Numerical Modeling and Parametric Optimization of the Press Plate for the Glass Compartment of a Three-Compartment Refuse Collection Vehicle with Variable Compartment Volumes

A coupled discrete-element/finite-element (DEM-FEA) framework was applied to evaluate and optimize the press plate of the glass compartment in a three-compartment refuse collection vehicle with variable compartment volumes. Contact loading generated during a 0.6 m compaction stroke was obtained in Ansys Rocky and transferred to Ansys Mechanical for static structural analysis. The baseline design produced a maximum Z-direction displacement of -10.8 mm and a maximum von Mises stress of 229.88 MPa, exceeding the adopted limits of 8 mm and 196 MPa. Three design variables were considered: main-plate thickness t, hydraulic-strut attachment position a, and stiffening-rib thickness b. A response-surface model based on Non-Parametric Regression was used for parametric optimization. Three feasible candidate designs were obtained. The lightest candidate had t = 14.936 mm, a = 283.02 mm, b = 36.877 mm, a stress of 146.81 MPa, a mass of 1072.2 kg, and a displacement of -7.483 mm. The results demonstrate that DEM-derived loading combined with FEA and surrogate-based optimization can support rational press-plate design, although experimental calibration of contact parameters and verification of load transfer remain necessary before production implementation.