A North America manufacturer of complex compressor systems was experiencing a high rate of piping cracking on one of their systems. Six DOF Testing & Analysis (6D) was asked to help develop an economical approach to validating new product iterations and next generation designs while addressing any structural issues along the way.
Video Amplification Technology
It was decided to use video motion amplification tools in conjunction with localized Finite Element Modeling to create an efficient process to validate designs and solve structural problems. Video motion amplification technology can quickly and economically isolate areas of interest within geometrically complicated systems. This includes areas related to high stresses, vibration, or similar factors.
Video amplification techniques save time and money by pinpointing areas where more detailed analysis should be focused, and physical measurements taken. Because of the complexity of the structure, proceeding without this information has traditionally been a best guess on the part of the engineer. What’s more, creating a Finite Element Model of the entire structure would be overly complicated, costly, and time-consuming.
Isolating Areas of Interest
Once areas of interest were determined, some limited physical measurements using accelerometers or strain gauges were taken. This data helped to determine vibration amplitudes or other factors that could be exciting the system.
In areas where failure was observed, or areas with a potential for failure, localized Finite Element Models are created to examine, compare, and validate possible remedies. This could include introducing a different bracket, modifications to a pipe’s supporting structure, or completely changing the way it is supported. Such alternatives can be developed and validated with a simpler model – quicker, and at less cost.
A Path Forward
Together, 6D and the client identified an efficient yet cost effective approach to developing an accurate understanding of the dynamics associated with complex mechanical systems.