Analysis and Design on Air Controlled Hydraulic System about Dump Truck Lifting Mechanisms

Taoping Yan
Faculty of Transportation Engineering HuaiYin Institute of Technology Huaian, China e-mail: ytp709803816@sohu.com
AbstractBy analyzing the composition and working principle of air controlled hydraulic system and referring to similar models, the design of the tank, the limiting mechanism and power taker are conducted. 3201Z-type dump truck is modification desiged by EQ3208GJ dump truck chassis which the technical performance parameters are known, and using a lifting mechanism of air controlled hydraulic system. By calculating the main technical parameters, including in the performances of the hydraulic cylinder and the hydraulic pump, the dump truck's special oil cylinder HG-E180X780 and gear pump CBT-E563 are selected. By the stability of the piston rod, the system pressure and cars lifting time are checked, the reasonability and safty of the design can be proved. Keywords- Air Controlled Hydraulic System Lifting mechanism ; dump Truck; Analysisdesign checking

lifting tanks2.The power of lifting mechanism is driven by the engine.The hydraulic system pump is taken off by transmission pump to produce high-pressure oil tank and then lift out the oil cylinder .The lever, connecting rod are forced to rotates around its hinge point, lead carriage tilting around the support points of rear bracket turn to complete the discharge operation. Small part of the lifting mechanism has simple structure and low manufacturing cost with small parts[2].

I.

INTRODUCTION III.

With the development of our construction, a variety of municipal engineering, construction and urban sanitation, traffic and other material cause the increasing demand on the dump truck, to meet the fast, convenient, affordable, safety demand of project transportation, the 3201Z-type dump truck is developed in such a market. It is modification desiged by EQ3208GJ dump truck chassis which the technical performance parameters are known. The dump truck's air controlled hydraulic system lifting mechanism (power take off - drive shaft - hydraulic pump - lifting cylinders)is driven by engine power to gives rise to a certain point to discharge, and reset the truck relyed on gravity. The main technical parameters of the vehicle: the maximum load weight is 11000kg; the car lifting time is 13s; the car landing time is 10.3s; the maximum lifting force is 239538.06N; the engine model is EQB210-10; the maximum engine speed is 2500r/min[1]. II. 3201Z-TYPE DUMP TRUCK AIR CONTROLLED HYDRAULIC SYSTEM LIFTING MECHANISM

Figure 1. 3201Z-type lifting mechanisms.

THE AIR CONTROLLED HYDRAULIC SYSTEM DESIGN OF 3201Z-TYPE DUMP TRUCK LIFTING MECHANISMS

A. The air controlled hydraulic system work principle of the lifting mechanism The system consists of tank, pump, check valve, control valve lift, lifting cylinders, pneumatic control valve, car bodies angle limit mechanisms and piping and other components. It works as shown in figure 2.

As shown in figure 1, the air controlled hydraulic system lifting mechanism used by 3201Z-type dump truck consists of the carriage 5, the Deputy frame 4, lever 1, 3 and the

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1.Storage cylinder 2. The power take off control valve 3. cylinder power take off. 4.Gas controlled lift valve 5. Tank 6. Pump 7. One-way valve 8. Limit valve 9. Hydraulic cylinder 10. Lift Control Valve Figure 2. Schematic of air controlled hydraulic system lifting mechanism.

1) Control of power take According to the instructions dashboard Installed in the bottom plate. Take the power take control valve handle to "take power" position, the compressed air come from storage cylinder1 take into the power take off cylinder 3 through the power take off control valve 2. Power take off cylinder piston driven power to take fork to promote the engagement set to gear meshing, and power take off pump 6 will be driven to work. When breathing stops, the power take off in the compressed air cylinder through the power take off control valve vent returned to the atmosphere, cutting off power of oil pump. 2) Lift car Lift pump begins to work when the power take off bonded.Compressed air come into the air control valve 4 through the lift control valve lift when the handle of control value10 is taken into "Lift" position. The oil export route of the lifting value is closed. Pump output pressure of hydraulic oil can only enter tank 9. The car lifted by the pressure produced by oil tank. The limit plate installed in the bottom of the car hit the limit mechanisms when the car rise to the maximum angle.Pump output oil pressure limit valve 8 flows to tank 5, then the car will stop lifting. 3) carriages stop In any positions in the lifting process, oil pump can stop through torning off or separation of the clutch, so the car can be stopoed in any position in lifting process. 4) car down

