Wheel loaders are fundamental construction equipment to assist handling of bulk material e.g. gravel and stones. During digging operations, it withstands forces that are both large and very complicated to predict. Moreover, it is very expensive to develop prototypes of wheel loader for verification. Consequently, the Discrete Element Method (DEM) was introduced for gravel modeling a couple of years ago to enable prediction of these forces. The gravel model is connected with a Multibody System (MBS) model of the wheel loader, in this thesis a Volvo L180G. The co-simulation of these two systems is a very computer intensive operation and hence, it is important to investigate which parameters that have the largest influence on the simulation results. The aim of this thesis is to investigate the simulation sensitivity with respect to co-simulation communication interval, collision detection interval and gravel normal stiffness.The simulation results are verified by comparison with measurement data from previous tests performed by Volvo CE. The simulations are compared to investigate the relevant parameters. The conclusion of this thesis is that DEM is a method that in a very good way can predict the draft forces during digging operations.

This diploma thesis deals with the creation of models simulating the processes of an emission-free wheel loader, which was created by rebuilding the original version with a combustion engine. Part of the work is the methodical creation of models from the basic part of the machine to a simplified model of the overall machine, its functional verification and calibration based on available information’s and measurements. In this paper, selected parameters of the overall machine model are verified based on performed measurements, the suitability of selected components is verified, and the optimization and modification of the model is performed based on verification. The aim of the thesis is to present the simulation and verification procedure and its practical use in the development of an emission-free wheel loader with electric drive.

Wheel loaders are heavy duty machines that are ubiquitous on construction sites and in mines all over the world. Fully autonomous wheel loaders remains an open problem but the industry is hoping that increasing their level of autonomy will help to reduce costs and energy consumption while also increasing workplace safety. Operating a wheel loader efficiently requires dig plans that extend over multiple dig cycles and not just one at a time. This calls for a model that can predict both the performance of a dig action and the resulting shape of the pile. In this thesis project, we use simulations to develop a data-driven artificial neural network model that can predict the outcome of a dig action. The model is able to predict the wheel loader’s productivity with an average error of 7.3% and the altered shape of the pile with an average relative error of 4.5%. We also show that automatic differentiation techniques can be used to accurately differentiate the model with respect to input. This makes it possible to use gradient-based optimization methods to find the dig action that maximises the performance of the wheel loader.

Volvo Construction Equipment is one of the leading construction machinery manufacturers in the world. To stay amongst the leaders, research and development projects for new technologies are crucial. The most important path of development today is the reduction of emissions produced by these heavy duty vehicles. To tackle this challenge, several technologies are already used in industry. One example are hybrid machines that combine a conventional diesel engine with batteries, resulting in reduced engine size and pollutants. Another option are full battery-electric vehicles, which can reduce the on-site emissions to zero. The electrochemical processes within batteries are however comparable slow and result in long recharge times. A new focus of development within the industry are hybrid systems combining fuel cells and batteries. Since hydrogen can be refueled almost as fast as convenient fuel, it solves the issue of long recharge times. Additionally, the reaction is emission free, since there is no combustion process and the only byproduct that is emitted from the fuel cell is chemically clean water. This thesis aims to propose an architecture and packaging solution to replace the diesel engine in a large size wheel loader with a fuel cell power system. This also includes all respective auxiliary systems, i.e. energy storage, cooling and electric systems. Achieving the same performance as a conventional large size wheel loader as well as keeping the spatial envelope the same are the main objectives of this work. To achieve these goals, an extensive study on the most common drive cycles is carried out to understand the power demand of the machine. After the selection of an energy storage system based on a MATLAB simulation script, a cooling system is modelled and scaled to fulfill the operating requirements of the different components. Eventually, all systems are modeled and installed into the wheel loader in CATIA V5. The study showed, that the new system architecture of the vehicle can be fitted into the existing engine bay with a slight extension of the rear frame and hood. Two power optimized batteries are combined with one fuel cell. Hydrogen tanks with a filling volume of 478 [L] can be installed in the machine, covering 50% of the customer population curve without degradation of performance. This includes one refill of the wheel loader during the day. The performance parameters match the conventional machine up to a high degree, concluding that the conversion of a large size wheel loader into a fuel cell powered wheel loader is feasible.

