Design and Finite Element Analysis of an Automatic Electromechanical Overload Detecting System for Trucks

Abstract

This paper presents a simple design, low‐cost, electromechanical overloading system, which is easy to use and install and suitable for all types of truck chassis and suspension. This design can detect an overload, signal the driver, and also interrupt ignition when the truck is overloaded. The system was modelled using CAD software, and FEA was performed on the spring component to verify analytical solutions. Components of the overload detection system include a load carrying springs, an electrical relay, ignition system, an LED for signaling overload, and an electrical circuit. Results showed that, for a 3‐axle trucks, the allowable pay load was 15.125 tonnes, and each spring in the design supports a minimum weight of 74.183 kN. A spring index of 4.009 was achieved in line with safe design conforming to 4 ≤ C ≤ 12 with a spring rate of 1464305.5 N/m. The spring displacement needed to actuate the overloading system was 51 mm. FEA which was performed validated analytical solutions in that the induced von Mises stress which was 69.92 MPa was below the yield strength of the material (200 MPa) and the factor of safety obtained was 1.24 signifying safe design. The designed electromechanical system is capable of detecting an overloadand also interrupting the truck ignition. Installation can be installed on new trucks or by retrofitting onto old trucks.