Check out some of our projects

The primary objective of this project was analyzing an autonomous solar charger designed for electric vehicles. The aim was identifying critical stress locations and suggest design improvements. This work entailed a comprehensive structural assessment and load capacity analysis, evaluating the charger’s performance under various wind and snow loads in compliance with EUROCODE standards. The charger, mainly constructed from aluminum alloy and steel, comprises components that are either welded or bolted together.

The reaction forces, moments, stresses, and strains were analyzed utilizing 3D and shell elements and complex contact formulations (over 150 contact definitions) to ensure structural integrity. This project confirmed the charger's design's robustness and offered valuable insights into potential enhancements.

Further information about this innovative solar charger, which has recently entered the market, can be found here.

This project focused on the structural integrity assessment of a planet carrier within a planetary gearbox system using finite element analysis (FEA). The carrier was subjected to various static and dynamic loading conditions, necessitating a detailed fatigue analysis. A strain-life method  (ε - N) was employed under the assumption of fully reversed loading to evaluate fatigue performance at critical stress locations. Additionally, the influence of residual stresses on fatigue life was incorporated to enhance the accuracy of the assessment.

To improve durability and performance, the carrier’s geometry was optimized by reducing stress concentrations, thereby extending its operational lifespan. Second-order tetrahedral elements were utilized to accurately capture geometric features such as fillets and improve result precision. Furthermore, the stiffness of bearings was incorporated into the analysis through a stiffness matrix, ensuring more realistic displacement predictions.

This study provided valuable insights into the carrier’s structural behavior, leading to design refinements that enhance reliability and longevity in demanding operating conditions.

At Sinamar, we are currently engaged in an intricate project focusing on the design and optimization of various aluminum frame glass door systems. Our responsibilities encompass designing pivot, hinge, and sliding systems, with a keen emphasis on optimizing profile cross-sections to reduce mass while retaining structural rigidity.

In addition to the optimization tasks, we also provide R&D support by investigating existing solutions and identifying areas for improvement. Our work includes designing various types of connections between profiles, meticulously considering manufacturing methods, tolerances, and potential assembly issues. This ensures that the final designs are not only functional but also manufacturable and easy to assemble.

Moreover, our process involves comprehensive static load capacity calculations. By considering the allowable stresses of different components such as bolts, screws, aluminum profiles, and cast zinc alloy parts, we ensure that each system can withstand the required loads without compromising safety or performance. This holistic approach results in high-quality, efficient, and reliable aluminum frame glass door systems.

The primary objective of this project was providing a comprehensive numerical simulation analysis of a heat exchanger comprising over 100 components. The analysis utilized symmetric boundary conditions due to the heat exchanger's symmetrical constraints, loads, and geometry. Compared to their other dimensions, shell elements were predominantly used given the relatively thin features of the components, supplemented by a few 3D finite elements.

The heat exchanger was subjected to a combination of pressure loads from steam, hydrostatic pressure from water, and thermal loads. Special attention was given to the variation in the elasticity modulus with respect to temperature and thermal expansion coefficients. Over 200 contact formulations were defined based on either welded or bolted connections.

Critical locations exhibiting the highest stresses and strains were identified, and stress linearization was performed in accordance with relevant standards. These results were then compared against allowable values to ensure structural integrity and performance reliability.

This project focused on conducting a comprehensive structural integrity analysis of a heat exchanger comprising over 200 components, predominantly made from construction steel. The exchanger faced diverse challenges, including exposure to varying wind loads and high temperatures. Special consideration was given to the fluctuating Young's modulus to accommodate thermal-induced loads arising from thermal expansion coefficients.

Most components were modeled using shell finite elements, supplemented by a selection of 3D elements where necessary. Rigorous analysis encompassed critical stress, strain, and rigidity assessments during transportation and positioning of the exchanger, as well as under wind loads exceeding 100 km/h. With over 300 defined connections (primarily welded), meticulous attention was paid to ensure structural resilience and operational reliability.

This project entailed simulating a four-point bending cyclic test to analyze the vertical deflection of a carbon-fiber-reinforced oak beam. A composite sandwich structure was modeled, incorporating oak beams and two distinct reinforcement layers crafted from combinations of carbon or glass fibers with either epoxy or polyurethane resin. The simulated deflections were meticulously compared with experimental results from four-point bending tests, revealing a strong alignment between the findings.

The primary aim of this investigation was to assess the impact of various reinforcement types on structural durability and rigidity. By exploring the effects of different reinforcements, valuable insights were gleaned into enhancing composite structures' overall performance and longevity.