Table of Contents
Background
A leading implement manufacturer recognized the need to enhance their product’s versatility and efficiency in response to customer demand. The proposed feature improved the implement’s efficiency and accuracy and could adapt to changes in load and terrain. The packaging was complex to integrate into the existing implement design.
Objective
The goal was to develop and integrate the load compensating feature to improve the implements’ functionality without compromising performance while minimizing the new subsystems’ material and assembly cost. This new feature required comprehensive hydraulic, mechanical, and kinematic design work, supplemented by Finite Element Analysis (FEA) to ensure structural integrity, functionality, and operational safety.
Team Composition
The project team comprised mechanical engineers, hydraulic specialists, a kinematic analyst, and an FEA expert. This team collaborated closely to design the new feature and oversee its implementation.
Design Phase
The design process involved several vital steps.
Mechanical Design
Engineers designed the load-compensating feature, focusing on materials and mechanical properties that would withstand various loading conditions and fit the current manufacturing and joining methods. The team conducted regular checks to ensure compatibility with the existing assembly tooling. This design included significant sheet metal and weld design to accomplish a final solution that was manufacturable in the current facility.
Hydraulic System Integration
Hydraulic specialists developed a new hydraulic circuit to control the movement of the subsystem, ensuring seamless integration with the implement’s existing hydraulic system.
Kinematic Analysis
A kinematic analyst modeled the implement’s movement along with the new subsystem to optimize the range of motion and ensure efficient operation.
FEA Implementation
The FEA expert analyzed stress and strain to validate the design’s durability and safety under operational loads.
Findings and Adjustments
The initial FEA highlighted areas where stress concentrations exceeded safe limits. The team made necessary adjustments by altering the design to distribute loads more evenly and selecting higher-grade materials for critical stress points.
Prototyping and Testing
The client built a prototype of the subsystem using the modified designs. This prototype underwent rigorous field testing to evaluate its performance in real-world conditions and to gather feedback for further refinements.
Implementation
The final designs were approved after successful prototype testing. Detailed documentation and manufacturing guidelines were prepared to facilitate production.
Conclusion
Adding the load compensation feature significantly improved the implementation performance by increasing its utility in various operational contexts. The project aimed to strengthen product functionality and adhere to stringent safety and performance standards, demonstrating the effective collaboration of multiple engineering disciplines in product development.