Virtual Testing Methodology for TPL Lifting Capacity of Agricultural Tractor TPL
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1 Virtual Testing Methodology for TPL Lifting Capacity of Agricultural Tractor TPL Dheeraj Pandey AM CAE International Tractors Limited Jalandhar Road, Hoshiarpur India dheerajpandey@sonalika.com Pritam Prakash Manager CAE International Tractors Limited Jalandhar Road, Hoshiarpur India pritam.prakash@sonalika.com Vibhay Kumar Chief Manager CAE International Tractors Limited Jalandhar Road, Hoshiarpur India vibhay.kumar@sonalika.com Abbreviations: TPL- Three Point Linkage. HV & HG- HyperView & HyperGraph MV & MS- MotionView & MotionSolver Keywords: TPL, Lift Capacity, Transport Height, MBD, Kinematics Abstract This paper explains the use of MBD tool (MotionView & MotionSolver) and post processing tools (HV & HG) of Altair HyperWorks for simulating kinematic behavior of Three point Linkage of Tractor. The Three-Point Linkage (TPL) is a standardized method of attaching implements (equipment) to tractors which consist of pair of lift arms, lower links, leveling rod, one top links & drawbar. This system permits not only lifting an implement but also stabilize it in working conditions. A kinematic simulation is carried out using MV& MS with the complete TPL assembly. Hydraulic pressure is applied on the piston as input and measure torque at lower hitch point as output which gives the range of lift capacity of TPL. HyperView & HyperGraph gives the easiness of tracking TPL movement, calculate transport height & reaction forces at each joint. The MBD results provides good visualization for identifying any fouling in the assembly, working of joints etc. Analytical calculation & testing is done for calculating lift capacity and transport height to co-relate the MBD results which gives approx. 90% accuracy. Introduction The three-point hitch also called three-point linkage is a simple way of joining any implement to the tractor. The implement can be attached on to the tractor by one operator, as well as implement that are pulled they can be lifted up for transport. The three-point hitch is made up of several components working together. These include the tractor's hydraulic system, lifting arms, leveling rod, lower link and top link. There are three movable arms in Three point Linkage. The two lower arms the hitch lifting arms are controlled by the hydraulic system, and provide lifting & lowering of arms. The upper center arm called the top link is movable, but is usually not powered by the tractor's hydraulic system. Each arm has an attachment device to connect implements to the hitch. Although the lifting capacity is the main parameter used by manufacturers to define three-point hitch performance. Measures of the lifting performance are regulated by standards including ASAE S and 1
2 ISO+730-1:1994, which define the procedures for measuring the lifting force at the hitch points. In this paper, three-point linkage is simulated for measuring maximum lift capacity, transport height and reactions at each joints. The mechanism consists of a number of rigid bodies or links connected to each other in such a way that the desired output for a given input can be derived. Multibody dynamics is the analysis of dynamic behavior of interconnected rigid or flexible bodies when they undergo translational and rotational displacements. The study of MBD is important to understand how a mechanism behaves under the influence of forces and what forces are necessary to make the mechanical system move in a specific manner. Hence MBD simulations tool can help to predict kinematic and dynamic behavior early in the stage of design cycle. In the current study kinematic and dynamic analysis of three-point linkage involving translation, revolute & spherical joints is conducted using MotionView and MotionSolve modules of Altair HyperWorks. The mechanisms under consideration are mainly for lifting applications. The main objective is to check the mechanism feasibility, maximum lift capacity, transport height and to extract the joint forces. The extracted force information can be further used for optimum selection of the components such as Lower link, leveling rod, ram arm, etc. MBD model of mechanism is created in MotionView with appropriate mass inertia properties and relevant joints between rigid or flexible bodies. The feasible motion is defined and model is solved in MotionSolve. The output results are post-processed using HyperView and HyperGraph, later compared with analytical calculations and testing results. Process Methodology Three-Point Linkage Mechanism Presented below is a list of basic names for the key components that is used throughout this report. The hitch system is divided into following components- 2
