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Abstract: Rapidly growing rate of industry of earth moving machines is assured through the high performance
construction machineries with complex mechanism and automation of construction activity. Design of backhoe link
mechanism is critical task in context of digging force developed through actuators during the digging operation. The
digging forces developed by actuators must be greater than that of the resistive forces offered by the terrain to be
excavated. This paper focuses on the evaluation method of bucket capacity and digging forces required to dig the
terrain for light duty construction work. This method provides the prediction of digging forces and can be applied for
autonomous operation of excavation task. The evaluated digging forces can be used as boundary condition and loading
conditions to carry out Finite Element Analysis of the backhoe mechanism for strength and stress analysis. A
generalized breakout force and digging force model also developed using the fundamentals of kinematics of backhoe
mechanism in context of robotics. An analytical approach provided for static force analysis of mini hydraulic backhoe
excavator attachment.
Key words: Digging Forces, Autonomous Excavation, Resistive forces, Heaped capacity
*Correspondence Author’s Address: Mechanical Engineering Department, U. V. Patel College of Engineering, Ganpat University,
Kherva-384012, Dist. Mehsana, State-Gujarat, India, bppmech@gmail.com
Bhaveshkumar P. Patel, Jagdish M. Prajapati: Evaluation of Bucket Capacity, Digging Force Calculations and Static Force Analysis of Mini
Hydraulic Backhoe Excavator, Machine Design, Vol.4(2012) No.1, ISSN 1821-1259; pp. 59-66
have looked into the free motion planning problem within Excess material capacity V for angle of repose 1:1 can be
the context of the mass excavation task. Also, much of the calculated from Fig. 1 as:
autonomous excavation research has concentrated on
functionality, where simply digging a full bucket of V 0.00709 m (3)
material is good enough [4]. To perform an excavation
task it is necessary that the digging forces produces by By using equations (1), (2), and (3) the bucket capacity for
actuators must be higher than that of the resistive forces the proposed 3D backhoe bucket model comes out to be
offered by the terrain. For autonomous excavation task it 0.02781 m3 = 0.028 m3.
is very important to evaluate the digging forces. The
presented research work is on the evaluation of digging 4. DIGGING FORCES
forces, which are according to standards of SAE. In
addition, a generalized digging force model developed Bucket penetration into a material is achieved by the bucket
based on fundamentals of kinematics of backhoe curling force (FB) and arm crowd force (FS). The rating of
excavator attachment in context of robotics which can be these digging forces is set by SAE J1179 standard
use as a boundary condition (time varying or dynamic) to “Hydraulic Excavator and Backhoe: Digging Forces” [6].
carry out the dynamic finite element analysis of the These rated digging forces are the forces that can be exerted
proposed backhoe excavator. Moreover; static force at the outermost cutting point (that is the tip of the bucket
analysis carried out by considering the maximum teeth). These forces can be calculated by applying working
breakout force condition and static force analysis done for relief hydraulic pressure to the cylinders providing the
the different parts of the backhoe excavator and can be digging force.
taken as boundary conditions for static FEA.
F (4)
60
Bhaveshkumar P. Patel, Jagdish M. Prajapati: Evaluation of Bucket Capacity, Digging Force Calculations and Static Force Analysis of Mini
Hydraulic Backhoe Excavator, Machine Design, Vol.4(2012) No.1, ISSN 1821-1259; pp. 59-66
configuration as shown in Fig. 4, it holds the values of As can be seen from the Fig. 3 the digging force from the
the parameters as: dA = 257 mm, dB = 220 mm, dC = 181 arm cylinder FArm (acting on the teeth of the bucket in the
mm, dD = 547 mm, dE = 285 mm, and dF = (547 + 723) = tangential direction of A2A4 radius) will be the moment
1270 mm. The working pressure p = 157 bar or 15.7 MPa, created by the arm cylinder MArm divided by the distance
DA = DB = 40 mm. So by using equations (4) and (5) the A2A4. This leads to;
calculated bucket curl or breakout force FB = 7626.25 N =
7.626 KN, and calculated arm crowd force or digging F (7)
force FS = 4427.419 N = 4.427 KN.
