how jcb cope with the stress of collecting...
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How JCB cope with the
stress of collecting strain
Jamie Shenton IEng. MIMechE Senior Structures Engineer
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JCB » Family business » Off highway construction machines » WHQ: Rocester » Global presence » 300+ machine models
Group Structures » Internal consultancy to business units » Based in Research/ Group engineering (WHQ) » 15 people in three sections
» Engineers » Strain-Gauge » RIGS
» Extended team » Loadall, Compact products, India
Who are we?
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» Strain Gauge (SG) » Weatherproofing » Cable management
» Vibration resistant » WIFI connectivity » Power
» 256 Channels (most SG channels) » 37 tests (high) » 1000hz (typical) » 1200s (average fatigue test)
Stress of collecting Strain
Physical Challenges Analysis Challenge
300+ machines 3,409,920,000,000 data points
9,472 unique channel traces
1,200,000 data points per channel
11,366,400,000 data points
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»Two instances in product development
5 (6) Box method
Boundary conditions
Results
Materials Shape CAD
FEA
Loading
Fatigue Analysis
Materials Shape
Field test
MODS Structural recommendations
Digital Loop Physical Loop
Preparation perform
ing Solving
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»Loading » Defined by how customers use the
machines » Typical use vs Abuse » Hundreds of tests per machines
Preparation
» Data base of all tests with sign off lives for every machine
» Feeds TEST PROG excel sheet
5 Box How do we use it
»Materials » Typically steel in varying grades and
gauges
»Shape » Welded plates and castings » BS7608
» STD11 JCB material database, standard authorised materials
» Governed by design guides & experience
» Determines gauge positions » Feeds SGauge. excel sheet
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Preparation CONT.
Loading Materials Shape
Field test
TEST PROG
Drawings
SGauge Fitting
Cabling & Boxing
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Field Testing »World wide testing
» Standard tests defined from database. (TEST PROG)
» JCB Quarry in UK replicated around world.
Performing
Pune, INDIA
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Performing
»Custom software » Step by step run though of data acquisition » Uses TEST PROG and SGauge automatic
data population
Test Log
Notable events during tests
RAW Field Data TEST PROG SGauge Test Log
METATDATA
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»Fatigue analysis » nCode/ Prenscia – GlyphWorks
Solution
& METADATA
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»Post analysis scripts
Solution