Industrial

Are you in the Industrial Sector? Are you planning a project which requires an innovative solution or do you require assistance with designing and building equipment to the Australian Standards? DEC can assist you with your general engineering and design requirements and all work complies with the Australian Standards. Scroll down for examples of recently completed projects.

Contact us now to discuss your specific needs.

Container Monorail

When a shipping container is used to transport heavy items, it might be advantageous to install a monorail which can extend outside the container to lift and move items from inside of the container. Dynamic Engineering was asked to design such a retractable container monorail according to the relevant Australian Standards (AS1418). In addition, the support beams, which connected to the container needed to be strong enough and were included in the design. DEC took the client’s initial concept and turned it into a working model with fabrication drawings. The following picture show the final design.

Final monorail design

 

Sliding plate drill rod fall protection system

During up-hole drilling, a centraliser, using hydraulic force, holds the rod while the next drill rod is being inserted. It is very important that the rod doesn’t slip as it can cause serious damage to the drilling equipment or injury to the operator. To protect the equipment and operator, a sliding plate drill rod fall protection system could be installed as a fail-safe. The sliding plate assembly has to withstand the weight of the rod string including a safety factor. One such sliding plate was designed by Dynamic Engineering in conjunction with the client. The analysis was done to check that it complies with the Australian standard and is strong enough for the weight of the rod string.

Sliding plate assembly

Sliding plate assembly

 

Crane Attachment

Cranes are great to move heavy items into position, however need lots of space, but what to do when there are limited roof clearances? Recently DEC designed a specialized crane attachment that addressed the end client’s need for restricted height and specific access angles. The attachment was designed taking into consideration safety requirements and was analysed with Finite Element Analysis to ensure adherence to the Australian Standards AS1418. Afterwards it was manufactured, load tested and is now in use by the client.

Design of crane attachment, shown connected to the boom

Design of crane attachment, shown connected to the boom

 

Fabricated crane attachment fitted onto boom

Fabricated crane attachment fitted onto boom

Design Certification Service

Computer assisted stress analysis streamlines the certification of equipment. A 3d-computer model takes the guesswork out of new designs. Changes can be made quickly and inexpensively and the result can be checked straightaway. With Finite Element Analysis (FEA) different loads can be applied, including gravity, remote force and torque. The resultant stresses and deflection can be checked against design specifications. The first step in computer modelling is drawing the equipment or tool in three dimensions. The CAD software then meshes the model by subdividing it into smaller elements. The loads and constraints are added and the resultant stresses and deflections are calculated for each of these numerous elements. Lastly stress/deflection equations are solved for each of these elements and the results are combined to find the overall solution. Below are some stress analysis examples showing the resultant stresses.

Engine Stand:

engine stand

3D model of an engine stand

Track Guide Lifter:

track guide lifter

3D model of track guide lifter

Jacking Tool:

3D model of jacking tool

Belt Reel Frame:

3D model of reel drum frame

 

Design Certification of Equipment

Design certification is becoming more and more popular and in the case of some mining clients is now a requirement for all new equipment. Design certification can be achieved for both new and used equipment, provided certain information is known:

1) For new equipment the following is required:

  • A drawing that fix the design (dimensions, materials and welding)
  • Engineering calculations (require loads and load combinations)

2) For existing equipment

  • A drawing that fix the design (dimensions, materials and welding). The equipment would therefore need to be measured up (in some cases dismantled)
  • Engineering calculations (require loads and load combinations)
  • Actual load test to confirm the design calculations and construction.

We can help with all of the above. By developing a 3D model of your equipment and applying the loads, we can produce a stress plot that can be used to prove the design or even to increase the reliability of the design. It is fast, cost effective and saves a lot of time and money associated with breakdowns – not to mention the safety risks associated with failures.

Stress analysis of a tool table

Stress analysis of a tool table

 

Stress analysis of a belt lifter

Stress analysis of a belt lifter

In some cases we are asked to give our opinion if certain maintenance activities would be safe. One such  assignment was to check if a corroded tailing pipe could be lifted while in operation. Our analysis showed this to be a high risk activity and we advised our client against this – showing areas of concern as well as the behaviour of the model under certain load cases. With our model we were able to predict load versus deflection curves, as well as the required crane tonnage.

Pipe lifting analysis

Although our analysis indicated that the lift should not take place, our client still received the benefit of avoiding a large clean-up bill and other associated incidents. Sometimes it really pays to check out the engineering aspects of a job before it is attempted.

Designing for impact damage and wear

A cyclone barrel’s 3D model was analysed with Finite Element Analysis and CFD to determine if it would be structurally adequate to resist the impact force associated with the air stream and ore particles in accordance with AS3990. By calculating a bulk density for the flow stream (which includes the air and the ore particles), the force acting on the plate was calculated. This force was then applied to the 3D model and FEA was used to evaluate the stresses and deflections.

failure-cyclone

Falied cyclone barrel clamp

 

 

 

 

 

flow-distribution

Flow distribution inside barrel

cyclone-fea

FEA model of cyclone barrel

Forklift and Access Ramps

These forklift ramps are used for the loading and unloading of food trucks. They were never rated for a safe working load and thus needed to be certified for a specific capacity. Analysis done by Dynamic Engineering Consultants showed that the ramps were indeed not fit for purpose as it did not comply with the relevant standards. Dynamic Engineering recommended modifications to the ramps to ensure compliance and issues a design report based on the proposed modifications.

forklift-ramps

Forklift ramps before design check

Forklift ramps after design check and refurbishment

Plate racks

Dynamic Engineering has designed and built several vertical and horizontal plate racks. These racks are available in either either welded or bolted configurations – depending on the client requirements.

The plate rack is also equipped with lifting lugs for easy loading and unloading for transport purposes.

