Volvo G990 Grader
 

Hello all,

Finally I got the time to start the already promised thread about my grader build. Having started the planning in 2005 this is already a long time project bound to take still quite some years to finish. So expect some frequent postings until I catch up with the present state of things and thereafter... hmm, you´ll probably need some patience :o *. Anyway, here some basic model data:

Scale . . . . .: 1:8

Length . . . .: 1222 mm (48") over front wheels
Width . . . . : 363 mm (14.3")
Height . . . . : 408 mm (16")

Moldboard
Width . . . . : 533 mm (21")
Height: . . . : 85 mm (3.4")

Tires
Diam. . . . . : 185 mm (7.3")
Width . . . . : 70 mm (2.75")

Weight : 40 to 50 kg (88 - 110 lbs) (estimated depending on equipment)
Material: Mainly stainless steel, some brass

Drive: Electric 200 W (planned).
All hydraulic, 10 circuits + 5 for implements, max pressure estimated 40 bars (580 psi).
Radio not yet decided, but will need to control some 30 functions.

Here some CAD drawings for a first overview:

https://drive.google.com/uc?id=0B_yT...GxQZGYzOGtOalk
https://drive.google.com/uc?id=0B_yT...GwyWGo1LVBnRFk
https://drive.google.com/uc?id=0B_yT...VhGeHhwX3lKOHc

Stefan

*) If you read some German and can´t wait you could also visit this forum for the latests additions ;).

Edit: Sorry to say, the picture links in posts #1 to #263 have been broken due to a takeover of the cloud service provider :mad:. I managed to save the pics to another, hopefully more reliable provider, but the work to repair the links turns out to be very tedious, and will take quite some time.

Re: Volvo G990 Grader
 

What's happening? All the grader threads are so professional, like real ones.
Are you going to make hydraulics yourself?

Re: Volvo G990 Grader
 

How I'd like to have a grader model, but it such a complex piece of machinery to build accurately... I think I will have to settle with a 6-way pull type.

I be drooling at this one too. :cool:

Re: Volvo G990 Grader
 

Wow, this grader thing is really picking up speed. Glad to see another grader coming onboard. Gonna follow this one two.

Re: Volvo G990 Grader
 

Looks like this forum will need a sub topic for road graders soon :D
I haven't started designing the one I'll be building yet. But I'll be stepping way back in time on my build. The 1930's ;)

Re: Volvo G990 Grader
 

Looking promissing Stefan. Will be following this closely.
As " Madda" said, looks like the grader people are setting a new standard here. There´s a lot of functions to be included in a small space, guess you need to do a good home work before starting to be sure everything fits inside, maybee that´s why Cad is used.
Hope to see pics soon on this build.
Dan

Re: Volvo G990 Grader
 

Stefan... Nice work on the CAD! What software are you using?

I'm curious - Why did you decide to build in 1:8 scale and why Stainless?
This thing is going to be a beast! It will be very interesting to me seeing how you deal with some of the design issues associated with building a project like this. How soon before some of the parts start rolling in?

MPE

Re: Volvo G990 Grader
 

Graders are taking over the forum! That's fine. I enjoy watching these builds take shape. Especially since it seems like the only way to really build one well is to CNC machine everything. Great eye candy.

Re: Volvo G990 Grader
 

Hi Stefan!

Welcome here - I haven't seen the full CAD images before - cool :)

30 functions? Is that including light and sound?
I have "only" 16 in my grader.
Are you going to do a floating position of the main lift cylinders, too?

> MPE
> Why did you decide to build in 1:8 scale and why Stainless?

I can't claim to speak for Stefan, but 1:8 is fairly common in Germany and often considered to be the "premier league". (Larger than that, the scales start to become inconsistent.)

Stainless - why not? You get the necessary weight, no worries about rust and when the main chunk of your model is laser-cut, the price differential and machining woes are less of an issue.

Cheers
Jens

Re: Volvo G990 Grader
 

Hey Tim, I have the flier on that big grader, Champion 100t, the 70T is basically the same machine. 24' moldboard.
Cheer's, Neil.

