Computational Analysis Study for the Failure Analysis of Rotating Couplers in Excavators

Rotating couplers used in excavation machinery are vital for optimizing operational efficiency and versatility. Ensuring the reliability of these couplers is crucial to maintain uninterrupted performance and safety during demanding excavation tasks. This study introduces a comprehensive computational analysis approach aimed at exploring potential failure causes in rotating couplers employed in excavators. The analysis begins by developing an accurate finite element model that replicates the mechanical behavior of the rotating coupler system. Diverse loading conditions, encompassing torsional stress and dynamic forces encountered during excavation, are applied to assess the structural integrity of the coupler. Through this computational framework, critical stress points, deformation patterns, and potential failure modes are discerned. Furthermore, parametric investigations are conducted to evaluate the impact of design variations and material choices on the coupler's performance. The obtained results are validated against experimental data and existing failure instances to augment the analysis's reliability. The fatigue life of the central joint shaft, a pivotal component within the rotating quick coupler, is prognosticated using stress data garnered from real-world field tests. The outcomes of this study provide invaluable insights into the failure mechanisms of rotating couplers, thereby assisting in refining design strategies and material selection to enhance durability and safety. The proposed computational analysis framework not only facilitates a deeper comprehension of the underlying factors contributing to failure but also propels excavator technology advancement by advocating robust engineering practices. This research bridges the gap between theoretical analysis and pragmatic application, presenting a methodical approach that manufacturers and engineers can adopt to elevate the reliability and longevity of rotating couplers in excavators and analogous heavy machinery.