Altair > Case Studies > Rapid Development of a Robust, Life-saving Defence Vehicle Module

Rapid Development of a Robust, Life-saving Defence Vehicle Module

Technology Category

Application Infrastructure & Middleware - Data Exchange & Integration
Robots - Autonomous Guided Vehicles (AGV)

Applicable Industries

Automotive
Transportation

Applicable Functions

Product Research & Development
Quality Assurance

Use Cases

Time Sensitive Networking
Vehicle Performance Monitoring

Services

System Integration
Testing & Certification

About The Customer

The primary customer for this project was the Australian Defence Organization (ADO), which includes celebrated names such as the Capability Acquisition and Sustainment Group (CASG), Defence Science and Technology Group, Land Engineering Agency, Battlespace Communications and Operations Group, and the Joint Proof and Experimental Unit. The ADO is responsible for the procurement of defence equipment and services for the Australian Defence Force. In this case, the ADO had procured around 2,200 Mercedes-Benz G-Wagon light trucks for the Australian Army, and IDES was tasked with designing, building, and fitting all mission modules for these vehicles.

The Challenge

Integrated Design and Engineering Solutions (IDES), a Melbourne-based engineering product development and systems integration company, was tasked with a challenging assignment by the Australian Defence Organization (ADO). The project, known as LAND 121 Phase 3A, involved the procurement of around 2,200 Mercedes-Benz G-Wagon light trucks for the Australian Army. One of the variants of these vehicles was intended to be used as a surveillance and reconnaissance (S&R) vehicle. The IDES team was required to design a module for this vehicle that would provide adequate protection for the rear observer in the event of a vehicle rollover. The team decided to build a vehicle rollover protection structure (ROPS) in the form of a tubular roll cage structure. However, the traditional method of developing such a structure, which involves iterative physical testing, was deemed too time, effort, and cost-intensive for the project's tight timeline.

The Solution

To overcome the challenge of developing a robust ROPS within the project's tight timeline, the IDES team decided to leverage Altair HyperWorks, a computer-aided engineering (CAE) software suite that they had been using for many years. The team began by creating a finite element model of the pendulum test rig, base vehicle chassis, and S&R module using Altair HyperMesh. They then simulated the physical testing process using Altair Radioss and processed the results in Altair HyperView. This approach allowed the team to optimize the product structures and minimize the need for physical prototyping and testing required for product verification and validation. By using HyperWorks, the IDES team was able to quickly, efficiently, and accurately develop an optimum design for the ROPS.

Operational Impact

The use of Altair HyperWorks in the LAND 121 Phase 3A project not only enabled IDES to meet the project's tight timeline but also resulted in a high-quality, tough, and reliable ROPS. The software suite allowed the team to simulate the physical testing process, thereby minimizing the need for time, effort, and cost-intensive physical prototyping and testing. This approach also allowed the team to optimize the product structures, resulting in a ROPS design that had adequate strength to protect the vehicle occupant. The successful completion and deployment of the G-Wagon S&R Module in the Australian Army is a testament to the effectiveness of this approach. The IDES team is enthusiastic about leveraging the capabilities of the Altair HyperWorks suite for future projects to enable rapid, reliable, accurate, and safe development of mission and safety-critical systems.

Quantitative Benefit

The use of Altair HyperWorks allowed for rapid development of the ROPS, saving invaluable time on the LAND 121 Phase 3A project.
The final design was verified through a physical test, which demonstrated a good correlation to the simulation results, ensuring the reliability of the design.
The G-Wagon S&R Module is now in service with the Australian Army, indicating successful completion and deployment of the project.