Stress Analysis and Redesign of Traction Motor Trolley Case Study

Our client, a leading transportation company faced challenges with the performance and durability of their traction motor trolley. The trolley was used to transport heavy loads, and the company noticed that it was experiencing frequent breakdowns, which resulted in significant downtime and maintenance costs. They needed to conduct a stress analysis to identify the root cause of the problem and redesign the trolley to improve its performance.

HRL, as experts in stress analysis and design, was asked to perform Finite Element Analysis (FEA) on both the existing and new trolley designs. FEA is a computer-based simulation technique that helps engineers analyse complex structures by dividing them into smaller, more manageable parts called finite elements. HRL used FEA to simulate various loading conditions on both designs, including static loads, dynamic loads, and thermal loads. The FEA results provided valuable insights into the stress distribution in both designs, which helped identify areas for improvement.

The experts found that the existing design had several areas of high stress concentration, which were causing fatigue failure in critical components such as the frame and wheels. They also found that the new design had several areas where stress concentration was higher than expected due to improper material selection. Based on these findings, the experts recommended several design changes to improve performance and durability. These changes included optimising the frame geometry to reduce stress concentration, selecting appropriate materials for critical components, improving weld quality, and adding reinforcement where necessary.