Load Development

Calculating Real-World Load Development

Finding the right data to analyze real-world loads can be one of the biggest challenges when engineering for linear stress, such as in vehicles or construction equipment. Dynamic structural loading is arguably the most important piece of the analysis puzzle, yet few truly have a contemporary, CAE-driven digital workflow in place.

Most companies follow a time-consuming and expensive process of creating round after round of physical prototypes to gather and analyze data. For each round they make comparative analysis with CAE data. It can take weeks to develop the right load cases, but even then the process is only matching to one or two load gauges, at a single point in time, and generally only for singular worst-case events. The FE model needs load cases that match physically measured strain values from the accumulation of small events, not just the one-time strain. Adaptive offers a unique solution for accurately calculating real-world structural loads for linear motion.

How Load Development Works

Our solution calculates the real-world linear data required to test load development in your FEA software. It works by following a virtuous looping principle that states loads are proportional to displacements; displacements are proportional to strains; and strains are proportional to loads.

Load development gives your engineering team the following capabilities:

  • Transform any structure into its own load transducer;
  • Bring proven algorithms for load development into the digital workflow;
  • Identify the optimal strain gauge locations for an FE model;
  • Correlate an FE model to test data at digital speeds with high accuracy;
  • Reduce or eliminate assumptions;
  • Reduce or eliminate the need for expensive physical testing equipment;
  • Understand why some loads can be detrimental to the final design.

Load development calculations give engineers the ability to do in-depth FEA study to predict fatigue life and true optimization with real-world loads and comprehensive duty cycles. And it does so while significantly increasing understanding of how equipment performs in operation.

The Right Data for a Digital Analysis Workflow

We offer a proven process to reduce the time, complexity, and costs related to acquiring test data and easily translating it into the appropriate FEA and fatigue analysis software inputs. It brings an engineering challenge into the digital workflow, saving time and reducing the need for expensive physical testing equipment and multiple physical prototypes.

Watch this Simulation Video Example of a Cavator

This video is a visualization of a concept dual arm excavator named Cavator simulated with advanced CAE tools. The Cavator mechanical system model is coupled with a granular material model to determine accurate material loads on the Bucket and providing insight into system level performance. ADAMS has been coupled with SIMDEM to provide a leading-edge solution.