FACTA UNIVERSITATIS

Series: Mechanical Engineering Vol. 2, No 1, 2004, pp. 109 - 124

PROCESSING THE LIFETIME OF BUCKET WHEEL

EXCAVATOR PARTS IN STRIP MINE TECHNOLOGIES 1
UDC 621.87:622.23.08

Zoran Marinkovi, Goran Petrovi

Mechanical Engineering Faculty, University of Ni

A. Medvedeva 14, 18000 Ni, Serbia and Montenegro

Abstract. The paper presents a complex model of calculating the parts of complex
machine systems exposed to variable load and strain. This model includes calculation
of operational safety and lifetime of parts, on the example of the bucket wheel
excavator driving mechanism. The goal is to apply this calculation model to making
safe and reliable machine systems, i.e. bucket wheel excavators, which will operate
efficiently under complex exploitation conditions in coal mines.
Key Words: Bucket Wheel Excavator, Load, Operational Stress, Discretization, Lifetime

1. INTRODUCTION
A large number of complex machine systems (MS) operate under highly variable
exploitation conditions. For this reason, their component parts are exposed to variable
load, i.e. strain, which is usually random. In exploitation, it is required that each MS has a
certain operational safety and reliability for the given lifetime. However, as a result of the
effect of variable strain with sufficient intensity and duration, some parts may be
damaged, and failures may occur. Failures, i.e. damage of parts, are manifested as
excessive or permanent deformation, static or violent fracture, dynamic fracture caused by
fatigue, increased wear, corrosion, overheating, etc.
The modern concept of calculating these complex MS involves making a complex
calculation model. This model should cover checking the relevant failures, i.e. calculation-
based determination or assessment of the safety, lifetime, and reliability of component parts and
the system as a whole, on the basis of real MS exploitation conditions.
The paper describes a calculation model of this type on the example of the bucket
wheel excavator as a complex MS for operation in coal strip mines. A particular treatment

Received November 26, 2003

1
The paper was written within the project Development of MIN-ENGINEERING products on the basis of software for
structural analysis from Program of Technological Development, No. MIS. 3.07.0082, financed by Ministry of
Science and Environmental Protection of Republic of Serbia.
110 Z. MARINKOVI, G. PETROVI

is given to the bucket wheel driving mechanism, whose vital parts are used to check the
safety and lifetime on the basis of real exploitation conditions. This is done by employing
analytical modeling procedures within a simulation model with originally developed
computer programs. The goal is to fabricate highly efficient bucket wheel excavators in
the phase of modular and variant design of these machine systems; their reliable operation
supports gives support to energy efficiency of the country [1, 2].

2. DESCRIPTION OF THE COMPLEX MODEL

OF CALCULATING THE BUCKET WHEEL DRIVING MECHANISM

The bucket wheel excavator is a complex machine with mining technology within
modern technology of coal strip mining. It consists of a complex spatial structure, several
driving mechanisms, and the control mechanism (Fig. 1). The most peculiar among these
mechanisms is the bucket wheel drive, located on top of the arrow. Figure 2 shows the
kinematic scheme of the bucket wheel driving mechanism in excavator SRs 470.20.3
LAUHAMER, consisting of a motor (1), elastic coupling with a brake (2), four-step
reduction gear (3) with a lamellar coupling (4) on the second shaft of the reduction gear, and
the bucket wheel (5) with 8 buckets [1].

Fig. 1. Bucket Wheel Excavator

Fig. 2. Scheme of the Bucket Wheel Driving Mechanism

 Processing the Lifetime of Bucket Wheel Excavator Parts in Strip Mine Technologies 111

The process of direct digging by the bucket wheel excavator is realized in a

combination of continual rotation of the bucket wheel in the vertical, and arrow
movement in the horizontal plane. As a result of the drive's performances, characteristics
of the soil, and inequality of digging resistances on the buckets, the bucket wheel
excavator is subject to a number of external loads changing dynamically and randomly.
As a consequence, the vital parts of the excavator's structure and driving mechanisms are
exposed to a variable load which, when it exceeds critical values, causes damage and
delay in the operation of the entire system.
An adequate design of bucket wheel excavators requires the application of a complex
analytical model for calculating its vital parts, which consists of several steps [2]:
modeling the bucket wheel driving mechanism in order to choose an equivalent and
mathematical model adequate to its characteristics,
simulating the operation of the driving mechanism in order to determine the functions of
operational loads and strains of vital parts for characteristic bucket wheel excavator's
operation modes,
discretizing the functions of operational stresses in order to obtain corresponding
characteristics and their spectrums, required for calculation, and,
calculating operational safety and lifetime of vital parts for certain types of strain
in order to prevent their destruction and failure.

