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 fabricating equipment to the Australian Standards? Dynamic Engineering can assist you with your general engineering and design requirements and all work complies with the Australian Standards. Completed projects include access platforms, lifting equipment, crane attachments, racks, transport frames and forklift attachments. We can also assist in ROPS and FOPS testing and front underrun protection devices. Another service we offer is design certification.

Scroll down for examples of recently completed projects.

Contact us now to discuss your project requirements.

Pedestrian Bridge Design

Over the years, Dynamic Engineering has successfully designed pedestrian bridges in cyclone and non cyclone areas. A pedestrian bridge provides readily and safe access to areas for people such as students and the elderly where sidewalks are not available. Our design includes the civil (footings) and structural design of the bridges and complies with the relevant Australian Standards. It is painted with a high quality coating to withstand expose to the elements and to ensure a long life span.

Below are some pictures and screenshots of recently completed bridges:

Footbridge
Pedestrian bridge

Space gass model of pedestrian bridge:

Space Gass model of bridge

Photo of completed bridge:

Pedestrian bridge

The best designs are likely to amount to nothing if they are not implemented properly. Due to our practical experience on operating plants and mine sites, we understand that quality assurance and project management are integral to the overall success of a project.

Whether we operate as independent subcontractors or as part of our client’s team, we aim to exceed expectations and provide a quality service that will lead to a long term relationship with our clients. To see how Dynamic Engineering can help you, please contact us to discuss your needs.

Sample scoop

Dynamic Engineering Consultants can help you with your scoop sampling needs. For example, one of our clients had an existing sample scoop which was unable to keep up with the slurry flow. This resulted in spillage and unnecessary additional maintenance costs. Consequently our client requested Dynamic Engineering to design and supply a larger scoop to handle the flow. Following discussions with the client, the scoop was optimally design with finite element analysis to withstand this high flow. It was also enlarged to avoid spillage, while still being able to fit in the existing space.

Below the existing scoop is shown, the spillage can be clearly seen.

Existing sample scoop

The next picture shows the 3D model we designed in accordance with our client’s requirements. This model is now ready to be analysed with Finite Element Analysis. In addition fabrication drawings were made.

sample scoop

Model of new scoop

Afterwards the scoop was fabricated and shipped to the client.

sample scoop

Fabricated sample scoop

In addition Dynamic Engineering can design some manual sample scoops to easily obtain samples for metallurgists.

The manual scoop below has a long reach and a scooping mechanism at the handle to gain access in tight spaces.

Manual sampler scoop

Below is an example of a simpler manual scoop.

Manual sampler scoop

When analysing any new designs, the applicable Australian Standards are taken into account.

Contact us to discuss your requirements.

Civil and Structural Facility Audits

Dynamic Engineering Consultants performs civil and structural facility audits to help you ensure that you provide a safe working environment for your employees. These audits are typically divided into three phases: site visit, compile report and lastly individual repair procedures.

Phase 1 Site visit

The audit consists of a site visit in which our engineers do a detailed inspection of our client’s facilities. The time for the inspection depends on the size of the facilities and the severity of any problems encountered. The report and site visit is compiled by an experienced civil/structural engineer that is a Chartered member of Engineers Australia.

Site visit

Phase 2 Compile report: Outcome of civil and structural facility audits

A detailed report is compiled back at base. This report will include photos, a description the problems and will group problems together in terms of severity. The report will also provide a clear direction as to which areas must receive attention first and the time in which it should receive attention. This will give the client direction on what areas to fix first to avoid safety hazards or production loss.

Phase 3 Repair procedures

If required by our client, we will also help with the specific repair procedures for the problems encountered.

You can book civil and structural facility audits or inspections by contacting us via the details listed on our contact page.

Transport Cradle Design

Dynamic Engineering Consultants can help you with your new transport cradle design or the analysis of your existing cradles. The goal of the design or analysis is to ensure cradles comply with the National Transportation Council’s load restraint guide. This guide requires that the transport cradle are able to safely withstand specified loads in three directions (longitudinal, vertical and lateral).

Below are some examples of transport frames:

First the transport frame is modelled in a 3D package and prepared for analysis. We typically use solidworks to do this, but we can also use our client’s existing model that is sometimes in other formats.

Transport frame
Modified Transport Frame

The next step is to analyse the frame by applying the required loads, evaluating the stresses and upgrading the model where required. This may include lifting via lifting lugs, forklift guides and the loads required by the load restraint guide.

Analysis of transport frame
Stress plot of the frame during turning

The last steps are to generate detail fabrication drawings and then fabricating the cradle. The fabrication drawing may also include plate developments and lasercut dxf files.

