Case Study Making the Worldls Largest and Most

GREGG MONTGOMERY (MDI) & DARIN MOTZ (AGCO) CASE STUDY One could be forgiven for tracked behemoths, giving it a thinking that the new highly competitive range capable of Challenger MT900B series tractors matching and even surpassing many are AGCO Corporation’s first foray of the 4WD units in the market. into the rarified world of 4WD However, farming practices die hard, agricultural tractors. Earlier four- and although there had been wheel drivers that now fall under converts to the track-type machines, the AGCO umbrella include 1928’s there were many farmers who were Massey Harris General Purpose unwilling or unable to make the tractor, perhaps the world’s first change. Also, companies such as such tractor, the Minneapolis- Case IH and John Deere were upping Moline A4T-1400, the White 4-150 the ante with extra horsepower, Field Boss, the Allis-Chalmers Super more torque and bigger tyres. Beast, the Massey–Ferguson 4000, Never one to miss an opportunity, and the AGCOStar which ceased Robert Ratliff, AGCO’s founder and production in 2002. then-executive chairman, decided But that same year, AGCO there was a hole that needed to be acquired Caterpillar’s highly filled in the company’s tractor line- regarded Challenger line of rubber- up. However, not just any tractor Tall order Making The World’s largesT and MosT poWerful 4Wd agriculTural TracTor called for special design and engineering inpuTs 58 iVT International September 2008 iVT International September 2008 59 CASE STUDY would do: the hole was to be filled AbOve: The Challenger by the world’s largest, most powerful 4WD was the first tractor to use the new Michelin 4WD agricultural tractor – the Axiobib radial which is Challenger MT900B series. capable of handling 20% balance, hydraulics, steering and Challenger tracked machine and had more weight New beginnings overall ergonomics. This initial work penned its well-known Challenger Left AND beLOW: Concave Tasked with the job, the then resulted in a preliminary product script logo. It had also worked on fuel tank blends with Dekalb, Illinois-based Challenger specification that would guide both several 4WD tractor projects for both vehicle form language and provides excellent visibility engineering group made several key marketing and engineering. Case IH and New Holland when it to hitch personnel appointments that After a few months it became was contracted with CNH Global. brought in 4WD engineering talent, clear that another piece of the MDI’s first input to the project giving the project a running start. puzzle was missing, namely an was the fuel-tank design and The challenge was to develop an industrial design and styling input. improved visibility to the hitch. articulated 4WD tractor that would While it was a given that the tractor With a machine this size, visibility complement the successful needed to maintain a family can be a struggle due to the large Challenger MT800 series rubber- appearance and keep the hood and tyres, fenders, engine hoods and fuel tracked tractor, yet provide an grille of the Challenger track tanks. The industrial design and entirely new paradigm for the machines, it became obvious that engineering team explored a Challenger brand. A small there were many other areas where number of options capable of exploratory team was formed to choices needed to be made. achieving the desired results, but identify the key defining features It was at this point that only one design stood out as a and specifications of the MT800B Montgomery Design International solution that fitted the overall form tracked machine that were critical to (MDI), a Chicago-based design, factor of the tractor and achieved all the Challenger brand and needed to development and styling firm that the other goals for the design. The be incorporated into the new tractor. had worked in the agricultural and now-concave rear surface of the This exercise was followed by construction equipment machinery MT900 fuel tank became another extensive review and benchmark industry for 25 years, was brought immediately recognisable design testing of competitors in the areas of on board. MDI had collaborated element, as well as providing chassis configuration, weight and with Caterpillar on the original excellent visibility to the hitch. iVT International September 2008 61 CASE STUDY new members were added to the Left & AbOve: Small team at the Jackson facility, and not adjustments were made to the cab used on the tracked all of the DeKalb members were models, including relo- willing to move with the project. cated door components Still working on the rear half of step on the left side for filter access However, in time, the move was below: Alias CAID file for the articulated Challenger, MDI then and on the right for exhaust clearance. accomplished and the project was new Challenger fenders began investigating rear fender The concepts and ideas generated running smoothly again. shapes and access steps to the fuel during this first phase would tank. A number of options were