Automatic Generation of HVAC Ducting System Designs using Topology and Shape Optimization

Topology and shape optimization of a vehicle Heating, Ventilation and Air Conditioning (HVAC) system is presented in this paper. The CFD and optimization methodologies are implemented within AcuSolve™ software. The topology optimization algorithm computes the geometry, where the design domain is parameterized with a field of porosity design variables which indicates the material, fluid or solid, throughout the domain. The optimization is performed using the continuous adjoint approach by the Galerkin Least Squares solver on which the AcuSolve™ solver is based. The design is further improved by using shape optimization. To optimize the geometrical shape, a combination of smooth perturbations, in terms of so called morph shapes, are used to deform the geometrical shape in the optimization algorithm. To this end, a parameterization of the design space is done using a moderate number of design variables, each associated with a morph shape. The two optimization phases are connected by means of automatic computation of the morph shapes from the topologically optimized geometry and the flow field. The topology and shape optimization methods are applied to the design optimization of a car HVAC ducting system for minimum power dissipation and minimum fluid volume constrained by specified flow rates at the exits of the ducts.