DESIGNING A BUCKET MECHANISM OF A BACKHOE LOADER

7/23/2019 DESIGNING A BUCKET MECHANISM OF A BACKHOE LOADER

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DESIGNING A BUCKET MECHANISM OF

A BACKHOE LOADER

A PROJECT REPORT

Submitted by

MECHANICAL ENGINEERING DEPARTMENT

HACETTEPE UNIVERSITY

MAY2015

Alperen KALECantrk SANANFetihhan GRANM.Emre PAKSOY


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i

ABSTRACT

This is the final and third report of the stationary backhoe design project. This project is

combination of both design of systems and selection of systems. Design of systems includes

all the necessary calculations of a mechanical system, such as; static, dynamic, stress, fatigue

analysis so on and so forth. All of the calculations carried out with the help of Statics,

Dynamics, Strength of Materials, Design of Machine Elements and in particular Vehicle

Component Design courses. Selection of systems depends on online part selection tools of

firms and inspection of equivalent systems. These two main design processes combined

together to constitute the proper stationary backhoe for required work conditions with the

comprehensive effort of group members.


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ii

Table of Contents

I. Introduction ......................................................................................................................... 3

A. Problem Statement .......................................................................................................... 3

B. Motivation ....................................................................................................................... 3

C. Challenges and Goals ...................................................................................................... 3

D. Work Plan ........................................................................................................................ 4

II. LITERATURE SURVEY AND PRELIMINARY DESIGN ............................................. 5

A. Literature Survey ............................................................................................................. 5

B. Pugh Chart ....................................................................................................................... 6

C. Design Approach ............................................................................................................. 6D. Schematic Drawing ......................................................................................................... 7

III. DESIGN AND SIMULATION ....................................................................................... 9

A.Static Analysis .................................................................................................................. 10

B. Stress Analysis ................................................................................................................. 14

C. Dynamic Analysis ............................................................................................................ 21

D. Fatigue Analysis .............................................................................................................. 23

E. Machine Components Design ....................................................................................... 27

F. Simulation Results ............................................................................................................ 40

Mesh Information - Details ................................................................................................... 48

Mesh Control Information: ................................................................................................... 49

G. Cost Analysis ................................................................................................................... 55

H. 3D Drawings .................................................................................................................... 56

IV. CONCLUSION AND DISCUSSION ........................................................................... 62

A. Summary and Discussion of the Results ......................................................................... 62

B. Future Works ................................................................................................................... 62V. REFERENCES ................................................................................................................. 63


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iii

List of Tables

Table 1 - Task timetable ............................................................................................................. 4

Table 2 - Pugh Chart .................................................................................................................. 6

Table 3 - Cost Table ................................................................................................................. 55

List of Figures

Figure 1 - Free body diagram of the Bucket .............................................................................. 7

Figure 2 - Free body diagram of the Stick ................................................................................. 7

Figure 3 - Free body diagram of the Boom ................................................................................ 8

Figure 4 - Critical points of Factor of Safety ........................................................................... 53

Figure 5 - Critical points of Factor of Safety ........................................................................... 53

Figure 6 - Fatigue analysis and total life .................................................................................. 54Figure 7 - Static Factor of Safety Critical points ..................................................................... 54

Figure 8 - Side view technical drawing of closed position ..................................................... 56

Figure 9 - Top view technical drawing of closed position ....................................................... 56

Figure 10 - Front and back view technical drawing ................................................................ 57

Figure 11 - Top view technical drawing of opened position .................................................... 58

Figure 12 - Isometric view technical drawing of opened position ........................................... 58

Figure 13 - Isometric view technical drawing of closed position ........................................... 59

Figure 14 - CAD view 1 ........................................................................................................... 60

Figure 15 - CAD view 2 ........................................................................................................... 60

Figure 16 - CAD view 3 ........................................................................................................... 61


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Hacettepe University Department of Mechanical Engineering 3

I. Introduction

A.Problem Statement

Stationary backhoes are widely used in almost every mass production sector to carry

products from one place to another effectively. One can examine and find out that these

backhoes are mostly over safe and oversize for most applications. This projects aim is to

design a stationary backhoe which is safe enough, less cost and capable of performing the

duty without any restrictions.

B.

Motivation

The basic reason behind this project is to prevent large amount of energy losses which are

produced while the production of these oversize backhoes and during the operation of these

backhoes. Realizing that the most urgent problems of the World are the energy shortage and

the climate change which is directly affected by the energy production methods, even a small

amount of energy gain is very important.

C.

Challenges and Goals

Design of this project includes two main parts. The first one is designing a stationary

backhoe with the ability of lifting 500 kg load and the second one is designing necessary

components to run this stationary backhoe. Optimization of the geometry of the backhoe to

reach reasonable factor of safeties and reasonable sizes is the main difficulty, lots of iterations

needed. Another challenging is designation of driver components, there are billions of options

and most effective ones have to be chosen.


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D.Work Plan

1. Preparing first report and completing literature survey: 1st and 2nd weeks.

2. Completing hand calculations: 3

rd

and 4

th

week.3. Machine components design (Shafts and Bearings): 5th week.

4. Schematic drawings: 6th week.

5. Setting Second Report: 7th week.

6. CAD drawings and FEM analysis: 8th week.

7. Machine components design: 9th week.

8. Technical drawings- Parts list cost analysis: 10th week.

9. Setting final report- Preparing presentation: 11th

week.

Table 1 - Task timetable


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II. LITERATURE SURVEY AND PRELIMINARY DESIGN

A.

Literature Survey

At the beginning of this project the textbook has been exhaustively examined. A general

idea about for each component has gained by group members. Afterwards applications of

these component has been researched and compared with similar ones. These researches are

made via internet or speaking with the firms at phone.

Some of these sources;

1.