3. MODELING THE BUCKET WHEEL DRIVING MECHANISM

In this case, modeling means substitution of a complex real system, i.e. the bucket wheel
driving mechanism (Fig. 2) with the corresponding equivalent dynamic and analytical model.
Research of this issue has shown that this complex real system is successfully replaced by the
torsional elasto-kinetic model with a finite number of discrete rotary masses and elastic bonds
between them. The masses are defined by moments of inertia Ji, and the bonds by coefficients
of rigidity ci and damping bi. However, suitable reduction of these characteristics reduces the
complex equivalent dynamic model to a very simple one, with only two rotary masses and one
elastic bond (Fig. 3) [2, 3, 4, 5]. This model can yield results relevant for analyzing the
operation and calculating this mechanism.
For the concrete example, the
characteristics of the equivalent model
during reduction at the reduction gear's
input referent shaft (Fig. 3), are: J1 =
17.2 kgm2, J2 = 6.25 kgm2, c1 = 86210
Nm and b1 = 14.00 Nms.
The masses of the model in Fig. 3 in
Fig. 3. Equivalent Torsional Elasto-kinetic bucket wheel operation, with 8 buckets and
Model with Two Rotary Masses diameter DRT, under the effect of disturbing
moments from motor M1 = MM and digging
resistance M2 = MW, are in forced damped oscillatory motion. It is for this reason that the
mathematical model describing this motion is given through the system of two non-
homogenous differential equations of the order of two [2, 3, 4]:
112 Z. MARINKOVI, G. PETROVI

J 1
1 + b1 ( 1  2 ) + c1 (1 2 ) = M 1 = M M = f ( 1 )
, (1)
J 21 b1 ( 1  2 ) c1 (1 2 ) = M 2 = M W = Ft ( ) DRT 2

where, apart from the values which have already been explained, j ,  j ,  j - coordinates
of the angle, angular velocity, and angular acceleration of the driving (i = 1) and driven
(i = 2) masses, are generated.
The characteristic of starting motor M 1 = M M = f (n) = f ( = n / 30) is modeled by
observing its two intervals separately (Fig. 4): from initial moment Mp to maximal Mm and from
maximal Mm to nominal Mn. The first interval can be defined by a polynomial of the fourth
order, while the second is best described by the so-called Clos's equation. The complete
procedure of modeling this characteristic is performed in MatLab software package, with
graphical representation in Simulink module, as given in Fig. 4. [3, 4].

Fig. 4. Modeling the Motor Starting Curve

 Processing the Lifetime of Bucket Wheel Excavator Parts in Strip Mine Technologies 113

The disturbing moment on the second - driven mass, i.e. on the bucket wheel with 8 buckets,
M2 = MW = Ft () DRT / 2 depends on digging resistance, i.e. tangential component Ft() and
bucket wheel diameter DRT. Digging resistance can be represented as multiplication of specific
linear digging resistance kl (characteristics of the soil) and mean sum of the length of cutting edges
lsr. The relatively good accuracy of change in tangential force on the buckets which are at that
moment in the process of digging is given by the following relation [3, 4]:
sin 0 / 2
Ft ( ) = kl lsr f o ( ) , f o ( ) = ( ) /( / 2 )
/ 2 (2)
0 >

This discussion can be used as the basis for simulating the value of specific digging
resistance by using the modules from MatLab software package. This module is relatively
simple to use, as it automatically generates a string of random numbers according to the pre-
given distribution and sample size. Having thus obtained the values of specific digging
resistance and assumed active length of cutting edges, we proceed to the block-scheme of
Simulink module for generating digging resistance of a single bucket. The final step implies
the summing up of individual resistances in order to obtain total digging resistance (Fig. 5)
[3, 4].