Re: Volvo G990 Grader
 

Hi all. Thanks a lot to everyone for the friendly comments.

I also find it very interesting that there are so many grader builds at the moment. When I started, I couldn´t find any reference whatsoever to RC graders on the web, and now there are plenty of them. The first one I noticed was a 1:8 O&K F 206 which has been running on the German fairs for the last 5 years. There was even an incredibly detailed, fully functioning O&K F 206 in 1:24 :eek: featured in a magazin last year.

@ mpe + JensR
Why stainless?: Well, I could hardly have said it better than Jens did.

Why 1:8?: I want to be able to build working details to scale and in the Volvo graders you have in particular this steam engine-like circle turn mechanism with a control valve which even in 1:8 will probably be on the limit of what´s feasible - it has to fit in a dia. 8 mm cylindrical housing just 15 mm high. Another reason is that I dream of doing some semi-serious playing like levelling the gravel in the yard and clearing the snow (it doesn´t snow that much here).

I use the TurboCAD Pro v.11 software. Quite happy with that, except for the rendering functions. You can tweak on almost every aspect of that program, and that´s probably why I haven´t found out yet how to make really good renderings. The default light doesn´t seem that useful to me. Maybe that has been improved now, they being already at v.18.

The +30 functions include a couple of individually controlled lights, sound and additional implements like a side snow wing. I just consulted my old list of functions and saw that 2 float valves are included, but I think they where intended for the snow wing, but, of course, I would like that for the main lift as well. By the way, yesterday I met one of the guys involved in the design and testing of the Veroma valves, and he claimed you can get them with an integrated float position intended for tractors with a plow. I´m not sure I understood him correctly, because, as far as I understand it, if float is integrated as one position of the valve it has to be either near the closed position or at one (or both) end(s) and I didn´t ask which is the case. In any case you could have some unwanted behaviour when operating the valve, so I´m not sure this valve would be useful in the grader. Moreover, I couldn´t find any reference to such a valve in the Veroma shop.

@ Madda
I´ll build the cylinders and said circle turn control valve myself. Soon (in my standards :p) to start that.

This is the original circle turn control valve. Behind the hose coupling is the 100 mm ruler. (As Jens once was the first to notice, I used magnetic strips for reference. Very convinient. But I really miss that I didn´t include sub-divisions on the rulers :().

https://drive.google.com/uc?id=0B_yT...khiT1o4YzRINzg

https://drive.google.com/uc?id=0B_yT...UNra3VPU3dVSXc

These are pictures of the lasered parts

https://drive.google.com/uc?id=0B_yT...V8xdWVFQnZMQ0E

https://drive.google.com/uc?id=0B_yT...0xJdlVoSzZLR1E

Stefan

Re: Volvo G990 Grader
 

Really sweet! Definitely going to be a another top build!

30 functions, what radio are you going to use?

Re: Volvo G990 Grader
 

Oh, that´s a nice package for christmas. Can see you spent a lot of hours behind computer, was everything designed before you started cutting anything?

Re: Volvo G990 Grader
 

Hi Stefan!

The float position is rather nice to have, I found.
I solved this mechanically, which won't help you - but the experience of the float position has convinced me that it is worth some headaches to get right.

Have you thought about adding an extra valve for each cylinder's float?
Similar to this:
Blade lift float circuit for motor graders 4034815
http://www.google.com/patents?id=Aks...0valve&f=false

On Caterpillar's new M-series, the float is activated by the operator pressing the joysticks forward over an indent - not sure what Volvo does and also, with electrohydraulics, the joystick does not tell us anything about what happens on the valve side of things.

I see that you have laser-cut the gears for the circle - can you comment on how good the quality of the surface is - do you think it is good enough?

Cheers
Jens

Re: Volvo G990 Grader
 

@ Madda: Thanks! The most suitable radio I know of is the Brixlcontrol.

@ D8R: Having put in the order in November (some years ago), I also considered it a Christmas package, but I had to wait until late February, before I got the parts :mad:. The frame, front axle, drawbar, circle and moldboard designs, i.e. almost everything involving plates except the covers, were practically complete before I started cutting.