How Caterpillar Backhoe Loaders Work

http://science.howstuffworks.com/transport/engines-equipment/backhoe-loader1.htm

2.New Backhoe Loaders CAT 422F

http://www.cat.com/en_ZA/products/new/equipment/backhoeloaders/sideshift/18346265.html

3.CAT Backhoe Loader Brochure

http://s7d2.scene7.com/is/content/Caterpillar/C768535

4.Backhoe Loader

http://en.wikipedia.org/wiki/Backhoe_loader

5.Backhoe

http://opensourceecology.org/wiki/Backhoe

6. SKF Rolling Bearings

http://www.skf.com/binary/138-121486/SKF-rolling-bearings-catalogue.pdf

7. SKF Extra Power Belts

http://www.skf.com/binary/92-118145/Xtra-Power-belts---10552_3-EN.pdf

8. SKF Belt Drive Design Calculations Tool

http://www.skf.com/group/knowledge-centre/engineering-tools/belt-drive-design-

calcalutions-tool.html

9. Gamak 3 Phase Asynchronous Electric Motors

http://www.gamak.com/images/urun-pdf/standart_motorlar.pdf


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B.Pugh Chart

Table 2 - Pugh Chart

C.

Design Approach

The basic design approach of this project rely on the motivation of this project. The

sufficient and necessary design method for less energy loss is downsizing. Cost of the project

is another issue that has to be minimized, avoiding from over safe parts will result less energy

loss and less cost. The reliability of this stationary backhoe must be satisfactory so an

optimization is essential between downsizing approach and safety. Such an optimization has

been considered through whole project.

0

0

0

0

Reference Design 1 Reference Design 2 Our Design


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D.Schematic Drawing

1. Free Body Diagram of the Bucket

Figure 1 - Free body diagram of the Bucket

2. Free Body Diagram of the Stick

Figure 2 - Free body diagram of the Stick


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3. Free Body Diagram of the Boom

Figure 3 - Free body diagram of the Boom


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III. DESIGN AND SIMULATION

In this part static analysis, dynamic analysis have been made by hand calculations. Also

stress and fatigue analysis have been completed by hand calculations. Assumptions needed to

make analysis are decided after an intense literature survey. A rough sketch of boom, stick

and bucket is completed.

Decision and design of back parts of the system such as electirc motor, shafts and

bearings are made according to necessary power to carry a 500 kg load. The static analysis for

bucket is made in this part.

To begin with, the mass of bucket is assumed as 200 kg and a factor of safety is

considered as 4. The factor of safety is used at the begining of static analysis instead of using

at the end of the stress values consideration.

The desired maximum load is 500 kg. The calculations are made due to this approach,

and therefore the maximum load is taken as 2000 kg. According to this value, the piston

forces and the reactions forces are determined. The formulas and calculations are shown

below.


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A. Statc Analyss

1. Bucket:

Bucket mass mbucket 200 kgkgkgkg

Mass carred by bucket mload 500 kgkgkgkg

Bucket length Lbucket 130 cmcmcmcm

Bucket to pston rod angle bucket 70

Bucket max. closed angle b.closed 30

Bucket to pston dstance db.p 45 cmcmcmcm

Bucket jont dstance db.j 20 cmcmcmcm

Stck to ground angle s.g 0

Factor of Safety FoSbucket 4

Pston 1 Force:

FP1

+mload FoSbucket mbucket gggg Lbucket

2 cos b.closed

db.p sin bucket db.j

=FP1 54.494 kNkNkNkN

Force balance for ont 1 at y axs:

R1y +mload FoSbucket mbucket gggg

=R1y 21.575 kNkNkNkN

Force balance for ont 1 at x axs:

R1x FP1

=R1x 54.494 kNkNkNkN

Hacettepe University Department of Mechanical Enginnering 10


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2.Stck:

The mass of stck, lengths and angles are assumed and gven below. Due to these

values, the reactons and pston forces are determned.

Stck Length Lstick 2.6 mmmm

Stck Mass mstick 200 kgkgkgkg

Dstance between stck and pston 1 ds.p1 25 cmcmcmcm

Pston to ground angle p2.g 30

Stck arm !ont to !ont " dstance ds.j2.j3 60 cmcmcmcm

Pston #orce$

FP2

+Lstick

2 mstick gggg R1y Lstick FP1 ds.p1

sin p2.g ds.j2.j3


#orce balance for %ont at & a&s$

R2x +R1x FP2 cos p2.g FP1


#orce balance for %ont at ' a&s$

R2y ++R1y mstick gggg FP2 sin p2.g

=R2y 98.57 kNkNkNkN



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3.Boom:

The mass of boom, shape, lengths and angles are assumed and gven below. Due to

these values, the reactons and pston forces are determned.

Boom length 1 Lb1 1.5 mmmm

Boom length 2 Lb2 1.7 mmmm

Mass of boom mboom 350 kgkgkgkg

Pston 3 to groung angle p3.g 60

Pston 2 perpendcular dstance to ont 3 dp2.j3 +Lb2 sin p3.g ds.j2.j3 sin p2.g

=dp2.j3 1.772 mmmm

!ont 2 to ont 3 hor"ontal dstance dj2.j3x +Lb2 cos p3.g Lb1 cos p2.g

=dj2.j3x 2.149 mmmm

!ont 2 to ont 3 vertcal dstance dj2.j3y +Lb2 sin p3.g Lb1 sin p2.g

=dj2.j3y 2.222 mmmm

#o$ of Boom to ont 3

perpendcular dstance

dcogb.j3 Lb2 cos p3.g

=dcogb.j3 0.85 mmmm

Pston 3 to ont 3

perpendcular dstance

dp3.j3 ds.j2.j3 sin p2.g

=dp3.j3 0.3 mmmm

Moment balance for boom%

Mj3 0

FP3 ++mboom gggg dcogb.j3 R2y dj2.j3x R2x dj2.j3y FP2 dp2.j3

dp3.j3




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&orce balance for !ont 3 at ' a(s

R3y ++R2y mboom gggg FP3 sin p3.g FP2 sin p2.g

=R3y 580.923 kNkNkNkN

&orce balance for !ont 3 at ( a(s

R3x +R2x FP3 cos p3.g FP2 cos p2.g




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B. Stress Analyss

1.Bucket:

Wdth of bucket Wbucket 70 cmcmcmcm

Abucket Lbucket Wbucket 1.5 =Abucket 1.365 mmmm2

bucket mload FoSbucket

Abucketgggg =bucket 14.369 kPakPakPakPa

Snce the total stress s too small the stress analyss s not necessary. The bucket

wll not fal.

2. Stck:

The lengths (wdth, heght and wall thckness) of stck and ts profle are assumed and

gven below. Due to these values, the stress analyss s done and the results are shown.

