毕 业 设 计（论 文）

自动化立体仓库轻量化结构设计计算

姓 名 ABDALLAH EMAD BAKER AL-NAIFEH

学 号 1811511141
所在学院 MECHANICAL ENGINEERING SCHOOL
专业班级 20LQ
指导教师 Dr. Yan Guoping
日 期 2024 年 06 月 16 日
自动化立体仓库轻量化结构设计计算

一篇论文

提交是为部分满足要求

机械工程设计与自动化学士学位

通过

阿卜杜拉·艾玛德·贝克尔·奈菲

注册号 1811511141

2020 年级 lq 班

机械工程设计与自动化学院

湖北工业大学

指导老师：闫国平 博士

2024 年 5 月 25 日
 2024 届湖北工业大学本科生毕业设计（论文）

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1
 2024 届湖北工业大学本科生毕业设计（论文）

摘 要
对高效和可扩展的存储解决方案的需求不断增长，推动了自动化仓库的发展，这些
仓库严重依赖先进的机器人和自动化系统。本论文探讨了为自动化仓库量身定制的
轻质结构框架的设计和计算，旨在优化材料使用，同时确保结构完整性和与自动化
系统的兼容性。该研究首先进行了全面的文献综述，以了解现有的自动化仓库设计
并确定影响结构要求的关键参数。主要目标是开发一种框架，在不影响强度和耐久
性的情况下最大限度地减少材料重量。高强度、轻质材料，如先进复合材料、铝合
金和高强度钢，因其良好的强度重量比而被考虑。.研究方法包括几个阶段：概念设
计、详细建模、结构分析和优化。使用计算机辅助设计 solidworks （CAD） 软件生
成和评估初始设计概念，从而开发详细的 3D 模型。采用有限元分析（FEA）来模
拟各种载荷条件，并评估所提出设计的结构性能。优化过程的重点是减轻重量，同
时确保结构能够承受自动化仓库环境中典型的操作载荷和应力。此外，该设计还包
含集成自动化系统的规定，包括自动存储和检索系统 （ AS/RS）、输送系统和机器
人技术。这种集成确保了无缝操作，并提高了仓库的整体效率。验证和测试通过虚
拟模拟进行，并在可行的情况下通过物理原型进行。结果证明了轻质结构设计的可
行性，突出了在不牺牲结构完整性的情况下显着减少材料使用和整体重量。本论文
的发现有助于开发更具可持续性和成本效益的自动化仓库。该设计框架为满足物流
和电子商务行业日益增长的需求提供了实用的解决方案，强调了材料效率和结构优
化在现代仓库建设中的重要性。
关键词：有限元法，三维仓库，应力分析，建模。

摘要
The increasing demand for efficient and scalable storage solutions has propelled the evolution
of automated warehouses, which rely heavily on advanced robotics and automation systems. This
thesis explores the design and calculation of a lightweight structural framework tailored for
automated warehouses, aiming to optimize material usage while ensuring structural integrity and
I
 2024 届湖北工业大学本科生毕业设计（论文）

compatibility with automated systems. The study begins with a comprehensive literature review to
understand existing automated warehouse designs and identify key parameters influencing
structural requirements. The primary objective is to develop a framework that minimizes material
weight without compromising strength and durability. High-strength, lightweight materials such as
advanced composites, aluminum alloys, and high-strength steel are considered for their favorable
strength-to-weight ratios. The research methodology encompasses several phases: conceptual
design, detailed modeling, structural analysis, and optimization. Initial design concepts are
generated and evaluated using computer-aided design SolidWorks (CAD) software, leading to the
development of detailed 3D models. Finite element analysis (FEA) is employed to simulate
various load conditions and assess the structural performance of the proposed designs. The
optimization process focuses on reducing weight while ensuring that the structure can withstand
operational loads and stresses typical in automated warehouse environments. Furthermore, the
design incorporates provisions for integrating automation systems, including automated storage
and retrieval systems (AS/RS), conveyor systems, and robotics. This integration ensures seamless
operation and enhances the overall efficiency of the warehouse. Validation and testing are
conducted through both virtual simulations and, where feasible, physical prototypes. The results
demonstrate the viability of the lightweight structural design, highlighting significant reductions in
material usage and overall weight without sacrificing structural integrity. The findings of this
thesis contribute to the development of more sustainable and cost-effective automated warehouses.
The proposed design framework offers a practical solution for addressing the growing demands of
the logistics and e-commerce industries, emphasizing the importance of material efficiency and
structural optimization in modern warehouse construction.
Keywords : Finite element method, Automated Warehouse, Stress analysis, Modeling.

I
 Contents
Abstract……………………………………………………………………........................I
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Keywords…………………………………………………………………………............II
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摘 要 ……………………………………………………………………………………
IIIError: Reference source not found
CHAPTER 1 Introduction ……………………………………………………………..01
1.1 Background……………………………………………………………………………………02
1.2 Literature Review……………………………………………………………………………. .03
1.3LiteratureReview……………………………………………………………………………….04
……………………………………………………………………………….04
CHAPTER 2 Materials
2.1 Brief Introduction of The
Analysis……………………………………………………………..11
2.2 The Finite Element Method……………………………………………………………………
13
2.3 Computer Software…………………………………………………...
………………..............14
2.3.1 Analysis Procedure…………………………………………………………...………...........14
2.3.2Difference between CAD solidwork and models…………………………………………….16
2.4 Definition of Loads and Standards…………………………………………………………….17
2.5Summary……………………………………………………………………………………….21
CHAPTER3Methodology and design optimization Single-column laneway stacker
designMethodology and design optimization Single-column laneway stacker design
3.1 Design raw Data and Lifting Device…………………………………………………………..22
3.1.1Maindesignofchain drive……………………………………………………………………..23
3.1.2 Chain wheel design
………………………………………………………………………….24
3.1.3 Chain selection and verification structure……………………………………………………
26
3.2 Design of Pickup Device ……………………………………………………………………...26
3.2.1 Overall design of horizontal conveying
……………………………………………………..27
3.2.2 Gear design and verification
………………………………………………………………...30
3.2.3 Motor selection and calculation
……………………………………………………………..31
3.3 Shelf design
…………………………………………………………………………………....33
3.3.1 Overall design of shelves
…………………………………………………………………....34
3.3.2 Calculation of shelf strength
………………………………………………………………....34
3.4
Summary………………………………………………………………………………….........39
CHAPTER 4 Finite Element Analysis of Key components
4.1 FEA importance ………………………………………………………….….………………..40
4.2 Finite Element Analysis of frame ……………………………………………………………..40
4.3 Finite Element Analysis of shaft ………………………………………………..….
………….45
4.4 Finite Element Analysis of chain wheel …………………………………………….…………
50
4.5 Finite Element Analysis of lifting dicice
frame………………………………………………..52
4.6 Finite Element Analysis of several plates………………………………………………………
56
4.7 summary……………………………………………………………………………………….60
CHAPTER 5 Economic analysis…………………………………………………….61-
62
CHAPTER 6 Conclusions
6.1 Conclusions……………………………………………………………………………………62
6.2 Recommendations and Future scope ………………………………………………………….63
References……………………………………………………………………………………........64
Acknowledgment……………………………………………………………...................66
Summary ………………………………………………………………………………...67

List of Figures

Figure 2-1:Model of at rain´s axle shaft (TadeuszStorlaski,2006)

