An analysis of the causes of a BWE counterweight boom support fracture

A bucket wheel excavator (BWE) collapsed in a brown coal mine. As a result of a tie rod fracture the counterweight boom, the discharge boom and several other components of the other assemblies underwent plastic deformation. This paper presents the results of computer simulations of the collapse. A finite element method analysis of the counterweight boom tie rod showed stress concentrations exceeding the allowable level. Also material tests of the fracture surface were carried out to identify the causes of the collapse. Macroscopic and microscopic images of areas within the fracture were obtained. Measurements of hardness and microhardness in the vicinity of the weld were performed. The FEM analyses and material tests showed that the causes of the collapse were design and welding faults.