MECHANICAL DESIGN TOOLS

Mobile Gantry Design

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Nowdays, developing new product design can be done so fast with the right software, in this opening post I'll shows you an overview how to made structure design for mobile gantry crane starts from raw concept until final design that ready for fabrication.
Start with mobile gantry concepts which is should be light enough to achieve the mobility purpose then how many max Safe Working Load (SWL) will carry <span style="text-indent: 0.5in;">by this structure</span><span style="text-indent: 0.5in;"> of course keep considering</span><span style="text-indent: 0.5in;"> common material availability to gain manufacture ability that will affecting in low fabrication cost.</span><br />
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In this design I'll wrapped all above aspect and max SWL for this mobile gantry will carry become main issue to optimize, so my structure will be:<br />
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<ul>
<li>Made from steel structure which is easy to get and vary in size if compared with aluminium material
With steel can achieve high SWL in small dimension </li>
<li>Foldable to get storage space when not in use and easy to assembly </li>
</ul>
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First step is use Staad pro modeling to gain overall structure dimension, material selection, preliminary strength analysis. In this stage, I decide my structure will be SWL 5T x 4000mm SPAN and effective height until around 4000 mm, the structure calculation report in staad pro as per pict. below.</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEimyPy-oXzx9mZQiszCWgB7mGbu_wCFMb5zOpJTRq6gpnHb1QYbLPHo2uCcvQL0cHvefpXHmYKm7KyioZSu4HF5WCMWQJfuVWaTUCoUTdHMrHw2lTgop-h_5-LLOWwWV7PoWSJvn4Dl9io/s1600/mobile_gantry_2x.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="440" data-original-width="1600" height="176" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEimyPy-oXzx9mZQiszCWgB7mGbu_wCFMb5zOpJTRq6gpnHb1QYbLPHo2uCcvQL0cHvefpXHmYKm7KyioZSu4HF5WCMWQJfuVWaTUCoUTdHMrHw2lTgop-h_5-LLOWwWV7PoWSJvn4Dl9io/s640/mobile_gantry_2x.jpg" width="640" /></a></div>
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Applying feature "moving load" with DIN15018 as design code and BS-EN 466 as deflection criteria will result H beam for girder, Square Hollow Section (SHS) for pillars support, UNP as legs and end carriage.</div>
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Next step is advance in detailing by using solidwork, in this 3D modeling software we'll get detail for each component, investigate how its folded and assembly as it's material handling purpose, generate 2D fabrication drawing also doing motion simulation.</div>
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In this 3D environment a lifting mechanism can be set up to adjust girder height after assembly. Manual calculation for sizing bevel gears with lead screw required, so user can easily do manual lift up the girder.
After all of steel structure and accessories component are selected, the last thing and optional stage is getting an overview for mobile gantry crane equipment from its folded condition to become ready to use refer to physical joint behavior that can be visualize with animation and motion analysis feature in solidwork.</div>
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Now we get the final product that ready to fabricate and launch to the market.
For detail how to collaborate design  code and software analysis will explain in other post. Thanks for reading and hopefully can inspire others especially young designer in this digital ages, where so many design tools are able to help you out with just by "blinked your eyes", so keep your design instinct gone wild and make it real not only circled around in your head.
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Mobile Gantry Design

Nowdays, developing new product design can be done so fast with the right software, in this opening post I'll shows you an overview h...

