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Typical Conveyor Design

Typical Conveyor Design

I really enjoyed this project. We were tasked to analyze and optimize a structural part of the conveyor system manufactured by our Customer.

This was a fun project, especially since the stability of the main beams was strengthen by perpendicular beams bolted to the webs of C-Sections. We couldn’t simply assume that the lateral torsional buckling won’t happen (we proven later that failure mode is indeed LTB thanks to FEA analysis!). On another hand we knew, that the perpendicular beams help to some degree, and that the impact will be high! This is a perfect example of a problem where FEA shines as a solution!

In the analysis we managed to assess the structural capacity of the system, find the weakest points and proposed an optimized solution. The cool thing is, that the final version not only had smaller weight, it was also more robust with higher capacity, since we strengthen a few key areas (they were ok, but with small adjustments they became so much better!).

I think that this is a perfect case study for FEA use in optimization design. It’s not always only about “making thing weight less”. What we do instead, is we asses each component of the system, and we reduce the overdesigned things, while strengthening the weakest links – this always leads to a robust design!

Project Takeaway:

Stability is a sneaky thing. If not for the fact that I suspected that we may have a Lateral-Torsional Buckling problem in this project we could have gone with the beam model… and we would completely miss this failure mode! So it’s always good to be careful, when stability is involved!

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What Enterfea’s customers say

The first project we did with Enterfea was a silos design in 2015. Their non-linear FEA analyzes allowed to significantly reduce the costs of that project. Recently with the enormous support and commitment of Enterfea, we did a pressure vessel with imperfections design. Non-linear FEA analyzes allowed to save a project that seemed to be hopeless. The level of complexity and detail of analyzes provided by Enterfea always exceeds my expectations. Łukasz with his knowledge and commitment is a top-class expert in the field of FEA. Having 15 years of experience in the design industry, I can say that at the current level, Enterfea is no longer competing with the competition, they set new standards in the design projects and can only compete with themselves.

For many years, Enterfea has been performing for us the static calculations of complex acid-resistant steel tanks for the pharmaceutical, food and chemical industries, meeting the requirements of international standards (EN 13445, ASME Sec. VIII div.2, AD-2000 Merkblatt and others). Most often, static calculations are made taking into account earthquakes for tanks that are installed in all parts of the world. Łukasz and his team have vast experience and practical knowledge in the field of performing these calculations, they are always willing to help and never leave us with problems. Thanks to this, they solve the most difficult technical problems for us related to projects and customer requirements.

We have used Enterfea for a number of large steel tank designs. With the cost of raw materials increasing rapidly, it is vital for our customers that our designs are efficient whilst still being safe and code compliant. This is why Enterfera is so important. The level of detail involved in their complex non-linear analyses provide unrivaled value for money and the service is exceptional – Lukasz goes above and beyond to ensure any queries are answered even after a contract has been completed. His extensive knowledge of FEA gives us peace of mind that value is maximized and risk is mitigated as much as possible in our designs.

Enterfea proved a high-quality approach with the NL analysis of the post-deformed storage tank they did for us. Thorough diagnosis of the issue has resulted in complex output, a detailed report has explained the phenomenon step by step, allowing even non-technical users to follow it up. Łukasz has soft skills allowing him to rebuild one's confidence and engineering knowledge in the so-called “complex-stress-state” with a single phone call. He has never refused to answer any questions and was always calm and patient, while straightforward when talking about his results. If a truly fiendish engineering case exists, Łukasz definitely has the power to deal with it!

We have been working successfully with Enterfea for many years. Enterfea is always a reliable partner for the static design of our conveyor technology. In our current project, we are jointly developing a completely new, statically optimized conveyor system for integration into our standard.

Enterfea is performing all of the designs of silos for us with nonlinear FEA for over 5 years now, and we are very satisfied with the cooperation. Especially since our Customers appreciate the quality of the designs, which leads to more sales for us and no issues with verification of designs by the authorities.