Wdth of stck wstick 200 mmmmmmmm

eght of stck hstick 150 mmmmmmmm

Wall thckness of stck sstick 10 mmmmmmmm

!ont dameter Djoint 50 mmmmmmmm

Stress concentraton factor Kt.stick 2

"rea of stck#

Astick hstick wstick hstick 2 sstick wstick 2 sstick 2 Djoint sstick

=Astick 0.006 mmmm2

"rea moment of nerta of stck#

Istick hstick

3wstick wstick 2 sstick hstick 2 sstick

3

12

=Istick 2.33 105

mmmm4



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Axal Stresses:

a.stick +FP1 R1x R2x

Astick

=a.stick 23.208 MPaMPaMPaMPa

Bendng Stresses:

b.stick +

mstick gggg Lstick

2

hstick

2

Istick

R1y Lstick hstick

2

Istick

FP1 ds.p1 hstick

2

Istick

=b.stick 144.946 MPaMPaMPaMPa

Total Stresses:

tot.stick +a.stick b.stick Kt.stick

=tot.stick 243.477 MPaMPaMPaMPa

3. Boom:

The lengths (wdth, heght and wall thckness) of stck and ts profle are assumed and

gven below !ue to these values, the stress anal"ss s done and the results are shown

#dth of Boom wboom 350 mmmmmmmm

$eght of Boom hboom 300 mmmmmmmm

#all thckness of Boom sboom 30 mmmmmmmm

Stress concentraton factor Kt.boom 1.5

Area of Boom

Aboom hboom wboom hboom 2 sboom wboom 2 sboom

=Aboom 0.035 mmmm2



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Area moment of nerta of boom:

Iboom hboom

3wboom wboom 2 sboom hboom 2 sboom

3

12

=Iboom 4.534 104

mmmm4

Axal Stresses:

a.boom +FP2 R2x FP3 cos p3.g

Aboom

cos p3.g

=a.boom 4.801 MPaMPaMPaMPa

Bendng Stresses:

b.boom Kt.boom hboom

2

+++

FP3 dp3.j3Iboom

FP2 dp2.j3

Iboom

mboom gggg dcogb.j3Iboom

R2y dj2.j3x

Iboom

=b.boom 143.314 MPaMPaMPaMPa

4. Jont between bucket and stck

Materal IS2062

Stress lmt for bucket pn

jont

max.bpj 205 MPaMPaMPaMPa

Allowable sear stress bpj 42 MPaMPaMPaMPa

Maxmum bearng pressure Pbpj 40 MPaMPaMPaMPa

!ameter of bucket pn jont dbpj 50 mmmmmmmm

"engt of bucket pn jont Lbpj 300 mmmmmmmm



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Effectve length of pn jont Lbpje 225 mmmmmmmm

Ymax.bpj dbpj2

=Ymax.bpj 25 mmmmmmmm

R1xy+R1y

2R1x

2=R1xy 58.61 kNkNkNkN

Bearng Force of bucket pn

jontPbpj1

R1xy

dbpj Lbpje

=Pbpj1 5.21 MPaMPaMPaMPa


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Maxmum bendng stress

developped n the bucket pnbpj

Mbpj Ymax.bpjIbpj

=bpj 134.324 MPaMPaMPaMPa


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Shear force actng on bucket spj1 R2xy

Aspj

=spj1 18.461 MPaMPaMPaMPa


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Effectve length of pn jont Lbopje 285 mmmmmmmm

Ymax.bopj dbopj

2 =Ymax.bopj 60 mmmmmmmm

R3xy+R3y

2R3x

2=R3xy 663.144 kNkNkNkN

Bearng Force of bucket pn

jont

Pbopj1 R3xy

dbopj Lbopje

=Pbopj1 19.39 MPaMPaMPaMPa


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Maxmum bendng stress

developped n the bucket pn

bopjbopj max.bopj

Ibopj=bopj 139.258 MPaMPaMPaMPa


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The angular velocty gven below s the angular velocty of the stck at z axs.

stick

4

radradradrad

ssss

Accordng to ths angular velocty, dynamc force analyss has been evaluated:

Fsmax.x +mcombined stick2

Lstick R1x

=Fsmax.x 58.183 kNkNkNkN

Fsmin.x R1x

=Fsmin.x 54.494 kNkNkNkN

Boom Analyss

Same approach whc has been used for stck dynamc analyss s also used for

boom analyss.

mcombined.b +++mstick mbucket 4 mload mboom

2

=mcombined.b 2575 kgkgkgkg

The acceleraton gven below s angular acceleraton of the boom on z axs.

boom.z

8

radradradrad

ssss2

Accordng to ths acceleraton, dynamc force analyss has been evaluated:

Lboom 3.09 mmmm

Fbmax.y +mcombined.b boom.z Lboom sin 25 R3y

=Fbmax.y 580.51 kNkNkNkN

Fbmin.y mcombined.b boom.z Lboom sin 25 R3y

=Fbmin.y 581.337 kNkNkNkN



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The angular velocty gven below s the angular velocty of the boom at z axs.

boom

4

radradradrad

ssss

Accordng to ths angular velocty, dynamc force analyss has been evaluated:

Fbmax.x +mcombined.b boom2

Lboom R3x

=Fbmax.x 324.734 kNkNkNkN

Fbmin.x R3x

=Fbmin.x 319.826 kNkNkNkN

D. Fatgue Analyss

The selected materal for ths backhoe applcaton s AR !" #teel.

