Lightweight research on excavator working device considering extreme operation modes

Abstract The working device of an excavator is a critical component that directly impacts the performance, reliability, and safety of the machine. In light of growing demands for energy efficiency and cost reduction, lightweight design of the excavator’s working device becomes essential. This study presents an innovative optimization method that integrates the response surface method (RSM) to achieve the lightweight design of the excavator’s working device under two extreme operating conditions, aiming to enhance design efficiency while ensuring a balance between structural strength and lightweight goals. A parametric model of the working device is first created using SolidWorks, capturing key design elements with high precision. This model is then analyzed in ANSYS Workbench, where two extreme working modes—the bucket digging mode and the combined digging mode—are simulated to evaluate performance under varied conditions. By focusing on structural strength, a Design of Experiments (DOE) methodology is employed to identify key design variables, and RSM is applied to optimize the design, balancing structural integrity with lightweight goals. The optimization process results in significant improvements in quality, volume, and cost, demonstrating the potential of RSM as a powerful tool for efficient and sustainable excavator design. The optimized boom weight was reduced by 351 kg, a 3.4% reduction, while the stick weight was reduced by 188 kg, a 1.8% reduction.