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StructuralStructuralStructuralStructuralDesignDesignDesignDesign andandandand PerformancePerformancePerformancePerformanceAnalysisAnalysisAnalysisAnalysis ofofofofa a a a LengthenedLengthenedLengthenedLengthened WorkingWorkingWorkingWorking DeviceDeviceDeviceDeviceofofofof HydraulicHydraulicHydraulicHydraulic ExcavatorExcavatorExcavatorExcavator BasedBasedBasedBasedonononon GeneralGeneralGeneralGeneral HydraulicHydraulicHydraulicHydraulic CylinderCylinderCylinderCylinder Jingang Liu1,a,Shuizhang Kuang1,b,JianwenChen2,Xiaopeng Zhang2,Linglin Xia1 1Department of Mechanical Engineering, XiangtanUniversity, Xiangtan411105, China 2Jiang Lu Mechanical device;device;device; HydrualicHydrualicHydrualicHydrualic excavator;excavator;excavator;excavator; ADAMSADAMSADAMSADAMSsimulationsimulationsimulationsimulation; ; ; ; dynamicsdynamicsdynamicsdynamics simulationsimulationsimulationsimulationanalysisanalysisanalysisanalysis I.INTRODUCTION Working device as the main actor of basic movements of hydraulic excavator,in the dual promotion of market and technology, the structure design is developing toward trend of diversity, in order to meet the needs of different specific work environment. INTERMAT construction machinery exhibition in 2012 April held in Paris of France,can be found in hydraulic excavator is moving in the direction of the development of multi function. That according to the specific needs design and manufacture a working device witha specificfunction. Suchas KomatsuKomatsu PC350LC lengthened working device, greatly exceeded the ordinary working device operating range. Domestic manufacturers of excavators alsohave exhibitedtheir products.However,Chinasproductionofhydraulic excavators used limited by its main parameters, the main job in the construction process parameters such as maximum digging radius, maximum digging height and depth can not meet the construction needs. To meet clean ditches, water conservancy construction, digging ramp, built underground engineering, demolition construction high-rise buildings and other specific needs, the study design with a wider range of operations that can be remote operation of a hydraulic excavatorworkingdevicelengthenedhasimportant practical significance. In view of the traditional design of lengthened working device of hydraulic cylinderdesign difficult, complex processing,can not satisfy the original machine parts commonality problem, we design a kind of lengthened working device to modify the standard working device size and adjust the hydraulic cylinder hinge point 1. II.IMPROVEMENTPROGRAM ANDDYNAMICANALYSIS The lengthened working device design requirements as shown in Table1: TABLE I.THE LENGTHENEDWORKINGDEVICEDESIGN REQUIREMENTS ParametersParametersParametersParametersOperatingOperatingOperatingOperating weightweightweightweight MaximumMaximumMaximumMaximum diggingdiggingdiggingdigging heightheightheightheight MaximumMaximumMaximumMaximum diggingdiggingdiggingdigging radiusradiusradiusradius MaximumMaximumMaximumMaximum diggingdiggingdiggingdigging depthdepthdepthdepth CN150 lengthened 3000Kg10460mm12580mm10060mm Using Pro / E to its three-dimensional solid modeling, based on the ADAMS dynamics simulation verifies that the design could meet the requirements of mining depth, mining height index, and conduct the interference test by using fullconditionsimulation2-3.Basedonworking device in 15 tons of standard type hydraulic excavator do several improvements, afteranalyzingandcomparing, determine the optimal program. The holes of arm defined in Fig.1below. Figure1.Thediagram of lengthened arm Carry out the ADAMS simulation, using the boom pivot as the origin. The boom pivot from the ground is 1m, away from the rotary center 1.2m. The improved programs are shown in Table2. 2013 International Conference on Information Technology and Applications 978-1-4799-2876-7/13 $31.00 2013 IEEE DOI 10.1109/ITA.2013.87 354 TABLE II.THEIMPROVEDPROGRAMSOF LENGTHENEDWORKINGDEVICE ProgrProgrProgrProgr amamamam ImprovementImprovementImprovementImprovement measuremeasuremeasuremeasure s s s s MaximumMaximumMaximumMaximum diggingdiggingdiggingdigging heightheightheightheight MaximumMaximumMaximumMaximum diggingdiggingdiggingdigging depthdepthdepthdepth MaximuMaximuMaximuMaximu mmmm diggingdiggingdiggingdigging radiusradiusradiusradius DesignDesignDesignDesign GoalsGoalsGoalsGoals 10460 mm 10060mm 12580 mm 1 1 1 1 middlemiddlemiddlemiddleholeholeholeholeofofofof armarmarmarm rightrightrightright inininin 200mm200mm200mm200mm LeftLeftLeftLeftholeholeholeholeupupupup 225mm225mm225mm225mm 8837.6 mm 11164.6 mm 13444.6 mm 2 2 2 2 middlemiddlemiddlemiddleholeholeholeholeofofofof armarmarmarm rightrightrightright inininin 100mm100mm100mm100mm CylinderCylinderCylinderCylinder strokestrokestrokestroke increasedincreasedincreasedincreased 100mm100mm100mm100mm 8783.7 mm 9294.7 mm 13554.7 mm 3 3 3 3 ModifiedModifiedModifiedModified armarmarmarm andandandand bucketbucketbucketbucket