Structural simulation erected storage tank with jacking system

<img src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjUpVw4maNqjhnYo3F0Uef64ytsANn4gjZc-4LDkj_0D4mQ5efUwMYYTsIWRYJ0ju3hAopFmENlYm-G5xRtllun9jj1z5fVowURp99YToKKH2Bw-hs30zVAs1UU5k9iuXE0KujMGBauD_8/s320/Load.png"/>
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Common tank erection usually from bottom to top structure but sometimes in certain location its impossible to apply, for example at tank farm live plant which is hot work not allowed in certain elevation so other erection method should be developed in this condition such as application of water curtain, welding habitat etc. <br />
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An alternative method is building it from top to bottom by using jacking equipment, in this posting I'm not going to discuss about the erection method since there are so many article and video in youtube with clear explanation, I’d like to share my previous experience how to decide required  qty of jacking tools base on structural simulation.<br />
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<strong><u>PRELIMINARY DATA:</u></strong><br />
Tank Spec:</div>
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<ul>
<li>Roof type : Dome Roof </li>
<li>Diameter : 34747 mtrs </li>
<li>Total Shell Height : 23200 mtrs </li>
</ul>
Jacking tools spec:<br />
<ul>
<li>Each Jack capacity = 12 Ton </li>
<li>Max space between jack = 3.5mtrs (from manufacturer) </li>
<li>Max. actual safe wind load at lifting = 15 m/s </li>
</ul>
Other Data:<br />
<ul>
<li>Max Height allowed for hot work = 14 m </li>
<li>Wind speed at site = 35 m/s per year </li>
</ul>
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<strong><u>SIMULATION DATA:</u></strong><br />
Simulation model build in STAAD-PRO software with sequence as below:<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgK7jVar2urex-sbwZf_zZI2H5W8KdChfcyHAPdpAu8zWremzPEodQriFcNl7Lmhs-rU2rlQ9pG1xEyVKKbFj9dUlsW0TmtvPfvji_xnSB2MxDogmclKGdDnBQ2C04DHo0fZI6N1V39RC8/s1600/Jack_Sequence.png" imageanchor="1" style="margin-left: 1em; margin-right: 1em; text-align: center;"><img border="0" height="226" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgK7jVar2urex-sbwZf_zZI2H5W8KdChfcyHAPdpAu8zWremzPEodQriFcNl7Lmhs-rU2rlQ9pG1xEyVKKbFj9dUlsW0TmtvPfvji_xnSB2MxDogmclKGdDnBQ2C04DHo0fZI6N1V39RC8/s320/Jack_Sequence.png" width="320" /></a><br />
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Jacking device layout inside of tank structure with qty = 34 divided equally at circumference<br />
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Shell Plate thickness arrangement:<br />
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Dead load of roof with all of appurtenance generate by manual calculate = 119546.5 kg, then additional weight of shell plate will generated by software. <br />
First erected structure by jack as per picture below:<br />
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<strong><u>DESIGN LOAD:</u></strong><br />
<ul>
<li><strong>Dead Load (DL)</strong> </li>
</ul>
Roof Load = Roof weight / Top angle Lenght<br />
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<span style="color: #333333;">= 119456.5/(3.14 x 34747) =1092 kg/m = 10706.42 N/m</span>
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<ul>
<li><strong>Roof Life Load (Lr)</strong> </li>
</ul>
<span style="color: #333333;">Roof life load as per API 650 </span><br />
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<span style="color: #333333;">= 122.1 kg/sq. mtr (apply in top angle)</span></div>
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<span style="color: #333333;">Roof life  load = 122 x roof area / top angle length </span><br />
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<span style="color: #333333;">=122 x 1042.97 / 109.5 = 1163 kg/m = 11404.97 N/m</span></div>
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<ul>
<li><strong>Wind Load</strong> </li>
</ul>
    Wind pressure Refer to ASCE, use below equation for height variation                                                                            <br />
    qz    =    0.613 Kz Kzt Kd V2      (ASCE 7-10 Para. 27.3.2)                <br />
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    P    =    q G Cp - qi (G Cpi)       (ASCE 7-10 Para. 27.4.1)                 <br />
Result as per below table :<br />
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With simplification in applying load as hidrostatc load, vary lineary as per height function<br />
Load Model: 
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<ul>
<li><strong>Combination Load:</strong> </li>
</ul>
<span style="color: #333333;">Shell ring plate analysed with load combination for Allowable Stress Design as per ASCE 7-10 para. 2.4</span>
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<ol>
<li>DL </li>
<li>DL + Lr </li>
<li>DL + 0.6 W </li>
<li>DL + 0.75(0.6W) + 0.75Lr </li>
</ol>
Design criteria to be applied with max. Von misses equivalent stress compare with yield strength of plate material<br />
Result for plate stress distribution by STAAD PRO for each combination load :<br />
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<ul>
<li><strong>Max. Plate Stress :</strong> </li>
</ul>
Max Stress caused by Load Combination no.6 DL + LR with result find<br />
11.8 Mpa < 205/2 Mpa (Plate Yield Strength/Safety Factor) ==> <span style="color: blue;"><strong><em>OK</em></strong></span><br />
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<ul>
<li><strong>Reaction Force</strong> </li>
</ul>
Max. Reaction Force caused in last lifting stage 8 with result find<br />
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Max. vertical force that carry by jack device = 11.95 ≤ 12 Ton ==> <strong><span style="color: blue;"><em>OK</em></span></strong><br />
(below max. jack capacity)<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgxYNfmwsGpbx9_hPrHvGpF4jh0jiblu0ORkq4QT3qbRnK13_OlDWBAjSPaBCtXD2qElsFjymFuiI9caKD0pOQ1J-tH5PQNbKNQlwTPdgLfhGwY0Dsmjcsg_eVeRf7U1jPKwbCoBdmZefU/s1600/Reaction+Result2.png" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="259" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgxYNfmwsGpbx9_hPrHvGpF4jh0jiblu0ORkq4QT3qbRnK13_OlDWBAjSPaBCtXD2qElsFjymFuiI9caKD0pOQ1J-tH5PQNbKNQlwTPdgLfhGwY0Dsmjcsg_eVeRf7U1jPKwbCoBdmZefU/s320/Reaction+Result2.png" width="320" /></a><a href="https://www.blogger.com/$clip_image0024.gif" style="margin-left: 1em; margin-right: 1em;"></a><a href="https://www.blogger.com/$clip_image0024.gif" style="margin-left: 1em; margin-right: 1em;"></a><a href="https://www.blogger.com/blogger.g?blogID=5587740760374181364" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"></a><a href="https://www.blogger.com/$clip_image0024.jpg" style="margin-left: 1em; margin-right: 1em;"></a><a href="https://www.blogger.com/$tank13.png" style="margin-left: 1em; margin-right: 1em;"></a><a href="https://www.blogger.com/$image5.png" style="margin-left: 1em; margin-right: 1em;"></a><a href="https://www.blogger.com/$image2.png" style="margin-left: 1em; margin-right: 1em;"></a><a href="https://www.blogger.com/$image5[1].png" style="margin-left: 1em; margin-right: 1em;"></a><a href="https://www.blogger.com/$image13.png" style="margin-left: 1em; margin-right: 1em;"></a><a href="https://www.blogger.com/$image12.png" style="margin-left: 1em; margin-right: 1em;"></a><a href="https://www.blogger.com/$image17.png" style="margin-left: 1em; margin-right: 1em;"></a><a href="https://www.blogger.com/$image25.png" style="margin-left: 1em; margin-right: 1em;"></a><a href="https://www.blogger.com/$image21.png" style="margin-left: 1em; margin-right: 1em;"></a><a href="https://www.blogger.com/$image9.png" style="margin-left: 1em; margin-right: 1em;"></a></div>
<br />
<strong><u>SUMMARY:</u></strong><br />
<ol>
<li>Plate stress in elastic region for every combination load, no indication shell plate will deform in plasticity since von misses equivalent stress result still below yield stress material </li>
<li>Generated Max. reaction force smaller than max. capacity of jacking device </li>
<li>Number of jacking device = 34 ea are sufficient to support stability and integrity of structure with considering structure weight and additional wind load </li>
</ol>

