Parametric Design Optimisation of Planetary Hub Reduction Equipped in Rigid Frame Dump Truck

Abstract

Even though the information is not leveraged in the contemporary environment, still designing the planetary hub reduction for the off-highway dump truck application without the benchmarking is a sophisticated and exceptional one, because of robust design criteria, including dynamic and maximum loads under different load spectrum. Adopting the conventional planetary gearbox/transmission design used on On/off-highway applications can cater to adequate information. However, in terms of accuracy, it substantially lags, especially for off-highway planetary hub reduction application. The primary objective of this paper is to describe the most viable and reliable procedure of designing, as well as optimizing the planetary hub reduction for off-highway dump truck in the preliminary design stage, which is suitable for industrial application with the help of gear design and simulation software called KISSsoft/KISSsys in rapid manner. Further, this paper describes designers input factors based on benchmarked and ascertained data which significantly reduces iterative steps economically. This design methodology for designing from scratch with a required reduction ratio of 7.235:1 in a short space constraint carried out for 100-ton dump truck, with the gradeability which suits the design requirements and the results of optimised design compared with existing design used for similar tonnage BEML dump truck with the same reduction ratio in higher constructive volume. The compared results found to be in very well accordance concerning the safety factor, life cycle and also the system-level weight of the planetary gear train reduced by 17% in a diminished constructive volume for the optimized new design. This design approach is versatile and time saving and can also be used as an integral approach which is suitable from the conceptual design stage to proto development for industrial application.