Miniscopic Boom Design Theory

Outer Boom
Lo

2.096m

e1
e11

1.918m
0.125m

d1
a1
a11
Pf1
W1
X1
Y1
Inner Boom
Li
Pr2
d2

0.250m
0.103m
0.052m
0.088m
120.0kg
1.934m
0.177m

a2
W2
d
Of
Op
Wg (Mass of Carrier and Ram)
Wf (Mass of Forks)
y2
Chassis
DSH
DSV
Other
Diameter Lift Ram
Area Lift Ram
Coefficient Of Friction
Diameter Extension Ram Bore
Area Extension Ram Bore
Diameter Extension Ram Rod
Area Extension Ram Rod
Pad Area mm^2

0.482m
225.0kg
0.438m
0.540m
0.770m
134.0kg
102.0kg
0.538m

2.503m
0.088m
0.200m

40
1500 kg
1.55 m

Results

Exte nd/Re tract Ram Pre s s ure

Boom Ram Press ure Curve (Lifting)

8.0

Pressure to Extend Ext. Cyl.

Pressure to Retract Ext. Cyl.

226.9 Bar
251.0 Bar

4.0

6.0

150.0
100.0
50.0

2.0

0.0
0

0.0

6.56 N/mm2
6.08 N/mm2

Extend Pressure

200.0
10.0

8480.2kg
188.3 Bar

Wear Pad Pressure (Fr, Bot)

Wear Pad Pressure (Rear, Top)

250.0

12.0

Force on Lift Cylinder

Prssure In Lift Cylinder

-5

15
Boom 25
Angle 35

45

55

0.2

-50.0

65

1.4

1.6

R3

0.667m
0.631m

Wp
Wf

F30

0.075m
0.004m2
0.15
0.060m
0.003m2
0.040m
0.001m2
13650

Dave Price JCB - Cecilly Mills 03/03/2016

1.2

OX2
S

0.698
0.916m
1.728m
1.956m
1.08
0.385
1736.0 kg
1810.4 kgm
2.130m
0.286m
5223.3 kgm
4843.0 kgm
16933.5 kg
18263.3 kg
7503.7 kgm
1260.5 kg
5279.5 kg

0.4
0.6
0.8
1
Ram Stroke (m)

GEOMETRY LAYOUT DRAWING

BOOM OVERLAP

Wg

R4
a11

Of

a1

Op

e1
Lo

Calculated Values
Boom Angle (Rads.)
DX
DY
Lift Cylinder Length
Angle 1
Angle 2 (Omega)
W=Wp+Wf+Wg
Moment (M)
X2
Ox2
MR3
MR4
R3
R4
MBP
F30 (Thrust Down Boom)
F31 (Load On Pads)

RAM PRESSURE GRAPHS

Pressure (Bar)

Variables
Boom Angle (a)
Payload (Wp)
Boom Extension (S)

Pre s s ure (Bar)

Known Values

e11
a

DY

An1

W1
CL

Pf1

Pr2

a2

d1
DSV
W2

d2

DSH

DX

y2

Li

307195508.xls

Miniscopic Boom Design Theory

LAYOUT DRAWINGS
Variable
Carrier Cyl. Stroke (d1)

430.0 mm
M

Results
Fork Angle
Grashof Angle (An2)
Breakout Force (PF)
Breakout Force (VF)

a=

CH

35.1
16.9
5847 N
3429 N

r1

DSH

CV

An2
Ca1
R1

a1

DSV

PF

DY

Known
r1
DSH
DSV
CH
CV
Carrier Ram Dia. (D)
System Pressure (P)

150.0 mm
211.3 mm
198.3 mm
35.9 mm
145.7 mm
80 mm
225 Bar

BSH
BSV
BP
90-Ban

774.8 mm
333.3 mm
843.4 mm
19.0

d1

d1

BSV
An1

FORK ANGLE

+VE

BSH

100

DX
X1

BP

-VE

An3

GRAPHS
Bucket Breakout Force

Carrier Rotation
25000.0

10.0
20000.0
8.0
Force PF (N)

Fork Angle () - Boom Horizontal

43.6 mm
289.8 mm
43.2
8.7
265.7 mm
338.1 mm
-54.4 mm
139.8 mm
-68.7
13.8
113097 N
4931.7 Nm

VF

Y1

An4

12.0

Calculated
a1
R1
An1
An3
DX
DY
X1
Y1
An4
Ca1
Ram Force (F)
Moment (M)

1
4 d 2 R 2 (d 2 r 2 +R2 )2

6.0
4.0
2.0

10000.0

5000.0

0.0
140

190

240

290

Ram Stroke d1 (m m )

Dave Price JCB - Cecilly Mills 03/03/2016

15000.0

340

390

440

0.0
140

190

240

290

340

390

440

307195508.xls

Known Values

Variable

Outer Boom
e2
Y3
Chassis

Boom Angle
Tilt Ram Starting Pos. (d1)