@ Jens: An extra valve for each cylinder's float was the first thing I had in mind, that's the reason I considered it a separate function. The "SVAB" joystick solution for Volvo has separate buttons for float.

Considering the slow speed, infrequent use and the fact that the gears for the circle are about module 4 it seems to me that the laser cut surface is smooth enough. When hand-cranking the 6-teeth wheel the 56-teeth one turns OK (but not perfect) without to much mesh play. I hope some running in will further improve it.

Stefan

Re: Volvo G990 Grader
 

What-a-Christmas present!!!:eek: I told santa that other package did have my name on it:D

Re: Volvo G990 Grader
 

Can santa deliver this to my house!!

Re: Volvo G990 Grader
 

NO STOP FOWL. LASERED PARTS? Come on man thats cheatin. LOL .OMG that stuff looks amazing. Wish I had that machine.

Re: Volvo G990 Grader
 

Hi!
Here some more pictures...

Testing the fit of the (at the time) newly cut parts:
https://drive.google.com/uc?id=0B_yT...F9pS2Y5ZGlUSXc

https://drive.google.com/uc?id=0B_yT...HBlcnk5SzlSVjg

https://drive.google.com/uc?id=0B_yT...014ZDRpa1drbG8

https://drive.google.com/uc?id=0B_yT...UJSOVNKcGhUVGc

https://drive.google.com/uc?id=0B_yT...lNKSkhlbkQzcW8

Front frame ...
...bending, plate thickness is 5 mm:
https://drive.google.com/uc?id=0B_yT...29mZUg5cWFMUkE

https://drive.google.com/uc?id=0B_yT...F9sY05STjJycUk

https://drive.google.com/uc?id=0B_yT...Up3ZHdfQXU0Y2M

https://drive.google.com/uc?id=0B_yT...zBNaEFzZE9qdUE

...removing the overstanding edge portions:
https://drive.google.com/uc?id=0B_yT...FFSQ0Q2UGtfZUE

https://drive.google.com/uc?id=0B_yT...3ZtLWJYb2c2RFk

Stefan

Re: Volvo G990 Grader
 

Bending those thick plates so precisely is no small feat, especially considering that the notches and fingers still line up perfectly! Wow!

Re: Volvo G990 Grader
 

Looking good Stefan. Can almost see the smile on your face when putting the parts together. Will parts be TIG ' ed together?
I learned from my model that if MIG 'ed it was easier to have the fingers a little shorter, more room for weld in hole.

Dan

Re: Volvo G990 Grader
 

Thanks! I'm glad :) you realised that, Jens. However, this time it was necessary to file a little bit on the fingers after the bending before everything would fit :p.

Dan, I usually spot weld using the TIG and afterwards the rest is hard soldered or glued (where strength is of less concern). I haven't actually learned TIG'ing :( and prefer to just fuse together touching parts without adding any additional material and therefore it's actually good to have the fingers a little longer to have some spare material for TIG filling the gaps where the fit between the finger and the notch is not prefect.

Stefan

Re: Volvo G990 Grader
 

Top notch work! A lot of the 1:1 equipment I work on have parts built by the same tab / notch system -- makes welding everything together fast and accurate.

Re: Volvo G990 Grader
 

Thanks! That´s really interesting. I didn´t know it is actually used in real life 1:1.

Re: Volvo G990 Grader
 

I have now started assembling the "quadrants", i.e. the immediate supports for the grader blade. This is the original right side quadrant:

