Heavy Mobile Machinery Design & Simulation

Operation safety and comfort are crucial, especially in preventing injuries from thrown objects and rollovers. Simulia Abaqus’ dynamic explicit simulation solution is leveraged to assess virtually the impact of thrown objects and the performance of rollover protective structure (ROPS) against strict safety standards.

Furthermore, SIMULIA solutions can also be used to design an energy-efficient cabin in the early development stage, considering multiple key performance indicators.

1. Operator thermal comfort for summer/winter conditions in different locations, with different gender & physiology of operators

2. Defrost on the glasses and ways to optimize/improve flow pattern & design to achieve faster defrost to pass legislation and safety

3. Provide accurate noise levels for the HVAC system, without having to build a prototype. Give indications of where the dominant noise sources can be found, and determine what changes need to be brought forward to improve the system

These solutions help improve cabin safety by simulating real world impact scenarios, optimizing design for structural performance, comfort , and compliance with regulations.

35-40% of heat generated from engine combustion dissipated to cooling system. In contrast to automobiles, these slow moving and stationary machinery do not have any “free” ram air to help with the cooling but rely solely on the performance of the cooling package including cooling fan(s) and heat exchangers to reject the excess heat. Thus, an effective cooling system is extremely important for them. SIMULIA automated workflow solution can virtually test various configurations of cooling systems to optimize both cooling airflow and noise level requirements and predict failure points. Furthermore, the thermal workflow can be used to identify problematic components in the underhood that will exceed design temperatures, leading to critical failure

The HVAC system is traditionally oversized to achieve performance in extreme environments; however, the large systems decrease energy efficiency, limit operational time in electric machinery, and use up valuable cabin space. This conundrum makes for a complex design problem, which is further complicated by the need to meet multiple legal certification requirements, such as defrost performance and roll over protection, to name a few. SIMULIA simulation solutions can help in sizing the HVAC at the early design stage thereby achieving energy efficiency for different cabin designs.

The shift to electrification on heavy mobile machinery requires durable and efficient battery systems. Simulia’s simulation tools enable the optimization of battery module strength, and safety by evaluation critical interactions between components. Through reduced order cell models and multi-physics simulations, engineers can enhance battery design while ensuring compliance with safety standards and minimizing the risk of failures during operation.

Heavy machinery must perform under various harsh conditions, from farming to construction to mining. .Simulia’s advanced simulation tools enable the evaluation of structural integrity, durability, and thermal management under extreme conditions. By simulation mechanical behavior, fatigue, and thermal performance, engineers can enhance design, robustness, extend equipment life, and reduce maintenance costs, ensuring reliable performance across diverse environments.

Lightweight design is crucial for enhancing efficiency and reducing costs in heavy mobile machinery. Simulia’s generative design capabilities allow engineer to create optimized, lightweight component that maintain strength and performance. By utilizing advanced optimization techniques, designers can reduce part weight while maximizing stiffness, ultimately improving equipment performance and affecting positively on the TCO of end customer.

Simulia’s structural and durability Physical Simulation tools allow the evaluation of equipment component under extreme operation conditions, helping identify potential failures early. By simulating the equipment full system behavior, including welded structures, the need for expensive physical prototypes and testing facilities are reduced, ultimately minimize warranty costs.