Joy Global Inc. Dragline Boom and Mast Project · Joy Global Inc. Dragline Boom and Mast Project...

Joy Global Inc. Dragline Boom and Mast Project

Presenter: Joe Huffman

Date: 6/17/16

WYOMING MINING CONVENTION

Jackson, Wyoming

6/17/2016 WYOMING MINING CONVENTION 2016 Joy Global2

© 2016 Joy Global Inc. All rights reserved


Project Initiation

• A Partnership is required between the Customer and JGI to

determine the proper performance of the finished product.

• Each machine is as unique as the customer and mine-site.

• A full disclosure of previous updates, upgrades and

modifications needs to be available for JGI Engineering to

perform their analysis.

• Initial Engineering Requirements and possible correction to

ongoing issues. (Roller issues, Symmetry, Cracking)




Pre Engineering




Project Overview

• PHASE I FEASIBILITY STUDY

Can we do it?

• PHASE II DATA COLLECTION, PRELIMINARY DESIGN AND FEA

How do we do it?

• PHASE III COMPLETE ENGINEERING DESIGN OF SOLD KIT

Sold, do it!

• PHASE IV MANUFACTURING , FIELD LIAISON & VALIDATIONFollow through to completion



PHASE I – FEASIBILITY STUDY

• PROJECT DESCRIPTION

• SPECIFICATION

• BOOM LENGTH

• BOOM ANGLE

• RATED SUSPENDED LOAD

• COMPARATIVE ANALYSIS

• ANALYSIS RESULTS

• BOOM & BALLAST COMPARISON

• MAXIMUM DESIGN PARAMETERS (BASELINES)

• CONCLUSIONS REACHED

• FOLLOW-UP / SCHEDULE




•SWING ACCELERATION

•ROLLER LOADING

•DECK VERTICAL SHEAR LOADING

•DECK OVERTURNING MOMENT

•BOOM AXIAL LOADING (PINS)

•BOOM DECK LUG LOADING

•MAST AXIAL LOADING (PINS OR MAST)

•MAST DECK LUG LOADING

•SUSPENSION PENDANT LOADS

•AFRAME FRONTSTAY LOADING

•AFRAME BACKSTAY LOADING

•SWING INERTIA

•SWING MOTOR HEATING (RMS VS RATED)

•CYCLE TIME EFFECTS

•STABILITY (COUNTERWEIGHT)

COMPARATIVE ANALYSIS – DESIGN PARAMETERS




ANALYSIS

• ESTABLISH LOADING SPECTRUM OF EXISTING MACHINES ON

AFOREMENTIONED AREAS / COMPONENTS

• REVIEW DATA FOR ANOMALIES

• TABULATE RESULTS AND FIND MAXIMUMS

• ANALYZE NEW BOOM AND MAST

• REVIEW RESULTS RELATIVE TO EXISTING MAXIMUMS




2570W MAXIMUMS




What else needs to be accomplished?

• Customerization

• Reuse of existing components

• Machine Audit ( All bore locations)

• Additional work to be performed on the machine during installation

(lug replacements, boom length, boom angle and any upgrades)




Collect Data & FEA etc.



MAJOR FEA, WEIGHTS AND SECTION SIZING

Phase II - Data Collection

• FIELD TRIPS TO GATHER NECESSARY DATA

• PRELIMINARY DESIGN LAYOUTS

• CREATE 3D SOLID MODELS

• FEA BOOM AND MAST

• REPORT RESULTS



Hoist, Drag & Swing Settings

• Motor Settings

• Gear Ratios

• Hoist & Drag

• Swing

• Drum Pitch Diameter




Field Measurements

• Foot Lug & Pins

• Boom Point Cradle

• Suspension Links

• Sheave Diameters

• Location Mast

Deflection Sheave

• Number and Size of

suspension ropes

• Ladder, Platform &

Walkway

Arrangement




Components That Might Be Reused

• Boom Point Cradle & Sheaves

• Mast Deflecting Sheaves

• Boom Deflecting Sheaves




Recover Methodology For Raising Boom & Mast

2 hoist ropes reeved from hoist drum over Aframe sheaves to mast

sheaves and back over 2nd Aframe sheaves to dead ends at deck.