Fig. 5. Modeling Total Digging Resistances and Resistance on a Single Bucket

114 Z. MARINKOVI, G. PETROVI

4. SIMULATING THE OPERATION OF THE BUCKET WHEEL DRIVING MECHANISM

Simulation means a procedure for imitation and analysis of a real system's operation by
means of its dynamic and mathematical model. By solving the system of differential equations
(1) for defined disturbing moments (M1 = MM and M2 = MW) and initial conditions, the
example of the bucket wheel driving mechanism is used to obtain the laws of motion of the first
driving mass 1(t) and the second driven mass 2(t) of the model in Fig. 3 [4].
On the basis of these laws of motion, it is easy to determine deformation of elastic
bond (t) = 1(t) 2(t), i.e. change in the torsional moment of the referent shaft, as:
M t ( t ) = T ( t ) = c1 (t ) = c1 ( 1 ( t ) 2 ( t )) . (3)

For the concrete example of the bucket wheel driving mechanism in excavator SRs 470.20.3
LAUHAMER, MatLab program package and its Simulink module were used to obtain change in
the torsional moment of the driving shaft Mt (t) = T(t) (Fig. 6). This change lasts 30s, of which the
first 5s belong to the period of acceleration of bucket wheel rotation without digging.

Fig. 6 Change in the Torsional Moment Mt (t) = T(t)

of the Mechanism's Driving Shaft

Apart from torsional moment Mt (t) = T(t), the driving mechanism's referent shaft at
cogwheels is also loaded by cross forces: tangential Ft (t), radial Fr (t) and axial Fa (t) in
corresponding planes, in the way shown in Fig. 7a. These forces, which cause bending of the
shaft, depend on the torsional moment Mt (t) = T(t) and cogwheel dimensions.
These external loads, in the form of torsional moment Mt (t) = T(t) and cross forces Ft (t),
Fr (t) and Fa (t) cause the shaft's corresponding complex strain, i.e. cause the occurrence of
tangential torsional stresses t (t) and orthogonal bending stresses f (t). As can be seen, these
operational stresses are time functions and are determined by means of known expressions from
the resistance of materials at certain characteristic points of the shaft.
The time function of shaft torsion t (t), which is concurrent with change in torsional
moment Mt (t) = T(t), can be written in the following form:
t ( t ) = M t ( t ) W 0 = T ( t ) W 0 = 16 T ( t ) ( d v3 ) . (4)
 Processing the Lifetime of Bucket Wheel Excavator Parts in Strip Mine Technologies 115

where W0 = Wp - is polar moment of inertia of the shaft's cross section with diameter dv.
The function of bending the shaft f (t) is not concurrent with change in torsional moment
Mt = T(t). The way in which this force is determined in loading the shaft by forces Ft (t), Fr (t)
and Fa (t) and moments Mx (t), My (t) and M(t) in function T(t), is given in Fig. 7b. Due to shaft
torsion, the position of the edge point of the section changes in relation to the neutral axis
between maximal value in zones of pressure and straining according to law (t) = (dv /2)sin (t),
as shown in Fig. 7a. The analytical expression for the function of the shaft's bending stress
s = f (t) will be:

f (t ) = M (t ) y(t ) I x = M (t ) (1/ Wx ) sin((t ) + 0 ) , (5)

where: I x = d v4 64 , Wx = d v3 32 - are moment of inertia and axial resistance moment

of the shaft's cross section with diameter dv.
.
x ( t ) = (t ) t


F t (t) y(t)
0 A B z o
y
FAx al bl FBx .
(t )

y Fa (t)
dw1 dv
Fr (t)
0 A 2 B z
x y ( t ) = ( d v / 2 ) sin ( t ) =
FAy l FBy .
= ( d v / 2 ) sin ( t ) t

a)

