Maplesoft Engineering Solutions team helps FLSmidth develop revolutionary mining equipment
FLSmidth discovered the advantages of system-level modeling while working with Maplesoft's Engineering Solutions team on the development of a Dual Truck Mobile Sizer (DTMS). The level of design detail and the amount of insight the team gained by using MapleSim enabled the company to revolutionize onsite crushing. The Maplesoft Engineering Solutions team enabled FLSmidth to keep the project on track and save millions of dollars.
In the mining industry, processing plants are generally constructed on the site of extraction. Mined ore gets transported by super-heavy duty trucks to the plant, where it gets crushed into smaller sizes before being stockpiled, or transported offsite for further processing. Besides the ore, the mine typically has to move four times as much overburden as ore. Big mines typically have to move 700,000 tonne of material per day. As the mine gets larger, the trucks have to travel longer distances to deposit their load, resulting in significant increases in the cost of fuel and vehicle maintenance.
To address this problem, FLSmidth engaged the services of Maplesoft’s Engineering Solutions team to develop design and analysis tools that would help them design a Dual Truck Mobile Sizer (DTMS) - an innovative machine that can be relocated throughout a project, as the haul distances increase.
The DTMS increases in-pit crushing efficiency due to its dual-skip configuration. A truck backs into one skip until it reaches a restraining curb in the floor. After dumping its load on the skip floor, it then slowly pulls ahead, lowers its bed, and pulls away. Once the truck clears the end of the skip, the skip can be raised. As the skip is elevated, it pours material from the discharge of the skip and deposits the material into the apron feeder hopper. As material is introduced onto the apron feeder, it conveys the material to the sizer where it is crushed to the appropriate size. After being crushed, the material is deposited onto the discharge conveyor where it is taken to the bench conveyor. This process is performed while another haul truck is depositing material into the twin skip, thereby increasing the number of truck cycles.
To create tools that would help FLSmidth to design this innovative piece of equipment, the Maplesoft team first had to develop a deep understanding of the dynamics of the skip system. They began by using MapleSim, the advanced modeling and simulation platform, to develop a fully parameterized model of the skip. Taking advantage of MapleSim’s multidomain modeling capabilities, they were able to create a high-fidelity model that incorporated all the key components of the skip - from its geometric structure and mechanical operation, to the hydraulic circuits and controllers. “The DTMS is a very large and complex machine,” says Willem Fourie, Global Product Line Manager - Mobile Sizer Stations, FLSmidth. “The ability to model all aspects of its operation during the design phase using MapleSim gave us confidence that the product we would ultimately build would function correctly the first time. We cannot even begin to put a value on what this means to us.”
MapleSim’s modeling approach not only addresses the basic requirements of dynamic multidomain simulation, but through seamless access to the underlying symbolic equations, enables the user to rapidly create targeted design tools using Maple’s high-performance symbolic computation engine. ...
MapleSim’s modeling approach not only addresses the basic requirements of dynamic multidomain simulation, but through seamless access to the underlying symbolic equations, enables the user to rapidly create targeted design tools using Maple’s high-performance symbolic computation engine.
The creation of the skip model was complemented with the development of multiple design tools to aid in adjusting the model to achieve the desired behavior. One such design tool is the Geometric Design Evaluation tool, which provides the ability to evaluate changes in the dimensions of the skip design and their effect on the dynamics of the system. The tool uses Maple -Maplesoft’s symbolic computation tool - to perform a parameter sweep, by simultaneously running simulations using the different parameter values provided. Maple then presents the results overlaid on a single plot window for easy comparison and evaluation. Other tools developed include tools for sizing the hydraulics and components, designing the motion profile, investigating the dynamic loading on the bearings, and estimating the material flow load.
As part of developing and testing the skip model, Maplesoft’s technical team also evaluated the design, to identify the sources of vibrations and their effects. They developed an approach to perform stability analysis, which was made possible by the fact that the skip model provided easy access to key geometric features and dynamic properties of the design. The stability analysis approach was demonstrated using a case study in which the location of the feedback sensor was varied. The analysis identified a potential issue very early in the design phase, enabling engineers at FLSmidth to develop a more robust design.
“The stability analysis performed by the Maplesoft team was very insightful,” said Fourie. “Knowing about a potential issue early on enabled us to design with it in mind, rather than having to go back and rework our design at a later stage. This contributed to keeping our project on track, and saved us millions of dollars down the line.” The stability analysis design approach and all the other analysis tools developed by Maplesoft were delivered to FLSmidth, enabling them to apply them to future projects.
Once the modeling and testing of the skip system was completed, during the following phases of the project, Maplesoft staff went on to develop the chassis model, and finally the full DTMS. Many more design tools were created, providing the ability to evaluate joint flexibility, center of mass variations as the skip was raised and lowered, and even soil modeling to investigate the vertical displacement of the system on different types of soil.
From start to finish, Maplesoft provided truly knowledgeable and professional service,” concludes Fourie. “Their team worked tirelessly to accommodate our schedule, and the power of the Maplesoft toolset is second to none. The level of design detail and the amount of insight we gained have enabled us to revolutionize onsite crushing through the development of the DTMS. We could not have achieved this without the services of Maplesoft’s Engineering Solutions team.”