eventually find their way onto the Good pedigree explored in sketch form; some first prototype, but more One of the early decisions made providing more tyre coverage, some immediately there was another area regarding the MT900B project was less. The overall design was that needed attention. The AGCO that it should heavily leverage complicated by the fact that the design team began working closely existing components from the world’s largest tractor would also with an Indian engineering firm that MT800B track-type tractor. This need the world’s heaviest duty was contracted to construct the commonality of parts benefitted the agricultural tyre. The MT900B front and rear frames, source the internal production and purchasing became the first tractor to fit prototype frame components locally departments, and shortened time to Michelin’s huge new Axiobib radial and perform final construction. The market by reducing validation tyre, capable of handling 20% more Indian company also conducted the requirements on new components. weight at the same tyre pressures as FEA, which was then reviewed by It also meant there were fewer new standard tyres. the AGCO engineers. parts requiring expensive tooling It was eventually decided that a It was around this time that and servicing. more minimal fender would be AGCO decided to relocate The complete engine, including offered for the base machine, and Challenger design engineering to its all installation and cooling packages, that any increased coverage facility in Jackson, Minnesota, where was taken directly from the MT800B. requirements could be handled with the manufacturing base for track- For product identity purposes and optional fender extensions. The type tractors had been moved the the elimination of expensive new front fenders were designed to previous year. This decision could tooling, the hood, grille and lighting match the rear and incorporated a have delayed the project as several package were similarly adopted – iVT International September 2008 63 CASE STUDY slightly modified – for the rubber- cab. Another major styling challenge field tests and analytical analysis. tyred chassis. Caterpillar’s 16-speed was to provide rear side panel covers The front and rear frames underwent powershift transmission in the new and a lower rear trim panel for the extensive FEA followed by strain- four-wheel drive tractor has some cab that masked the former fender gauge testing on prototype tractors to unique parts owing to gear ratios cutouts for the MT800B tracks and verify strength. The hydraulic system and higher road speeds, but it too is matched up with an HVAC duct and underwent exhaustive lab testing borrowed in large part from the upper trim panel that had to be including a full vehicle cold-room MT800B transmission. carried over for cost reasons. test to verify proper functionality MDI helped to modify the MDI provided the concept design, under extreme conditions. MT800B cab for use on the new styling and CAID surface development Powertrain components were tractor. Taking its basic structure, the and, ultimately, CNC machining of tested individually on dynos as well first project was to reorient entry/ masters or moulds of all these as undergoing thousands of hours of egress to the cab by incorporating a components plus hand-laid field testing in the most demanding front-hinged door with a relocated fibreglass parts where required. applications. Key performance and redesigned latch mechanism, Other items included in this phase metrics were tested and measured actuator and trim cover. of the project were revised controls using a towed dynamometer on the AbOve: MDI concept sketch and CNC machining opera- Several concepts were looked at and displays and a new custom concrete test track at the Jackson tion for new steering wheel in sketch form and, after selecting a steering wheel intended for use on Design Engineering Center. This design, prototype hinges, latch and all Jackson-built products. allowed the engineers to verify that bOttom: MDI sketch proposal for new 4WD cover were constructed in MDI’s One of the final and more critical the new tractor would meet their Challenger tractor workshop for fitment to a prototype design elements that MDI was goals and customer expectations. Sweet smell of success In 2006, the Challenger MT900B received the PTC Design Award, recognising the use of Pro/Engineer in getting the concept to market with a substantial saving in design and engineering time. Most recently, the tractor was recognised with a Good Design award from the Chicago Athenaeum and Museum of Architecture and Design. This most prestigious and long-established design competition rewards designers and manufacturers for their adherence to good design principles in the development of new products. Each year, thousands of products from hundreds of countries are evaluated by an international team of highly respected jurors, and awards are then bestowed on the most deserving products and designers in 20 categories.

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