Research on the Compilation Method of Transmission Shaft Load Spectrum for ZL50 Wheel Loader Used in Mines

The ZL50 wheel loader functions under highly fluctuating and intricate load conditions, which significantly impact the longevity of its transmission shaft. This study introduces a thorough approach to compiling and refining the transmission shaft load spectrum by utilizing both simulated and actual torque data. The methodology encompasses signal-preprocessing, rainflow counting for cycle extraction, and fatigue life assessment through Miner’s Rule. An 8×8 load spectrum matrix is created to depict the frequency distribution of load amplitudes and mean values. Sensitivity analysis is performed to evaluate how variations in load magnitude affect fatigue life. Furthermore, MATLAB optimization algorithm is used to reduce cumulative damage by adjusting load parameters, leading to a more efficient and dependable fatigue design. Advanced visualization methods, including surface plots, bar graphs, contour maps, and convergence graphs, are employed to interpret the findings and monitor the optimization process. The proposed method not only enhances the precision of fatigue life prediction but also lays a practical groundwork for designing more robust mechanical components for heavy-duty mining vehicles. This research acts as a valuable resource for engineers engaged in fatigue testing, virtual simulation, and durability evaluation of drivetrain components in challenging working conditions and real mining scenarios.