7495 Electric Rope Shovel MBD

2012 Regional User Conference

Presented By: Saiphon Jacque & Dave Riesland

May 07, 2013

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Introduction
Saiphon Jacque

Dave Riesland

Engineering Specialist
Caterpillar Global Mining
Graduated UW-Madison with
PhD in Engineering Mechanics
Taught engineering classes in
Milwaukee and Thailand

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Consulting Engineer
MSC Software
18 years in Consulting
Services group

Over 25 years Adams

experience

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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