Ft(t) My1(t)
2/dw1 a1b1/l
2 2 1/2
M(t)
T(t) Fr(t) Mr(t) (Mx +My )
2tgwt/dw1 a1b1/l
Mx1(t)
Fa(t) Ma(t)
2tgw/dw1 dw1/2

M(t) f(t)
y(t)/IA=(dv/2IA)sin[(t)+0]
i(t)
(f +(0 t ))
2 2 1/2

T(t) ft(t)
A=1/WP

Fig. 7. Scheme of Loading the Shaft by Cross Forces (a) and Calculation
of Equivalent Operational Stress (b)
116 Z. MARINKOVI, G. PETROVI

As in this case expression y(t) / Ix = (1 / Wx) sin((t) + 0) is a function of time, then

change in bending moment f (t) also depends on both function of load Mt = T(t), i.e.
Ms = Mi (t), and position of the edge fiber y(t) and initial angle 0.
According to the hypothesis on equivalent stress at complex straining, the total stress
will be:
i (t ) = 2f (t ) + ( 0 t (t )) 2 , (6)

where 0 = Df (-1) / Dt (0), and Df (-1) denotes permanent dynamic endurance of the material from
which the shaft is made at randomly varying bending, while Dt (0) denotes permanent dynamic
endurance at unidirectional variable torsion.
Figure 8 shows change in the functions of operational stresses of torsion t (t) (4), bending
f (t) (5) and total strain i (t) (6), obtained by analyzing the concrete example through
simulation by means of MatLab program package and its sub-program Simulink.

Fig. 8. Change in the Functions of the Shaft's Operational Stresses f(t), t(t) and i(t)
 Processing the Lifetime of Bucket Wheel Excavator Parts in Strip Mine Technologies 117

5. DISCRETIZING THE FUNCTIONS OF OPERATIONAL STRESSES AND THEIR SPECTRUMS

The obtained functions of operational stresses reflect their character of change, and
relevant parameters (features) for further calculation. Such parameters are maximal values
of operational stresses max which may cause a violent fracture or deformation of parts, as
well as variable amplitudes ai and mean values mi , which also contribute to fatigue
breakdown of parts, etc.
To separate these features, methods of discretization and statistical processing are employed
in order to obtain so-called spectrums of operational stresses. In this case, spectrum means a
simplified representation of the results of statistical processing for separated features of
operational stresses as a function of distribution. In this way, the history of operational stress
occurrence is lost, and a simpler set of relevant features for further calculation of parts is
formed. Broadband functions t(t) (Fig. 8a) require bi-parameteric discretization of the
distribution of amplitudes and mean values f (a ,m), while in narrow-band functions f (t) (Fig.
8b) uni-parameteric discretization yields only the distribution of amplitudes f (a) [5].
The essence of this statistical processing lies in variability of operational stresses and their
features' property of dispersion. Apart from the function of distribution density, these spectrums
are often given in the form of cumulative declining distribution with logarithmic division, as such a
form is comparative with Whler's curves of parts' material fatigue. There is a large number of
methods - procedures for separating, counting, and classifying features of the functions of
operational stresses, which can be classified into several groups. However, the preferred method
today is the cycle method, i.e. its popular variant - Rain Flow Method [5, 6].
The originally developed computer program 'SPECTRUM' [5], which, apart from
other things, employs the cycle method, was used to process broadband change in com-
plex stress i(t) by bi-parametric discretization (Fig. 8c). In this type of change, the num-
ber of extreme values is Next = 1868, and maximal, i.e. minimal value, is: max = 408.73 MPa
and min = 0 MPa (1 MPa = 10 kN/cm2). Variational strings of amplitudes a = 0 210 MPa
and mean values m = 10 340 MPa separated by bi-parametric discretization, are divided
into 10 classes with widths a = 21 MPa and m = 34 MPa. Statistical processing of these
strings results in the following Table 1 for the seventh class of mean values m = 225 MPa.

