How JCB cope with the

stress of collecting strain

Jamie Shenton IEng. MIMechE Senior Structures Engineer

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?

» 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

»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

»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

Preparation CONT.

Loading Materials Shape

Field test

TEST PROG

Drawings

SGauge Fitting

Cabling & Boxing

Field Testing »World wide testing

» Standard tests defined from database. (TEST PROG)

» JCB Quarry in UK replicated around world.

Performing

Pune, INDIA

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

»Fatigue analysis » nCode/ Prenscia – GlyphWorks

Solution

& METADATA

»Post analysis scripts

Solution