Kinematic Analysis, Force Calculation, Reach Optimization

(Min-Max Method) For Front end Shovel.

Description of vectors
Position Analysis:
1st vector loop is written as:
   ---------------------------(1)
r1 + r2 + r3 = 0

Where vector r1 is defined between Boom cylinder foot point and arm cylinder foot
point.

Vector r2 is defined boom foot point and Boom cylinder- boom point.

Vector r3 is defined Boom cylinder- boom point and Boom cylinder foot point.

2nd vector loop is written as:

   
r4 + r5 + r6 + r7 = 0 ---------------------------(2)

Vector r4 is defined between boom foot point and boom –arm pivot point.

Vector r5 is defined between boom –arm pivot point and arm - arm Cylinder pivot
point.

Vector r6 is defined between arm - arm Cylinder pivot point and boom – arm
cylinder point.

Vector r7 is defined between boom – arm cylinder point and boom foot point.

3rd vector loop is written as:

   
r8 + r9 + r10 + r11 = 0 -------------------------------(3)
Vector r8 is defined between boom arm pivot point and bucket cylinder –Boom
pivot point.

Vector r9 is defined between bucket cylinder –boom pivot point and bucket
cylinder-arm pivot point.

Vector r10 is defined between link 1 - arm and link1-link2.

Vector r11 is defined between link 1- bucket cylinder and bucket cylinder and –
boom.

4th vector loop is written as

    
r12 + r13 + r10 + r14 = 0 --------------------------------(4)
Vector r12 is defined between link1-link2 and bucket hinge point 2.

Vector r13 is defined between bucket hinge points.

Vector r14 is defined between bucket hinge point and arm pivot point.

5th Vector loop is

  
r13 + r15 + r16 = 0
-------------------------------(5)
Vector r15 is defined between bucket hinge point 2 and bucket tip point.
Vector r16 is defined between bucket hinge point 1 and bucket tip point
Solving for the above loop closure equation using the methods we can establish the
bucket position at any instant. i.e.

    
Note: The above
r4 + r9 + r1 3+ r1 6= rb − − − − − − − − − − − − (6)
described position analysis is for the configuration shown for the configuration
shown in the fig shown in page 2.

Bucket tangential force:

The force generated by the bucket cylinder is given as
  D 2 *Π
Pbuc *  buc 

 4 
Fbuc =
Where
Pbuc is working pressure of bucket cylinder.
Where Parm is in Pascal (10 5
Bars = 1Pascal )
Dbuc is Bore Diameter of Bucket cylinder.
The moment generated about the Link1-Arm pivot point is:
Mbuc = (r10*Sin ( Θ10 −11 )) * Fbuc
Hence Bucket tangential force is given by:
Fbuc = Mbuc / r15
Arm Crowding force Calculation:
Working pressure in the Arm cylinder = Parm = ___________ Bars
Bore Diameter = Darm = ___________ mm
Force generated by the arm cylinder = Working pressure * C/S Area of the
Piston rod = __________Newton.
D 2 * Π
Parm *  arm 
 4 
Farm =  

Where Parm is in Pascal (10 5

Bars = 1Pascal )
The moment generated about the Arm – Boom pivot point is
Marm = (r5*Sin ( Θ5−6 )) * Farm +(r8*Sin ( Θ8−11 ))*Rbuc
Where Rbuc is the reaction force generated by the bucket cylinder.
According to SAE J1179 when Θ5−6 is 900 in other words vector r6 is
perpendicular to vector r5, then Maximum Moment is given by
Marm (max) = r5 * Farm+(r8*Sin ( Θ8−11 ))*Rbuc
Maximum Arm crowding force can be calculated as
Fcrowd (max) = Marm (max) / H
H is the perpendicular distance between bucket tip point as shown in fig
The above equation can be simplified by substituting for reaction force
generated by the bucket cylinder, i.e.
Fcrowd (max) = (r5 * Farm )/(H – h (b/c))
Where b is perpendicular distance between bucket cylinder and boom-arm
pivot point. Mathematically represented as
b = r8*Sin ( Θ8−11 )
Where c is perpendicular distance between bucket cylinder –link1 pivot
point and arm-bucket pivot point.
Where h is distance between the bucket tip point and bucket –arm pivot
point from Boom –Arm Pivot point.
Using Loop Closure equation we can obtain H i.e.
   
