考虑测量干扰抑制的风洞天平拓扑优化方法

Topology optimization method for wind tunnel balance considering suppression of measurement interference

  • 摘要: 针对大载荷比天平小量值分量易受干扰、测量精度低,以及传统方法难以突破性能瓶颈问题,发展了考虑测量干扰抑制的风洞天平拓扑优化设计方法。基于轴向力测量干扰模式,提出“最小柔度”和“最小干扰”两种拓扑优化模型并建立数值优化流程,结合设计域“上下镜像”和“非镜像”策略完成多组算例,并开展典型算例实物加工和地面加载验证。结果表明:该方法可获得结构清晰、可制造拓扑构型,“最小干扰”模型所得构型更简洁可靠,“非镜像”策略虽能拓展设计空间,但工艺复杂度与计算成本提升;天平实物目标分量Fx灵敏度显著,单独施加其余载荷时最大干扰输出小于2.3%。该方法显著提升天平抗干扰能力和测量精度,为高精度天平及力传感器设计提供了新途径。

     

    Abstract: The strain gauge balance is the core device for accurately measuring aerodynamic loads acting on aircraft models in wind tunnel tests. As a special type of six-component force sensor, its design faces greater challenges due to the constrainted design space, extreme mismatch in load magnitudes across the measured components, and harsh testing conditions. For sting-type balances, the measurement accuracy of the axial force component is inherently limited, as the measuring elements are prone to nonlinear deformation and torsional interference within the restricted design space – problems that are further exacerbated under high load-ratio conditions (e.g., when subjected to large longitudinal loads). To address the interference susceptibility and low accuracy of low-magnitude components under high load-ratios, as well as the limitations of conventional design methods, a topology optimization method considering measurement interference suppression was developed for wind tunnel balances. Based on the interference patterns of axial force measurement, two optimization models- “minimum compliance” and “minimum interference” —were proposed, and a numerical optimization framework integrating the SIMP model, the MMA algorithm, and filtering/projection techniques was established. Multiple design cases were studied using mirrored and non-mirrored design domains strategies, and a prototype was fabricated and calibrated through ground loading tests. Results show that the proposed method yields clear and manufacturable topological configurations; the “minimum interference” model produces simpler and more reliable layouts; the non-mirrored strategy expands the design space but increases manufacturing complexity and computational cost. The fabricated balance exhibits high sensitivity in the target component Fx, with a maximum interference output below 2.3% when other loads are individually applied. The proposed method significantly enhances the anti-interference capability and measurement accuracy of the wind tunnel balance, providing a new approach for the design of high-precision balances and multi-component force sensors.

     

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