STRUCTURAL AND FUNCTIONAL OPTIMIZATION OF A CONTROL STATION HOUSING

Henrik HALMOSI, Dan LEORDEAN, Tudor SUHAN, Mircea Aurelian RUSU

Abstract


This paper presents the constructive-functional optimization of a control station housing, with the objective of improving its mechanical performance and cost-efficiency through modern simulation techniques. The enclosure is designed to ensure explosion resistance and prevent the ingress of dust and liquids, withstanding internal pressures up to 10 bar. The methodology involved an initial assessment of the existing model, definition of working conditions, and the development of 3D models followed by static structural analyses. Based on the simulation results, design modifications were progressively implemented, including the addition of central lugs and adjustments to wall thickness, joint radii, and rib geometry. After conducting 44 static analyses, the optimized solution (Variant 6) demonstrated a significant reduction in equivalent stress from 374 MPa to 209 MPa, below the material yield strength of 220 MPa. Additionally, the weight was reduced by approximately 36%, from 2921.72 g to 1867.03 g. The final design ensures structural integrity under operational conditions while offering material and cost savings.


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References


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