R&D
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OVERVIEW
R&D activities were started in KGF & Bangalore divisions during the mid 70s and at Mysore during mid 80s. The initial focus was on technology absorption and Indigenisation. Subsequently, products and aggregates were taken up for design and development.
Fully equipped R&D Centre with facilities for design, simulation and testing was established in 1984 at KGF with an investment of INR 50 crores and further upgraded over the years, and is one of the biggest development centres in India. R&D Centres at KGF, Mysore & Bangalore are recognized by the Department of Science & Technology, GoI. These Centres are making vital contribution towards strengthening the Earthmover and related industries in the country. R&D Division is equipped with CAD Centre and dedicated Laboratories in the areas of Fluid Power, Power Train, Structural Engineering and Material Science.
R&D division is manned by highly qualified engineers with specialisation in advanced fields of mechanical design, engine technology, structural engineering, material science, fluid power and electronics and has gained significant experience and technical knowhow in design and development of complete machinery as well as aggregates
| CONTACT | HEAD OF R&D (Mining & Construction)BEML Limited |
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Vision
BEML Limited will build the future business around its core competencies in high tech engineering products for Mining & Construction, Rail & Metro, Defence and chosen areas by developing competency, upgrading technology, innovating and adding value with in-house R&D efforts aiming towards self-reliance.
Policy
The R&D policy is
- Development of new products & technologies for entering new / existing markets
- Up-gradation of existing products with state-of-the-art features
- Continuously enhance the quality and reliability of the products
- Up-grade the products to meet regulatory requirements
- Promote energy saving devices and environment friendly technologies
- Continuously up-grade products to enhance safety features
Mission
- Design & Development of new products / continuous up-gradation of existing products and aggregates in line with the customer feedback / innovation.
- Provide sound technological base to the company.
- Identification of new products/aggregates for design and development by scanning technological innovations, to meet the strategic needs of the customers.
- Acquire technologies through Technology transfer or in-house development
- Digital design & evaluation of products and aggregates
- Indigenization of products and aggregates.
- Establish, maintain and upgrade test facilities for evaluation of performance and reliability of equipment and aggregates.
- Patenting and Protection of Intellectual Property Rights (IPR).
- Structured evaluation of benefits derived through R&D activities.
- Keeping pace with technological development by continuous interaction with other R&Ds and technical institutes at national and international levels, DSIR / DRDO laboratories & user industries.
- Planning & imparting training to R&D engineers in the areas of new technologies to upgrade their skill sets
Products Developed by In-House R&D
Mining & Construction (Surface Eqpt.)
- Dump Trucks : 35t to 205t capacity (Model: BH35-2, BH40, BH60M, BH70, BH85-1, BH100, BH150E & BH205E)
- Water Sprinklers : 28kl to 70kl with mist system (Model: WS28-2 & WS70)
- Excavators: 7 t to 180t (Model: BE75, BE100, BE200, BE220G, BE300LC, BE450, BE700, BE1000-1, BE1000E-1, BE1800E & BE1800D)
- Dozers: 90 hp to 860 hp (Model: BD50 HST, BD65-1, BD65-1PAT, BD85, BD155-A/P/E versions, BD355 E/P/A/T versions, BD355-1 CLSS & BD475-1)
- Motor Grader: 10ft to 16ft Blade (Model: BG405A, BG605I, BG605A & BG825)
- Pipe Layer : 41 t to 100 t (Model: BP41, BP70 & BP100)
- Wheel Dozers : 145 to 340hp (Model: BD14W & BD30W)
- Tyre Handler : 145hp (Model: BL14TH)
- Wheel Loaders : 130 to 340 hp (Model: BL200-1 & BL40)
- Back Hoe Loaders: 76 to 100 hp (Model: BL9H 4X2, BL9H 4X4 & BL120H)
Technology Demonstrator Products :
- Remote Controlled Dozer on BD50 & BD155
- Disaster Management versions of BE300
- Optional attachments:
- Giant Ripper with Pin puller, Multi shank Ripper& Coal Dozer on BD155 & BD355.