Structural simulation erected storage tank with jacking system

Common tank erection usually from bottom to top structure but sometimes in certain location its impossible to apply, for example at tank ...

Eurocode footbridge design

<div style="margin: 0in 0in 0pt; text-align: justify; text-indent: 0.5in;">
Footbridge as an access for passenger to step in floating dock are need to consider its strength and integrity so can accomodate any potential unsafe situation that would happend for example in peak season when passengger are overloaded has to be considered in design.<br />
Below pict. Are General arrangement for floating dock service with preliminary bridge design. The bridge are flexible mounted so can be follow vertical movement of pontoon as tidal effect, there are other structure that holding pontoon to prevent horizontal movement.<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgWd6lohRhJGxEHtyj8gT-V2pu9kAkVMcSICw-Ryqk9FGKzcbv6glHTFToCAe4sc9HBWlv_R66-PcXt4FSp4l-FZ9S7hswmKPX3Q9Li95wyesjtS7D15hK9WHV8dHl3fhTQQskm5Dpuz1k/s1600-h/image%25255B8%25255D.png"><img alt="image" border="0" height="184" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgbb5SCtZK1gDrKhdIBqIg4qrvB8o3vS4KG71DH8LRcq2np2x1oBpPjdLvjhXzHdxI0RS9yvyE0lkiM7srK8zQmQsJa9j2uYLvGHYoV-8tfBi6A49pdgyIuFV08NFQTrnqhtxlhbbYU9ZI/?imgmax=800" style="background-image: none; border-bottom: 0px; border-left: 0px; border-right: 0px; border-top: 0px; display: block; float: none; margin: 0px auto 5px; padding-left: 0px; padding-right: 0px; padding-top: 0px;" title="image" width="299" /></a><br />
<br />
<div class="fullpost">
As per project spec, the bridge consist of aluminium framebase structure with steel handrailing also several condition need to be fullfilled.<br />
<div style="margin: 0in 0in 0pt; text-align: justify; text-indent: 0.0in;">
<br />
<ol>
<li>The bridge are assembled from two structure with hinge connection for mobility reason</li>
<li>Total bridge weight not more than 1Ton since the availabe winch at site has SWL 1Ton for bridge lifting purpose.</li>
<li>Design optimization only allowed at framebase section.</li>
</ol>
</div>
</div>
</div>
<span style="text-align: justify; text-indent: 48px;"><b>Bridge modeling :</b></span><br />
The bridge are modeled in 3D space structure.<br />
<blockquote>
Bridge Section 1                                                                                        Bridge Section 2</blockquote>
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg6vL73Jjngvuf3-1-R23W0Sz2pkX1J8GknO5t1juFQsTWBjrfREGPc86tHuV9uaqF0nYTyhKlcYuT1_KXLLewvseCkp4iAc1sFBzsTagcg96IALbsnCcxVf4-pXUeNcQIl_aDhHfz37ME/s1600-h/clip_image004%25255B6%25255D.jpg" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img alt="clip_image004" border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh1oFDgESszs-XlbnVuGgBJv2xqxLofVSd3D8Dn_Pvw2f9r2R1eMyV3J-e5XX-JAyx-grlSjtPGH7T7TVUiZWVXtTMC4Qnv0F8TXcryTKzpjzTR5AJu06pYNklZY_5W9Ohl2wcOiGOwesQ/?imgmax=800" style="background-image: none; border-width: 0px; display: inline; margin: 0px 0px 5px; padding-left: 0px; padding-right: 0px; padding-top: 0px;" title="clip_image004" /></a><i><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEicPGniUwdSCnLvZ8dnsINciVPqLCsxAPDZXh4ES-sZUR55QoX5Uq5xQjHIcvyHMbfHnVKSbRSSeVsWmmuURxO94TX9IPyg4GHMjxvHpPgEPRq-r7Dzi99bfnmobuTL3vPdj3TL_LpFip0/s1600-h/clip_image002%25255B20%25255D.jpg"><img alt="clip_image002" border="0" height="173" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhoE6tgriGPjTe4nIFeNs_hG4atvgZuiCZ78Bi563mHtrjexa0Hr9xt5t7EHgIyYzQrPjZp0IVBccgEyUT-7skj0Bd9UayQN1t4lIChp9J1v6uSH8m-B4U0a2-rd6X4NiaiKSu0khZO5IU/?imgmax=800" style="background-image: none; border-bottom-width: 0px; border-left-width: 0px; border-right-width: 0px; border-top-width: 0px; display: inline; margin: 0px 0px 5px; padding-left: 0px; padding-right: 0px; padding-top: 0px;" title="clip_image002" width="204" /></a></i> <br />
