Engineering & Mining Journal

JUL 2014

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80 E&MJ; • JULY 2014 www.e-mj.com O P E R AT I N G S T R AT E G I E S Simulation's Role Expands Across the Industry Computer programmers are sometimes asked—or may occasionally just prefer—to do what's called "coding down to the metal." It means they're writing code directly to an electronic component, such as a specific chip or a graphics board, with- out having to deal with intermediary layers of protocol or other abstractions. In mining, coding down to the metal generally has an entirely different connota- tion: the "metal" is most likely a massive piece of equipment, and the coding isn't designed to make the latest console game more exciting—its intent is more likely to save companies millions of dollars in prod- uct development costs, to save equipment operators from injury or death, help them operate conventional equipment more effi- ciently, or understand new technologies. Nowhere in the industry is this more evi- dent than in the simulation sector. Here are a few examples: Getting a Head Start on Machine Design Engineers in Volvo Construction Equip- ment's Technology arm are developing new methods to increase the amount of virtual testing and simulation that can be con- ducted before a first machine prototype is built. Not only does this shorten the devel- opment cycle, but it also ensures that when prototypes are built, they are much closer to the final product, reducing costs. Virtual testing and simulation isn't new to Volvo CE—the company has an estab- lished virtual product development (VPD) team that works with everything from early stage simulation, to simulating future tech- nology and even understanding operator behavior via a real-time, human-in-the-loop system. However, a recent breakthrough by Volvo CE engineers is allowing more early- stage simulation than ever before. Until now, the structure and dynamics team required a prototype to test the strength of machine components, such as frames. Now, the early simulation team can use computers and simulation to provide the structure and dynamics team with the forces they need to analyze structural integrity and performance. This allows the team to estab- lish how strong parts need to be a year ear- lier than was previously the case—all before any money is spent building prototypes. Currently, this method is only being applied to Volvo CE's articulated haulers, but the company's engineers plan to adapt the tech- nology for use on all Volvo CE machines. "If an articulated hauler is working on an uneven road and the wheel hits a bump, forces are created in the hauler and distrib- uted from the tire to the framework," explained Lennarth Zander, manager of the VPD team. "Through simulation and math- ematical calculations, we can accurately measure this force, which allows the struc- ture and dynamics team to determine struc- tural response and the required strength of parts. Previously this was established with a prototype on a test track but now we can achieve the same results faster using a computer. We have created an accurate 3-D model of an articulated hauler in the computer, which is equipped with every- thing the real machine has. The move- ments—such as braking and turning—are exactly the same. Watching the animated 3-D machine is like watching a movie." Another advantage of this technology is that virtual measurements can be taken in locations where it's not possible to do physical measurements. For example, there isn't room for a physical sensor in confined areas, such as on a bolt, but now forces in these places can be measured via simulation. The simulation model can also be used to determine how the machine would behave in different environments, from freezing temperatures to blistering heat or at high altitudes where there is much less oxygen in the air. "It's becoming increasingly important to shorten the development cycle and use computers to carry out as much virtual testing and simulation as possible," Zander said. "With this new technology, we will increase efficiency and enhance the product development process without com- promising accuracy, and that's a big break- through. In the future, we should be able to skip early prototypes and build a more mature model with a higher level of accu- racy that's much closer to the final machine—saving both time and money." Cutting Costs Cipta Kridatama, a major Indonesian min- ing contractor, improved haul-truck fuel efficiency by 6.9% using simulation-based training, according to simulator developer Immersive Technologies. Presenting at a recent Immersive Technologies Users Group Forum, Cipta Kridatama's talent development manager, Gemilang Adi Perdana, said, "With com- modity prices going down, like many sites, we are looking at ways to cut costs, and fuel consumption was identified as a problem area. We were over budget by nearly 10,000 liters per month at one site and identified the contributors affecting fuel consumption. Operator skill level was the focus." Fuel records for 30 haul-truck operators were collected over a one-month period and 18 of the 30 exceeded budgeted liters per hour consumption. All operators were assessed using an Immersive Technologies Advanced Equipment Simulator to estab- lish a baseline, followed by simulation- based training and a reassessment. Once Volvo Construction Equipment's design team replaced its previous, less-integrated product prototype process with a new, more efficient system that simulates the behavior of major vehicle subsystems in its articulated haulers— hydraulics, powertrain and thermal management—as well as driver input and reaction. EMJ_pg80-81_EMJ_pg80-81 7/1/14 2:50 PM Page 80

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