By SysCAD Techno Solutions | Experts in Heavy Equipment Simulation
In industries where machinery is exposed to extreme forces, unpredictable environments, and critical safety standards, engineering accuracy is non-negotiable. Heavy equipment must perform reliably—whether it’s operating in open-pit mines, offshore oil rigs, or high-load manufacturing facilities.
At SysCAD Techno Solutions, we bring deep domain expertise in CAE (Computer-Aided Engineering) and CFD (Computational Fluid Dynamics) simulations for heavy engineering applications. Our simulations help manufacturers reduce physical testing costs, extend equipment life, and ensure compliance with global standards like ASME, API, ISO 19426, and DIN.
What Makes Heavy Machinery Unique?
Heavy engineering involves design challenges such as:
- High static & dynamic loads (e.g., >100 tons)
- Exposure to abrasive materials, heat, and pressure
- Complex hydraulics and multi-body interactions
- Fatigue due to long duty cycles (10,000+ hours)
- Harsh operating environments (dust, fluid ingress, etc.)
Our simulations solve real-world problems before they happen in the field.
CAE for Heavy Equipment – Structural Engineering & Fatigue
🔧 Structural & Multibody Analysis:
- Excavator Arm FEA
- Load capacity: 10–120 tons
- Peak stress zones validated for 3x safety factor
- Weld and bolt fatigue prediction over 1M cycles
- Hydraulic Cylinder Simulation
- Pressure ratings: up to 350 bar
- Seal deformation & leakage risk under dynamic loading
- Buckling analysis on long-stroke actuators
- Boom & Frame Durability
- Displacement: ≤ 8 mm under full payload
- Fatigue life: Designed for 20,000 hours duty cycles
- Dynamic analysis under sudden impact & load reversal
- Earthmover Chassis
- Torsional stiffness targets: 40–60 kNm/deg
- Natural frequency tuning: > 25 Hz to avoid resonance
CFD for Heavy Machinery – Fluids, Cooling & Dust Control
🌬️ CFD Applications in Heavy Engineering:
- Engine & Transmission Cooling
- Radiator airflow velocity: 3–5 m/s
- Fan performance: 1500–5000 CFM
- Coolant temp rise control: < 10°C under full load
- Hydraulic System Flow
- Pressure loss across valves: < 10% max rating
- CFD validation for complex pipe routing
- Cavitation zones detected under fast retraction
- Dust Control & Ventilation (Mining Equipment)
- Particle dispersion analysis
- Filter efficiency: > 95% at 2.5 μm
- Airflow CFD to reduce operator exposure
- Thermal Insulation & Heat Shielding
- Surface temps: up to 600°C near exhaust zones
- Heat soak duration control: < 20 minutes shutdown
Tools & Techniques Used at SysCAD
- Nonlinear Contact & Weld Fatigue Simulation
- Explicit Dynamics for Impact & Drop Tests
- Modal Analysis for Natural Frequencies
- Transient CFD with Dust/Mist Tracking
- DOE (Design of Experiments) for Optimization
Real-World Industry Use Cases
🏗️ Construction Machinery (Excavators, Cranes)
- Boom fatigue life improved by 38%
- Hydraulic buckling failure resolved pre-production
⛏️ Mining Trucks & Loaders
- Chassis deformation reduced by 22 mm under peak load
- Air filter design improved particle control by 93%
🌾 Agricultural Equipment (Harvesters, Tillers)
- CFD analysis reduced overheating by 28%
- Structural redesign enabled 15% weight reduction
🏭 Industrial Equipment (Presses, Kilns, Mixers)
- Rotational part balancing improved reliability by 35%
- Heat shield efficiency increased to 91% with CFD redesign