<blockquote>
<div align="center">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhR9ofzkimZQa6Q7ph03tUFWZW1Ct_E2ZzecJh6QiJ1pYaDL8mL-SwB8vuLMJGQbe99BICeYgMoq59JQUqxbBnYV9b0kpo9daUTVJ5umsUAPOfKvAPxLk5AFcQjAAfs9TamBnfe3sswG4I/s1600-h/image%25255B11%25255D.png"><img alt="image" border="0" height="284" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiguYtlm6KW0JXivEGBF7Fb2wZ5E_sh1G8EgXm3bsFfqm71ZqwqbGNAyKGOhdRVTleyktOHFDnRg0dWCIxp7bZbla1pJq0gcrsxgbedfCSbJwMpSnf5isYIHiGKMKy1Su-nLz57fmRFsaY/?imgmax=800" style="background-image: none; border-width: 0px; display: block; float: none; margin: 0px auto 5px; padding-left: 0px; padding-right: 0px; padding-top: 0px;" title="image" width="400" /></a></div>
</blockquote>
<blockquote>
<div align="center">
Bridge Assembly</div>
</blockquote>
Update general arrangement by applying new design structure:<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgS6gXcgJcvvoJpGW3ekkDqyO2FGillxFHtsljdZsD-Oc-dg8rLg5i0CxT6j6RijF4nw6q3iLYADhL90vtw7wE9orwtwxDDKND6T7-GukwMZ7rcpZINL440r-Y9eoWuu6PcU08KQbmpCMg/s1600-h/image%25255B12%25255D.png"><img alt="image" border="0" height="184" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi1ydhGU3-TKJlEefzqGxJXEiUc6TEWPh6Coqd1b9yAoNYl7ruUiObzPjHZCJpQ4rE1VQFEMc1MePU8WmAWdjj8aImidFu5Yn1JkuiePHcXgjaWFxj_oudehnOqa-Aj4ozT8XhAwKFbY6w/?imgmax=800" style="background-image: none; border-bottom: 0px; border-left: 0px; border-right: 0px; border-top: 0px; display: block; float: none; margin: 0px auto 5px; padding-left: 0px; padding-right: 0px; padding-top: 0px;" title="image" width="296" /></a><br />
Note: There are possibility colliding between bridge frame structure with pontoon handrail.<br />
Structure size and weight:<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjgsrce0r6ToMgUsu5MZ6B9n9ba7DveR0SYt0zAmmvvJWMvgZKv16KY2zqpPk0Y_2Ymfff6U1h7sucOsqzPBWufQaok0BvuH7FZ5oH1828KkEeaawmylJwGp7yXvP1S8h4UwVDYXOH58Ko/s1600-h/image%25255B163%25255D.png"><img alt="image" border="0" height="112" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjJ3LMbS_Cm2zPfq8zDwB2aUYCC4xJufGFzUjqQZWijVtqQ1JFrfnjtLs78AHxd33O9ThV4dnY_54eOvciFySXdltZ9p1UqNSHctB3Odje8pXDtFkZvA7sYikwhbXA_MnSNHwgz0ff9WhU/?imgmax=800" style="background-image: none; border-bottom-width: 0px; border-left-width: 0px; border-right-width: 0px; border-top-width: 0px; display: inline; margin: 0px 0px 5px; padding-left: 0px; padding-right: 0px; padding-top: 0px;" title="image" width="404" /></a><br />
Bridge portion at quay use wheel support and hinge connected to pontoon walkway<br />
PICT.3<br />
Bridge hinge for this model assume as fix node and the other have release nodes behaviour at splice area.<br />
PICT.4<br />
There are several bridge code that can be use as guidance but eurocode has more conservatife approach for public fasilities related with safety service. The design parameter refer to eurocode are below:<br />
<span style="font-size: small;"><strong>Applied load :</strong></span><br />
1. Selfweight of bridge structure<br />
2. Trafic load (See EN 1991-2 Part. 5)<br />
- Uniform distributed load 5 kN/m<sup>2</sup> applied perpendicular to floor surface<br />
3. Wind load (See EN 1991-1-4)<br />
- With site data for wind are:<br />
<ul>
<li>Air Density (r) = 1.25 kg/m<sup>3 </sup></li>
<li>Wind Velocity (Vb) = 10.3 m/s </li>
</ul>
- Calculated wind force :<br />
<ul>
<li>Peak velocity pressure (q(z)) = 0.16 kN/m<sup>2 </sup></li>
<li>Wind force at direction (F<sub>w,i</sub>) :       <ul>
<li>Perpendicular to the bridge = 1.14 kN </li>
<li>Paralel to the bridge = 0.94 kN </li>
<li>Vertical direction = 0.28 kN </li>
</ul>
</li>
</ul>
