Proficiency in Failure Analysis and Field Testing: With extensive experience in failure analysis and field testing, POW brings valuable insights to the design and construction of reliable solutions for clients. This expertise allows us to identify potential weaknesses and design robust structures and equipment that prioritize safety, reliability, and operation.

Advanced Analysis and Engineering Capabilities: POW’s advanced analysis and engineering capabilities enable us to tackle complex design-build projects with confidence. We leverage our expertise to develop innovative and customized solutions, tailored to the specific requirements of each project. This approach ensures that our designs meet or exceed industry standards, leading to successful, reliable, and predictable project outcomes.

Turnkey Delivery and Project Management: As a turnkey solutions provider, POW offers comprehensive project management from concept to completion. Our multi-disciplined team seamlessly integrates various project deliverables in-house, streamlining the design-build process. This cohesive approach ensures efficient communication, collaboration, and timely project execution.

Expertise in Dynamic Loaded and Purpose-Built Structures: POW has a proven track record of delivering reliable engineered solutions for dynamically loaded and purpose-built structures and equipment. We understand the unique challenges associated with such projects and have the technical know-how to design structures and equipment that can withstand demanding operational conditions while meeting safety and performance requirements.

In summary, POW’s extensive experience in failure analysis and field testing, advanced analysis and engineering capabilities, turnkey delivery approach, and expertise in dynamically loaded and purpose-built structures position us as a reliable partner for successful new design-build projects. Our focus on safety, reliability, and operation ensures that clients receive tailored solutions that meet their specific needs.

Overview: POW was contracted to provide a comprehensive turnkey solution for the design, fabrication, and installation of all components for two Boundary Layer Wind Tunnels. The project encompassed multi-disciplinary design-build and turnkey integration, including the implementation of PLC-controlled testing and safety systems, servo rotating/elevating test turntables, servo adjusting flaps and spires, servo-controlled fan testing system, CLT and steel structure, precision formed turning vanes, precision formed contraction/expansions, acoustic baffles, heat exchanger, and civil elements.

Challenges: The project presented several challenges that required specialized expertise. A highly skilled team with experience in wind engineering, PLC systems, structural steel fabrication, precision engineering, and mechanical design was essential. Close collaboration with RWDI and Aiolos was necessary to meet the design specifications, adhere to project timelines, and manage the allocated budget effectively.

Solutions: POW’s team of experts approached the project with meticulous planning and advanced technologies to overcome the challenges and deliver a successful outcome.

• Comprehensive Project Planning: Working closely with RWDI and Aiolos, POW developed a detailed project plan that included a comprehensive timeline, budget, and clear milestones. This plan served as a roadmap for the entire project, ensuring efficient coordination and management of all aspects.
• Advanced 3D Modeling and Simulation: Utilizing the latest technology and software, POW created detailed 3D models and conducted simulations of the wind tunnels. This allowed them to visualize the integration of various components, ensuring a perfect fit and optimal functionality. The simulations provided insights into the airflow patterns, enabling design refinements for enhanced performance.
• PLC-Controlled Testing and Safety System: POW’s team designed a PLC-controlled testing and safety system to monitor and regulate all aspects of the wind tunnels during testing. This system ensured the highest level of safety, precise control, and reliable data acquisition, contributing to the overall success of the project.
• Precision Engineering and CNC Machining: To ensure the servo rotating/elevating test turntables and servo adjusting flaps and spires met stringent standards, POW’s team employed precision engineering techniques. CNC machining was utilized to fabricate components with exceptional accuracy and quality, ensuring reliable and precise operation of the wind tunnels.
• CAD to CMM and Virtual Point Clouds: To guarantee fabrication and installation met the required tolerances, POW utilized CAD to CMM (Coordinate Measuring Machine) technology and Virtual Point Clouds. These tools enabled precise measurements and ensured fabrication and installation accuracy within tolerances as small as 2 thousandths of an inch.

Results: POW successfully completed the project within the specified timelines and budget. Both wind tunnels were fully operational and functioned as intended, providing RWDI with essential testing capabilities for a wide range of products and designs. Due to the success of the initial wind tunnels, POW has been contracted to build two additional wind tunnels, further establishing their expertise in the field.

Introduction: In this case study, POW highlights our recent collaboration with Northbank Civil and Marine and Timberland Equipment for the design and supply of the structural and mechanical system (excluding hoist) for a 25 T Gantry Crane at Dexter Dam. The project was performed for the United States Army Corps of Engineers. POW’s role involved the comprehensive design, analysis, simulations, calculations, fabrication, and certifications of the structural and mechanical system, with a focus on adherence to regulations, progress reporting, and operating within the guidelines of the “Buy America Act.”

Project Scope and Challenges:

Collaborative Efforts: POW joined forces with Northbank Civil and Marine and Timberland Equipment to ensure a seamless execution of the project. The collaboration allowed us to leverage each party’s expertise and deliver a comprehensive solution that met the client’s requirements.