Figure2-2:Simulated model
Figure2-3:Physical model and discredited model (StephanieWehner,2013)
Figure2-4:Steps to obtaining results in FEM analysis(Too-good,2012,2-5)
Figure2-5:Bigelementsrepresentedbythewidebars
Figure2-6: Smaller h lengths of nodes
Figure2-7:model (Using mirror symmetry)
Figure2-8:cold-formed steel (CFS) angles
Figure2-9:Defination of Loads and Standards
Figure2-10:Live Load
Figure 2-11:Wind Load
Figure 2-12:Wind pressure and suction on a building (The effects of imperfections, n. d)
Figure 2-13:Effects of earth quake on a building
Figure 2-14: Pressure load to uniformly distributed load
Figure3-1: Lifting Device
Figure3-2 : Chain Lifting slide structure
Figure3-3: Chain lift is carried out using chain sprockets to lift the load
Figure3-4: Traveling mechanism-wheel design
Figure3-5; Orbital size diagram
Figure3-6: Chain Lifting slide structure
Figure3-7: Pickup Device
Figure3-8: Overall plan Lightweight Structural Design for Automated Warehous
Figure3-9: Ground speed, i.e.. Load weight, self-weight.
Figure3-10: Gear
Figure3-11 : Decelerator motor parameter diagram
Figure3 -12: Dimension drawing of the reduction motor
Figure3-13: stereowarehouse shelf design
Figure 3-14: final angle
Figure3-15:Shelf design
Figure 4-1:FEA farme model
Figure 4-2:2D Figur
Figure4-3: FEA Frame
Figure4-4: FEA Frame
Figure4-5:3D model of cantilever beam
Figure4-6:The CREO model is imported into the respective file format of the FEM design software
Figure4-7 :3D Model.
Figure4-8: Simulated model
Figure4-9:3D wheel
Figure4-10: 2D Model wheel
Figure4-11:The maximum wear depth and temperature in each contact patch along the wheel
profile.
Figure4-12:2D Model lifting dicice frame
Figure4-13:Idealized model showing axial force
Figure4-14:dimensional model
Figure4-15:Analysis results
Figure4-16:Column showing simulation parameters
Figure4-17:showing simulation parameters
Figure4-18:2D middle plate
Figure4-19:several plates
Figure4-20:side several plates
Figure4-21:Simplified model of column and the base
Figure4-22:Isolated results of the Frame
Figure4-23:Detailed model
Chapter 1 INTRODUCTION
Enhancing the ware house Automated Warehouse design is the thesis's main goal. As the
structure's dependability is examined, structural analysis is crucial. Can the structure withstand the
loading circumstances? For the most part of the analysis, it is the question posed. The structural
analysis is crucial because it highlights the areas that require more care and attention. Moreover,
the study facilitates a deeper comprehension of the structure's design. It is important to understand
the purpose of each component of the structure before making any changes. Figures one and two
below depict the actual building's exterior as well as the inner sections that will be examined. The
facility under analysis is a warehouse that houses goods and equipment for farming. Different
loading circumstances put a lot of stress on different portions of the building. Analyzing the
building as a whole is impractical. The structure is divided into several smaller sections for easy
analysis in order to provide more detailed information. Additionally, certain areas of the edifice
have more significance than others. The roof truss, column support, and join are considered to be
the most important components in this thesis. Figure 3 below displays one of the building's
technical drawings. After modeling this technical drawing using solid work and CAD software,
analysis is done. Later on, this is illustrated A structure is affected by loads in a variety of ways.
The load functions alone or simultaneously depending on the situation. The worst-case loading
scenarios that produce the largest stresses are applied while analyzing the structure. High buckling
or Von-Mises stressed sections of the structure are isolated for additional examination.
Engineering principles mainly used in this analysis derives knowledge from the following topics:
 Statics
 Strength of materials
 Machine elements
 Material selection
 Finite element method for mechanical engineers
Later, the study is updated to include the new designs in order to see if the high stresses have
decreased. An essential component of the analysis is redesigning the members. Apart from the
remodeling, a new office Automated Warehouse building is conceptualized and designed into a
physical structure.
1.1 Background
Designing a lightweight structural system for an automated warehouse involves several critical
considerations to ensure safety, efficiency, and cost-effectiveness. Here's a comprehensive guide
to approach this Site Analysis and Requirements
Location: Understand the geographic and environmental conditions of the site, including soil
type, seismic activity, and climate. Load Requirements: Determine the loads, including dead loads
(weight of the structure), live loads (loads due to usage like forklifts, goods), wind loads, and
seismic loads.
 Structural System Selection Frame Type: Choose between steel, aluminum, or a combination of
materials for the frame. Steel is commonly used for its strength and durability, while aluminum
can be used for its lightweight properties. Foundation: Design a suitable foundation that can
support the lightweight structure, considering soil conditions and load distribution.
Material Selection Steel: For high-strength, lightweight steel alloys such as ASTM A572
Grade 50 or A992. Aluminum: Use high-strength aluminum alloys like 6061-T6 or 7075-T6
for elements that benefit from reduced weight .Composite Materials: Consider using
composite materials for certain parts of the structure to further reduce weight without
compromising strength. Structural Design Principles
Optimization: Use design optimization techniques to minimize material usage while maintaining
structural integrity. This can include using software like ANSYS, SAP2000, or STAAD.Pro.
Modular Design: Incorporate modular elements to facilitate easy assembly and disassembly,
which can be beneficial for maintenance and scalability. Automated Systems Integration
Automated Storage and Retrieval Systems (AS/RS): Design the structure to accommodate
AS/RS, ensuring that the bays and aisles align with the automated machinery's operational
requirements.
Conveyor Systems: Plan for the integration of conveyor systems for efficient movement of
goods. Dead Load: Calculate the weight of the structural components. Live Load: Estimate
the weight of goods, equipment, and human occupancy. Environmental Loads: Include
wind, snow, and seismic loads according to local building codes (e.g., ASCE 7-16). Dynamic
Loads: Consider the impact of moving automated systems and vibrations.
Safety and Compliance Building Codes: Ensure compliance with local building codes and
standards, such as IBC, AISC, or Eurocode.
Fire Safety: Integrate fire suppression systems and design for fire safety regulations. Structural
Redundancy: Incorporate redundancy to prevent catastrophic failure Simulation and Testing.
Finite Element Analysis (FEA): Use FEA software to simulate structural performance under
various load conditions.
Prototyping: Create small-scale models or sections to test the design before full-scale
implementation. Sustainability
Material Efficiency: Optimize material use to reduce waste. Energy Efficiency: Design for
energy efficiency in lighting, HVAC, and other systems within the warehouse. Budgeting:
Develop a detailed cost analysis that includes material, labor, transportation, and installation costs.
Lifecycle Costs: Consider the long-term maintenance and operational costs of the structure.
1.2 Research significance and purpose
Efficiency and Productivity: Operational Speed: Lightweight structures can enhance the speed of
automated systems by reducing the load that robots and conveyor systems need to handle, leading
to faster operation cycles.
Energy Savings: Reducing the weight of the structural components decreases the energy required
for material handling, transportation, and overall system operation, leading to significant energy
savings.
Cost Reduction: Material Costs: Using lightweight materials can reduce the overall cost of
construction and maintenance. Lightweight materials such as aluminum and advanced composites
might be more expensive per unit but can result in lower total costs due to their strength-to-weight
ratio.
Transportation Costs: Lighter materials and structures can reduce shipping and installation costs,
as they are easier and cheaper to transport and handle.
Sustainability and Environmental Impact: Reduced Material Use: Lightweight design often
involves the use of less material, which can reduce the environmental footprint of the warehouse
construction.
Energy Efficiency: Lower energy consumption for operation and transportation aligns with
sustainability goals and reduces greenhouse gas emissions.
Structural Safety and Durability: Seismic Performance: Lightweight structures can perform better
in seismic events due to lower inertial forces, enhancing the safety of the warehouse.
Longevity: Materials used in lightweight design, such as composites, can offer enhanced
durability and resistance to environmental factors, leading to longer lifespans and reduced
maintenance costs.
 Flexibility and Scalability: Modular Design: Lightweight structures can be more easily modified,
expanded, or reconfigured to meet changing business needs, offering greater flexibility for future
warehouse expansions or reconfigurations.
Adaptability: These structures can support various automated systems and technologies,
making it easier to integrate new innovations and adapt to evolving industry standards.
Research Purpose: Developing Innovative Design Strategies: Optimization Techniques:
Investigate and develop new optimization techniques for lightweight structural design that balance
strength, weight, and cost. Material Innovation: Explore new materials and composites that offer
superior strength-to-weight ratios and durability for use in warehouse structures.
Enhancing Automation Integration: Design Compatibility:Create designs that seamlessly
integrate with automated systems, ensuring that structural components do not impede the
efficiency of robotic systems and automated processes. Load Management: Develop methods to
manage loads effectively, minimizing the impact on automated systems and enhancing their
operational efficiency.
Improving Sustainability: Environmental Impact Assessment: Assess the environmental impact
of different lightweight materials and design approaches, aiming to minimize the carbon footprint
of warehouse construction and operation.
Lifecycle Analysis: Perform comprehensive lifecycle analyses to determine the long-term
benefits and sustainability of lightweight structural designs.
Enhancing Safety and Compliance: Regulatory Standards: Ensure that new lightweight
designs meet all relevant safety and regulatory standards, particularly concerning structural
integrity and fire resistance. Risk Mitigation: Develop strategies to mitigate risks associated
with lightweight materials, such as susceptibility to damage or wear.
Economic Viability: Cost-Benefit Analysis: Conduct detailed cost-benefit analyses to
demonstrate the economic advantages of lightweight structural designs over traditional methods.
Return on Investment (ROI): Quantify the ROI for businesses adopting these new designs,
focusing on long-term savings and operational efficiencies.
Scalability and Reproducibility: Prototype Development: Design and test prototypes of
lightweight warehouse structures to evaluate performance and scalability.
Standardization: Work towards standardizing lightweight structural components and design
methodologies to facilitate widespread adoption across the industry.
1.3 Literation Review
In this paper, Unidirectional glass fiber reinforced plastic (GFRP) was developed, produced
(using a hand-lay up approach), and tested to provide a single leaf with mechanical and
geometrical attributes equal to those of a multi leaf spring while maintaining a uniform cross-
sectional sectional area and related variables. An explanation of the computer method for
designing a mono composite leaf spring with a changeable width and thickness is provided. The
experimental results are checked using a three-dimensional finite element analysis. Which uses
the solid 45 element for steel leaf springs and the solid layered 46 element for composite leaf
springs. Additionally, study was done for composite leaf springs made of glass/epoxy,
graphite/epoxy, and carbon/epoxy composite materials with bonded end joints, and the outcomes
were compared to steel leaf springs with eye ends. With a significant weight decrease, composite
leaf springs are shown to be superior than steel.
In this paper a study has shown, weight was reduced by 65.5% when composite springs were
used in place of steel springs. An additional weight reduction of 23.4% came from the
optimization of the composite leaf spring, for a total weight reduction of 75.6%. When comparing
an optimized composite spring to a traditional steel spring and during the weight-reduction
process, adequate strength and stiffness requirements are kept as constraints. Most conventional
optimization techniques solve a mathematical simplification rather than the original design
challenge. New non- traditional methods, such as the genetic algorithm (GA), provide a global
optimum, while conventional methods are of limited use here. Genetic optimization emulates the
development of natural processes and retains a strong relationship to the design's physical
character. In this research, the author provides a genetic algorithm (GA)-based method for
optimizing leaf spring designs; specifically, to formulate a fitness function that may be used in
this context.
There has been significant progress in the use of composite material leaf springs in automobiles
over the past two decades, especially in the last few years. n this paper Glass fiber reinforced
plastic (GFRP) ] single leaf springs of varying thicknesses were developed, manufactured, and
tested to achieve the same mechanical and geometrical qualities as the multi leaf steel spring.
Compared to graphite/epoxy, glass fiber reinforced plastic (GFRP) has advantages such as being
less sensitive to wear, impact, and crack damage. The model of a leaf spring took the form of a
parabolically curved, constant-width beam supporting a concentrated load; the two arms of the
spring were thought to have different chord lengths. The operation of a leaf spring is simulated in
a finite element software program and utilizes analytical analysis to get an equation that depends
on the spring's thickness and location along its length. This research proved that composite
materials may be utilized in place of metal for leaf springs in light vehicles (jeeps), resulting in
both compliance with regulations and significant weight savings. The significant decrease in
airplane weight may not have the same technical effect on vehicles.
Many research has evaluated the deflection and stresses of traditional steel leaf spring under the
same static load circumstances as composite leaf spring and has performed modeling and analysis
of composite leaf spring under static load conditions. To achieve this, they used Eggless/Epoxy
as their composite material of choice; ANSYS V1 0 was used to model both steel and mono E-
Glass/Epoxy components and assess them under different stresses. They came to the conclusion
that using composite material resulted in an 84% weight reduction for the same level of
performance while having stronger stiffness, less stress, and higher natural frequency than the
current steel leaf spring.
In this paper the author developed an elliptic spring for use in automotive applications [15] that
is based on a composite material. The goal is to contrast the steel leaf spring's lateral load
capability, fatigue behavior, and weight savings with that of the composite leaf spring. They
came to the conclusion that the weight reduction ratio is obtained under static load conditions,
and that composite elliptical springs exhibit superior fatigue behavior than traditional steel leaf
springs. Based on vibration characteristics, internal delamination in composite mono leaf springs
has been detected experimentally[8] mode forms are more sensitive to the delaminated region
and delaminated spring exhibits a significantly different dynamic stiffness in the delamination
area than a healthy leaf spring,demonstrating the proper placement of the delamination.To assess
different delamination phases in composite mono leaf springs, vibration parameters including
natural frequency, mode morphologies, and dynamic stiffness have been discovered.
The modification with maleic anhydride in the composite most obviously results in a stronger
fiber/matrix interaction. Debonds are prone to form at a fragile interface. Fatigue, as noted by
Owen [16] has been shown to have a role in the initiation of debonds that may lead to large-scale
matrix fissures and final collapse. Therefore, it would be helpful to look at the relationship
between interfacial adhesion and fatigue performance in polypropylene composite systems, as
well as the micro mechanisms behind this relationship.
The properties of composite materials include better strength to greater fatigue resistance,
stronger natural resistance to weight, and the feature makes them more appropriate for leaf spring
instead of ordinary steel. An analysis of fatigue design and simulation is presented in this study
[17], characteristics of SAE1045-450-QT steel and E - Glass/ Epoxy Composite material has
compared and the design uses the finite element technique to determine the performance of a glass
fiber/epoxy composite leaf spring and demonstrate the reducing time, resources, and
manufacturing costs for a validation technique that relies only on simulation.

CHAPTER 2 Materials
2.1 Brief Introduction of The Analysis
Since the approach used to investigate the structure almost totally determines the outcomes, the
analytical method employed is extremely important. If this examination is carried out by hand, it
could be a difficult and error-prone process.
The finite element method (FEM) is applied throughout this investigation as a result. This
approach is a practical and expedient means of conducting the structural analysis.
To reproduce the actual structure, individual drawings of the structures to be evaluated are
modeled In the software. The software also models the forces and limits. The distinction between
a modeled and real structure is depicted .
 Figure 2-1 : Model of at rain´s axle shaft
The process of modeling entails using computer software to replicate the drawing. The beam
cross-section properties, forces, and limitations (boundary conditions) of the structure are among
the most crucial details in the models. Automated Warehouse care is used throughout this process
because precise modeling of the software's architecture can result in a build-up of mistakes. The
model will then be simulated in order to determine the outcome. The model's displacements,
buckling, and Von-Mises stresses are displayed in the results. Here is an example of a simulated
Graphics are used to display the results. High stresses or displacements are indicated by the red
regions, and mild stresses or displacements are indicated by the blue regions.

Figure 2-2 : Simulated model (Auto fem,n. d)

This is how a portion of the analytic process is carried out; however, the following chapter
provides more in-depth explanations
Expected Challenges
Even with the aid of extremely sophisticated computer software, the analytical procedure is not
simple.The two biggest obstacles that are expected are keeping the operations consistent and
accurate at high levels. Every outcome need to make reason and be anticipated to be grounded in
reality. Very strange outcomes and conclusions can be reached if caution is not used. It's common
knowledge that "garbage in, garbage out" applies while utilizing computer software, so keep that
in mind at all times. For this reason, it is beneficial to be aware of the difficulties ahead of time so
that they can be overcome as needed.
It is imperative that the thesis maintains a high standard of accuracy throughout. As previously
stated, a build-up of errors results in inaccurate results and incorrect designs.Numerous
circumstances may result in the incorrect data being used in the research. For instance, when
modeling, certain features may be left out of the drawings, which could have an impact on the
outcome. To be sure everything is accurate, each step is verified twice. Easy strength of material
computations contribute to increased accuracy levels. To raise the confidence levels, the outcomes
ought to make sense. It is easier to compare results and designs when the problem-solving
approach is consistent throughout the investigation. For instance, the units utilized in the start of
the analysis ought to be applied throughout the entirety of the thesis project. If one calculation was
done in English units and the others were done in metric units, that may have disastrous
consequences. Steer clear of mistakes and it’s crucial to maintain consistency while working on
this thesis.
2.2 The Finite Element Method
Numerous engineering disciplines, including electronics, dynamics, thermodynamics, solid and
fluid mechanics, and electronics, face physical challenges. Engineers utilize numerical analysis as
a method to solve differential equations that best explain physical models. One numerical method
for resolving the physical issues is the finite element method (FEM). FEM analysis can be used in
many fields. Some of the fields include:

 Structural analysis (stress, strain, buckling and modal)

 Temperature analysis
 Magnetic and electrical analysis
 Crush simulations
 Connected problems (wind load on a building causing deflections)
FEM is used in structural analysis to look at how the product design will be impacted by the
applied forces. Because hand calculations are unable to identify the solution, the FEM approach
provides a thorough analysis of complex structures. Because the FEM method requires solving
multiple simultaneous equations, very powerful computers are necessary. The residential building
has an intricate design. Because of the complicated loading circumstances and geometries of the
residential building, calculations that produce direct solutions during analysis are not feasible. For
this reason, the answers are found by the application of numerical techniques like FEM.
Repeating an operation repeatedly yields a series of approximations in numerical method
procedures. (Technical Approaches, n. d.) In other words, the problems cannot be solved by
simple, direct mathematics like calculus. Utilizing numerical techniques, approximate answers are
found. This just provides a rudimentary overview of the mathematical theory underlying finite
element theory. The use of the software is the main focus, not the theoretical underpinnings of
FEM.
Design simulation is becoming more and more common, and FEM is largely responsible for this
development. The simulations are crucial, particularly when trying out novel concepts. Since the
actual design, or prototype, is not made and tested in the real world, they do away with the need to
pay for testing. So not only does the FEM method aid in the analysis, it is also capable of testing
the new designs in simulations.
FEM entails dissecting the issue into discrete parts and identifying discrete fixes. Nodal points
link the elements, and boundary conditions are stated clearly at the outset. Then, while modeling
the structure, it is evident that odes have the ability to translate, rotate, or stay fixed. The elements
all move in response to any displacement experienced by the odes. To determine the ultimate
approximate solution for the entire structure, the finite elements are once more connected. The
actual physical object and a theoretical model split into finite pieces with boundary conditions are
depicted in Figure 6. The FEM program produces results that are clearly displayed and simple to
understand. None the less, it is important to verify the results twice.

Fig3: Physical model and discredited model

2.3 Computer Software

The structural analysis function is performed by numerous computer programs. There are two
types of programs: heavy duty commercial programs and small, specialized programs.
The particular programs aren't meant to handle diverse kinds of problems; they are meant to solve
specific difficulties. These programs are broadly accessible and less expensive. However, the
commercial applications are capable of doing design simulations and solving a wide range of
problems.
Due to the complexity of the analysis, both types are used in this thesis, however the commercial
program is used more often. The applications utilized are cero-simulate and a math-cad based
program. The smaller program is based on Math-cad and was created by HAMK instructor Esa
Murtola.
Several other commercial programs are available and can be used to perform the same analysis.
They include:
 ANSYS
 ABACUS
 ANSA
 ALGOR
The list is very long and the choice of program that is used for this thesis is explained in detail
later in the next sub-chapter.
2.3.1 Analysis Procedure
The following steps are followed when using the FEM software Cero simulate. (Too good, 2012,
2-5)
 Create the geo me try with Creo parametric SolidWorks and (CAD software)
 Transfer the model to Creo-simulate
 Add the simulation parameters (material properties, model
constraints and loads)
 Run the model (model is discretized to form fin it element mesh)
 Display desired results

The steps are also illustrated

Simplified Mathematical-
Real Physical Model
Physical Model
Problem

Discreti
zed FEA
del

Figure 2-4:Steps to obtaining results in analysis

 It is crucial to confirm the accuracy of the results after they have been calculated. Convergence
analysis is the process used to accomplish this validation. Convergence determines which
outcomes are valid and deserving of acceptance by using the same problem to exhibit many
results.
The convergence analysis method divides FEM programs into two categories. For convergence,
one group utilizes h-elements and the other employs p-elements. While other applications, like
ANSYS, employ h-elements for convergence analysis, Creo-Simulate uses p-elements.
H Elements
The convergence technique for improving performance in these FEM systems is mesh refining.
Reducing the size of the pieces through mesh refinement yields more precise outcomes. To obtain
more dependable results, certain parts of the models are highlighted and the mesh is refined.
Since the nodes link the little components together, figuring out the nodes' displacement is the
first step in finding the answer. In mathematical terms, the simplest form of the node's
displacement is a linear function. The stress is found by applying the modulus of elasticity to the
derivative of the displacement, which yields the strain. The two equations that follow illustrate
this.