This thesis aims to create a system using colour markings for Volvo’s autonomous wheel loaders which determines their restricted area and operation using sensors available on the machine. The wheel loader shall be able to interpret and distinguish different colours of spray paint, and depending on the colour, act accordingly. Six different colours are evaluated across two different colour types to find the most suitable ones for the system. Multiple tests are presented throughout the thesis to find the approach with the most optimal performance that meets the system's requirements. The system is evaluated in various weather conditions to determine how the weather affects the performance of the system. The thesis also compares two different line-following approaches, where one is based on edge detection using Canny Edge and Hough transform, and the other uses histogram analysis and sliding window search, to distinguish and track the colour markings. While the wheel loader is in operation, it collects GPS coordinates to create a map of the path taken by the wheel loader and the location of various tasks. The evaluation shows that red, green and blue in fluorescent colour type are the most suitable colours for such a system. The line-following algorithm that utilises perspective warp, histogram and a sliding window search was the most prominent for accurate line detection and tracking. Furthermore, the evaluation showed that the performance of the system was affected depending on the weather condition.

In recent years many companies have investigated the use of hybrid technology due to the potential of increasing the driveline’s efficiency and thus reducing fuel consumption. Previous studies show that hydraulic hybrid technology can be favourable to use in construction machinery such as wheel loaders, which often operate in repetitive drive cycles and have high transient power demands. Parallel as well as Series hybrid configurations are both found suitable for wheel loader applications as the hybrid configurations can decrease the dependency on the torque converter. This project has investigated a novel hydraulic hybrid concept which utilizes the wheel loaders auxiliary pump as a supplement to enable both Series and Parallel hybrid operation. Impact of accumulator sizes has also been investigated, for which smaller accumulator sizes resembles a hydrostatic transmission. The hybrid concept has been evaluated by developing a wheel loader simulation model and a control system based on a rule-based energy management strategy. Simulation results indicate improved energy efficiency of up to 18.80 % for the Combined hybrid. Moreover, the accumulator sizes prove to have less impact on the energy efficiency. A hybrid system with decreased accumulator sizes shows improved energy efficiency of up to 16.40 %.

<p><p>To improve the speed measurement of construction equipment, different sensor technologies have been investigated. Many of these sensor technologies are very interesting but to keep the extent of the thesis only two was chosen for testing, magnetic absolute angle sensors using Hall and GMR technology, to investigate if those are a valid replacement for the current measurement system that is using a passive sensor. Tests show that these sensors are capable of speed measurement, but because of noisy angle estimates they need filtering for good speed computation. This filtering introduces a large time delay that is of significance for the quality of the estimate. A Kalman filter has been implemented in an attempt to lower the time delays but since only a very simple model has been used it does not give any improvements over ordinary low pass filtering. For these sensors the mounting tolerance is of great interest. For best performance the offset between the sensor and magnet centres need to be kept small for both sensors. This is due to a non-linearity effect this causes. The distance between the sensors and the magnet is not critical for linearity issues, but only for the quality of the signal, where it might drop out when the distance is too large. This is where the sensor using GMR technology stands out. Compared to the Hall technology sensor, the GMR sensor can handle distances that are more than 10 times larger. The conclusion is that these sensors can be a valid replacement of the current measurement system. They will introduce more functionality with the capability of detecting rotational direction and zero velocity. In an application with more than one sensor they can also be used for more purposes, like detecting slip in clutches etc. Depending on the application, the time delays may not be critical, else more work need to be done to improve the estimate, e.g. with a more advanced model for the Kalman filter.</p></p><p> </p>

