DEVELOPMENT OF AN DIGITAL AND MULTI-BODY MODEL OF A DUMP TRUCK BY REVERSE ENGINEERING FOR SIMULATION MODELING

Original paper

UDC 622.684 c D.M. Dubinkin1, I.P. Popov1,2, A.I. Bokarev2, V.A. Dianov2, L.A. Zaitsev2, 2025

ISSN 0041-5790 (Print) • ISSN 2412-8333 (Online) • Ugol’ – Russian Coal Journal, 2025, №12

DOI: http://dx.doi.org/10.18796/0041-5790-2025-12-51-57

Authors

D.M. Dubinkin1, I.P. Popov1,2, A.I. Bokarev2, V.A. Dianov2, L.A. Zaitsev2

1 T.F. Gorbachev Kuzbass State Technical University, Kemerovo, 650000, Russian Federation

2 Bauman Moscow State Technical University, Moscow, 105005, Russian Federation, e-mail: ddm.tm@kuzstu.ru

Authors Information

Dubinkin D.M. – PhD (Engineering), Associate Professor, T.F. Gorbachev Kuzbass State Technical University, Kemerovo, 650000, Russian Federation, e-mail: ddm.tm@kuzstu.ru

Popov I.P. – Lead Designer, R&D “KAMAZ-BAUMAN”, Bauman Moscow State Technical University, Moscow, 105005, Russian Federation; Postgraduate, T.F. Gorbachev Kuzbass State Technical University, Kemerovo, 650000, Russian Federation, e-mail: popovip@bmstu.ru

Bokarev A.I. – Senior Researcher, R&D “KAMAZ-BAUMAN”, Bauman Moscow State Technical University, Moscow, 105005, Russian Federation, e-mail: bokarev@bmstu.ru

Dianov V.A. – Designer, R&D “KAMAZ-BAUMAN”, Bauman Moscow State Technical University, Moscow, 105005, Russian Federation, e-mail: vadianov@bmstu.ru

Zaitsev L.A. – Designer, R&D “KAMAZ-BAUMAN”, Bauman Moscow State Technical University, Moscow, 105005, Russian Federation, e-mail: zaitsev@bmstu.ru

Abstract

The article presents the results of developing electronic and multibody models of the most common and widely used BELAZ-7513 mining dump truck using reverse engineering methods. The aim of the work was to create a complex of mathematical models that adequately reflect the geometric, mass-dimensional, physical-mechanical, kinematic, and dynamic properties of the real object for subsequent simulation modeling. Given the unavailability of design documentation, the digital CAD model was developed based on technical drawings from repair and operation manuals, as well as empirical control measurements of critical dimensions, ensuring their full compliance within the model. Particular attention was paid to the accurate modeling of undercarriage components (frame, front axle beam, axle housing) and the placement of attachment points for key components. Based on the digital model, a multi-body simulation model was developed in a specialized environment, including subsystems of the front and rear suspension, the frame with the body, and the steering system. The model considers kinematic points, force interactions, linear and nonlinear characteristics of elastic and damping elements (pneumatic-hydraulic springs), as well as the mass-dimensional and inertial properties of the components. The developed model complex is intended for further research into the stress-strain state of load-bearing structures and assessing their durability by simulating real operational loading modes on a virtual test rig.

Keywords

Mining dump truck, electronic model, reverse engineering, simulation modeling, multi-body model.

References

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Acknowledgements

The work was carried out with the financial support of the Ministry of Science and Higher Education of the Russian Federation under the agreement dated 30.09.2022 № 075-15-2022-1198 with the Kuzbass State Technical University named after T.F. Gorbachev’s “Comprehensive scientific and technical program for a full innovation cycle ‘Development and implementation of a set of technologies in the fields of exploration and extraction of solid minerals, industrial safety, bioremediation, creation of new products of deep processing from coal raw materials while consistently reducing the environmental impact and risks to the life of the population’ (KNTP ‘Clean coal – Green Kuzbass’)” approved by the decree of the Government of the Russian Federation dated May 11, 2022 No. 1144-r within the framework of the event “Development and creation of an unmanned shuttle-type mining dump truck with a lifting capacity of 220 tons” in terms of carrying out research and development work.

For citation

Dubinkin D.M., Popov I.P., Bokarev A.I., Dianov V.A., Zaitsev L.A. Development of an digital and multi-body model of a dump truck by reverse engineering for simulation modeling. Ugol’. 2025;(12):51-57. (In Russ.). DOI: 10.18796/0041-5790-2025-12-51-57.

Paper Info

Received October 3, 2025

Reviewed November 15, 2025

Accepted November 28, 2025