Transport cradle for 785 – 3/5
Stress plot for a CAT C18 transport frame

Have a similar requirement of a transport cradle design? Click on the following link.

Maintenance Steel Platform Design

A steel platform can provide easy and safe access to equipment for maintenance purposes, which can reduce downtime/shutdown costs. There are several different types of custom made platforms to suit a range of requirements: Maintenance platforms are permanently located around large critical equipment to provide continual access. For a smaller application or one with restricted access, Access Platforms may be the answer to access restricted work areas. If you only need a temporary platform, which can be moved into and out of position, there is a lightweight, movable platform that will suit your needs. And if you are after a more robust mobile platform, please look at steel portable platforms. Dynamic Engineering Consultants can help you with the design of a platform, which will suit your specific needs.

Maintenance Platforms

Maintenance platforms adjacent to the equipment they belong to can provide significant savings in terms of maintenance downtime and other costs. This is especially true for large equipment like Gyratory Crusher main shaft assemblies and Flotation Mixer. These platforms can be custom made for most equipment and installations. Below is a couple of examples of large maintenance platforms designed by Dynamic Engineering Consultants.

Gyratory crusher platform: 3D model

Gyratory crusher platform: actual platform

Flotation cell rotor stand: 3D model

Flotation cell rotor stand: actual platform

Crusher access platform

Crusher access platform

Access Platforms

Occasionally mining operations require tailor made engineering solutions due to space and operational constraints. Below is an example where Dynamic Engineering provided designs for such an access platform extension. The underground platform is suspended from the “back” of the portal and is furthermore connected to an existing platform.

3D model of underground platform

Installed underground platform

Lightweight, Movable Platform

When performing maintenance, lightweight platforms can easily access equipment. Dynamic Engineering can design custom maintenance platforms to suit specific needs. One of our recent projects were to design and analyse a lightweight ball mill inspection platform. This project was recently completed and the maintenance platform used during the shutdown is shown below:

Inspection platform: 3d model and actual platform

Steel Portable Platform

Dynamic Engineering Consultants has completed several portable steel platform designs, which are used for inspections. These platforms are used in the mining industry to inspect, amongst others, excavator buckets and truck trays. The platforms are moved into position with a forklift and are then adjusted and levelled by means of adjustable jacks.

This specific design is certified for 500kg load but can be tailored to the client’s requirements.

830e-platform combined

Portable 830E platform: 3D model and actual platform

Looking for something similar? Contact us today to see how we can help you.

Design Certification Service

Australian Standards require that equipment or structures be designed according to a specific standard. We at Dynamic Engineering make this process as easy as possible for our clients by providing a design certification service. We specialise in Civil/Structural, Maintenance Tools and Lifting Equipment design certification.

There are several different ways in accomplishing certification, through physical testing of equipment and computer simulations, such as Finite Element Analysis.

Finite Element Analysis

Computer assisted stress analysis streamlines the design 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.

engine stand

3D model of an engine stand

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 stress plots 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.

Typical stress plot produced for the design certification of the rig

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.

Load cases showing stresses and deflections associated with lifting the tailing pipe

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.

Short description of FEA

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 and 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:

Stress analysis of a belt lifter

Stress analysis of a belt lifter

jacking tool

3D model of jacking tool

reel drum frame

3D model of reel drum frame

track guide lifter

3D model of track guide lifter

Finite element analysis can be applied to several different applications, such as Machine design, Maintenance tools and Civil/Structural design.

Physical testing of equipment

In some instances, computer simulation cannot be used to certify a design. Then it is necessary to build a prototype and physical test the equipment, often to destruction. This approach is sometimes specified in the standard – for example for ROPS, FOPS and FUPS devices.

It is important to understand that to certify a ROPS or FOPS structure, physical testing must be conducted (calculations are not allowed in terms of the Australian standard). To do this, you would need a test rig and a sacrificial physical ROPS/FOPS structure. In most cases, to produce a test bed and destructively test a ROPS would be an expensive exercise and only makes sense if you are going to build larger quantities of these units.

FOPS testing

Testing of prototype FOPS

ROPS being tested

We are also able to assist with testing of Bullbars and bullbar subframes in accordance with UNECE reg 93.

Bullbar load testing

Bullbar deflection testing at one of our clients

Specialised Lifting Equipment Design and Certification

Dynamic Engineering’s capabilities include specialised lifting equipment design and certification to suit our client’s requirements. These specialised lifting equipment is designed based on Australian Standards AS1418 and AS4991. Following are some examples of previously completed projects:

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.

lifting equipment design

5T coil lifter: 3D model and actual lifting in action

Another example of specialised lifting equipment design 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

Below is an example of a purpose built lifting beam, used to remove a broken sheave assembly

lifting equipment design

35T lifting beam: 3D model and actual beam in operation

Below a stress plot is shown of an articulated alternator lifter along with the actual lifter, awaiting delivery.

