant of the plate and
shell unit, which is the thickness of the plate. [Km i ] i
ni ×ni and [ Kb ]ni ×ni are the membrane
stiffness and bending stiffness of the plate in the stiffness of the shell unit. While the
coordinates of each node in the cell of i are related to [K1i ]ni×ni and [K2i ]ni×ni , they are not
related to the modulus of elasticity E and the thickness of the plate d, and as we know:
h h
K,d i ]ni×ni = E[ K1i ]ni×ni + 3Ed2 K2i ]ni×ni = Fc[ K1i ]ni×ni + 3Fc3 [K2i ]ni×ni (10)

Therefore, the value of [K i ,d ]ni×ni can be obtained by performing only one more
calculation of the stiffness matrix of each cell.

4. Optimized Design of Structures

4.1. Sensitivity Analysis
The mass of the large body skeleton of a pile driver is related to the mass of each of the
thin plates that make up its structure. For thin slabs, the dimensional properties that affect
their mass are dominated by the thickness of the slabs. Therefore, the sensitivity analysis
of the bulk skeleton structure to the thickness of each slab is the main consideration. The
results of the sensitivity calculation are typically derived from the design of experiment
analysis [19]. The experimental factors that have a big effect on the performance of the
skeleton structure can be obtained by screening from several design variables. The sensi-
tivity calculation method can be used to achieve a reasonable allocation of materials, so
as to improve the light weight of the large body structure. The influence of the change of
Appl. Sci. 2023, 13, 4774 9 of 14

the design parameters of the large body skeleton structure on the performance and extent
of the large body structure are quantitatively studied. Then, the parameters that are most
sensitive to the response of the large body structure performance in the optimization design
process will be screened out. In turn, the optimal range of variables for optimal design is
obtained, and the optimal design variables are further extracted. The sensitivity analysis
of the large body structure of the pile driver in the most dangerous working conditions
involves the large body strength, stiffness and total mass of the large body structure of the
pile driver. Considering that the large body structural members are all thin steel plates,
the thickness of large body plates is selected as the structural design variable. Sensitivity
analysis is performed for the maximum stress at the nodes of the large body structure, the
maximum displacement, and the mass of the large body skeleton of the pile driver.
Design of experiment is computed analytically using an iterative approach, and for
experiments, the maximum and minimum values of the design variables, that is, the
upper and lower limits, must be determined. After consulting with relevant technical
experts, R1 is taken as between 0.03 m and 0.05 m, R2 is taken as between 0.02 m and
0.04 m, R3 is taken as between 0.025 m and 0.045 m, R4 is taken as between 0.025 m and
0.045 m, R5 is taken as between 0.04 m and 0.06 m, and R6 is taken as between 0.05 m and
0.07 m. There are numerous commonly used experimental design methods, such as Central
Composite [20–22], Fractional Factorial, Full Factorial, Latin Hypercube, Orthogonal Array,
Sobol Sequence, etc. The Latin square experimental method is a sampling method based on
the principle of equal probability or equal distance for multidimensional stratified sampling
by constraining the locations of sample points. It allows the sample points to be distributed
more evenly throughout the design space. Compared with other experimental methods,
the advantage of this sampling method is that it has a sampling memory function, which
can avoid repeated sampling. The Latin square experimental method can cover the whole
design space with a smaller number of sample points, so as to efficiently obtain more
comprehensive spatial information. Moreover, this sampling method does not require
too much for the number of sample dimensions and sample points. Therefore, in order
to obtain sample points for experimental design more efficiently and comprehensively,
this paper adopts the Latin square experimental method to obtain data on the variation of
each performance value of the large body structure with independent variables [23]. The
sensitivity analysis results of the thickness of the large body structure’s steel plate to the
mass, displacement and structural stress were obtained after the arithmetic analysis, as
shown in Tables 2–4.

Table 2. Sensitivity analysis of mass to plate thickness.

Parameter Name Quality Sensitivity Parameter Name Quality Sensitivity

R1 0.94 R4 0.21
R2 0.16 R5 0.23
R3 0.12 R6 0.12

Table 3. Sensitivity of displacement to plate thickness.