https://drive.google.com/uc?id=0B_yT...DZxeWZ5d05GTGs

https://drive.google.com/uc?id=0B_yT...mRCRjY2VURNZkE

https://drive.google.com/uc?id=0B_yT...EZ6bjdSdW1pMEU

Here the left side one:
https://drive.google.com/uc?id=0B_yT...DBjQlRUT1NDMXM

And here my 1:8 attempt:
https://drive.google.com/uc?id=0B_yT...HBpTnhpbVdNeWM

https://drive.google.com/uc?id=0B_yT...XhCYmVKeGNqQk0

https://drive.google.com/uc?id=0B_yT...2NyTVdSTHV1MVE

https://drive.google.com/uc?id=0B_yT...2FCemMtUXE1MG8

https://drive.google.com/uc?id=0B_yT...GVTR19LVGstRkE

https://drive.google.com/uc?id=0B_yT...jdvdzNkSWt4TWs

https://drive.google.com/uc?id=0B_yT...ncwTmM5NS1IN28

https://drive.google.com/uc?id=0B_yT...kJYNG9OTzMxYlk

https://drive.google.com/uc?id=0B_yT...jhZV0xTUmVyS3c

https://drive.google.com/uc?id=0B_yT...TZxc0RQbEdSQlE

https://drive.google.com/uc?id=0B_yT...jllVjlSRk1GczA

https://drive.google.com/uc?id=0B_yT...VZGcXBQNHRHRjg

https://drive.google.com/uc?id=0B_yT...jU2UXY4OU5uSWM

Stefan

Re: Volvo G990 Grader
 

Stefan, I´m speechless :eek::):)

Re: Volvo G990 Grader
 

Amazing work!

Re: Volvo G990 Grader
 

Alot of intricate parts... your head must be spinning at times!!! :eek:

Re: Volvo G990 Grader
 

Nice work. This thing will be indestructible.

Re: Volvo G990 Grader
 

Thanks guys!
@ Lil Giants
You are right, it´s mostly spinning :D Despite a 50 page document with notes for all parts and some excel pages.

Here a few close-ups of parts for the articulation:

https://drive.google.com/uc?id=0B_yT...jRqQXB6eUZWU3M

https://drive.google.com/uc?id=0B_yT...kJldTBMOW9zVmM
The two center bolts (M3) and their nuts will be replaced by ones having a scale head.

https://drive.google.com/uc?id=0B_yT...UNpSlp0QjhlLXc

https://drive.google.com/uc?id=0B_yT...0kxNEJvR3B4TUE

https://drive.google.com/uc?id=0B_yT...DNld09HYi03Q1E

Edit: The rear eyes for the articulation cylinders are combined with the rear axle supports.

Stefan

Re: Volvo G990 Grader
 

I made some additional brackets and fixed them to the quadrants. As you´ll notice, the outermost parts of the bearing holders have now been attached. Today I´ll hard solder the joints.

https://drive.google.com/uc?id=0B_yT...kx3MnAyem5pUzA

https://drive.google.com/uc?id=0B_yT...jZ5VWdqX1BIZGc

https://drive.google.com/uc?id=0B_yT...m1YdnRjblBEeEk

At a late stage I noticed that there is a recess in the quadrant for the cross bar, so I added that to the model (adding by removing :D:D).
https://drive.google.com/uc?id=0B_yT...WxzbHIwNHRMUDA

Stefan

Re: Volvo G990 Grader
 

Soldering the joints looks realy good, did you have a owen to heat the parts (I don´t see any darkening in material from heat)?
And you used TIG to position the parts before soldering them together?

Dan

Re: Volvo G990 Grader
 

Hi Dan, I already polished those parts rather thoroughly. Next pictures show the same parts after final soldering and acid cleaning in 25% vinegar with salt :eek: for some hours but not yet rubbed (which I´m not going to do this time, as they will later be sandblasted). They are a bit darker but right out of the torch they looked pretty ugly :o. I use an oxygen/propane torch. And yes, they were positioned with the TIG, some 70 amperes for 0,5 to 1 seconds.

https://drive.google.com/uc?id=0B_yT...zVNSVVRdTIzcW8

https://drive.google.com/uc?id=0B_yT...kU5dkV4TWVZU2c

Stefan

Re: Volvo G990 Grader
 

Hi, below some pictures from the build of the front frame.

