Altair Case Studies Optimising the COLLAPSECON C-400: A Case Study in IoT and Shipping Logistics

	Optimising the COLLAPSECON C-400: A Case Study in IoT and Shipping Logistics Altair

Optimising the COLLAPSECON C-400: A Case Study in IoT and Shipping Logistics

Altair

Technology Category	Functional Applications - Manufacturing Execution Systems (MES) Platform as a Service (PaaS) - Application Development Platforms
Applicable Industries	Marine & Shipping Transportation
Applicable Functions	Logistics & Transportation Product Research & Development
Use Cases	Additive Manufacturing Intelligent Packaging
Services	System Integration Testing & Certification
Challenge	The shipping and logistics industries are responsible for facilitating over 90% of global trade, utilizing an estimated 35 million containers worldwide. However, global trade deficits result in 1 in 5 containers being shipped empty, leading to losses of over $30 billion annually. CEC Systems’ COLLAPSECON® provides an innovative solution to this problem, with a collapsible container design that improves operational efficiency and reduces environmental impact. However, the COLLAPSECON® design faced challenges due to over-engineering to meet industry ISO standards and pass manufacture testing. The units were nearly three times heavier than a standard container, due to the addition of moving parts and unique structural components. The complex geometries used in the design were also incompatible with traditional manufacturing methods, potentially leading to increased manufacturing costs. To optimise the COLLAPSECON® C-400 design for mass production and operational use, CEC Systems partnered with The Singapore Institute of Manufacturing Technology (SIMTech). Read More
About Customer	CEC Systems is an industrial technology company founded in 2015, developing integrated solutions to the complex global challenges facing the shipping and logistics industries. Their innovative product, the COLLAPSECON®, is the world’s first semi-automated Collapsible Economic Container. Achieving a 4:1 ratio, COLLAPSECON® enables 4 empty containers to be collapsed and combined to form a single container. This solution improves operational efficiency, enhances return on investment, and reduces the impact on the environment. However, the design of the COLLAPSECON® faced challenges due to over-engineering and the use of complex geometries, which led to increased weight and potential manufacturing costs. Read More
Solution	SIMTech utilised the Altair HyperWorksTM software suite, and in particular Altair OptiStructTM, to find potential solutions for weight reduction without increasing manufacturing costs. The process involved constructing Finite Element (FE) models in Altair HyperMeshTM and solving optimisation problems with Altair OptiStructTM. The container design was reduced to seven sub-assemblies, and size optimisation of all container components was done by considering all critical load cases. High strength steel was used for hinges in the COLLAPSECON® C-400 units, which were costly and difficult to manufacture. Following a strength and deflection assessment of the current hinges, new hinge designs were proposed. SIMTech also investigated the damage tolerance of selected critical parts, simulating simple cracks, tears, and slits scenarios, and the effect of localised deformations. The morphing capabilities in Altair HyperMeshTM were used to locally deform the model to simulate accidental impact or other failure events. Read More Log in to view content
Contents

Technology Category

Functional Applications - Manufacturing Execution Systems (MES)

Platform as a Service (PaaS) - Application Development Platforms

Applicable Industries

Marine & Shipping

Transportation

Applicable Functions

Logistics & Transportation

Product Research & Development

Use Cases

Additive Manufacturing

Intelligent Packaging

Services

System Integration

Testing & Certification

Challenge

The shipping and logistics industries are responsible for facilitating over 90% of global trade, utilizing an estimated 35 million containers worldwide. However, global trade deficits result in 1 in 5 containers being shipped empty, leading to losses of over $30 billion annually. CEC Systems’ COLLAPSECON® provides an innovative solution to this problem, with a collapsible container design that improves operational efficiency and reduces environmental impact. However, the COLLAPSECON® design faced challenges due to over-engineering to meet industry ISO standards and pass manufacture testing. The units were nearly three times heavier than a standard container, due to the addition of moving parts and unique structural components. The complex geometries used in the design were also incompatible with traditional manufacturing methods, potentially leading to increased manufacturing costs. To optimise the COLLAPSECON® C-400 design for mass production and operational use, CEC Systems partnered with The Singapore Institute of Manufacturing Technology (SIMTech).

About Customer

CEC Systems is an industrial technology company founded in 2015, developing integrated solutions to the complex global challenges facing the shipping and logistics industries. Their innovative product, the COLLAPSECON®, is the world’s first semi-automated Collapsible Economic Container. Achieving a 4:1 ratio, COLLAPSECON® enables 4 empty containers to be collapsed and combined to form a single container. This solution improves operational efficiency, enhances return on investment, and reduces the impact on the environment. However, the design of the COLLAPSECON® faced challenges due to over-engineering and the use of complex geometries, which led to increased weight and potential manufacturing costs.

Solution

SIMTech utilised the Altair HyperWorksTM software suite, and in particular Altair OptiStructTM, to find potential solutions for weight reduction without increasing manufacturing costs. The process involved constructing Finite Element (FE) models in Altair HyperMeshTM and solving optimisation problems with Altair OptiStructTM. The container design was reduced to seven sub-assemblies, and size optimisation of all container components was done by considering all critical load cases. High strength steel was used for hinges in the COLLAPSECON® C-400 units, which were costly and difficult to manufacture. Following a strength and deflection assessment of the current hinges, new hinge designs were proposed. SIMTech also investigated the damage tolerance of selected critical parts, simulating simple cracks, tears, and slits scenarios, and the effect of localised deformations. The morphing capabilities in Altair HyperMeshTM were used to locally deform the model to simulate accidental impact or other failure events.

Impact #1	Through the use of the Altair HyperWorks platform, testing on loading conditions, damage tolerance, critical load, buckling analysis and shape optimisation a number of outcomes were achieved. Altair OptiStructTM was instrumental in discovering how over-engineered some parts of the COLLAPSECON® C-400 design were, and how to simplify some components whilst still meeting industry certification (ISO) standards. The team was able to determine specific target areas for weight reduction, leading to a lighter, more efficient design. The re-design of the link and hard stop hinges also reduced manufacturing complexity. The optimisation of the COLLAPSECON® C-400 design not only improved its operational efficiency but also its environmental impact, contributing to a more sustainable shipping and logistics industry.

Impact #1

Through the use of the Altair HyperWorks platform, testing on loading conditions, damage tolerance, critical load, buckling analysis and shape optimisation a number of outcomes were achieved. Altair OptiStructTM was instrumental in discovering how over-engineered some parts of the COLLAPSECON® C-400 design were, and how to simplify some components whilst still meeting industry certification (ISO) standards. The team was able to determine specific target areas for weight reduction, leading to a lighter, more efficient design. The re-design of the link and hard stop hinges also reduced manufacturing complexity. The optimisation of the COLLAPSECON® C-400 design not only improved its operational efficiency but also its environmental impact, contributing to a more sustainable shipping and logistics industry.

Benefit #1	A 30% weight reduction across several key sections of the COLLAPSECON® C-400 design.
Benefit #2	A reduction of 2mm of corten steel on the floor alone would save 750kg.
Benefit #3	A reduction in support beam thickness under the floor.

Benefit #1

A 30% weight reduction across several key sections of the COLLAPSECON® C-400 design.

Benefit #2

A reduction of 2mm of corten steel on the floor alone would save 750kg.

Benefit #3

A reduction in support beam thickness under the floor.

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Overview

Optimising the COLLAPSECON C-400: A Case Study in IoT and Shipping Logistics

Operational Impact

Quantitative Benefit