Construction machines, also referred to as engineering vehicles or earth movers, are used in a variety of tasks related to infrastructure development and material handling. While modern construction machines represent a high level of sophistication in several areas, their suspension systems are generally rudimentary or even nonexistent. This leads to unacceptably high vibration levels for the operator, particularly when considering front loaders and dump trucks, which regularly traverse longer distances at reasonably high velocities. To meet future demands on operator comfort and high speed capacity, more refined wheel suspensions will have to be developed. The aim of this thesis is therefore to investigate which factors need to be considered in the fundamental design of suspension systems for wheeled construction machines. The ride dynamics of wheeled construction machines are affected by a number of particular properties specific to this type of vehicle. The pitch inertia is typically high in relation to the mass and wheelbase, which leads to pronounced pitching. The axle loads differ considerably between the loaded and the unloaded condition, necessitating ride height control, and hence the suspension properties may be altered as the vehicle is loaded. Furthermore, the low vertical stiffness of off-road tyres means that changes in the tyre properties will have a large impact on the dynamics of the suspended mass. The impact of these factors has been investigated using analytical models and parameters for a typical wheel loader. Multibody dynamic simulations have also been used to study the effects of suspended axles on the vehicle ride vibrations in more detail. The simulation model has also been compared to measurements performed on a prototype wheel loader with suspended axles. For reasons of manoeuvrability and robustness, many construction machines use articulated frame steering. The dynamic behaviour of articulated vehicles has therefore been examined here, focusing on lateral instabilities in the form of “snaking” and “folding”. A multibody dynamics model has been used to investigate how suspended axles influence the snaking stability of an articulated wheel loader. A remote-controlled, articulated test vehicle in model-scale has also been developed to enable safe and inexpensive practical experiments. The test vehicle is used to study the influence of several vehicle parameters on snaking stability, including suspension, drive configuration and mass distribution. Comparisons are also made with predictions using a simplified linear model. Off-road tyres represent a further complication of construction machine dynamics, since the tyres’ behaviour is typically highly nonlinear and difficult to evaluate in testing due to the size of the tyres. A rolling test rig for large tyres has here been evaluated, showing that the test rig is capable of producing useful data for validating tyre simulation models of varying complexity. The theoretical and experimental studies presented in this thesis contribute to the deeper understanding of a number of aspects of the dynamic behaviour of construction machines. This work therefore provides a basis for the continued development of wheel suspensions for such vehicles. / QC 20110531

To improve the speed measurement of construction equipment, different sensor technologies have been investigated. Many of these sensor technologies are very interesting but to keep the extent of the thesis only two was chosen for testing, magnetic absolute angle sensors using Hall and GMR technology, to investigate if those are a valid replacement for the current measurement system that is using a passive sensor. Tests show that these sensors are capable of speed measurement, but because of noisy angle estimates they need filtering for good speed computation. This filtering introduces a large time delay that is of significance for the quality of the estimate. A Kalman filter has been implemented in an attempt to lower the time delays but since only a very simple model has been used it does not give any improvements over ordinary low pass filtering. For these sensors the mounting tolerance is of great interest. For best performance the offset between the sensor and magnet centres need to be kept small for both sensors. This is due to a non-linearity effect this causes. The distance between the sensors and the magnet is not critical for linearity issues, but only for the quality of the signal, where it might drop out when the distance is too large. This is where the sensor using GMR technology stands out. Compared to the Hall technology sensor, the GMR sensor can handle distances that are more than 10 times larger. The conclusion is that these sensors can be a valid replacement of the current measurement system. They will introduce more functionality with the capability of detecting rotational direction and zero velocity. In an application with more than one sensor they can also be used for more purposes, like detecting slip in clutches etc. Depending on the application, the time delays may not be critical, else more work need to be done to improve the estimate, e.g. with a more advanced model for the Kalman filter.