cylindercylindercylindercylinder blockblockblockblock ModifiedModifiedModifiedModified boom,boom,boom,boom, arm,arm,arm,arm, 10504 mm 11557mm 14240 mm The lengthened working device was improved according to scheme three. According to the requirements of the gap, the boom cylinder mounting seat back and up, the safe distance for the cylinder set aside at least 30mm. Boom and the arm safety distance needs more than 40mm. Move bucket cylinder mounting seat, to ensure the safety of bucket and arm distancemore than 40mm. For improved working device ADAMS kinematics simulation analysis, the largest excavator digging height is 10504mm, maximum digging depth is 11557mm, and maximum digging radius is 14240mm. Program3maximum digging height, maximum digging depth of ADAMS kinematics simulation shown in Fig.2,3. Figure 2. Maximum digging heightofprogram 3 Figure 3.Maximum digging depth ofprogram 3 Compared with the previous two programs, identify program three can meet the original design requirement. Therefore, the program three lengthened working device is best. Boomweightoflengthenedworkingdeviceis 1187.10Kg, arm weight is 527.2Kg, and bucket weight is 249.55Kg. The weight of lengthened working device is 1964.35Kg. The bucket capacity is 0.3m3and soil weight is about 1000Kg, the total actual weight is less than 3000Kg. Therefore, the lengthened working device meets the weight requirements of the final model. III.DYNAMICSSIMULATIONANALYSIS Referencingstandarddynamicssimulationmethod, conduct dynamic simulation for the lengthened working device 4,5.Its external load force calculated as follows: Tangential digging resistance:KNhKW19b 01 = Normal digging resistance: KNWW7 . 5 12 = The gravity of materials:KNVG5 . 4Vg= Figure 4. The pressurecurve ofhydrauliccylinders Figure5.Thestress curvesof hinge points Through dynamics simulation, the pressure curve of three hydraulic cylinders as shown in Fig.4. The stress curves of boom and arm hinge point, arm and bucket, connecting rod and bucket as shown in Fig.5. 355 As can be seen from the simulation diagram, the hinge point force and the hydraulic cylinder force are consistent with the actual working conditions. The maximum stress of hinge point occurs at 8.2s, and it similar with the most dangerous attitude theoretically. Take this attitude as the most dangerous, get the force of each hinge point on this attitude 6. IV.DIGGINGTEST OFEXCAVATOR To verify the ADAMS dynamic simulation on hydraulic excavator is feasible and its accuracy, and further verify thelengthenedworkingdevicecanmeetthework performance. For this paper, design the 15 tons lengthened hydraulicexcavatordiggingtest.Foreachhydraulic cylinder pressure and displacement data measurement, to obtainatestdatacurve.Thencomparedwith the ADAMS dynamics simulation results, dynamic model of theverificationiscorrect,andthemostdangerous work attitude of the simulation is accurate. Figure 6.Dataacquisitioninterface Figure7.Diggingtest ofexcavator By displacement sensors measure displacement of the hydraulic cylinderto achieve the purpose of indirect measure attitude of the working device. Based on the data acquisition, use Labview software development program as a data acquisition interface. As shown in Fig.6.Through digging test and data acquisition, select the data of same dynamics simulation process from the collected data. The curve of corresponding pressure and displacement of the hydraulic cylinder can obtained. Figure8.Hydrauliccylinderdisplacementcurve 05101520253035 0 100 200 300 Pressure / MPa Time / s boom arm bucket Figure9.Hydrauliccylinder pressurecurve From the experimental curve can be seen, the test curve and the dynamic simulation curves are consistent. When hydrauliccylinderpressurereachmaximum,the displacements tested andsimulated are basically the same as. Itillustratesthemostdangerousworkingattitude obtained from dynamic simulation is correct. It verified the method ofthe ADAMSdynamicsmodelingand simulation is feasible, and further validate the lengthened working device can meet job performance 7. V.SUMMARY 1)The optimal design of lengthened working device was determined upon ADAMS kinematics simulation. The working device adopted a combined style which meets the common requirements of the15tons of standard hydraulic excavator key parts and easily process, repairs and replaces. Furthermore, it could achieve efficient use of resources. 2)The authorgot the most dangerous working state and the joint force in this state through the dynamics simulation analysis to the ADAMS simulation model of the lengthened working device and verified that it could meet the work performance. 356 3)The lengthened working device excavator test verifiedthe feasibilityand accuracyof the ADAMS dynamics simulation, and further validated it could meet the work performance. ACKNOWLEDGMENT This project was supported by the Natural Science Foundation of Hunan Province (No.13JJ8005), Research FoundationofEducationBureauofHunanProvince (NO.12B124), Hunan Provincial Strategic New Indust