基于数字孪生的新能源张力机关键部件的优化*

doi:10.16731/j.cnki.1671-3133.2026.04.004

摘要/Abstract

摘要： 新能源张力机需要满足结构紧凑和动力性能等要求,卷筒作为其主要的承载部件在工作时受力复杂且需高强度、轻量化,其安装使用方式直接影响设备工作时的结构刚性,因此对卷筒进行结构优化设计是新能源张力机研发的关键。针对新能源张力机轻量化与动力性能协同优化的技术需求,提出一种融合数字孪生与拓扑优化的关键部件设计方法。通过孪生体实时映射卷筒在极限工况下的应力/应变场与失稳临界载荷;以结构刚度最大化和质量最小化为目标,在数字空间中迭代优化腹板减重孔布局及内筒加强筋构型;结合增材制造约束生成轻量化设计方案。实验表明,优化后卷筒减重22.3 %,屈曲临界载荷提升15.64 %,且动力响应特性显著改善。该方法突破传统经验设计局限,可以为高端装备的数字化协同优化提供理论支撑与工程参考。

关键词: 数字孪生, 卷筒, 拓扑优化, 轻量化, 动力性能

Abstract: The new energy tension machine needs to meet requirements such as compact structure and dynamic performance. The reel,as the main load-bearing component,experiences complex forces during operation and requires high strength and lightweight design. Its installation and use also affect the structural rigidity of the equipment during operation,so structural optimization design of the reel is key to the research and development of the new energy tension machine. To meet the technical needs for lightweight design and collaborative optimization of dynamic performance in the new energy tension machine,a design method for key components that integrates digital twins and topological optimization is proposed. This involves real-time mapping of the stress/strain field and instability critical load of the reel under extreme working conditions using a twin body;with the goals of maximizing structural stiffness and minimizing mass,the layout of the weight-reduction holes in the web and the configuration of the inner cylinder reinforcements are iteratively optimized in digital space;and a lightweight design scheme is generated in conjunction with additive manufacturing constraints. Experiments show that the optimized reel achieves a weight reduction of 22.3 %,the buckling critical load increases by 15.64 %,and the dynamic response characteristics are significantly improved. This method overcomes the limitations of traditional empirical design and can provide theoretical support and engineering references for the digital collaborative optimization of high-end equipment.

Key words: digital twin, reel, topology optimization, lightweight, power performance

中图分类号:

TH122

王海燕, 周俊宏, 王涛, 沈春杨, 钟良, 曾志. 基于数字孪生的新能源张力机关键部件的优化^*[J]. 现代制造工程, 2026, 547(4): 29-36.

WANG Haiyan, ZHOU Junhong, WANG Tao, SHEN Chunyang, ZHONG Liang, ZENG Zhi. Optimization of key components of new energy tension machinebased on digital twin[J]. Modern Manufacturing Engineering, 2026, 547(4): 29-36.

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基于数字孪生的新能源张力机关键部件的优化^*

Optimization of key components of new energy tension machinebased on digital twin

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