Published by Maplesoft, Inc. on 4 Feb 2016
For more information send an inquiry directly to Maplesoft, Inc.
Engineers - Stop Doing Algebra by Hand!
Manual equation manipulation is labor intensive, time consuming, and notoriously prone to error. Simply put, doing algebra by hand is expensive. When faced with expensive processes, engineers find ways to mechanize and cut costs. Math should be no different. Computer algebra systems mechanize equation manipulation, reducing the need for human involvement and hence eliminate a source of risk. Pioneered originally by mathematicians and physicists, they are now more capable than ever to address a full range of engineering problems. Read this whitepaper to understand the benefits of computer algebra systems in the context of various engineering domains, to see how symbolic computation offers simplified solutions for many engineering tasks, and to learn how to use calculation management software to reduce the overall amount of errors commonly associated with working by hand.
Calculation Management Done Right
In the marketplace of technical products, growing competition has required faster design cycles and iterations in almost every sector. Companies take great steps to invest in their most important assets - namely, the products they deliver. These products are comprised of various designs, techniques, and intellectual property, all of which are managed across an organization with careful thought and attention. There’s something fundamental to these company assets which is often overlooked, and responsible for the aches and pains that most engineers face on a regular basis. This essential company asset is known as calculation management.
Maplesoft Makes Model Based Systems Engineering Accessible to More Engineers with New MapleMBSE
MapleMBSE is a new product from Maplesoft that provides engineers with greater accessibility to model-based systems engineering tools, helping them create, maintain, validate requirements efficiently, with fewer errors29 Aug 2017
Engineer in France Develops Motorcycle Racing Simulator Using MapleSim
Mr. Frédéric Nicolo wanted to develop a motorbike simulator that performed at the same level as current automobile simulators, accommodating the unique features of motorbikes. He started his own venture, developing a simulator using MapleSim that ...22 Jun 2017
Maple 2017 Offers Increased Mathematical Power, Stronger Visualizations and Flexible Deployment Options
Maplesoft today announced a major new release of its flagship product, Maple, the mathematical software that makes it extremely easy to analyze, explore, visualize, and solve math problems. The result of over 30 years of development, Maple already has ...22 Jun 2017
New Connector by Maplesoft and Phoenix Integration Combines Engineering Insight and Efficiency
Maplesoft and Phoenix Integration announced a new plugin that enables engineers to easily incorporate Maplesoft software products Maple and MapleSim into the ModelCenter workflow integration and automation platform from Phoenix Integration. Th...11 May 2017
Designing an Industrial Pick-and-Place Robot
A leading provider of packaging machines was experiencing repeated motor failures with their pick-and-place robots, facing substantial replacement costs on a regular basis. The company chose Maplesoft to develop a high-fidelity parameterized model...11 May 2017
Researchers at the University of Waterloo use MapleSim in New Approach to Tire Modeling
Ideally, a tire model will accurately simulate the dynamics of the system and result in simulations that execute quickly. Unfortunately, existing tire models typically either do not model behavior to a high degree of accuracy, or they are very resource...15 Mar 2017
Maple Drastically Reduces Downtime of Steam Turbines by Improving the Ultrasonic Testing of Rotor Blades
Rotek, the maintenance branch of Eskom, South Africa’s state-owned electricity provider, is using Maple, the technical computing software from Maplesoft, to design a comprehensive pre-inspection simulation model for use in the ultrasonic inspections of...8 Feb 2017
Maple Helps Hiab Simplify Their Crane Operation
Hiab, a leading provider of load handling equipment, is using Maple to design new ways to lessen the burden on crane operators and maintain safe and precise machine operation. Hiab selected Maple because of its ability to process complex matrix ma...7 Feb 2017
Latest MapleSim Release Improves Engineering Design Productivity
Maplesoft today announced a major new release of MapleSim™, an advanced system-level modeling and simulation platform used by engineers to reduce development time and gain insight into system behavior. The latest release provides tools that increa...6 Feb 2017
MapleSim used to speed up development of high-fidelity robotic manipulator models
ABB's Robotics business unit evaluated MapleSim, the high-performance modeling and simulation platform from Maplesoft, to develop high-fidelity manipulator models that included flexible joints, gears, and dynamic friction, and to determine the ease wit...4 Feb 2016
Maplesoft Engineering Solutions team helps FLSmidth develop revolutionary mining equipment
FLSmidth discovered the advantages of system-level modeling while working with Maplesoft's Engineering Solutions team on the development of a Dual Truck Mobile Sizer (DTMS). The level of design detail and the amount of insight the team gained by using ...4 Feb 2016
New MapleSim Toolbox Enables System-Level Modeling with CAD Designs
Maplesoft recently released the MapleSim CAD Toolbox, a new add-on to MapleSim that allows engineers to understand and improve their mechanical designs by bringing their CAD assemblies into MapleSim, the advanced system-level modeling and simulation p...4 Feb 2016
Modeling the Nao Robot in MapleSim
Engineers at Maplesoft used MapleSim to develop a model of Nao, a 58cm tall humanoid robot created by Aldebaran Robotics. The model simulated the movements of the robot, allowing the engineers to simulate its behavior accurately and teach it to do...10 Jul 2015