Maintenance Equipment Design

Have you got a maintenance improvement project that requires engineering input? Do you require design certification for your existing maintenance tools?

Or are you tired of the big consultancies not performing to your expectations or not giving your projects the attention they deserve?

The chances are that we have completed a similar project and that will be able to help you. Why re-invent the wheel? We specialise in the design and certification of maintenance tools, jigs, frames and equipment. Examples include hydraulic push and pullers, forklift attachments, transport frames and so forth.

Contact us now to discuss your specific needs. Click “contact us” on the menu bar above or scroll down for examples of recently completed projects.

Vehicle Lifter

Occasionally, a prototype needs to be checked against the relevant standards/specifications before more money is committed to the development of the final product. One such prototype was a vehicle lifter. The lifter is attached to the rear of the vehicle and could be used to change a tyre. Initial analysis found that the stresses were too high and modifications were suggested, which were incorporated into the final design.

 

Prototype

Prototype

Drill Mast Stand

Many of our clients are happy to fabricate their own equipment, but need help converting their concept ideas into a design that complies with the Australian Standards. Dynamic Engineering works with the client, fine tuning the design until complies, and can then assist with generating accurate fabrication drawings.

In one such an example, our client wanted to analyse a drill mast stand with a WLL = 25T. Below is the concept along with the final design.

Client's concept

Client’s concept

 

 

 

 

 

 

 

 

Final Design

Final Design

 

 

 

 

 

 

 

 

 

 

 

 

The concept had to undergo several modifications to comply with the stress, deflection, stability, buckling requirements. In addition the pins were checked to see if they were strong enough and finally the stand was checked while being lifted with the forklift.

Finite Element Analysis

Finite Element Analysis

 

 

Radiation Source Cradle Design and Supply

A radiation source cradle was designed to assist plant metallurgists to easily and safely move radiation sources around inside a process plant.

Due to the weight of the source the cradle was designed to that it can be carried by two people. The cradle weight was kept low by using aluminium for its construction and was fitted with spacers that made it multi functional. It was also furnished with a stainless steel nameplate that contained information regarding the load rating and use.

Radiation Cradle

Radiation  Source Cradle

 

 

 

 

 

 

 

 

 

 

 

Radiation Source Cradle

Radiation Source Cradle

Monorail Design Checks and Certification

Corrosion is part of everyday life in an underground mine and when equipment has been in use for several years, it can become a safety concern. Dynamic Engineering Consultants was requested to determine if an existing corroded monorail beam is still fit for purpose and if not, to specify repairs. Structural analysis (based on Australian Standards AS1418) was done to determine the minimum required thicknesses of the beam to support the hoisted load. The thicknesses were then compared with the actual thickness of the beam to ascertain if the beam was still strong enough and a repair procedure was developed accordingly.

monorail-beam

Monorail beam with some corrosion

 

 

Maintenance monorail systems

Dynamic Engineering Consultants can assist with the design of your maintenance monorail system in accordance with AS1418. A typical design would include a discussion with the maintenance team in which their requirements are recorded and noted. After this initial consultation we can produce 3D models for discussion / approval. From there we complete the detailed structural design and drawings. The extent of the drawing range from GA drawings down to shop drawing level. This is all performed in-house.

For simpler (straight) monorails no 3d modelling may be required, and we can skip directly to the detail design calculations. Below are some examples of completed or currently being designed monorail systems.

3D model of mill maintenance monorail system

3D model of mill maintenance monorail system

 

Mill maintenance monorail system - view 2

Mill maintenance monorail system – view 2

 

Typical monorail GA drawing

Typical monorail GA drawing

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 Flotation Mixer Assemblies and Gyratory Crusher mainshaft assemblies. 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 maintenance platform:

Crusher mainshaft maintenance platform 3d model and actual platform

Crusher mainshaft maintenance platform 3d model and actual platform

Flotation cell rotor maintenance platform:

Rotor stand 3D model and actual stand

Rotor stand 3D model and actual stand

Do you have a similar requirement? Refer to the “Contact us” page on this site and let us know how we can assist.