<span style="font-size: small;"><strong>Load combination :</strong></span><br />
Load combination will refer to EN 1990 with using Ultimate Limit State (ULS) and Service Limit State (SLS), since only wind that considered as environmental load so load factor can be simplified as per below:<br />
<blockquote>
1. Service Limit State</blockquote>
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgWVHHZzAjpq3BB5hw4ZQMcwq2YlVbLC_nJadeR6S7IeYoR9_pInpF-6XX8LqQ_PqW6SGWeJr8LmACuopeK8MP8Fho_xdpEM0XMIXznGhPx70SYEdAW9LXqGAxho3pzNjc2eg7pqJFLWGs/s1600-h/clip_image008%25255B3%25255D.jpg"><img alt="clip_image008" border="0" height="68" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgTfmZSqBnOoePB_ZCp5nGCRljZ04t_3aZFoIf6BulHNad22rZ2BnOI1Q_ybNTlQJZaS19nxsDUBq29_5J3JLmvwgakh-BPt5vIfnjX7m5_dYnydnyHnn4qfVxxtMyBnU6c8qBSZ0VSDMg/?imgmax=800" style="background-image: none; border-bottom-width: 0px; border-left-width: 0px; border-right-width: 0px; border-top-width: 0px; display: inline; margin: 0px; padding-left: 0px; padding-right: 0px; padding-top: 0px;" title="clip_image008" width="244" /></a><br />
<blockquote>
2. Ultimate Limit state</blockquote>
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjgTNLIV7Td77V7H4KwdiooIixy4T3zZT-lxsbEvrn7kbIxwaNCL_efI3gecYXr_h2bsjaA_m8CrAE61YO3dDPCSofX6V2mb0huTT0-M_3mchtnN6QdHkRCCVr_uK1myq81qQPiBlkFrfA/s1600-h/clip_image010%25255B3%25255D.gif"><img alt="clip_image010" border="0" height="66" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEghXKyOEURXgaisnnNs8n9k9rX88x3UC0IyDIHRE4Nk3LI288NMk1p6K9XUJ5geMYCoQ92ZVfl9mab2wvrN-Lz1BUbIQOTJ-Dm0SvjG7A2kEyZmYwF-qwDdEWdkbCt7ZuADsTdoM4cvEK0/?imgmax=800" style="background-image: none; border-bottom-width: 0px; border-left-width: 0px; border-right-width: 0px; border-top-width: 0px; display: inline; margin: 0px 0px 5px; padding-left: 0px; padding-right: 0px; padding-top: 0px;" title="clip_image010" width="244" /></a><br />
<span style="font-size: small;"><strong>Acceptance criteria :</strong></span><br />
1. Stress material<br />
For material propertied for aluminium structure refer to EN 1999<br />
<table border="0" cellpadding="2" cellspacing="0" style="width: 400px;"><tbody>
<tr>         <td valign="top" width="178">- Material</td>          <td valign="top" width="11">:</td>          <td valign="top" width="106">AL 6061 T6</td>          <td valign="top" width="103"></td>       </tr>
<tr>         <td valign="top" width="178">- Density</td>          <td valign="top" width="11">:</td>          <td valign="top" width="106">2712.6</td>          <td valign="top" width="103">kg/m<sup>3</sup></td>       </tr>
<tr>         <td valign="top" width="178">- Yield Strength (f<sub>y</sub>)</td>          <td valign="top" width="11">:</td>          <td valign="top" width="106">240</td>          <td valign="top" width="103">Mpa</td>       </tr>
<tr>         <td valign="top" width="178">- Ultimate Strength (f<sub>u</sub>)</td>          <td valign="top" width="11">:</td>          <td valign="top" width="106">290</td>          <td valign="top" width="103">Mpa</td>       </tr>
<tr>         <td valign="top" width="178">- Modulus of elasticity (<em>E</em>)</td>          <td valign="top" width="11">:</td>          <td valign="top" width="106">68900</td>          <td valign="top" width="103">Mpa</td>       </tr>
<tr>         <td valign="top" width="178">- Shear Modulus (<em>G</em>)</td>          <td valign="top" width="11">:</td>          <td valign="top" width="106">26000</td>          <td valign="top" width="103">Mpa</td>       </tr>
<tr>         <td valign="top" width="178">- Poisson’s Ratio</td>          <td valign="top" width="11">:</td>          <td valign="top" width="106">0.33</td>          <td valign="top" width="103"></td>       </tr>
</tbody></table>
<br />
Permissible stress for tension, compression and bending members:<br />