5T articulated alternator lifter: stress plot and actual lifter

5T articulated alternator lifter: stress plot and actual lifter

Dynamic Engineering has unique solutions to your lifting problems, just contact us to discuss your requirements.

Crane Attachment Design

Dynamic Engineering recently completed a specialised crane attachment design that addressed the end client’s need to do maintenance in a restricted area. Not only were there height restrictions, but the access angle at which the crane operated was restricted as well. In addition to these conditions, the attachment also needed to be designed taking into consideration safety requirements and the requirements of  Australian Standard AS1418.

To complete this design in a timely manner, it was analysed with Finite Element Analysis. A model of the crane attachment was made and the stresses and deflections in the plate were determined to ensure it was below the maximum values allowed.

Below is a model of the crane attachment, which was used in FEA.

Design of crane attachment, shown connected to the boom

Design of crane attachment, shown connected to the boom

Afterwards it was manufactured, load tested and is now in use by the client.

Below is a picture of the attachment fitted to the crane.

Fabricated crane attachment fitted onto boom

Fabricated crane attachment fitted onto boom

The load testing is shown below:

Crane attachment load test

Here the crane attachment is in use:

Crane attachment in place ready for use

Reports form our client indicate that this attachment improved their maintenance procedures by reducing maintenance time and also made the whole process safer. Efficiency and safety improvements are a core value at Dynamic Engineering Consultants.

Do you have similar needs? Then contact us to discuss your requirements.

Impact damage and wear of a cyclone barrel

Dynamic Engineering was asked to determine if a cyclone barrel was sufficiently strong enough without the use of an over centre clamp (which had failed). So the barrel had to be structurally strong enough to resist the impact forces associated with the air stream and ore particles (in accordance with AS3990). To ascertain this,  a 3D model was created and analysed with Finite Element Analysis and CFD. 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

Failed cyclone barrel clamp

Below the 3D flow through the barrel is shown:

flow-distribution

Flow distribution inside barrel

The deflection is shown in the picture below:

cyclone-fea

FEA model of cyclone barrel

Our client was able to make significant monetary and time savings by using our expertise as opposed to using one of the larger engineering consulting companies.

Whether we operate as independent subcontractors or as part of our client’s team, we aim to exceed expectations and provide a quality service that will lead to a long term relationship with our clients. Contact us today to see how we can help you.

Plate racks

Dynamic Engineering has designed and built several vertical and horizontal plate racks depending on our client’s requirements. Likewise these racks are available in either welded or bolted configurations, making the design very flexible. In addition, the plate racks are also equipped with lifting lugs for easy loading and unloading for transport purposes. These racks are designed to Australian Standards AS3390.

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’s needs. The fabricated rack is shown first, followed by the 3D model.

Fabricated plate rack

Horizontal plate rack

Horizontal plate rack

One of our clients required a rack to store square bundles of rods. They had limited space and needed to have as large a storage space as possible, while have enough space for a forklift to place the rods onto the shelves. Below is a 3D model of the final design.

Rod rack

A typical design analysis consists of three parts. The first part is to convert the client’s design into a 3D model, see below:

3D model of rack

Secondly the various loads and constraints are added to the model and with Finite Element Analysis to determine the stresses and deflection of the model.

Stresses in rack

Deflection in rack

The above deflection is exaggerated for easy visual reference.

Lastly Dynamic Engineering issues a report certifying the design along with shop drawings, if required by the client. If the design is not compliant with the Standards, then we would, in conjunction with our client, modify the design until it complied.

Contact us to discuss your requirements for a plate rack.

Safety Related Equipment Design

At Dynamic Engineering Consultants we design, certify and supply specialised safety equipment that is tailored to our client’s specific requirements. This will ensure that no compromises need to be made in the implementation of safety related or critical procedures. All our work complies with the relevant Australian Standards.

Below are some examples of recent safety equipment design that we did: a drill cradle, scissor lift , tyre cage , cement kibble and a sliding plate assembly.

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

Drill cradle

Scissor lift

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

Scissor lift

Tyre cage

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

Tyre cage

Cement kibble

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

Sliding plate assembly

During up-hole drilling, a centraliser, using hydraulic force, holds the rod while the next drill rod is being inserted. If the rod slips it can cause serious damage to the drilling equipment or injury to the operator. To prevent this, a sliding plate drill rod fall protection system could be installed as a fail-safe. This 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 design was analysed to ensure that it was strong enough for the weight of the rod string. In addition the new assembly was checked against the Australian Standard.

