| The off-highway mining dump truck is a new kind of off-highway dump truck which is developed from the traditional heavy-duty dump truck. This kind of truck is famous in the small and medium mine for its great price advantage and performance better than ordinary heavy dump truck. Nowadays, the production and sales of this dump truck is increasing rapidly. However, the research and design of this dump truck is far from satisfaction. Most of the manufacturing companies will simply strengthen the mechanical structure and powertrain system to meet the performance requirements. However, the off-highway mining dump truck often has different kinds of problems which takes long time to repair. As a result, the cost increases. In this paper, the key technologies will be researched to make a better off-highway mining dump truck.The structure features of the off-highway mining dump truck are analyzed. The hydraulic lift system which can meet the special using conditions of the dump truck is designed according to the analysis results of common dump truck lift system. The mathematical model of the lift system is built based on the structure of the dump truck. The hydraulic cylinder and dump is selected according to the schematics. In order to verify the accuracy of the design, the MATLAB software is used to simulate the lift system.The AMESim simulation software is used to model and analyze the hydraulic lift system. Using the Hydraulic Component Design part and the Mechanical part, the four-stage hydraulic cylinder is modeled. The model of load part is simplified by fitting using least squares algorithm. The lift system model is constructed by connecting the four-stage hydraulic cylinder and the load part. The cylinder stroke, lifting angle and the pressure of hydraulic cylinder rod chamber of lifting and declining are analyzed. The results indicate that this lifting system has stable pressure and the velocity and pressure fluctuation is small, which means the hydraulic lift system designed can meet the using condition.The climbing performance and full load acceleration are simulated by the powertrain model built in AVL-Cruise software. The results indicate that the dynamic characteristics of the off-highway mining dump truck are good. The C-WTVC test cycle is analyzed and adjusted to satisfy the using condition of the off-highway mining dump truck. The fuel consumption is simulated and the diagram of velocity, acceleration, and fuel consumption is drawn.According to the analysis results of the powertrain model, the match of powertrain parameters is optimized. Take the gear ratio of every gear and the ratio of the reduction final drive as the design variables. The power objective function and economy objective function is weighed to get a combined objective function. The iSIGHT and AVL-Cruise software is used as optimization tool. Using DOE and MIGA and NLPQL combined optimization strategy, the powertrain parameters are optimized. The optimization results are compared with the parameters unoptimized. The AVL-Cruise software is used to simulate the dynamics characters and the fuel consumption. The simulation results show that the optimization of the powertrain parameters lows the fuel consumption while ensure the power. |
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