Bucket chain excavator: Failure analysis and redesign of the counterweight boom supporting truss columns |
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| Affiliation: | 1. University of Belgrade, Faculty of Mechanical Engineering, Kraljice Marije 16, 11120 Belgrade 35, Serbia;2. Institute Kirilo Savić, Vojvode Stepe 51, 11010 Belgrade, Serbia;1. INEGI – Institute of Science and Innovation in Mechanical and Industrial Engineering, Rua Dr. Roberto Frias, 400, 4200-465 Porto, Portugal;2. Department of Mechanical Engineering, Faculty of Engineering, University of Porto, Rua Dr. Roberto Frias, 4200-465 Porto, Portugal;1. Science and Technology on Remanufacturing Laboratory, Academy of Armored Forces Engineering, Beijing 100072, China;2. College of Materials Science and Engineering, Beijing University of Technology, Beijing 100124, China;3. National Engineering Research Center of Mechanical Product Remanufacturing, Academy of Armored Forces Engineering, Beijing 100072, China;1. Institute of Process Equipment and Control Engineering, Zhejiang University of Technology, Hangzhou, 310014, China;2. Shanghai Institute of Applied Physics, Chinese Academy of Sciences, Shanghai, 201800, China;1. School of Electrical Engineering and Computer Science, University of Newcastle, Callaghan, NSW 2308, Australia;2. Department ELEC, Vrije Universiteit, Brussel, Building K, Pleinlaan 2, 1050, Brussels, Belgium;1. School of Automation, Huazhong University of Science and Technology, Wuhan, 430074, China;2. School of Electrical and Electronic Engineering, University of Manchester, Manchester, M13 9PL, United Kingdom |
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| Abstract: | The supporting truss of the counterweight boom is a vital part of the bucket chain excavator’s (BCE) superstructure. The occurrence and propagation of cracks in the supporting truss columns’ heads may lead to BCE collapse. The goals of the study presented in this paper were to: (a) diagnose the cause of cracks occurrence; (b) define the reconstruction design of the supporting truss columns and (c) validate the reconstructed structure by numerical–experimental analysis. In order to clarify the causes of cracks occurrence, experimental investigations were performed with the purpose of defining the chemical composition, tensile properties, impact toughness and macrohardness of the columns’ material. Metallographic examinations were also conducted. Based on the results of finite elements analyses (FEA) and experimental analyses it can be concluded that cracks are caused by the ‘design-in’ defects. The redesign solution enabled repair and reconstruction in field conditions, without previously dismantling any substructure of the BCE superstructure. Thereby the time required for performing reconstruction is shortened and indirect costs due to the BCE downtime are considerably diminished. Both the experimental analysis of the stress state of the reconstructed columns in regular working conditions and the failure-free exploitation have confirmed the validity of the reconstruction design, while the BCE excavated approximately 8.5 × 106 t of coal and 1.8 × 106 m3 of overburden after the reconstruction. |
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| Keywords: | Bucket chain excavator superstructure Failure diagnostics Redesign Finite element analysis Experimental validation |
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