Table 1. Results of Processing a Random Process

Classes ai fi =
ni
ni nuki Fi Hi H i nb log( H i nb )
No MPa nuk
1 0 21 0 0 0 0 1 1000000 6
2 21 42 31 31 0,1245 0,1245 0,8755 875500 5,9423
3 42 63 141 172 0,5663 0,6908 0,3092 309200 5,4903
4 63 84 32 204 0,1285 0,8193 0,1807 180700 5,2570
5 84 105 19 223 0,0763 0,8956 0,1044 104400 5,0188
6 105 126 12 235 0,0482 0,9438 0,0562 56200 4,7499
7 126 147 10 245 0,0402 0,9839 0,0161 16100 4,2059
8 147 168 3 248 0,0012 0,9960 0,0040 4000 3,6038
9 168 189 1 249 0,0040 1 0 0 -
10 189 210 0 249 0 1 0 0 -
118 Z. MARINKOVI, G. PETROVI

Fig. 9. Frequency Stereogram and Histogram of the Seventh Class of Mean Values

Fig. 9a shows the stereogram as a graphical interpretation of statistical processing f (a,m).

From it, it is relatively simple to obtain the histogram of amplitude change for a pre-given
constant mean value m = 225 MPa, (Fig. 9b), as shown in Table 1.

6. CALCULATION OF OPERATIONAL SAFETY AND LIFETIME OF PARTS

The final step in the complex model for calculating vital parts of the bucket wheel
driving system includes the determination of their safety and lifetime. One of the criteria
of choosing the shape and dimensions of parts is that operational stresses should be below
the values leading to critical states (deformation, fracture, and other types of damage),
whereby the material which is used should be used rationally. In practical calculations,
these critical and operational stresses are compared. A properly dimensioned part requires
that critical stresses should be larger than operational ones in order to ensure operational
safety and reliability for a given lifetime.
Critical states, i.e. critical stresses, are characteristic for the material of which these parts are
made. They are obtained experimentally by examining so-called standard test specimens or
model parts for certain types of strain by a standard procedure on adequate machines.
Information about material characteristics can be found in technical literature.
A large number of methods and procedures for calculating machine parts is used
today; their development is determined by the development of more accurate theoretical
and experimental methods of determining operational and critical stresses. The practical
application of these methods depends on a number of criteria, which can, in general, be
divided into several groups, according to:
design phase into preceding and final,
type of change of operational stresses into static and dynamic, and,
character of input and output calculation values into deterministic and probabilistic, etc.
A concrete example of checking the referent shaft of the bucket wheel driving
mechanism involves final calculations of operational safety and lifetime for a dynamic
 Processing the Lifetime of Bucket Wheel Excavator Parts in Strip Mine Technologies 119

change of operational stresses within deterministic calculations. As in this case time

functions of operational stresses are given (Fig. 8), which can be used to easily determine
their maximal values, the shaft's operational safety can also be checked with respect to the
static material characteristics.
As has been mentioned, operational safety is checked by comparing critical and
operational stresses, i.e. their ratio should be more than one in order to satisfy a standard or
desired degree of safety. In general, this is expressed by the following relation:
= [ kr ] r < doz , (7)
where:
[kr] is critical stress as material characteristic which may be the breaking strain
M = RM, yield strain M = RM, dynamic endurance D or A for corresponding
type of strain,
r operational stress, which may be maximal or amplitude value of corresponding
change in operational stresses,
doz allowed degree of safety.
For example, in the concrete example of bending the shaft made of carbon-structural steel
0545 with mechanical characteristics: M = RM = 600 MPa and V = RV = 350 MPa, for known
maximal value of bending stress max = 320 Mpa (Fig. 8b) the following values of degree of
safety are obtained: M = M/max = 600/320 = 1.9 and V = V/max = 350/320 = 1.1.
Previous calculations of operational safety have been static, when maximal values of opera-
tional stresses max were compared with static material characteristics (M and V). They can
also be dynamic, when maximal amplitudes a max of time change are compared with material
endurance D or A. However, it is not always advisable to dimension parts so that maximal
operational stress amplitude is below material endurance. This means that the part is dimen-
sioned within permanent dynamic strength so that it will theoretically have unlimited lifetime.
For this reason, it is allowed for a certain number of amplitudes to exceed material resistance,
which contributes to material fatigue and possible occurrence of cracks and fatigue breakdown.
In this case, calculations are performed in the field of operational strength, i.e. what is calcu-
lated is the lifetime.
To determine the lifetime of the part for the case given above, we observe Fig. 10. In
this figure, what can be seen from the semilogarithmic division stress - number of changes
log N is the uni-parametric spectrum of operational stresses - amplitudes, and
Whler's curve of the part's material fatigue [6, 7].
The given uni-parametric spectrum in Fig. 10 represents a declining step function of the
amplitudes of irregular change in operational stresses in the discrete form (ai, nib) and it applies
to a certain exploitation period (strain block nb), repeated r times in the part's total lifetime.
The following can be determined for the known parameters of the strain block: total number of
changes of all amplitudes in one strain block (nuk), number of amplitude changes ai in the i-th
degree (ni) and total number of amplitude changes in all degreed (1k) for total lifetime
(Nuk = Nr), respectively, from the following expressions, as:
k k k
nuk = nib = nb , ni = r nib , N uk = ni = r nib = r nb = N r . (8)
i =1 i =1 i =1
120 Z. MARINKOVI, G. PETROVI

