Large Construction Machinery ROPS / FOPS Test System Development

Since reform and opening up, the national economy has developed rapidly,additionally a large number of infrastructures (such as buildings, bridges andrailway, etc.) has started to be constructed, which gives rise to a widely used oflarge engineering machinery. Generally, the circumstance which thesemachinery working is too adverse, it can either induce tilting accident or theimpact of the falling objects easily. Thus the driver’s life and property securitywould be caused a great damage at any time.In order to improve the safety of driver’s protection, the western developedcountries make mandatory provisions that ROPS/FOPS or safe cab must beinstalled around the cab of construction machinery. In order to meet the needs ofthe international market competition, our country also required to installROPS/FOPS around the cab of construction machinery or safe cab. However,performance of safety protective structures (ROPS/FOPS) is directly related tothe driver’s life safety. The most effective way of verifying the performance ofsafety protective structures is to do the test. On the current situation, the test wasmade on the test bench in the laboratory, and the loading capability of testsystem can’t meet the development trend of the large-scale engineeringmachinery.After referring to the related data of safety protective structures(ROPS/FOPS) and testing system, this paper both discussed laboratory testingmethod of safety protective structure (ROPS/FOPS) for the large engineeringmachinery, and analyzed and studied loading ways of domestic existing test bed.Combined with the requirements of the task, the consultation of the largeengineering machinery hydraulic loading system of ROPS/FOPS test system hasbeen completed.According to the function of test system, overall scheme of loading systemhas been formulated. Beyond loading capacity of the test system, the maincomponents of loading system was selected and calculated. Under the analysis of working condition, the simulation analysis of loading system was carried onby using AMESim, and the dynamic response of the loading system was verified.In order to solve the hydraulic impact phenomenon appeared in the process ofsimulation and improve the precision of the response of loading system, the gainvalue of the test system was optimized. In the end, a data acquisition system wasdesigned，and made up the software by using graphical programming language.This research has certain theoretical guiding significance for design andresearch of safety protective structures (ROPS/FOPS) of large-scale constructionmachinery in our country.