Product Description
MAIN FEATURES
Model Characteristics
LW600KN wheel loader is rooted in the customers’ needs and based on the international R&D platform to thoroughly improve the product reliability, economy, comfort, efficiency, maintenance convenience, and adaptability and is a preferential machinery product for the production organization in the fields of ports, mines, engineering constructions, and logistics.
The super-strong heavy-duty structural parts, enhanced drive system, and globally supplied critical parts can carry the torsion and impact loads under diversified working conditions.
The high-efficiency electronic control countershaft transmission matches perfectly with the engine. The optimally designed working device equipped features automatic leveling, pilot control, and high operation efficiency.
With wide scope design, this machine is applicable for diversified working environments, including high altitude, heavy dust, high temperature, and low temperature. The diversified attachments can be equipped to meet the needs of diversified working conditions.
The centralized pressure measurement, “one-stop” maintenance, easily cleanable single-row radiator with large fin spacing, and extended replace ment interval of hydraulic oil realize short shutdown time and low maintenance cost.
The globalized full-enclosed and slightly pressurized cab with heating and air conditioning system features a broad vision and enlarges the interior space by 20%. The multi-direction adjustable control box and steering column and the scientific ergonomic design bring about a first-class driving/riding experience.
Engine
The three-stage air filter is designed especially for severe working environment of construction machinery industry.
The multi-stage fuel filter ensures good fuel adaptability and guarantees cleanliness of engine system.
Heavy-duty electronic control countershaft transmission
The material and heat treatment for pump shaft connecting spline are improved and the forced lubrication is applied to prolong the life by 20%.
Enhanced drive axle
With optimized materials and processes, the main reducer and wheel reducer passed the industry’s leading reliabilitylife test of >900,000 cycles.
The axle housing is design optimized and the cross section of the housing is enlarged to increase the carrying capacity and bending resistance by 10%.
The optional maintenance-free wet brake axle improves the braking reliability.
Structural parts
The super-strong heavy-duty design eliminates partial weaknesses and meets the needs under diversified severe operating conditions with fatigue destruction test of millions of cycles.
The robot welding process ensures stable weld quality and high fusion depth.
Hydraulic system
The double-pump confluence/distribution technology is applied so that the steering pump preferentially supplies oil to the steering system. When no steering operation is made, the oil flow of the steering pump completely flows into the working hydraulic system to reduce the displacement of working pump, improve the reliability of hydraulic units, and at the same time reduce the generated heat of hydraulic system
and realize energy-conservation.
The automatic unloading function is provided to reduce the energy loss of high pressure overflow of the hydraulic system, increase the traction force by 15% under combination operation, and remarkably improve the working efficiency.
Working device
The high-efficiency linkage system features fast motions, high breakout force, and powerful lifting capacity.
With optimal shape design, the bucket features low insertion resistance and high fullness rate.
The CZPT plates are additionally installed for the standard bucket and the rock bucket to prevent the splashing of material.
Comfortable operations
The full-hydraulic pilot controlled working device and steering system features handy control and reduces the working strength of the driver.
The steering gear, seat, and control box are freely adjustable depending on the operator’s needs.
The strong human-machine interactivity for the pedals and controls mitigates the fatigue during long-time operations.
The combination (flexible mode first and rigid mode second) of hydraulic flexible mode and mechanical rigid mode is adopted for the steering limits, in order to relieve the impact and ensure driving/riding comfort.
Comfortable driving environment
Well insulated against noise, dust, and heat, the full-enclosed integral framework cab creates a healthy driving environment.
The panoramic glasses and super-large spherical rearview mirrors ensure a broad vision and easy and safe operations.
The utilizable space of the cab is enlarged by 20% and the seats are backward inclinable in large angle to bring about more comfort.
The slightly pressurized A/C system with filtration function provides the operator with a comfortable working environment.
The graceful and elegant instruments bring about a car-style visual enjoyment.
Reversing camera: The optional reversing camera system realizes higher reversing safety.
Operation economy
The working device is design optimized to reduce the unnecessary consumption and improve the power utilization rate.
The high energy-conservation and high-efficiency hydraulic system is applied to realize higher fuel utilization efficiency and more powerful working capacity.
The replacement interval is extend ed from 250h to 500h for the engine oil and is extended to 2,000h for the hydraulic oil to shorten the shut down time and reduce the mainte nance cost. In addition, the replace ment volume of hydraulic oil is reduced by 20% compared with the like models.
