Reducing Truck Load Body Costs: A Case Study on VR Steel

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

Hardware Design & Engineering Services
Testing & Certification

The Challenge

VR Steel (Pty) Ltd, a company that designs, builds, and repairs fabricated mining equipment attachments, including truck load bodies, was faced with a significant challenge. The company aimed to reduce the mass of a truck load body while maintaining its structural integrity and increasing its performance. The challenge was not only to streamline the design process but also to reduce prototyping costs. VR Steel needed a simulation tool that could help them achieve these goals. Their customers also demanded proof that the new design would unload more quickly, lower operating costs, and withstand heavy use. The challenge was to find a solution that could meet all these requirements while also providing a competitive edge in the market.

About The Customer

VR Steel (Pty) Ltd is a company that specializes in designing, building, and repairing fabricated mining equipment attachments, including truck load bodies. The company is committed to innovation and continuously seeks ways to improve its products and services. VR Steel values efficiency and cost-effectiveness, striving to reduce prototyping costs and streamline the design process. The company also places a high priority on customer satisfaction, aiming to provide products that not only meet but exceed customer expectations in terms of performance, durability, and operating costs.

The Solution

VR Steel turned to Altair EDEM™ virtual prototypes to address their challenge. The engineers at VR Steel imported 3D CAD models of the new load body design and generated EDEM material models of various media for testing. Using EDEM simulations as virtual prototypes, they were able to simulate the loading and unloading patterns of both the conventional load body and their new, lighter design. EDEM provided a virtual environment for conducting 100% repeatable tests with a variety of materials, all at a fraction of traditional physical prototyping and testing costs. This solution not only helped VR Steel meet their design goals but also gave them a distinct market advantage by enabling them to quickly design and test a new load body that outperforms competitor designs.

Operational Impact

The use of EDEM virtual prototypes brought significant operational benefits to VR Steel. The company was able to perform virtual repetitive testing under the same conditions every time, reducing the need for physical prototypes. This not only saved costs but also shortened the design cycle, increasing the company's productivity. The ability to simulate loading and unloading patterns of the new design allowed VR Steel to demonstrate to their customers that the new load body would unload more quickly and lower operating costs. Furthermore, the use of EDEM gave VR Steel a distinct market advantage, enabling them to quickly design and test a new load body that outperforms competitor designs, thereby enhancing their market position.

Quantitative Benefit