Sliding plate assembly

Sliding plate assembly

ROPS and FOPS Testing and Certification

ROPS provide added safety measures for motorists when a vehicle rolls over in an accident. Dynamic Engineering performs ROPS (Roll Over Protection Systems) and FOPS (Falling Object Protection Systems) testing certification in accordance with AS2294 / ISO3449 / ISO3471. These standards require that the equiopment be destructively tested. This is a costly step if the ROPS fails. To ensure passing of the destructive test, the ROPS is modelled in 3D and the anticipated deflections determined with Finite Element Analysis. If FEA shows that the deflections are too much, then modifications can be made before fabrication, therefore reducing costs.

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

3D model of ROPS

Finite Element Analysis is used to check the overall design before physical testing.

Below the fabricated ROPS is placed into position, before destructive testing is performed.

Before

Testing

Dynamic Engineering provides a quick, flexible response to your immediate needs. In addition, we provide an affordable service and are focused on strengthening long term alliances with our clients. We bring together and offer proven expertise in engineering analysis and best practice in its implementation. Our flexible approach also means that no assignment is too small. Contact us to enquire how we can assist you.

Transport and Support Frames

Transport and support frames can make moving and maintaining equipment much easier. Dynamic Engineering Consultants can design frames to suit your needs. 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 on 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 transport and support frames:

The frame below has forklift sleeves and can be easily moved into position. The stress analysis of this frame is also shown.

Transport  and support frames

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.

transport and support frames

Container frame

Below a jig is shown used for  the rotation of equipment during repairs. The CAD model is shown below, following with the fabricated jig.

Welding Rotation Jig 7.5T

Welding Rotation Jig 7.5T

Completed weld jig

The engine support frame below can be adjusted to improve maintenance.

transport and support frames

Universal engine frame

Forklift Attachment Design

Most fabricators have forklifts on hand and bespoke attachments can make this equipment more versatile. In addition attachments can make accessing and moving equipment much safer and easier. Dynamic Engineering has the capability to design and certify your forklift attachment in accordance with worksafe requirements.

The first step in analysis is to model the attachment in CAD to ensure that it is strong enough according to Australian Standards. This is done by using Finite Element Analysis to calculate the stresses and deflection and if needed, the design is tweaked to ensure the maximum values are below the allowable values set out in the standards. The next step is to ensure that the attachment is stable as the centre of mass is moved further out. This is dependant on the type of forklift available on site. After fabrication each forklift gets a nameplate with information relating to working load, type of forklift and other safety information.

Below is an example of an attachment which is used to remove load rollers.

forklift attachments

Maintenance forklift attachments used to remove track wheels

The forklift attachment being used on site:

Typical use for forklift attachments

Forklift attachment being used

We are also able to provide details required by the Australian Standards such as lost load, centre of gravity etc. In the example below, the forklift attachment is shown as well as the centre of mass calculations.

forklift attachment

Forklift attachment

Centre of mass

Special projects

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

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:

special projects

Stress plot of the tank under hydrostatic pressure

Deflection plot of the tank

The actual training watertank

The best designs are likely to amount to nothing if they are not implemented properly. Due to our practical experience on operating plants, we understand that quality assurance and project management are integral to the overall success of your special projects. All work complies with the relevant Australian Standards.

Have you got a special project that are special or in some way different to the norm? We may be able to help, please contact us to discuss your requirements.

Front Underrun Protection Devices

Front Underrun Protection Devices (FUPDs) improve the overall safety of other road users by minimising the impact of a collision. Dynamic Engineering has recently completed deflection testing on several FUPD’s 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:

Front Underrun Protection Devices

3D model (rear view) of Bullbar

Deflection plot for load at high position

With Finite Element Analysis the expected deflection of the Front Underrun Protection Devices is determined to see if it within acceptable limits before costly destructive testing is done. The physical testing is done conveniently at the client’s premises. Below a test in progress is shown.

Testing

New FUPDs improve safety and increase protection, but could also be very costly or pose a safety risk if not designed properly.  At Dynamic Engineering, we reduce this risk by means of Finite Element Analysis before physical testing is done. A 3D model of the equipment is constructed and loads and constraints are placed on the model to simulate real life use. The resultant stresses and deflections are analysed to ensure a safe working design. Full fabrication drawings and laser cut files can also be produced. Contact us to discuss your requirements.