= arctgm
V m N = im N i = m
W A N0 = C
a1
1 N i = N 0 ( A ai )m
ai 2
i
aj A , m = za ai < A
j
N i = N 0 ( A ai )m1
j+1
xA l
ak m1=2m-1
n1b n2b nib k p=m p

N1 Ni N0 p
log N
nuk = nib = nb

Fig. 10. Calculation of Lifetime of Parts, Whler's Curve

and Spectrum of Operational Stresses
The equation of Whler's curve from Fig. 10 for steels with represented horizontal
part to the right of the breaking point is:
m N = mA N 0 = const . for A and N N 0
, (9)
N = for < A and N > N 0
where:
and N - are current values of stress and number of its changes,
A and N0 - dynamic endurance and base number of changes, as material characteristics,
m - the exponent defining the left part of Whler's curve, and depending on type of ele-
ment and type of strain.
In spectrum from Fig. 10, a part of amplitudes ai from i = 1 j exceed A, while the
others from i = j + 1 k are below A. This means that the first amplitudes can contribute
to material fatigue and fracture of the part. In this case, calculation of strength of parts by
means of direct comparison of the characteristics of operational stresses ai and material
A is not possible, as the change in stress is irregular, while the Whler's curve is obtained
by regular change in strain. For this reason, these types of calculation make use of linear
hypotheses on accumulation of damage due to fatigue. Some of these hypotheses are Palm-
green-Miner's (P-M), Corten-Dolan's (C-D), Haibach's (H), Serensen-Kogaev's (S-K) etc [6,
7].
The first hypothesis introduces linear accumulation of damage by those amplitudes of
operational stresses which exceed permanent dynamic strength. This is expressed through
the following relation [6]:
j j
n
D uk = D i = Ni 1 for ai > D (i = 1 j ) , (10)
i =1 i =1 i

where the new values are:

Duk - total damage as linear sum of partial damages Di,
 Processing the Lifetime of Bucket Wheel Excavator Parts in Strip Mine Technologies 121

Ni - so-called tolerable number of changes the part's material stress according to Whler's curve
for the corresponding amplitude of operational stresses ai (Fig. 10), which is determined from
equation (9) as:
N ( ) m for ai A (i = 1 j )
N i = 0 A ai . (11)
for ai < A (i = j + 1 k )

The lifetime of parts expressed in a number of blocks until fatigue breakdown r is obtained
when expressions for ni (8) and Ni (11) are substituted in the relation which determines total
damage Duk (10), as in the following:
j
N 0 ( A ai ) m N 0 mA
r = n ib
= j
. (12)
i =1
m
ai n ib
i =1

In the Palmgreen-Miner's (P-M) hypothesis, the calculated total number of changes in

amplitudes of operational stresses until fatigue breakdown Nr, is obtained if in the third ex-
pression (8) the expression obtained for r (12), is substituted as:
N 0 mA n b N0 N0
N r = r nb = = = , (13)
j j
KN
m
mai nib ( a 1 A ) m ( ai a 1 ) m ( n ib n b ) p

i =1 i =1

where:
a1 = a max - is maximal amplitude in the spectrum, = a1 / A - overload coefficient, and
j
KN = ( ai a 1 ) m ( n ib n b ) - coefficient of spectrum fullness.
i =1

