Challenge:

Hydraulic block size was to be minimized and 28 components were to be integrated in the hydraulic block manufactured in steel by additive manufacturing. The challenges of printing a big steel component and fabrication of internal channels must be accounted for.

Solution:

Enmac designed orientation of the components in concept phase. Enmac specified suitable additive manufacturing methods and materials for the application. Additively manufactured hydraulic block was designed to fulfill the requirements. The structure was checked with FEA against pressure loads.

Result:

Light and compact 3D-printed hydraulic block. Manufacturing cost was minimized by means of design. In addition, a 3D-printed cover was designed and manufactured according to customer’s wishes to cover the hydraulic block for presentation purposes.

Challenge:

A cornerblock in rack chassis has complex geometry and there are several machined corner blocks in the device. Corner blocks manufactured by machining have a long delivery time that do not fit the schedule of the project.

Solution:

Enmac applied topology optimization to the load bearing corner block and designed the block to be manufactured by additive manufacturing / SLM (Selective Laser Melting). Necessary post-processing was considered in design to minimize manufacturing cost and delivery time.

Result:

By utilizing topology optimization a cost-effective corner block was manufactured quickly. Corner block weighs 55% less and delivery time is 70% shorter.

Challenge:

Customer´s slurry equipment needed to be renewed. In the process and in the narrow process rooms, there were items where better solutions were needed when replacing the equipment.

Solution:

Equipment was placed in an existing space so that work would be facilitated and the blockage problems in the slurry process would be reduced.

Result:

Due to the new equipment placement, the working space improved and the bottlenecks causing blockage of the slurry process were broaden out.

Challenge:

The customer modernized the equipment of the carton plant’s mass section. Placement of new equipment and piping planning in tight spaces had to be made within a tight schedule.

Solution:

The factory environment was measured and modeled as accurately as possible. Equipment placement and pipeline design were implemented taking into account the requirements and usability of the process.

Result:

Customer got a more efficient process with a fast schedule.

Challenge:

Customer´s glue gun had a single, expensive nozzle made of stainless steel. The part is small and machined geometry is complex. Customer wanted the nozzle to be redesigned.

Solution:

Enmac redesigned the nozzle to be manufactured by additive manufacturing / SLM. The top design priorities were nozzle surface quality and small manufacturing cost. Minimizing post-processing and maximizing manufacturing accuracy was considered in design.

Result:

Depending on the production volume, the manufacturing cost of additively manufactured nozzle was reduced by 63-77%. Additively manufactured SLM nozzle is compatible as a spare part.

Challenge:

The customer needed the equipment to heat treat their own product. The starting point was the temperature at which the product had to be heated for a moment.

Solution:

Enmac performed a heat transfer analysis and design, which defined the process and  then the pressure vessel was manufactured. Enmac supplied the approved pressure vessel and documentation to the customer. Enmac also provided documents for approval of the equipment.

Challenge:

Customer wanted to create a new logstacker model that would revolutionize current market 

Solution:

Through Enmac’s concept design a new asymmetric T-frame construction was implemented. New configuration enabled a totally new modular design

Result:

A machine that utilizes hybrid technology, digital hydraulics, lightweight construction and new design with affordable costs 

Challenge:

There was a need for a standard-size laser module.

Solution:

Enmac designed the laser module casing as well as the internal mechanical parts and fibre webs.

Outcome:

A standard-size unit that is easy to manufacture and visually attractive.

Challenge:

Development of a glass processing line that produces precisely curved mirrors for solar power use in a rapid cycle.

Solution:

In cooperation with the customer, Enmac developed a modular bending line and took care of the documentation of product information. Both the design and documentation work was carried out online via a remote connection directly into the customer’s database. 

Outcome:

An energy-saving glass processing line that utilizes heat recovery and produces curved glass with a precise focal point at low production costs.

Challenge:

Designing of a wind turbine sub-assembly and product development of tools suitable for assembly.

Solution:

Enmac developed an assembly method and prepared plans for the required tools and lifting equipment.

Outcome:

A wind turbine assembly station based on Enmac’s documentation as well as lifting equipment and special tools suitable for assembly in compliance with the relevant requirements and standards.

