An innovation active set strategy reliability optimization method for cushioning design based on dynamic stress–strain curve

Abstract

The uncertainty of cushioning volume in the process of manufacturing is the main cause of products damaged during transport. Many methods have been presented in protecting the products from damage. However, the uncertainty factors are still difficult to overcome in practical engineering. In order to handle those issues, an innovation active set strategy (IASS) reliability method with probabilistic constraints is proposed. This proposed method is tested through a packaging uncertainty problem, and the results obtained are compared with the modified reliability index approach (MRIA) by evaluating the probability constraints to demonstrate the cost‐effectiveness and efficiency. The results obtained have been indicated that the IASS not only solves the uncertainty problems in packaging engineering but also an efficient and faster reliability analysis method in the reliability‐based design optimization (RBDO) process without sacrificing numerical accuracy and stability. Furthermore, the proposed IASS provides a new design method for cushioning packaging design based on the dynamic stress–strain curve of cushioning material with minimum materials cost. In addition, the application of the RBDO methods to handle the uncertainty problems in packaging engineering has not been studied so far.

Cushioning properties and application of expanded polystyrene for a dynamic nonlinear system

“…It is assumed that the impact energy is completely absorbed by the outer cushion, resulting in maximum deformation of the outer cushion and not transmitted to the product box. Taking m 1 + m 2 as the research objective, the energy balance is formulated as: 23,24 (m…”

“…It is assumed that the impact energy is completely absorbed by the outer cushion, resulting in maximum deformation of the outer cushion and not transmitted to the product box. Taking $$$ {m}_1+{m}_2 $$$ as the research objective, the energy balance is formulated as: 23,24 $$$$ \frac{\left({m}_1+{m}_2\right) gh}{A_1{t}_1}={\int}_0^{\overline{\varepsilon}}{\sigma}_1\left({\varepsilon}_1\right) d\varepsilon $$$$ where $$$ \overline{\varepsilon} $$$ is the maximum strain of the cushion material and $$$ g $$$ is the acceleration due to gravity. $$$ h $$$ denotes the drop height of the packaged product.…”