7495 Electric Rope Shovel MBD

2012 Regional User Conference

Presented By: Saiphon Jacque & Dave Riesland

May 07, 2013

MSC Software Confidential

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Introduction

• Saiphon Jacque • Dave Riesland

– Engineering Specialist – Consulting Engineer
– Caterpillar Global Mining – MSC Software
– Graduated UW-Madison with • 18 years in Consulting
PhD in Engineering Mechanics Services group
– Taught engineering classes in – Over 25 years Adams
Milwaukee and Thailand experience

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Outline
• Caterpillar Global Mining
• 7495 Electric Rope Shovel (ERS)
• ERS Field Testing
• ERS MDB Modeling
– Flexible bodies
– Flexible & extensible ropes
– Free-play
– Model inputs
• Model Correlation
• Next Steps
• Q&A
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Caterpillar Global Mining

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7495 Electric Rope Shovel

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7495 Electric Rope Shovel

• Large scale mining machine

– Typical payload of 100 – 120 tonnes
– 3,200,00 total machine weight
• Used for digging:
– Coal & coal over burden
– Hard frozen oil sands
– Hard rock iron ore
• Average duty cycle: 30 – 45 sec

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7495 Electric Rope Shovel

• Driven by electric motors; hoist, crowd and swing motors for

digging, swing and propel motors for propelling
• Most load carrying structures are high strength steels
• Machines are utilized full time, reliability is crucial!

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7495 Electric Rope Shovel

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7495 Electric Rope Shovel

• http://www.youtube.com/watch?v=DqvnElD5r3E

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ERS Field Testing – Description

• Caterpillar recently conducted extensive testing on machines in

the field
• More than 200 channels of data were collected
• Strain gauges, accelerometers and position gauges were placed
mainly on the front end – (see slide 12)
– Strain gauges and load cell pins were used to measure loads on
structures
– Strain gauges were placed at hot spot for life predictions

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ERS Field Testing – Description

• Machine motions & loads were recorded

– Motions: hoist, crowd, swing positions and speeds
– Loads: motor torques and hydraulic pressures
• Static events (load holding and motor stalling) and dynamic
events (swing in air and swing in bank) were used to validate the
model
• Main purpose:
– Determine loads on the machine
– Predict fatigue lives of structural components

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ERS Field Testing – Strain Gauge Locations

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 ERS Adams Modeling

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ERS Adams Model

• Flexible bodies
• Flexible & extensible ropes
• Free-play
• Model Inputs

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ERS Adams Model – Flexible Boom

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ERS Adams Model – Flexible A-Frame

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ERS Adams Model – Complete Model

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ERS Adams Model – Model Inputs (motions)

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Model Correlation

• Stress results from flexible body (boom) correlate very well with
test data for static loads
• With dynamic load amplifications, static FEA can be done for
fatigue life predictions
• Dynamic load simulations were done by applying resistive forces
at the dipper teeth. Resistive forces were determined from tests
and they are material dependent

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Next Steps
• Use correlated model to resolve field service issues
– Reduce down time & improve reliability
• Co-simulate with electrical control system and/or hydraulic
systems
• Applying resistive forces in conjunction with soil interaction
software, material properties can be determined and used to
predict machine performance
• Use knowledge gained on this project to assist in the design and
analysis of similar machines in the future
• Model will be used to predict, control and reduce misused
operations so that fatigue lives of structures are predictable

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 Q&A

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