A Method to Optimise Semi-Trailers with the Use of FEM Analysis and Durability Tests with a Road Simulator

Abstract

This paper presents a method developed by Wielton company – a manufacturer of trailers and semi-trailers – for the optimization of semi-trailer’s construction, supported by FEM analysis and the modern road simulator – a test stand included as part of the method for optimising semi-trailers. The aim of the research was to optimize the process of developing a technical measure in terms of shortening the time of implementing new products while guaranteeing high durability and functionality of the products. As a result of the optimization of the construction with the use of FEM analysis and the road simulator, the semi-trailer as a new product for sale is delivered quickly and possible defects of construction are eliminated on early stage of new product development. The method assumes the following stages of the development process: determination of input data to the process, development of a 3D model, FEM numerical analysis (static and dynamic), development of an optimized 3D model based on numerical analyses, construction of the first prototype, prototype validation tests using the road simulator and other test stands. Important feature of the developed method to optimise construction is connected with specific data achieved from FEM analysis and used in tests with the road simulator. The effect of using presented method is the elimination of 98% errors in construction and technology. These errors concern not only the key parts of the semi-trailer, i.e. the body and the frame, but also less important components, i.e. fixing of tanks and boxes, ladder, spare wheel basket, extinguisher mounting. The method to optimise semi-trailers developed in Wielton have many advantages, such as: limiting the risk of launching breakthrough solutions on the market, faster increase in vehicle competitiveness, optimizing vehicle construction, reduction of production time and costs, and as a consequence - faster implementation of new products, reducing the number of complaints and service costs, increasing the value and prestige.