Designing Versatile Cabs for Dual Machine Compatibility
“They had two different machines with very similar cabs, so we merged them into one solution. By implementing a few options and modifications, this new cab will now work for both machines.”
In this dynamic manufacturing climate, streamlining and simplifying machine production is necessary for OEMs to both meet their production and sales goals while still exceeding the high quality standards operators expect. In this video, one of our account managers explains how we merged two similar cab designs into a single, versatile solution that accommodates different operator controls, operator access methods, and component accessibility. Our experienced engineering team collaborated with this OEM to also implement a number of beneficial features to this final cab solution, including a repositioned HVAC system and adjustable controls like the display and armrest, ultimately leading to a more comfortable operator experience.
Challenges: Different access, Controls, and Boom Geometry
The customer originally had several underground machine models that used two slightly different cab configurations, creating complexity in manufacturing and aftermarket support. Key differences included how operators access the cab, so the handle and latch placement had to accommodate both approaches. Controls also varied: joystick functions and mounting differed enough that a single fixed solution wouldn’t work without options. Lastly, boom pin locations that pass through the cab structure were offset by roughly six inches between models, requiring adaptable access for maintenance and boom securing.
Engineering the Solution: a Single Cab, Dual Compatibility
To solve these problems, the design team created a single cab envelope that met the OEM’s mounting and size constraints while adding modular features to bridge the differences between models. A removable or swappable joystick option was implemented so each machine’s control feel and function could be preserved without completely different cab shells. For the differing access heights, the door geometry and handle placements were modified so operators can reach them comfortably whether entering from either approach. An internal access port was also added to the cab wall to allow service and boom-pin engagement for both pin locations despite the six-inch variance.
Simultaneously Improving Operator Comfort and Serviceability
Inside the cab, ergonomics and adjustability were prioritized. Monitors are mounted on a vertical pillar that lets them slide up and down to suit operator sightlines and seating position. Also the armrests now adjust with the joystick mounts, keeping controls and support aligned for comfort during long shifts. Finally, during testing, the original seat wasn’t durable enough for the application, so the team upgraded to a stronger seat and improved armrests to meet the rigors of underground operations.
Serviceability was a major driver in the redesign. The HVAC unit was relocated outside the cab to the front of the machine, which freed internal space and made filter changes and servicing easier without also changing the machine’s exterior appearance. A large, contoured grille was incorporated into the front for airflow while maintaining protection from falling objects. These choices reduced in-cab clutter and simplified routine maintenance tasks in harsh underground environments.
Collaboration for Practical Benefits
For every project, GS Global Resources engineering team begins by taking the time truly understand an OEM needs and goals. In this instance, we worked together to establish a common cab envelope that fit the OEM’s existing mounting points and service clearances. With the overall structure defined, our team created an control layout, HVAC placement, seating, and access features together with the customer to ensure the merged cab met functional and durability requirements. Close collaboration allowed the team to deliver a single cab that could be mounted across the product line with minimal changes at the machine level.
By consolidating two similar cabs into one adaptable design, every group that touches the machine saw benefits. The OEM’s cab parts complexity was reduced and production, tooling, and inventory management were all simplified. Operators benefit from improved ergonomics, better visibility of displays, and easier access to service points—changes that increase uptime and operator satisfaction in demanding underground conditions. Maintenance teams see faster HVAC servicing and simpler boom-pin access thanks to the access port and externally mounted HVAC arrangement.
Contact us today to find out how we can improve the cab for one your machine lines and create a more versatile, flexible solution.
