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Topology Optimization of a Bend Restrictor System: A Study on Structural Weight Reduction
Blekinge Institute of Technology, Faculty of Engineering, Department of Mechanical Engineering.
Blekinge Institute of Technology, Faculty of Engineering, Department of Mechanical Engineering.
2025 (English)Independent thesis Advanced level (professional degree), 20 credits / 30 HE creditsStudent thesis
Abstract [en]

This thesis, conducted in collaboration with NKT HV Cables, aims to prove the concept that the mechanical parameters of a high voltage cable can be used as an input for topology optimization of a bending restrictor to reduce weight. The work follows a Design Science research, which is the scientific study and creation of artefacts for solving practical problems of general interest. The thesis processes two different models: a simplified tube to mimic the assembly of a bend restrictor system and a sectioned design. The tube model provides strategies for reducing weight on the overall assembly while the section model targets the optimization of individual bend restrictor sections. Both models are subject to two different force profiles, an evenly distributed load and a novel loading method called pipe-in-pipe. The pipe-in-pipe method of loading consists of a dummy cable to simulate realistic contact behaviour combined with a evenly distributed load at the cable end to obtain the maximum specified torque on the fixture flange. The loading methods produced slightly different results for the simplified tube, but generated almost identical topologies for the section model. By interpreting the topology obtained, the following  principles for reducing weight was identified, orientation based design, unique section topology and usage of multiple materials with different stiffness characteristics and densities. The raw topologies obtained from the topology optimization were insufficient in practicality use, however, by post processing the results a design concept was made. The last design almost satisfies the practical and mechanical requirements, but is in need of further work. The concept shows further potential for optimization.  The concept will be benchmarked against a current design employed by NKT. The design concept is 17.7% lighter, is subject to 27.24% lower maximum stress but displaces 138.1% more with respect the benchmark, which is accounted for in the increased minimum bending radius. The total system of the design suggestion weighs 545.6 kg compared to the benchmark of 662.6 kg. The findings confirm that HV cable parameters can effectively guide topology optimization and further post-processed the topology optimization results can lead to weight optimized bend restrictor designs.

Place, publisher, year, edition, pages
2025. , p. 82
Keywords [en]
Parameter Driven Topology Optimization, Bend restrictor, HV Cables, Mechanical Engineering, FEM
National Category
Solid and Structural Mechanics
Identifiers
URN: urn:nbn:se:bth-28528OAI: oai:DiVA.org:bth-28528DiVA, id: diva2:1991127
External cooperation
NKT HV Cables AB
Subject / course
Degree Project in Master of Science in Engineering 30,0 hp
Educational program
MTACI Master of Science in Mechanical Engineering
Supervisors
Examiners
Available from: 2025-08-26 Created: 2025-08-21 Last updated: 2025-09-30Bibliographically approved

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