Finite element analysis methodology for transportation-induced stress mitigation in electrical distribution network component

Manufactured electrical distribution units must be transported from assembly site to customer site through roadways, airways, or seaways, which can induce vibration-related stress in the panels. These vibrations are often random in nature, necessitating robust structural design to withstand the rigors during transportation. This study focuses on evaluation of a Power Distribution Unit that requires certification for environmental conditions, here, for road transportation. This paper explores the Finite Element Analysis (FEA) methodology which is used to evaluate structural integrity of this Electrical Distribution Network component and to suggest improvements in the zones of high stress. A simulation methodology was developed and followed, using the input of random vibration characterized by Gaussian distribution of amplitudes. The unit was structurally assessed using FEA techniques to determine the deformations, equivalent stress and strain on the system’s structural members. The use of simulation in this study enabled a comprehensive analysis of the unit’s structural integrity under realistic transportation conditions without the need for extensive physical prototypes. This approach significantly reduces development time and costs while allowing for iterative design improvements, leading to improved safety and robust characteristics of the design.