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Stackable industrial platform — transport validation

Finite-element study of a loaded, stacked industrial platform under acceleration and braking. The report compares global response, local points, displacements and reactions to substantiate structural integrity.

DisciplineHandling · Stackable structure · Dynamic calculation

Documented scope6 project stages

Stackable industrial platform — transport validation — FORGIA industrial project

01 — Project journey

From requirement to industrial reality.

A documented view of the decisive engineering, manufacturing and validation steps.

01Operating configuration & geometry
02Solid mesh & quality
03Contacts & boundary conditions
04Acceleration & braking
05Global stresses & local diagnosis
06Displacements, reactions & conclusion

Stage 01

Operating configuration & geometry

Representation of the lower platform, stacked upper platform, inclined forks and six transported loads as point masses connected to the structure.

Model data2 platformsStacked configuration

Lower platform calculated and upper platform represented by mass

Model data6 × 137.5 kgTransported payload

825 kg total

Model data12°Maximum inclination

Critical transport configuration

Technical review points

Technical objective
Interfaces
Acceptance criteria

Stackable industrial platform — transport validation — Operating configuration & geometry — view 1

Stackable industrial platform — transport validation — Operating configuration & geometry — view 2

Stage 02

Solid mesh & quality

Hybrid hexahedral and tetrahedral mesh, refined on cylindrical tubes and adapted to the stiffeners, with checks on transitions and element quality.

Model data5 to 10 mmElement size

5 mm on tubes · 10 mm on stiffeners

Model dataHexa + tetraSolid mesh

Geometry-based refinement

Model dataS235JRStructural material

Re = 235 MPa

Technical review points

Technical objective
Interfaces
Acceptance criteria

Stackable industrial platform — transport validation — Solid mesh & quality — view 1

Stackable industrial platform — transport validation — Solid mesh & quality — view 2

Stage 03

Contacts & boundary conditions

Definition of contacts between tubes, stiffeners, forks and masses, followed by restraints representative of platform retention on the truck during transport.

Model dataBonded contactsStructural assemblies

Continuity between welded components

Model dataForks + stopsRetention interfaces

Transport supports and restraints

Technical review points

Load cases
Boundary conditions
Mechanical response
Reviewable results

Stackable industrial platform — transport validation — Contacts & boundary conditions — view 1

Stackable industrial platform — transport validation — Contacts & boundary conditions — view 2

Stackable industrial platform — transport validation — Contacts & boundary conditions — view 3

Stage 04

Acceleration & braking

Two unweighted load cases reproduce the critical cycle phases: tipping under acceleration and retention on the forks during braking, including gravity and transported masses.

Model data5.2 m/s²Case 01 — acceleration

Platform tipping

Model data4.9 m/s²Case 02 — braking

Retention on forks

Model data1 gSelf-weight

Gravity applied to the structure

Technical review points

Technical objective
Interfaces
Acceptance criteria

Stackable industrial platform — transport validation — Acceleration & braking — view 1

Stackable industrial platform — transport validation — Acceleration & braking — view 2

Stage 05

Global stresses & local diagnosis

Comparison of Von Mises fields for both phases. The slight exceedance in the braking case is isolated to a very local area and analysed separately from the global structural response.

Validated164.37 / 235 MPaAcceleration case — S235JR

Maximum / allowable stress

Model data235.93 MPaBraking case — local point

Localised exceedance analysed

Model data235 MPaReference limit

S235JR allowable stress

Technical review points

Technical objective
Interfaces
Acceptance criteria

Stackable industrial platform — transport validation — Global stresses & local diagnosis — view 1

Stackable industrial platform — transport validation — Global stresses & local diagnosis — view 2

Stackable industrial platform — transport validation — Global stresses & local diagnosis — view 3

Stage 06

Displacements, reactions & conclusion

Review of maximum displacements in each phase, extraction of interface reactions and assessment of overall platform strength under the defined operating conditions.

Model data3.62 mmDisplacement — acceleration

Global response for case 01

Model data51.65 mmDisplacement — braking

Global response for case 02

Model dataFx · Fy · FzExtracted reactions

Forces at connections and supports

Technical review points