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Article(id=1207658078263157517, tenantId=1146029695717560320, journalId=1205116883411038211, issueId=1207658076900008717, articleNumber=null, orderNo=null, doi=null, pmid=null, cstr=null, oa=null, hot=null, price=null, onlineType=0, articleFormat=0, articleType=null, articleTypeStr=null, receivedDate=null, receivedDateStr=null, revisedDate=null, revisedDateStr=null, acceptedDate=null, acceptedDateStr=null, onlineDate=1765857723060, onlineDateStr=2025-12-16, pubDate=null, pubDateStr=null, doiRegisterDate=null, doiRegisterDateStr=null, onlineIssueDate=1765857723060, onlineIssueDateStr=2025-12-16, onlineJustAcceptDate=null, onlineJustAcceptDateStr=null, onlineFirstDate=null, onlineFirstDateStr=null, sourceXml=null, magXml=null, createTime=1765857723060, creator=13701087609, updateTime=1765857723060, updator=13701087609, issue=Issue{id=1207658076900008717, tenantId=1146029695717560320, journalId=1205116883411038211, year='2025', volume='23', issue='2', pageStart='189', pageEnd='376', issueExtLink='null', onlineDate='null', pubDate='null', beforeIssueId=null, nextIssueId=null, price=null, status=1, issueComplete=1, articleOrder=1, issueType=-1, specialIssue=null, createTime=1765857722735, creator=13701087609, updateTime=1765862348176, updator=13701087609, preIssue=null, nextIssue=null, ext={EN=IssueExt(id=1207677477451833566, tenantId=1146029695717560320, journalId=1205116883411038211, issueId=1207658076900008717, language=EN, specialIssueTitle=, coverIllustrator=null, specialIssueEditor=, specialIssueAbout=), CN=IssueExt(id=1207677477451833567, tenantId=1146029695717560320, journalId=1205116883411038211, issueId=1207658076900008717, language=CN, specialIssueTitle=, coverIllustrator=null, specialIssueEditor=, specialIssueAbout=)}, issueFiles=null}, startPage=340, endPage=345, ext={EN=ArticleExt(id=1207658081039786851, articleId=1207658078263157517, tenantId=1146029695717560320, journalId=1205116883411038211, language=EN, title=Load test method and experimental research of mine excavator working device, columnId=1207658078934246168, journalTitle=Chinese Journal of Construction Machinery, columnName=Performance Mensuration, Experimentation and Fault Diagnosis, runingTitle=null, highlight=null, articleAbstract=

Based on the stress model of excavator working device, a pin dynamic load test method considering eccentric load and side load of excavator working device is proposed. According to the stress characteristics of the pin shaft at the articulated hole between the bucket and the stick, a pin shaft load test sensor is designed to measure the dynamic load in the horizontal, vertical and lateral directions at the articulated point, and measure the displacement of the three oil cylinders of the excavator at the same time. A dynamic test system for the pin load of the excavator working device was established. Taking the domestic 50 t excavator as the prototype and the stonework as the working material, the excavation simulation loading test was carried out. The results show that the proposed pin load test method can accurately obtain the three-dimensional dynamic load of the pin at the joint of the bucket and the bucket. The maximum load occurs in the excavation section. The lateral load is negligible compared with the normal load. The results of the study provide the basis for the structural load spectrum test and fatigue optimization design of excavator.