The construction industry is facing a reality where the dependency on fossil fuels needs to cease and be replaced by options that are more climate friendly. One such option is the electrification that has not made a breakthrough in the construction industry yet and therefore needs to be examined. In this thesis an investigation is made by two different systems of wheel loaders and trucks. One system that conducts machines run by electricity and another one where the system is powered by diesel. The investigation is based on goal formulation which serves as the basis for answering these questions. The machines were examined in such as to obtain results that illustrate which system of machines that are profitable with regards to time, energy consumption, carbon dioxide emissions and total costs. This thesis has also as an intent to identify any advantages and disadvantages of each transport method. This is done in order to lend structure to any further research conducted in the future. To be able to compare and examine the properties of the machines, these machines were applied to a tunneling project. The project that was received was the metro station Hagalunds industriområde. The planned expansion of the subway will lead to a new metro line between Arenastaden and Odenplan, where Hagalunds industriområde will become an intermediate station. In order to truly optimize our efforts and carry out the calculations, the focus was placed on a partial stretch of 1 000 meters with respect to the main tunnel and working tunnel. The result obtained shows that the electric wheel loader leads to less time, carbon dioxide emissions and better energy efficiency than the diesel-powered wheel loader. On the other hand, the disadvantage is that the purchase cost of the electric wheel loader leads to greater total costs. These investments may be necessary to break the dependence on fossil fuels. When comparing the trucks, the result showed that the electric truck is a better alternative from an environmental perspective and total costs. While the diesel-powered truck saves on both time and energy. The reason why the total cost of the diesel-powered truck differs greatly from the electricpowered truck is the rental costs. If the diesel-powered truck was instead purchased, the total cost difference could be reduced. / Bygg- och anläggningssektorn står inför en verklighet där beroendet av fossila bränslen behöver brytas och ersättas med miljövänligare alternativ. Ett sådant alternativ är elektrifieringen som inte riktigt har slagit igenom för anläggningssektorn och därför behöver undersökas. I detta examensarbete undersöks två olika system av hjullastare och lastbilar. Ett system där maskinerna drivs med el och ett annat system med maskiner som drivs på diesel. Undersökningen hade målformuleringen som utgångspunkt för att besvara frågeställningarna. Maskinerna granskades för att erhålla ett resultat som visar vilket system av maskiner som är lönsammare att använda med avseende på tidsåtgång, energiförbrukning, koldioxidutsläpp samt totala kostnader. Examensarbetet har även som syfte att redogöra eventuella för-och nackdelar för respektive transportmetod. Detta för att ge ytterligare underlag till vidare forskning. För att kunna jämföra och undersöka maskinernas egenskaper applicerades dessa maskiner på ett tunneldrivningsprojekt. Projektet som erhölls var tunnelbanestationen Hagalunds industriområde. Den planerade utbyggnaden av tunnelbanan kommer att leda till en ny tunnelbanelinje mellan Arenastaden och Odenplan, där Hagalunds industriområde kommer bli en mellanliggande station. För att avgränsa arbetet och genomföra beräkningarna lades fokus på en delsträcka om 1 000 meter med avseende på huvudtunnel och arbetstunnel. Resultatet som erhölls visar att den eldrivna hjullastaren leder till mindre tidsåtgång, koldioxidutsläpp och bättre energieffektivitet än den dieseldrivna hjullastaren. Däremot är nackdelen att inköpskostnaden för den eldrivna hjullastaren leder till större totala kostnader. Dessa investeringar kan vara nödvändiga att vidta för att beroendet av fossila bränslen ska brytas. Vid jämförelse av lastbilarna visade resultatet att den eldrivna lastbilen är ett bättre alternativ ur miljöperspektiv och totala kostnader. Medan den dieseldrivna lastbilen sparar på både tid och energi. Anledningen till att totala kostnaden för dieseldrivna lastbilen skiljer sig mycket från den eldrivna lastbilen är hyreskostnaderna. Om den dieseldrivna lastbilen istället köptes in, kunde den totala kostnadsskillnaden reduceras.