so that XF limit access to the oil port valve connected, the output oil pressure pump valve out of limit Oil export flows to tank, in order to achieve the maximum lift angle of car restrictions. 3) Power Take The main parameters of the power take off: a) Power take off transmission ratio determination device The maximum engine speed ( v max ) is 2500r/min, the investigation known power take the maximum rotational speed of output shaft ( v output shaft max ) is 2400r/min. Engine to power take off transmission ratio( i ) between the outputshaft shou as formula 1

i=

v max voutput shaft max

2500 = 1.04 2400

(1)

b) Power take off gear of the main parameters Transmission power take the main parameters of gear from table 1.
TABLE I.
THE MAIN PARAMETERS OF TRANSMISSION POWER TAKE OFF GEAR AND POWER TAKE OF GEAR

Intermediate shafTrans mission Gear IV Gear I Normal module Pitch circle normal pressure angle Radial coefficient Points Helix Angle Spiral direction Number of matching gear Installation of center distance Tooth width 33 3.5 2230 +0.0095 23 right 23 107.66 27

MainGear Reduction gear shaft driven gear Power take Gear1 Gear2 Fourth gear power take off gear 23 25 22 3.5 4 4 20 +0.3257 25 960.05 15 2230 20 +0.01650 +0.2100 23 left 33 22

The pump stop running through disengage of the power take off by retrieving the first power take off control valve control handle. The compressed air of lifting gas control valve 4 returned to the atmosphere through lift controlled valve. The oil port of gas controlled lift valve is connected. The hydraulic oil of car lifting cylinder 9 flow back into the fuel tank in gravity, so the truck achieves down[3].
B. Gas control the selection and design of hydraulic components 1) Tank

107.66 16 15

The main function of the tank is oil storage, cooling, separation of oil and other impurities in materials. The design of the tank capacity is selected to 160L refer to similar models.
2) Limit institutions Limit institutions is to limit the car to the maximum lift angle and make the lift automatically stops.The maximum lift angle of cars can be achieved by adjusting the nut. XF limit selection limit valve is selected. The limit board in the bottom of the truck hit the limit plate roller when the car give rise to the maximum lift angle.The lever is forced to put left,

c) Installation of power take center distance Power take off gear axis with the axis of transmission power take off gear in the same horizontal plane, theoretical center distance is 107.66mm, installation of center distance is 107+0.48 =107.48mm (Ignore the compression gasket). d) The center distance Power take off gear and power take center distance of the driven gear Between 95.95 mm to 96.05 mm. e) Output power take the size of the junction. Output power take the size of the junction for the CBT series gear pump is designed, the power take off output flange of the only port to do radial positioning, with four M10 bolts to fasten the gear pump flange on the power take off. Power take off output shaft spline shaft as the

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rectangular hole, with the pump spline shaft connection for power output[4,5]. 4) Power Take Hydraulic cylinder selection and calculation of performance parameters Cars in the whole process of hydraulic tipping the largest lifting force is F = 239538.06 N, reference to similar vehicles, maximum working pressure of primary is p = 16 Mpa. Maximum lift force formula

ne Engine speed, ne =2000r/min;

i Drive ratio, i = 1.361 ;
Then n pump = 2000 1.361
e

= 1469.5 r/min, select the hydraulic

pump rated speed nB = 2000 r/min. Hydraulic pump displacement determined by the following formula: Q 1654.1 q= 60 60 = 49.6 mL/r (6) nB 2000
e

F p

D 2
4

(2)

Where, Mechanical efficiency of hydraulic cylinder, = 0.8 ;

d Lift Cylinder Bore.

Can be introduced

Based on the above parameters, select the gear pump CBTE563, the main parameters are as follows: Nominal displacement
q = 63
e

4 FEC p

4 239538.06 16 0.8

mL/r; rated pressure

= 154

(3)

p = 16 Mpa; nominal speed nB = 2000 r/min.

Also known L = 780 Based on the above calculation, select special cylinder dump truck HG-E180X780, the main parameters: bore

C. Check the parameters of hydraulic system 1) Check the stability of hydraulic cylinder piston rod When l/d0<10, Strength check is ok. When l/d0>10, must calculate the stability. Known, Piston rod material of hydraulic cylinder HGE180X780 is A3 steel, length is 1245mm, cylinder rod diameter d 0 = 80 , F = 239538.06 N. As l/d0=1245/80>10, therefore need to check the stability P (7) of the piston rod, The stability condition: P K nk Where, P Maximum thrust cylinder P = F = 239538.06 N;

d = 180 , cylinder rod diameter d 0 = 80 , cylinder stroke L = 780 .