3 Fig. 2 -Measurements standardized by ASAE Fig. 3- Hydraulic Rear cover assembly Three Point Linkage Working Hydraulic pressure is acting on piston (holding into cylinder block of rear hydraulic housing (25)). As the piston (24) moves, force is transfer from piston to ram arm (26) through connecting rod (23) which has a ball joint with piston and revolute with ram arm. Splines of ram arm are engaged with rock shaft splines. Due to force transfer from connecting rod, ram arm rotates with rock shaft (27) about rock shaft longitudinal axis. Lift arms (21) are assembled with rockshaft at both ends which also rotates with ram arm & rockshaft assembly at an angle with respect to the piston movement. As lift arm rotates from lowest to highest position, the whole assembly of TPL (lower link (2), leveling rod (11) & drawbar (28)) rotates about lower link points (6). Lift capacity is measure at drawbar or lower link hitch points which varies at the time of TPL working. The minimum value in load curve of TPL is the maximum lift capacity of TPL. MBD Models in Motion View Defining correct mass inertia properties and CG location will ensure accurate output response in MBD analysis. This can be done by importing CAD model in MotionView and assigning density which will automatically calculate its CG location and mass inertia or we can create body at appropriate CG location and assign relevant mass inertia properties. 3
4 S. No. Body 1 Body 2 Joint Removed D.O.F. 1. Drawbar Lower Link RH Ball 3 2. Drawbar Lower Link LH Ball 3 3. Leveling Rod LH Lower Link LH Revolute 5 4. Leveling Rod RH Lower Link RH Revolute 5 5. Lower Link LH Mounting Bracket LH Revolute 5 6. Lower Link RH Mounting Bracket RH Revolute 5 7. Mounting Bracket LH Ground Fix 6 8. Mounting Bracket RH Ground Fix 6 9. Lift Arm LH Leveling Rod LH Ball Lift Arm RH Leveling Rod RH Ball Lift Arm LH Rockshaft-Ram arm Fix Lift Arm RH Rockshaft-Ram arm Fix Connecting Rod Rockshaft-Ram arm Revolute Connecting Rod Piston Ball Rockshaft-Ram arm LH Lift Cover Revolute Rockshaft-Ram arm RH Lift Cover Revolute Lift Cover ground Fix Top Link Lift Cover Revolute Top Link Drawbar Revolute Piston Ground Translational 5 Total no. Of bodies = 13 Total D.O.F. Removed (all joints)= 95 To remove redundancy, Lower Link and Lift Arms are modeled as a FLEX BODY, rest are RIGID BODY. The MBD model is simplified into links of TPL mechanism as shown in Fig. 4. Kinematic analysis is used to check motion feasibility of TPL by applying rotation at Lower Link joints. The dynamic analysis is performed by applying a force F on piston face along its longitudinal axis. The value of F is calculated from hydraulic pressure and piston diameter. Force F is acting as a resisting force for calculating torque at Lower Links 4
5 point as an output. Lift Capacity Fig. 5- Torque at Lower link hitch point and angle of lower links 5
6 Transport Height Fig. 7- Transport height Note: Transport height is the total height traveled from ground. Lower link initial position is 200mm from the ground and Movement range of TPL assy. observed is 455mm. The transport height for this TPL assembly is 655mm. Fig. 8- Reaction forces at each joints Analytical calculation & Testing Results for TPL lift capacity To co-relate the MBD results, analytical calculation is done to calculate maximum value of Lift capacity and transport height. Coordinates of each linkage are extracted from the 3D modal and 1-D diagram is drawn at Z-X plane. From that line diagram, load P (Lift capacity at point E) is calculated against pressure value. 6
7 From this line diagram, angle of each linkage, load P, height of lower link from ground, etc. can be calculated at any value of piston stroke. Fig. 9- Input sheet of TPL analytical calculation Fig. 11- Lift capacity Vs Piston travel (Ref. output sheet) From the output sheet, minimum value of Load is Kg, which is the maximum Lift capacity of the assembly. Transport height from output sheet is 660 mm. 7
8 Results & Discussions 1. Lift Capacity: The following are the lift capacity measured in all three methodology: S. No. Method Lift Capacity (kg) %age variation 1. Testing 488 Taken as reference 2. Analytical MBD It is observed that the result are within the limit i.e. 10% variation from all the three methodology. 3. MBD helps in visualizing the physical testing aspects and finding the actual lift capacity. Benefits Summary With the help of MBD through MotionView & MotionSolve, the lead time for testing and designer s visualization is reduced in a major proportion. It helps in designing the product at right at the first time. Within the same platform i.e. Altair s, we are able to visualize kinematic simulation, joint behavior, reaction forces, etc. Challenges To understand and replicate the joints as per actual data. Joints modeled as per the physical assembly were creating redundancy in the structure. Hence, Future Plans some linkages are used as FlexBody with alteration of some joints. Currently, MV & MS are used only for kinematic simulation not for structural analysis. So, next target is to compile both analysis i.e. kinematic & structural within the same platform by using all linkages as FlexBody. It will definitely help us to reduce the modeling & simulation time and will provide the easiness to track all the desired output in a single model. Conclusions Multi body Simulation using MotionSolve / MotionView is a very effective tool for kinematic design. The designer can carry out iterations on the mechanism to achieve desired results. The simulation model was well correlated with testing & analytical results for the identified load case. ACKNOWLEDGEMENTS The authors would like to thank International Tractors Limited - R&D and Altair India for their technical support in publishing this work. [1] ITL testing methodology REFERENCES [2] Reference standard: ASAE S & ISO+730-1:1994 8
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