$ropertes of AR !":

%eld strength y.235 482.6 MPaMPaMPaMPa

Tensle strength u.235 792.89 MPaMPaMPaMPa

&ndurance lmt S'e 396.45 MPaMPaMPaMPa

&ndurance lmt correlaton factors are set as :

#urface condton modfcaton factor

for machned steel

ka 0.88

#ze factor for bendng kb 0.667

'orkng condtons are always at

reasonable temperatures. #o the

temperature factor

kd 1

Relablty factor for (() ke 0.814

*scellaneous effects factor kf 1



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Corrected endurance lmt:

Se ka kb kd ke kf S'e =Se 189.418 MPaMPaMPaMPa

1. Stck Analyss

a.stick.max +FP1 Fsmax.x R2x

Astick=a.stick.max 22.549 MPaMPaMPaMPa

b.stick.max

+

mstick gggg Lstick

2 h

stick

2

Istick

Fsmax.y Lstick hstick

2

Istick

FP1 ds.p1 hstick

2

Istick

Kt.stick

=b.stick.max 329.207 MPaMPaMPaMPa

stick.max +b.stick.max a.stick.max =stick.max 306.658 MPaMPaMPaMPa

a.stick.min+FP1 Fsmin.x R2x

Astick=a.stick.min 23.208 MPaMPaMPaMPa

b.stick.min

+

mstick gggg Lstick

2

hstick

2

Istick

Fsmin.y Lstick hstick

2

Istick

FP1 ds.p1 hstick

2

Istick

Kt.stick

=b.stick.min 250.576 MPaMPaMPaMPa

stick.min +b.stick.min a.stick.min =stick.min 227.369 MPaMPaMPaMPa

Alternatng stress of crtcal pont of stck:

stick.alt stick.max stick.min2

=stick.alt 39.645 MPaMPaMPaMPa



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Mean stress of crtcal pont of stck:

stick.mean +stick.max stick.min2

=stick.mean 267.013 MPaMPaMPaMPa

Soderberg Falure Crteran:

Fatgue factor of Safety for stck

nstick.f Se y.235

+stick.alt y.235 Se stick.mean

=nstick.f 1.311

2. Boom Analyss

a.boom.max Kt.boom +FP2 R2x FP3 cos p3.g

Aboom

cos p3.g

=a.boom.max 0.843 MPaMPaMPaMPa

Kt.boom 0.41

b.boom.max Kt.boomhboom

2

+++

FP3 dp3.j3Iboom

FP2 dp2.j3

Iboom


Fbmax.y dj2.j3x

Iboom

=b.boom.max 179.652 MPaMPaMPaMPa

boom.max +b.boom.max a.boom.max =boom.max 178.809 MPaMPaMPaMPa

a.boom.min ++FP1 Fbmin.x R2x

Astick=a.boom.min 70.588 MPaMPaMPaMPa



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b.boom.min Kt.boomhboom

2

+++

FP3 dp3.j3Iboom

FP2 dp2.j3

Iboom


Fbmin.y dj2.j3x

Iboom

=b.boom.min 159.011 MPaMPaMPaMPa

boom.min +b.boom.min a.boom.min =boom.min 88.423 MPaMPaMPaMPa

Alternatng stress of crtcal pont of stck:

boom.altboom.max boom.min2

=boom.alt 133.616 MPaMPaMPaMPa

Mean stress of crtcal pont of stck:

boom.mean+boom.max boom.min

2

=boom.mean 45.193 MPaMPaMPaMPa

Soderberg Falure Crteran:

Fatgue factor of Safety for stck

nboom.f

Se y.235+boom.alt y.235 Se boom.mean

=nboom.f 1.251

NOTE: All the factor of safetes are actually 4 tmes of ther values snce at the

begnnng of the analyss load has taken to be 2000 kg nstead of 500 kg



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E. Machne Components Desgn

Assumptons:

Time for liftng the bucket to 5m

y 5 mmmm

tlift 4 ssss Vy y

tlift=Vy 1.25

mmmm

ssss

Power Caluculatons:

Requred power n drecton

of y asPy +

+mload mbucket gggg y

tlift

mstick gggg y

2

tlift

=Py 9.807 kWkWkWkW

The dstance between the Co! of the bucket and "ont #:

rbucket.x ++Lb1 sin p3.g Lb2 cos p3.g Lstick Lbucket cos b.closed

rbucket.y +Lb1 cos p3.g Lb2 sin p3.g Lbucket sin b.closed

rbucket+rbucket.x

2rbucket.y

2

=rbucket 3.95 mmmm

The dstance between the Co! of the stck and "ont #:

rstick.x ++Lb1 sin p3.g Lb2 cos p3.g

Lstick

2

rstick.y +Lb1 cos p3.g Lb2 sin p3.g

rstick+rstick.x

2rstick.y

2

=rstick 4.103 mmmm



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The dstance between the CoG of the boom and Jont 3:

rboom.x Lb1 sin p3.g

rboom.y Lb1 cos p3.g

rboom+rboom.x

2rboom.y

2

=rboom 1.5 mmmm

Angular velocty:

w

4

radradradrad

ssss

Angular acceleraton:

8

radradradrad

ssss2

Moment of Inertas:

Ibucket.p +mbucket mload rbucket2

=Ibucket.p 1.092 104

kgkgkgkg mmmm2

Istick.p mstick rstick2

=Istick.p 3.367 103

kgkgkgkg mmmm2

Iboom.p mboom rboom2

=Iboom.p 787.5 kgkgkgkg mmmm2

Actng toqrue:

++Iboom.p Istick.p Ibucket.p

= 5919.562 NNNN mmmm

equred !ower to rotate the system n drecton of " a#s:

Pz w

=Pz 4.649 kWkWkWkW

Total requred !ower:

Pdet +Py Pz

=Pdet 14.456 kWkWkWkW



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Effcences:

mechanical 0.9

hydraulic 0.7

Power of hydraulc motor:

P Pdet

hydraulic mechanical

=P 22.946 kWkWkWkW

Electric motor efficiency and gearbox efficiency

el.motor 0.91

gb 0.9

Pel.motor P

el.motor gb

=Pel.motor 28.017 kWkWkWkW

It s assumed that, the backhoe s workng at a fxed poston wth AC electrcty

Consderng rough calculatons, the speed of electrc motor s found low !o t s

con"enent to use AC motor wth # poles

Power of electric motor $ %& kw choosen

Propertes of electrc motor:

MARATHON 404 TTFS8102 % phases, '& (), %&k*, +'& rpm, -+. eff

P 30 kWkWkWkW

N 750 rpmrpmrpmrpm



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1. Shaft Desgn:

When desgnng the shaft, smlar applcatons are researched. Theconvenent materal for ths shaft s determned as AISI 440 C steel.