<blockquote>
<span style="font-family: "universalmath1 bt";">s</span><sub>perm</sub> = f<sub>y</sub>/y<sub>m</sub> = 240 Mpa</blockquote>
Permissible shear stress :<br />
<blockquote>
<span style="font-family: "universalmath1 bt";">t</span><sub>perm</sub> = f<sub>y</sub>/(y<sub>m</sub>xÖ3) = 139 Mpa</blockquote>
Where :<br />
<blockquote>
f<sub>y</sub>= Yield stress of material</blockquote>
<blockquote>
y<sub>m</sub>= material factor = 1.0</blockquote>
2. Deflection<br />
With refference to EN 1990-Annex A1.4 limits for vertical deflections according to figure A1.1 should be specified for each project and agreed with the client. Due to no specified maximum vertical deflection by client, maximum vertical deflection in SLS cases in the middle of bridge span assumed as L/250 = 9500mm/250 = 38mm <br />
<br />
3. Frequency<br />
With <span style="font-size: small;">assumption:</span><br />
1. No horizontal force acting on the brige because of pontoon movement<br />
2. Analysis structural in frame-base, the handrail and any other appurtenance only contribute self-weight loading.<br />
<br />
<span style="font-size: small;"><strong>Analysis result :</strong></span><br />
1. Max stress generated at ULS cases are 137.2 Mpa at L.C 1.2 still below permissible <br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiGr0cAtKFT_P4Gw19WHh3T3W35aeZGEERtmbVN0K-nBPqV61ifDYuUqCa1ZeKlxlLqQdVajojb7xzKjN1DKpZyMImFMK5DHVJwLLCeKbyJhDzIqDFKkjiURhL6GFSoK5Xmx_D_z_J9tdM/s1600-h/image%25255B212%25255D.png"><img alt="image" border="0" height="244" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi3_Cb_CI8RxG-Kne__1pYiDmjh7f5_aiXAWh6NOme9u0MEvoCX8NWL3hyphenhyphenA7LOA7HEB9RmCBYWVDHAL5HX7eTZ1Yc5dedvEbeM-aGHSVdfQ8xglgz3WrK004ECeNJpRR-ytoQwgm2IXAxE/?imgmax=800" style="background-image: none; border-bottom-width: 0px; border-left-width: 0px; border-right-width: 0px; border-top-width: 0px; display: block; float: none; margin: 0px auto 5px; padding-left: 0px; padding-right: 0px; padding-top: 0px;" title="image" width="304" /></a><br />
2. Max deflection at SLS cases are 16.7mm at L.C 1.2 still below allowable deflection limit<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj6PLgoZmt8NfeOfx4VN56XsfLo9EGWig-BW9zFnzXw2Y9toGVle2iq3sm1TSyFuOukv6Q_BbqXnPmg_FaKWEz0ZwB8goNcD1DYJtJ2W6edH6eumvMmpY2FKG7dNFOFuADJZH1u-msj0Zs/s1600-h/image%25255B216%25255D.png"><img alt="image" border="0" height="239" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhW_A1FXSVoLYjxfUfAuCqiLJrZ6aHTKWelgywnG5OeLN3OTGjSXxFSD2tZOGBLZoosqIElAc-jmLqmTIscZQqE5alrbLwrrW8JPF1ylr3x3bJYESerHetlbKHdwWRJgHFkhN1-YdlpZt4/?imgmax=800" style="background-image: none; border-bottom-width: 0px; border-left-width: 0px; border-right-width: 0px; border-top-width: 0px; display: block; float: none; margin: 0px auto 5px; padding-left: 0px; padding-right: 0px; padding-top: 0px;" title="image" width="304" /></a><br />
3. Frequency at mode shape 1 is 2.97 hz still in alowable limit<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhN8chZvSwA0aiSSpNATDiL5N2p1Xyj95Kvzt6Cd8kFRKLR6orHk-ZLH8sIThClJMmVYKWdIVfHrKXyVcvZQIxH1EnMyYNwx53cX8iae8vEr1v2U9IKmU6lmwIYxbrxFr7t0U5sangxODM/s1600-h/image%25255B220%25255D.png"><img alt="image" border="0" height="298" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhSTzT-U15d98BwqtQScY3HCCKovA9W4Qte8VZMOdJCpaAZgQtTCfJM33o_2IRmr8bEbbXmr-BxKmgyk3m9DDQdG9w-xQTKkJ7bl1wfBmAn08jFexKnj8Z88bhUKox42hN2mXG_QAGp6Ig/?imgmax=800" style="background-image: none; border-bottom-width: 0px; border-left-width: 0px; border-right-width: 0px; border-top-width: 0px; display: block; float: none; margin: 0px auto 5px; padding-left: 0px; padding-right: 0px; padding-top: 0px;" title="image" width="304" /></a><br />
New foot-bridge structure design comply with Eurocode

