LIGHTER AND BETTER BUCKET

The payload capacity of a wheel loader is directly related to the weight and volume of its bucket, by reducing the weight of bucket,the payload capacity is increased and can handle more cargo, using same amount of fuel.

A lighter and better bucket has been designed, which is eco-friendly, cheaper to manufacture and economical to operate. The difference in design is stated below.

Fabrication of standard buckets

In standard buckets fig 1, longitudinal stiffeners, transverse stiffeners,are made of steel plates (ASTM A 36,IS 2062)cut to shape by oxy/plasma torch, the edges prepared by grinding. The torque beam is made by bending plate into 'L' shape,in bending machine/hydraulic press. Then the stiffeners and the torque beam are welded on top of the bucket.

Fabrication of modified buckets

In modified design fig 2, all the stiffeners on top of the bucket, have been replaced with steel HSS(hollow structural sections YST 3100
The torque beam has been replaced with HSS 6x 200x 100mm.
Longitudinal and transverse stiffeners are replaced with HSS 3.6x 122x 61mm.
The rest of body/shell has not been modified.

This design helps in reducing weight, provides higher strength to weight ratio and higher torsional rigidity.
Fabrication details of standard and modified loader bucket of same 3.1cbm. capacity is given below as case study.

Standard bucket Modified bucket
fig1 fig2

Weight 1605kg 1485kg

Plate bending Required Not required
for Torque beam

Plate cutting Required Reduced by
by oxy/plasma 20.300rmt.

Welding of Continuous Only stitch
stiffeners

Benefits observed in fabrication of modified bucket.

a.Reduction in requirement of steel plates .......... 8-10%
b.Reduction in oxy/plasma cutting.................... 20%
c.Reduction in edge grinding......................... 20%
d.Reduction in welding............................... 20%
e.Reduction in man power............................. 20%
f.Reduction in manufacturing time.................... 25%
g.Reduction in plate cutting wastage................. 10%
h.Reduction in manufacturing cost.................... 20%
i.Plate bending for torque beam is not required.

Advantages in manufacturing

Manufacturing of the modified bucket requires, less amount of steel, welding consumables and energy.Is less polluting and is environmentally friendly. It reduces capital investment in tools, assembly floor area and raw material requirement. This bucket fabrication process is quicker, easier and cheaper.

Advantages in operation

The weight of the modified bucket being lighter,requires less power,
improves fuel efficiency and lowers operating cost.

Millions of loaders, excavators and back-hoes,will be benefited by this innovation.They are integral part of cargo handling system in mines,ports,construction sites and factories all over the world.

Reduction in weight is more for loader bucket,because of its length
and is less for excavator bucket because of its short length.The advantages and benefits of simpler and lean manufacturing are applicable to both loader and excavator buckets,fabrication process being similar.

In future all buckets will manufactured using this design.