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基于挖掘机工作装置受力模型，提出考虑挖掘机工作装置偏载和侧载的销轴动态载荷测试方法。根据斗杆与铲斗铰接孔处的销轴受力特点，设计销轴载荷测试传感器测取铰接点处水平、竖直和侧向这3个方向的动态载荷，同时测取挖掘机3个油缸的位移量。建立挖掘机工作装置销轴载荷动态测试系统，以国产50 t大石为作业物料进行挖掘模拟装车试验测试。结果表明：提出的销轴载荷测试方法能够准确地获得挖掘机斗杆和铲斗铰接点处销轴3个方向的动态载荷，载荷最大值出现在挖掘作业段，侧向载荷与正载相比可以忽略不计。研究结果为挖掘机结构载荷谱测试与抗疲劳优化设计提供了基础参考。

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王蕊（1984—），女，高级工程师，硕士。E-mail：

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王蕊（1984—），女，高级工程师，硕士。E-mail：

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王蕊（1984—），女，高级工程师，硕士。E-mail：

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caption=实测销轴动态载荷时间历程, figureFileSmall=jaaymq4Y6WRXCdhwdPMwgg==, figureFileBig=9Ym3A49wTgbhliaY5fBpvA==, tableContent=null), ArticleFig(id=1207748674952728729, tenantId=1146029695717560320, journalId=1205116883411038211, articleId=1207658078263157517, language=EN, label=Tab.1, caption=

Pin shaft sensor calibration test data

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试验对象力/kN应变1/με应变2/με应变3/με应变4/με均值
A⁃X000000
100715709716712713
2001 3581 3481 3681 3581 358
3001 9721 9721 9831 9831 977
A⁃Y000000
100655650694691672
2001 3051 2911 3371 3281 315
3001 9181 9111 9451 9451 929
A⁃Z000000
201 3101 3851 3141 4141 355
402 5502 6602 5522 6562 604
603 7673 7673 7633 7633 765
B⁃X000000
100702702702701701
2001 3531 3531 3551 3521 353
3001 9941 9941 9931 9931 993
B⁃Y000000
100693691692689691
2001 3221 3211 3201 3161 319
3001 9421 9421 9411 9411 941
B⁃Z000000
201 1511 3111 1401 2801 220
402 2932 4132 2732 3792 339
603 4153 4153 3783 3783 396
), ArticleFig(id=1207748675053392031, tenantId=1146029695717560320, journalId=1205116883411038211, articleId=1207658078263157517, language=CN, label=表1, caption=

销轴传感器标定试验数据

, figureFileSmall=null, figureFileBig=null, tableContent=
试验对象力/kN应变1/με应变2/με应变3/με应变4/με均值
A⁃X000000
100715709716712713
2001 3581 3481 3681 3581 358
3001 9721 9721 9831 9831 977
A⁃Y000000
100655650694691672
2001 3051 2911 3371 3281 315
3001 9181 9111 9451 9451 929
A⁃Z000000
201 3101 3851 3141 4141 355
402 5502 6602 5522 6562 604
603 7673 7673 7633 7633 765
B⁃X000000
100702702702701701
2001 3531 3531 3551 3521 353
3001 9941 9941 9931 9931 993
B⁃Y000000
100693691692689691
2001 3221 3211 3201 3161 319
3001 9421 9421 9411 9411 941
B⁃Z000000
201 1511 3111 1401 2801 220
402 2932 4132 2732 3792 339
603 4153 4153 3783 3783 396
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矿用挖掘机工作装置销轴载荷测试试验研究
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王蕊 1 , 朱晓君 2 , 万一品 2 , 杨庆勇 3
中国工程机械学报 | 性能检测、试验及故障诊断 2025,23(2): 340-345
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中国工程机械学报 | 性能检测、试验及故障诊断 2025, 23(2): 340-345
矿用挖掘机工作装置销轴载荷测试试验研究
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王蕊1 , 朱晓君2, 万一品2, 杨庆勇3
作者信息
  • 1.广西生态工程职业技术学院，广西 柳州 545004
  • 2.长安大学 道路施工技术与装备教育部重点实验室，陕西 西安 710064
  • 3.柳州柳工挖掘机有限公司，广西 柳州 545007

