Structural Optimization of Drive Unit Bracket Using OptiStruct

Ms. Nazia .S. Ansari

Mr. Naushad Ansari

Mr. Vinay Kulkarni

Manager
Godrej Material Handling Div
Godrej & Boyce Mfg Co Ltd

Manager
Godrej Material Handling Div
Godrej & Boyce Mfg Co Ltd

Assistant Vice President

Godrej Material Handling
Godrej & Boyce Mfg Co Ltd

Abstract
This paper deals with optimization of Drive Unit Bracket Assembly for Tow Truck. Drive Unit Bracket Assembly is the important
part of the Tow Truck Chassis .The motor which provides the traction to the Equipment is mounted on the Subject Drive Unit
Bracket.
This paper describes development of a Finite element model and subsequent analysis and simulation of Drive Unit Bracket
Assembly consisting of structural members which are designed using basic principles of structural design.
Topology & Size optimization is applied to Drive Unit Bracket Assembly considering volume as the objective along with stress
constraints. Manufacturing constraints are considered to provide the manufacturability and interpretable design proposal.
From the interpretations of Topology & Size optimization, one conservative design is proposed. Drive Unit Bracket Structure is
optimized to minimize the mass and the stress requirements.

Introduction
Tow trucks are a vital part of the material handling chain in many operations like large factories, plants,
warehouses, airports and ports where goods have to be transported over significant distances. Tow
trucks offer exceptionally high productivity and economics compared to options like transporting goods
on various types of forklift trucks.
This advantage is even more pronounced when the load to be transported consists of a relatively large
number of small items. Tow trucks are a very efficient and cost competitive form of transporting goods
because they do not carry any goods themselves but pull the load placed in trolleys. A trolley train can
transport a large number of items at a time, something other mobile material handling equipment cannot
do.
Always conscious of the impact on the environment and the rapidly growing need for clean, quiet and
energy efficient material handling equipment, Godrej brings to you electric battery powered towing
solutions with 3 models of tow trucks in capacities of 2,5 and 6 tonne with variants for stand-on and sitdown operation.
Electric powered tow trucks to cut your transportation costs and time. Godrej Electric Tow Trucks are
ideally suited for indoor work on industrial flooring due to their compact profile and high degree of
manoeuvrability.
The 5 and 6 tonne sit-down models are also available with higher ground clearance and pneumatic
tyres for outdoor use on concrete or paved surfaces. The emphasis on safety, operator comfort,
efficiency and serviceability ensures that the user gets a productive, cost effective and durable towing
solution.

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Application
The Drive Motor which is the Main power source for the Tow Truck is mounted on the Drive Unit
Bracket Assembly as shown in Fig 1 below
Fig1 Layout for Drive Unit Bracket Assembly

Drive Unit
Mountings on
Frame
Drive Unit
Bracket Assembly
Drive Unit
Objective
The main objective of this simulation is the re-design of Drive Unit Bracket Assembly with optimum
mass while maintaining Stress constraints.
Fig2 Geometric Model Of Drive Unit Bracket Assembly

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Drive Unit Plate(1 No)

Fig 3 Finite Element Model

Gusset(2 No's)

Fig 3 Shows the Finite Element Model for the

Bracket.
FE Model Description
Total No of Elements= 10256
Total No of Nodes
= 10645

Design Space

The elements used for FE model are 2d shell elements for sheet metal components like Drive Unit
Plate,Gusset,Channels & Back Plate & 1d rigid elements are used for Welded connections.
The material defined for all components is Steel with following properties:
Youngs modulus, E =210 GPa
Poissons ratio, =0.30
Density, = 7900 kg/m3
Yield strength, =260 MPa
Gravity has been defined in the model

GFfIG 3

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Fig 4 Boundary Conditions:

Constraints at 4
Mounting points

Tractive Effort=538
N

Impact exerted during

Bumping =8000 N

Process Methodology
Design & Non-Design space has been defined for the Optimization Setup in OptiStruct
Initially Size Optimization is performed on the Bracket to determine the Optimum material thickness of
components used in the Bracket. Size Optimization is a concept level design method that determines
the optimum material Thickness for a give optimization problem within the identified Design space. In
Size optimization, the thickness of each Element is a Design variable. The problem is solved using
several problem formulations to have a better understanding of Underlying physics.
Parameters defined during Size Optimization Setup are
Design Variables
- Gauges of all Parts in Design space
Design Constraints - Stress < 130 N/mm2
Objective
- Minimize Volume
Size Optimization is followed by Topology Optimization in OptiStruct. Design space is again defined for
Topology Optimization setup in OptiStruct. Topology Optimization method helps to determine the
optimal material Distribution for a given optimization Problem.
Parameters defined during Topology Optimization Setup are
Design Variables
- Density of each element in Design space
Design Constraints - Stress < 130 N/mm2
Objective
- Minimize Volume