The propertes of shaft are gven below:

ength of shaft L 2 mmmm

!eld strength y 450 MPaMPaMPaMPa

Shear mod"l"s G 77.2 GPaGPaGPaGPa

#lasc mod"l"s E 210 GPaGPaGPaGPa

$enst% 7800kgkgkgkg

mmmm3

Shear %eld strength y 0.5

The cl"tch ma% ca"se mpacts on the shaft so&

'actor of safet% n 2.4

Allowable shear stress:

all

n

=all 93.75 MPaMPaMPaMPa

(a)m"m tor*"e appled on the shaft:

T P

N

=T 381.972 NNNN mmmm

Shaft dameter calc"latons:

$ameter

d3

T 16

all

=d 2.748 cmcmcmcm



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The shaft dameter s assumed as 3 cm;

d 3 cmcmcmcm

Mass of shaft

m d

2

4 L

=m 11.027 kgkgkgkg

Weght of shaft W m gggg

=W 108.138 NNNN

Weght dstrbuton wdistW

L

Polar moment of nerta J d

4

32 =J 7.952 10

8mmmm

4

Area moment of nerta I

64 d

4=I 3.976 10

8mmmm

4

Angular deflecton

t T L

J G360

2

=t 7.13

Bendng deflecton

max5 wdist L

4

384 E I

=max 1.349 103

mmmm

Maxmum speed

Nmax 0.75

gggg

max

=Nmax 610.628 rpmrpmrpmrpm

The maxmum speed s lower than requred speed of shaft. o the new

dameter s selected as ! cm



34/70

"ameter of shaft d 4 cmcmcmcm

Mass of shaftm

d2

4 L

=m 19.604 kgkgkgkg

Weght of shaft W m gggg

=W 192.245 NNNN

Weght dstrbuton wdistW

L

Polar moment of nerta J d

4

32 =J 2.513 10

7mmmm

4

Area moment of nerta I

64 d

4=I 1.257 10

7mmmm

4

Angular deflecton

t T LJ G

3602

=t 2.256

Bendng deflecton

max 5 wdist L

4

384 E I

=max 7.588 104

mmmm

Maxmum speed

Nmax 0.75

gggg

max

=Nmax 814.171 rpmrpmrpmrpm

Maxmum speed s hgher than the requred speed. o t can be used.



35/70

2. Bearng Selecton

Lfe assumpton:

It s assumed that the backhoe wll work 30 years,

9 month per year and 8 hour per day

Life 750 30 270 8 60

106

=Life 2.916 103

mllon cycle

ka 1.1 because of clutch impactmay occur

kr 1 90% reliability is enouh

FbW

2 a 3

C a

Life ka Fb =C 1.511 kNkNkNkN

!earin selection

"eep roo#e ball bearin is choosen because of low radial forces

$& '(808 s choosen

d " ! ) )0

$& *+plorer bearin

0 -. / ,9 3,- .'000 ('000



36/70

3. Gear and Belt

Np 5500 rpmrpmrpmrpm

Nem 750 rpmrpmrpmrpm Electrc motors speed s low because of shafts vbratonrestrcton.

Reducton rato

RR Np

Nem=RR 7.333

Desgn Crteron

Gear part of the reducton s set to be 5; RRG 5

So the belt part s;

RRB7.333

RRG=RRB 1.467

Nmain Nem =Nmain 750 rpmrpmrpmrpm

Npinion Nmain RRG =Npinion 3.75 103

rpmrpmrpmrpm

P 30 kWkWkWkW

L 100 106

50 HRC

m 4 mmmmmmmm Assumpton

zpinion 20

dpinion m zpinion =dpinion 80 mmmmmmmm

dmain Npinion

Nmaindpinion =dmain 400 mmmmmmmm



37/70

b 10 m =b 40 mmmmmmmm Assumption between 9m-14m

Spur Gear-Tooth Bending Stress (AGMA)

FO !"#"O#

V Npinion dpinion

2 =V 15.708

mmmm

ssssTpinion

P

Npinion

=Tpinion 76.394 NNNN mmmmFt

Tpinion

dpinion=Ft 0.955 kNkNkNkN

J 0.35 From graph

Kv1

0.6From graph Ko 1.25 From Tab$e

Km 1.3 From Tab$e %&4 (sma$$ bearing '$earan'es)

pinion Ft

b m JKv Ko Km =pinion 46.183 MPaMPaMPaMPa

Assume ast "ron grade * as materia$ o+ both gear

sf 482 MPaMPaMPaMPa ut 240 MPaMPaMPaMPa 'e 97 MPaMPaMPaMPa

kL 1 kV 1 ks 0.8 kr 0.814 (,99) kt 1 kf 1

km 1.33

e 'e kL kV ks kr kt kf km =e 84.011 MPaMPaMPaMPa

B#."#G FO MA"# GA

V Nmain dmain

2 =V 15.708

mmmm

ssssTmain

P

Nmain

=Tmain 381.972 NNNN mmmmFt

Tmain

dmain=Ft 0.955 kNkNkNkN



38/70

J 0.35 From graph

Kv 1

0.6From graph Ko 1.25 From Table

Km 1.3 From Table 7.4 (small bearing clearances)

main Ft

b m JKv Ko Km =main 46.183 MPaMPaMPaMPa

this values are same with

pinion

Assume Cast Iron grade 3 as material o! both gear

'sf 482 MPaMPaMPaMPa ut 240 MPaMPaMPaMPa

"ith hardening # $%C assumed

ut 1665 MPaMPaMPaMPa 'e =ut

2 832.5 MPaMPaMPaMPa

kL 1 kV 1 ks 0.8 kr 0.814 (&'') kt 1 kf 1

km 1.33

e 'e kL kV ks kr kt kf km =e 721.025 MPaMPaMPaMPa

I sin 20 cos 20

2

5

6

Cp 149 MPaMPaMPaMPa0.5

H Cp

Ft

b dpinion IKv Ko Km =H 339.983 MPaMPaMPaMPa

KL 0.9 KT 1 KR 1

sf 'sf KL KR KT =sf 433.8 MPaMPaMPaMPa



39/70

4. Hydraulic Calculations for Hydraiulic Pump Selection

To calculate piston volumetric flow rate, piston rods speeds are needed. That

speed is directly depend on speed of bucket , stick and boom. That's why relationbetween these speeds must be defined. These relation basically ratio of length piston

arms and parts length (bucket,stick,boom). On this assumption effect of angle

between parts are ignored to easier calculations.

Analysis have been made by pi! ma"imum lifting for boom and stick. #ut on a

combine movement these speeds will limited to pi$ for each.

