Design and Structural Analysis of Diesel Genset Heavy Canopy Frame using SOLIDWORKS and Finite Element Analysis

This study investigates the design, modelling, and structural optimization of a heavy duty diesel genset canopy frame engineered to sustain a maximum load of 25 tonnes under industrial operating conditions. Traditional canopy frames often suffer from excessive self weight, poor material utilization, and susceptibility to localized stress concentrations, leading to premature structural failures or increased manufacturing costs. To overcome these limitations, a rigorous computer aided design CAD and finite element analysis FEA workflow was established using SOLIDWORKS, enabling precise geometry creation, load application, and iterative performance refinement. The canopy frame was constructed using standard rectangular and tubular steel sections connected through full welded joints to ensure adequate load transfer and structural integrity. Material properties for mild steel were assigned as per standard engineering data, and boundary conditions were selected to accurately reflect real life mounting and operational scenarios. Static structural analysis was performed under the worst case loading condition of 25 tonnes, including considerations for vertical loads, potential load eccentricity, and frame rigidity. Initial simulation results revealed areas of elevated stress and excessive deflection, prompting geometric modifications such as reinforcement placements, cross member redistribution, and optimization of section sizes. The optimized design demonstrated substantial improvements in stress distribution, reduced peak stresses, increased global stiffness, and minimized deflection within acceptable engineering limits. Additionally, the optimized configuration achieved a favorable balance between structural performance and material usage, reducing overall weight while maintaining safety margins. The study concludes that a simulation driven design approach significantly enhances reliability, manufacturability, and cost effectiveness compared to traditional empirical design methods. The final canopy frame design is robust, production ready, and suitable for deployment in heavy duty industrial, construction, and power generation environments where high load bearing capability and structural durability are essential. Mr. Govind Rajabhau Bhosle | Dr. B. S. Allurkar | Prof. S. M. Nagure "Design & Structural Analysis of Diesel Genset Heavy Canopy Frame using SOLIDWORKS and Finite Element Analysis" Published in International Journal of Trend in Scientific Research and Development (ijtsrd), ISSN: 2456-6470, Volume-9 | Issue-6 , December 2025, URL: https://www.ijtsrd.com/papers/ijtsrd98806.pdf Paper URL: https://www.ijtsrd.com/engineering/manufacturing-engineering/98806/design-and-structural-analysis-of-diesel-genset-heavy-canopy-frame-using-solidworks-and-finite-element-analysis/mr-govind-rajabhau-bhosle