Research On Lightweight Of Working Device Of Large-duty Loader

As an important part of the loader working device, its structure and weight design willdirectly affect the overall productivity and fuel consumption. In order to enhance theproducts competitiveness, domestic manufacturers have to study various loader newenergy-saving technologies, new structures, especially the working device lightweightdesign is becoming the main direction of the large loaders structural design.This paper takes the XCMG LW1200K wheel loader working device as an objective tooptimize design by the finite element analysis software Hyperworks, static analysis carriedout under different conditions to implements boom lightweight design on the basis of staticanalysis of LW1200K working devices. The optimized working device has been betteredthan the original one in energy-saving respect.(1) Establish a complete parameterization simulation model of LW1200K workingdevice, the model includes the boom, swing arm, rod, bucket. Carry out detailed analysis andcalculations of the loaded parts considering LW1200K positive load and partial load inshovel condition. Determine the force on hinge points in order to provide design data forfuture product development.(2) Based on force analysis of LW1200K under shovel conditions，carry out the finiteelement analysis module of Hyperworks on LW1200K working device under positive loadand partial load, to obtain stress and displacement distribution of boom in shovel conditions.(3) The boom has been optimized under the same condition, and the boom has beenreduced by11%from1165.7kg to1026.4kg.(4) Apply lightweight materials for bucket lightweight design with weight reduction of750kg, which bettered the strength and lead in bucket total weight reduction as well.(5) The finite element analysis and modal analysis of optimized boom model in thesame conditions has showed that stress and displacement are within the allowable range.These results illustrate the lightweight design of the working device is accurate and reliable. (6) Testing on site. The optimized boom applies shovel testing under the Max. tractionforce after LW1200K optimization. After comparing data and FEM analysis of6stresspoints on the boom, its basic error is less than10%. Besides the testing results showvehicle fuel consumption has been reduced by1.92L/h, vehicle weight reduced by900kg,which illustrated the lightweight design results of the working devices is obvious.