%ovement on rotat&onal a"&s' &s not calculated because of these mot&ons w&ll

reduce each other on comb&ne movement to decrease forces that act&ng on arms and

s&e of pump.

Distance between stick and piston 1 dp1 25 cmcmcmcm

Distance between boom and piston 2 dp2 30 cmcmcmcm

Distance between boom and piston 3 dp3 30 cmcmcmcm

Bucket rotational velocity for lifting motion wbucket

2 radradradrad

ssss

Stick rotational velocity for lifting motion wstick

4

radradradrad

ssss

Boom rotational velocity for lifting motion wboom

8 radradradrad

ssss

Typical pressure for pistons are 300 bar but piston type pumps can reach

420 bar so 400 bar is selected and forces on pistons are already known

from report 2 than;

Hydraulic pressure for pistons P 400 barbarbarbar

Forces acting on piston 1 Fp.1 54.494 kNkNkNkN





40/70

Area and bore of pistons are ;

Area of piston 1 Ap.1 Fp.1

P

=Ap.1 1.362 103mmmmmmmm

2

Dp.1

4 Ap.11

=Dp.1 41.649 mmmmmmmm

to standardization Dp.1 45 mmmmmmmm

Ap.1 Dp.1

2

4

Area of piston 2 Ap.2Fp.2

P

=Ap.2 3.752 103mmmmmmmm

2

Dp.2 4 Ap.21


Dp.2 70 mmmmmmmm

Ap.2 Dp.2

2

4

Area of piston 3 Ap.3Fp.3

P

=Ap.3 159.913 cmcmcmcm2

Dp.3

4 Ap.31


Dp.3 145 mmmmmmmm

Ap.3 Dp.3

2

4



41/70

Speed and volumetric flow rate of piston rods are ;

Speed of piston rod 1 vp.1 dp1 wbucket

Volumetric flow rate of piston 1 Qp.1 vp.1 Ap.1

=Qp.1 0.625 LLLL

ssss

Speed of piston rod 2 vp.2 dp2 wstick

=vp.2 0.236 mmmm

ssss


=Qp.2 0.907 LLLL

ssss

Speed of piston rod 3 vp.3 dp3 wboom


=Qp.3 1.945 LLLL

ssss

Speed of piston 4 (for rotating)

Needed volumetric flow rate for pump selection;