Challenge:

There was a need to develop a device for the spent nuclear fuel repository that would enable installing compressed clay blocks in the deposition tunnels deep underground safely and at the required speed. In addition to installation precision, quality control and safety, the design had to consider the repository’s location approx. 400 metres below ground, the environmental conditions and limited space in the tunnel as well as the possibility of changes, for example, in the blocks’ backfill patterns. 

Solution:

Enmac developed a processing method and a related device concept that takes into consideration the criteria affecting product development, i.e. the planned size of the backfill blocks, the speed of the filling process and the dimensions and structure of the tunnel. The device created as a result of product development is almost entirely electromechanical. In addition to the design, Enmac will supervise the manufacturing of the prototype and take part in the testing of the prototype.

Outcome:

A prototype of a mobile controlled and almost entirely electromechanical device. The device, which will be built on the basis of the prototype, will be introduced in the future when the spent nuclear fuel from nuclear power plants is placed inside the bedrock in final disposal canisters. 

Challenge:

Structural analysis was needed to design and manufacture an exit gas scrubber and its channels.

Solution:

Enmac carried out the structural analysis and reporting.  The amount of materials needed for the final product as well as material thicknesses were optimized with the help of FEM calculations.

Outcome:

The FEM calculations and reporting enabled the customer to manufacture a safer exit gas scrubber cost-effectively while optimizing the use of materials. 

Challenge:

There was a need to further develop a brush unit designed for oil spills and to reduce its weight by 30%.

Solution:

Enmac designed the unit by utilizing high-strength steel and structural analysis and ensured that the desired goal was achieved in cooperation with skilled manufacturing partners.

Outcome:

The mass of the brush unit was reduced by 35%.

Challenge:

The aim was to modernize a drilling platform used for compacting the bottom of water areas and to improve work safety.

Solution:

Enmac carried out the technical design and structural analysis for the platform’s drilling unit as well as the documentation required for the implementation of the project.

Outcome:

A safer drilling unit with improved performance.

Challenge:

The product development of a bioethanol plant that utilizes local biowaste so that the plant can be duplicated in a cost-effective manner.

Solution:

Enmac took care of the plant and mechanical design in its entirety based on the customer’s process specification.

Outcome:

A modular plant structure with an ethanol production capacity that exceeded the customer’s goals. This plant has been duplicated and there are several in operation in Finland. 

Challenge:

A need for a set of cooling machines.

Solution:

Enmac designed a set of cooling machines that use seawater and in which the seawater pipelines are made of plastic and the closed-cycle cooling system is made of acid-resistant steel.

Outcome:

This solution produced costs savings as the expensive freshwater used in cooling was replaced with saltwater.

Challenge:

There was a need for an enrichment plant and reducing the time of installation work done on site. 

Solution:

Enmac carried out the plant design project, designing modules that can be equipped at the workshop.

Outcome:

An enrichment plant that can be installed within a short period of time. Its modules are lifted in place on site and the pipes’ flange joints are connected where modules meet. 

Challenge:

Improvement and productization of a biogas power plant prototype placed in a container and built almost entirely without manufacturing drawings.

Solution:

Enmac modelled all parts of the prototype, prepared manufacturing and isometric drawings and improved the framework to make it more suitable for serial production.

Outcome:

A precisely modelled biogas power plant container that is suitable for serial production and that can be equipped at the factory so that it is immediately ready for use.

Challenge:

Transportation of a 250-tonne wind turbine on land and at sea.

Solution:

Enmac utilized high strength steel and a box structure to develop the lightest possible transportation platform for a wind turbine.

Outcome:

The lightest possible wind turbine transportation base that meets the size, weight and strength requirements.

Challenge:

Equipment for lifting and turning a wind turbine’s main axis in connection with assembly.

Solution:

Enmac specified the lifting and turning events and designed the required equipment and also took care of the CE documentation for the equipment.

Outcome:

Lightweight box-type lifting and turning equipment for a wind turbine’s main axis.

Challenge:

There was a need for a quick automatic testing system for butterfly valves.

Solution:

Enmac designed, in cooperation with the customer’s personnel, a testing station with a fully automatic work cycle.

Outcome:

The testing of butterfly valves was automated, which led to shorter turnaround times and improved safety of valves.