Displacement Displacement
Parameter Name Parameter Name
Sensitivity Sensitivity
R1 −0.95 R4 0.04
R2 0.21 R5 −0.21
R3 −0.02 R6 0.05
Appl. Sci. 2023, 13, 4774 10 of 14

Table 4. Sensitivity analysis of stress to plate thickness.

Parameter Name Stress Sensitivity Parameter Name Stress Sensitivity

R1 −0.95 R4 −0.08
R2 0.21 R5 −0.22
R3 −0.04 R6 0.03

Appl. Sci. 2023, 13, x FOR PEER REVIEW 10 of 14

Combined with the results of the sensitivity analysis of the design parameters, the
parameters that have a greater impact on weight reduction, but have a minor impact on the
stiffness and strength of the large body structure, are selected as design variables. Therefore,
the
R1, stiffness
R3~R6, aand
totalstrength of the largeare
of five parameters, body structure,
selected are variables
as design selected as design variables.
[24].
Therefore, R1, R3~R6, a total of five parameters, are selected as design variables [24].
4.2. Constructing Optimal Design Model
4.2.
(1) Constructing OptimalThe
Design variables: Design Model
large body skeleton of the pile driver is mainly made of thin
steel plates
(1) Design welded
variables: Thetogether, andskeleton
large body the steelof
plate
the thickness
pile driverRisis mainly
chosen made
as the of
design
thin
variable.
steel plates welded together, and the steel plate thickness R is chosen as the design
(2) variable.
Constraints: The strength and stiffness of the large body skeleton are the constraints.
(3) Constraints:
(2) Objective function: The large
The strength body skeleton
and stiffness of the mass
large M is minimized
body skeleton areasthe
theconstraints.
objective.
(3) Objective function:
An optimization The large body
mathematical skeleton
model mass Mas
is developed is follows:
minimized as the objective.
An optimization mathematical
 model is developed as follows:
Find X = [ R1 , R2 , ..., Rn ]
 𝐹𝑖𝑛𝑑 𝑋 = [𝑅 , 𝑅 , . . . , 𝑅 ]


Min M
𝑀𝑖𝑛 𝑀 (11)

 S.t
𝑆. 𝑡 σmax
𝜎 (11)

ω𝜔max

where: 𝑅
where: Rn is the thickness of of the plate,nnisisthe
theplate, thenumber variables,𝜎σmax is
numberofofvariables, is the
themaximum
maximum
stressobtained
stress obtainedby calculation,𝜔ωmax is the maximum
bycalculation, maximum deflection
deflection obtained
obtainedbybycalculation,
calculation,
andM
and Misisthe
themass
massof of the
the large
large body
body structure.
structure.
ISIGHTsoftware
ISIGHT softwareisisaa“software
“softwarerobot”
robot” thatthat can
can quickly
quickly integrate
integrate and
and couple
couple various
various
softwareby
software by building
building blocks.
blocks. ItIt includes
includes specialized
specialized integration
integration components
components for for various
various
CAE software such
CAE such as
asAbaqus,
Abaqus,CATIA,CATIA,SolidWorks,
SolidWorks, ANSYS,
ANSYS, MATLAB,
MATLAB, etc.etc.
ISIGHT
ISIGHTcan can
also
integrate various software that cannot be used directly through the common
also integrate various software that cannot be used directly through the common integra- integration
component
tion componentSIMCODE
SIMCODE for efficient and quick
for efficient simulation.
and quick By integrating
simulation. ANSYS
By integrating APDL
ANSYS
parametric language design programs, Windows batch files and
APDL parametric language design programs, Windows batch files and output files intooutput files into ISIGHT,
calls to ANSYS
ISIGHT, calls tocan be implemented.
ANSYS In this paper,
can be implemented. a workflow
In this paper, aconsisting
workflowofconsisting
an optimization
of an
calculation component
optimization calculation and a call to the
component andSIMCODE component
a call to the SIMCODE of the ANSYS APDL
component of thesoftware
ANSYS
is usedsoftware
APDL to perform theto
is used optimization
perform the model calculation.
optimization modelAs shown inAs
calculation. Figure
shown 8, in
a circular
Figure
workflow of SIMCODE and optimization is created in ISIGHT.
8, a circular workflow of SIMCODE and optimization is created in ISIGHT.