Eurocode footbridge design

Footbridge as an access for passenger to step in floating dock are need to consider its strength and integrity so can accomodate any potent...

Design from scratch

<p style="margin: 0in 0in 0pt; text-indent: 0.5in; text-align: justify">Mostly in my blog are about design software but now I’ll be discuss “how to design from scratch”, start from design purpose until become drawing that ready to machining or prototyping stage of course still involve software as a tool. For example I made some simple gearbox as our case. I will explain stage by stage in design:  <p><strong>1. Design purpose </strong> <p align="justify">Before starts everything we need to know what kind of design purpose or a case that become our target, in this example I’ll make a gearbox with input by motor 1800rpm, but I expect three option output 900, 1800 and 3600rpm so I could use it in more wide range ability from my motor.  <p><strong>2. Layout concept </strong> <p align="justify">Now begin to planning gearbox layout, but before that I’ve to choose standard component that available in the market, the most clearly part that needed are motor. I start with baldor motor 3hp 1800rpm (you can googling for available catalogue) that has detail frame dimension so this is our first guide to decide required space or dimension for gearbox. <span class="fullpost" style="font-size: 100%"><br> <p align="justify">As you know for common gearbox are consist of components that need to be designed such as Gear, Shaft, keys, Casing, Speed transmission also don’t forget other peripheral like bearing, screw, cap, rubber seal that will affect in overall design dimension. 
<br />
<div class="fullpost">
 <p><strong>3. Engineering calculation</strong>  <p align="justify">In this stage we will face the core of design it self, how to make rough component spec base on equation or mechanical rule such as gear ratio, transmitted torque, overall load in every speed option. The result is we have data’s that will become our guideline to choose the right material and dimension each component (minimum spec).  <p><strong>4. Engineering Criteria</strong>  <p align="justify">After runs for some calculation we can advance to choose what material that will be use and detail dimension with considering market availability, price, machining process, installation difficulties. Beside that our designs have to pass engineering criteria as perquisites to operate perfectly for example in gear are tooth strength and wear stress also in shaft have to pass moment and shear stress criteria. In this stage we have detail gear train as a core for gearbox design.  <p><strong>5. Peripherals component</strong>  <p align="justify">Other supporting component in our gearbox can follow previously designed component, price are become main issue here since this is not our main focus so you would consider to us as many as common part and standard part that will be helpful for replacement and reduce price too. Sometimes there are also custom part that need to be created but don’t forget common part’s rule so can cut some machining price and time.  <p><strong>6. Technical drawing</strong>  <p align="justify">Base on data in previous stage, we can start to make a technical drawing to translate our design so technician can follow what designer want, how precision the component is, how to assembly, what kind material that will be used. Of course don’t make mistake in adjusting tolerances or double dimension standard that will be confusing and become problem in assembling.  <p><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgAwcEAquP2k6p6ZCYueefoDkrjVOyHyazaHre8MIIzAE1erYNxWJQAtC5xnyp_Iwc4fOu6pCkdBzcppUx_0z9pki7762dQ6JkXkbTWoVL4n4K2EjVZlh9ewKikKLzRgE0eHogAa9vr14g/s1600-h/clip_image002%5B1%5D.gif"><img alt="clip_image002" border="0" height="270" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjNate8IqPJ3qenfVEjhqv6I52_RrPwB6UtMgeB7YK_oo0j7ea8X2HSS0dTrnYrEuBI4vy3UNiG2hl-o153RZ0FVopdpK_OS5Kw_tSBN1f28X1e6zxbKp_r7Fk-l0kahASj_k175NxFfLg/?imgmax=800" style="border-top-width: 0px; display: block; border-left-width: 0px; float: none; border-bottom-width: 0px; margin-left: auto; margin-right: auto; border-right-width: 0px" title="clip_image002" width="384"></a></p> <p style="margin: 0in 0in 0pt; text-indent: 0.5in; text-align: justify">After those stage are completed, now can be advance in machining component and prototyping to test whether our calculated design are appropriate or not, just remember above step are made by theoretical aspect especially for mechanical component (gear and shaft) since I’ve neglected the effect from vibration and heat generated by high speed mechanism that will contribute failure in operating condition so any improvement are still open to make final design base on actual operational condition from our product.  <p>There are several tips in engineering design:  <ol> <li> <div align="justify">For designer, experience and strong engineering background become main issue to make good design so never stop learning new technologies. </div> <li> <div align="justify">Always keep price as our consideration and benefit for any designed component, this will give value add in our design. </div> <li> <div align="justify">Remember that our design doesn’t end in a drawing paper, this will be applied and produced by manufacturing process so always be aware about how to process the component. Don’t make difficult shape that impossible to make and giving another problem when assembly. </div> <li> <div align="justify">Give as clear as possible information in technical drawing and avoid redundant item so not confusing everybody that read our design. </div></li></ol> <p style="margin: 0in 0in 0pt; text-indent: 0.5in; text-align: justify">For technical drawing I use Pro-Engineer WILDFIRE 3 and collaborate with Vn4D for visualization, actually with Vn4D our analysis can be spread more wider from monitoring load and stress analysis in every component but I’m use it just for visualization purpose.  <iframe allowfullscreen="" frameborder="0" height="344" src="https://www.youtube.com/embed/xqb5aQyTAZ0" width="400"></iframe> <p style="margin: 0in 0in 0pt; text-indent: 0.5in; text-align: justify">  <p style="margin: 0in 0in 0pt; text-indent: 0.5in; text-align: justify">I also include presentation file and technical drawing for designed gearbox, this article are my thought about design engineering and base on my experience in my workplace (even though I’m not in design dept.) so maybe there some other opinion from experts in mechanical engineering design, I would be open minded to learn more. <br></span>  </div>

Design from scratch

Mostly in my blog are about design software but now I’ll be discuss “how to design from scratch”, start from design purpose until become dra...

