Application Research of Durability Test Bench Based on Strain Gauge in the Design of Excavator Structural Components

The finite element method (FEM) is currently an important theoretical basis for the design of excavator structures. However, static analysis primarily focuses on the investigation of the force and deformation characteristics of structures under static loading conditions. Excavators operate under specific working pressures, with the load on structural components varying with the load itself. This results in constant impacts occurring. Therefore, it is insufficient to rely on FEM as the sole method for controlling the design in such a complex working situation. Furthermore In the event that the analyst lacks experience, the structural 3D model is not handled correctly, and even the boundary conditions and load spectrum settings are inaccurate, it will result in the inability of their data to be adopted, and even mislead the design direction, causing significant losses to the enterprise. This article employs the finite element method (FEM) to preliminarily simulate and determine the stress and strain distribution of excavator structural components under dangerous and complex working conditions. Subsequently, the correlation and mutual verification of the FEM data and the durability test data are studied through the application of strain gauges in durability test benches and manual excavation, as well as through R&D, manufacturing, testing data and experience. The utilisation of a strain gauge represents an efficacious and precise methodology for the estimation of the remaining operational lifespan of excavator onboard systems and pivotal structural components. This is achieved through the imposition of the target operational load spectrum upon the endurance test rig. The theoretical basis of design work is reinforced and program evaluation becomes more efficient. Enterprise development examples demonstrate that the original 3-5 year development cycle can be shortened to 1-2 years, with a concomitant improvement in the reliability of the entire machine.