MECHANICAL DESIGN TOOLS: 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...

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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 />
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As per project spec, the bridge consist of aluminium framebase structure with steel handrailing also several condition need to be fullfilled.<br />
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<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>
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<span style="text-align: justify; text-indent: 48px;"><b>Bridge modeling :</b></span><br />
The bridge are modeled in 3D space structure.<br />
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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 />
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<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>
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Bridge Assembly</div>
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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 />
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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 />
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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>
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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 />
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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 />
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