Environment adaptability
Normal operation under environment temperature of -35ºC~+45ºC.
No power drop under altitude of up to 3,000m
A high-flow ventilator is installed for various systems to meet the operation needs under heavily dusty environment.
Convenient maintenances
The engine hood adopts upturning large door design in large opening angle to ease the daily maintenances.
The “one-stop” maintenance can be fulfilled for the engine oil filter, diesel filter, transmission and torque converter filters, and air filter.
The centralized pressure measurement and the centralized lubricating for the hinges ease the services and maintenances.
The externally arranged booster cylinder, air reservoir, and A/C achieve reasonable structural arrangement and easy maintenances.
parameters
| Item | Specification | Unit | |
|---|---|---|---|
| Rated operating load | 6000 | kg | |
| Bucket capacity | 3.0~4.5 | m³ | |
| Machine weight | 20000±300 | kg | |
| Dump clearance at maximum lift | 3170~3750 | mm | |
| Reach at maximum lift | 1200~1360 | mm | |
| Wheel base | 3350 | mm | |
| Tread | 2265 | mm | |
| Max.breakout force | 205 | kN | |
| Hydraulic cycle time-raise | 5.9 | s | |
| Total hydraulic cycle time | 10.9 | s | |
| Min. turning radius over tyres | 6005 | mm | |
| Articulation angle | 38 | ° | |
| Gradeability | 28 | ° | |
| Tyre size | 23.5-25 | ||
| Overall machine dimension L×W×H | 8505×3220×3515 | ||
| Rated Power | 178 | Kw | |
| Travel speed | i-gear(F/R) | 6/6 | km/h |
| ii-gear(F/R) | 11/11 | ||
| iii-gear(F/R) | 22/22 | ||
| IV-gear(F/R) | 34/34 | km/h | |
| No further information of sample contents, product structure and configuration parameters updates.There maybe some difference bet | |||
How to Calculate Stiffness, Centering Force, Wear and Fatigue Failure of Spline Couplings
There are various types of spline couplings. These couplings have several important properties. These properties are: Stiffness, Involute splines, Misalignment, Wear and fatigue failure. To understand how these characteristics relate to spline couplings, read this article. It will give you the necessary knowledge to determine which type of coupling best suits your needs. Keeping in mind that spline couplings are usually spherical in shape, they are made of steel.
Involute splines
An effective side interference condition minimizes gear misalignment. When 2 splines are coupled with no spline misalignment, the maximum tensile root stress shifts to the left by 5 mm. A linear lead variation, which results from multiple connections along the length of the spline contact, increases the effective clearance or interference by a given percentage. This type of misalignment is undesirable for coupling high-speed equipment.
Involute splines are often used in gearboxes. These splines transmit high torque, and are better able to distribute load among multiple teeth throughout the coupling circumference. The involute profile and lead errors are related to the spacing between spline teeth and keyways. For coupling applications, industry practices use splines with 25 to 50-percent of spline teeth engaged. This load distribution is more uniform than that of conventional single-key couplings.
To determine the optimal tooth engagement for an involved spline coupling, Xiangzhen Xue and colleagues used a computer model to simulate the stress applied to the splines. The results from this study showed that a “permissible” Ruiz parameter should be used in coupling. By predicting the amount of wear and tear on a crowned spline, the researchers could accurately predict how much damage the components will sustain during the coupling process.
There are several ways to determine the optimal pressure angle for an involute spline. Involute splines are commonly measured using a pressure angle of 30 degrees. Similar to gears, involute splines are typically tested through a measurement over pins. This involves inserting specific-sized wires between gear teeth and measuring the distance between them. This method can tell whether the gear has a proper tooth profile.
The spline system shown in Figure 1 illustrates a vibration model. This simulation allows the user to understand how involute splines are used in coupling. The vibration model shows 4 concentrated mass blocks that represent the prime mover, the internal spline, and the load. It is important to note that the meshing deformation function represents the forces acting on these 3 components.
Stiffness of coupling
The calculation of stiffness of a spline coupling involves the measurement of its tooth engagement. In the following, we analyze the stiffness of a spline coupling with various types of teeth using 2 different methods. Direct inversion and blockwise inversion both reduce CPU time for stiffness calculation. However, they require evaluation submatrices. Here, we discuss the differences between these 2 methods.