The other hypotheses have been corrected, as they take into account the effect of amplitudes
below A on accumulation of fatigue damage. The effect of these amplitudes differs from one hy-
pothesis to another [6, 7]. Thus, the Corten-Dolans (C-D) hypothesis introduces from point W in
Fig. 10 a new continual oblique line of fatigue with another exponent p = KCD m = (0.7 1.6) m
and assumes that all amplitudes a1 (i = 1 k) contribute to fatigue.
Haibach (H) introduces a correction in the field of permanent dynamic strength below A to
the right of the breaking point in Fig. 10, a new fictive fatigue line with another inclination
m1 = 2m 1. This correction has enabled linear summing of all damages from i = 1 k for both
parts of the broken fatigue line without discarding small amplitudes.
The Serensen-Kogaev's (S-K) hypothesis introduces the so-called function of interaction
ap < 1, which is multiplied by the calculated number of changes Nr (13) obtained from the Palm-
green-Miner's hypothesis.
Finally, the expressions for calculated values of total number of changes Nr, number of blocks
r and lifetime Tr (h) until fatigue breakdown can be generalized for all hypotheses as [6, 7]:
ap N0 ap N0 Nr
Nr = = , r = , Tr = r tb , (14)
( a1 A ) K Nm
KN
m
p nb
where
122 Z. MARINKOVI, G. PETROVI

KN - is coefficient of the fullness of strain spectrum (block), which, for previously stated cor-
rected linear hypotheses, respectively for hypotheses (C-D), (H) and (S-K and P-M), is:
k
p
n ib
KN = ai
a 1
for ai > 0 (i = 1 k ) ,
i =1 nb
j
m
n ib k

2 m 1
n ib
KN = ai + mp 1 ai

for ai > 0 (i = 1 k ) , (15)
i =1
a1 nb i =1
a1 nb
j
m
n ib
KN = ai
a1
for ai > A (i = 1 j ) ,
i =1
nb

ap - function of interaction, which has values from 0.2 1.0 for Serensen-Kogaev's hy-
pothesis, and for the other functions 1.0, and is determined from expressions [6, 7]:
l
a p = ( p ) /( p ) , = 0,5 , = ( ai / a1 ) ( nib / nb ) , (16)
i =1

tb(h) - duration of strain block.

Figure 11. shows comparison of the unit spectrum of operational amplitudes from Fig. 9b
and Whler's curve of amplitude endurance 0545. The unit amplitude spectrum, as strain
block log (Hi nb) from Table 1, for mean values m = 225 Mpa with maximal amplitude amax
= a1 = 204 Mpa, has 106 changes within time tb = 30106/3600 = 8333 h. The characteristics of
Whler's curve have the following values: amplitude endurance A = D m = 370 225 =
145 Mpa from Smith's diagram for 0545, base number of changes in cycle N0 = 2106 and
exponent m = 8.

Fig. 11. Strain Block and Whler's curve for Discussed Calculation Example
 Processing the Lifetime of Bucket Wheel Excavator Parts in Strip Mine Technologies 123

The originally developed computer program was used as the bases for calculating the shaft's
lifetime for all four discussed hypotheses. Table 2 shows the results of this calculation, i.e. gives
values Nr, r and Tr (h), among which there is not much difference.

Table 2. Results of Calculating the Shaft's Lifetime

P-M C-D H S-K
ap 1 1 1 0.2
KN 0.0079 0.0122 0.0097 0.0079
Nr 36.845 106 23.859 106 30.008 106 7.369 106
r 36.84 23.86 30.01 7.37
Tr (h) 307039 198820 250063 61407

7. CONCLUSION
On the basis of this discussion, the following general conclusions can be made:
bucket wheel excavators are highly complex mining machines used in coal strip mines,
whose safe and reliable operation affects the country's energy efficiency,
adequate calculation of vital parts of the excavator's driving mechanisms provides the basic
preconditions of their more efficient operation, which are realized during exploitation,
the proposed calculation model is highly complex, with a large number of relevant values
obtained analytically and which were successfully realized by means of existing and
originally developed computer programs and PC computers,
by applying this calculation method, it is easy to determine critical points in the
excavator's driving mechanisms, which provides the preconditions required for
their supervision, tracking, and diagnostics under exploitation conditions [1].

