Identification of extreme load cases for a surface drill rig by means of MBS simulations

Abstract: This master thesis is Atlas Copco Craelius’ first step in incorporating numericalmethods in load case analysis during the development process. Atlas Copco needs toconstantly evolve and refine their methods in the design process to remain as thenumber one manufacturer of mining and construction equipment. Poor knowledge ofloads results either in structural failures or in oversized structures, both very costlyfor Atlas Copco.The main goal of this thesis is to examine the potential in MBS software by using it toidentify extreme load cases in one of Atlas Copco Craelius’ surface drill rigs, Mustang5. The MBS-software ADAMS View is used to build a model of the Mustang 5 drill rigand evaluate simulation results. The rig model is subject to motions which representreal case scenarios. The feed positioning possibilities are examined thoroughly since it was expected that the positioning has impact on the load levels. 25 different feedpositioning are simulated.The main conclusion is that the load levels are highly dependent on the feedpositioning. For example, the load levels in the boom raising cylinder can increaseseven times, if the rig is operated with the most unfavorable positioning compared tothe recommended. It could also be concluded that not only one positioning isextreme in terms of loads; it depends on which part of the boom system is beingobserved. Thus, several positioning cases have to be taken into consideration in orderto optimize the design of parts in the boom system.