Figure
Figure8.8.ISIGHT
ISIGHTworkflow
workflowdiagram.
diagram.

In engineering practice, there are three main types of optimization algorithms: direct
search, gradient optimization, and global optimization algorithms. The pointer algorithm
is actually a library of algorithms. During the optimization process, the pointer algorithm
automatically captures information about the design space, and automatically combines
Appl. Sci. 2023, 13, 4774 11 of 14

In engineering practice, there are three main types of optimization algorithms: direct
search, gradient optimization, and global optimization algorithms. The pointer algorithm
is actually a library of algorithms. During the optimization process, the pointer algorithm
automatically captures information about the design space, and automatically combines
four of the three types of optimization algorithms to form an optimal strategy. During 11 of 1
Appl. Sci. 2023, 13, x FOR PEER REVIEW
computation, the algorithm can switch between the four algorithms and continue to find a
better design solution as long as it is still running. Therefore, in order to find a better optimal
solution for the optimization mathematical model and to use the minimum number of
number
optimization of optimization
computation computation
simulations, simulations,
this paper adopts thethis paper
pointer adopts the
algorithm forpointer
solvingalgorithm
for solving the optimization
the optimization mathematical model [25]. mathematical model [25].

5. Results5. Results
After calculation, the variable
After calculation, thevalues, maximum
variable stress, maximum
values, maximum displacement
stress, maximum and
displacement and
structuralstructural
mass of the optimization
mass process can
of the optimization be obtained,
process as shownas
can be obtained, in shown
Figure in
9. Figure
The 9. Th
thickness thickness
of the design variables
of the before and
design variables after and
before optimization and the rounded
after optimization and the thickness
rounded thicknes
after optimization are shownare
after optimization in shown
Table 5.inThe comparison
Table results of results
5. The comparison mass, maximum stress
of mass, maximum stres
and maximum displacement
and maximum of the structure
displacement before and
of the structure after and
before optimization are shownare
after optimization inshown in
Table 6. Table 6.

(a) (b)

(c) (d)
Figure 9. Cont.

(e) (f)
Appl. Sci. 2023, 13, 4774 12 of 14

(c) (d)

Appl. Sci. 2023, 13, x FOR PEER REVIEW 12 of 1

(e) (f)

(g) (h)
Figure
Figure 9. The 9. The
value valuevariable
of each of eachin
variable in the optimization.
the optimization. (a) The
(a) The value ofvalue ofthe
R1 ; (b) R1; value
(b) theofvalue
R3 ; of R3; (c
theof
(c) the value value of Rthe
R4 ; (d) 4; (d) the value of R5; (e) the value of R6; (f) the value of stress; (g) the value of displace
value of R5 ; (e) the value of R6 ; (f) the value of stress; (g) the value of
ment; (h) the value of mass.
displacement; (h) the value of mass.

Tablevariables
Table 5. Design 5. Designbefore
variables
andbefore and after optimization
after optimization andthickness
and rounding roundingafter
thickness after optimization
optimization.
Thicknessbefore
Thickness before Optimi- Optimized Thick-
Optimized Thickness
Thickness after after
Variable
Variable Name Name Optimization
zation Thickness ness Rounding
Rounding
/m /m /m /m /m /m
R1 R1 0.04 0.04 0.03 0.03 0.03 0.03
R3 R3 0.03 0.03 0.02 0.02 0.02 0.02
R4 R4 0.035 0.035 0.025 0.025 0.025 0.025
R5 0.05 0.0599979 0.06
R6 R5 0.06 0.05 0.0500 0.0599979 0.05 0.06
R6 0.06 0.0500 0.05
Table 6. Comparison of structural stress and displacement before and after optimization.
Table 6. Comparison of structural stress and displacement before and after optimization.
Maximum Stress Mass Maximum Displacement
Maximum Stress
/Mpa /kg Mass Maximum
/m Displacement
/Mpa /kg /m
Before After Before After Before After
Before optimization
optimization optimi- After optimi- Before optimization
optimization optimi- After optimi- Before optimization
optimization optimi- After optimi-
110 zation 162 zation82,556.1 zation64,282.6 zation0.00201 zation0.00326 zation
110 162 82,556.1 64,282.6 0.00201 0.00326
In practice, design variables are always subject to artificial influences that lead to
In practice,often
uncertainty. Uncertainty design variables
makes are always
the optimal subject
solution to artificial
beyond influences
the feasible range, that
and lead
it to un
eventually certainty.
becomesUncertainty often makes
infeasible. Moreover, thethe optimal
complex solution
structure ofbeyond
the pile the feasible
driver makes range,
it and i
eventually becomes infeasible. Moreover, the complex structure of the
difficult to directly design the dimensions of each design variable, and judge whether the pile driver make
it difficult to
design requirements aredirectly design
satisfied. the dimensions
As shown in Table 5, of
theeach design
values variable,
of each variableand
arejudge
well whethe
the design requirements are satisfied. As shown in Table 5, the values of each variable ar
well optimized and satisfy the respective value ranges. Therefore, the method of con
structing parametric modeling, building a mathematical model, and finding the optima
solution is to satisfy the expected effect of the design.
As can be seen from Table 6, the maximum stress value of the large body skeleton i
Appl. Sci. 2023, 13, 4774 13 of 14

