Better Design Choices through Engineering Analysis
6D's engineering analysis and simulation services allowed the client to identify structurally unsound areas of the new design and make modifications to ensure lasting durability.
Overview
Generally used in rugged field applications, utility trailers such as stringing, overhead and underground cable pullers, and related equipment must be safe, reliable, and durable. With a mission to build upon its leading reputation for quality, a leading trailer manufacturer launched a program to enhance the design of its product line.
Operating in rugged off-road environments and under high stress, it was essential for the equipment to meet the manufacturers rigid standards and the lofty expectations that the industry has come to expect.
Design Validation
With extensive testing and analysis experience, Six DoF Testing & Analysis (6D) was called on to review the new designs and provide a report along with any enhancement recommendations to ensure structural integrity.
With more than 25 years of Finite Element Analysis (FEA) and simulation experience, 6D’s Senior Technical Specialist, Steve Biel led the project. 3D CAD models of the new designs were created. Stress tests were performed to ensure that the designs were robust enough to go off road and get pulled and pushed in any direction imaginable. Loads and stresses replicating (and exceeding) real-world operation conditions were applied to the models to ensure that the new designs would meet performance and durability targets.
Designing for Applications
Running the designs through a variety of loading schemes uncovered areas where the frame could be solidified. Biel explained that material choices and weld placement can have a big impact on durability and overall cost.
“Geometry can be complicated, and frame weld locations are important considerations with equipment of this type. For example, where you place the weld is critical to durability. It can be cheaper to purchase a more expensive piece of material, such as an L channel, to get a better overall joint.”
Biel cautions that it’s also important to design for specific processing requirements.
“Design engineers often approach product development heavily from a usability or ergonomics perspective. While those are important considerations it’s also critical to consider the manufacturability element – such as when galvanizing a frame. The bottom line is, we can help the client to make sound choices at the design point, so they don’t have to deal with fatigue and durability issues and excessive warranty claims down the line.