An example of a welded horizontal plate rack are given below. This rack had a 10T capacity, but designs can be tailored to the client requirements.

Fabricated plate rack

Fabricated plate rack

Horizontal plate rack

Horizontal plate rack

 

 

Specialised Lifting Equipment Design and Certification

Dynamic Engineering’s capabilities include specialised lifting equipment design and certification to suit our client’s requirements. An example of a 5T capacity coil lifter is given below. This design enables the lifter to “fold inwards” when the coil is engaged, and then by lifting on the outside “ears” the lifter kicks out to enable the lifter to lift the coil vertically. The design was built and tested and is currently in daily use.

 

5T coil lifter

5T coil lifter

 

Coil lifter in action

Coil lifter in action

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Another example of specialised lifting equipment is a 12T magnet spreader beam that was recently designed. This spreader beam has the capability of lifting 12T via 4 magnets. 4 LIfting points were used to improve stability.

Adjustable magnet lifting spreader beam

Adjustable magnet lifting spreader beam

 

 

 

 

 

 

 

Safety Related Equipment Design

At Dynamic Engineering Consultants we can design, certify and supply specialised safety equipment that is tailored to the client’s specific requirements. This will ensure that no compromises would have to be made in the implementation of safety related/critical processes and procedures. Below are some examples of recent safety equipment design that we did: a drill cradle, scissor lift, tyre cage and cement kibble.

A drill cradle is used to hold the drill head in place (avoid damage and injuries associated with drill head coming loose).

Drill cradle

This scissor lift was designed to improve access to dump truck rim parts.

Scissor lift

A tyre cage was modelled and analysed with non-linear Finite Element Analysis to see if it would be able to withstand a tyre burst event.

Tyre cage

A cement kibble was modelled and analysed to see if it would safely lift 1T. In addition the kibble also comes equipped with forklift guides.

Cement kibble

ROPS and FOPS Testing and Certification

Dynamic Engineering also performs ROPS/FOPS testing certification in accordance with AS2294 / ISO3449 / ISO3471. Note that we do not have our own testing facility – we generally use our client’s facilities. We can also design a dedicated test bed for our clients – if required. Some examples are shown below:

ROPS

Before

Testing

Lifting Equipment Design

Dynamic Engineering Consultants design specialised lifting equipment based on AS1418 and AS4991. Below are some examples of previously completed projects:

 

35T lifting beam (purpose built)

35T lifting beam (purpose built)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

35T lifting beam used to remove broken sheave assy

 

Specially designed 5T capacity alternator lifter

Stress plot of a 5T articulated alternator lifter

 

A photo of the actual alternator lifter is given below:

Actual 5T alternator lifter awaiting delivery

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

We can also design lifting adapters that are specific to your application. An example of a 7T lifting adapter is shown below:

7T lifting adapter

7T lifting adapter

 

 

 

 

 

 

 

 

 

 

 

 

Have you got a specific lifting equipment design requirement? Contact us today to discuss your requirements we would love to help…..

Transport and Support Frame Design

Dynamic Engineering Consultants design transport and support frames. We make use of the applicable Australian Standards as well as the National Transport Commission’s load restraint guide. In summary the design has to be sufficient to withstand imposed longitudinal and lateral loads associated with transport applications.
In some cases the frames are only used to transport the equipment around site. In these cases we also perform forklift stability calculations in addition to the structural design. We also adhere to the Australian Standard’s requirements in terms of nameplate requirements.
Below are some examples of transportation and other frames.
Modified Transport Frame

Modified Transport Frame

Stress plot of the frame during turning

Stress plot of the frame during turning

 

 

 

 

 

 

 

 

 

 

 

 

This container frame is used to suspend chemical containers like cyanide. It comes equipped with ISO container mounts and is of a very heavy construction.

 

Container frame

Container frame

 

Other examples include adjustable engine support frames as well as jigs used for the rotation of equipment during repairs.

Welding Rotation Jig 7.5T

Welding Rotation Jig 7.5T

 

 

 

 

 

 

 

 

 

2015-01-19 09.12.09

Completed weld jig

 

 

Universal engine frame

Universal engine frame

 

 

Forklift attachments

Maintenance forklift attachments used to remove track wheels

Maintenance forklift attachments used to remove track wheels

DEC also has the capability to design and certify forklift attachments in accordance with worksafe requirements. The analysis includes strength as well as stability considerations.

The attachments shown above are used to remove load rollers as per the photo below:

Typical use for forklift attachments

 

 

 

 

 

 

Forklift attachment being used

 

 

 

 

 

 

 

 

 

 

 

 

 

 

We are also able to provide details required by the Australian Standards like lost load, centre of gravity etc.

 

Forklift attachment

Centre of mass

 

 

Special projects

Because engineering principles can be applied to a variety of problems, we sometimes get involved in projects that are a bit out of the ordinary. The example below is just one such a project.

Have you got a project that are special or in some way different to the norm? We may be able to help.

In response to problems encountered with a competitor designed water tank, Dynamic Engineering Consultants was contracted to design a new water tank for one of our international clients. With the help of FEA we were able to fine tune the design to achieve acceptable material strength while minimising construction costs. We were also able to predict deflection due to hydrostatic forces very accurately, making sure that the problems experienced on earlier (competitor) designs did not re-surface.

A stress and deflection plot of the design is given below:

Stress plot of the tank under hydrostatic pressure
Stress plot of the tank under hydrostatic pressure

 

Deflection plot of the tank

 

The actual training watertank

Front Underrun Protection Devices

DEC has recently completed deflection testing on several FUPD’s (Front Underrun Protection Devices) for K Craft products. The testing was done in accordance with United Nations ECE Reg 93.

An example of the 3D model is given below:

3D model (rear view) of Bullbar

Deflection plot for load at high position