https://drive.google.com/uc?id=0B_yT...E5wY09Gd05Hd00

https://drive.google.com/uc?id=0B_yT...moyNGt6ZmRwUm8

https://drive.google.com/uc?id=0B_yT...25iS0o1YzhZczg


https://drive.google.com/uc?id=0B_yT...UtxQUtmMVFFdWs

https://drive.google.com/uc?id=0B_yT...zlGSHpRN0pTNHc


https://drive.google.com/uc?id=0B_yT...DdqLS1EVUFvbGM

https://drive.google.com/uc?id=0B_yT...3lZZkpnYWtuQ2M


https://drive.google.com/uc?id=0B_yT...kUzd3BfSlNQeGc

https://drive.google.com/uc?id=0B_yT...0NSR0F1WkhzM2M

https://drive.google.com/uc?id=0B_yT...mpZenRQNjlsQ28


https://drive.google.com/uc?id=0B_yT...TkyblctZzBGRDA

https://drive.google.com/uc?id=0B_yT...UgxWXV4SV96ZFE

https://drive.google.com/uc?id=0B_yT...VlVTlpIRjNvUk0

https://drive.google.com/uc?id=0B_yT...lRfcWFSemF0TnM


https://drive.google.com/uc?id=0B_yT...lFUdGlaQzlkN3M

https://drive.google.com/uc?id=0B_yT...DdTYk80WWhROTg

https://drive.google.com/uc?id=0B_yT...VZhTG9jcVhnZDA


https://drive.google.com/uc?id=0B_yT...lV0U19PNWEzeHM

Stefan

Re: Volvo G990 Grader
 

WOW!!!:eek::eek::eek::eek: This is amazing! Great work. your moving along good too.

Re: Volvo G990 Grader
 

Very interesting! I get so used to seeing guys machine all these great models that I forget all about the possibility of laser cutting parts, and welding them together. Seems once you have your parts, the build would go a bit quicker then having to machine everything. You're making excellent progress! Keep it up.

Re: Volvo G990 Grader
 

Agreed, although we should not forget that the skill to design something like that in CAD in a cost-effective and functional way is also considerable.
Ideally, you'd still need have some machined/turned parts, like Stefan's axle carriers.

For smaller scales/models, I think you might find that glueing degreased metal offers more than enough strength, especially if you take it into account during design.

Re: Volvo G990 Grader
 

Very nice hard soldering joints. Looking like a 1:1 machine with all those weldments. Modern machines such as this are built from welding plates together. Much cheaper than yesterdays iron casting for everything. I'm stuck in yesterday with my antique machines; Riveting,casting,bolting, and sometimes welding.

Re: Volvo G990 Grader
 

That's a great idea for building, using the tabs. It is inspiring to see what can be done. Any idea how long it might take you get this completed? Do you think the building process is going quicker with the tab design? Sure seems like a solid design.

Re: Volvo G990 Grader
 

Thanks for the comments guys!

@ Espeefan & JensR: Yes, as 9W Monighan said, the real one is mostly plates, and since there is in any case quite enough work to be done, I decided to have most of the plates cut in a laser cutting shop. But some parts, like the hose bundling plate, I did myself ;) What to do yourself is of course a trade-off question between time, money, difficulty and fun, but in the case of the plates, everything speaks for having them done. I´ll give you an example, for the moldboard slide guide I´ll need four stainless strips (for the two models I´m building) 487 mm x 9 mm x 1,5 mm (about 19” x 11/32” x 1/16”). Not a big deal, but also not much fun and only four bucks apiece from the cutting shop...

Even by the size of my model there are several small-strain-to-area-ratio parts for which gluing will be quite sufficient.

@ Vanisle: Someone in this thread said that the tab concept is used on some of the real machines, too. And yes, I reckon it´s much faster for a given accuracy (at least the one I want), in particular when you take advantage of the inherent accuracy of laser cutting. Just think of it - once the parts are made you can put them correctly together almost blindfolded.

Regarding the time to completion I´m sorry: What you see started almost five years ago and is surely bound to take another five, if not more :(:(:( (but positively seen, I´ve saved you five long years :D:D:D)

And here´s the hose bundling plate (never shown to anyone, anywhere before :D). It´s used at the waist of the machine.
https://drive.google.com/uc?id=0B_yT...U1UQkZVcmd1Q0E