Cable Shovel Component Stress Evaluation using a Hybrid Virtual Prototype Modeling and Simulation

CIM Montreal 2007
Samuel Frimpong, Ying Li,
Abstract The cable shovel excavator is a dominant primary production equipment in surface mining applications. The initial capital investment is very high for large-capacity shovels, but with careful preventive maintenance strategies, the overall life time unit ownership and operating costs could be relatively lower for bulk production operations. The key to maintaining machine health and longevity depends on material fragmentation and diggability and a proper understanding of component stress profile during excavation. In this paper, a hybrid virtual prototype is developed for analyzing the stress profiles of cable shovel components by integrating flexible bodies into rigid multi-body model. The general mechanical system of the cable shovel is modeled as a seven-bar linkage with four degrees of freedom. The relevant theories applied for the dynamic model are described in terms of Lagrangian dynamics equation. The flexible body stress related to the body deformation is obtained by the dynamic equilibrium equation for a structural component based on the finite element method. A P&H 4100A cable shovel is used to validate the hybrid virtual prototype by loading the motions and loads on the model. Von Mises stress distributions of the boom, handle, hoist rope and sleeve are visualized during cable shovel operation 3 seconds. The results show that high stress field is around the hoist rope. The maximum stress of 313.31 MPa is occurred at node 441. By comparing the simulation results with reliability analysis results, the former is found to match well with the latter. This study provides a comprehensive modeling and analysis that provide key to cable shovel health and longevity.
Keywords: Cable shovel, Virtual Prototype, Component mode synthesis, Von Mises stress, Stress visualization
Full Access to Technical Paper
PDF version for $20.00
Other papers from CIM Montreal 2007