Structural Design, Analysis, and Simulation: As POW, we took charge of the structural design, advanced analysis, and simulations for the gantry crane. Our team meticulously designed the main gantry structure, trolley, beams, and supports, ensuring compliance with the specific requirements of Dexter Dam. Through rigorous analysis and simulations, we optimized the design for performance, safety, and longevity.

Mechanical System Design: In addition to the structural components, POW was responsible for designing the mechanical system of the gantry crane, excluding the hoists supplied by Timberland Equipment. This encompassed selecting and sizing motors, gears, brakes, and other essential components. Our goal was to ensure the crane’s load capacity, movement, and control mechanisms aligned with the operational needs.

Fabrication, Inspection, and Certification: POW managed the fabrication process, adhering to industry standards and conducting strict quality control measures. Stringent inspections were carried out to ensure compliance with safety regulations, and necessary certifications were obtained to guarantee the fitness of the components for operation.

Ultrasonic Impact Treatment: To enhance the longevity and durability of critical structural elements, POW implemented Ultrasonic Impact Treatment (UIT). This technique was applied to the gantry crane’s structural components, increasing their resistance to fatigue and wear, thereby ensuring a reliable and long-lasting system.

Fit-Up and Tolerances Adherence: At POW, we assembled the gantry crane’s structure at our facility to ensure precise fit-up and adherence to tolerances. This approach allowed for thorough testing and verification of the crane’s structure, ensuring its readiness for installation at Dexter Dam.

Compliance with Regulations and “Buy America Act”: Working with the Corps required diligent attention to detail, navigating through various certifications and compliance requirements. POW ensured that all calculations and designs adhered to regulations and received the necessary approvals.

Conclusion: POW successfully completed the design, analysis, simulations, calculations, fabrication, and certifications of the structural and mechanical system (excluding hoist) for the 25 T Gantry Crane at Dexter Dam. Through close collaboration with Northbank Civil and Marine and Timberland Equipment, we delivered a comprehensive solution that met the specific requirements of the USACE.

Project Overview: POW was entrusted with a challenging high-profile project for an Indiana-based automotive manufacturer. If proven successfully, this process would be implemented throughout their N.A facilities. The project required the design, build, and installation of a comprehensive solution for selecting, picking, and installing moon roof/panel roof trim options (9) for three vehicle models on the same production line. Our responsibilities included mechanical, structural, and controls design-build services, turnkey installation, and commissioning.

Project Scope: To meet the project requirements, we shipped three full-sized flatbed trucks to the client’s facility in Indiana. Our scope of work encompassed the design and implementation of key equipment such as the Automated Pick Tool, Install Tool, and Backup Tool. Additionally, we provided Mod Racks, Platforms, Overhead System, PLCs, and other components essential for a successful solution.

Challenges and Solutions: Leveraging our increased in-house capabilities, we utilized our mechanical, structural, welding, materials, and controls knowledge to develop an automated and reliable solution for selecting, picking, and installing trim options. Overcoming challenges related to integration and coordination, we conducted site interference detections as well as a planed order of sequential installation, the shipping was arranged to match installation on site due to limited lay-down space.

Benefits and Results: Our turnkey solution delivered significant benefits to the client. By implementing our automated pick, place, and install solution, we streamlined the client’s operations and improved production efficiency. Our versatile design allowed for the selection and installation of various trim options across multiple vehicle models, enhancing the flexibility of their production process. The robust controls and automation technologies ensured safe, precise and consistent trim installation, minimizing errors and rework.

Conclusion: POW  successfully executed a complex project, delivering a turnkey solution for the moon roof/panel roof trim selection and installation needs of our Indiana-based automotive manufacturer client. Our in-house capabilities and expertise in engineering and automation enabled us to seamlessly integrate various components, resulting in improved production efficiency, reliability, and customer satisfaction. This project further established our reputation as a reliable and versatile partner for projects requiring multiple design-build disciplines. After a successful completion of the system, the client has now asked for additional copies for other locations.

POW was tasked with performing the structural and mechanical design and supply of the overhead support system for a major expansion project at a Truck Assembly Plant in Tijuana, Baja California, Mexico. The project was completed for our client, Daifuku America, and involved designing a robust overhead support system to handle the primary loads from a conveyor system moving 2000kg trucks above the production areas of the plant.

Challenges and Considerations:

As-Built Conditions and Existing Building: Working with existing structures and brownfield conditions required careful consideration. We utilized 3D scanning software and CAD-to-BIM integration to create a virtual environment that accurately represented the dimensions of the site, ensuring a precise design.

Seismic and Fatigue Design Criteria: Operating in a Category D seismic zone, we had to account for substantial seismic and fatigue-related design criteria. Our design underwent rigorous lateral load testing and optimization to ensure reliability during earthquakes.

Bracing Design: We designed bracing off the existing structure to accommodate large high-cycle vehicle lifts and transfers that operate above an active automotive manufacturing floor. The design had to adhere to stringent safety and reliability requirements.

