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Sandvik

Simulators play a key role in the development of control systems

The challenging conditions of the mining industry require complicated digital control systems, which are made possible with the help of product development simulators. Sandvik remains firmly in its position as the industry’s technology leader, thanks to the simulators created by Gofore’s subsidiary Creanex.

objective

A flying start to product development digitalisation with simulators

The manufacturer of mining industry machinery, Sandvik, was getting ready to take the digital leap, and the company set its sights on the product development simulators of Gofore’s subsidiary Creanex.

Technological progress and the rising demand for more automated solutions meant that it was an appropriate time for the company to replace the old hydraulic control systems with new digital solutions. The move towards digital transformation also opened doors to the development of more advanced and complicated control systems. However, this change also meant that new virtual design and testing tools had to be created to meet the needs of product development.

“Mining industry machinery is operated in challenging conditions, and the modernisation and creation of smarter control systems for the machines means that we need to develop them as far as possible under controlled and reproducible conditions prior to producing a prototype,”, says Sami Hanski, R&D Manager at Sandvik.

We could not live without simulators.

Sami Hanski, RnD Manager, Sandvik

Solution

Simulation brings the actual operating environment to the development workbench

Sandvik and Creanex have perfected their co-operation over two decades, and today creating simulators is an established part of the development cycle for each new product. The design process for a new machine model starts with Sandvik delivering 3D models of the machine and its required functionalities to Creanex. Creanex then uses this information to build a simulator model.

Sandvik’s software development gains access to a virtual testing tool easily and effortlessly on a turnkey basis. Creating a simulator for a new machine model takes around two months.

The product development simulator is a HIL system (hardware-in-the-loop), in which the simulator tricks the control system into thinking that it is being fully operated in a real environment. The actual control system can be connected to the simulator because the simulator comes with all of the necessary IO-interfaces.

Simulators are useful beyond the development phase – they can be used throughout the machine’s lifecycle to help with developing and testing new versions of the control system. Product development simulators are seamlessly connected to test automation, which allows for round-the-clock testing and ensures high quality in software releases.

Simulators created for product development are also used for training purposes. In product development, it is essential to be able to connect the control system to test automation as opposed to training simulators, where a compact size and interface with virtual training modules are the most significant features.

Mining industry machinery is operated in challenging conditions, and the modernisation and creation of smarter control systems for the machines means that we need to develop them as far as possible under controlled and reproducible conditions prior to producing a prototype.

Sami Hanski, RnD Manager, Sandvik

Result

“We could not live without simulators”

Simulators have been a time-saver for Sandvik. Software development can begin at an early stage, and the functionality and safety of control systems can be ensured prior to creating a physical prototype. The road to a finished machine becomes shorter, and the costs to create it smaller. Hanski highlights even more significant benefits:

“The fact of the matter is, we could not live without simulators. They enable us to develop complex technologies, create unique solutions and hold our position as the industry’s technological leader. Simulators also help us establish the conditions for the utilisation of other technologies, such as AI. These benefits cannot simply be measured in time or money.”

Sandvik also uses simulators to increase the commitment of its stakeholders to the new machine models.

“Their voices are heard already during the product development stage, which not only improves the quality of the machine but also the stakeholders’ commitment,” says Hanski.

Project highlights

Objective

Sandvik wanted to modernise the control systems of its mining industry machinery using smart, digital solutions. This change required new virtual design and testing tools because control systems need to be developed as far as possible under controlled and reproducible conditions prior to creating a physical prototype.

Solution

Gofore’s subsidiary Creanex uses comprehensive HIL simulation to create product development simulators that can be connected to Sandvik’s control systems. Simulators are an established part of the product development process of each new machine, and they remain an effective part of the machine’s software development throughout its lifecycle.

Result

Simulators bring time and cost-savings to Sandvik and, above all, they enable Sandvik to develop complex technologies, produce unique solutions and hold its position as the industry’s technological leader. Furthermore, simulators increase stakeholder commitment and help with training the machine’s users.

Co-operation in numbers

  • 30+ developed simulators
  • 20 years of co-operation
  • 2 months to completed simulator

The skills & competences utilised in the project

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