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MSC Software Confidential MSC Software Confidential

7495 Electric Rope Shovel MBD 2012 Regional User Conference

Presented By: Saiphon Jacque & Dave Riesland

May 07, 2013

MSC Software Confidential

• Saiphon Jacque

– Engineering Specialist

– Caterpillar Global Mining

– Graduated UW-Madison with

PhD in Engineering Mechanics

– Taught engineering classes in

Milwaukee and Thailand

Introduction

• Dave Riesland

– Consulting Engineer

– MSC Software

• 18 years in Consulting

Services group

– Over 25 years Adams

experience

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• 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

Outline

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Caterpillar Global Mining

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7495 Electric Rope Shovel

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• 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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• 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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[ Insert Large Graphics ]


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


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






• 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

ERS Field Testing – Description

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• 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

ERS Field Testing – Description

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ERS Field Testing – Strain Gauge Locations

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ERS Adams Modeling

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• Flexible bodies

• Flexible & extensible ropes

• Free-play

• Model Inputs

ERS Adams Model

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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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MSC Software Confidential 19


• 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

Model Correlation

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• 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

Next Steps

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Q & A

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MSC Software Confidential 23

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