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Those both sound like kinds of ways the real maximum load could be higher than what you've called your maximum load


Only as long as your "real maximum load" != "announced maximum load". For the type of stupidity mitigation I mentioned, you want the real maximum load to be greater than the max load you announce to the customer/users. For mitigating cascade failures, you want the real maximum load to be greater than the maximum load value meant to be used internally by people designing other components in the system (though here, a smarter way would be to do a system-wide analysis of load flows to prevent cascade failures under user stupidity; however, here we're rapidly approaching the point at which I just talk out of my ass, having no real expertise on the topic).


There's also some benefit in throwing a moderate safety factor on something if it doesn't actually compromise the intended form or function of the component, just as future insurance. For example, if you design a bit of equipment to take a certain load, but there's no size or mass constraints on it, and you can throw a 1.5x safety factor on, then it's not necessarily a bad thing. Even if your 'true' load as measured over several years of service only ends up being 1.2x, then the extra 0.3 or so can come in useful if a future engineer has to make modifications to the function of the device, or if they are asked to evaluate a life extension, etc.

In less words, I'm eternally thankful that I work in an era where much of the older equipment I used was designed in an era of slide rule. This means there's a bit of extra 'meat' in the designs which often means that when I do a more precise computational analysis, I can deal with 10% material loss through corrosion, or extend out the life by some period of time because it's not been designed precisely to the material limits.


> I'm eternally thankful that I work in an era where much of the older equipment I used was designed in an era of slide rule.

Yes, I feel this way too. The knowledge and tooling of modern engineers is amazing, and can do miracles when applied to tasks that seemed impossible just a century ago. But more often than not, it's used to pinch pennies from old designs. This makes me wish for infrastructure projects to be forced to be designed with slide rules again - the less precise your determination of maximum load is, the less the beancounters can "optimize" it.

This is doubly sad in our era, where matter is cheap and labor is expensive - adding extra safety margin can be almost free, but it's an easy target for cost reduction.


This is getting into the "really absolutely certain of the input criteria" category your initial parent was talking about




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