Preliminary Calculations

• Hoist rope pulls

• Swing accelerations and machine inertia

• Free body foot reactions




Range Diagram – Original

Boom Configuration – Twin Triangular, Tubular

Boom Length

Boom Angle

Dump Radius

Dump Height

Dig Depth

RSL

Mast Length

Mast Angle

No. Boom Aux Sheaves

Mast Sheave Location




Range Diagram – New Proposal

Boom Configuration – Wide Flange, 4

Chord, Rectangular

Boom Length

Boom Angle

Dump Radius

Dump Height

Dig Depth

RSL

Mast Length

Mast Angle

No. Boom Aux Sheaves

Mast Sheave Location




Phase II - New Design Layouts

• Wide flange chords

• Pipe lacing

Boom

Mast



Concept Layouts for FEA

Boom foot weldment Boom point weldment




Concept Layouts for FEA

Mast foot weldment

Mast head weldment




SolidWorks Stick Diagram to export into FEA model




Three dimensional model created and finite element analysis

performed.

FEMAP pre- and post-processor software used to build model

and gather results.

MSC NASTRAN software used to perform analysis.

Joy Global BMCHK (Boom Check) program used to tabulate

stress ranges and compare maximum tensile and compressive

stresses to AISC (American Institute of Steel Construction)

allowable stress and buckling criteria.

FEA model elements were changed and model re-run until Joy

Global design criteria for stress range and AISC allowable stress

and buckling criteria were met.

Phase II - FEA



• Preliminary sizing of elements

• Boom & mast chords

• Boom & mast lacing and bracing

• Suspension ropes

• Materials needed for cold weather operation (if required)

• Wide Flange Beams – ASTM A992 Normalized

• Pipes – ASTM A333

• Plate – ASTM A633

• Determine additional masses not part of FEA structure model

• Stairs, ladders & platforms

• Misc. hardware such as links, sheaves and pins

• Air, lube & electrical components

• H & D ropes

• Winches

Phase II - FEA



Determine FEA Load Cases

Combinations of:

• Dead Weight

• Pickup

• Hoist

• Dump

• Boom Rebound

• Return

Phase II - FEA



FEA Model – 609 Nodes & 1605 Elements

Phase II - FEA



Views with Element Shapes Shown

Phase II - FEA



FEA Model – Dead Weight, Bucket on Ground

Phase II - FEA



FEA Model – Pickup & Start Swing CCW

Phase II - FEA



FEA Model – Hoist & Swing Accel CCW

Phase II - FEA



FEA Model – Dump & Swing Plug CCW

Phase II - FEA



FEA Model – Rebound

Phase II - FEA



FEA Model – Return & Swing Accel CW

Phase II - FEA



FEA Model – Boom Raise with Intermediate Suspension

Phase II - FEA



Phase II - Report on Results

DESIGN PARMETERS RESULTS

WEIGHT TARGETS

BALLAST REQUIREMENTS

FOOT PIN REACTIONS

SUSPENSION ROPE FORCES AND SIZES

BOOM RAISING LOADS



Customer Places Order

Detailed FEA of Feet & Point Sections

Final Detailed Design of Components

Calculations updated as needed

Final Weights of all components

Formal Manufacturing Drawings Completed

Manufacturing commences

PHASE III



Boom Feet & Head Mast Feet & Head

Phase III - Detailed FEA



EXTENSIVE BOOM PLATFORMS

Phase III - Final Design



EXTENSIVE MAST PLATFORMS

Phase III - Final Design



Phase IV - Manufacturing, Field Assembly & Commission

Manufacturing

Facility Criteria

• Logistics

• Road Restrictions

• International Borders

• Freight Costs

• Component Size and Weight

• Fabrication Shop Capabilities

• Raw Material location and quantities

• Schedule to meet

Quality Control

• JGI on-site personnel

• Customer Visits

• Documentation

• Engineering Review

• Construction Team Visits












Field Assembly



















Phase IV - Manufacturing, Field Liaison & Validation

BACK AT WORK !!



Drone Video





QUESTIONS ?



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