Structural analysis for peace of mind: A case study

Manufacturers (both small-business concerns and large-scale production companies) often require custom machines, tools, jigs, and other support systems to enable their processes. Further, employers have an OSHA responsibility to ensure that the work environment is safe. Manufacturing efficiency and employee safety should never be at odds. Is it possible to maximize economic goals and maintain a safe workspace? Absolutely, yes!


Our Specialties

KTM Solutions partners with manufacturing companies needing mechanical solutions such as lift systems, custom machines, engineering analysis, and fixtures. We employ a robust group of mechanical engineers with decades of experience solving manufacturing and material-handling problems. We love new challenges, so they’re always welcome.


We offer structural analysis using both hand calculations and Finite Element Analysis (FEA) to uncover potential flaws and ensure that your designs are safe. Analysis is crucial for the safety of everyone and for the longevity of the product. We’ve found that considering both static and dynamic analysis (whenever a system involves movement) can provide important information for increasing both design life and, even more important, safety.


Do You Even Lift?

It is common for organizations to have great ideas for new or improved products, but an incomplete sense of how to ensure that these products are sized to handle the required load capacities. One particular KTM client has a great reputation as a provider of forklift attachments for unique lifting applications. Even with years of practical experience, our client had limited structural-analysis capacities and involved KTM Solutions early in the design process. Our clients have found that reliable analysis early in the process helps them to avoid frustrating discoveries later in their project development.


The Problem:

Our client needed to develop a unique forklift attachment. This client had a concept in mind and had already developed a preliminary layout. In fact, our client had already shown this concept to their customer for approval. The load path for this system needed to be somewhat complex in order to achieve the load manipulations their customer needed. This required a thorough analysis, which involved strength checks on several complex and expensive components. If undersized, these components could contribute to an unsafe lifting operation or lead to life cycle–costing issues.


KTM Solutions structural evaluation of a heavy lift system

KTM’s Solution and Results:

KTM Solutions developed a comprehensive analysis package, including finite element models and hand calculations, which demonstrated that the original conceptual design would work but that some of the components were significantly undersized. Drawing on the results of this analysis, we developed cost effective solutions that improved the overall design of the lifting system. The end result was an efficient design, ready to provide years of reliable service.



About KTM

KTM Solutions is a US-based mechanical-solutions company. We offer licensed professional-engineering services and turnkey mechanical systems. We develop mechanical systems that keep your production employees safe while improving your manufacturing process flow and efficiency. Our PE-sealed engineering documentation gives an employer peace of mind that their equipment is in compliance with OSHA requirements. Our services are underpinned by proven systems-engineering principles, ensuring successful project management and satisfaction of project goals. Client satisfaction is a key measure of our ISO 9001:2008–compliant quality system.


Let Us Help

Perhaps you have an immediate requirement for mechanical services? Or, maybe you have no needs today, but would like to learn more about KTM Solutions so that you are prepared for the next challenge? If you are interested in learning more, contact us. Our engineers are registered in multiple states and are ready to assist you.