Q ++Qp.1 Qp.2 Qp.3

=Q 208.603LLLL

minminminmin



42/70


F. Simulation Results


43/70


Model name: Gen.V2

Current Configuration: Varsaylan

Solid Bodies

Document Name and

ReferenceTreated As Volumetric Properties

Document Path/Date

Modified

Fillet4

Solid Body

Mass:115.931 kg

Volume:0.0147683 m^3

Density:7850 kg/m^3

Weight:1136.12 N

D:\Gen.V2\hyd.cyl\1.SL

DPRT

May 20 01:00:14 2015

Fillet3

Solid Body

Mass:71.1489 kg

Volume:0.00906355 m^3

Density:7850 kg/m^3

Weight:697.259 N


DPRT

May 20 01:00:14 2015


44/70


Fillet3

Solid Body

Mass:28.0339 kg

Volume:0.0035712 m^3

Density:7850 kg/m^3

Weight:274.733 N


DPRT

May 20 01:00:14 2015

Fillet1

Solid Body

Mass:13.5738 kg

Volume:0.00172914 m^3

Density:7850 kg/m^3

Weight:133.023 N

D:\Gen.V2\boom

pin_V2.SLDPRT

May 20 00:39:04 2015

Fillet1

Solid Body

Mass:2.01023 kg

Volume:0.00025608 m^3

Density:7850 kg/m^3

Weight:19.7002 N

D:\Gen.V2\boom

pin_V2.SLDPRT

May 20 00:39:04 2015

Fillet1

Solid Body

Mass:7.78129 kg

Volume:0.000991247 m^3Density:7850 kg/m^3

Weight:76.2566 N

D:\Gen.V2\boompin_V2.SLDPRT

May 20 00:39:04 2015

Fillet1

Solid Body

Mass:1.27543 kg

Volume:0.000162475 m^3

Density:7850 kg/m^3

Weight:12.4992 N

D:\Gen.V2\boom

pin_V2.SLDPRT

May 20 00:39:04 2015

Fillet1

Solid Body

Mass:5.92278 kg

Volume:0.000754494 m^3

Density:7850 kg/m^3

Weight:58.0432 N

D:\Gen.V2\boom

pin_V2.SLDPRT

May 20 00:39:04 2015


45/70


Fillet1

Solid Body

Mass:2.01527 kg

Volume:0.000256723 m^3

Density:7850 kg/m^3

Weight:19.7497 N

D:\Gen.V2\boom

pin_V2.SLDPRT

May 20 00:39:04 2015

Fillet1

Solid Body

Mass:5.92278 kg

Volume:0.000754494 m^3

Density:7850 kg/m^3

Weight:58.0432 N

D:\Gen.V2\boom

pin_V2.SLDPRT

May 20 00:39:04 2015

Fillet1

Solid Body

Mass:2.27422 kg

Volume:0.000289709 m^3

Density:7850 kg/m^3

Weight:22.2873 N

D:\Gen.V2\boom

pin_V2.SLDPRT

May 20 00:39:04 2015

Fillet1

Solid Body

Mass:5.36096 kg


Weight:52.5374 N

D:\Gen.V2\boompin_V2.SLDPRT

May 20 00:39:04 2015

Fillet1

Solid Body

Mass:2.49617 kg

Volume:0.000317984 m^3

Density:7850 kg/m^3

Weight:24.4625 N

D:\Gen.V2\boom

pin_V2.SLDPRT

May 20 00:39:04 2015

Fillet1

Solid Body

Mass:6.29235 kg

Volume:0.000801573 m^3

Density:7850 kg/m^3

Weight:61.665 N

D:\Gen.V2\boom

pin_V2.SLDPRT

May 20 00:39:04 2015


46/70


Fillet1

Solid Body

Mass:7.78129 kg

Volume:0.000991247 m^3

Density:7850 kg/m^3

Weight:76.2566 N

D:\Gen.V2\boom

pin_V2.SLDPRT

May 20 00:39:04 2015

Fillet27

Solid Body

Mass:253.134 kg

Volume:0.0322463 m^3

Density:7850 kg/m^3

Weight:2480.71 N

D:\Gen.V2\boom

rev1_V2.sldprt

May 20 00:39:00 2015

Fillet25

Solid Body

Mass:479.509 kg

Volume:0.0610839 m^3

Density:7850 kg/m^3

Weight:4699.18 N

D:\Gen.V2\boom_V2.SL

DPRT

May 19 17:27:25 2015

Fillet5

Solid Body

Mass:38.6272 kg


Weight:378.546 N

D:\Gen.V2\bucketlink1_V2.SLDPRT

May 20 00:36:35 2015

Fillet1

Solid Body

Mass:12.1638 kg

Volume:0.00154952 m^3

Density:7850 kg/m^3

Weight:119.205 N

D:\Gen.V2\bucketlink2_

V2.SLDPRT

May 20 00:36:07 2015

Fillet4

Solid Body

Mass:74.7706 kg

Volume:0.00952495 m^3

Density:7849.98 kg/m^3

Weight:732.752 N

D:\Gen.V2\bucketlink3_

V2.SLDPRT

May 20 00:35:41 2015


47/70


Fillet7

Solid Body

Mass:241.524 kg

Volume:0.0307674 m^3

Density:7850 kg/m^3

Weight:2366.93 N

D:\Gen.V2\myownbucket

2_V2.SLDPRT

May 19 15:47:21 2015

Fillet2Solid Body

Mass:1.21139 kg

Volume:0.000154317 m^3

Density:7850 kg/m^3

Weight:11.8716 N

D:\Gen.V2\hyd.cyl\Holde

r.SLDPRT

May 20 00:16:58 2015

Cut-Revolve2Solid Body

Mass:44.2107 kg

Volume:0.00563194 m^3

Density:7850 kg/m^3

Weight:433.265 N

D:\Gen.V2\hyd.cyl\Rod.S

LDPRT

May 20 00:24:40 2015

Fillet2Solid Body

Mass:1.21139 kg

Volume:0.000154317 m^3

Density:7850 kg/m^3

Weight:11.8716 N


r.SLDPRT

May 20 00:16:58 2015


Mass:25.345 kg

Volume:0.00322866 m^3

Density:7850 kg/m^3

Weight:248.381 N


LDPRT

May 20 00:24:40 2015

Fillet2Solid Body

Mass:1.21139 kg

Volume:0.000154317 m^3

Density:7850 kg/m^3

Weight:11.8716 N


r.SLDPRT

May 20 00:16:58 2015


Mass:7.32229 kg

Volume:0.000932776 m^3

Density:7850 kg/m^3

Weight:71.7584 N


LDPRT

May 20 00:24:40 2015

Fillet16

Solid Body

Mass:349.622 kg

Volume:0.0445379 m^3

Density:7850 kg/m^3

Weight:3426.3 N

D:\Gen.V2\stick

v2_V2.SLDPRT

May 20 00:24:39 2015


48/70


1. Study Properties

Study name dinamik

Analysis type Static

Mesh type Solid Mesh

Thermal Effect: On

Thermal option Include temperature loads

Zero strain temperature 298 Kelvin

Include fluid pressure effects fromSolidWorks Flow Simulation

Off

Solver type FFEPlus

Inplane Effect: Off

Soft Sprin: Off

Inertial !elief: Off

Incompati"le "ondin options Automatic

#are displacement Off

$ompute free "ody forces On

Friction Off

%se Adaptive Method: Off

!esult folder Solidorks document !d"#temp$

%nit system: SI !MKS$

#enth&'isplacement mm

Temperature Kelvin

Anular velocity %ad&sec

(ressure&Stress '&mm(2 !MPa$


49/70


2. Loads and Fixtures

Fi)ture name Fi)ture Ima*e Fi)ture +etails

Fi)ed,-

Entities: ) face*s+

Type: Fi,ed -eometry

%esultant Forces

$omponents . / Z !esultant

!eaction force*0+ 1112)13 )443325 61112437 )445425

!eaction Moment*02m+ 8 8 8 8

.oad name .oad Ima*e .oad +etails

Force,-

Entities: 3 face*s+!eference: Ede9 3

Type: Apply force;alues: 666< 666< 38888 0

/ravit0,-

!eference: =st '>?lem;alues: 8 8 61273

%nits: SI

Force,2




50/70


Force,1



3. Mesh Information

Mesh type Solid Mesh

Mesher %sed: urvature 3ased mesh

@aco"ian points 4 Points

Ma,imum element si?e 2596247 mm

Minimum element si?e 4-68494 mm

Mesh uality i*h

!emesh failed parts with incompati"le mesh Off

Mesh Information - Details

Total 0odes 18715

Total Elements 22894

Ma,imum Aspect !atio 216-

B of elements with Aspect !atio 9 C ::6:

B of elements with Aspect !atio 38 164

B of distorted elements*@aco"ian+ 5

Time to complete mesh*hhDmmDss+: 55"55"29

$omputer name: A.PE%E',P


51/70


Mesh Control Information:

Mesh ontrol 'ame Mesh ontrol Ima*e Mesh ontrol +etails

ontrol,-

Entities: 3 Solid ody *s+

%nits: mmSi?e: 5528131

!atio: 32

ontrol,2

Entities: C Solid ody *s+%nits: mm

Si?e: 3428337!atio: 32

ontrol,1

Entities: 7 Solid ody *s+%nits: mm

Si?e: C4217G1!atio: 32


52/70


ontrol,4

Entities: 3G Solid ody *s+%nits: mm

Si?e: C2131!atio: 32

3. Study Results

0ame Type Min Ma,

Stress- ;O'" von Mises Stress 16-7521e,55 '&mm(2

!MPa$

'ode" 119287

45:6858 '&mm(2 !MPa$

'ode" 4971

/en6;2,dinamik,Stress,Stress-

0ame Type Min Ma,

+isplacement-


53/70


/en6;2,dinamik,+isplacement,+isplacement-

0ame Type Min Ma,

Strain- ES=%'" E>uivalent Strain -6:29-2e,5-5

Element" :758

5655-:949

Element" 2454

/en6;2,dinamik,Strain,Strain-


54/70


0ame Type Min Ma,

Factor of Safet0- Automatic -6-14

'ode" 4971

-64824e?557

'ode" 119287

/en6;2,dinamik,Factor of Safet0,Factor of Safet0-


55/70


Figure 4 - Critical points of Factor of Safety

Figure 5 - Critical points of Factor of Safety


56/70


Figure 7 - Static Factor of Safety Critical points

Figure 6 - Fatigue analysis and total life

This is the critical point of the first work. In order to avoid this huge stress concentration, the sizeof joints are made bigger and stronger.


