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Lightweight Design and Structural Strength Optimization for Single-Arm and Double-Curvature-Arm Rock-Drilling Rigs
Release time:
2026-09-29
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Summary:
In the design of rock‑drilling rigs, a fundamental trade‑off exists between weight reduction and structural strength: reducing weight entails using less material, which often compromises load‑carrying capacity. This conflict is particularly pronounced in the rig’s working mechanism—especially the boom system—where the boom must both withstand the reaction forces generated during impact drilling and repeatedly reposition itself within the tunnel cross‑section. Excessive self‑weight significantly degrades maneuverability and positioning accuracy. Consequently, achieving lightweight construction while maintaining adequate strength remains the central challenge in the structural design of rock‑drilling rigs.
I. Drivers and Constraints of Lightweighting
The need for weight reduction in rock‑drilling rigs stems from multiple considerations. For single‑arm rigs, a lighter design facilitates agile maneuvering in low‑clearance tunnels and narrow cross‑sections; for double‑curved‑arm rigs, the self‑weight of the boom directly determines the working envelope and the coverage achieved with a single positioning. From an energy‑efficiency standpoint, every unit of mass shaved off moving components such as thrusters and drill booms translates into a corresponding reduction in the power required by the hydraulic system, thereby enhancing the equipment’s overall energy efficiency.
However, weight reduction must not come at the expense of structural strength. During drilling, the rock‑drilling rig’s boom is subjected to high‑frequency impacts and cyclic loads; insufficient stiffness can lead to excessive boom vibration, compromising drilling accuracy and speed, while inadequate strength poses a safety risk to operators. The boom base, serving as the connection between the chassis and the drill boom, experiences substantial loading; likewise, the rotary cylinder, an integral part of the drill boom, endures significant forces during operation, with its strength directly affecting the rig’s reliability and safety. Therefore, lightweight design must be predicated on meeting stringent requirements for both strength and stiffness.
II. Material Selection: The Foundation of High Strength and Lightweight Design
Materials constitute the first line of defense in lightweight design. In the structural design of rock‑drilling rigs, the use of high‑strength steels has become quite widespread. The thruster employs heavy‑duty aluminum alloy U‑beams, which are both lightweight and offer excellent flexural and torsional strength; the box‑section frame and wing‑type arm mounts, paired with premium cast steel components, strike a balance between strength and fatigue resistance. For double‑curved‑arm rigs, high‑strength steels or advanced composite materials are utilized to reduce the arm’s self‑weight while maintaining load‑carrying capacity and stiffness, thereby enhancing the equipment’s maneuverability and operational efficiency. The application of light‑aluminum alloy beams likewise reflects this approach, delivering superior flexural, torsional, and fatigue performance.
The use of lightweight materials is also advancing in components such as hydraulic cylinders—by employing high-strength alloy steels and other materials, manufacturers are reducing cylinder weight and lowering energy consumption while optimizing internal structures to minimize frictional resistance and enhance motion efficiency.
III. Structural Optimization: From Empirical Design to Precise Calculation
If material selection lays the “hardware” foundation for lightweight design, then structural optimization serves as the “software” approach. In modern rock‑drilling rigs, lightweight design has shifted from empirical estimation to precise calculations based on finite element analysis.
Static analysis and strength verification. By establishing a static simulation model of the rock‑drilling rig’s boom system, the structural strength is analyzed under extreme deployment configurations—such as top‑face drilling, side‑face drilling, and face‑drilling—representing typical limit‑state operating conditions. Taking a specific type of articulated‑boom rock‑drilling rig as an example, after optimizing the boom design based on the simulation results, the maximum stress in the boom was reduced by 25.4%, while the mass was decreased by 9.6 kg. Validation through rock‑drilling simulation tests shows that the average error between experimental and simulated values is less than 10.0%, thereby confirming the reliability of the finite‑element model.
Optimized selection of the drill‑arm cross‑section. The cross‑sectional shape of the drill arm directly affects its stiffness and strength performance. A comparative analysis of circular and rectangular drill‑arm cross sections reveals significant differences in deformation and stress distribution under identical operating conditions. By employing finite element modeling and comparative analysis, it is possible to select a cross‑sectional configuration that achieves the required strength while minimizing weight.
Topology optimization and size optimization. To reduce the weight of the drilling boom while meeting strength requirements, it is necessary to perform both size optimization and topology optimization on key components such as the boom base and the propulsion beam bracket. By identifying stress concentration zones and areas of redundant strength within the structure, material can be selectively removed from non-load-bearing regions, achieving weight reduction while maintaining overall structural integrity. An example is the design of the detachable suspended basket for a three-boom rock‑drilling rig: under the condition of satisfying structural strength, a lightweighting approach was adopted, resulting in a single basket with a mass of less than 89 kg after optimization.
Modular and compact design. CRRC Heavy Industry’s modular architecture distributes functional modules across the machine, eliminating front-end overhangs and significantly reducing the vehicle’s overall length and turning radius. At the same time, it replaces conventional swing cylinders with a rotary drive, enhancing the compactness of the boom root and effectively preventing interference with other components. This compact design itself represents a pathway to weight reduction—by minimizing unnecessary structural redundancy, it lowers the machine’s own weight.
IV. Typical Achievements in Lightweighting
Engineering practice has provided quantifiable validation of the lightweight design of rock‑drilling rigs. For high‑altitude rock‑drilling rigs, after optimizing the drill boom, the weight was reduced by 13% while still meeting the required stiffness and strength criteria, thereby achieving the lightweighting objective. In the case of the articulated‑boom rock‑drilling rig, optimization of the boom reduced the maximum stress by 25.4% and decreased the mass by 9.6 kg. The pronounced stress concentration at the thruster saddle has been mitigated through optimized design, further confirming the effectiveness of the integrated approach that combines finite element analysis with structural optimization.
V. A Complete Closed Loop for Strength Verification
The ultimate goal of lightweight design must be validated through strength verification. For single‑arm and double‑curved‑arm rock‑drilling rigs, lightweighting is not simply about reducing weight; it follows a complete closed loop of “analysis–optimization–validation”: first, static analysis models are built using finite‑element software such as ANSYS to assess the strength and stiffness of critical components—including the drill boom, boom mount, rotary cylinder, and propulsion unit; next, structural optimization is carried out in a targeted manner based on the analysis results; finally, the effectiveness of the optimization is confirmed through rock‑drilling simulation tests or stress‑measurement experiments. Only when the design meets the required standards for strength, stiffness, and weight reduction simultaneously can a rock‑drilling rig transition from the design drawings to actual field operations.
The lightweight design and structural strength of single‑arm and double‑curved‑arm rock‑drilling rigs are, in essence, two sides of the same coin. Lightweighting is not merely about reducing material; rather, it involves, on the basis of precise calculations, selecting appropriate materials, optimizing the structure, and adopting a compact design to minimize self‑weight while ensuring adequate strength and stiffness. From a 13% reduction in drill‑arm weight to a 25.4% decrease in stress, these figures demonstrate that lightweighting and high strength are not mutually exclusive—the key lies in the level of refinement in design methodologies.
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