Autodesk MoldFlow

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<span style="font-family: "times new roman";">Software simulasi ini lebih dikenal para engineer yang berkecimpung dalam bidang molding terutama injeksi plastik baik desainer ataupun user dari molding itu sendiri, dalam aplikasinya software ini cukup banyak membantu dalam memperkirakan bagaimana produk hasil injeksi berdasarkan konstruksi molding maupun parameter injeksi yang diaplikasikan.</span></div>
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<span style="font-family: "times new roman";">Dari sisi fungsi software ini sendiri dibagi menjadi dua :</span></div>
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<b><u>AMA (Autodesk Moldflow Adviser)</u></b> </div>
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<span style="font-family: "times new roman";">Adviser memberikan analisa lengkap hasil injeksi berdasarkan struktur produk dan material yang digunakan misal untuk mengetahui area shortmold, pressure drop, filling time, dsb. Dimana informasi tersebut dapat digunakan mold desainer sebagai referensi untuk mendesain konstruksi molding begitu pula bagi seorang desainer produk plastik untuk melihat defect yang mungkin terjadi sehingga improvement dapat dilakukan dari konstruksi produk.</span></div>
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 <b><u>AMI (Autodesk Moldflow Insight)</u></b> </div>
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<span style="font-family: "times new roman";">Setelah desainer sudah memiliki gambaran konstruksi molding seperti apa yang akan dibuat seperti posisi core-cavity-slider, insert, cooling, gate dsb. Selanjutnya tinggal mensimulasikan dengan Insight dimana versi ini dilengkapi dengan fasilitas basic desain mold plan seperti core plate, cavity plate, runner plate, cooling system, material molding dsb. Disamping itu bisa juga disimulasikan parameter injeksi yang akan dipakai seperti speed, pressure, V/P change, cooling time dan holding mengingat setiap mesin injeksi memiliki karakteristik sendiri dan kelebihannya lagi kita dapat membuat mesin virtual dimana karakteristiknya disesuaikan dengan kondisi actual mesin yang dipakai.</span></div>
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<span style="font-family: "times new roman";">Jadi ketika seorang plastic engineer dihadapkan pada suatu desain part plastik yang pertama dilakukan adalah analisa part defect dengan AMA untuk menentukan improvement apa saja yang dapat dilakukan baik dari struktur molding yang akan dibuat atau desain part itu sendiri, kemudian simulasi dengan AMI untuk optimalisasi ketika didepan mesin injeksi.</span></div>
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<span style="font-family: "times new roman";">Dari hasil simulasi Moldflow seorang plastik engineer dapat menentukan perbaikan apa saja yang bisa dilakukan sebelum suatu cetakan atau molding dibuat untuk menghasilkan produk seperti spesifikasi </span><span style="font-family: "times new roman";">konsumen serta melihat cacat produk seperti apa yang mungkin terjadi dan apakah masih dalam level acceptable atau tidak.</span></div>
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<span style="font-family: "times new roman";">Secara garis besar untuk mengasilkan produk yang baik adalah bagaimana lelehan material plastic dapat memenuhi rongga didalam mold dengan sempurna dengan density yang optimal tanpa mengabaikan life-time dari molding itu sendiri, tentu saja factor cost produksi seperti cycle-time juga menjadi pertimbangan tersendiri bagi designer tooling, beberapa factor tersebut dapat dijadikan variable constraint dalam software ini sebagai item optimasi.</span></div>
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<span style="font-family: "times new roman";"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEibcw21uQBYwhXL7cFvmnQHbLdNppWir8bRJCXcwEgh_OYOFTNY1aoRLbiysG9Rm72AdE-YfyhrU0cGfJhQYorJ4ybObdOUG_VTu8LYxzPDBZWklYaoy8Nxn3zUHPh18H1vFWX9oJ1oyGU/s1600-h/view%5B8%5D.jpg"><img alt="view" border="0" height="237" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgSHPbBKB6HU3-HIVF6C_mBTfP9Smf7WHPQd9iRfE6xU9KhlKnm0BJ6YAxbiIOgK-su-Eia2LVr1u239eldXpeb7H_9j6cWFMDye_QOLQta_j_CqFExzWE_A67wYo_J8wWahLWbki-VOAQ/?imgmax=800" style="border-bottom-width: 0px; border-left-width: 0px; border-right-width: 0px; border-top-width: 0px; display: block; float: none; margin-left: auto; margin-right: auto;" title="view" width="354" /></a> </span></div>
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<span style="font-family: "times new roman";">Video dibawah ini adalah salah satu contoh output yang dihasilkan moldflow versi Adviser (AMA) untuk filling time.</span></div>
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<iframe allowfullscreen="" frameborder="0" height="315" src="https://www.youtube.com/embed/g-SpB6xXCnk" width="420"></iframe>
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</div>

Autodesk MoldFlow

Software simulasi ini lebih dikenal para engineer yang berkecimpung dalam bidang molding terutama injeksi plastik baik desainer ataupun use...

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