    • 王蕊（1984—），女，高级工程师，硕士。E-mail：

Load test method and experimental research of mine excavator working device
Rui WANG1 , Xiaojun ZHU2, Yipin WAN2, Qingyong YANG3
Affiliations
  • 1. Guangxi Ecological Engineering Vocational and Technical College, Liuzhou 545004, Guangxi, China
  • 2. The Key Laboratory of Road Construction Technology and Equipment of MOE, Chang'an University, Xi'an 710064, Shaanxi, China
  • 3. Liuzhou Liugong Excavator Co., Ltd., Liuzhou 545007, Guangxi, China
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摘要
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基于挖掘机工作装置受力模型，提出考虑挖掘机工作装置偏载和侧载的销轴动态载荷测试方法。根据斗杆与铲斗铰接孔处的销轴受力特点，设计销轴载荷测试传感器测取铰接点处水平、竖直和侧向这3个方向的动态载荷，同时测取挖掘机3个油缸的位移量。建立挖掘机工作装置销轴载荷动态测试系统，以国产50 t大石为作业物料进行挖掘模拟装车试验测试。结果表明：提出的销轴载荷测试方法能够准确地获得挖掘机斗杆和铲斗铰接点处销轴3个方向的动态载荷，载荷最大值出现在挖掘作业段，侧向载荷与正载相比可以忽略不计。研究结果为挖掘机结构载荷谱测试与抗疲劳优化设计提供了基础参考。

矿用挖掘机  /  工作装置  /  销轴载荷  /  测试试验

Based on the stress model of excavator working device, a pin dynamic load test method considering eccentric load and side load of excavator working device is proposed. According to the stress characteristics of the pin shaft at the articulated hole between the bucket and the stick, a pin shaft load test sensor is designed to measure the dynamic load in the horizontal, vertical and lateral directions at the articulated point, and measure the displacement of the three oil cylinders of the excavator at the same time. A dynamic test system for the pin load of the excavator working device was established. Taking the domestic 50 t excavator as the prototype and the stonework as the working material, the excavation simulation loading test was carried out. The results show that the proposed pin load test method can accurately obtain the three-dimensional dynamic load of the pin at the joint of the bucket and the bucket. The maximum load occurs in the excavation section. The lateral load is negligible compared with the normal load. The results of the study provide the basis for the structural load spectrum test and fatigue optimization design of excavator.

