<p>This masters thesis concerns a modeling project performed at Volvo Technology in Gothenburg, Sweden. The main purpose of the project has been to develop a physical model of the climate in construction vehicles that later on can be used in the development of an electronic climate controller. The focus of the work has been on one type of wheel loader and one type of excavator. The temperature inside the compartment has been set equal to the notion climate. </p><p>With physical theories about air flow and heat transfer in respect, relations between the components in the climate unit and the compartment has been calculated. Parameters that has had unknown values has been estimated. The relations have then been implemented in the modeling tool Simulink. </p><p>The validation of the model has been carried out by comparison between measured data and modeled values by calculation of Root Mean Square and correlation. Varying the estimated parameters and identifying the change in the output signal, i.e the temperature of the compartment, have performed a sensitivity analysis. </p><p>The result of the validation has shown that the factor with the greatest influence on the temperature in the vehicle is the airflow through the climate unit and the outlets. Minor changes of airflow have resulted in major changes in temperature. The validation principally shows that the model gives a good estimation of the temperature in the compartment. The static values of the model differs from the values of the measured data but is regarded being as within an acceptable margin of error. The weakness of the model is mainly its predictions of the dynamics, which does not correlate satisfyingly with the data.</p>

Skid-steer loaders are also called mini loaders. Skid-steer loaders are capable of zero turning radiuses, which make them extremely maneuverable and suitable for confined spaces. The aim of this thesis study is to design the loader mechanism for skid-steer loaders. Primarily, the loader mechanism synthesis will be performed to determine the basic link dimensions for the mechanism of the loader. Genetic algorithm will be used in the design process. Besides, the hydraulic cylinders dimensions and working pressure of the loader mechanism will be chosen according to the forces that will be applied. After the link dimensions of the loader are determined, 3D modeling of the loader mechanism will be performed. Afterwards, the finite element analysis of the system will be carried out. Finally, improvements will be made on the model according to the results of the analysis.

This report represents the bachelor thesis examination by Julia Kastehelmi Rintamäki. The examination has been performed during spring semester 2013 at Volvo Construction Equipment in Eskilstuna. This report, Development of parking brake component, describes the product development process of the parking brake component for articulated hauler, wheel loader and grader. Volvo CE has problems with the parking brake switch that exist today on articulated hauler, wheel loader and grader. The purpose of this project is to develop one common solution for the parking brake component for articulated hauler, wheel loader and grader. The secondary purpose is to find final concept proposal for each machine. Employees at the Volvo CE were interviewed; they were contacted via e-mail, phone calls and via meetings to get the information about the machines and the information around the parking brake component. Volvo CE databases were also used for gathering information about standards and pictures. Lots of different ideas were sketched and concept proposals were created with the aid of material from marketing analysis, competitor analysis, target group analysis, requirement specification, function analysis, standards and ergonomics. Eight concept proposals were chosen to be evaluated with QFD, Pugh’s matrix and FMEA. Two concepts were most suitable and developed further to three dimensional models with the aid of Solid Works. The different aspects were taken into account when designing and dimensioning the final concepts. Two models were created with the aid of plasticine for figuring out the ergonomics and dimensions of the product. DFM, DFA, DFE, D4S were used for taking into account costs, assembly, dimensions and environmental impacts of this product. One of the concepts could replace the existing parking brake switch and suit in different cabins because of its size and design. This concept can be located on vertical or on horizontal plane. The other final concept solution functions better for the  articulated hauler on account of the double function with exhausting brake system activating before parking brake system. Suggestion for next steps for the project could be to make prototypes of the two concepts and test these components in real machines. Also interviewing users for further development of the final concepts and redesign if needed.