The combination of the backhoe excavator’s arm crowd This is because while excavating, firstly the X and the
force FS and bucket curling force FB give this machine X axes are made collinear (i.e. A2, A3, and A4 points are
configuration more effective bucket penetration force per collinear points), then the bucket is made to contact with
mm of bucket cutting edge than is available with other the ground and curled inwards. While arm cylinder is only
machine types such as wheel and track loaders. As a active the bucket is made curling inward from the point
result of high penetration force, a backhoe excavator A2 to point A4. Now moment created on arm MArm will be
bucket is comparatively easy to load. Also, the higher unit the product of the force created by the arm cylinder F
breakout forces allow the backhoe excavator’s economic and the perpendicular distance to the cylinder, so MArm
application range to be extended further into the tougher can be given by;
soils (coral, shale, limestone) before blasting or ripping is
required. Maximum resistive force offered by the ground M A A sin A A A F (8)
for the proposed tool dimensions is 3916.7 N [1], and the
breakout force calculated is 7626 N which is higher than Now in equation (8) the distance A2A8 is fixed from the
the force required to cut the soil (3916.7 N), thus this geometry of the backhoe excavator as shown in Fig. 3,
calculated breakout force is adequate and accepted for the and the arm cylinder force F can be determined from
job to be performed by the proposed mini backhoe equation (6), now the only unknown remained is the
excavator i.e. light duty construction work. A A A Γ . From the cosine rule applied to the
The SAE J1179 standard provides the bucket curling force triangle ∆A A A the angle Γ can be given by;
FB, and arm crowd force FS, only for the position of the
maximum breakout force condition as stated in standards, Γ tan (9)
which is helpful for static analysis, but for autonomous
application it is important to know the digging forces The length of the piston rod in the arm cylinder A7A8 can
generated during the entire digging operation. During the be determined either from the sensors (in case of
digging operation the digging forces may vary with autonomous backhoe operations) or from the joint angle
respect to the position of the bucket configuration θ from kinematic equation as:
therefore it is necessary to develop a generalized breakout
and digging force model for digging operation which can A A A A A A 2 A A A A cos 3π
provide the breakout and digging forces for all positions δ δ θ (10)
of the bucket configurations, this can be helpful for better Where, A1A2A7 = δ1, and A8A2A3 = δ2 are constant for
controlling of the autonomous digging operation. the geometry of boom and arm respectively as shown in Fig.
3. By using equations (9) and (10), the moment MArm can be
5. DEVELOPMENT OF GENERALIZED determined from equation (8). Now let us determine the
BREAKOUT AND DIGGING FORCE length A2A4. If the cosine rule is applied to the ∆A A A
MODEL one yields;
A A
Hydraulic cylinders apply force to boom, arm and the
A A A A 2 A A A A cos θ π (11)
bucket to actuate the mechanism. Depending on the
mechanism position, working pressure and diameter of In equation (11) all terms are known except the joint 4 angle
the hydraulic cylinders, the amount of excavation force θ . This can be determining from kinematic equation, if the
changes. In practice, boom cylinders are used for length of the piston rod in the bucket cylinder A9A10 is
adjusting the bucket position not for digging. Arm known.
cylinder and bucket cylinder are used for excavating.
Thus, calculation of digging force must be carried out ζ 2π ε1 tan 1
A9 A12 A10 A12 A9 A12 2 A10 A12 2 A9 A10 2
(12)
separately when arm cylinder or bucket cylinder is the A9 A12 2 A10 A12 2 A9 A10 2
active cylinder.
Where ε = the major A9A12A3 and it is constant and thus
5.1. Force calculation when the arm cylinder is known for us. From equation (12) ζ can be determined.
active Now by putting this value of ζ into the following equation
Force created by the arm cylinder A7A8 (length of the arm (13) will give the value of ζ (rest of the terms are known).
cylinder) F can be found by using its end cylinder A A A A 2 A A A A cos ζ
diameter and working pressure as described in the A A A A 2 A A A A cos ζ (13)
previous section.
By putting these two values of ζ , ζ , A12A3A2 = η
F p π
4 D (6) (fixed from the geometry), and A4A3A11 = η
61
Bhaveshkumar P. Patel, Jagdish M. Prajapati: Evaluation of Bucket Capacity, Digging Force Calculations and Static Force Analysis of Mini
Hydraulic Backhoe Excavator, Machine Design, Vol.4(2012) No.1, ISSN 1821-1259; pp. 59-66
(fixed from the geometry) into the following equation will Now in equation (17) the distance A10A12 is fixed from
determine the joint 4 angle θ . the geometry of the backhoe excavator which is shown in
θ ζ ζ π η η ζ (14) Fig. 3, and the bucket cylinder force F can be
determined from equation (15), now the only unknown
So by using equations (12), (13), and (14) the distance A2A4 remained in the equation is the A A A Γ . From
can be determined from equation (11). And by using the cosine rule applied to the triangle ∆A A A the
equation (11) and (8), the digging force when the arm
angle Γ can be given by;
cylinder is active, FArm can be determined by equation (7).
