Structure Optimization Design Study Of The Boom Of Electric Mining Shovel

Electric mining excavator is famous for its characteristics, such as big bucket volume,high intensity and high productivity, etc. So it is regarded as one of the most importantengineering machinery in the construction of modern engineering, and widely used. Withthe rapid development of economy, the infrastructure construction scale of traffic,large coalmine,large theater,port city is increasing everyday, demand for excavators and other largeengineering machinery is becoming more and more big, requirement is also more and morehigh. The traditional design method has already can’t meet the needs of its rapiddevelopment, therefore, it is necessary to use the excellent modern design method on thedesign of the cable shovels.In this paper, the study object based on a inland WK-35cable shovel. After in-depthresearching and analyzing on the moving relationship between components of workingdevice and the structure of boom, the parameterized model of working device has beencreated through the ADAMS software, after simulation and optimization analysis, it has gotdimension parameters of the most components of working device which is "least effort" andthe most dangerous stress of boom in dynamic excavation process. At the same time, inorder to reduce the weight of the working device to the maximum extent, as an example, thepaper has conducted the lightweight design on the boom structure. Will the "least effort"dimension parameters of the most components of working device and the most dangerousstress applied to the APDL secondary development of boom, it has obtained the finiteelement optimal design system specified for the boom of cable shovels. Not only realize thebutton style operation in the whole optimization design process, also get the lightest qualityof boom. Eventually reach the " double light " design effect for the least effort in miningprocess and the lightest quality working device. Main contents can be summarized as the following aspects:1.Kinematic analysis of the working deviceTry to make the bucket be of the highest efficiency and the least resistance, the paperhas analyzed the movement of bucket’s tooth tip under ideal condition, and the diggingbucket tooth ideal trajectory curve has been obtained. Using it as a base, the paper hasobtained some kinematics parameters after vast detailed analysis and calculation on thehoisting and pushing mechanism respectively, such as hoisting speed, pushing speed, etc. Atthe same time, got the point coordinates of the Wire rope and head sheave according tothe actual physical prototype.2.Parametric modeling and optimal design of the working deviceIn this section, modeling hinge points and design variables of the working device havebeen determined, and the parameterized model of working device has been created based onthe ADAMS software. Then do dynamics simulation analysis on it, plot the contrast curvebetween the ideal and simulation mining trajectory by MATLAB to verify the correctnessof established dynamic model of the working device. Set the smaller lift and push pressureto overcome the given digging resistance as the objective function to optimize, the paperhas obtained dimension parameters of the most components of working device which is"least effort" and the most dangerous stress of boom in dynamic excavation process.3.The development of the optimal design system interface specified for boomset up the toolbar buttons correspond with each function of the optimal design system ofboom, so, user just need click the corresponding button to complete the design, analysisand optimization operations of boom. Finally, the paper hasperfected the interactioninterface of boom optimization.4. Movable arm parametric modeling and analysisWill the boom of WK-35cable shovel as an example, the paper applies secondarydevelopment tools APDL of ANSYS to write each function file with the method of definingmacro file, the finite element parametric model of boom has been established. Through thestatic and modal analysis, the paper has fully verified the strength stiffness and stability ofboom. 5.The optimization design of boom structureDetermine design variables, state variables and objective function of the boomoptimization scheme, and write the macro files of optimization analysis, control and resultssearching at the same time to realize the button style operation in the whole optimizationdesign process. The paper has obtained the optimal solution of the boom structure byapplying the two order optimization algorithm. And then reprocess for the optimal solution,the paper has passed the security conditions of boom, such as stiffness, reliability of thereprocessing optimal solution after reviewing the results, eventually realized the lightweightdesign of boom structure, also verified the practicability and reliability of the optimizationdesign system.