mining excavator  /  working device  /  pin shaft load  /  testing experiment
王蕊, 朱晓君, 万一品, 杨庆勇. 矿用挖掘机工作装置销轴载荷测试试验研究. 中国工程机械学报, 2025 , 23 (2) : 340 -345 .
Rui WANG, Xiaojun ZHU, Yipin WAN, Qingyong YANG. Load test method and experimental research of mine excavator working device[J]. Chinese Journal of Construction Machinery, 2025 , 23 (2) : 340 -345 .
正文
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挖掘机施工具有稳定性好、工作效率高、灵活适应各种工作环境的特点，在煤矿、铁矿等露天矿场作业中被广泛应用。挖掘作业时，工作装置不断调整姿态，各关键铰接点受力随之发生变化，导致挖掘机关键结构发生疲劳破坏现象。
陈进等[1-2]通过挖掘机工作装置转动角位移和油缸压力，采用理论模型计算载荷变化。向清怡等[3]利用油缸压力和位移数据，建立动力学模型间接计算铰点载荷。李运华等[4]建立作业物料模型，利用离散元法计算挖掘机所受外载荷。盛亚君等[6]采用接触分析法模拟销轴铰接处受力，计算典型工况下的结构强度和变形。刘广军等[7]通过刚柔耦合动力学分析，模拟最大挖掘力作用下结构应力响应。刘文国等[8]在铲斗上加载经验计算外力，模拟挖掘作业过程，仿真得到了铰点力的变化。
额定载重量为50 t的挖掘机，主要用于矿石开挖与装载的重载工况，其对挖掘机结构件性能提出了较高的要求。然而现有研究大多基于理论模型和仿真模拟分析挖掘机工作装置受力特性，缺少实测外载荷进行结构设计计算，导致挖掘机相关仿真分析与模拟计算存在较大的不确定性。为解决上述问题，需要获得目标样机的工作装置动态载荷。对挖掘机工作装置动态载荷测试的公开研究较少，仅有的测试方法也是基于油缸压力的间接测量。本文在分析挖掘机铲斗受力的基础上，提出一种利用销轴力传感器获取动态载荷的测试方法。本文设计销轴力传感器，搭建载荷测试系统，完成实际工况下的挖掘测试试验与试验结果分析。
1　挖掘机工作装置受力分析
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挖掘机工作装置的关键部件包括动臂、斗杆和铲斗等。挖掘机工作环境比较恶劣，铲斗是工作装置中直接与物料接触的构件，铲斗挖掘阻力的测试是挖掘机工作装置载荷获取的关键。挖掘机工作装置三维结构如图1所示。
以铲斗为单独的分析对象，将斗杆和铲斗的铰接点M与铲斗和连杆的铰接点K连线为X轴，过铰接点M垂直X轴且指向铲斗斗齿尖为Y轴，建立挖掘机铲斗局部坐标系。铲斗铰接点的力学分析模型如图2所示。
FM为斗杆与铲斗铰接处的销轴M处的受力，FIK为连杆与铲斗铰接处的销轴K处的受力，G3为铲斗重力，F为铲斗阻力。α、β、μ、θ分别表示为铲斗上所受外力FM、FIK、G3、F与x轴的夹角。角度β、μ是挖掘机工作装置的姿态参数，随工作装置各油缸工作长度变化而改变。挖掘阻力F在x、y方向上的分力记作Fx、Fy。
对铲斗建立力平衡方程：
根据上式可以得到外载荷F为
当角度参数α、β、μ以及力FM、FIK、G3已知时，利用式（1）~式（3）即可求出挖掘机的外阻力F。角度参数由挖掘机的作业姿态确定，通过对动臂油缸、斗杆油缸和铲斗油缸位移的测试，得到受力模型中的角度参数α、β和μ。铲斗结构尺寸和材料已知，可确定重力G3。将连杆视为二力杆，将连杆制作为拉压力传感器，确定力FIK。此时，只需确定力FM即可实现挖掘机工作装置外阻力的求解。将力FM分解为铲斗局部坐标系下销轴的径向力Fx和Fy，提出一种销轴力传感器方法，获取其动态载荷。
2　销轴力测试传感器设计