(1)

xEx (2)

With large elements the stress distribution is the same in the structure which is not true in reality.
This is represented below where then odes are at a wider distance

Figure 2-5: Frame Angle

The mesh refinement in valves causes the elements' sizes to decrease, which in turn causes the
nodes' lengths, represented as h, to decrease. As a result, the stress distribution within the structure
becomes more precise and uneven.
 Figure 2-6: Smaller h lengths of nodes (H method, n. d)

illustrates the mesh refinement, which produces more precise results. The fact that the smaller
pieces lengthen the computation time is the only drawback of this mesh improvement. There must
be a trade-off between precision and time.
P-Elements
The elements in elements have constant sizes. The precision of the outcomes is impacted by the
elements' interpolating polynomials' order. Higher order poly-nominal yields superior results,
whereas lower or deploy nominal yields tonic curative results. Polynomials undergo order changes
as they approach convergence. Though it changes in complexity, the element's size stays constant.
Typical sources of error sin Finite Element Method
The analytical procedure consists of numerous steps. Not every information or
presumption has to produce untrue outcomes. Errors in analysis can also result from
knowledge loss during the progression from one stage to the next. As a precaution, each
stage in this thesis is examined before moving on to the next. The sources of common mistake
NUMERICAL
REALPHYSICAL SIMPLIFIED MODEL SOLUTIONS
PROBLEM
causes are depicted.

errors errors

Physical Modeling
It might be challenging to sketch the real model into solid work and CAD software, particularly
for intricate constructions. When creating the 3-D model, information could be lost. As an
example, the dimension may differ from the actual model. This may cause a few little mistakes in
the solution.
Simulation Parameters
The primary cause of errors is this. The outcomes that are obtained depend on how the settings
are set up. Large constructions, for example, have several beams that need to be positioned
precisely. The modeling should accurately represent the real scenario in terms of load amount and
direction. A crucial first step is defining the limitation, which needs to be done precisely to
prevent mistakes.
Rounded off values
As previously mentioned, the computation of the difficulties in the computations is done by
numerical methods. These are extremely complicated problems with large integers that are
rounded off. Erroneous outcomes may arise from the accumulation of these rounding off errors.
To lower these mistakes, convergence analysis is performed at the conclusion of the simulation.
Nonetheless, some of the findings in this thesis are supported by straightforward computations
based on the strength of the materials.
2.3.2 Difference between CAD and solid work models
Understanding the distinctions between CAD and FEM models improves the analysis's
accuracy in modeling. Every aspect of a physical model, such as the chamfers and rounding,
is included in a CAD model. The primary usage of an ACAD model is in manufacturing. It is
also possible for FEM and CAD programmers to use basic, low-resolution CAD models in
tandem.

For structural analysis, on the other hand, the AFEM model is employed. Surface finish details
may not be necessary. Symmetry might be quite important in some analyses. Because symmetry
makes the problem easier to understand and requires fewer components and equations to be
calculated, the solutions are more accurate. The following figures 11 and 12 help explain in more
detail the difference between a CAD and FEM model.

Figure 2-7: model (Using mirror symmetry)

Cold-formed steel (CFS) angles

Lightweight for warehouses often means cold-formed steel (CFS) angles. Here's a short
description:
Material: Thin gauge, high-strength steel. Shape: L-shaped profile.
Advantages: Lighter than traditional beams for reduced weight on building structure.
Strong and versatile for racking and support systems. Cost-effective compared to heavier options.
Applications: Pallet rack supports. Conveyor system framing. Building envelope support.

Figure 2- 8 : cold-formed steel (CFS) angles

2.4 Definition of Loads and Standards
It is general knowledge that structures need to be built to withstand potential damage-causing
forces. For structures to withstand the strains brought on by loads, they must be robust and rigid.
Knowing the expected loading conditions is therefore crucial.The allowed stress levels for design
are determined by calculating the loads operating on a structure. The design of the building's
joints, columns, and beams is determined by these values. Structures are made with a certain
purpose in mind. For example, the loading requirements of a disco and a residential building
differ, hence their designs are different. A disco is designed to withstand larger loads because it
has a large number of patrons and equipment. According to the Euro-Code standard, different
building types require different loads. "Areas within social, commercial, residential, and
administrative Automated Warehouse shall be categorized based on their respective uses.".
Automated Warehouse loads can be divided into two main groups. Both lateral and gravitational
pressures. While lateral stresses work horizontally, gravity loads draw downward in a vertical
fashion. As seen in figure 13, they have subcategories of their own.
These are the main kinds of loads that affect a structure. They may behave independently or, as is
often the case, in concert. Following the loads from one section is crucial to the building because
not every structural component is subjected to direct forces. Newton´s per square meter (N/m2) is
used to represent loads on a surface area, whereas Newton´s per meter (N/m) is used to express
loads online, such as on a beam.
2.4.1 Load
As the name implies, this kind of load acts on the Automated Warehouse permanently and is not
variable over time. Dead loads are referred to as permanent actions in the euro code requirements.
"The self-weight of construction works should be classified as a permanent fixed action,"
according to the definition. Dead load also includes structures that are fixed permanently, like
finishing.

Figure 2-9: Definition of Loads and Standards

In most situations, the overall weight of a structure might not be readily available. Redesigning
the structure also affects the overall weight. The weight of the construction is determined using
material attributes like the volume and density of each component. To get a structure's weight,
utilize formulas 3 and 4 as follows.

Mass = Density (Kg/mm3) x Volume (mm3) (3)

Weight= Mass (Kg)x Gravity (m/s2) (4)
2.4.2 Lifting Load
Variable and Occupancy Dependent:Unlike load (weight of the building itself), lifting load
changes depending on the type and amount of goods stored in the warehouse.
Warehouse Function Considered: A warehouse storing heavy machinery will have a higher
live load compared to one storing books.
Building Codes and Standards: Local building codes will specify minimum lifting load
requirements for different warehouse occupancies. When designing your warehouse
structure, live load is crucial for determining the following:

Figure 2-10: Lifting Load

Strength of Floor System: The floor needs to be strong enough to support the weight of the
stored goods without excessive deflection.
Racking System Capacity: The racking system that holds the goods needs to be designed to
handle the anticipated live load.
Overall Building Capacity: The total live load needs to be factored in along with the lifting
load to determine the overall weight the structure can support.
Tips for Considering Live Load in your Warehouse Design:
Identify Warehouse Usage: Clearly define the type of goods to be stored and their weight.
Consult Building Codes: Refer to local building codes for minimum live load requirements
for your specific warehouse occupancy.
Plan for Future Needs: Consider potential changes in storage requirements and design with
some buffer in your live load capacity.
.Distribute Load Uniformly: When possible, distribute the weight of stored goods evenly across
the warehouse floor to avoid overloading specific areas. By carefully considering the live load,
you can ensure your automated warehouse structure is efficient, safe, and can handle the demands
of its intended use.
Wind Load
A structure is subject to horizontal wind, which varies in strength and direction over time.
The building may react dynamically in reaction to wind pressure. Therefore, it may
occasionally result in fatigue stresses, particularly on the foundation. The following
variables influence the effects of wind load on a structure:
 The height above the ground; obstacles on the ground
level reduce wind speed.
 Exposure of the building to its surroundings; trees and
other tall buildings block the wind speed.
 Figure 2-11: Wind Load
The major methods of resisting the wind load are adding stiffening elements and properly
anchoring the foundation. Structures are often forced to move horizontally by lateral forces, which
places a lot of stress on the foundation. Braces and other stiffening components keep columns in
their original positions. The effects of wind pressure on a structure are depicted in pictures 15, 16,
and 17 below

Pressure Suction
Figer 2-12: Wind pressure and suction on a building
Earth quake Loads
A ground-based tremor is called an earthquake. Various forms of vibration are anticipated based
on the building's height. The magnitude of earthquakes varies according to a Automated
Warehouse geographic location. An Automated Warehouse foundation experiences dynamic
loading from an earthquake, which results in shear and fatigue stresses as well as structural
deformation. Automated Warehouse design necessitates that the structure be able to tolerate a
certain amount of foundation displacement
The structure is harmed by the inertia force that is applied. Inertia force acts on the roof as a
result of the building's foundation moving while its top portion moves in the opposite direction.
This results in the building's columns buckling. That is the fundamental manner in which an
earthquake causes harm. The columns' ability to resist strong buckling forces is crucial.
 Figure 2- 13: Effects of earth quake on a building (Flowing events, nd)

Designing to prevent earthquake

Earthquake resistance design is based on the following principles.
 The building can experience minor shaking
 Moderate shaking with minor movements of the building
 Extreme shaking but without total collapse of the building
to protect human life and property
The fundamental idea behind engineering against seismic forces is vibration damping, which
absorbs vibration. There should be dampening structures constructed at the base of the building.
Installing dampening devices on the building's bracing is another way to achieve efficient design.
Selecting the right building material is crucial to mitigating the impacts of the earthquake that
follows vibration. Compared to brittle materials, ductile materials undergo deformation more
gradually. Structural steel is one of the preferred materials. High-stiffness materials are crucial,
particularly for columns as they minimize the risk of buckling. The bracings between the columns
aid in limiting the columns' lateral motions. The resistance is increased when dampening devices
are installed on the building's bracing.
Tracking and defining the loads
It is critical that the loads are initially defined precisely. This is typically a significant cause of
analysis errors. The forces brought about by the loads are defined by simple hand calculations.
Standards are utilized in this way to further ascertain the precise loads
Basic calculations for determining the loads
The majority of the loads are expressed in pressure units, such as psi in the standard manuals.
There are situations where converting the pressure load into a uniformly distributed line load is
necessary. In certain circumstances, the line load must also take the shape of a point load ( 𝑁). It is
crucial that the methods used to transform the loads are clearly specified.
Line load to pressure load
Equation is used to find a uniformly distributed load on a pressure surface. The axis on which
you want the line load to be is what determines the length,if line load one is required, the length
perpendicular to the line load, such as b, is employed, and vice versa.

Figure 2-14: Pressure load to uniformly distributed load

Line load to point load
Since the structure is static, equations of equilibrium are used to determine the point loads.
Equation 7 is used to determine one of the forces involved in the statics calculation.
Line load (𝑘𝑁) x 𝑙𝑒𝑛𝑔𝑡ℎ(𝑚)=𝑅𝑒𝑠𝑢𝑙𝑡𝑎𝑛𝑡𝑙𝑜𝑎𝑑(𝑘𝑁)

The force calculated is used to find the resultant forces at A and B which represents the point
loads of the two columns. Compiling a list of all the loads acting on a building is crucial for doing
stress calculations. If needed, loads can be mixed to find the stress. For instance, the snow load
and wind load are frequently coupled loads.
2.5 Summary
Material: Thin geare high-strength steel Shape: L-shaped profile (angle)
Advantages Lightweight: Reduces weight on the building structure compared to traditional
beams.
Strong and Versatile: Suitable for racking, support systems, and various warehouse
Applications Cost-Effective: Offers a balance of strength and affordability compared to
heavier options.
Applications: Pallet Rack Supports: Provides a strong frame for storing goods on pallets.
Conveyor System Framing: Creates a lightweight yet sturdy structure for conveyor systems.
Building Envelope Support: Can be used for non-load-bearing elements like bracing.
Overall, this design CFS angles to achieve a lightweight, strong, and cost-effective structural
solution for automated warehouses.

CHAPTER 3 Methodology and design optimization Single-

column laneway stacker design
3.1 Design raw Data and Lifting Device
Table 2 data
Overall Loading Tram Vertica Fork
length (m) capacity(k speed speed m/s running
g) m/s. speed m/s
7.5x3.5x1.46 100 1.33 0.2 0.2

Figure 3-1 : Lifting Device

Here are two options for lightweight lifting devices in an automated warehouse
Aluminum Cantilever Arms: Strong, lightweight for fast movements, ideal for picking
Stage2: individual
items. Free Carbon
3.1.1 body Main
diagram
design of
chain drive
The power of the
motor is driven by
Stage Σ f(x) =0 Σf(y) =0 ΣM =0
the coupling to
drive the
3: f(y)=Ay+CyResultant
sprocket,
Equation MA= Cy+l2esultantl
which in turn
s of
causes the chain to
equilibri
lift the load.
um
Because the main
shaft of the lifter turns, which drives the sprocket, the chain drives the carrier up and down, so in
the design process, The demands on the shaft are very high. A separate motor is used to control
the lifting mechanism, and to prevent damage or safety from falling the lifting platform in the
event of a power failure, a motor with brake function is used. So the main components are:
Motors, sleeves, chains, sprockets, Standards. The following figure shows the overall structure:

Figure 3-2: Chain Lift

Gear ratio
Excessive gear ratios can cause small sprocket pockets to angle and reduce the number of
engaged teeth, which will accelerate sprocket tooth wear and tend to skip teeth. It is
therefore best to have an angle of no less than 12^0 For this reason, limit the transmission
ratio i≤ 7. In this task, in order to ensure that the carrier moves vertically along the
standard, the primary and driven sprockets are the same size, so the ratio
Number of sprocket teeth
In this design, the chain speed is 0.2m/s, which is a low speed. The number of teeth Z1 of the
small sprocket can be selected according to the chain speed reference chart.
The number of teeth should be determined according to the transmission ratio i, and Z1 = Z2 = 17
should be taken from the table.
 Determine the calculated power
Type P — Power transmitted, KW;
KA — working condition factor, chart knowledge KA = 1.3;
KZ — active sprocket tooth count factor, KZ=0.85, as shown in table Kz=0.85:
KP — Multi-row chain coefficient, single-row chain KP=1.