JIT Fabrication and Delivery: To optimize material handling costs and available layout space on-site, we coordinated closely with the site and fabricators to ensure just-in-time (JIT) fabrication and delivery of parts. Effective communication among all stakeholders was crucial to maintain uninterrupted construction and installation progress.

3D Point Cloud and CAD Models: We utilized 3D point cloud and integrated CAD models to virtually check the fit-up of fabricated assemblies and identify potential interferences with the existing structure. This approach ensured the accuracy and compatibility of fabricated assemblies.

Budget and Project Management: To effectively manage the project budget, we established fixed pricing agreements with the client and sub-consultants. Key project management strategies included:

• Weekly meetings with the client, trades, designers, and fabricators to ensure project milestones were being met.
• Coordination with site progress to provide JIT delivery of fabricated assemblies, involving the transportation of 60 truckloads of steel (45,000 lbs/load) from South-Western Ontario, Canada to Tijuana, Mexico.
• Constantly adjusting the fabrication schedule and delegations between shops to align with installation priorities, progress, and changes.

Key Takeaway:  POW was specifically requested by the OEM to be the preferred supplier of critical lifting and structural reliant structures. The structure was required to transport 2000 kg vehicles above automotive production workers in an area that is prone to earthquakes. The overhead vehicle conveyance system experiences millions of repetitive loading/unloading cycles.

Project Overview: The Taipei 101 is a 101-story skyscraper located in Taipei, Taiwan, known for its height and unique architecture. Due to its height, the building is vulnerable to wind and seismic forces. To address this, the building features a massive tuned mass damper (TMD) system that helps to reduce the effects of these forces.

Responsibility: Pow was involved in the project by assisting the Canadian engineering firm RWDI, with the structural connection design and fatigue modeling of the steel structure that connects the 1,000,000 lbs damper to Taipei 101’s building structure.

Challenges/Solutions:

• Structural Modeling: Pow’s primary task was to create a structural model of the steel structure that connects the TMD to the building. The model needed to take into account the forces exerted on the structure due to the damper’s weight and motion. The team used advanced software and analytical tools to create an accurate structural model.
• Fatigue Analysis: In addition to the structural modeling, Pow also performed a fatigue analysis of the steel structure. Due to the building’s height and unique design, the damper is subject to high-frequency oscillations, which can cause fatigue in the steel structure over time. Pow used advanced analytical tools to accurately model the fatigue life of the steel structure and ensure that it would withstand the forces exerted on it over the long term.

Results: Pow’s work was critical to the success of the TMD system, which has been credited with improving the quality of life for residents and saving the building from damage during typhoons and earthquakes. The team’s accurate modeling and fatigue analysis ensured that the steel structure connecting the damper to the building could withstand the forces exerted on it over the long term. Today, the Taipei 101 is recognized as one of the most innovative and resilient buildings in the world, due in no small part to the TMD system.

Project Overview: POW collaborated with Daifuku America and FM Sylvan to provide a new Assembly Shop for a Michigan Automotive OEM, and also upgraded an existing production line located nearby. POW was responsible for providing all the structural supports, screen guarding, drive decks, rail supports, header grid, inclines and declines while supporting the Daifuku designed steel.

Responsibility: POW provided the design, detailing, fabrication, and delivery of support steel and associated hardware to site in a sequential method that was discussed with the installers. POW was also responsible for finding potential interferences through scanning of the existing conditions and working directly with the OEM and DAC to resolve these solutions from an engineering perspective.

Considerations: POW used 3D and 2D reference files and 3D point cloud of the conveyor system to support the rails, drives, feeders, etc. The company also used Navisworks to create a collaborative model and designed the steelwork through Tekla Structures

Challenges and Solutions:

• One of the significant challenges faced by POW was incomplete layout while designing support steel. To overcome this issue, the company reworked rail layouts with scanned site conditions and proposed solutions to interferences to push the schedule along and meet the project requirements.
• POW also faced a quick turnaround requirement, which was addressed by working directly with the fabrication shops and the installers to balance design, installation, and fabrication constraints to optimize efficiency of all three.
• The existing steel posed another challenge for POW, and the company used 3D scans to eliminate interferences by avoiding bridging between trusses, HVAC, conduit, etc. when required and did not impact structural integrity/cleanliness of design.
• Organization of fabricated steel was also a critical aspect of the project, and POW arranged trucking and completed a Bill of Materials (BOM) referring to every support member sent to the site, which truck it belonged to, # of similar locations, and their approximate location through the plant. The company also provided support steel and naming conventions in a manner that if misplaced and found on site would indicate the area of the plant that it belonged to.

Results: POW delivered over 7,000 assemblies to the site, approximately 1,250 tons of steel over 6 months, with 6 months to design. The project was completed within the timeframe and budget constraints, meeting all the requirements of the Michigan Automotive OEM.