optimized and satisfy the respective value ranges. Therefore, the method of constructing
parametric modeling, building a mathematical model, and finding the optimal solution is
to satisfy the expected effect of the design.
As can be seen from Table 6, the maximum stress value of the large body skeleton
is 110 MPa under pile compression before optimization and 162 MPa after optimization.
With a safety factor of 1.34 and a maximum safe stress value of 175 MPa, the optimized
stress value still has a large margin and thus meets the design requirements. The maximum
displacement is increased to 3.26 mm before and after optimization, compared to 2.01 mm
before optimization. However, there is still a large excess for the stiffness condition for
large body structures. It can be seen that the optimized structure satisfies the design
requirements. At the same time, the mass of the optimized large body structure was
reduced from 82,556.1 kg to 64,282.6 kg before optimization, which is in line with the
optimization goal of reducing the structural mass in this paper.

6. Conclusions
In this paper, the typical working conditions of a pile press are used as an example to
study how to improve the light weight of the large body structure of a static pile press. This
paper first aimed to develop a finite element model of the large body structure of a static
pile driver. The strength and stiffness of the large body of the pile driver were verified
through finite element analysis to meet the design requirements. On this basis, the structure
optimization based on sensitivity analysis was carried out. A mathematical analytical
model of the optimization was constructed, and the results of the optimization showed
that the strength and stiffness of the optimized large body structure of the hydrostatic pile
driver are within reasonable limits. Therefore, the hydrostatic pile driver has great safety
and reliability, which can completely ensure the safety of the pile driver during the working
process. Compared to the mass of the preoptimized bulk structure, which was 82,556.1 kg,
the optimized bulk structure has a mass of 64,282.6 kg, a 22.1% reduction in mass. It reduces
the production cost and has some guiding implications for future lightweight designs of
piling machinery. The shortcoming of this paper is that the effectiveness of various single
optimization algorithms for solving the mathematical model of the large body structure
is not verified due to time constraints. In future research work, the construction of some
optimization algorithms such as genetic algorithm, particle swarm algorithm, etc. and the
comparison of their respective optimal solutions will be added.

Author Contributions: Conceptualization, J.W.; methodology, Y.Y.; software, Y.Y.; validation, Y.Y.;
formal analysis, J.W.; investigation, J.H.; resources, J.H.; data curation, J.H.; writing—original draft
preparation, Y.Y.; writing—review and editing, Y.Y.; visualization, Y.Y.; supervision, J.W.; project
administration, J.W.; funding acquisition, J.W. All authors have read and agreed to the published
version of the manuscript.
Funding: This research was supported by key scientific research projects of colleges and universities
in Henan Province and funded by School of Mechanical Engineering, North China University of
Water Resources and Electric Power. (Grant No. 17A460020).
Institutional Review Board Statement: Not applicable.
Informed Consent Statement: Not applicable.
Data Availability Statement: Not applicable.
Conflicts of Interest: The authors declare no conflict of interest.
Appl. Sci. 2023, 13, 4774 14 of 14

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