 Select the model and pitch of the chain

If the transmission ratio of the reducer is i=31.5, then

 Calculate the power

The Pitch List of the Chain selects the Chain Number as 20A, and the Pitch List of the Chain is
p=31.75mm.

 Check the chain speed and determine the lubrication method

V<6m/s in low speed range, eligible.

The lubrication method is determined by the v=0.26m/s and the chain number 20A chart as the
regular manual lubrication method.

 Sprockets 45 steel quenched and tempered (40~50) HRC is selected

3.1.2 Chain wheel design
Chain lift is carried out using chain sprockets to lift the load.

Figure 3-3: Chain lift is carried out using chain sprockets to lift the load

Figure 3-4:Mechanism-wheel design

In the chain lift method, the drive chain first transfers the kinetic energy to the top of the pillar
and then the lifting chain lifts the load. The chain drive is driven by the engagement of the
sprocket teeth with the chain link. The chain drive has no elasticity slip and overall slippage to
ensure accurate gear ratios and high transmission efficiency. There are chain flexible components,
do not need to be installed too tight, so the pressure on the shaft is not great, the overall size of the
chain drive is small, Compact construction allows operation in both hot and humid conditions. The
advantage of chains over wire ropes is that they are more flexible, the sprocket can have a small
number of teeth and therefore a small diameter. Compact structure, its disadvantage is the high
sensitivity to impact, the possibility of sudden short break, wear is also faster. Also not for high
speed, lifting chain for small lifting weight, small lift height, low lifting speed machinery.

Wheel tread fatigue strength calculation

Wheel tread fatigue strength calculation

Pc.--- load of wheel tread base (N)

Pmax---wheel pressure (X) when the equipment is working normally
Pmin--- wheel pressure (N) when the equipment is working normally
 D---wheel diameter (mm)
l--Effective bonding length between wheel and track (mm)
C1---Work level coefficient, select according to the table C1 "Work Level Coefficient Value"
C2---Speed speed coefficient, select according to the table C2 Speed Speed Coefficient.

Table 4
Coefficient k1 value Work level coefficient c2 Speed coefficient c1 value
value

Σb/Mpa K1 Operating C2 Wheel speed C1

organization (r/min)
work level
500 3.8 M5 1.00 200 0.66
600 5.6 M6 0.9 160 0.72
6500 6.0 M7/M8 0.8 125 0.77

3.1.3 Chain selection and verification structure:

The take-off slide structure consists mainly of the slide, guide wheel sets, and other components.
The lift and landing slide structure is mainly used to hold the load table, to bear the weight of the
load table and load, designed to meet the strength and rigidity requirements. The load table
module contains a number of guide wheel blocks, which mainly consist of the guide wheel, the
bearings and the guide wheel shaft. The guide pulley block mainly contacts the pillar or rail,
which connects the load table module to the pillar module. The following figure shows the
structure of the lifting and lowering slide:

Figure 3-6 : Chain Lifting slide structure

Chain selection and verification for an automated warehouse involve two key steps:
Selection: Choose the right chain based on:
Load Capacity: The chain needs to be strong enough to handle the weight it will be lifting
(working load limit).
Application: Consider factors like chain speed, operating environment (dusty, wet), and required
flexibility.
Type of Lift: Different lifts (hoists, conveyors) may require specific chain types (roller chain,
overhead hoist chain).
Verification: Ensure the chain is safe and functional: Inspection: Regularly inspect for wear,
damage, or corrosion.
Maintenance: Follow proper lubrication and cleaning procedures.
Proof Load Testing: Conduct periodic proof load tests to verify the chain's working load capacity
hasn't degraded.

3.2 Design of Pickup Device

In an automated warehouse, a pickup device refers to the robotic or mechanical equipment
responsible for retrieving specific items from storage locations. The exact design varies depending
on the type of goods being handled and the overall warehouse system. Here's a breakdown of
some common pickup devices:
Forklifts (Automated): Automated forklifts equipped with sensors and cameras can navigate
aisles, locate pallets, and pick them up for transport.
Shuttle Systems: These use robotic shuttles on rails to retrieve storage bins or trays from shelving
units.
Stacker Cranes: Automated stacker cranes retrieve pallets or individual items from high-bay
storage racks.
Robotic Arms: For picking individual items, robotic arms equipped with grippers or suction cups
can handle a variety of shapes and sizes.
Choosing the Right Pickup Device:
Several factors influence the selection of a pickup device for your warehouse:
Item Size and Weight: For bulky or heavy items, forklifts or stacker cranes might be suitable. For
smaller items, robots or shuttles might be more efficient.
Storage System: The pickup device needs to be compatible with your existing storage system
(shelving, racks, etc.).

Figure 3-7 Pickup Device

Throughput Needs: Consider how many items need to be picked per unit time. Robots might
be slower for high-volume picking, while forklifts might be faster for bulk pallet movement.
Warehouse Layout: The device needs to navigate aisles and reach designated storage locations
efficiently.
Additional Considerations:
Safety: The pickup device should be equipped with safety features to prevent collisions and
injuries.
Integration: Ensure the device can seamlessly integrate with your warehouse management system
(WMS) for order fulfillment. By carefully considering these factors, you can select the most
appropriate pickup device to optimize efficiency and accuracy in your automated warehouse
operation.

3.2.1 Overall design of horizontal conveying

The single-column laneway stacker consists mainly of the lifting mechanism, the tramming
mechanism, the forks, the shelves, Complete the automatic transportation and storage of items,
realize the efficient operation of unmanned warehouse. The single-column laneway stacker
designed in this article is mainly designed for small loads (maximum weight not exceeding
1000N). the specific rawing is as follows：

Figure 3-8 : Overall plan Lightweight Structural Design for Automated Warehouse
Horizontal conveying systems are the workhorses of many industrial and warehouse
settings. They efficiently move materials in a straight line, ideal for transporting goods
from one processing point to another. Here's a breakdown of the overall design
considerations for horizontal conveying:
 Belt Conveyor: The most common type, featuring a continuous loop of belting material
(rubber, fabric) supported by a frame and powered by a motor-driven pulley.
Roller Conveyor: Uses powered or gravity-fed rollers to move items along a track.
Chain Conveyor: An endless chain with attachments pulls or carries materials along a
track.
Select Conveyor: Similar to a belt conveyor but uses individual slats that offer more
rigidity for specific applications.
Design Considerations:Material Handling: Consider the size, weight, and shape of the
items being conveyed.
Capacity and Speed: Determine the required throughput (items per unit time) and desired
speed of the conveyor.
Conveying Distance: The overall length of the horizontal path the materials need to
travel.
Inclination (if any): While horizontal conveyors are typically flat, slight inclines can be
incorporated for specific purposes (feeding into machines, drainage).
Transfer Points: Plan for smooth and efficient transfer of materials between conveyors or
to other handling systems.
Safety Features: Include safeguards like emergency stops, guards around pinch
points,and proper signage.Choosing the Right Conveyor:The type of horizontal conveyor
best suited for your application depends on the factors mentioned above. Here's a general
guide:
Belt Conveyors: Versatile and suitable for bulk materials, boxes, or individual items.
Roller Conveyors: Ideal for lightweight to medium-weight items with flat bottoms (boxes,
pallets).
Chain Conveyors: Often used for heavy-duty applications or for conveying items that
require specific positioning.
Slat Conveyors: Good for uneven or unstable items that might not track well on a belt
conveyor.
Additional Considerations:
Frame Material: Steel is common, but aluminum can be used for lighter weight
applications.
Belt/Roller Material: Selection depends on the materials being conveyed and
environmental factors.
Controls: Systems can be manually operated, automated with sensors, or integrated with
warehouse management systems (WMS).
By carefully considering these design aspects and choosing the appropriate type of
horizontal conveyor, you can create an efficient and reliable system for material handling
within your facility.

Main parameter selection for chain drives

Figure 3-9:Ground speed, i.e.. Load weight, self-weight.

 Institutional Utilization Level (Extracted from GB/T 3811-1983) Table 5
Level of Total running Theoretical average Notes
utilizatio hours t/h. daily working
n hours/h:
T6 12500 ＞2；≤4 Use infrequently
and frequently
T7 25000 ＞4；≤8 Busy use
T8 50000 ＞8；≤16 Busy use
T9 100000 ＞16 Busy use

Mechanism load conditions Table 6

Load condition Notes
L1 (Light) The mechanism is often subjected to light and
small loads and occasionally to maximum
loads
L2 (Medium) The mechanism is often subjected to medium
loads, less to maximum loads
L3 (Heavy) The mechanism is often subject to large loads
and is often subject to maximum loads
L4 (Extra Heavy) The mechanism is often subjected to maximum
loads

Classification of types of work in institutions (extracted from GB/T 3811

1983)Table 7
Load Level of institutional utilization
condition T5 T6 T7 T8
L1 (Light) M4 M5 M6 M7
L2 M5 M6 M7 M8
(Medium)
L3 (Heavy) M6 M7 M8

The working requirements of the tramming mechanism obtain the mechanism utilization level T7
and the mechanism load situation L2, thus determining the mechanism work type M7.

3.2.2 Gear design and verification

The gear is an important part in the machine, its function is to support the rotating part,
give the rotating part a definite working position, and transmit motion and power. In
general, reasonable construction and sufficient strength are the basic requirements that
must be met by the design of the gear shaft. If the structural design of the shaft is not
reasonable, it can affect the processing and assembly process of the shaft, increase
manufacturing costs, and even affect the strength and rigidity of the gear shaft. If the
shaft is not strong enough, plastic deformation or breakage can occur, preventing it from
working properly. The general design steps for the gear shaft are:

 Select the material according to the job requirements.

 Estimate the basic diameter of the gear.
  Structural design of the gear.
Estimate the basic diameter of the gear shaft .In the design of the shaft, the gear is
generally transferred torque to estimate the smallest diameter of the torsional shaft
segment on the gear, and the structural design of the shaft is based on this as the basic
reference dimension.

The material used for the spindle in this project is 45 steel, which can be found by looking up the
table T =60 MP, =103 P=×η = 1.5×0.8 = 1.2 kw
It is also known that n=n1=501440=28.8r/min.
D. == 35.7mm

D should be the diameter of the torsional gear segment, i.e. the shaft diameter at the drive pulley.
Due to the influence of other factors, the standard diameter d=40mm is taken.
2. Structural design of Gear
(1) Initial determination of the diameter of each shaft segment
Taking into account the coupling connection and other factors, calculate and check
Table 8
position shaft diameter/mm illustrate
Output transmission 40 Basic diameter estimated by
motor power
Bearing 45 Estimate the diameter based
on the bending moment the
bearing bears during
transmission
sprocket 50 Estimated diameter based on
transmitted torque
Shaft collar 60 The sprocket is positioned
by the shaft ring. According
to the diameter of the
sprocket d-50mm, the shaft

(0.07-0.1)d, take h-5mm.

(2) Determine the length of each shaft segment

Table 9
Position Shaft segment length/mm illustrate
Output transmission 80 Estimation of power
transmitted by belt drive
Bearing 150 Estimated based on the
thickness of the frame and the
bending moment it will bear
sprocket 122 Estimate according to the
outline size of the sprocket
shaft diameter 873
Estimate based on cabinet
frame size
Overall shaft length 1255 The sum of each axis segment
 Figure 3-10: Gear

(3) Structural design of the shaft

 Determine the diameter of each shaft sectionTak nto account factors such as coupling
connection, calculate and check the machine manual to determine the diameter of each
shaft end:
 B Diameter of each shaft end.
 Determine the length of each axis segment
 The circumferential fixing of the drive parts, the sprocket and the belt drive are the type A
normal flat key, the sprocket is the key 16×9 GB1096.
 Other dimensions, in order to facilitate processing, reference to the installation dimensions
of 6209 type C bearing (see bearing manual), the shaft over-fillet radius all take r=1mm,
the shaft end chamfer is 2×45.
3.2.3 Motor selection and calculation
Usually the first consideration in choosing a motor is the torque and speed that the motor can
provide for the load. The power required by the lift motor is calculated as the static power of the
lift mechanism at stable full load operation, by:

(6)
P-1 maximum lifting load (N) in the formula;
v 一 Rated lifting speed (m/min);
Increase the overall efficiency of the mechanism together.
Lifting platform and total load weight: Slide, V=0.2m/s
To take into account other uncertainties, check the brake motor of the lift motor model YEJ
90L-4, =1.5kw, n=1440r/min.
Select the lift motor according to the required static power of the mechanism. After selecting the
motor, the motor is
also checked for overload capacity and heat. The lifting mechanism requires that the motor can lift
1. 25 times the rated lifting weight in the event of a voltage loss. Therefore, the power of the
motor should conform to the requirements of the format to ensure sufficient overload capacity.

Rated lifting speed (kw) ;

P-- one maximum lifting load (N)
v--- a rated lifting speed (m/min);
Total efficiency of the lifting mechanism.
H-- Coefficient, asynchronous motors take H = 2. 1, DC motors take H = 1. 4;
The number of drive motors of the Z--- mechanism。
Qualified.
Select the motor
 Consider other running resistance, add a drag coefficient Therefore, select the geared motor to
view the SEW geared motor for selection, consider overload, etc., and select the geared motor
SEWS57DV100M4P=2.2KW T=295N.m

Figer3-11;Decelerator motor parameter diagram

Dimension drawing of the reduction motor

Figure 3-12: Dimension drawing of the reduction motor

Table 10
3.3 Shelf design
For an automated warehouse with lightweight structure and efficient shelving:
Structure:Use high-strength, lightweight materials (steel, aluminum).
Consider trusses and open floor plans for efficient weight distribution and flexibility.
Calculations:Factor in dead load (structure weight), live load (stored goods), and local
wind/seismic loads (if applicable).Use engineering software to model and analyze the
structure.
Shelving:Choose material based on weight capacity (wood, metal, etc.).
Design for item size and accessibility (adjustable shelves, dividers).
Consider aesthetics (style, color) for a balanced look.

Figure 3-13: Shelf design

（1）Frame sturcture: 2 Use aluminum alloys or high-strength steel for lightweight and strength.
Modular design for scalability.Calculation: Perform load capacity and stress analysis using finite
element analysis (FEA).
（2）Lift moving line Design: Optimize path for minimal travel time and energy use. Use reliable
guidance systems like rails or tracks.Calculation: Calculate optimal 3 trajectory and energy
consumption
（3）Lifting plate: Use lightweight, durable materials like carbon fiber. Ensure stability and load
capacity.Calculation: Perform load distribution and strength analysis.
（4）Lifting device: Choose efficient lifting mechanisms (hydraulic, electric). Implement precise
control and safety features.Calculation: Determine force and power requirements, and perform
structural analysis.

