Structural qualification of a 29.5-tonne containerised inverter station — 500 MW PV plant
49+ load sub-cases across wind, snow, ice, and seismic combinations. Governing case: seismic at 225.8 MPa / 96% utilization. All columns in net compression — no uplift connection required.
Windshield impact reliability — 6-ply laminate, three load cases
JH-2 + XFEM + Prony PVB + CZM. HIC(d) = 834, zero fragments detached, 22% mass-efficient PVB optimum at 0.76 mm.
EV battery coolant pressure drop — 30% reduction pre-tooling
k-ω SST on 7.8M cells. T-junction manifold (31%) + bends (28%) identified as dominant losses. Four geometry changes restore pump power budget.
Johnson–Cook calibration of Inconel 625 — VFM + DIC, 3 specimens
Full-field inverse identification of all 5 JC parameters simultaneously. 4.2% peak force error vs 11% for classical methods. LS-DYNA/Abaqus card delivered.
Transient CHT finds the failure mode steady-state missed
A 12-second startup transient drove peak stress at a cooling-channel fillet nobody had flagged. One geometry change moved predicted life from 8,200 to 24,000 cycles.
Moldflow → Ansys fiber orientation catches weld-line failure pre-DVP
Isotropic analysis predicted 2× margin. Process-aware fiber orientation showed 58% strength drop at the weld line — exactly where the prototype cracked.