Using Finite Element Analysis (FEA) To Ensure Our Products Optimise Performance and Ensure Cost Effectiveness
Innovation is a core value at Lift-Rite, and we are always using advanced engineering techniques like Finite Element Analysis (FEA) to ensure our products perform to the very highest standards.
What is Finite Element Analysis?
Finite Element Analysis (FEA) is a computer-based tool used for predicting the response of structures and materials to real-world conditions. This could be the forces exerted on a structure by heavy loads, the impact of vibration or the effects of thermal changes, all of which are simulated virtually.
The underlying principle of FEA is to break down any complex structure into simpler, smaller parts that are easier to analyse. These small parts are called ‘finite elements’ because they are bounded in terms of their size and shape. These finite elements are then calculated separately, leading to a relatively simpler and easier set of calculations. They elements are then combined in order to get a complete picture of the entire structure.
The Process of FEA
At Lift-Rite we use FEA to ensure all our products perform in real work situations. We break the FEA process into:
Model creation: With an initial product supplied, we draw a digital model of the structure. For Lift-Rite products, this includes anything from a pallet jack to a lifting mechanism.
Mesh generation: The model is cut up into a large number of small, finite elements. This step is critical to the accuracy of the analysis: the more elements used, the finer the mesh, and usually, the more accurate the results.
Applying loads and boundary conditions: the conditions of the real world, such as forces, pressure, temperature, or vibration are applied to the model. The FEA software predicts how those will affect each element.
Resolving solutions: The applied forces are resolved for each element, assessing the levels of stress at each point and reporting levels of material utilisation.
Results Interpretation: After the FEA solver has completed the analysis, the results are inspected. Engineers check the locations of high stress, deformation, heat transfer or other factors that could compromise the integrity and performance of the structure.
How FEA Benefits Lift-Rite’s Product Development
Prediction of Performance under Stress: Using FEA, we can predict how a material will perform under specific loading or working conditions. This allows us to know with confidence that our products will resist applied loads and remain constantly dependable in the most extreme conditions.
Design Optimisation: FEA can quickly identify areas of high stress or weakness within a model that our engineers can then refine, saving time and material costs by optimising the structure to be stronger or lighter or redesigned where necessary.
Safety Assurance: Safety is paramount at Lift-Rite. FEA allows us to test our equipment in the most extreme conditions, giving us the reassurance the product will not fail when used in the real world. Whether it’s a hot environment or a low temperature, consistent high pressure or operation with heavy loads, we know FEA gives our products the assurance our customers demand.
Cost efficiency: Physical prototypes are eliminated since there are so many different design scenarios that can be virtually assessed in a short amount of time. This saves materials, reduces development costs and helps to quickly cut down on the turnaround time of production.
Real-World Applications of FEA at Lift-Rite
We use FEA at all stages of product development. For example, when we develop a new lifting beam, we can use FEA to analyse the way the beam will react to the dynamic forces present when the beam is used to lift and suspend loads over a long period of time, in order to ensure that the structural integrity will be preserved every time the beam is used.
Likewise, with FEA, companies can determine the suitability of a custom lifting solution for a particular scenario. The solution might be something as straightforward as adapting a standard design, or it might be a completely new design, but in either case FEA will provide information about how slight changes in design detail will affect the product’s performance or lifespan.
Conclusion
FEA is a must-use tool in modern engineering, and at Lift-Rite we use FEA to improve the function, safety and efficiency of the material handling products we ship daily. By seeing and predicting how real-world forces and conditions affect our equipment, we’re able to get innovative, usable products to market quicker without sacrificing the stringent requirements of our customers.
Utilising FEA, as part of our ongoing product development process, Lift-Rite continues to remain at the cutting edge of modern technology, ensuring our products continually deliver on cost effectiveness and performance in some of the most demanding environments.