3.3.1 Overall design of shelves

The design of shelving systems in an automated warehouse is critical to maximizing storage
efficiency, ensuring ease of automation integration, and maintaining safety. Here are the key
considerations and steps for designing an effective shelving system:
Lightweight Warehouse: Steel/aluminum structure, trusses for efficiency.
Shelving: Choose based on weight (wood/metal) and size (adjustable).
 Table 11

Material Young’s modulus

(GPa)
Aluminum 69,5

Steel 210

Titanium 110,3

3.3.2 Calculation of shelf strength

Axes are commonly used for the sum of several materials
Mater Q235-a, 20 Q275, 35 45 40Cr, 35SiMn
ial for
the
shelf
15~25 20~35 25~45 35~55
149~126 135~112 126~10 112~97
3

Operating speed
Load (kg) Run drag coefficient
(m/s)
100 0.2 0.85
 Drive
scheme selection

The forks mainly carry out the load action, the forces are greater, so a multi-stage reduction is
required, first the motor starts the reduction via the reducer. The second reduction is then made via
the sheave, transmitting torque to the rack of gears. The double rack gear mechanism is used to
achieve the telescopic effect as the shelf plate requires retracting.

 Motor selection,

By friction Ff=μ x m x g=0.85x 100 x 9.8=833N.

Check for information:
η v band = 0.99 η teeth = 0.98 .9
The total efficiency of the drive is:
η total = η with η teeth η teeth η teeth = 0.99X0.98X0.98X0.98 = 0.88
Motor running static power: P0=Ff xV=210W
Therefore, the selected motor model is: brushless DC motor 80BL89S25-430TK0 power is P =
250W, speed nm = 3000r/min
 Determine the transmission ratio
Select drive gear wheel diameter D=50mm
n3y v/σDx60 = 2.0/3x20x60 = 76.4r/min.
I Total = nm/n3y 3000/76.4 = 39.26
Subtract i = 25, i.e. i band = 1.57
  Select the type of reducer: PX80N025SW, low speed shaft allowed torque is
70N*m, reduction ratio is 25
Calculation of the motion and power parameters of the drive unit
 1)peed calculation for each shaft:

n0
=n m=3000r /min
n1 =n0/i1/4 = 120r/min.
n2n1/iθ =76.4r/min.
 2) Input power calculation for each axis
P0=P η m=250X0.9=225 W.
P1=P0 η minus = 225X 0.85=191W
P2= P1 η band = 191X0.99 = 189W
P3= P2 η teeth = 189X0.98 = 185.22W
P4=P3 η teeth=185X0.98=181.5W
 3) Input torque calculation for each shaft
T0=9550P0/n0=716.25N·mm
T1=9550P1/n1=15200.4N·mm
T2=9550P2/n2=23625N·mm
Fork belt drive design calculation
1) incoming power P1 = 191W, take the working condition coefficient Ka = 1.7
2) Design power: Pd=Ka x P1 = 1.7X191 = 324.7W
3) Determine the model and pitch of the synchronous belt: the model of the selected belt is H
and the pitch is 12.7mm by the design power: Pd=324.7W, n1=120r/min s
Select the number of teeth on the small sheave:
4) Check the table: the number of small pulley teeth: Z1 = 14, the number of large pulley teeth
Z2 = Z1 x i = 14X1.57 = 21.98 Take the standard number of teeth: Z2 = 22
5) Determine pitch diameter: D1 = 56.6mm d2 = 89.0mm
6) Determine the length of the synchronous belt thread: L p.
7) Initial center distance
7 d d 1  d d 2） a0  2(d d 1  d d 2 )
0.（
…………………………………………(7)
8) Therefore, 101.92mm<α0<291.2mm is preliminarily determined = 200mm
9) = 4.64Lp=2a x cos++ = 629.9mm .
10) The standard node length L p=635mm is the closest to the calculated value
11) Calculate the number of simultaneous teeth: =50
12) Calculation of the distance of the drive center to alpha
13) α = where

14) Seek α =202.55mm , take α=203mm0 0

15) Determine synchronization bandwidth:
16) Determine the reference power rating of the H-band synchronous
17) Including:: Permitted working pressure: 2100.85N
18) M: Unit length mass: 0.448
19) V == 0.36m/s.
Substitution:
20) Calculate the number of teeth in the small sheave: Zm = 42mm
21) Determine the actual bandwidth: b primary
22) P meets the design requirements

To sum up, the pulley parameters are as follows: Table 13

Z1 Z2 D1 (mm) D2 (mm)
14 22 56.6 89
H-type timing belt parameters
Pb(mm) Zb Lp(mm) b(mm)
12.7 42 533.4 38.1
Calculation of the fork drive gear, rack
The input power P2=185.22W, the speed of the pinion n1=76.4r/min, because of the gear rack
transmission, so the number of teeth ratio u1=1. Driven by electric motor, with a life of 8 years
(with 300 days of work per year), 2 shifts, then:
1 Select gear type, accuracy class, material and number of teeth
1.1) According to the transmission scheme, select the spur gear rack drive, b. Forks are the
normal working machine, speed is not high, 8-stage accuracy is chosen
1.2) Material selection. Check the table: Choose the pinion material is 40Cr (modulated), hardness
is 280HBS, rack is 45 steel (modulated), hardness is 240HBS, The material hardness difference
between the two is 40HBS.
1.3) Primary Pinion Tooth Count Z1=19
Designed for tooth surface contact strength

d 1 t ≥2.32 3
√ K t T 1 u±1 Z E 2
φd
×
u
×(
[ σH ]
)

1.4) Determine the calculated values within the formula

(8)

1.4.1) Trial load coefficient Kt=1.3

1.4.2) Calculate the torque transmitted by the pinion T=23625N·mm.
φ φ
1.4.2) Tooth width coefficient: From Table 10-7, Mechanical Design Book P205: = 1 d d
F. Elasticity Impact Factor of Materials: Check the Mechanical Design Book from P201 Form 10-

6: =189.8MP1/2 E a
Z
1.4.3) From the Mechanical Design textbook P209 page Figures 10 - 21, the contact fatigue
strength of the pinion gear according to the hardness of the tooth face Mpa, the contact fatigue
σ
strength of the rack = 550 MPa H lim 1
=600σ H lim 2
1.4.4) Calculate the number of stress cycles: The number of stress cycles is calculated by the
Mechanical Design Book P206 formula 10-13
N 1 =60n1 jLh =60×74.6×1×（2×8×300×8） =1.76×108
1.4.5) Exposure Fatigue Life Factor: See Figure 10-19 of Mechanical Design Book P207: KHN1 =
0.95
1.4.6) Contact fatigue of the gear Approved stress: Failure probability 1%, safety factor S=1, use
the Mechanical Design Book P205 formula 10-12 to obtain:
K HN 1 σ H lim1
σ
[]==570 H 1 S MPa

1.4.7) Calculation:
1t
Indexing circle diameter d of the pinion

d 1 t ≥2. 32 3
√ K t T 1 u+1
φd
×
u
Z
×( E )2
[σH ] (9)

Where gear rack ratio

Get d1t=34.9mm

1.5) Calculate the circumferential velocity v.

 πd1 t n 1   47. 32  1465
v= =  3. 63m / s
60×1000 60  1000
b
1.6). Calculate the ratio of tooth width to tooth height h

H=2.25 m=2.25 ×1.84=4.14mm nt

Check the Machine Design textbook P193 Table 10 - 2 Use factor KA=1.25, according to
v=0.14m/s, class 8 accuracy, check the textbook from P194 Figure 10-8 KV=1.12, Check in
Mechanical Design Book P197 Table 10-4 for KH β = 1.42. Check the mechanical design
textbook from P195 Form 10-3: KH α = 1.
So load factor:
K= K = 1.25 \cdot 1.12 \cdot 1.42 \cdot 1.0 = 1.9904
1.9) Correct the calculated index circle diameter for the actual load factor
D1= 1.4108
1.10) Calculate the modulus m.
M = 1.4108z
Designed with the strength of the root bend

√
3
2 KT 1 Y F ∂ Y S ∂
( )
mn ≥ φd Z
2
1 [ σ F ]
(10)
2 Determine the calculated value in each display
2.1) Load factor K.
K= K = 1.25 \cdot 1.12 \cdot 1.42 \cdot 1.0 = 1.9904
2.2) Initial selection of tooth width coefficient: Symmetrical arrangement, obtained from table = 1

2.3). Retrieve the tooth form factor YFa and the stress correction factor YSa
Check Mechanical Design Book P200 Form 10-5:
Tooth coefficient YFa1 = 2.85
Stress correction factor YSa1 = 1.54Sa2 = 1.785
Y F FS
α α

[σ F ]
2.4) Calculate the of the pinion (11)
Check workbook P208 for bending fatigue strength limits from Table 10-20:
σ FE 1=500 MP a
Pinion gear
Check the textbook for bending fatigue life coefficient from P206 Table 10-18:
KFN1 = 0.92
Take the bending fatigue factor of safety S=1.4, then
K FN 1 σ FE1 0 . 92×500
[ σ F ]1= = =328 . 57 MPa
S 1.4
Y Fa 1 F sa 1
=0 . 0134
[σ F ]1
2.5) Design calculations
 The modulus m calculated by the tooth surface contact fatigue strength is greater than the
modulus calculated by the tooth root bending fatigue strength compared to the calculation. Take m
= 2.5mm, you can already meet the bending strength. However, in order to satisfy the contact
fatigue strength at the same time, the
number of teeth should be calculated by the index circle diameter d1 = 40.22 calculated from the
contact fatigue strength. Thus by:
Z1=, root cut occurs. When the number of teeth is adjusted to 19 teeth, that is d=47.5mm
Circumferential speed: V= and the set speed V=0.2m/s, which is similar and meets the
requirements.
3 Geometry calculation
3.1) Pinion geometry calculation:
According to the tooth width factor b=47.5mm
Tooth tip height: ha=m=2.5m
Root height: =3.125mm
Tooth Dome: hf=1.25 x m = 1.25 x 2.5
hf=3.125nm
Root Circle Diameter: df= d-2 x hf
df=47.5-2 x 3.125
df=47.5-6.25
df=41.25mm
3.2) Calculation of rack geometric parameters:
Root height: =3.125mm
Tooth tip height: ha=m
ha=2.5mm
Rack width: p= π x m
P= π x 2.5
P=7.854mm
Rack height: H = 6.25mm is the height from the bottom of the gear to the bottom of the rack
Tooth pitch: P= π x m
P= π x 2.5
P=7.854mm
Tooth thickness: S= p/2
S= 7.854/2
S= 3.927mm
Cogging width: e=p/2
e=7.854/2
e=3.927mm
Center distance: L=d/2=m x Z/2
2.5 x 19/2
23.75mm
Know,ha=2.5
L= 23.75+ 2.5
L= 26.25mm
stereo warehouse shelf design Shelf Overview
Storage automation construction is a system engineering, the three-dimensional shelf plays the
role of storing goods in the entire system.
There is a motion fit with the lift, the stacker.
Design Parameters
The three-dimensional warehouse is 8 columns and 7 floors
Overall height is 3.5m
8 bars per shelf
Size of compartment: L x W x H = 550 x 500 x 550mm
 Figure 3-14: stereo warehouse shelf design

Study results

Name type smallest maximum

Stress1 Von: von mises 0N/m^2 543.25N/m^2
stress

Figure 3-15: final angle

3.4 Summary
Here's a super short summary of key component design and verification for your automated
warehouse:
Structure: Design with lightweight, high-strength materials (steel, aluminum) and utilize trusses
for efficiency. Verify through engineering software and consider consulting a structural engineer.
Chains: Select chains based on weight capacity and application. Verify with regular inspections,
lubrication, and proof load tests.
Gears: Choose gears based on function (drive, lifting, etc.). Verify with visual inspections,
lubrication checks, and potential non-destructive testing.
Pickup Devices: Select based on item size, weight, and storage system. Ensure safe operation and
integration with warehouse management systems.
Horizontal Conveying: Choose the right type (belt, roller, etc.) based on materials and capacity.
Design for smooth transfers and safety features.
Shelving: Select based on weight capacity and item size. Consider adjustability and aesthetics for
a balanced look. Ensure safety with proper mounting.
Remember, verification is crucial for all components to ensure smooth operation and safety in
your automated warehouse

CHAPTER4 Finite Element Analysis of Key components

4.1 FEA importance
FEA, or Finite Element Analysis, is important for designing and verifying key components in
your automated warehouse for several reasons:
Predicts Performance: FEA simulates how a component will behave under stress and strain,
allowing you to identify potential weaknesses before building it. This helps ensure the structure
and components can handle the expected loads without failure.
Optimizes Design: FEA allows you to test different design variations virtually. This helps you
find the most efficient design that uses the least material while maintaining strength and
functionality. This can lead to cost savings in material and construction.
Reduces Prototyping: FEA can replace the need for many physical prototypes, saving time and
money during the design process. You can test various configurations virtually before building a
physical model.
Improves Safety: By identifying potential weak points early on, FEA helps ensure the safety of
your warehouse structure and personnel. It can help you avoid accidents caused by structural
failures.
Overall, FEA is a valuable tool for designing efficient, safe, and cost-effective automated
warehouses. The racking action is load-bearing, so must have a certain degree of stiffness,
strength. Therefore, using SolidWorks, the static pressure FE analysis of the most important stress
areas in a single grid is as follows:
4.2 Finite Element Analysis of frame
Finite Element Analysis (FEA) of the frame in an automated warehouse system is critical to
ensuring the frame’s structural integrity and reliability under various loading conditions. Here’s a
step-by-step approach to conducting FEA on the frame:

Discretization
Complex and arbitrary geometry)

Real Simplified Mathematical D

Word (Idealized) Model i
Physical s
Model c
r
e
t
i
z
e
d

(
m
 e
s
h
)
M
o
d
e
l
Figure 4-1: FEA farme model
Model body by dividing it into an equivalent system of many smaller bodies or units (finite
elements) interconnected at points common to two or more elements (nodes or nodal points)
and/or boundary lines and/or surfaces.