- Multi shank ripper, Waste handling Blade & Coal Dozer attachment on BD65-1 & BD85 Dozer.
- Towing winch on BD65-1 & BD155 Dozer.
- Tree Pusher attachment with Forestry Canopy on BD65-1 & BD85 Dozer.
- Super long front, Trapezoidal bucket, slope finishing bucket & Ripper Bucket on BE220G.
- Rock Breaker & Clamshell Bucket on BE220G & BE300LC
Mining & Construction (Underground Mining Eqpt.)
- 1 cu.m. Bucket Capacity Side Discharge Loader (Model: BL-10C)
- 1 cu.m. Side Discharge Loader with Cable Reeler Drum (Model: BL-10C CRD)
- 65 cu.m. Side Discharge Loader with Side Tipping Bucket
- Load Haul Dumper with 1.5 cu.m. Push Plate Bucket (Model: BL15 LHD-1)
- 5 t, 5.4 t & 7.5t Granby Car
- 4 t& 12 t Battery Operated Locomotives (FLP / Non FLP) (Model: BU4F & BU12F)
Axle Technology
- Planetary Axles for 100 to 450hp class Loaders
- Planetary Rear Axles with wet multiple disc brakes for 35 to 100t Dumpers
- Planetary Rear Axles with Integral Parking Brake
- Front Axle with wet multiple disc brakes for 100t class Dumpers
- Final drive & Tandem drive with differential lock up for 173hp class Motor Grader
Transmission Technology
- Planetary powershift transmission for 230hp class Dozer
- Proportional Control Valve for Dozer Transmissions
- Planetary Automatic Transmissions for 35 to 100t class Dumpers
- 420hp Loader Transmission with Electro-Hydraulic Control
Electronics & Automation Applications on Products
Vehicle health monitoring, increased productivity, compliance to safety standards will require extensive use of sensors and electronics on equipment and dedicated team of engineers and electricians is focusing on automation projects.
The Products developed by Electronics Group are :
- Unified Electronic Controller for transmission, pay load monitoring, vehicle health monitoring
- Multi-Functional Vehicle Data Recorder
- Radio Control Dozer
- Portable Equipment Weighing System
- Transmission Controller
- Programmable Digital display with diagnostics & data storage
- Payload monitoring system
- LCD display based centralized monitoring system with enhanced diagnostics & data storage
The Products
developed by Electronics Group are:
- Unified Electronic Controller for transmission, pay load monitoring, vehicle health monitoring
- Multi-Functional Vehicle Data Recorder
- Radio Control Dozer
- Portable Equipment Weighing System
- Transmission Controller
- Programmable Digital display with diagnostics & data storage
- Payload monitoring system
Patents
Granted due to R&D efforts
- Field programmable gate array module based Unified Electronic Controller for off-highway dump truck
- New GMAW / CO2 welding process improvement for better weld quality & mechanical strength
- Multi Functional vehicle Data Recorder
- Forged Design Tooth Point for Backhoe Loader
- Tooth Point assembly for Walking Dragline Buckets
- A Control System for an Automatic Power shift Transmission
- Radio Control System for Clutch Control Geared Dozer
- A system for induction hardening of concave profile components
- An exhaust after treatment system for an engine
- Wheel steering control system
- Accelerated fuel filling system
Awards
for R&D Excellence
- CII Award – Excellence In Technology in the year 1986-87
- DSIR Award – Outstanding R&D Achievements in the year 1990- 91
- SEI Award – Company Standardisation in the year 1990, 1992 & 1995
- SODET Award for Design of 35t class Dumper Transmission in the year 2009
- Best Engineering Marvel for Self-Reliance, Engineering Excellence Public Choice Award & Best Engineering Marvel of the Year for BH150E Dumper in the year 2013
- Innovation Award from NRDC for Generic Electronic Modulation Transmission Control System in the year 2013
- Raksha Mantri Award for Design effort for BE1800E electrical excavator in the year 2017
- 8th CII Design Excellence Award 2018 in Industrial Design category for BD65 Hydraulic Torque Converter
TECHNOLOGY
Software
- Pro-E, Autodesk Product Design and Manufacturing collections (PDMC), Autodesk Inventor Professional, Solidworks software packages for 3D modelling.
