OMIS 661 Presentation – Intelligent System Case

1. OMIS 661 Presentation – Intelligent System Case Caterpillar uses optimization to reduce structural mass while improving structural strength Presenters – Celeste Latham and John Kearsing

2. OMIS 661 Presentation – Intelligent System Case Agenda • Agenda • Concept Introduction • Structural optimization • Terminology • Optimization process • Caterpillar’s Virtual Product Development position • Optistruct demo • CAT optimization

3. OMIS 661 Presentation – Intelligent System Case Concept Introduction • Structural optimization is an automated technique that derives the optimal design of a structure given design criteria. • Structural optimization has the potential to:. • Significantly reduce material costs by optimizing structural designs with respect to specified goals • Accelerate product development through the elimination of manual design and analysis iterations • Improve product quality and reliability by promoting early and frequent analysis of structural strength and life

4. OMIS 661 Presentation – Intelligent System Case Concept Introduction Material optimization Terminology Optimal material layout in a given package space Topology optimization Optimal Shape of a given geometric feature Shape optimization Parametric optimization Ex. Gage thickness, Beam sections etc Size optimization

5. OMIS 661 Presentation – Intelligent System Case Concept Introduction Structural Optimization Process Topology Optimization Size & Shape Optimization engineer engineer engineer Different Iterations Final Design Design Interpretation Intelligent System Intelligent System

6. OMIS 661 Presentation – Intelligent System Case CAT & VPD A Fortune 100 company, Caterpillar is the world's leading manufacturer of construction and mining equipment, diesel and natural gas engines and industrial gas turbines. The company is a technology leader in construction, transportation, mining, forestry, energy, logistics, electronics, financing and electric power generation. Key company facts : • ~$23,000,000,000 company • ~69,000 employees • Averages 500 patents per year • Over 1000 PhDs/CEO PhD

7. OMIS 661 Presentation – Intelligent System Case CAT & VPD • Every component on a CAT tractor is modeled in a 3D modeling system prior to creation – Millions of models. This has set the stage for Caterpillar’s Virtual Product Development Strategy.

8. OMIS 661 Presentation – Intelligent System Case CAT & VPD VIRTUAL PRODUCT DEVELOPMENT • More time spent in the early stages of virtual product development to better reduce time spent maintaining the product in the later stages.

9. ` Accelerated Knowledge Freedom Product Knowledge OMIS 661 Presentation – Intelligent System Case CAT & VPD VIRTUAL PRODUCT DEVELOPMENT Product definition Product design/refinement Detailed Design Testing Concept

10. OMIS 661 Presentation – Intelligent System Case CAT & VPD VIRTUAL PRODUCT DEVELOPMENT • Structural Optimization is one focus of VPD • Caterpillar is using Optistruct, a product developed by Altair Engineering, to help achieve the goals of VPD

11. Optistruct Demo

12. Topology Optimization Radiator Bracket – Design Package Space • Original bracket failed • Reduce stress in bracket Courtesy TECOSIM GmbH, Ruesselsheim

13. Topology OptimizationRadiator Bracket – Optimization Results Courtesy TECOSIM GmbH, Ruesselsheim

14. Topology OptimizationRadiator Bracket– Geometry Extraction/Design Interpretation VOLUME = 0.3 Density Threshold = 0.6 Courtesy TECOSIM GmbH, Ruesselsheim

15. Topology OptimizationRadiator Bracket– CAD Detailing of Concept Design Courtesy TECOSIM GmbH, Ruesselsheim

16. Topology OptimizationRadiator Bracket– Final Detailed Design Design from Optistruct Final Interpreted Design Courtesy TECOSIM GmbH, Ruesselsheim

17. Topology OptimizationRadiator Bracket – Design Validation Original Design Optimized Design Max. v. Mises Stress Max. Displ. Mass Courtesy TECOSIM GmbH, Ruesselsheim

18. Optimization Objectives: Re-design the Chassis Frame Minimize the Mass Maintain the same structural stiffness Optimization of SUV Chassis Frame