Figure 4-2: 2D Figure

Examples of FEA – 3D
Advantages Figure 4-3: FEA Frame

 rregular Boundaries
 General Loads
 Different Materials
 Boundary Conditions
 Variable Element Size
 Easy Modification
 Dynamics
 Nonlinear Problems (Geometric or Material)
The following notes are a summary from Fundamentals of Finite Element Analysis
 Figure 4-5: FEA Frame
Principles of FEA
The finite element method (FEM), or finite element analysis (FEA), is a computational
technique used to obtain approximate solutions of boundary value problems in
engineering.
Boundary value problems are also called field problems. The field is the domain of
interest
and most often represents a physical structure. The field variables are the dependent
variables of interest governed by the differential equation.
The boundary conditions are the specified values of the field variables (or related
variables such as derivatives) on the boundaries of the field. For simplicity, at this point,
we assume a two-dimensional case with a single field variable φ(x, y) to be determined at
every point P(x, y) such that a known governing equation (or equations) is satisfied
exactly at every such point.

A finite element is not a differential element of size dx × dy.

A node is a specific point in the finite element at which the value of the field variable is to be
explicitly calculated.
Shape Functions
The values of the field variable computed at the nodes are used to approximate the values at
non-nodal points (that is, in the element interior) by interpolation of the nodal values. For the
three-node triangle example, the field variable is described by the approximate relation φ(x, y) =
N1(x, y) φ1 + N2(x, y) φ2 + N3(x, y) φ3
where φ1, φ2, and φ3 are the values of the field variable at the nodes, and N1, N2, and N3 are
the interpolation functions, also known as shape functions or blending functions.
In the finite element approach, the nodal values of the field variable are treated as unknown
constants that are to be determined. The interpolation functions are most often polynomial forms
of the independent variables, derived to satisfy certain required conditions at the nodes.
The interpolation functions are predetermined, known functions of the independent variables;
and these functions describe the variation of the field variable within the finite element.
Degrees of Freedom
Again a two-dimensional case with a single field variable φ(x, y). The triangular element
described is said to have 3 degrees of freedom, as three nodal values of the field variable are
required to describe the field variable everywhere in the element (scalar).
φ(x, y) = N1(x, y) φ1 + N2(x, y) φ2 + N3(x, y) φ3
In general, the number of degrees of freedom associated with a finite element is equal to the
product of the number of nodes and the number of values of the field variable (and possibly
its derivatives) that must be computed at each node.
Finite Element Analysis of Frame Objective: To analyze the structural behavior of the frame
under operational loads and ensure it meets safety and performance requirements. Steps Involved
in FEA of Frame Geometry Creation Modeling: Create a detailed 3D model of the frame using
CAD software. The model should include all relevant structural features such as beams, columns,
joints, and any load-bearing elements. Simplification: Simplify the geometry if necessary to
reduce computational complexity while retaining critical features that affect structural integrity.
Material Properties Definition: Assign material properties to the frame. Common materials include
structural steel, aluminum, or composite materials
.Young’s Modulus (E): Measure of the stiffness of the material.
Poisson’s Ratio (ν): Describes the ratio of transverse strain to axial strain.
Density (ρ): Mass per unit volume.
Yield Strength (σy): The stress at which the material begins to deform plastically.MeshingMesh
Generation: Divide the frame geometry into smaller finite elements. A finer mesh is used in areas
with high stress gradients or complex geometry. Element Types: Use appropriate elements such as
tetrahedral or hexahedral elements for solid structures, and beam elements for structural members.
Mesh Quality: Ensure the mesh quality is high to avoid numerical errors. This includes checking
for element distortion, aspect ratio, and convergence. Boundary Conditions Supports and
Constraints: Define the boundary conditions that replicate real-world supports and constraints.
This could include fixed supports, pinned supports, or roller supports. Fixed Support: No
translation or rotation (zero degrees of freedom).Pinned Support: No translation but allows
rotation. Roller Support: Allows translation in one direction and rotation. Loading Conditions
Application of Loads: Apply the loads that the frame will experience in operation. This includes:
Static Loads: Weight of the stored goods, equipment, and frame itself. Dynamic Loads: Loads due
to moving parts, impact loads, and operational vibrations. Environmental Loads: Wind loads,
seismic loads, and thermal effects. Load Cases: Create different load cases to simulate various
scenarios the frame might encounter.SolvingFEA Solver: Use FEA software (e.g., ANSYS,
Abaqus, SolidWorks Simulation) to solve the equations governing the behavior of each element
under the applied loads and boundary conditions. Simulation: Run the simulation to obtain results
such as stress distribution, displacement, strain, and reaction forces. Results Interpretation Stress
Analysis: Examine the stress distribution throughout the frame. Identify areas of high stress that
may be prone to failure. On Mises Stress: Used to predict yielding of materials under complex
loading. Maximum Principal Stress: Important for brittle materials. Displacement Analysis: Check
the displacement results to ensure that the frame does not undergo excessive deformation. Factor
of Safety (FoS): Calculate the factor of safety to ensure the frame design is within acceptable
limits. Optimization and Validation Design Optimization: Based on the FEA results, optimize the
frame design to reduce weight, improve performance, and ensure safety. Validation: Compare
FEA results with physical tests or existing designs to validate the accuracy of the analysis.
Documentation and Reporting Report Findings: Prepare a detailed report that includes the
methodology, material properties, boundary conditions, load cases, results, and conclusions.
Recommendations: Provide recommendations for design improvements, if any, based on the FEA
results. Example Workflow for FEA of Frame Create Geometry in CAD Software Use a software
tool like SolidWorks or AutoCAD to create the 3D model of the frame. Assign Material Properties
Steel (E = 200 GPa, ν = 0.3, ρ = 7850 kg/m³, σy = 250 MPa).Generate Mesh Use tetrahedral
elements with finer meshing around joints and areas of load application. Define Boundary
Conditions Fixed supports at the base of the columns. Pinned supports at connection points. Apply
Loads Static load: Weight of stored goods (distributed load on shelves).Dynamic load: Impact
load from automated handling equipment. Run FEA Solver Use ANSYS to solve the model.
Analyze Results Check Von Mises stress distribution. Ensure maximum displacement is within
acceptable limits. Optimize Design If high-stress areas are found, reinforce those regions or adjust
the frame design. Prepare Report Include all findings, methodologies, and recommendations for
design improvements.
1.Study Properties

The study name Study 2

Analysis type Static stress analysis
Mesh type Mixed mesh
Thermal Effects: Open the
Thermal options Include temperature loads
Zero strain temperature 298 Kelvin
Including the hydraulic effect in Solid Close
Dvox Frosis Mlatian
The solver type FFEPlus
In-plane effect: Close
Soft spring: Close
Inertia Relief: Close
Incompatible bonding option Automatic
Large displacement Close
Calculates the free body force Open the
Friction Close
Use adaptive methods: Close
Results folder SolidWorks Documents (C:\Users\JE\
Desktop\Mechanical Equipment Design)
Unit System: metric system (MKS)
Length/Displacement mm
Temperature Kelvin
Angular velocity Radians per second
Pressure/stress N/m^2
 2.loads and fixtures

Load
Load the image Load details
name
Entity: 1 side
Type: Normal to
Press the selected face
ure -1 Value: 250
Unit: N/m^2

3.Study results

Name tyoe smallest maximum

Stress1 Von: von mises stress 0N/m^2 543.25N/m^2

4.3 Finite Element Analysis of shaft

The majority of the knowledge available on FEM analysis thus far has been theoretical in nature.
It is vital to use elementary physical problems to illustrate the operation of the analysis. Increasing
user trust in the usage of FEM software is another goal of these demos. These challenges are
suitable for comparison with Creo-Simulate because they can be resolved by manual calculations
of the strength of materials and statics.
The physical difficulties are first computed using the laws of statics, and then basic strength of
materials calculations are performed. Afterwards, the outcomes are contrasted with those of the
FEM model. Additionally, convergence analysis is shown. The structural analysis of the
residential building employs the same analytical methods.
The two physical problems include:

 Cantilever beam

 Simple truss

The cantilever beam is significant because it exemplifies the application of solid modeling
techniques. The modest FEM software covered in chapter 2 is introduced, and the basic truss
serves as an example of the beam and frames modeling method.
A. Shaft assembly that is designed in Creo
shows the pictorial representation of the shaft assembly. The following model is designed in the
Creo.
 Figure4-6: The CREO model is imported into the respective file format of the FEM
design software
B. FEM Modal

Figure4-7: 3D Model.
FEA Modelling helps in efficient managing of deformation, von misses stress and shear stress
and also in finding the natural frequencies and mode shapes in any mechanical component and
system. The figure shows the discrete modelling of a shaft assembly.
A structural steel cantilever beam (S355) with a point force at one end of the beam presents the
physical challenge. The primary goal is to determine the beam's maximum stresses and deflection.
The cross section and physical issue are depicted in Figure 20.
Static stress analysis
It is used to define a displacement, stresses, deformation etc.., due to the influence of static
loading condition. It estimates the properties of a steady loading condition on a component, but
over loading the inertia and damping effects, such as the one affected due to time varying load.
The some of the result that is taken from the ANSYS Software when it is subjected to 2 bearing
loads and 1 gear and 1 pinion loads,
 Figure4-8: Total 2D shaft.
Table 15 Results of the simple cantilever analysis

PROPERTIES VALUE(UNITS)

Maximum bending stress 32.52MPa

(𝜎max)

Maximum deflection 8.259mm

(mm)

Allowable deflection 5.556mm

(mm)

Allowed Stress(MPa) 177.5MPa

FEM analysis results

The cantilever is first modeled in Cero-parametric as a 3-Dimensional model
as shown in figure 21.

Figure 4-9:3D model of cantilever beam

The beam is moved to the FEM portion of the Creo software, Creo-simulate. As seen, one
benefit of fusing ceros is that it's simple to move from the CAD to the FEM model. Setting up the
parameters is the next step. The problem incorporates the limitations, boundary conditions
(material and displacements), and forces. This section is critical and the primary cause of errors in
the majority of issues. The outcome is displayed in figure 22 below.
 Figure 4-10: Model in FEM before analysis
The moment the parameters are verified twice, the simulation process begins. When the problem
is run, the many differential equations are actually solved by the software, and the results are
graphically displayed as figures 23 and 24 below illustrate.

Figure 4-11:3Displacement solution

The hand calculations results and FEM results are compared

Table 4 FEM and hand calculated
PROPERTIES CALCULATED RESULTS FEM RESULTS

Maximum bending stress 32.52MPa 33.5004MPa

(δ max)

Maximum deflection 8.259mm 8.678mm

(mm)

Allowable deflection 5.556mm 5.556mm

(mm)

Allowed Stress(M Pa) 177.5MPa 177.5MPa

results comparison
The analysis's findings indicate that stresses will peak at 33.5004 MPa. The FEM result closely
resembles the predicted value. The results are acceptable because the discrepancy has no bearing
on these deflection values are the same situation. There aren't many differences between them.
Still, the outcome is the same. There has been more deviation than permitted.
This presentation demonstrates the FEM analysis's level of reliability when error sources are
kept to a minimum. Furthermore, there are a few more benefits that the FEM program offers over
manual computations. First, it shows the displacement and stress results for each section of the
cantilever. Additionally, if there is a requirement to modify the cross section's measurements.
Simple Truss Analysis
An essential component of the warehouse building analysis is the truss strength analysis. Thus,
the beam idealization approach must be used to illustrate the truss analysis. The ensuing example
aids in comprehending the fundamental ideas of truss analysis.
Table 16 Stress values for the truss elements

ELEMENTS NUMERS VALUE(UNITS)

Element1 4.619MPa

Element2 9.238MPa
 Element3 0
Element4 4.619MPa
Element5 9.238MPa

Creo-Simulate Analysis
The three-dimensional members are not initially represented; instead, the truss is idealized as a
beam member. Beams are three-dimensional elements that have comparable material, length, and
cross-sectional characteristics. As seen in the figure 27 below, each beam is handled as an
element.
The results of solving the problem are shown in figure 28, which is below. Beams three and five
are under a lot of stress. The outcomes of the smaller FEM program are comparable to this.

Figure4-12: Simulated model

Table 17 Comparison of the values
ELEMENTS VALUE(MPa) VALUE(MPa)
NUMERS

Element1 10000 10000

Element2 80000 80000

Element3 5000 5000

Element4 200 200
Element5 100 100
The values areal most identical which illustrates the authenticity of the FEM
programs. For structural analysis, FEM software such as Creo-simulate is
ahighly helpful tool. If mistakes are minimized or prevented, this happens.
Sometimes it's okay to accept slight variations in the outcomes, particularly if
the permitted pressures are avoided. The aforementioned examples are a major
source of confidence for the primary residential building study.

4.4 Finite Element Analysis of wheel

Finite Element Analysis (FEA) of a frame is a powerful engineering technique used to analyze
the structural behavior of frames subjected to various loads. Here's a breakdown of what it
involves:
Process:Frame Model Creation: The frame geometry is represented in a computer program using a
mesh of elements (small, interconnected pieces). Each element has assigned material properties
(strength, stiffness).Load Application: External loads (weight, wind, seismic) are applied to the
model at designated points.
Boundary Conditions: Constraints on the frame's movement are defined (fixed supports, rollers,
etc.).
Solving the Equations: The computer program solves a complex system of equations based on
material properties, loads, and boundary conditions. This determines the stresses, strains, and
deflectio

Figure4-13 :3D wheel

Rim-free wheel tread shape and dimensions match track (from JB/T 6392.1-1992)
Table18
D/mm B2 ≤/mm Track Track Track Track
160 40 9kg/m. 12kg/m. ___ ___
200 40 9kg/m. 12kg/m. ___ ___
250 45 9kg/m. 12kg/m. 15kg/m. ___
315 980 15kg/m. 22kg/m. 30kg/m. 38kg/m.

