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.

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 https://www.business.gov.au/risk-management/health-and-safety/whs-oh-and-s-acts-regulations-and-codes-of-practice. 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.

Phase 2 Compile report

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 a civil and structural facility audit or inspection by contacting us via the details listed on the following page: http://www.dynamicengineering.com.au/contact/

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 ( https://www.ntc.gov.au/heavy-vehicles/safety/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? Click on the following link http://www.dynamicengineering.com.au/contact/

Maintenance Steel Platform Design

Platforms can provide easy 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 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.

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.

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

5T coil lifter: 3D model and actual lifting 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.

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

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

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

 
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

 

Crane Attachment Design

Dynamic Engineering recently completed a specialised crane attachment design that addressed the end client’s need for restricted height and specific access angles. In addition to these requirements, the attachment was also designed taking into consideration safety requirements. To ensure adherence to the Australian Standards AS1418, the design was analysed with Finite Element Analysis. Afterwards it was manufactured, load tested and is now in use by the client. 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.

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

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

flow-distribution

Flow distribution inside barrel

cyclone-fea

FEA model of cyclone barrel

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.

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.
Contact us to discuss your requirements.

Fabricated plate rack

Fabricated plate rack

Horizontal plate rack

Horizontal plate rack

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

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

 

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

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 Attachment Design

Maintenance forklift attachments used to remove track wheels

Maintenance forklift attachments used to remove track wheels

Dynamic Engineering also has the capability to design and certify your forklift attachment 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

Dynamic Engineering 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

Testing