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The Optimization Process Flowchart is as shown below:

Static Analysis

Size optimization

Converged

Optimized design

Topology Optimization

Converged

Optimized Design
Design Modification
based on Static
Analysis Results

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Concept Design & Optimization Process

Original Design

Design Modification based on

Static Results

Size Optimization gives

Optimum thickness of 10 mm
for all plates
of the Bracket

Topology Optimization gives

Optimum Material
Distribution for all 10mm
plates

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Final Design Concept based

on results from Optimization

Size Optimization Results

Optimization Parameters
Design Variables
design space

- Gauges of all Parts in

Design ConstraintsConstraints Stress < 130 N/mm2

Objective

- Minimize Volume

Fig5Density
Density Plots from Size Optimization show that all the plates can be reduced to 10mm Thickness
Topology Optimization Results (Fig 6)

Topology optimization was performed to

find the material densities for all the

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Final Design derived based on

Outputs from Topology & Size
Optimization

(Fig 7)

Result & Discussion

Displacement Plots

Max Displacement= 1.3mm

Stress Plots

Max Stress= 156 MPa which

will be shared by mounting

Due to Manufacturing Constraint, Fabricated design of Bracket was recommended as shown in Fig
below

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Fabricated Design Of
Mounting Bracket

Fig 8

Displacement & Stress Plots For The Fabricated Design

Max Stress= 166 Mpa which

will be shared by mounting
Bolts

Table for Material Savings

Sr no

Part description

Thickness(mm)

Weight(Kgs)

Motor Mounting Plate

Vertical Plates
Mounting Plates

16
10
20

9.5
6.4
4.5

Bend Design of Bracket

10

Fabricated Design of Bracket

10

Material
Savings(Kgs)

20.4

12.4
11.4

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Conclusion
Using Concept Design & Optimization techniques the weight of the Bracket was reduced
re
by 61% which
is significant savings in weight and these savings amount to Rs 1240/bracket
Monthly production of Tow Truck is 5 Nos. Hence Annual Savings =74400 Rs (5*1240*12)
The work presented in this paper is in the early phases of ongoing work and it is important to note these
promising results will strongly
trongly demand more detailed Analysis as mentioned
mentioned in the further scope of
Study

Benefit Summary

Reduce Development Time

Through OptiStruct's
ct's design synthesis approach,CAE is applied upfront in the product
development cycle, thereby driving the design process and enabling a reduction in the number
of design iterations

Improve Design Performance

OptiStruct helps to develop structurally sound, lightweight products by applying
applyin the most
advanced optimization methods to solve the design problem.

Explore More Design Alternatives

OptiStruct's advanced optimization engine allows users to combine topology, topography, size
and shape optimization methods to create more alternative design proposals. Manufacturing
requirements can also be defined as input to the simulation to create design proposals that are
easier to interpret and to manufacture.

Higher Productivity Through Hyper Works Integration

OptiStruct's integrated
ted analysis and optimization approach enables computationally efficient
concept design synthesis and design optimization studies. A highly organized and intuitive userinterface greatly simplifies user effort through the optimization process.

Further Scope of Study

The study was extended to Motor Mounting Brackets used on other Equipments.
Topology & Size optimizations techniques of optimization were used to arrive at Optimum sizes of
plates Density Plots of Size Optimization Results are as shown in Fig

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Initial (Base Design )

Final (Optimised Design)

Using optimization, thickness of plates used in the bracket were reduced to 8mm & 6mm.Total Weight
reduction of 61% achieved from the Final Optimized Design of Bracket
Annual savings from this Analysis amounted to 4,68000 INR

ACKNOWLEDGEMENTS
The authors would like to acknowledge our company M/s. Godrej and Boyce Mfg. Co. Ltd, Material
Handling Equipment Division and Altairs Technical support.
REFERENCES
1. OptiStruct Users Manual-Altair Engineering
2. Practical Finite Element Analysis- Nitin S.Gokhale, Sanjay S. Deshpande, Sanjeev V.Bedekar, Anand N.Thite.
3.Altair HyperWorks 3.RADIOSSv11 help Manual.

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