Dimensions and specifications of light rail (from GB/T 11264-1989) Table 19

Mod Section dimensions
el Rail Botto Head Head Waist Botto Lumba Theoretical
num height m Width height height m r qualityW/kg:
ber A. width C. D. E. height thickn
B. F. ess t.
12 69.85 69.85 38.1 19.85 37.7 12.3 7.54 12.2

Figure4-14: 2D Model wheel

 In this investigation, steel alloy, magnesium alloy, and aluminum alloy were used for the rim
wheel materials. As low-carbon steel, the steel used to make steel alloy has a carbon percentage of
0.25 or less. It is also the most budget-friendly option. Al (95.85–98.58%) and Si (0.4–0.8%) are
the two primary alloy components of aluminum alloy; silicon contributes properties such
as corrosion resistance . Finally, magnesium alloys are alloys in which magnesium constitutes at
least 97% of the total metal. For its strength to weight ratio, magnesium has the lowest density of
all structural metals at just 1.77 g/cm3. The rim wheel casting technique impacts the cost of raw
materials. With casting, the finished product will have the same mass as the original raw material.
Titanium wheel bolts are a popular component in bicycle customization. They are often regarded
as one of the quickest and easiest ways to boost a vehicle's performance. Titanium is used for
many racing vehicles' wheel bolts because of the material's durability and low weight. Most
people know that a lighter bike with less sprung weight can go faster. As can be seen in , the three
materials in question all have distinct characteristics .siliconcorrosion resistancestrength
The excellent strength-to-weight ratio, superior machinability, and inexpensive cost of
magnesium alloys make them a desirable material. When compared to more common alloys like
aluminum or steel, their 1800 kg/m3 specific gravity and 45 GPa Young's modulus are relatively
low. The problem is that they are extremely fragile and difficult to shape when temperature room.
Their malleability improves with heat, but only at the expense of considerable effort. In addition,
research has demonstrated that the basic texture of the Mg alloys can be weakened to improve
flexability at the expense of strength .shows the properties of wheel alloy
materials.machinabilityspecific gravityYoung's modulus

Table . Properties of wheel alloy materials.

Wheel Density (kg/m3) Young’s Poisson’s Ratio
Materials Modulus (GPa)
Al – Alloy 2770 71 0.33
Mg – Alloy 1800 45 0.35
Ti – Alloy 4420 120 0.36
Fuel efficiency is said to improve by about 0.7% for every 1% decrease in vehicle mass.
However, reducing the weight of the engine's moving elements is expected to be considerably
more successful than reducing body weight in improving fuel economy. The density of titanium
alloy is roughly 60% that of steel, and its elastic modulus is roughly 50% that of steel. Although it
is not always the optimal course of action, replacing steel components with titanium should result
in an immediate 40% reduction in weight. Titanium's low modulus makes it an excellent material
for springs, although in stiffness-constrained applications, it may be required to rethink some of
the components. Titanium has superior specific strength, specific toughness, and fatigue limits
compared to steel and aluminum alloys .elastic modulus

Two wavelengths of the prescribed polygonal wear. 15 time steps with an two-point wheel-rail
contact occurs, and the corresponding contact interval of 0.12 ms are selected for the analysis to
cover the wheel positions along the wheel profile are indicated by the orange and pink passage
within one wavelength (between 36◦ and 41.5◦). At t5 and t6, vertical lines. Because prescribing
the 4 principal radii for contact geometry in CONTACT cannot deal with two-point contact, only
the FE contact solutions at t5 and t6 are displayed.

Center of contact area. As to the results shown in (b), despite the underestimated without
considering thermal effects (EP-POL vs EPT- smaller normal contact stress, the wear depth
obtained with model EP- POL), whereas the wear depth can be either underestimated POL is
greater than that of model EPT-POL, due to the remarkably larger (b)) or overestimated (b)),
depending also on the value of micro- micro-slip (dashed curve) than that of model EPT-POL
(solid curve). This slip. suggests that, again, the maximum wheel-rail normal contact stress is
 This section investigates the influence of initial defect amplitude on the development of
polygonal wear. Three amplitudes of initial wheel polygonal profiles are applied to the elasto-
plastic models (EP-POL and EPT-POL): A= 0.014 mm, 0.029 mm, and 0.043 mm (1/7 scaled
down from 0.1 mm, 0.2 mm, and 0.3 mm), denoted by Profile-1, Profile-2 and Profile-3
respectively also displays the simulated wear depths along the prescribed initial profiles. In the
legend, EP-POL-1 represents the wear depth simulated with model EP-POL with Profile- 1, etc.
We may see from that the simulated wear depth peaks increase with the initial wear amplitude,
suggesting that the development of polygonisation is an accelerating progress: the larger the
polygonal wear, the faster the development is . In addition, the 1st peak and 2nd peak of the wear
depth move closer to the crest of the profile with the increase of initial wear amplitude, which
indicates that locations at these peaks suffer from large-amplitude wear and result in the
development of new polygonal profile. Furthermore, for all the simulation cases, the wear depth
simulated with model EP-POL is smaller than that of model EPT-POL at the 2nd peak along the
wheel profile where the wheel-rail contact-induced temperature is high. cases, the wear depth
simulated with model EP-POL is smaller than that of model EPT-POL at the 2nd peak along the
wheel profile where the wheel-rail contact-induced temperature is high.

4.5 Finite Element Analysis of lifting device frame

The column is analyzed using the FEM analysis program to visualize the simulation and
determine whether the same critical buckling load will occur. Creo-Simulate has modeled the
analysis, as seen in figures 31 and 32 below.

Figure 4-15:Frame Weight

TABLE Material Properties

The shape of the lifting frame refers to the shape of the FEA. The width of the lifting frame is
about 2 m and the length is about 6.6 m, and the lifting frame weighs 1180 kg. The lifting frame is
made of 11 H-shaped carbon steels. All the welding between H-shaped carbon steels are
completed by full penetration, which ensures the lifting frame has sufficient structural strength.
There are 4 upper lifting lugs bolted on the upper flange of the frame, 12 lower lifting lugs are
bolted on the frame bottom flange for lifting the FEA. 6 lifting supports under the lifting frame
allow the frame to be flat on the ground. The structure of the lifting frame is shown in Fig. 2.

Figure 4-16: 2D Model lifting dicice frame

The lower lifting lugs are connected to adapters with the FEA through turn buckles, shackles
and slings, and the upper lifting lugs are connected to the building crane. The turn buckles are
used to extend the length of the slings until all the slings are tightened and the FEA is in a
horizontal level.

Figure4-17: Idealized model showing axial force

Figure4-18: Lode dimensional model

 When inserting the parameters, a force of 1Nisused as the axial force so as to anticipate a
backling load factor (B.L.F)of133,392. The following figure shows the results after simulation.

Figure 4-19: Analysis results

The B.L.F is 133,661 which are almost similar to the theoretical results. Therefore, the critical
load (P.cr) that will cause the column to buckle is 1N x B.L.F.

From the FEM analysis and theoretical calculations, the buckling load is estimated to
be133,900N. A safety value is applied to the critical load and the allowed axial load is as shown
below. The applied load at the top of the column is 35,500 N which is less than the allowed load
of 66,970N. Therefore, it is concluded that the load on the column caused by the snow load will
not cause the column to buckle.
Wind Load on Colum
First, the wind load has to be defined according to the standards. The wind pressure on an external
surface is calculated using the following formula. (EN – 1991 – 1 -4, 43)
WeqpZeCpe .(12)
Where qp (ze) is the peak velocity pressure and Cpe is the pressure coeffi-cient for external
surface.
Peak velocity pressure=600N/m2 Pressure co-effective= 1.4 We=840N/m2
Finally, the UDL (N/m)on the column is solve during. Pressure load = 840 N/m2 Length=4.797m
UDLpressureloadLength4.029x103
The problem is modeled in Creo–Simulate as shown in figure 34 below.

Figure 4-20: Column showing simulation

 Figure 4-21: column showing simulation Regular
High stresses are found toward the column's base, much like in the previous model depicted in
figure 35. On the other hand, the maximum stress levels vary greatly. The stress has changed from
an earlier value of 18 MPa to a new value of 37.52 MPa. The new value is now very close to the
critical level and is much lower than before. The vast disparity can be attributed to the various
modeling techniques employed. The roof truss is still attached to the column in the first instance.
When the column is subjected to wind loads, the weight of the snow and truss lessens the column's
bending. This is why the model in figure 37 experiences high stress compared to the one in figure
35. The conclusion is the same since both stresses are way below the critical stresses set according
to the safety factor and yield stress.

4.6 Finite Element Analysis of middle plates and several plates

The column's base should be extremely stable in order to offer the necessary rigidity even
under slight vibrations. The building's walls and roof truss are supported by the column, which is
supported by the base. This indicates that a very high level of base strength integrity is required.
The concrete base support, a plate, and anchor bolts are all part of the base joint. The plate holds
the anchor bolts in place as they are embedded in the concrete. The technical drawing's base is
depicted in figure 38 below

Taking advantage of symmetry, one-quarter slab FE meshes were created for each slab. A
primary-secondary displacement-controlled loading procedure was used to apply loads in the
analyses. With this approach, an incremental nodal displacement was applied to one of the
perimeter loading points considered in the test programme (i.e., the primary loading point), and
the corresponding computed force required to induce this nodal displacement in the model was
applied to all other equal magnitude loading points (i.e., the secondary loading points) that were
employed in the test. Using this approach, the NLFEA models employed the same load-controlled
testing protocol employed experimentally; however, abrupt drops in slab shear resistance
coinciding with slab punching could be captured numerically, providing clear evidence of model
failure. In addition to the applied loading, slab self-weight was considered in all analyses and was
estimated using an assumed RC density of 2400 kg/m3.
All slabs were meshed using an unstructured meshing technique to reduce the computational
costs of the analyses while providing adequately dense meshes within the critical regions near the
supports and loads, without excessively increasing the required number of elements. Node
locations corresponding with applied loads and instrumentation measurements were predefined
prior to meshing. The mesh density considered for these analyses were defined according to a
mesh sensitivity investigation performed for slab PT31 from . Six different trial meshes were used
to model slab PT31. Each layered thick-shell element was divided into 20 equal thickness concrete
layers based on that employed in and, typically, an additional two, or four, steel material layers
were used to represent in-plane reinforcement (two layers for each mat of steel). In all cases,
perfect bond between the in-plane reinforcement and concrete was considered. As illustrated in
the results obtained from the mesh sensitivity study showed that meshing that produced planar FE
sizes measuring approximately 25% of the average flexural depth in the slab regions immediately
surrounding the column, and 50% of the average flexural depth of the slab in all other regions,
provided a balanced approach between computational cost and numerical convergence. It is
important to note that the experimental response of PT31 was not considered in the mesh
sensitivity study, and no attempt was made to calibrate the mesh to improve agreement with
experimental results. For reference, using the meshing procedure noted above, the one-quarter slab
FE model for slab PT31, which was typical for all PT series slabs, required 275 thick-shell FEs,
resulting in a total number of degrees-of-freedom of 5020. An overview of the test specimens
comprising the different series of flat plate connection tests and the shell element meshing
employed are presented in .

Figure4-22: 2D middle plate

Figure4-23: several plates

The bolts used for the joint are uniqueincetheirmain function is to act as anchors to the column.
Figure 39 below shows an example anchor bolt in use connected with concrete.
 Figure4-24: side several Frame
The loads on the column determine the loads that occur on the bolt. These loads consist of
column weight, wind load, and snow load on the roof. The bolt is subjected to shear, compression,
and tension forces from these loads. Sometimes the forces act alone, as in the case of tension and
compression, or they act in tandem. The bolt is also subjected to bearing stress as a result of the
plate.
A bending moment is created at the base of the column by the wind load on its side. The bolt's
bending stress causes tension in half of the bolt and compression in the other half. Because of the
snow load and column load, the point load at the top of the column causes compression at the
base, which aids in anchoring. Consequently, the wind-induced bending moment of the bolts is
lessened. This leads to the deduction that the bolts are most critically loaded by the wind load.
The basic model below serves as the foundation for the analysis of the bolts. It should be
mentioned that the bolts are only analyzed in relation to the wind, which is the critical load.

Figure4-25:Simplified model of column and the base

 The comprehensive computation used to determine the bolt's stresses is displayed in Appendix .
One anchor bolt has an axial stress of about 309 MPa. Given that the bolt material has a yield
strength of 355 MPa, this is a high value. However, the column weight and point load force at the
top of the column greatly diminish this amount.

The displacement model differs greatly from the wind or snow load models, as previously
demonstrated. That bracing element, though, remains the same despite the large deflection. This
time, the displacement is measured at 41.99 mm. This figure is extremely high and cannot be
justified. The bracing's primary goal is to maintain stability in the face of wind forces. The bracing
deflects at high levels, which leads to a corresponding deflection in the truss components. In
contrast to the earlier models, the truss deflection now measures 25 mm.
To learn more about the stress distribution, the members with high stresses and deflections are
separated and examined. The middle member, which was subjected to extremely high stresses, is
depicted in the simulation results in the picture below.

Figure4-22: Isolated results of the Frame

Different parts of the member experience different amounts of stress. The maximum stresses
using the above figure are 70.46MPa, which is less than the values previously obtained. Higher
strains are seen in the member's smaller elements. When the left side end is magnified, the stress is
displayed as follows. The zoomed section demonstrates the member's range of stresses, with the
peak stress being 89.75 MPa.

Figure4-23:Detailed model
To withstand all combined loads, the bracing needs to be changed to make it more robust and
stiff. The deflection is nearly identical to the previous bracing study and is small in comparison to
the permitted deflection. Drakatos et al.
As reported by Drakatos et al. , a series of thirteen isolated slab-column connections, denoted
as PD specimens, were tested at EPFL under different combinations of punching shear and
unbalanced moment. Slabs measuring 3000 × 3000 × 250 mm were centrally supported on 390 ×
390 mm steel bearing surfaces used to represent interesting columns. To stabilise the test setup and
minimise the separation of slab-column connection interfaces, four 15-mm diameter post-
tensioned bars were used to anchor the column bearing plates to the slab surfaces. The PD slabs
were tested to the failure using one of three loading conditions: 1) under four-edge gravity loading
(V); 2) under constant four-edge gravity loading and increasing monotonic unbalanced moment
(V+M); and 3) under constant four-edge gravity loading and increasing cyclic unbalanced moment
(V+C).
 Hydraulic jacks were used to apply out-of-plane shear forces to the system, and unbalanced
bending moments were introduced to the connections by applying two equal and opposite loads
(couple loads) at the free ends of four 2,100-mm long steel beams attached to the slabs' edges.
Hydraulic jacks and steel beams generated moments about the y-axis with a lever arm of 7200
mm. All thirteen slabs of the PD series were constructed without out-of-plane shear reinforcement.
In terms of the in-plane reinforcement, two reinforcement arrangements were used for the slabs of
the PD series. Group A slabs were symmetrically reinforced with a reinforcement ratio of 0.75%
in the tension mat and 0.38% in the compression mat, and Group B slabs were constructed with a
reinforcement ratio of 1.50% in the tension mat and 0.75% in the compression mat. Additional
reinforcing bars were provided at the slabs at the edges to connect the steel loading beams to the
slabs. The test specimen geometry and the loading setup are shown in.

