This conference paper was submitted for presentation at the NAFEMS World Congress 2025, held in Salzburg, Austria from May 19–22, 2025.

Abstract

RESEMIN is a custom mining equipment manufacturer from Peru. They build wide range of equipment for underground mining operations around the world. They adopted unified modeling & simulation approach in 2009 in order to overcome their business critical engineering challenges. Key challenges experience by RESEMIN include: i. field failure of boom arm - resulting in warranty costs and expensive operational breakdowns for their Customers ii. expensive physical testing for safety of operator cabin - which is mandatory for meeting safety compliances (ROPS & FOPS) iii. Increasing complexity of machines increasing simulation time, thereby limiting design & simulation iterations with the shrinking product development timelines. In this session, Structural Analyst and Engineering Manager from RESEMIN will discuss how they accelerated innovation of underground mining equipment and overcame the challenges mentioned above with unified modeling & simulation approach across structural, fluid, thermal, electromagnetic and plastic injection molding simulation workflows. This session will cover technical details of structural simulation (FEA) workflows for boom strength and durability analysis, virtual Roll-Over-Protection-Safety ( ROPS) test, virtual Falling Object Protection Saftey (FOPS) test, and automation of component level simulations for Designers. Computational Fluid Dynamics (CFD) analysis methodology for HVAC and Operator cabin thermal comfort, electromagnetic simulation workflow for electromagnetic compliance for IoT, and plastic injection molding simulation for assessing manufacturability of head lights will be discussed in detail. Lastly, design exploration done with automation as well as integration between modeling and simulation for democratizing simulation for Designers at RESMIN will be highlighted in this session. Processes and rationale behind geometry preparation, identifying meshing best practices, operating scenario definition ( how they were obtained), solver choices and extraction of KPIs from results post-processing will be covered during this session. Presenters will discuss how RESEMIN overcame some of the challenges related to reducing field failures, expensive regulatory costs, shortening product design timelines, servicing costs, large complex simulation models and hardware limitations.