From the above fig by r9 + r14 + r16 + H = 0 equating moments we have
Fdig *h = 2*Rbuc *c
Rbuc = (Fdig * h)/(2*c)

Hence substituting the above relation into the equation

We have
Marm = a * Farm+Rbuc *b
Marm = a * Farm + (Fdig * h)/(2*c)*b
Fdig * H = a * Farm + (Fdig * h)/(2*c)*b
Fdig (H- (h*b)/(2*c)) = a * Farm

Fdig = (a * Farm )/ (H- (h*b)/(2*c))

Payload Calculation :
P al oy a dt B kv to l u* Dm e en* Fs iiftl ayl c t o r
>
m ar ex a  c h S a ff ea t cyat ops reI rS O

Min-Max Method : Reach Optimization

Step1: Input
Boom Length= r4 ; Arm Length = rarm ; Bucket = r16 , r15 , r13
Link1= r10, Link2 = r14.
Cylinders: Boom = r3; Arm = r6; Bucket = r11
Revolving frame Points = r1

Step 2:Calculation of angles of known Values w.r.t. +ve X-axis

Step3: Initial Assumption

r2 ,r5 ,r6 ,r8 ,r9, r12

Assume r9 and r12 such that

  
r9 +r12 = rarm
Step 4: Calculate their respective angles w.r.t. +ve x-axis.

Step 5:Calculate Crowding forces and Bucket forces.

Step 6:Specify Maximum-Minimum Limit for the assumption done.

Step 7:Define the increment for the given range and %error/precision
points.

Step 8:Calculate initial Bucket Coordinates i.e.

    
r4 + r9 + r12 + r16 = rb

Step 9: for i=1 to N

{
i
r2 = r2

for i=1 to N
{
i
r5 = r5

for i=1 to N
{ i
r7 = r7
for i
i=1 to N
r
{ 8 8= r

for i=1 to N
{ i
r9 = r9
  
r9 +r12 = rarm

    
r4 + r9 + r12 + r16 = rb

If I ≠ 1
Then i −1
{ If ( r b > rb
i
 Calculate Crowding force and Digging force.
Check for Pressure in cylinders.)
i
r x b = rb
Store value.
Else
Continue}
Else
Continue}}}}}

Step 10: Finding maximum from database

i
Max = rb
For I= 1 to m
i +1
{If rb > max

i +1
Max = rb
Else
Continue}
Step 11: End
Note: For above algorithm rb is to be set for maximum reach condition; then
x coordinates of the above vector should be compared.
Vector Method:

First the independent closed loops are identified. A vector equation

corresponding to each independent loop is established. The vector equation
gives rise to two scalar equations, one for the horizontal axis x, and one for
the vertical axis y.
For an open kinematic chain with general joints (pin joints,
slider joints, etc.), a vector loop equation can be considered:
Closed loop Solution for vectors:

The above equation can be segregated in to two equations

r1 cos Θ1 + r2 cos Θ2 + r3 cos Θ3 = 0

r1 sin Θ1 + r2 sin Θ2 + r3 sin Θ3 = 0

Using known boundary conditions can solve the above equation.

Hint: Cosine Rule can be applied to solve equation. For further reading read
reference 3.

‘Theory is distilled essence of practice” –Rankine

Reference:
1.Robert.L.Norton, DESIGN OF MACHINERY: An Introduction to the
Synthesis and Analysis of Mechanisms and Machines, McGraw Hill Inc,
1999,Second edition.

2.Oleg Vinogradov, FUNDAMENTALS of KINEMATICS and

DYNAMICS of MACHINES and MECHANISMS, CRC-Press, 2000,First
Edition.

3.Shigley, J. “Theory of Machines and Mechanism”, McGraw-Hill, 1993.