Mass Reduction and Fatigue Design Solutions for Heavy-Duty Applications
ETA leverages its design optimization system, the ®, for product design and development to service the needs of the heavy truck and bus industry. With such heavy-duty applications, improving MPG, mass reduction and durability performance are naturally huge concerns for the OEMs and suppliers of the industry.
Using ACP, ETA engineers can reduce product development costs and mass by 20% to 30% and improve fuel efficiency, while meeting all durability and fatigue performance requirements using its proprietary mechanical system simulation software tool. Considering the market's sensitivity to rising fuel costs and increasingly stringent emissions regulations, the mass reduction capabilities offered by ACP present real cost-saving value and greater fuel efficiency.
Furthermore, VPG and ACP's ability to develop robust designs that improve durability performance promotes a longer fatigue life, which can equate to less warranty issues from customers.
ETA’s team designs and analyzes all aspects of the heavy vehicle including body, chassis, axle and suspension system, brakes and all related sub-systems.
Using ACP, ETA’s engineers have created a new front steer axle design concept for a heavy truck which analyzed an alternative manufacturing process in order to reduce 55% overall mass from the original design. When comparing this design to axles currently using a similar manufacturing process within the industry, the 3G Optimization saw a balanced design that is still 30% lighter maintaining equal or better performance.
In addition to this project, ACP has been applied to a truck brake system for cost and weight reduction. These methods are proving to be a mass compounding approach, enabling lightweight design solutions that allow fleets to achieve greater MPG, directly reducing fuel operating costs.
- Navistar Truck and Bus Group
- Thomas Built Buses