5.2. Force calculation when the bucket cylinder is Γ tan
4 A A A A A A A A A A
A A A A A A
active
(18)
Force created by the bucket cylinder A9A10 (length of the
arm cylinder) F can be found by using its end From the equation (18) the angle Γ can be determined
cylinder diameter and working pressure as described in either from the sensors (in case of autonomous backhoe
the previous section. operations) or from the joint 4 angle θ . If the joint 4 angle
F p π θ is known then by following the reverse procedure of the
4 D (15)
end of the section in which the arm cylinder is active, from
As can be seen from the Fig. 3 the breakout force from equations (14), (13) and (12) the length of the bucket
the bucket cylinder FBucket (acting on the teeth of the actuator A A can be determined. Thus by using the
bucket in the tangential direction of A3A4 radius) will be equations (17), and (18) the breakout force or bucket
the moment created by the bucket cylinder MBucket divided digging force can be determined in the generalized form
by the distance A3A4. This leads to;
from equation (16). In this section, both the breakout
F (16) force of bucket cylinder FBucket and the digging force of
the arm cylinder FArm have been determined in the
In equation (16) the length A3A4 is fixed from the generalized form. These two forces are the function of the
geometry of the bucket and thus known to us. Here, only respective joint angles, and these joint angles are the
the bucket cylinder is active and the bucket is made function of time while excavating the earth. So equation
curling inward from the point A3 to point A4 for the (7) and (16) provides the generalized digging and the
excavation operation to be carried out by bucket cylinder.
breakout forces as a function of time (dynamic), and thus
Now moment created on bucket MBucket will be the
can be used as a boundary condition for the dynamic FEA
product of the force created by the bucket cylinder F
of the backhoe excavator, but the dynamic FEA of the
and the perpendicular distance to the cylinder, so MBucket
can be given by; backhoe excavator is not the part of the research reported
in this paper. MATLAB code also developed for this
M A A sin A A A F (17) generalized digging force model.
62
Bhaveshkumar P. Patel, Jagdish M. Prajapati: Evaluation of Bucket Capacity, Digging Force Calculations and Static Force Analysis of Mini
Hydraulic Backhoe Excavator, Machine Design, Vol.4(2012) No.1, ISSN 1821-1259; pp. 59-66
6. STATIC FORCE ANALYSIS Where, ρ is the angle between the breakout force of
bucket and the ground level as horizontal reference
In this section, calculation for the static force analysis of surface of 38.23º as shown in Fig. 5. Now considering the
the backhoe excavator for the condition in which the bucket in equilibrium ΣM = 0, taking moment about the
mechanism produces the maximum breakout force has bucket hinge point A3 leads to;
been explained. Unlike the previous section’s flexibility
F ·l F ·l F ·l (21)
where the force analysis could be done for any of the
position and orientation (collectively known as the Where, F4 is the force acting at bucket tool tip when the
configuration) of the mechanism from the available bucket approaches to the earth in the maximum breakout
breakout and digging forces, in static analysis one force condition as shown in Fig. 4 and Fig. 5, which is
configuration of the mechanism has to be decided first for equivalent to the bucket breakout force FB.
which the analysis is to be carried out. From all the
configurations, the maximum breakout force condition is
the most critical one as it produces the highest breakout
force, and thus for this condition the force analysis is
done, and will be used as a boundary condition for static
FEA. The free body diagram of bucket, arm, and boom,
directions and magnitudes of the forces are explained in
the next section. Fig. 4 shows the configuration in which
the mechanism is producing the maximum breakout force.
