Size and design constraints in products such as soundbars and TVs require loudspeaker spiders of small diameter to allow for large voice-coil excursion. Spider designs that undergo exceedingly large displacements can exhibit buckling of the spider rolls, resulting in very audible distortion. Such buckling events are non-trivial to simulate with finite element methods and often lead to solver non-convergence. When wrapping numerical optimization algorithms around the finite-element simulations to achieve optimal spider designs, it is important to ensure that all simulated designs can be solved without errors or convergence issues. The optimal spider design might be right within the buckling limits and an automated numerical optimization algorithm will need to be able to resolve some designs that exhibit buckling. This work shows how an augmented FEM method can be used to circumvent issues when employing numerical optimization for a spider design near its buckling limits.
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