ESI ITI engineering - project examples in the plant and machinery sector

Plant and machinery manufacturers around the world appreciate our engineering knowledge in dynamic system simulations of machines and installations. Whether steady state or dynamic applications – ESI ITI engineers and the SimulationX software help you develop new and innovative plant and machinery concepts.

Holistic plant and machinery optimisation with ESI ITI Engineering

Like in many other industries, fluid technology plays a major role in the plant & machinery sector. Fluid power systems are among the most complex applications: large number of components, highly sophisticated geometries, non-linear behaviour, and varying physical requirements are extremely challenging for engineers. ESI ITI engineers with their broad project experience, profound knowledge of system simulation and excellent skills in using the SimulationX software are preferred partners for accurate holistic analysis and optimisation projects in the plant and machinery sector.

Printing press

Project example 1: Simulation for lower vibrations in collating machines

Our customer is a Germany-based machine manufacturer with more than 1000 employees. The company produces, inter alia, bookbinding machines for the post-printing industry.

Problem definition

Collating machines are used to manufacture reviews, brochures and books with adhesive binding. They are used in post-print finishing lines to gather sheets in a desired order and convey them to the adhesive binder. The collating chain should run at an even speed and without vibrations or jerks to ensure gentle sheet transfer.

Problem solution

ITI engineers developed a custom-tailored simulation model, which allowed to analyse the dynamic properties of collating chains, their drives and tensioning devices. Response-relevant features like irregular movements at the chain inlet (polygon effect), non-linear responses to chain loads and variable-speed drives were taken into account. The engineers found that vibrations at the first natural frequencies of the system could be removed by adding a friction element that locks the tensioning device in position after pre-tensioning of the chain.


The system oscillates with significantly lower amplitudes at a frequency corresponding to the chain inlet frequency at the wheels. This result means a considerable improvement of the system's behaviour. With the help of the ITI engineers and their simulation model it became possible to identify this change potential and to validate and implement these changes.

Bascule bridge

Project example 2: Model-based analysis of the dynamic behaviour of the hydraulic system

Our customer is a global player in fluid power technology with special expertise for large and specialised cylinders. The company employs more than 100 people.

Problem definition

Large steel structures in the water engineering sector are often operated by hydraulic means. This is especially true for bascule bridges, where the confined construction space requires compact actuating systems like hydraulic cylinders. Such bridges are subject to a broad range of loads from counterweight action or wind force, but also in special operating conditions such as emergency stop or power failure. That is the reason why the dynamic behaviour of hydraulic systems is of interest especially for general contractors.

Problem solution

A simulation model was developed for the central part of the opening mechanism – the hydraulic control unit. The model contains both the hydraulics and the kinematics of the bridge as well as the wind or dynamic traffic loads. The SimulationX model of the hydraulic subsystem includes valve behaviour, friction inside the cylinders, elasticities (oil, flexible lines), bearing friction and control unit actions. The ITI engineers were responsible for the entire process. They analysed the customer requirements to identify and define the problem, they developed the system and component models and they finally presented the results to the client and the client's customers.


After extensive testing with different load cases and scenarios, the simulation results were able to demonstrate the desired functions. Developers obtained conclusive information on how to design and dimension the control unit and improve its dynamic response.

Agricultural machinery

Project example 3: Optimisation of front-end loader kinematics

Our customer is a manufacturer of agricultural machinery with more than 100 employees.

Problem definition

Major criteria for front-end loaders in everyday use include e.g. high loading performance, high force and robustness as well as operator comfort. One development goal is to optimise the front-loader kinematics.

Problem solution

IT engineers develop a simulation model specifically geared to the needs of this customer. This model allows quick analysis and evaluation of movements e.g. during shovel contact with the material. It is based on several SimulationX modules such as mechanis (2D), fluid technology and controls.


The project benefits from the broad experience of ITI engineers e.g. in modelling work machines – and includes the transfer of this expertise to the user. The result is a novel loader concept that meets the requirements for an innovative and reliable long-life product. The simulation model makes analysis and optimisation much more efficient and accelerates variant studies.

SimulationX geared to your needs

Whether a novice or an old hand at simulation, you might wish to know that there are several versions of SimulationX – specifically geared to the needs of beginners or experts. Learn more.

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ESI ITI engineers see you through the entire product development process

We are well versed e.g. in building simulation models and assist you in SimulationX and interpretation of the simulation results. No matter what. Contact us.

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