Assembly Packaging

Assembly Packaging : Improvement In Space Utilization In a Container


Requirements

To Optimize Space utilized in transporting containers for stacking of Machines & ensure Quality of Goods delivered to the end consumer over long distances

To ensure timely delivery to End Consumers

Ease of Loading and Unloading of Machines


Benefits

Rs 7.77 Cr: Total Annual Logistics Cost Savings

33% Improvement in Container’s Machine Carrying Capacity

25% Reduction in Transportation Cost

Reduced Inventory of Finished Goods

Compliant with CMVR norms


Gear Casing Weight Optimization

Gear Casing Weight Optimization


Requirements

Design is safe or not against static load of 6000 Kgs

Weight optimization in the gear casing by 20%

Redesign Of Casing


Our Solution

Perform Structural Analysis to obtain design information.

Identified maximum stress area

Checked feasibility of casting design

Suggested changes in design


Benefits

Operational life achieved of 10 Lakhs

Lifting

Reduced weight & material of gear casing


Torque Carrying Capacity

Torque Carrying Capacity Improvement Of Worm Drive


Requirements

To improve Torque carrying capacity of worm drive from 152 KNm to 350 KNm without changing the mounting hole details


Benefits

Increased range of product offerings

Design changes which were 10% compact

Improved Design with high torque carrying capacity to 350 KNm

Analytical tool developed for calculating torque carrying capacity of Work


CAE Certification of Air Tank

CAE Certification of Air Tank


Requirements

Burst Test:

»  To perform static structural analysis and check failures of the reservoir tank at the welding joints

Vibration Test:

»  Plot Frequency Vs Deformation with input acceleration of 7g in the frequency range of 5-100Hz in

    *  Vertical direction (Z)

    *  Lateral direction (Y)

    *  Linear direction (X)

Fatigue Test

»  Find weld stability by checking the weld life


Our Solution

The impact of change in parameters on the system studied accurately

Detailed FE-mesh is done at the joints to understand stress concentrations for better correlation

Geometry clean-up

Selective mesh used for accurate results

The Hand Calc of natural frequency is verified with the CAE results and the deviation from the CAE is 7%.

Maximum stress is 1450 MPa at the weld

Fatigue life of weld is 145 cycles


Benefits

Certification of the product under actual working conditions

Accurate prediction of failure areas

Evaluating the natural frequencies of the product to avoid resonance and minimize the vibrations

Prediction of weld life for finding weld stability