Research on the efficient process-oriented structural optimization method of the large-scale vacuum cryostat for fusion reactors

Abstract An efficient optimization design for the large and complex components of fusion reactors is crucial to address the engineering design requirements and further promote technical standardization. Based on research status, current engineering designs for fusion reactors have some deficiencies, such as time and energy wastage, inefficiency, and difficulties in covering the typical ‘multi-variable multi-objective’ design requirements. These are pressing and common problems that urgently need to be overcome. To deal with the aforementioned technical challenges, it is vitally important to design an efficient, precise, and normalized approach that is tailored for the development of future fusion reactors. Therefore, this paper proposes a process-oriented optimization design method, which involves Coupled external parameterized modeling, Experimental points design, Response surface optimization, and Structural integrity validation (CERS), to improve the currently inefficient design methods. And the vacuum cryostat, the largest and complex component of a tokamak, is taken as an example to present the basic procedures of CERS. Firstly, the functions, basic structures, load types, analysis methods, and verification criteria of the cryostat are presented in detail. Then, real-time data interaction between external global parametric variables and ANSYS via coupling is established by CERS, which achieves parametric modeling of the cryostat and efficient experimental point design and optimization analysis with multi-variables and multi-objectives in an automatic way. Subsequently, this study demonstrates the significance and sensitivity of various structural parameters of the cryostat from such objectives as maximum deformation, maximum equivalent stress, and total mass. And the optimal set of its structural parameters is obtained by establishing a mathematical optimization model. Finally, the structural integrity is verified. The results indicate that the optimized cryostat maintains a minimum safety margin of 23% and will not suffer fatigue damage under various load events during its service. Moreover, the nonlinear buckling load multiplier ∅ is 5.4, obtained by analyzing the load-displacement curve of the cryostat according to the zero-curvature criterion. This shows that the designed cryostat is stable enough. The proposed method is simple, efficient, and reliable, and can be applied to both the cryostat and other complex components of fusion reactors in engineering design fields. It has great value of practical technical reference and can further promote the standardization of engineering design technology for future fusion reactors.