Altair Case Studies Optimization of Washing Machine Component by Samsung Using OptiStruct

	Optimization of Washing Machine Component by Samsung Using OptiStruct Altair

Optimization of Washing Machine Component by Samsung Using OptiStruct

Altair

Applicable Industries	Electronics Life Sciences
Applicable Functions	Logistics & Transportation Product Research & Development
Use Cases	Last Mile Delivery
Challenge	Suzhou Samsung Electronics Co., a joint venture between Korean and Chinese companies, has been focusing on optimizing the design of a belt pulley for one of its washing machines. The belt pulley, an essential component of a drum washing machine, was traditionally constructed from cast aluminum. However, with increasing cost pressures, the company sought to reduce the pulley’s weight by optimizing its design and/or using new materials for its production. The challenge was to consider alternative materials, taking into account both their performance and cost. To meet these challenges, Suzhou Samsung decided to employ topology optimization. Read More
About Customer	Suzhou Samsung Electronics Co. is a joint venture between Korean and Chinese companies that develops and produces major home appliances. Over the past 17 years, the company has introduced many new types of refrigerators and washing machines, each carefully engineered to provide the greatest value through optimization that reduces product weight while maintaining top-quality performance. Every component is designed to contribute to this goal, and the company has been focusing on ways to optimize the design of a belt pulley for one of its washing machines. Read More
Solution	To optimize the pulley, Suzhou Samsung chose OptiStruct, a key component of Altair’s HyperWorks suite of computer-aided engineering tools. OptiStruct provided important optimization features such as topology, size, and shape optimization. The company used the variable-density method of topology optimization, which uses the relative density of the elements as the design variable to determine the optimized material distribution. The process began with a static analysis of the original pulley model, followed by defining the topology optimization model. After solving the optimization problem, the model was rebuilt based on the results and size and shape optimization was conducted on the new model. The process concluded with a static analysis of the optimized structure, comparing results before and after optimization. The company also evaluated the potential benefits of switching from aluminum to a nylon-based belt pulley. Read More Log in to view content
Contents

Applicable Industries

Electronics

Life Sciences

Applicable Functions

Logistics & Transportation

Product Research & Development

Use Cases

Last Mile Delivery

Challenge

Suzhou Samsung Electronics Co., a joint venture between Korean and Chinese companies, has been focusing on optimizing the design of a belt pulley for one of its washing machines. The belt pulley, an essential component of a drum washing machine, was traditionally constructed from cast aluminum. However, with increasing cost pressures, the company sought to reduce the pulley’s weight by optimizing its design and/or using new materials for its production. The challenge was to consider alternative materials, taking into account both their performance and cost. To meet these challenges, Suzhou Samsung decided to employ topology optimization.

About Customer

Suzhou Samsung Electronics Co. is a joint venture between Korean and Chinese companies that develops and produces major home appliances. Over the past 17 years, the company has introduced many new types of refrigerators and washing machines, each carefully engineered to provide the greatest value through optimization that reduces product weight while maintaining top-quality performance. Every component is designed to contribute to this goal, and the company has been focusing on ways to optimize the design of a belt pulley for one of its washing machines.

Solution

To optimize the pulley, Suzhou Samsung chose OptiStruct, a key component of Altair’s HyperWorks suite of computer-aided engineering tools. OptiStruct provided important optimization features such as topology, size, and shape optimization. The company used the variable-density method of topology optimization, which uses the relative density of the elements as the design variable to determine the optimized material distribution. The process began with a static analysis of the original pulley model, followed by defining the topology optimization model. After solving the optimization problem, the model was rebuilt based on the results and size and shape optimization was conducted on the new model. The process concluded with a static analysis of the optimized structure, comparing results before and after optimization. The company also evaluated the potential benefits of switching from aluminum to a nylon-based belt pulley.

Impact #1	The optimized four-spoke aluminum belt pulley has been running smoothly in mass production, demonstrating the effectiveness of the optimization process. The company has applied for a patent on its redesigned pulley, indicating its uniqueness and innovation. The nylon pulley, which also underwent optimization, is currently in the experimental stage. The successful optimization of the pulley not only resulted in material and cost savings but also maintained the performance standards of the product. This case study demonstrates the potential of topology optimization in product design and material usage.

Impact #1

The optimized four-spoke aluminum belt pulley has been running smoothly in mass production, demonstrating the effectiveness of the optimization process. The company has applied for a patent on its redesigned pulley, indicating its uniqueness and innovation. The nylon pulley, which also underwent optimization, is currently in the experimental stage. The successful optimization of the pulley not only resulted in material and cost savings but also maintained the performance standards of the product. This case study demonstrates the potential of topology optimization in product design and material usage.

Benefit #1	The topology optimization resulted in the creation of a four-spoke pulley, reducing the total volume of the pulley by 6 percent compared with the five-spoke version.
Benefit #2	The company was able to determine the optimal divergence angle of the outer edge of the spoke through shape optimization.
Benefit #3	OptiStruct enabled a five-spoke nylon belt pulley that removed non-essential material without impacting performance and reduced the total volume of material by 10 percent compared with the original nylon model.

Benefit #1

The topology optimization resulted in the creation of a four-spoke pulley, reducing the total volume of the pulley by 6 percent compared with the five-spoke version.

Benefit #2

The company was able to determine the optimal divergence angle of the outer edge of the spoke through shape optimization.

Benefit #3

OptiStruct enabled a five-spoke nylon belt pulley that removed non-essential material without impacting performance and reduced the total volume of material by 10 percent compared with the original nylon model.

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Overview

Optimization of Washing Machine Component by Samsung Using OptiStruct

Operational Impact

Quantitative Benefit