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挖掘机作业工况较复杂，铲斗与斗杆铰接点处除有XMY平面内的力FM、FIK和G3以外，存在惯性制动引起的侧向力FZ，侧向力过铲斗与斗杆铰接点处销轴中心垂直XMY平面。准确测得实际挖掘作业过程中，销轴的径向载荷Fx、Fy和侧向载荷FZ的动态变化，其是挖掘机结构件静态力学分析和动态疲劳评估的关键。因此，提出一种基于销轴力传感器的挖掘机工作装置销轴载荷测试方法，设计的销轴三向力传感器结构原理和三维模型分别如图3、图4所示。
用图4所示的销轴传感器代替斗杆与铲斗铰接处的销轴。图3中铲斗耳板向内侧移动，新增销轴传感器支撑1和2。为增强支撑座的强度和安全性能，除了与铲斗连接处进行焊接外，还需在同侧两支撑座前后进行板材搭接增强结构刚性。销轴传感器与安装座2用螺栓固连，防止销轴传感器发生转动，避免销轴力Fx和Fy出现测量误差。堵头和U型套筒用来进行侧向力Fz的测量。
在图3所示销轴传感器的径向，选取2个到销轴传感器内支撑中心距离分别为L1和L2的截面，在末端选取一个截面，分别按照图示方式粘贴Rx1、Rx2、Rx3、Rx4和Ry1、Ry2、Ry3、Ry4以及Rz1、Rz2、Rz3、Rz4这3组应变片。桥路测量销轴径向力Fx、Fy和侧向力Fz如图5所示。
根据图5（a）所示，测量桥路在全桥模式下输入电压、输出电压分别为Uxi、Uxo，其关系为
式中：k为电阻式应变片灵敏度系数；εxn为应变片Rxn的应变值（n取1~4）。
销轴力Fx与电桥电压比Ux之间的关系为
式中：Ux=Uxo/Uxi；E、Wx分别为销轴传感器的弹性模量和抗弯截面系数；L1、L2为截面距离。
同理，由应变片Ry1、Ry2、Ry3、Ry4所组成的桥路可以计算得到径向销轴力Fy。如图5（b）所示，在测量桥路全桥模式下输入电压Uzi及输出电压Uzo的关系为
式中：εzm为应变片Rzm的正应变值（m取1~4）。
此时，末端轴段上应变片的正应变值可由末端轴段材料属性及侧向力Fz表示，销轴力Fz与电桥电压比Uz之间的关系为
式中：Uz=Uzo/Uzi；E1为末端轴段材料弹性模量；μ为材料泊松比；S为贴片截面的断面面积。
3　动态载荷测试试验研究
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销轴传感器代替原销轴进行测试前，需对销轴传感器3个方向进行试验标定，以确保其准确测量各个方向的力。挖掘机挖掘工作期间，驾驶员面向方向左侧斗杆与铲斗铰接点处的销轴定义为A，右侧销轴为B。径向力标定时，用SDS 500电液伺服动静试验机对A和B销轴传感器X和Y方向分别进行加载标定。标定试验采用加载—卸载—加载—卸载循环的方式进行，用DEWE数采仪分别记录传感器X、Y和Z方向的输出，并多次重复标定取均值。试验结果见表1。
以标定力为横坐标，传感器输出应变值为纵坐标，得到加载力-输出应变关系如图6所示。
用标定均值分析试验可进一步降低测试结果精度受偶然因素影响程度。利用最小平方法对标定试验的平均值进行参数拟合[9-11]，得到销轴传感器单向外载荷与传感器输出应变值之间的线性函数关系。销轴A 3个方向的标定函数关系分别为
销轴B 3个方向的标定函数关系分别为
各个测试力的桥路输出拟合优度R2均大于0.99，线性拟合精度高。挖掘机工作装置铲斗的耳板向两侧移动，形成增设的三维销轴传感器支撑座，但不改变销轴受力。将标定完成的销轴传感器从支撑座两侧安装在试验样机上，使用螺栓对销轴传感器大端面进行预紧，安装好的销轴传感器与铲斗保持相对静止，销轴传感器安装如图7所示。
采用DEWE数采仪对销轴传感器3个受力方向桥路输出的应变值信号进行采集，同时采用拉线式位移传感器测试油缸的位移行程。根据奈奎斯特采样定律以及挖掘机采样经验选择采样频率为20 Hz[10]，选取大石为挖掘作业介质，进行挖掘试验测试。
4　载荷测试试验结果分析
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采用挖掘试验测试方法分别测出斗杆与铲斗左右两个铰点处的销轴径向力和轴向力。使用Matlab软件编程对采样所得数据预处理，采用梯度与幅值门限法相结合的处理方法[12]，幅值门限法剔除大误差及超数量级奇异峰值，梯度门限法剔除小幅值奇异峰值。去除奇异值后工作装置液压缸位移时间历程及销轴A、B所受3个方向载荷时间历程分别如图8所示。