5) Pump selection and calculation of performance parameters Under the national standards, when fully loaded dump truck rated, compartments give rise to the maximum lift angle and the reduction of the time no more than 20s, lifting time 15s primaries. Working volume of hydraulic cylinder:

Vlifting = L

d
4

= 780

180
4

= 19.849 10

m3 (4)

Pk Hydraulic stability of the critical force,

when =

= 19849 ml

l
i

> 1 , PK =

EI
2

Hydraulic pump rated flow shall meet the following formula: Vlifting Q (5) tlifting v Where,

( l )

t lifting

lifting time,

t lifting

=15s;

When 1 > > 2 PK = A ( a b ) ,Calculation of coefficient of rod is ,length of the conversion coefficient is .Taking into account the supporting cylinder condition, = 1 ,rod cross-section radius of gyration is i , on the circular section i =

Volumetric efficiency of hydraulic

systems, v =0.8
Then Q
19849 15 0.8 = 1654.1 mL/s

4 nk Stability safety factor, usually 2 to 4, here take 4.

The investigation known A3 steel: a = 3100 , b = 11.4 ,

1 = 105 , 2 = 61 .
As 1 < =

Pump speed

n pump =

ne i

l
i

1245 4 80

= 62.25 < 2

5407

Pk = A ( a b ) = = 12009118.4N

d0
4

( 3100 11.4 62.25 )

Pk

(8)

V fall =

(d 2 d 02 )
4

L=
6

(1802 802 )
4

780 =
(14)

15.928 10 mm3 = 15928 mL

=

Can see from above, P

= 3002279.6 N nk 4 Therefore, the hydraulic cylinder piston rod to meet the stability requirements. 2) Check system pressure Maximum pressure system : F Pmax = (9) A

12009118.4

Then fall time:

t fall =

V fall Q

15928 60 = 10.3s20 s 92579

(15)

Therefore, the oil pump, fuel tank and reasonable parameters are chosen to meet the design requirements[6,7].
IV. CONCLUSIONS

Known, F = 239538.06 N , = 0.8

A=

D
4

180
4

= 25446.9 mm2 = 25446.9 10 m2

6

Then Pmax =

239538.06
6

25446.9 10 0.8 = 10.1 Mpa<16 Mpa It is Meet the requirements. 3) Check car curfew System flow: Q = n pump q = 1469.5 63 = 92579 mL/min
d
2

= 11.8 10 N/m2
6

(10)

Calculated by the above design, dump truck can be seen as features of some of the work itself. The lifting mechanism has a hydraulic system of air control equipment, hydraulic systems and other characteristics of different, in the design should take into account all factors, Sought to design a simple circuit and the convenience, projects run smoothly and meet the transport needs of the air control hydraulic system.
REFERENCES
[1] Qin Sicheng, Hu En, Huang Haidong, and Kuo Junwu, 8 ton dump truck lifting mechanism optimization design of new, J. Heavy Vehicle, vol 38, pp 22-23, Jan 1997. Zhang Haiying, 3201Z lifting Mechanism Design and Mechanical Analysis, J. Municipal Technology, vol 22, pp 22-25, Jan 2004.
Zuo Jianmin, Automotive Hydraulic and Pneumatic Transmission, Beijing: Machinery Industry Press, 2008

(11)

When lifting hydraulic cylinder working volume: Vlifting = L 4 = 19849 Ml Vlifting = 780

[2]
6

180
4

= 19.849 10 mm3 (12)

[3] [4] [5]

Lifting time: = 60 = 13s < 20s Q 92579 When the hydraulic cylinder working volume down: tlifting = 19849 (13)

[6] [7]

Pu Lianggui, Mechanical Design. The Seventh Edition. Beijing: Management Institute of Beijing University Press, 2009. Feng Jinxiang. Construction and maintenance of special purpose vehicles. shandong: Shandong Science and Technology Press, 2008. Zhu Zhangxiao, Engineering Materials. Beijing: Tsinghua University Press, 2007. Cui Jin, Special Purpose Vehicle Design. Shaanxi: Shaanxi Science and Technology Press, 2009.

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