19. Identify the maximum design space Optimization of SUV Chassis Frame Topology Optimization

20. Optimization of SUV Chassis Frame Topology Optimization Result Optimal Placement of Material

21. Optimization of SUV Chassis Frame Evaluation of topology optimization result First Concept Design

22. 300 Concept 1 250 Baseline 200 Mass (kg) 150 100 50 0 Optimization of SUV Chassis Frame Analysis of First Concept Design

23. Cross-member Open C-Section Closed C-Section Optimization of SUV Chassis Frame Topology Optimization of First Concept Design Topology optimization on shell structure: Re-define Material Placement

24. Cross-member 300 -12% 250 Open C-Section Baseline 200 Concept 2 Mass (kg) 150 100 50 Closed C-Section 0 Lighter Structure Optimization of SUV Chassis Frame Second Concept Design

25. 300 -23% 250 Baseline 200 Final Mass (kg) 150 100 50 0 Design tuning using shape and size optimization Optimization of SUV Chassis Frame Optimal Design

26. Optimization of SUV Chassis Frame Designs Comparison Optimized Frame: Lightweight Concept – 174 kg (-23%) Baseline Frame: Ladder Frame Design – 226 kg

27. Topology Driven Vehicle Concepts • Lightweight SUV Frame Concept • Baseline frame used for stiffness and modal targets • Including Torsion Bar & Trans C/M • Mass: 498(lbs) [226(kg)]** • Performance Targets: • Twist: 18.7 Hz • Vertical Bend: 27.1 Hz • Lateral Bend: 29.0 Hz • Bending Stiffness: 3278 N/mm • Torsion Stiffness: 121 kNm/rad ** Includes mass of welds (3kgs) Target Weight Reduction 125lbs (25%)

28. Define all available package space, Loading, and BC’s • Topology Optimization for gross concept features • Interpret into first concept design • Topology optimization for concept refinement • Interpret concept for final optimization and design details Final Concept Topology Driven Vehicle Concepts Concept Development Process

29. Topology Driven Vehicle Concepts • Final Concept Design • Primary Hydroformed Sections • Mid-Rail “C” Section • Welded Body Mount Brackets • 23% lower mass • 25% fewer parts • 50% less weld length • Cost penalty: • $0.25 cost per lb saved • Performance Results: • Twist: 25.0 Hz (+34%) • Vertical Bend: 27.8 Hz (+2.5%) • Lateral Bend: 26.4 Hz (-9%) • Bending Stiffness: 3278 N/mm (0%) • Torsion Stiffness: 159 kNm/rad (+31%)

30. OMIS 661 Presentation – Intelligent System Case CAT Optimization D8 Trunnion optimization

31. OMIS 661 Presentation – Intelligent System Case CAT Optimization Original Fabricated Trunnion Design – 2 pieces Fabricated Version: Mass=44.1 Kg

32. OMIS 661 Presentation – Intelligent System Case CAT Optimization Design Objective Minimized Weight Design Constraints Von Mises Stress (Yellow Part) < 785 Mpa Max Principle Stress (Yellow Part) < 372 Mpa • Design Variables-Five • Inside pocket • Neck Radius • Neck Transition • Bolt Plate Thickness • TRF Inserted Flange Thickness

33. OMIS 661 Presentation – Intelligent System Case CAT Optimization Weight Results Final Design

34. OMIS 661 Presentation – Intelligent System Case CAT Optimization Stress Results Requirement: Max Principle Stress < 372 MPa Result: 187.9 MPa Requirement: Von Mises Stress < 785 Mpa Result: 757.3 MPa Max. Load

35. OMIS 661 Presentation – Intelligent System Case CAT Optimization Financial Results • 40 % weight reduction from current production design • $136 cost savings per a part • 3260 parts are expected • $443,360 annual cost savings

36. OMIS 661 Presentation – Intelligent System Case CAT Optimization Future Uses • Expand the optimization process other product lines • Gain an estimated savings of $2 million in 2005

37. OMIS 661 Presentation – Intelligent System Case CAT Optimization Questions?