A lot of today’s new developments strive for energy efficiency. This includes the hydraulic side of industry. The Division of Fluid andMechanical Engineering Systems of Linköpings University in collaboration with Volvo Construction Equipment in Eskilstuna has developed a newhydraulic concept when it comes to the control of cylinder loads in a wheel loader. The concept differs from today’s application, where the cylinderload is controlled via a valve, in the way that the load is solely controlled by a pump. To control this system, an electrical feed back of operatorsdemanded signal is needed. These signals have to be correctly interpreted so that valve and the pumps perform the requested operation. The newsystem is going to need a unit that can perform these operations in a way that corresponds to the operating level of today’s hydraulically controlledsystem.The study aims to develop a software platform that solves this. This platform shall, besides performing the operators’ demands, monitor the system.The monitoring of the system is a crucial part because of security issues, but also when analyzing the systems functionality. The implementation ofthis software will be done in a real-time computer with the ability to collect data, interpret it and then control the connected units of the system.Further work that is to be done is an energy consumption study of today’s hydraulic system, and on the basis of this study, theoretically evaluate thenew system.The study has resulted in a great insight of an industrial mechanic machine, this in a level that includes an entire system. The wide range of thistask has brought analysis and development of both hydraul mechanical-, electrical- and software related systems. With an understanding of these,both separate and in interaction with each other, a platform has been designed that shall facilitate the forthcoming development of energy efficienthydraulics, both at VCE and LiTH.

This masters thesis concerns a modeling project performed at Volvo Technology in Gothenburg, Sweden. The main purpose of the project has been to develop a physical model of the climate in construction vehicles that later on can be used in the development of an electronic climate controller. The focus of the work has been on one type of wheel loader and one type of excavator. The temperature inside the compartment has been set equal to the notion climate. With physical theories about air flow and heat transfer in respect, relations between the components in the climate unit and the compartment has been calculated. Parameters that has had unknown values has been estimated. The relations have then been implemented in the modeling tool Simulink. The validation of the model has been carried out by comparison between measured data and modeled values by calculation of Root Mean Square and correlation. Varying the estimated parameters and identifying the change in the output signal, i.e the temperature of the compartment, have performed a sensitivity analysis. The result of the validation has shown that the factor with the greatest influence on the temperature in the vehicle is the airflow through the climate unit and the outlets. Minor changes of airflow have resulted in major changes in temperature. The validation principally shows that the model gives a good estimation of the temperature in the compartment. The static values of the model differs from the values of the measured data but is regarded being as within an acceptable margin of error. The weakness of the model is mainly its predictions of the dynamics, which does not correlate satisfyingly with the data.

This study aims to develop a computer program to optimize the performance of loader mechanisms in backhoe-loaders. The complexity and the constraints imposed on the loader mechanism does not permit the use of classical optimization techniques used in the synthesis of mechanisms. Genetic algorithm is used to determine the values of the design parameters of the mechanism while satisfying the constraints and trying to maximize breakout forces that the machine can generate.

The objective of this study is to present a dynamic model of a backhoe-loader including cab dynamics in order to simulate the vibration levels transmitted to the operator. For this purpose, analytical solutions of the cab and the machine are developed by deriving the equations of motion of the system and the state space forms of the solution are implemented in the commercially available simulation software, MATLAB/Simulink. In addition to the analytical solution, a model is developed using the physical modeling toolboxes of MATLAB/SimMechanics. Cab model developed in SimMechanics is extended to simulate whole machine dynamics by inserting machine body and tire parameters. Vibration data is acquired from the machine for experimental validation of the models. Analytical and SimMechanics solution are evaluated by comparing the seat acceleration results for the same inputs. Furthermore, simulation results obtained from the models and the measurement results are found to be in agreement in both time and frequency domain.

