These slides were presented at the NAFEMS World Congress 2025, held in Salzburg, Austria from May 19–22, 2025.

Abstract

The structural simulation team at Perkins Engines' site in Peterborough, UK, helped pioneer the use of finite element techniques in engine simulation applications. Since acquisition by Caterpillar Inc. during the 1990s, the team and its capabilities have continued to grow and flourish. The team has made significant contributions to many engine programmes throughout the Caterpillar business. In the early days, our work required the development of our own software codes, notably for the assessment of crankshaft dynamics, bearing performance and fatigue life prediction. Despite the subsequent proliferation of commercial software, these internally-developed codes are still seen to offer competitive advantage and continue to be developed. Historically, the team's focus was on core engine components, but this has steadily expanded to include ancillary items and integration within complex machinery. From the outset, our work has been under-pinned by detailed process documents that describe preferred methods. This ensures a consistency of approach, giving confidence in our decision-making process. One of our fundamental beliefs is that good simulation, early in the design process, leads to robust products. Since 2020 the team has been assisting the electrification of a number of machine-types through the simulation of battery packs and modules. Despite the obvious differences between engine and battery products, the team has been able to draw upon its accumulated knowledge to offer useful insight from the outset. As we gained experience with battery installations we were able to expand the range of simulations we could offer. In the fullness of time, it is anticipated that some of our newly-gained battery knowledge will be applied to engine simulation. The scope of work has ranged from simple static analysis to complex non-linear static and dynamic analyses that have stretched our capabilities and knowledge to their limits. However, by falling back on our engine knowledge and experience we have been able to maximise the degree of confidence we were able to give our design teams. This presentation discusses how we were able to take decades of learning in one field and apply it to another.