Heavy metal

28 October 2008

Stephen Holmes takes a look at some motorised heavyweights, and the design technologies that drove them into production

Rocking all over the world

Rock crushers have never been the most glamorous of heavy industrial machinery, but this doesn’t stop them from being inanely practical work horses that do exactly what the name says: crush rock.

At its heart the Terex Pegson Maxtrak 1000 has an Automax cone crusher complete with hydraulic settings, unblocking system and, curiously, a ‘tramp release’. Its crushing action produces high quality aggregate and sub-base materials, and in doing so has a lot of components under stress.

Pro/Engineer is the software behind the design “We have a lot of parts in the assemblies and a lot of complex geometry, it’s ideal for that sort of thing,” says Carl Adams of Terex Pegson. “We’ve got a number of large assemblies and parts that it’s good for handling from the top level down.

“We use the integrated Pro/Mechanica quite a lot as part of Pro/Engineer. We take models back and forward from Pro/Mechanica and manipulate them doing runs, and for static analysis. That’s another function that we’re particularly interested in. We look at it from the general form of stress analysis and displacements.” All understandable, considering the vast loads and differing variables of rocks being fed into it and spat out the other side.

Pulling power

Encountering an oncoming tractor down a country lane is the stuff of nightmares for most motorists, and the slick silhouette and aggressive lines of this monster concept would only heighten that fear.

As a study in digital design, the JCB 7000 series Fastrac is a polished example of seamless concept realisation. Built up from original sketchwork from JCB’s in-house design team, it was swiftly drawn up into 3D using Alias.

Giving them control over exterior and interior surfacing from the first pass through to production, the software not only proved the engineering team’s claims of space distribution, but also allowed for renderings for design review.

For full sign-off, the model was taken into Showcase to create photo realistic fly-by animations. On achieving design approval, the data set was used to cut pre-production tools for prototype components such as the roof mouldings.

Testing allowed modifications to be quickly built back into the Alias model, and the process moved into Unigraphics to build the fully parameterised master model with the raw sheet data.
Nigel Chell from JC Bamford, says, “By virtue of industrial design having the right tools, the vehicle’s original styling intent was maintained throughout the development process from initial artwork to product launch.”

Red devil

In the red corner, weighing in at eight tons, it’s ‘The Mover from Munich’, the Linde 396 series forklift.

Showcasing a series of significant design improvements, increasing the view through the mast by nearly 20 per cent, and introducing a variable suspension system that reduces body vibrations, the new design has improved the comfort and safety of the operator greatly.

Mark Stent, project manager at the UK arm of Linde Material Handlings is proud that the design team makes full use of the technologies they have to hand. “In today’s fast design and manufacturing world it would be virtually impossible to produce the designs that we do, to the timescales required, without the aid of a 3D modeling package,” he says.

His team rely on Siemens NX5. “You can then manipulate your view of the truck from any angle or position; thus allowing you to hide parts, make parts transparent and move parts around. All this is essential in order for us to properly design position and check clearances between components,” Stent continues, adding that they benefit greatly from the ability to produce renderings, conduct FEA’s and take parts straight to CAM from their software.


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