A Header Design Method for Target Flow Distribution among Parallel Channels Based on Topology Optimization

Flow maldistribution among parallel channels or tubes is a classical challenge concerning engineers in a wide range of areas like electronics cooling, solar energy, fuel cells, etc. Various headers and manifolds have been studied in literature to achieve target flow distribution. But most of them were based on intuition or experience of engineers. In this study, we introduce a method for designing headers based on multi-stage topology optimization of fluid flow. Minimizing power dissipation was set as the objective and target flow rates were set as the constraints in the optimization problem. A six-channel device was defined for study and headers were designed for not only uniform distribution but also specified non-uniform distribution targets. We also compared the method with a CFD-based evolutionary algorithm in literature, showing that topology optimization could generate a lower pressure drop penalty design. It is proved that the proposed multi-stage topology optimization of fluid flow is an efficient method for addressing general flow distribution device design problems.