Minimising Mass and Increasing Durability of a Vehicle Suspension System Using HyperStudy & OptiStruct
Technology Category
- Robots - Autonomous Guided Vehicles (AGV)
- Sensors - Torque Sensors
Applicable Industries
- Automotive
- Equipment & Machinery
Applicable Functions
- Procurement
- Product Research & Development
Use Cases
- Root Cause Analysis & Diagnosis
- Vehicle Performance Monitoring
Services
- System Integration
About The Customer
Gestamp is a global chassis component supplier for customers such as Ford, VW, BMW and Honda. Its technical centres which are based in the UK, Spain and Germany support an expanding global business with manufacturing sites throughout the world in developing low cost, high volume chassis products. Component mass and cost (strongly linked to mass) are drivers for every customer and Gestamp have been using an optimisation driven design process, based on Altair products, since 2005. Gestamp has recognised the potential for mass reduction through optimisation of a “U” section design.
The Challenge
Gestamp, a global chassis component supplier, was faced with the challenge of reducing the mass and increasing the durability of a rear twist beam (RTB) suspension system. The RTB design is a complex task that requires careful consideration of elastokinematic performance in addition to meeting stiffness and durability targets. The design of experiments (DOE) and optimisation methods were being used to explore the available design space and minimise the mass of a low cost RTB design. The durability requirement was identified as one of the main mass drivers for this type of RTB design. The design of a “U Section” RTB typically requires consideration of several interlinked targets, including Roll Stiffness and Roll Steer, which are strongly influenced by the shape, position and gauge of the torsion element.
The Solution
To address the challenge, Gestamp selected Altair to develop a set of custom tools, referred to as “The RTB Toolbox,” which can be used to generate an initial RTB concept that meets Kinematics and Compliance (K&C) requirements such as Roll Stiffness/Steer, thereby eliminating an initial “trial and error” design loop. The software used the functionality available within high-performance preprocessor HyperMesh to set up shape design variables for each component in the RTB assembly. HyperStudy was used to control DOE studies, which provided a detailed understanding of the sensitivity of each target to input parameters. This was followed by a final optimisation step from which the concept surfaces were generated. The next stage of the design process was to create a CAD model from the optimised Toolbox output. This model served as a baseline for work to meet durability and strength criteria.
Operational Impact
Quantitative Benefit
Case Study missing?
Start adding your own!
Register with your work email and create a new case study profile for your business.
Related Case Studies.
Case Study
Smart Water Filtration Systems
Before working with Ayla Networks, Ozner was already using cloud connectivity to identify and solve water-filtration system malfunctions as well as to monitor filter cartridges for replacements.But, in June 2015, Ozner executives talked with Ayla about how the company might further improve its water systems with IoT technology. They liked what they heard from Ayla, but the executives needed to be sure that Ayla’s Agile IoT Platform provided the security and reliability Ozner required.
Case Study
IoT enabled Fleet Management with MindSphere
In view of growing competition, Gämmerler had a strong need to remain competitive via process optimization, reliability and gentle handling of printed products, even at highest press speeds. In addition, a digitalization initiative also included developing a key differentiation via data-driven services offers.
Case Study
Predictive Maintenance for Industrial Chillers
For global leaders in the industrial chiller manufacturing, reliability of the entire production process is of the utmost importance. Chillers are refrigeration systems that produce ice water to provide cooling for a process or industrial application. One of those leaders sought a way to respond to asset performance issues, even before they occur. The intelligence to guarantee maximum reliability of cooling devices is embedded (pre-alarming). A pre-alarming phase means that the cooling device still works, but symptoms may appear, telling manufacturers that a failure is likely to occur in the near future. Chillers who are not internet connected at that moment, provide little insight in this pre-alarming phase.
Case Study
Premium Appliance Producer Innovates with Internet of Everything
Sub-Zero faced the largest product launch in the company’s history:It wanted to launch 60 new products as scheduled while simultaneously opening a new “greenfield” production facility, yet still adhering to stringent quality requirements and manage issues from new supply-chain partners. A the same time, it wanted to increase staff productivity time and collaboration while reducing travel and costs.
Case Study
Integration of PLC with IoT for Bosch Rexroth
The application arises from the need to monitor and anticipate the problems of one or more machines managed by a PLC. These problems, often resulting from the accumulation over time of small discrepancies, require, when they occur, ex post technical operations maintenance.
Case Study
Robot Saves Money and Time for US Custom Molding Company
Injection Technology (Itech) is a custom molder for a variety of clients that require precision plastic parts for such products as electric meter covers, dental appliance cases and spools. With 95 employees operating 23 molding machines in a 30,000 square foot plant, Itech wanted to reduce man hours and increase efficiency.