In this thesis a model is developed for calculating the loads on the wetclutches in apowershift transmission. This thesis was done at Volvo CE in Eskilstuna and is focusedon their 4-speed countershaft transmissions. The goal of the project is to be able tocalculate the loads automatically during the transmission tests and thus acquire increasedknowledge about what occurs during operation.The model was developed by first generating a number of concepts and then evalu-ating them to decide which one should be developed further. The chosen concept wasthen developed further and implemented into the test equipment as a calculation script.The chosen loads to model were the energy absorbed in each clutch, the coefficient offriction (COF) and the slip distance. The COF was later found to give too unreliableresults to be used in any other way than as a benchmark for how well the model wasconfigured and to see any large changes in COF.The model was validated by calculating the energy absorbed in a HTE-200 seriestransmission and comparing it to a reference calculation model. It was seen that theresults from the new model are very close to the reference result. The energy lostcalculated by the new model will be equal to 94 % of the energy lost calculated by thereference model, but only when measuring the inertia phase. The energy lost is equalto 135 % when the torque phase is included. The increasing difference is believed tobe because of an error in the reference model that means it does not cover the torquephase.

This thesis performed on master level covers an assignment given by the cab division at Volvo Construction Equipment (Eskilstuna, Sweden). The thesis has been carried out by Josefin Hult during the period 2014-01-23 to 2014-05-30 at Mälardalen University. Volvo Construction Equipment manufactures products including wheel loaders, backhoe loaders and articulated haulers. The assignment involves developing the standard door for larger wheel loaders. The current door has a welded frame surrounding the glass that is considered outdated and not cost effective. Volvo Construction Equipment wishes that the door was made in glass in a greater extent. The aim of the assignment has been to generate concepts regarding a glass door that fulfills given requirements. Three research questions have been stated and answered during the process. The product development process has consisted of three phases: information gathering, concept development process and development of detailed concept. For example, field studies and benchmarking have been performed to gather information about competitors’ products and the manufacturing and assembling of the current door. Concepts for handrails, sealant and overall door design have been generated in an iterative process. All components of the door have been developed into a detailed concept during the last phase of the process. The process has resulted in a frameless glass door. The concept suggestion consists of; a tempered sheet of glass, a clip list (sealant) that covers the edges of the glass, two different handrails, inner and outer handles, a gas spring, components to attach handrails against the glass, a cover and a lock mechanism. The major conclusion that is drawn is that it is fully possible to develop a door made in glass in a greater extent than the current door. Many competitors have machines where the door is made in glass in a large extent. This makes it believable that the glass door also will be perceived as timely and more modern and clear. Recommendations have been developed if there is interest in further development. The recommendations include, among others, development of handrail and test of prototype to ensure that all requirements are fulfilled. Figures are produced by the author if not stated otherwise.

Idag är det möjligt att modellera de hydrauliska och mekaniska systemen hos en hjullastare. Det går även i viss omfattning att simulera omgivningen samt de förarkommandon som krävs för utförandet av en önskad uppgift. Däremot är det enda sättet att få reda på hur en förare kommer att uppleva maskinen, dess körbarhet, att bygga en fungerande prototyp och be en förare att testa den. Syftet med det här examensarbetet var att hitta en korrelation mellan förarens bedömningar och mätdata insamlade från en hjullastare under körning. Resultaten är sedan tänkta att användas i framtida simuleringar. Olika hjullastare testades av en grupp provförare och deras subjektiva bedömningar såväl som mätdata från hjullastarna samlades in. Slutsatsen är att det går till en viss del att förutsäga körbarheten från insamlade data om förarens körstil är känd. Då förarnas körstil skiljer väldigt mycket är det är inte möjligt att dra allmänna slutsatser om körbarheten. / Today it is possible to model all hydraulic and mechanical systems of a wheel loader. To an extent the surrounding environment and the operator input required for a desired operation can also be simulated. However the only way to determine how an operator will perceive the handling qualities, the operability, of the wheel loader is to assemble a working prototype and ask an operator to try it out. The purpose of this Master thesis was to find some correlation between the drivers’ opinions and data recorded from the machines during operation. The results are intended to be used in future simulations. Different machines were tested by a group of drivers and their subjective impressions, as well as measurements from the machines were collected. The findings from the analysis are that the operability can be determined to a certain extent if the driver’s behaviour is known. Because of the differences in the way the drivers operate the machine it has not been possible to draw any general conclusions.