- ANSYS Mechanical CFD Enterprise for FEM Analysis/Fluid-Flow Analysis and Optimisation.
- KissSoft and KissSYS software for gear calculation and simulation
- ADAMS for Kinematics and motion Analysis of systems.
- AutoCAD for 2D drafting.
- UltraArc Robot Offline Programming Simulation for Arc Welding application.
- Visual Studio .NET, Visual Studio (Basic, C++, FoxPro) for application software Development.
- Adobe CS suit and Adobe Acrobat editing tools
In-House Developed Software
- BemlKam: Nesting of drawing profiles & production scheduling for CNC machines at Plate shop.
- Pipe bending: To create automated production drawings of pipes by a novice user.
- Gear design: Gear geometry for Internal and External Spur and Helical Gear pair. Contact & Bending Stress for Spur and Helical Gear pair. Addendum modification coefficient. Gear Inspection parameter.
- Vehicle Performance Simulation: Predicts vehicle performance for various operating condition considering engine and hydraulic torque converter matching.
- Library management Software:Library management through interactive user friendly screen.
- Torque Converter Design: Torque Converter Performance Prediction Software
Test Facilities
Laboratories are operated according to quality systems conforming to ISO/IEC 17025 Standards and are accredited by NABL for Mechanical calibration, Fluid flow calibration and Mechanical testing, chemical testing, ROPS /FOPS testing and Fatigue testing of structures.
Fluid Power Laboratory
- Pump test rig - Maximum pressure :320bar
- Control valve test rig (High pressure)– Maximum pressure:320bar& 600 LPM
- Hydraulic cylinder test rig - Maximum pressure :210bar
- High pressure power pack – Maximum pressure :1500 bar
(Proof pressure & Burst Pressure)
- Hose Impulse test rig – Maximum pressure : 800 bar
Powerline Laboratory
Powerline Laboratory was established by BEML at its R&D centre in KGF, in 1989.It has extensive facilities for evaluating transmissions, axles, torque converters and other gear drives. The following test rigs are available:
- Axle/ Transaxle Testing from power range of 50 - 350 kW
- Transmission Testing from power range of 50 - 900 kW
- Torque converter testing from power range up to 375 kW
- Calibration Services
- Pressure transducers up to 600 bar
- Torque wrench calibration up to 4000 Nm
Structural Engineering Laboratory
The structural engineering laboratory established in 1987 is equipped with state-of-the-art facilities in fatigue testing, experimental stress analysis using strain gauge technique. The laboratory is involved in testing, evaluation and validation of structural components.
The following facilities are available:
Data Acquisition Systems
- Experimental Stress Analysis – Static & Dynamic
- Field Data Acquisition.
- Noise and Vibration Measurement
Fatigue Testing
- Metro Bogies static & fatigue Testing
- Fatigue Testing of all heavy structures.
Earthmoving Machinery cabin
- Performance Test – Roll over protective Structures (ROPS) Test as per ISO 3471
Performance Test – Falling Object protective Structures (FOPS) Test as per ISO 3449
Material Science Laboratory
The Material Science laboratory was set up in 1987 for testing and analysis of materials to aid chemical, mechanical and micro structure studies. The following facilities are available
- Optical emission Spectrometer for determination of Ferrous material chemistry (up to 43 elements)
- Analysis of chemical composition of metals and non-metals
- Evaluation of mechanical properties of metals and non-metals
- Material micro structure study
Vehicle Testing Group
Dedicated team for conducting Vehicle Evaluation & Performance Tests has been created and it is equipped with facilities to carryout various testing activities as per relevant National and International standards.
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