Optimizing Dragline Performance and Productivity at VR Steel with Altair EDEM™
Technology Category
- Analytics & Modeling - Virtual & Augmented Reality Software
- Wearables - Virtual Reality Glasses, Headsets & Controllers
Applicable Industries
- Metals
- Mining
Applicable Functions
- Product Research & Development
- Quality Assurance
Use Cases
- Virtual Prototyping & Product Testing
- Virtual Reality
Services
- Testing & Certification
About The Customer
VR Steel (Pty) Ltd is a company that designs, builds, and repairs fabricated mining equipment attachments. Their clients include major players in the mining industry such as Anglo Coal, Arch Coal, BHP Billiton, BMA Coal, Coal India, CRM, and Xstrata. VR Steel has dragline bucket customers in the US, South Africa, Australia, Brazil, and India. The company is committed to providing innovative solutions that enhance productivity and efficiency in the mining sector.
The Challenge
VR Steel, a company that designs, builds, and repairs fabricated mining equipment attachments, was faced with the challenge of optimizing dragline bucket performance and productivity for a wide range of media and mining conditions globally. They needed to develop a new, optimized bucket design that balanced efficiency, capacity, durability, and projected O&M costs. The company wanted to streamline the design process and provide their customers with design solutions that were guaranteed to fill easily and empty completely, operate at maximum capacity, boost wear protection, reduce operating costs, and improve overall efficiency.
The Solution
To address this challenge, VR Steel utilized EDEM, in conjunction with multibody dynamics simulation software, to simulate both the bulk soil dynamics and the dynamics of the bucket and lifting gear. This innovative, integrated particle-machine dynamics solution successfully modeled the transient particle-structure interaction, simulating the complete digging cycle of a dragline bucket. This virtual performance testing predicted the prototype bucket's mode and rate of fill, transient loading of bucket and gear, and wear patterns and rates. The use of EDEM virtual prototypes allowed VR Steel to field-test new design options, create custom designs for specific users, build fewer physical prototypes, shorten the design cycle, and increase customers’ productivity.
Operational Impact
Quantitative Benefit
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