From Simulation to Success

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Case Study: Agriculture Vehicle Design and Prototyping

Section1: From Simulation to Success

Part 1: Introduction to Agriculture Vehicle Design and Prototyping

Part 2: 2D /3D CAD to Prototyping

Part 3: Material Science in Motion

Part 4: Vehicle Dynamics

Part 5: FEA and Gearbox Reinvention

Part 6: Machine Design

Section2: Field Validation

Part 1: Precision Parts Machining

Part 2: Assembly Gear and Vehicle Technique

Part 3: On-Site Adjustment & Training

Part 4: Hill Climb & Jump Test – Built for Harsh Terrain

Part 5: Customer Co-Design Experience

Part 6: Test, Fix, Retest – The Feedback Loop

Section 3: New Design and Prototyping

Part 1: Customer-Feedback Redesign

Part 2: Design for Manufacturing (DfMA) and Simplification

Part 3: New Rapid Prototyping

Part 4: Tolerance and Quality Control

Part 5: Gear Vibration Analysis – Fixing What You Can’t See

Part 6: Assembly and Tests and Improvement

Part 7: Re-design and FEA and Modification

Part 8: On-site Tests at Laos

Section 4: Mass Production & Strategy

Part 1: Ready for Scale – Mass Production Roadmap

Building Real-World Machines Through AI-Powered Engineering

Engineering for real-world terrain is unforgiving. A single failure in torque delivery or chassis stress could mean wasted time, cost, and opportunity.
This project demonstrates how our simulation-first methodology—integrating CAD, FEA, load mapping, and material science—helped transform an early-stage mechanical concept into a functional, CNC-ready vehicle validated in off-road conditions.

We applied our AI-enhanced design and diagnostic platform to avoid trial-and-error, shorten the build cycle, and ensure reliable performance before fabrication.

Simulation is no longer the last step—it’s the first layer of engineering logic.

In the previous development phase, the team successfully completed critical design and engineering foundations, including:

  • 2D/3D CAD Modeling
    Completed detailed models for the transmission system and full vehicle chassis, including gear layouts, frame structures, and drivetrain mounting points.
  • 3D Assembly & Animation
    Created full assembly simulations to visualize gear meshing, suspension movement, and drivetrain operation. Used for validation and communication with stakeholders.
  • Machine Design & Vehicle Dynamics
    Analyzed drivetrain alignment, weight distribution, turning radius, and load transfer during operation to improve handling and stability.
  • Finite Element Analysis (FEA)
    Simulated stress and deflection on chassis beams, gearbox housing, and suspension mounts to ensure structural reliability and inform design revisions.
  • Production & Manufacturing Analysis
    Preliminary review of fabrication methods and materials. Identified key manufacturing challenges and prepared data for future jig and process development.

All design activities were executed in a structured, step-by-step manner—starting from CAD modeling, dynamic simulations, and structural analysis, and progressing toward prototype validation. Each stage provided critical insights into geometry, mechanical behavior, and production constraints. This systematic approach enabled the team to identify weaknesses, validate improvements, and lay the foundation for a redesigned model that is not only mechanically sound but also manufacturable and field-ready.

About Finite Element Analysis

Next Phase: Structured Improvement and Implementation Plan (3–6 Months)

Building on the current prototype and field validation, the next 3 months will focus on developing a scalable, reliable version. The plan consists of 10 structured tasks:

  1. Prototyping a new O-ring-based model, with improvements to gear and vehicle assembly integration.
  2. Component fabrication and diagnostic testing, addressing real-world operational issues.
  3. Redesigning the vehicle and gearbox based on performance data and test feedback.
  4. Fabricating and evaluating a full prototype, incorporating structural and performance improvements.
  5. Establishing a quality control strategy with tolerance validation to ensure scalable production readiness.
  6. Analyzing gear vibration and failure modes to improve reliability.
  7. Running FEA simulations and redesigning structural components for enhanced strength and durability.
  8. Conducting field trials and making final adjustments to ensure real-use functionality.
  9. Collaborating with end-users in Laos to gather direct feedback and validate the design in actual operating conditions.
  10. Developing mass-production-oriented design modifications, targeting manufacturability and cost-efficiency.

About Engineering and Mechanical Works

In many parts of Southeast Asia, rural transport vehicles operate in terrain that destroys conventional assumptions—loose gravel, steep hills, sudden impacts, and no predictable surface.
The initial prototype for this vehicle could not survive these conditions:

Suspension failure under shock load

  • Frame twist during incline
  • Torque drop under full payload
  • No vibration management or fatigue modeling

The mission: Build something real—not just mechanically elegant, but terrain-ready and production-capable.

We deployed a fully integrated process from virtual testing to real-world resilience:

• CAD & Assembly Modeling

  • Designed complete drivetrain, gearset, and chassis in 3D
  • Modularized assembly for future DFM

• Load Mapping & Torque Simulation

  • Simulated engine output across gradient slopes
  • Verified torque path and structural force interaction

• FEA on Frame & Components

  • Identified stress hotspots on beams, joints, and gear housing
  • Adjusted weld zones and flange layouts to eliminate weak points

• Shaft Hardening & Tolerance Control

  • Applied selective surface treatment
  • Performed grinding, straightness test, and bearing seat precision validation

• CNC-Oriented Geometry

  • Reduced tool changes
  • Standardized hole patterns for fast jig production
  • Ensured machinability without compromising structure

Result & Future Outlook: Prototype to Production

The redesigned prototype passed multiple field tests:

  • Hill climb with full payload
  • Jump impact under sandbag simulation
  • Brake and drivetrain coordination
  • Noise and vibration tolerance in extended runtime

We are now preparing for scalable production with clear quality control metrics, vision-based inspection (gear shape & alignment), and mass fabrication data.

A digital twin that doesn’t just simulate—but builds trust between prototype and product.

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