The analytical model for spline couplings is derived in the second section. In the third section, the calculation process is explained in detail. We then validate this model against the FE method. Finally, we discuss the influence of stiffness nonlinearity on the rotor dynamics. Finally, we discuss the advantages and disadvantages of each method. We present a simple yet effective method for estimating the lateral stiffness of spline couplings.
The numerical calculation of the spline coupling is based on the semi-analytical spline load distribution model. This method involves refined contact grids and updating the compliance matrix at each iteration. Hence, it consumes significant computational time. Further, it is difficult to apply this method to the dynamic analysis of a rotor. This method has its own limitations and should be used only when the spline coupling is fully investigated.
The meshing force is the force generated by a misaligned spline coupling. It is related to the spline thickness and the transmitting torque of the rotor. The meshing force is also related to the dynamic vibration displacement. The result obtained from the meshing force analysis is given in Figures 7, 8, and 9.
The analysis presented in this paper aims to investigate the stiffness of spline couplings with a misaligned spline. Although the results of previous studies were accurate, some issues remained. For example, the misalignment of the spline may cause contact damages. The aim of this article is to investigate the problems associated with misaligned spline couplings and propose an analytical approach for estimating the contact pressure in a spline connection. We also compare our results to those obtained by pure numerical approaches.
Misalignment
To determine the centering force, the effective pressure angle must be known. Using the effective pressure angle, the centering force is calculated based on the maximum axial and radial loads and updated Dudley misalignment factors. The centering force is the maximum axial force that can be transmitted by friction. Several published misalignment factors are also included in the calculation. A new method is presented in this paper that considers the cam effect in the normal force.
In this new method, the stiffness along the spline joint can be integrated to obtain a global stiffness that is applicable to torsional vibration analysis. The stiffness of bearings can also be calculated at given levels of misalignment, allowing for accurate estimation of bearing dimensions. It is advisable to check the stiffness of bearings at all times to ensure that they are properly sized and aligned.
A misalignment in a spline coupling can result in wear or even failure. This is caused by an incorrectly aligned pitch profile. This problem is often overlooked, as the teeth are in contact throughout the involute profile. This causes the load to not be evenly distributed along the contact line. Consequently, it is important to consider the effect of misalignment on the contact force on the teeth of the spline coupling.
The centre of the male spline in Figure 2 is superposed on the female spline. The alignment meshing distances are also identical. Hence, the meshing force curves will change according to the dynamic vibration displacement. It is necessary to know the parameters of a spline coupling before implementing it. In this paper, the model for misalignment is presented for spline couplings and the related parameters.
Using a self-made spline coupling test rig, the effects of misalignment on a spline coupling are studied. In contrast to the typical spline coupling, misalignment in a spline coupling causes fretting wear at a specific position on the tooth surface. This is a leading cause of failure in these types of couplings.
Wear and fatigue failure
The failure of a spline coupling due to wear and fatigue is determined by the first occurrence of tooth wear and shaft misalignment. Standard design methods do not account for wear damage and assess the fatigue life with big approximations. Experimental investigations have been conducted to assess wear and fatigue damage in spline couplings. The tests were conducted on a dedicated test rig and special device connected to a standard fatigue machine. The working parameters such as torque, misalignment angle, and axial distance have been varied in order to measure fatigue damage. Over dimensioning has also been assessed.
During fatigue and wear, mechanical sliding takes place between the external and internal splines and results in catastrophic failure. The lack of literature on the wear and fatigue of spline couplings in aero-engines may be due to the lack of data on the coupling’s application. Wear and fatigue failure in splines depends on a number of factors, including the material pair, geometry, and lubrication conditions.
The analysis of spline couplings shows that over-dimensioning is common and leads to different damages in the system. Some of the major damages are wear, fretting, corrosion, and teeth fatigue. Noise problems have also been observed in industrial settings. However, it is difficult to evaluate the contact behavior of spline couplings, and numerical simulations are often hampered by the use of specific codes and the boundary element method.
The failure of a spline gear coupling was caused by fatigue, and the fracture initiated at the bottom corner radius of the keyway. The keyway and splines had been overloaded beyond their yield strength, and significant yielding was observed in the spline gear teeth. A fracture ring of non-standard alloy steel exhibited a sharp corner radius, which was a significant stress raiser.
Several components were studied to determine their life span. These components include the spline shaft, the sealing bolt, and the graphite ring. Each of these components has its own set of design parameters. However, there are similarities in the distributions of these components. Wear and fatigue failure of spline couplings can be attributed to a combination of the 3 factors. A failure mode is often defined as a non-linear distribution of stresses and strains.