60.0
386.0 mm

Results

RAISE
-63.3
87.2
-3.3

DSH 2
DSV 2
Rams
Diameter Tilt Ram Cyl
Area Tilt Ram Cyl
Diameter Tilt Ram Rod

700mm
218mm
118mm
201mm
0.080m
0.005m2
0.050m

Area Tilt Ram Rod Side

Diameter Comp Ram Cyl
Diameter Comp Ram Rod
Carrier
r1

0.003m2
0.064m
0.040m
150.0 mm

DSH
DSV
CH
CV

211.3 mm
198.3 mm
35.9 mm
145.7 mm

Calculated Values
Comp Ram
Boom Angle (Rads.)
DX
DY
Comp Ram Length (CRL)
Area Comp Ram Cyl
Area Comp Ram Rod Side
Carrier/Tilt Ram
a1
R1
An1
An3
DX
DY
X1
Y1
An4
Ca1
Tilt Ram length (d1)
Tilt/Comp Ratio (Cyl. Side)
Tilt/Comp Ratio (Rod Side)

1.047
421mm
698mm
815mm
0.003m2
0.002m2
149.8 mm
289.8 mm
43.2
31.1
65.0 mm
231.6 mm
146.3 mm
33.3 mm
12.8
13.8
240.6
0.630
0.624

Fork Angle
Grashof Angle (An2)
Fork Angle From Horizontal

-3.3
-5
0
5

Err:522
Err:522
Err:522
Err:522

10
15
20
25
30
35

Err:522
Err:522
Err:522
Err:522
Err:522
Err:522

40
45
50
55
60

Err:522
Err:522
Err:522
Err:522
Err:522

Variable
Calculated

Fork Angle off Level

0.01

Boom Angle

-8

Initial Tillt Cyl. Length R

1092.00

Compensated Tilt Length

1091.96

Result

Fork Angle

8.01

Known

r
d
<2
r3
H2
V2
R2
r2
<6
DSV
DSH
e1
e11
a11
d1
Tilt Cyl. Bore
Tilt Cyl. Rod
Comp Cyl Bore
Comp Cyl Rod

375.00
943.77
148.00
435.00
566.75
213.45
322.00
193.40
52.73
436.00
220.00
1430.00
63.00
106.00
378.00
140.00
80.00
80.00
45.00

<5
<5a
<5+<4
<5a+<4
(<5a+<4) or (<5+<4)

31.72
97.02
6.77
82.54
83.23
-30.50
45.27
-30.50

Calculated

a
zz+
z
d+/-z
<1+
<1<1
<3
H1
V1
H3
V3
d2
a2
<4
Y1
DX
DY
Comp Length
Delta Comp Length
Tilt Bore Area
Tilt Rod Area
Comp Bore Area
Comp Rod Area
Tilt/Comp Bore Ratio
Tilt/Comp Rod Ratio
Tilt Movement Bore
Tilt Movement Rod

365.17
-85.32
85.32
85.32
1029.09
19.27
-13.15
-13.15
71.15
140.54
411.67
426.21
-198.22
470.05
101.67
-24.94
421.00
1137.49
-179.92
1151.63
0.13
15393.80
10367.26
5026.55
3436.12
0.3265
0.3314
0.04
0.04

Chart Data (Forks)

0.01
-8
0
5
10
15
20
25
30
35
40
45
50
55
60
65
67.8

1430
0.01
-0.43
-0.41
-0.26
-0.05
0.20
0.43
0.64
0.78
0.85
0.84
0.76
0.60
0.39
0.16
0.04

3400 Levelling Chart (forks)

1.00
0.80
0.60
Degrees Off Level

Variable 1

0.40
0.20
0.00
-10

-5

10

15

20

25

30

35

-0.20
-0.40
-0.60
Boom Angle

40

45

50

55

60

65

70

75

Telescopic Handler Stability Calculations

Telehandler Model: John Deere 3400
Implement Type:

Bucket 1.6 cuyd

Manufacturer:
Implement Mass:

Frontier
510kg

10-Feb-03
D. Price

Calculations Carried Out According To EN 1459

Telescopic Handler Variables

Boom Extention (Max. 2.5)
Boom Angle (Max 67.8)

(m)
Degrees

Implement Variables
Material Mass in/on Implement
Implement Mass
Implement CG to Carrier Pivot (Horiz.)

lbs
2800
WP (kg) 1270.072
WI (kg)
510
WIH (m)
0.473

Implement CG to Carrier Pivot (Vert.)

Material CG to Carrier Pivot (Horiz.)
Material CG to Carrier Pivot (Vert.)

WIV (m)
WPH (m)
WPV (m)

0.285
0.554
0.396

(kg)
(kg)
%
%

8325
540
9.4%
59.3%

LIVE RESULTS
Front Axle Reaction
Rear Axle Reaction
Longitudinal For-Aft Tip Angle
Lateral Tilt Angle

(Min = 7%)
(Min = 12%)

554
473

WP
WI

285

P1
P2
P3
P4
P5
P6

Boom Angle
Degrees
67.8
67.8
67.8
61
55
48

Boom Ext.
Feet
0"
3' 11"
8' 2"
8' 2"
6' 3"
8' 2"

P7
P8

37
8

8' 2"
8' 2"

Position

Implement - Bucket 1.6 cuyd

Manufacturer - Frontier
Model Number(s) AT1016G-GP
Implement Mass - 510kg

396

Date
Engineer

2.5
7

Mass (WP) Long. Ang.

lbs
% (Min - 7%)
6600
41.5
4500
36.4
3000
34.9
4500
19.9
6600
11.6
4500
9.0
3500
2800

8.7
9.1

Lateral Ang.
% (Min - 12%)
13.4
12.8
12.8
13.0
14.0
18.2
25.8
57.6