Kalmar Kalmar, part of Cargotec, offers the widest range of cargo handling solutions and services to ports, terminals, distribution centres and to heavy industry. They are the industry forerunner in terminal automation and when Kalmar decided to move forward with the design of their automatic stacking cranes they chose Etteplan. The co-operation in Technical calculation area of engineering started in 2011. Case Kalmar Expertise Engineering The fully automated cranes operate in the ports by the sea. As the ports are windy and subject to high wind loads, it is critical that the cranes are robust enough to be fully operational in wind speeds up to 25 meters per second. Out-of-service wind speed requirements can be more than 50 m/s. Hence, the design and calculation process has to be extremely precise with relevant safety margins included. ”Traditionally crane wind loads has been calculated manually according to related design rules and standards. The only way to verify these calculations has been the use of wind tunnel testing, but this is a very time-consuming process and the modifications to the physical test model are difficult if several configurations need to be studied” says Matti Paloneva who is R&D Manager for Technical Calculation and Simulation at Kalmar. “The CFD-calculations fulfilled the Kalmar expectations. The goal was to compare the traditional hand calculated wind loads to CFD results instead of expensive and time consuming wind tunnel testing. CFD proved to be efficient and cost effective step. Another important lesson was how we easily can compare different designs in early stages of the R&D project by using CFD." Matti Paloneva R&D Manager for Technical Calculation and Simulation at Kalmar Designing the fifth generation ASC 5.0 crane To advance the design process for their fifth generation Automatic Stacking Cranes, Kalmar decided to move forward with Computational Fluid Dynamics (CFD) calculations. ”Etteplan assisted us with CFD. This method proved to be fast and efficient process to verify the design wind loads. Also the effect of different crane geometries is easy to study. Third point is that the simulation results are very visual and easy to explain to persons who are not so familiar concerning the crane wind loads. The 3D-prints are nice way to visualize the numbers for the loads in presentations” At Etteplan, Pasi Moilanen was responsible for performing the CFD simulations. Pasi works at Etteplans Centre of Expertise for CFD in Tampere in Finland, one of three offices that conduct the CFD calculations and simulations. ”In this assignment, Kalmar had very high requirements. We had to prepare the calculations with a 5 percent error margin. It is challenging and requires long experience to select the correct parameters to achieve this accuracy.” High accuracy The 3D CAD geometry is included in fine detail to achieve the desired 5 percent error level. To meet the set criteria Etteplan needed to consider and evaluate several possible error sources such as wind profile, temperature, pressure, humidity, turbulence, time dependent behavior, wind direction and CFD numerical procedures. It is demanding to predict the behaviour of different parameters, although Pasi Moilanen’s experience of over a hundred of industrial CFD assignments made the parameter screening faster. One single supplier for the entire CFD process Kalmar has cooperated with Etteplan earlier on to perform design work and structural analyses, but this time Etteplan was trusted with the CFD as well. The CFD adds the final piece of the puzzle that allow the structural analyzes to be performed more accurately. ”Usually, several suppliers are involved in the design processes but we felt that it was a major benefit for us to work with one single supplier who possess the expertise necessary for all calculations and simulations. One single point of contact is much more efficient and convenient”, says Matti Paloneva.
Developing a range extender device for Pexraytech Pexraytech is a Otaniemi, Finland based high-tech company that develops and manufactures cutting-edge portable X-Ray imaging systems. Pexraytech makes use of the extensive X-Ray engineering expertise that Finland has, providing innovative and intuitive solutions for two focus areas: Security market and Industrial NDT (Non Destructive Testing). They also offer advanced customized systems to users who need special X-Ray solutions for other applications
Machine risk assessment tools taken to a new level at Metsä Board Metsä Board specializes in eco-friendly fresh fiber paperboards, and its products are mainly used in food and consumer product packaging. The company has long been focusing on circular economy solutions to meet customers’ future packaging requirements, such as the traceability of renewable raw materials and the recyclability of packaging. Part of Metsä Group, Metsä Board has altogether eight mills, seven of which are located in Finland.
Hybrid manufacturing case: Rosendahl Nextrom While Etteplan’s AMO team is working hard to show our customers how to benefit most from additive manufacturing, we are always searching for the best manufacturing method for each design. This customer case is a good example of how “hybrid manufacturing”, a combination of additive and traditional subtractive manufacturing techniques, can be utilized to efficiently produce a very demanding product. 3d printing additive manufacturing
Carbon fiber composite – futureproof solutions to all industries Read more about Carbon fiber composite – futureproof solutions to all industries
Creating a digital era dental robot Rayo 3DToothfill aims to improve the lives of billions of people with affordable, high-quality dental health. Their solution provides the best results with comparable costs for the dentist and for the patients. To ensure their solution is usable in different surroundings, it is simple and easy-to use.
Additive Manufacturing Design Case for John Deere’s Hydraulic Block John Deere Forestry Oy asked Etteplan to redesign a hydraulic block for a tree harvester boom in order to best utilize the geometric freedoms offered by additive manufacturing, i.e. 3D printing. The goals from the redesign were to decrease pressure drop, make assembly easier, reduce weight, and minimize production costs. additive manufacturing