57/70


G. Cost Analysis

From,@rand Properties

Price of


58/70


H. 3D Drawings

Figure 8 - Side view technical drawing of closed position

Figure 9 - Top view technical drawing of closed position


59/70


Figure 10 - Front and back view technical drawing


60/70


Figure 11 - Top view technical drawing of opened position

Figure 12 - Isometric view technical drawing of opened position


61/70


Figure 13 - Isometric view technical drawing of closed position


62/70


Figure 14 - CAD view 1



63/70




64/70


IV. CONCLUSION AND DISCUSSION

A. Summary and Discussion of the Results

After the implementation of each subsystems to the system, analysis carried out and

results obtained. These results are evaluated and according to them methods has been

developed. The developed methods are depend on the motivation and design approach of this

project. Results are discussed whether the system provides requirements and whether the

system is over safe. If the system turned out to be over safe, downsizing has considered and

applied according to the amount of excess factor of safeties. For the present this system is safe

enough and reliable to perform a lifting of 500 kg.

B. Future Works

In our project the main approach was making the most optimal backhoe with high

speed and low cost. The cost depends on the material. In the future there will be more safer

materials with higher speed ability and lower cost. Also the manufacturing will cost less

because the technology will improve and that will cause decrease in cost. In other projects our

aim will be design a machine with longer life time, with safer material and high ability to

desired approach.


65/70


V. REFERENCES

1. How Caterpillar Backhoe Loaders Work

http://science.howstuffworks.com/transport/engines-equipment/backhoe-loader1.htm

2. New Backhoe Loaders CAT 422F

http://www.cat.com/en_ZA/products/new/equipment/backhoeloaders/sideshift/18346265.html

3. CAT Backhoe Loader Brochure

http://s7d2.scene7.com/is/content/Caterpillar/C768535

4. Backhoe Loader

http://en.wikipedia.org/wiki/Backhoe_loader

5. Backhoe

http://opensourceecology.org/wiki/Backhoe

6. SKF Rolling Bearings

http://www.skf.com/binary/138-121486/SKF-rolling-bearings-catalogue.pdf

7. SKF Extra Power Belts

http://www.skf.com/binary/92-118145/Xtra-Power-belts---10552_3-EN.pdf

8. SKF Belt Drive Design Calculations Tool

http://www.skf.com/group/knowledge-centre/engineering-tools/belt-drive-design-

calcalutions-tool.html

9. Gamak 3 Phase Asynchronous Electric Motors

http://www.gamak.com/images/urun-pdf/standart_motorlar.pdf


66/70


Engineering Skills

Firstly this project has improved the engineering skills of all of the group members.

All of the theoretical informations were used in order to get something perceptible. The most

important processes were the problems. Sometimes there was huge problems and it was hard

to solve them. Beacuse of these problems the project did not go easily straight forward. But at

this point all of the group members tried to create a way out and the brain stormings, which

are made during these problems were very important. During this continuum a lot of shiny

idea are took shape and the problems were solved. Besides the problems the technical drawing

and alaysis skills were improved.

This project was a good first step and a great experience for our engineering career.

Its sure that all of us will use these experiences and informations in the future.


67/70

1

A. Sample Cost Analysis

Shaft Manufacturing Analysis

Model ad: Long ShaftRapor tarih ve zaman: 5/20/2015 10:50:37 AM

Malzeme: lain !ar"on Steel

#retim $%re&i: Ma'ineleme

(amamlanm) par*a a+rl+: 55,03 l"

Sto' tipi: -lo&'

-lo&' Size: 1,57.1,57.7,7 in

Malzeme malieti/a+rl+: 1,1 S/l"

Shop Rate: 30,00 S

#retile&e' Mi'tar(oplam par*a $a$: 100

Lot "%%'l%+%: 100

ar*a "a)na 4ng4r%lenmaliet:

88.85 USD

6llanlan maliet )a"lon6:ma&hiningtemplatedefa6lt8engli$h$tandard9,$ld&tm

6llanlan maliet mod6: Man6fa&t6ring ro&e$$ Re&ognition

ar)la)trma:

Maliet a+lmMalzeme: 77,5 S 7;

#retim: 11,27 S 13;

Mar'6p 0,00 S 0;

ar*a "a)na 4ng4r%len$%re:

00:22:31

6r6l6mlar: 00:05:35


68/70

2

Maliyet Raporu

Model Ad: art1 Malzeme: lain !ar"onSteel

Malzeme malieti: 77,5 S (oplam maliet/par*a:

88.85 USD

#retim malieti: 11,27 S (oplam $%re/par*a: 00:22:31

Mar'6p 0,00 S

retim Maliyet Dalm

lem Ayarlar ama! "##:$$:##% Maliyet "USD%

Setup &peratio! 1 00:00:3= 0,30

'oplam 00:00:3( 0.30

)urulumlar *+,le -e )al$r ama! "##:$$:##% Maliyet "USD%Setup &peratio! 1 00:05:00 2,50

'oplam 00:05:00 2.50

re/e lemi*+/eyila#

,arla! aim"i!43%

ama!"##:$$:##%

Maliyet"USD%

Aletlee,ille!$ir

me

aima!aMaliyet

"USD6i!43%

7olume 1 Ro6ghing 10, 00:0:13 2,12>lat ?nd

Mill@/A


Mill@/A


Mill@/A

7olume Ro6ghing 10, 00:0:13 2,12>lat ?nd

Mill@/A

'oplam 1.91 00:1(:55 8.

)urulum lemleri1. Setup &peratio! 1

a. 7olume . 7olume 2. 7olume 3$. 7olume 1



69/70

B. Belt Specifications



70/70

Documents

DESIGNING A BUCKET MECHANISM OF A BACKHOE LOADER