Caterpillar 789C, 789D and Letourneau 1150 sound attenuation

The brief:

To mechanically design, analyse and integrate a variety of aftermarket sound attenuation components including mufflers, radiators and air intake cowls to reduce the sound levels emitted from a variety of large mobile mining machines.  Specific works included:

• New vehicle front assemblies for two fleets of 789C and 789D Caterpillar trucks.  This included new radiator inlet attenuation panels, bumpers, fold away access systems, mufflers and body cowls.  These works involved major structural modifications to both types of vehicles.

• Complete new rear body structures for a LeTourneau 1150 front end loader.  This included hinge to open radiator inlet attenuation panels (including heavy duty custom hinge designs), a new engine canopy structure with integrated walkways and muffler mountings, new mufflers, new collision bumpers and engine bay air intake covers.

The solution:

Making use of a variety of design tools such as 3D optical and laser scans coupled with derived digital representations of each vehicle, CAD models were constructed integrating each modification. Designs were validated against a number of collaboratively derived functional specifications using a variety of methods including FEA and hand calculations. Designs were transitioned into manufacturing detail for local manufacturers and onsite crews to implement and if necessary provide feedback to. All designs were supported from concept to implementation ensuring seamless integration.