REFERENCES
1. Jevti V., Jovanovi M., Marinkovi Z., Janoevi D. "Supervision of Bucket Wheel Excavator
Operation for Condition Diagnostics and Maintenance Purposes", XXVI-th National Conference
Maintenance of Technical Systems, YUMO-2002 Novi Sad, Proceedings, Yugoslav maintenance organization
YUMO, Novi Sad, 2002, pp. 147 156, (in Serbian).
2. Marinkovi Z., Jevti V., Janoevi D., Petrovi G.: "The Probability Statistic Estimation of the Vital
Elements of the Crane Systems of the Roto Dredges", 10th Jubilee Conference with International Participation
on System Analysis of Claims in Economy, Insurance and Preventive Engineering, Proceedings, Beograd
2002, DUNAV PREVING, Beograd, 2002., pp. 389 395, (in Serbian).
3. Petrovi G., Jevti V., Mitrovi M., Marinkovi Z.: "External Excitations and Disturbances with Bucket
Wheel Excavators as Nonlinear and Random Functions", Presented at 6th ISNM-NSA NI 2003, The
Scientific Journal Facta Universitatis, Series Mechanical Engineering, Vol. 1, N010, University of Ni,
Ni, 2003, pp. 1339 1346.
4. Marinkovi Z., Jevti V., Petrovi G., Markovi S., Mili P.: "Calculating Simulations of the Load of
Heavy Machinery", YU INFO 2003 Conference and Exhibition - Kopaonik, Proceedings CD ROM,
Association for Information Systems and Computer Networks, Belgrade, 2003, (in Serbian).
5. Petrovi G., Marinkovi Z.: "Bi-parametric Discretization of Wide-range Changes in Work Load and their
Specters", Research and Development Machine Elements and Systems, IRMES '04, Kragujevac 2004,
Proceedings, JUDEK and Faculty of Mechanical Engineering Kragujevac, Kragujevac, 2004, pp. 239
244, (in Serbian)
124 Z. MARINKOVI, G. PETROVI

6. Marinkovi Z., Petrovi G.: "Calculation of Bucket Wheel Excavator Vital Part Lifetime", 11th
Conference with International Participation Fire, Explosion, Accidents and Burglary Risk in Insurance and
Organization of Preventive Measures, Proceedings, Belgrade, 2003, DUNAV PREVING, Belgrade, 2003,
pp. 271 277, (in Serbian)
7. Marinkovi Z., Marinkovi D., Petrovi G.: "Calculation of the Lifetime of Elements for Work Stress
Spectres with Bi-parametric Distribution", Research and Development Machine Elements and Systems,
IRMES '04, Kragujevac 2004, Proceedings, JUDEK and Faculty of Mechanical Engineering Kragujevac,
Kragujevac, 2004, pp. 257 262, (in Serbian)

PROCESIRANJE RADNOG VEKA ELEMENTA ROTO BAGERA

U TEHNOLOGIJAMA POVRINSKIH KOPOVA
Zoran Marinkovi, Goran Petrovi
U radu je prikazan kompleksan model prorauna elemenata sloenih mainskih sistema, koji su
izloeni promenljivom optereenju i naprezanju. Ovaj model obuhvata proraun radne sigurnosti i
radnog veka elemenata na primeru pogonskog mehanizma radnog toka roto bagera. Cilj je da se
primenom ovog modela prorauna stvaraju sigurni i pouzdani mainski sistemi, tj. roto bageri koji
e efikasno raditi u sloenim eksploatacionim uslovima povrinskih kopova uglja.
Kljune rei: roto bager, optereenje, radni napon, diskretizacija, radni vek