Design Certification of Maintenance Tools

Sometimes a specific job requires a specific tool that is not available off the shelf. In these cases, in the interest of safety, the tool may have to be certified for certain loads. Certification is always done against a specific standard and requires the following:

1) Fixed design (Generally the design is fixed in terms of an accurate drawing that states the processes (welding etc) as well as the material standard and grades.

2) Fixed or specified loads (torque, Force etc).

Dynamic Engineering can assist our clients by certifying tool designs for certain applications and loads. Some examples are given below:

Push/Puller Model

Hydraulic Push / Puller

3D model of Hydraulic Push Puller

Stress Analysis of puller

Stress Analysis of Puller

Stress plot of Push Puller under Design Load

Lifting bracket

lifting bracket

3D model of lifting bracket

Stress Analysis of lifting Bracket

Stress PLot of lifting Bracket (including bolt stress)

Stress Plot of lifting Bracket (including bolt stress)

The above are just two of literally hundreds of design certification of maintenance tools we have completed. If you have a specific maintenance tool that you would like to get certified please give us a call or send us an e-mail.

Machine design and analysis

Machine design and analysis can be a laborious task. Dynamic Engineering Consultants has the capability to analyse existing and new machinery by means of 3D modelling and finite element analysis. This is a cost and time effective technique.

We have the following capabilities:

1) Linear Analysis

2) Buckling

3) Frequency analysis

4) Non linear analysis

And many more.

Examples where Dynamic Engineering used the above capabilities are given below:

1) Linear Analysis:

Stress analysis during clamping action for drill rig

 

 

 

 

 

 

 

 

 

 

 

 

 

with the completed drill rig (designed and analysed by Dynamic Engineering) shown below:

Actual drill rig being tested

 

 

 

 

 

 

 

 

 

 

 

2) Buckling:

Buckling analysis showing buckling load factors

 

 

Maintenance Stand Design

Dynamic Engineering specializes in the design of high capacity maintenance stands. These stands are designed using the principles of AS2538 and experience gained in this field over a period of 10 years.

Stability and strength as well as ease of handling are taken into account during the design process.

From a design point of view a tool called Finite Element Analysis is applied to each design, making it possible to ensure that the stand has adequate capacity to resist deformation and buckling.

All designs are engineer certified – meaning that a Chartered Engineer, Registered with Engineers Australia, has signed off on the design.

Below is an example of one of our many designs. These stands have a 200T capacity (100T each side) and is used for wheeled loaders in the Mining Industry. Feel free to contact us via info@dynamicengineering.com.au with your specific requirements.

3D model of the Maintenance stand

 

 

 

 

 

 

 

 

 

 

Stress Plot after loads have been applied

Actual maintenance stand set

 

115T stand with pneumatically actuated wheels

 

Curved top stand with spring loaded wheels

Movable Aluminium Platform and Stairway Design

Dynamic Engineering Consultants designs movable/transportable aluminium access platforms/stairways.

Mobile platforms offer a safe way of doing maintenance at elevated positions. This type of platform is made from Aluminium and can be easily moved into place. Further safety features include a self-closing and lockable wheels. In addition, jacks can be added to raise the platform to ensure the correct height every time.

These steps were designed to comply with the principles of AS1657 and have been stress checked at a load of 250kg – resulting in safety factors exceeding 4.

If you have an application for these, please contact us.

2.8m high access stairway with stabilizing jacks and swing gate

Access stairways……

Cantelevered platforms

 

CAT 995 platform set : This is a set of 3 platforms that is used for a CAT front end loader. All the platforms are movable by forklift and the whole assembly fits around the loader.

CAT995 Platform set

Over wheel access platforms…

Over wheel access platform

Double stair platforms….

Movable steps with stabilizing jacks

 

 

Completed access stairways and platforms

Completed access stairways and platforms

Lightweight Shutdown Maintenance platforms

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:

maintenance platforms

3D view of the inspection platform

This project was recently completed and the maintenance platform used during the shutdown is shown below:

maintenance platforms

Lightweight access platform being used during the shutdown