Integrated FEM Evaluation and Optimization of Excavation, Loading, and ROPS/FOPS Systems in a Skid-Steer Loader

Abstract

This study proposes an integrated finite element methodology for evaluating and redesigning three critical subsystems of an XCMG XC740K skid-steer loader: the excavation attachment, the arm–bucket charging system, and the ROPS/FOPS operator protection cab. The components were reconstructed by reverse engineering and 3D scanning, modeled in CAD, and simulated in ANSYS Workbench/Mechanical under load cases derived from hydraulic parameters, soil–tool interaction, and international safety standards. The novelty of the work lies in applying a single FEM-based workflow to three interacting subsystems of the same compact machine, rather than optimizing isolated components independently. The original configuration showed critical effort concentrations in the cab and charging system. Localized geometric reinforcements and the use of high-strength and wear-resistant steels improved stiffness and safety margins in the excavation bucket, loading bucket, and ROPS/FOPS cab. However, the arm–quick coupler region remained the controlling weak point of the loading assembly, indicating the need for further redesign. The proposed approach provides a transferable computational framework for identifying structural vulnerabilities and prioritizing redesign actions in compact earthmoving machinery. Because the study is numerical, future experimental validation is required before certification or field implementation.