6.1. Bucket static force analysis
Fig. 5 shows the free body diagram of the bucket. As can
be seen the reaction force on the bucket teeth at point A4
due to the breakout force 7.626 KN acts at the angle
38.23 for configuration of the maximum breakout force
condition. Static forces on joints can be calculated by
considering the summation of forces must be equal to
zero and summation of moments equal to zero for
equilibrium condition of the bucket, arm and boom Fig.5. Free body diagram of bucket
respectively. All the forces in the Fig. 5, Fig. 6, Fig. 7 and
Fig. 8 are in Kilo Newton (KN). Firstly the reaction force l4 is the distance of the tool tip of the bucket from the
acting on the bucket teeth (at point A4) is resolved in the bucket hinge point (547 mm), lgb is the distance between
horizontal (X) and the vertical (Y) directions by using the the C.G. of the bucket to the bucket hinge point (220
following equations (19) and (20). mm), l11 is the distance of the bucket hinge point to the
idler link hinge point on bucket (181 mm), Fgb is the
F F · cos ρ (19) gravitational force acting on bucket (0.235 KN) and F11 is
F F · sin ρ (20) the force acting on hinge point of the idler link on bucket
63
Bhaveshkumar P. Patel, Jagdish M. Prajapati: Evaluation of Bucket Capacity, Digging Force Calculations and Static Force Analysis of Mini
Hydraulic Backhoe Excavator, Machine Design, Vol.4(2012) No.1, ISSN 1821-1259; pp. 59-66
Forces (KN)
Joint of the
bucket Horizontal (X) Vertical (Y)
component component
A4 -5.933 4.716
A11 -9.977 -20.456
A3 15.97 15.74
(a)
64
Bhaveshkumar P. Patel, Jagdish M. Prajapati: Evaluation of Bucket Capacity, Digging Force Calculations and Static Force Analysis of Mini
Hydraulic Backhoe Excavator, Machine Design, Vol.4(2012) No.1, ISSN 1821-1259; pp. 59-66
shown in Fig. 4, F9 is the force acting on arm through (31) and (32). Here, β is the angle made by force on
bucket cylinder of 22.405 KN as shown in Fig. 6(b), and boom through arm cylinder with horizontal reference at
l9 is the distance between arm hinge point (A2) and the point A7 of 0º as shown in Fig. 7(b).
bucket cylinder end hinge point (A9) of 294 mm as shown
in Fig. 4. Considering ΣF = 0, force on the arm to boom F F · cos β (31)
hinge point A2 can be found out as shown in Fig. 6(b). F F · cos β (32)
The forces on each of the joints of the arm are shown in
Table 2. Considering the boom in equilibrium ΣM = 0 and taking
moment about the arm to boom hinge point (A1) leads to;
Table 2. Static forces on arm joints
F ·l F ·l F ·l F ·l
Joint of Forces (KN) F ·l (33)
the Horizontal (X) Vertical (Y)
bucket component component Where, force F5 is the acting at point A5 through boom
cylinder which is acting at angle β at point A5 of 45.58º
A3 -15.97 -15.74 as shown in Fig. 7(b). l5 is the distance between bomm
hinge point and boom cylinder end hinge point on swing
A12 -5.358 5.646
link of 218 mm as shown in Fig. 4. F2H and F2V are the
A9 13.264 18.057 horizontal and vertical components of the force acting at
point A2 of 52.26 KN and 7.963 KN respectively as
A8 -44.196 0 shown in Fig. 7(a). l2H and l2V are the horizontal and
vertical distances of point A2 form boom hinge point A1
A2 52.26 -7.949 of 1301 mm and 348 mm respectively as shown in Fig.
7(a). Fgbo is the gravitional force acts on boom of 0.432
KN as shown in Fig. 7(b), and lgbo is the horizontal
6.3. Boom static force analysis
distance between C.G. of boom and boom hinge point A1
of 524 mm as shown in Fig. 7(a). l7 is the vertical
distance between arm cylinder end hinge point A7 and
boom hinge point A1 of 633 mm as shown in Fig. 4. The
force F5 can be resolved in horizontal (X) and the vertical
(Y) directions by using the following equations (34) and
(35).
F F · cos β (34)
F F · cos β (35)
'
Considering ΣF = 0, force on the bucket hinge point A1
can be found out as shown in Fig. 7(b). The forces on
each of the joints of the boom are shown in Table 3.
(a)
Table 3. Static forces on boom joints
Forces (KN)
Joint of the
boom Horizontal (X) Vertical (Y)
component component
A2 -52.26 7.963
A7 44.196 0
A5 -69.032 70.444
8. CON
NCLUSION
N