挖掘机工作装置销轴载荷测试方法成功获取了挖掘作业过程中工作装置的真实受力特性。根据图8（a）实测油缸位移变化，可以将一个完整的挖掘周期划分为4个阶段：物料挖掘阶段（S1段）、提升回转阶段（S2段）、物料卸载阶段（S3段）以及空斗行进阶段（S4段）。物料挖掘阶段，动臂油缸长度基本保持不变，斗杆和铲斗油缸同时伸长进行物料挖掘。提升回转阶段，动臂油缸伸长使物料被抬起，斗杆油缸有所伸长保持物料不洒出，铲斗油缸保持不变。物料卸载阶段，动臂油缸略微调整，斗杆和铲斗油缸长度迅速缩短卸掉物料。空斗行进阶段，动臂油缸和斗杆油缸缩回进行姿态调整，铲斗油缸长度保持不变，工作装置进入下一个挖掘周期。通过上述分析可知，各测点3个方向载荷变化时间历程与挖掘机作业过程中各阶段相互匹配，工作装置销轴载荷动态测试方法的有效性。
对比分析图8（b）和图8（c），销轴传感器X和Y方向的外载荷均表现为压应力，拉压应力的判断与图2所示的坐标系定义的正负方向有关。另外，同一工作周期内，物料挖掘阶段销轴A在X方向和Y方向的受力峰值均比销轴B大2倍左右，但是在物料卸载阶段销轴A和销轴B在X方向和Y方向的受力峰值差异不显著，表明挖掘机工作装置在物料挖掘阶段受到明显的偏载作用。由于散装物料堆积厚度和高度不均匀，导致挖掘机工作装置在铲斗插入物料和崛起物料时载荷的偏向不一致。偏载的存在使工作装置的使用寿命发生改变，所以在挖掘机工作装置生产加工的理论计算中，需加入偏载因素。
由图8（d）可以看出，在挖掘机各工作循环中，侧向力的出现表现为随机性，在物料挖掘阶段、提升回转阶段和返回阶段均有出现，有时甚至卸料阶段也会偶尔出现一个峰值，但是数值上侧向力远远小于铲斗与斗杆铰点处销轴所受的正载力。由于研究结构抗疲劳强度最应关注的问题是载荷对结构危险位置产生的损伤，所以应通过计算侧载对结构应力最大位置产生影响的大小，进一步确定其是否需要被忽略。
在以挖掘效率最高为原则的一次挖掘作业中，销轴所受大载荷出现在物料挖掘阶段。物料卸载阶段，销轴B处有一个明显的径向载荷突变，突变主要是由于紧急制动导致。驾驶员在作业时，应该合理控制油缸的回收量，并避免在卸载过程中紧急制动。
5　结论
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根据挖掘机工作装置销轴载荷测试试验研究，得出以下结论：
（1）考虑挖掘机工作装置力学模型，设计了销轴三向力测试用的销轴传感器，通过挖掘试验准确获得斗杆和铲斗铰接处左右销轴3个方向的动态载荷。
（2）在挖掘、提升回转、卸载以及空斗阶段，销轴实测载荷均能合理地反映挖掘机工作装置受力特性，实测载荷反映挖掘机作业过程中存在明显的偏载现象。
（3）提出的销轴力载荷测试方法具有广泛适用性，不受限于挖掘机工作装置结构限制。研究结果为进一步挖掘机工作装置的动态载荷测试和载荷谱编制提供方法支撑。
基金
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  • 陕西省自然科学基础研究计划资助项目(2021JQ283)
  • 广西中青年资助项目(2023KY1262)
文献
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2025年第23卷第2期
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基金
陕西省自然科学基础研究计划资助项目(2021JQ283)
广西中青年资助项目(2023KY1262)
作者信息
    1.广西生态工程职业技术学院，广西 柳州 545004
    2.长安大学 道路施工技术与装备教育部重点实验室，陕西 西安 710064
    3.柳州柳工挖掘机有限公司，广西 柳州 545007
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2种不同金属材料的力学参数
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小菇属 Mycena 11 5.26
光柄菇属 Pluteus 5 2.39
红菇属 Russula 17 8.13
栓菌属 Trametes 5 2.39
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