Engineering simulation for heavy equipment

Performance engineering for heavy equipment is about finding the right balance between all performance requirements, including energy efficiency, safety, comfort and more. But as today’s heavy equipment products are increasingly complex, keeping this balancing act under control becomes very difficult. There are too many possible parameter combinations and the way those parameters interact is not always intuitive, especially when there is software involved. It’s impossible to be successful with a classic iterative approach that is based on recurrent physical prototyping. Therefore, you need a process in which engineering simulation for heavy equipment can drive the design. Our software includes engineering simulation tools that combine accuracy and solution speed to make that possible. These simulation tools are combined with powerful testing solutions to improve modeling realism and for final prototype validation testing.

To create a comprehensive digital twin, you need to develop a set of extremely realistic models and data that are always up-to-date and in sync with any parameters change that would apply. This allows you to predict the real behavior of the equipment in its actual state. Our solution for predictive performance engineering during equipment design and performance optimization does just that. During every product development stage, from concept to final validation, you can consider all physics and disciplines simultaneously so that your models fully reflect reality. We achieve this through a wide combination of technologies and solutions, primarily based on 1D system simulation and 3D analysis, so you can address any context and stage. By adding physical testing solutions, we enable you to leverage real data to make better modeling assumptions for physical properties, boundary conditions and duty cycles.

Integrating simulation and testing is key to Siemens predictive performance engineering solutions for heavy equipment. As product development processes become increasingly simulation-driven to master the growing complexity in multi-disciplinary products, many people mistakenly assume that physical testing becomes less important. When exploring new technologies to design today’s innovative equipment, you need continuous testing to validate modeling assumptions and achieve realistic simulations. Testing will always remain crucial for prototype validation and certification - assignments that will come in a more continuous flow as software-based capabilities blur the boundaries between various lifecycle phases. Simulation and testing activities should not occur in separate workflows. They should be part of the same platform so they can synergize. Siemens is the only partner that combines both worlds in one solution offering.

Electrification and digital innovations that enable data-driven operations are heavy equipment trends that have very specific requirements for product design and engineering. Both require multi-disciplinary design as they combine mechanical design with E/E systems design and software. For all performance aspects, multiple disciplines play a role. Numerous parameters mutually interact, with values depending on the machine’s operational status. You can’t manage that with a linear engineering process, where you optimize disciplines one after the other, with lots of iterations and recurrent prototyping. To enable data-driven operations, you need capabilities that let performance predictions continue after delivery, based on models that are up to date. With Siemens solutions, you can connect all product lifecycle stages through a common environment where you can track the entire history of each individual piece of equipment from design to the field, including changes, manufacturing deviations, upgrades, wear and maintenance.