Challenge:

The aim was to develop a cost-effective small gear suitable for serial production.

Solution:

Enmac designed a small gear with the best possible level of cost-effectiveness using the Design-to-cost method. The design process took into consideration the desired cost price as well as other required features including torque and service life.

Outcome:

A cost-effective small gear suitable for serial production. The selected manufacturing methods enabled the creation of a structure that was actually below the customer’s cost requirements.

Challenge:

A small and light electric drive for a sailboat.

Solution:

Enmac planned the dimensions and design of the saildrive shafts and bearings. This work was done in accordance with the finite service life theory in cooperation with a gear wheel manufacturer. The casting frame of the drive was designed on the basis of the designer’s sketch.

Outcome:

The service life target set for the saildrive was achieved and the power transfer components were fitted into a very small space in terms of cross-section.

Challenge:

There was a need for a gear casting frame with parts that are suitable for serial production. The aim was to keep the manufacturing costs as low as possible.

Solution:

Enmac took care of the casting design, structural analysis and consultation with the foundry.

Outcome:

Stronger and more economical frame parts that are well suited for serial production.

Challenge:

There was a need for a hybrid bus transfer box that would connect an electric motor generator and diesel engine to the vehicle’s transmission.

Solution:

Enmac designed the shafts, bearings, casting frame and other components based on the mesh loads received from the gear wheel manufacturer. The dimensions of all parts were designed in accordance with finite service life theory.

Outcome:

The service life target was achieved thanks to the sensible dimensions and design of the parts. The weight of the gear was reduced much more than what the target had been.

Challenge:

There was a need for plant and process design in order to store coal tar pitch. It had to be taken into consideration as part of the design process that coal tar pitch always has to be kept at a temperature of over 180 °C in order for it to remain fluid.

Solution:

Enmac designed the new tanks, pipelines and train loading areas in accordance with the requirements for demanding Nordic port conditions.

Outcome:

The storage and loading of coal tar pitch is possible while keeping the substance fluid, all year round. The design process enhanced the level of ergonomics for those working with coal tar pitch. It also improved the safety of the area and made it easier to carry out future repairs and extensions to the tanks and pipelines.

Challenge:

The customer needed a design partner for the ITER project to manufacture the Divertor Cassette Body, a part to be placed inside of the fusion reactor chamber of the world’s first fusion reactor. The large stainless steel part will be part of a structure that minimizes the amount of impurities in the fusion plasma and recovers some of the plasma’s thermal energy.

Solution:

Enmac planned the manufacturing of the Divertor Cassette Body structure. In addition, Enmac designed the equipment needed to handle the structure as well as the vacuum vessel needed during the testing phase.

Outcome:

The customer acquired a documented manufacturing plan for the DCB structure, assembly parts and vacuum vessel in compliance with the world’s strictest quality standards and quality management procedures.

Challenge:

There was a need for a project manager to oversee the replacement of non-return valves as part of a nuclear power plant’s turbine modernization. It was essential to stick to the schedule because the costs of production losses caused by a delayed start-up may in one day exceed the total costs of the actual maintenance project. 

Solution:

Enmac provided a project manager who ensured that the replacement of the non-return valves, which are located in the plant’s turbines and which are up to one metre in diameter, progressed smoothly. Project management followed the extremely high quality standards that apply to nuclear power plant projects.

Outcome:

Thanks to the high-quality project management, the project was carried out as planned and completed right on time because the project was controlled effectively during the different phases and problems were addressed quickly and proactively. The objectives set during the planning phase were achieved and budgeting was accurate.

Challenge:

There was a need for a modular lifting device for lifting and turning a 100-tonne wind turbine generator during the assembly phase.

Solution:

In addition to the mechanical design, Enmac took care of structural analyses in accordance with the standards, completed CE documentation as well as manufacturing of the device on behalf of the customer.

Outcome:

Delivery of a turnkey lifting and turning device within a short time frame.

Challenge:

There was a need for a lifting device that would enable the lifting of a 250-tonne wind turbine up to a height of 125 metres.

Solution:

Enmac designed the device using a plate structure that evens out the loads. Structural analyses and CE documentation were carried out in accordance with the lifting device standard (SFS-EN 13155). 

Outcome:

A lifting device that meets very high standards.