4.7 summary
The loads are coupled, same as previously, to simulate a potential severe weather event. The
results and model setup are displayed be The majority of the beams in the building can withstand
the forces brought on by the specified loads, which speaks highly of the strength of the design
before examination. To determine if the structure will remain stable, various loading conditions
are performed to it. On the other hand, some beams have a tendency to have large stresses and
deflection under specific loading situations.
The analysis starts with the calculation of safety values for stress and deflection. Redesigning
the structure's members is necessary if the stress and deflection values experienced by the
structure are extremely near to the safety values.
A few building components are experiencing unfavorable strains and deviations. Although these
values do not result in failure, redesign is necessary to increase the strength and reliability levels.
Two characteristics of the structural members must be altered in order to increase strength. The
beam member's material property (E) is one, while the beam's cross section attributes (I) are the
other. These comprise the beam's flexural stiffness. Stress in the beams is decreased by increasing
flexural stiffness.

Structural steel (S355) is what's used for the building's beams. This material has a high
Young's modulus and is notably stiff and strong. It is also very accessible and affordable, which
makes using it in this warehouse structure financially feasible. Structural steel is not the only
material type with superior strength and stiffness ratings. The materials utilized in this
construction are not the only ones with superior strength to weight ratios. It is not cost-effective to
utilize these materials in the building because they are significantly more expensive than structural
steel. The variation in high strength metal pricing is shown in the table below

Table 20 Metal price comparisons (RoyBeardmore,201)

 Clearly, steel is much more realistic to use than other materials which have a higher young´s
modulus than other materials such as titanium. The table below shows the different modulus of
elasticity for selected materials
Cost/tonne RelativeCost RelativeCost
C
Material
(weight) (volume) H
�/tonne
A
Steel(Billet)LME-Nov-2010 321 1 1 P
T
Steel(Hot Rolled Plate)-MEPS-July- 505 1,6 1,6 E
2010
R
304Steel(Hot Rolled Plate)-MEPS- 2 536 7,9 7,9
July-2010

316Steel(Hot Rolled Plate)-MEPS- 3 535 11 11

July-2010

Tin-LME-Nov-2010 15458 48 45

AluminiumAlloy-LME-Nov-2010 1 407 4,.4 1,5

Aluminium-LME-Nov-2010 1 425 4,4 1,5

Copper-LME-Nov-2010 5 279 16,4 18,7

Zinc-LME-Nov-2010 1 412 4,4 4,0

Nickel-LME-Nov-2010 14398 44 51

Lead-LME-Nov-2010 1 414 4,4 6,4

Titanium(ingot6AL-4V) 15700 49 28

5 CHAPTER 5 Economic analysis

The lightweight structural design for an automated warehouse, incorporating key components
such as the optimized frame, chain wheel, and other structural elements, offers several economic
benefits. These benefits are realized through cost savings, improved processing and manufacturing
efficiencies, and reduced energy consumption.

1. Cost Benefits
1.1 Material SavingsReduced Material Use: The lightweight design uses less material,
leading to direct cost savings in raw materials. High-strength materials can be used more
efficiently, providing the necessary structural integrity without excess weight.
Lower Transportation Costs: Reduced material weight decreases transportation costs for
both raw materials and finished products. This is particularly significant in large-scale
projects where shipping costs can be substantial.

1.2 Maintenance and Durability

Longer Lifespan: The optimized design, validated through Finite Element Analysis (FEA),
ensures higher durability and longevity. This translates to lower maintenance costs and less
frequent replacements.
Reduced Downtime: Improved durability reduces the likelihood of mechanical failures,
minimizing downtime and associated costs for repairs and lost productivity.
2. Processing and Manufacturing Benefits
2.1 Efficient Manufacturing
Simplified Fabrication: Lightweight designs often simplify manufacturing processes,
reducing labor and machining time. Simplified geometries and optimized components lead
to faster assembly and lower labor costs.
Automation Compatibility: The design is tailored for automated manufacturing processes,
increasing production rates and consistency. Automated welding, cutting, and assembly
processes can be utilized more effectively.
2.2 Improved Supply Chain Management
Standardized Components: The use of standardized and optimized components streamlines
the supply chain, reducing inventory costs and simplifying logistics.
Scalability: The lightweight design allows for scalable manufacturing, making it easier to
adapt production to varying demands without significant changes in infrastructure or
tooling.
3. Energy Consumption Benefits
3.1 Operational Energy Savings
Lower Energy Usage: Lightweight structures reduce the energy required for material
handling equipment, such as cranes and conveyors, leading to lower operational energy
consumption.Improved Efficiency: Reduced weight translates to less energy needed for
movement and operation within the warehouse, such as forklifts and automated guided
vehicles (AGVs).
3.2 Environmental Impact
Sustainability: Using less material and energy not only cuts costs but also reduces the
environmental footprint of the warehouse operations. This aligns with sustainable
development goals and can enhance the company’s reputation.
Energy Recovery Systems: The design can incorporate energy-efficient technologies such as
regenerative braking systems in automated equipment, further reducing energy
consumption.
4. Economic Summary
4.1 Return on Investment (ROI)
Initial Investment: While the initial investment in lightweight, high-strength materials and
advanced manufacturing processes might be higher, the long-term savings outweigh the
upfront costs.
Payback Period: The combined savings from material costs, energy consumption, and
maintenance reduce the payback period, leading to faster ROI.
4.2 Competitive Advantage
Cost Leadership: Lower operational and manufacturing costs enable competitive pricing for
warehouse services.
Enhanced Performance: Improved efficiency and reliability of the warehouse operations
increase customer satisfaction and business opportunities.
Conclusion
The lightweight structural design for an automated warehouse presents significant economic
benefits across various aspects:
Cost Savings: Reduced material and transportation costs, along with lower maintenance and
downtime expenses.
Manufacturing Efficiency: Streamlined fabrication processes and supply chain management,
enhancing scalability and reducing labor costs.
Energy Efficiency: Lower operational energy consumption and environmental impact,
contributing to sustainability goals and long-term savings.
These economic benefits not only enhance the financial performance of the warehouse operations
but also provide a competitive edge in the market, supporting growth and sustainability objectives.
 CHAPTER 6 Conclusion

6.1 Conclusion
In conclusion, the lightweight structural design for automated warehouses presented in this
thesis offers a compelling solution to the challenges faced by modern warehousing operations. By
combining innovative materials, advanced design principles, and seamless automation integration,
the proposed design achieves a balance between strength, efficiency, and sustainability. As the
logistics industry continues to evolve, the insights and methodologies developed in this thesis will
serve as a valuable resource for future advancements in warehouse design and automation.

The development of a lightweight structural design for automated warehouses represents a

significant advancement in optimizing storage solutions and enhancing operational efficiency.
This thesis has comprehensively addressed the design and calculation processes necessary to
achieve a robust yet lightweight structure capable of supporting the demands of modern automated
warehouses. This thesis' primary goal was to apply the finite element approach to the analysis of a
residential construction. The analysis approach was carefully selected because there are numerous
numerical techniques available. After a thorough investigation, the residential building's
architecture was altered as needed. Throughout, the central query was whether the structure could
withstand the forces brought about by the loads. Using the strength of the materials and additional
design knowledge of mechanics, changes were made. The building's integrity was strengthened by
the analysis, and the residential building's new design is thought to be stronger and more
dependable.
Because of the errors made by the analyst, this structural analysis method has occasionally been
heavily criticized. To ensure that no mistakes accumulated, great care was taken at the beginning
of the analysis. The case studies that were examined prior to the primary investigation were
crucial. This was due to the fact that they provide a summary of the entire procedure. The
movement of loads throughout the building is another illustration. Determining the appropriate
loads is crucial because it serves as the basis for analysis; if the loads are off, erroneous designs
are created.
The majority of the building's components were determined to be extremely sturdy and secure.
Just a small number of beams caused serious doubts about their dependability. However, more
beams encounter higher stresses when various loading conditions are used. Designing the
susceptible beams to higher safety values than previously is the solution. The residential building
was stronger and more dependable as a result of the recent modifications. The newly designed
models provide even more evidence for the design.
The most significant structural analysis technique in the thesis papers is the finite element
analysis. The approach can be widely used to study structures as long as the inaccuracies are kept
to a minimum. What would not have been possible with manual computations was made possible
by this technology. For instance, the analysis's conclusions are quite thorough because the stress is
clearly shown graphically across the beams and columns. This thesis's structural analysis of the
residential structure utilizing FEM provides a useful illustration of the efficacy of this analytical
technique. Still, there's more space for development in the FEM structural analysis. For example,
the structure's thermal study could be performed to determine whether temperature variations
impact the building's strength. Additionally, modal analysis could be performed to look into
vibrations, particularly those caused by earthquake forces.
The analysis conducted for this thesis project was successful since the initial objectives were met.
Numerous people have issued warnings regarding the use of FEM software as an analytical tool
because of its misleading presentations and images. However, if the analyst is knowledgeable
about the subject, it has been demonstrated that this method is trustworthy by following safety
measures and manually verifying the data. As seen in chapter five, the FEM analysis method can
therefore be applied to structural study of complex structures.
With great confidence, the new design and analysis can be presented to interested parties.
6.2 Recommendations
1.Consult with Structural Engineer: For complex designs, involve a structural engineer to
ensure the lightweight structure meets all safety and load-bearing requirements. They can
advise on material selection, optimal design, and perform detailed FEA analysis.
2.Life Cycle Cost Analysis: Perform a life cycle cost analysis to assess not just initial
construction costs but also consider potential maintenance needs and energy consumption
over the expected lifespan of the warehouse.
3.Sustainability Considerations: Integrate sustainable practices into your design. This could
involve using recycled materials, incorporating natural lighting, and installing energy-
efficient HVAC systems.
4.Fire Safety Planning: Lightweight materials may require additional fireproofing measures
to meet building codes. Plan fire safety measures like sprinklers and fire-resistant
compartmentalization.

Future Scope:

1.Integration with Automation Systems: Explore advanced automation technologies like

autonomous mobile robots (AMRs) for enhanced efficiency and flexibility.
2.Advanced Material Handling Systems: Consider innovative material handling systems like
automated storage and retrieval systems (AS/RS) for high-density storage and retrieval.
3.Smart Warehouse Design: Research and integrate smart technologies like Internet of
Things (IoT) sensors for real-time monitoring of inventory, equipment, and environmental
conditions within the warehouse.
4.Adaptive and Reconfigurable Design: Design with future adaptability in mind. Consider
modular components or easily reconfigurable layouts to accommodate potential changes in
storage needs or warehouse operations.
5.Focus on Sustainability: Explore further advancements in sustainable materials and
construction practices for even lower environmental impact. This could involve
incorporating renewable energy sources like solar panels or wind turbines to power the
warehouse.
By considering these recommendations and exploring future advancements, I will be able to
design and build a lightweight, automated warehouse that is not only cost-effective and efficient
but also adaptable, sustainable and future-proof.
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 Acknowledgment

This article was prepared with the help of my supervisor Dr. Yan Guoping, and some of the
contents was learnt from other research papers and was applied here. I want to thanks to my
supervisor for his whole-hearted help for finishing my project and the authors of the other research
papers.

1
 Summary
In the course design, the team analyzed the structural and functional principles of the existing
stacker by observing and analyzing the structure and function of the stacker, and redesigned the
structure of the stacker under the parameters developed by themselves. In the course design of this
project, on the one hand, the team members measured the existing equipment, and on the other
hand, compared each scheme, analyzed the advantages and disadvantages of the scheme, and then
designed the optimal scheme of the work. In the process of parameter development, course design
team members conduct parameter development and part selection by reviewing a wide range of
literature, including the Mechanical Design Manual, as well as industry standards for the stacker.
It is intended that the design of the program meets the relevant standards.
In the process of design calculation, also reference the former design calculation process,
strictly according to the formula calculation, for some difficult to calculate functions, Matlab
software is also used for calculations. In the process of 3D modeling, the project uses solidowrks
for drawing and analysis of critical force-bearing parts using finite element analysis software. The
design meets the requirements for use.
Design and Calculation of Lightweight Structural Design for Automated Warehouse This thesis
likely focuses on optimizing the structural design of an automated warehouse for lightweight
construction. Warehouses typically require a strong and stable structure to support storage racks
and automated equipment. However, using excessive materials can be expensive and inefficient.
This thesis proposes a design approach that prioritizes lightweight materials and efficient
structural elements while maintaining the necessary strength and functionality for the automated
warehouse. Here's a breakdown of what the thesis might cover:
Motivation: Highlighting the need for cost-effective and efficient warehouse structures.
Lightweight Materials: Exploring materials like advanced steel alloys, composite materials (e.g.,
carbon fiber), or even lightweight concrete for relevant structural elements. Structural Design
Optimization:
Analyzing and designing the warehouse structure using principles of strength analysis and
lightweight construction practices. This might involve optimizing column design, using trusses or
beams for efficient load distribution, and potentially incorporating seismic considerations for areas
prone to earthquakes.
Calculations and Analysis: Utilizing engineering mechanics principles and software tools to
calculate load capacities, deflections, and stresses in the lightweight structure. The summary might
reference specific design codes and standards used for warehouse construction.
Comparison with Traditional Design: Comparing the proposed lightweight design with a
conventional warehouse structure. This could involve showcasing benefits like reduced material
costs, faster construction time, and potentially lower energy consumption for building operation.
Conclusion Feasibility and Future Work: Discussing the practical implementation of the lightweight
design concept. This might include cost analysis, challenges associated with lightweight materials,
and potential areas for further research and development.