Diseño y simulación de un soporte rotador hidráulico con capacidad de 4 toneladas para un bloque de cilindros Caterpillar mediante software especializado

Abstract

The present technological proposal aims to design and simulate a hydraulic rotating support with a capacity of 4 tons for the maintenance of Caterpillar 3500 series engine blocks, using specialized software. This work arises from a critical need in the industrial sector to have support equipment that allows overhaul maintenance to be carried out safely and efficiently, due to the high risk involved in the manual handling or forklift-assisted manipulation of heavy components. The proposal seeks to minimize occupational risks and damage to components whose value may exceed USD 150,000, improving current procedures through a precise, reliable, and mechanically sound solution. The methodology was based on principles of machine element design and applied mechanics, such as mechanical strength, safety factor, proper material selection, standardization, and normalization. Considering the Von Mises failure theory, loading conditions, applicable safety criteria, and rotation ranges, the conceptual configuration parameters of the rotating support were established. Through calculations and simulations, it was observed that the obtained results are closely aligned, with a maximum stress difference of 3.37% for the structural components of the support and a safety factor of 3.2. For the main rotation shaft, a maximum stress difference of 5.47% and a safety factor of 2.6 were obtained. For the anti-tip foot, a maximum stress difference of 11.61% and a safety factor of 1.95 were achieved. The results obtained for the welds using an E7018 electrode showed a theoretical safety factor of 2.5 and 3.3 by simulation, demonstrating functionality and safety. The simulation results were compared with analytical design data, ensuring consistency between the theoretical model and numerical behavior. This comprehensive approach made it possible to validate the design, reducing prototyping risks, development costs, and lead times, while ensuring that the hydraulic rotating support meets the established capacity, safety, and performance requirements for a 4-ton load.