Application of the Finite Element Method in the Structural Maintenance Planning of a Ship Unloader

Resumo

The Finite Element Method (FEM) is widely used in industry to support product development, offering significant benefits such as the reduction of physical prototypes, identification of structural risks, and rapid evaluation of improvements in a computational environment. However, the advantages of FEM extend far beyond the initial development stages. The method is increasingly being applied in later phases of the asset's lifecycle, particularly in the operation and maintenance stages, where predictive insights and virtual validations can support decision making and reduce risks associated with field activities. This study focuses on the application of FEM in the context of structural maintenance planning for a large-scale port equipment: a ship unloader. Specifically, it addresses the engineering analysis conducted during the full jacking procedure—an essential maintenance operation required for inspecting and servicing the bogies and wheelsets of the machine. A complete computational model of the asset was developed in Ansys software. To enhance accuracy in critical zones, submodeling techniques were applied, allowing for refined local stress and deformation evaluations. The integrated modeling strategy enabled the development of a detailed and safe maintenance plan, offering enhanced reliability during field execution. Additionally, the virtual environment allowed for the simulation and comparison of multiple operational scenarios prior to implementation. This process supported the selection of the most appropriate configuration and the definition of control variables, ensuring a safer and more predictable maintenance operation.