FOPS & ROPS Test Bench Design And Structural Analysis For Mining Dump Truck

Mining dump truck is a kind of a heavy dump truck used for various of transportation materials in the mine. Because of the bad working environment and road complexity, falling-object smashing cab and vehicle rolling over accidents happened frequently, the security problem is becoming more and more serious. The driver’s personal safety will be threatened by the impact of the falling-object or by the external pressure of the cab. In order to improve the safety of the engineering vehicles and also the safety of the drivers, the structure of the FOPS & ROPS safety protection is generally installed around the cab.This paper is based on the cooperation project, the Mining dump truck cab FOPS & ROPS test bench design project. Mining dump truck has the largest volume and the most weight of ISO3471 standard required test models. It can be shown that mining truck loads have the largest energy absorption by the standard calculation, and due to the requirement of the standard that the cab is to be installed on the frame together with the detection in the test. But the mining dump truck frame size is too large to be transported. The size of the test mining dump truck in this project is larger, the rated load capacity sums up to 400 t, and the no-loading maximum dimension lengthens to16000 mm, widens to 9500 mm, heightens to 7800 mm, so the falling-object and rolling-over protection device test bench can only be established in the manufacturers, and the FOPS & ROPS safety protection structure is also tested at the manufacturers. At the same time, many domestic engineering machinery manufacturers emphasize on the improvement of the safety of the cab, so they also design FOPS & ROPS test device, which can carry on the test of the cab FOPS & ROPS structure. Only those cabs that meet the requirements of the standard can they protect the driver’s personal property safety to the greatest extent.Designing FOPS & ROPS test bench to test the safety protection structure of the cab to verify whether the structural performance of the cab safety protection can meet the requirements of the strength and stiffness in the standard specification.Based on Earth-moving machinery Falling-object and Rolling-over protection structures of Laboratory tests and the performance requirements of the standard, this paper discusses the necessity of FOPS & ROPS test bench system research situations abroad and home; it also analyzes the researches of FOPS & ROPS test bench system home and abroad systematically, which is combined with project requirements, the Falling-object and Rolling-over protection device test bench design and structural analysis of the mining dump truck is completed.According to the Earth-moving machinery Falling-object and Rolling-over protection structures of Laboratory tests and performance requirements of the standard, which is also the ISO3449 and ISO3471 standard, the designing test bench for simulation test is done in the laboratory to simulate the actual vehicle suffering from falling objects and the impact of vehicle rolling-over in the lab. The test bench design uses the whole closed type frame structure and open structure to compare the advantages and disadvantages of different designs, the best-design scheme can be assured, and also the hydraulic system is designed to cooperate with the use of that, and the main structure of the hydraulic system is designed and selected. Then based on the analysis of the dangerous working condition of the loading test bench, the paper uses the allowable stress design method and the design calculation to design and calculate the theory of main body structure of this test frame by ANSYS software, which analyzes strength and stiffness of the frame structure of the loading test bench, which guarantees that the test bench frame structure can meet the requirements of the safety performance and test contents of the project.The research contents of this article provides a theoretical basis for the design and analysis of Falling-object and Rolling-over protection device test bench of mining dump truck, which shows a certain practical value and theoretical significance for the design and research of the cab safety protection in the field of engineering machinery.