GUANGDONG XIEDA INTELLIGENT EQUIPMENT CO., LTD.
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Application of Finite Element Analysis in Warehouse Rack Design
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Publish Time:
2025-07-19
The application of finite element analysis in the design of warehouse racking is mainly reflected in the following aspects:
Structural optimization and safety assessment
- Load-bearing capacity analysis: By simulating the stress conditions under different loads (such as cargo weight, stacker impact, wind load, snow load, etc.), the load-bearing capacity and stability of the rack are evaluated to ensure the safety of the rack during long-term use.
- Seismic performance assessment: For earthquake-prone areas, the dynamic response of the rack under seismic action is simulated to verify its seismic performance and propose reinforcement or optimization schemes.
- Complex structural analysis: For special structures such as integrated warehouse racks (racks combined with warehouse structures), cantilever racks, and multi-drive-in racks, multi-directional loads and complex stress are simulated to ensure overall safety.
Model establishment and simplification
- Structural simplification: The rack is abstracted into a three-dimensional spatial frame model, and local or overall modeling is selected according to the regularity. For example, for ordinary beam racks, no less than 5 columns should be modeled, while large integrated warehouse racks need to be simplified into an overall planar model in two directions.
- Element and node simplification: Distinguish between rod elements (hinged, axial force) and beam elements (bearing bending moment) to reduce the amount of calculation; handle key connection methods such as foot nodes and beam-column nodes (hinged, rigid, or semi-rigid).
- Equivalent substitution of combined components: For complex combined components in ultra-large structures, a single equivalent component is used to replace them, improving modeling efficiency.
Load analysis and combination
- Load types:
- Static load: Rack self-weight, cargo load (point load or uniformly distributed load).
- Dynamic load: Stacker operation impact, cargo placement impact, etc.
- Hypothetical load: Added according to the code (such as 1/250 or 1% of the cargo weight).
- Environmental load: Seismic action (modal decomposition response spectrum method), wind load, snow load (can be ignored for indoor racks).
- Load combination: Combine multiple loads according to local codes to check the safety of the rack under the most unfavorable conditions.
Result analysis and design improvement
- Stress and displacement analysis: Obtain the stress distribution and deformation of each component of the rack through the solver to identify high-stress areas or weak nodes.
- Structural verification and optimization: Based on the analysis results, adjust material specifications, strengthen local structures (such as adding tie rods or supports), or optimize connection methods to improve performance.
- Efficiency improvement: Simplifying the model and reasonably dividing the mesh (such as adjusting the density according to the analysis requirements) can significantly improve the calculation efficiency and shorten the design cycle.
Practical application cases
- High-bay rack: Simulate high-bay loads to ensure structural stability.
- Earthquake zone rack: Use the response spectrum method to analyze the seismic performance and verify the improvement measures.
- High-bay warehouse rack: Use software such as ANSYS for three-dimensional analysis to optimize the structure and reduce material waste.
Summary
Finite element analysis accurately simulates the mechanical behavior of racks, helping designers verify schemes in a virtual environment, reducing physical testing costs, and improving structural reliability and economy. Its core value lies in balancing safety and material utilization, and it is indispensable in complex working conditions (such as earthquakes and high-density storage).
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