Italy's CIFA company has made significant progress in this area by adopting a thick ring plate steel casting design. This approach simplifies the overall structure and reduces the welding seams on the seat plate, ensuring high rigidity in the swing area while effectively addressing the issue of welding deformation. To enhance the anti-fatigue performance of the leg structure in the undercarriage, materials such as WELDOX700 and WELDOX960 are widely used. The main load-bearing welds are typically processed using bevel projection welding, which improves the fatigue resistance caused by vibrations and minimizes stress concentration. Therefore, the structural design of the leg support system must be carefully considered and optimized.
The connection between the pivot base and the leg hinge is one of the most critical and vulnerable areas of the chassis structure. As a result, the design of the pivot joint between the base and the leg becomes a key focus in chassis development. Different manufacturers use various calculation methods, experiences, and experimental approaches, leading to a trend toward more diverse and personalized designs. For example, Italy's ANTONELLI company tends to use a box-shaped structure for the hinge point, a design that aligns well with many domestic manufacturers' preferences. Many local companies have since adopted similar styles. Meanwhile, CIFA uses a thick plate docking connection, which offers advantages such as compact folding space and is also widely imitated. However, this method requires careful welding of thick and thin plates, including preheating and other technical challenges. Germany's PM company stands out with its unique approach, employing different connection structures depending on the model—such as thick-thin plate butt joints for models below 42 meters and box-shaped connections for higher models—showcasing their deep expertise in both design and manufacturing.
In terms of design optimization and calculation methods, the theories and techniques used in concrete pump truck design significantly influence the structural design of legs and rotating bases. Well-established companies often have dedicated research institutions that deeply study chassis design theories and manufacturing processes. Advanced methods like Finite Element Analysis (FEM) are widely applied, helping reduce the machine’s weight. While many Chinese enterprises also use FEM, they often only perform basic checks rather than full-scale simulations. Their calculation methods are still largely based on outdated crane frame theories from the 1970s and 1980s. Local structures are frequently designed empirically or simplified, and internal stresses from welding and bending are not fully addressed. Most studies remain theoretical, rarely influencing actual product design, which results in significant quality gaps between Chinese products and those from advanced countries.
As the chassis structure must withstand vehicle overturning and the vibration from the pumping system, fatigue failure in high-stress areas—especially at hinge points—is a major concern. Due to harsh working conditions, it is crucial to conduct in-depth research on the fatigue characteristics of the underframe structure. Optimizing the underframe will be a central task in the design process. Additionally, reducing welding stress and preventing delayed cracks in critical areas such as fuel tanks and water tanks are essential during manufacturing.
The chassis structure plays a vital role in the performance and appearance of a concrete pump truck. New materials, advancements in liquid and electric technologies, and improved manufacturing processes have greatly accelerated the development of these machines. The unified design of pump truck legs allows for parametric design possibilities. To close the gap with foreign counterparts, Chinese manufacturers should focus on optimizing the impact of calculation theories, manufacturing processes, and outrigger structures on vehicle stability. They should also analyze real-world usage problems and elevate them to a theoretical level. Improving tooling, technology, and staff training can help shift from rough to refined production, enhancing product quality. Finally, emphasizing practicality, economy, and innovation in new product design can boost customer appeal and highlight product differentiation and core competitiveness.
Looking ahead, the development trends of concrete pump chassis structures are becoming more artistic and efficient. At events like BAUMACHINA 2004 and other international exhibitions, manufacturers have showcased longer boom trucks, with 42-meter and above models adopting front and rear swing leg designs to improve stability and reduce height. With the application of advanced materials, calculation methods, and testing techniques, chassis designs are becoming more elegant and easier to produce. German companies like Waitzinger have introduced innovative "dragon" leg structures, blending aesthetics with functionality. Schweitzer’s super-X arc support system offers enhanced stability, saving space and weight while improving performance. Proprietary technologies such as unilateral support systems, like SCHWING’s EASY and PM’s OSS, allow construction in narrow or restricted spaces. With the advancement of electro-hydraulic technology, flexible chassis designs enable pump trucks to adapt to various job sites. Manufacturers are increasingly focusing on unique features to differentiate their products and create strong selling points.
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