ACARP ACARP ACARP ACARP
Open Cut

Investigation of Intelligent Dumper Hauler System

Open Cut » Health and Safety

Published: February 95Project Number: C3103

Get ReportAuthor: Peter French | Birrana Engineering

The current 'Intelligent Dumper and Hauler Suspension System' (IDHSS) project has evolved from a suspension system concept conceived by Birrana Engineering Pty Ltd.  This report documents work conducted to investigate the feasibility of the concept, and discusses the likelihood of the ultimate success of the project.

Project Aims

The ultimate aim of the project is to develop a retrofittable suspension upgrade package compatible with existing oleopneumatic (gas over oil) suspension systems used on off-highway dumpers and haulers in the surface mining industry. The envisaged package would automatically sense the load state of the vehicle and would optimise suspension characteristics accordingly.

If achieved this would have the following benefits:

Reduced harmful low frequency vibrations at the operator's seat.

Reduced peak tyre / haul road forces.

Reduced torsional frame stresses by addressing roll stiffness imbalance.

Initial Stage Objectives

The objectives of the initial stage of the project documented in this report were:

To test the hypothesis of anticipated operator vibration reduction through detailed computer simulation modelling.

To demonstrate the anticipated benefits of the concept through field trials.

To gain an insight into the likelihood of the ultimate success of the project.

Results

The results of computer simulation modelling conducted by BHP Research, Melbourne Laboratories on typical 2-axle dumper and 3-axle

haulers using a detailed vehicle ride model were very encouraging. Clear trends showing a significant reduction in the weighted r.m.s. vertical acceleration at the driver's seat in response to changes in suspension parameters were predicted.

With the co-operation and assistance of Leo and Green Pty Ltd, field trials of an instrumented Cat777 dumper were then conducted at Ebenezer Mine.

Instrumentation of the test vehicle and analysis of subsequently recorded data was conducted by Vipac Engineers and Scientists. Suspension stiffness characteristics were manually tuned by changing the amount of gas and oil within the struts. Suspension displacements, accelerations of the un-sprung vehicle mass and steering inputs were measured and recorded, as were vibration accelerations at the cabin floor and operator's seat. Handling and vibration data was recorded over haul road courses with various suspension settings and at various speeds with the truck loaded and unloaded.

Suspension displacements during normal operation were found to be much smaller than anticipated, which limited the ability of the trials to verify the predicted trends of reduction in operator vibration and tyre forces. Suspension strut friction also appeared to be affecting free movement of the front struts.

At low frequencies, a significant source of vibration appeared to be wheel rotation. Below approximately 3Hz, axle displacements were generally significantly greater than suspension displacement, indicating that the vehicle was bouncing on its tyres. This problem was particularly apparent at vehicle speeds of 41-45 km/hr corresponding to a system resonance at approximately 1.6Hz.

The simulation model for the 'typical' truck requires revision to more accurately represent the vehicle used in the field trials. Further studies are required to investigate the dynamics of the vehicle in more detail. In particular, the effect of strut friction on vehicle dynamics is to be examined.

Conclusions and Recommendations

Birranaremains confident that the project will be successful. The results of the computer simulation were extremely encouraging, with the potential for a significant reduction in operator vibration being predicted.

The trends predicted by the simulation modelling were unable to be validated due to the small suspension displacements observed during the field trials, however there was no evidence that the predicted trends would be incorrect under the harsher operating conditions of principal interest.

Whilst not as conclusive as desired, the field trials were informative and highlighted areas requiring further investigation.

The effect of front strut friction needs to be looked at in detail. A revised vehicle ride model that will allow strut friction to be investigated is required.

In order to develop a working IDHSS prototype, the parameters used in the revised vehicle ride model need to be updated to represent those of the Cat777 dumper used in the field trials. The revised model would be used to investigate the vehicle dynamics in greater detail, and to subsequently determine the required prototype suspension parameters.

Underground

Health and safety, productivity and environment initiatives.

Underground

Open Cut

Safety, productivity and the right to operate are priorities for open cut mine research.

Recently Completed Projects

C19024Establishing Ecologically Sustainable Mine Water Release Criteria In Seasonally Flowing Streams

Extreme rainfall conditions in the Fitzroy Catchment over an approxi...

C25030Coal Mine Open Pit Final Void Closure And Relinquishment - Addressing Uncertainty In Coal Mine Environmental Planning

This report addresses uncertainties faced by coal mine operators whe...

C27046Estimation Of True Deformation Vector From Slope Radar Monitoring

Slope deformation radar monitors are now widely used in open cut coa...

Open Cut

Coal Preparation

Maximising throughput and yield while minimising costs and emissions.

Recently Completed Projects

C27004Improving Coal Flotation With Oscillatory Air Supply

This report provides detailed information on coal flotation with os...

C25018Improving Solids Recovery And Moisture Reduction In Ultrafine Coal Dewatering

This report provides detailed information on fine coal dewatering in...

C27028Lab Froth Flotation Testing Guide With Coal Quality

Correct outcomes from laboratory froth flotation testing in coal bor...

Coal Preparation

Technical Market Support

Market acceptance and emphasising the advantages of Australian coals.

Recently Completed Projects

C26039Nanoporosity In Cokes: Their Origin, Control And Influence On CO2 Reactivity

This project using the outcomes of previous project C24060, examine...

C28063A Comprehensive Technical Review Of High-Efficiency Low-Emission (HELE) Pulverised Coal Combustion Technologies For Power Generation

Research and development has been undertaken worldwide to realise co...

C28064Carbon Structure Transformation During Coking Of Australian Coking Coals: Better Understanding The Coke Formation

Carbon structures of coke that are formed during the plastic layer a...

Technical Market Support

Mine Site Greenhouse Gas Mitigation

Mitigating greenhouse gas emissions from the production of coal.

Recently Completed Projects

C28076Selective Absorption Of Methane By Ionic Liquids (SAMIL) - Phase 2 Demonstration In A Packed Bed Reactor

An alternative approach to high temperature oxidation of ventilation...

C26004CFD Modelling Of Reverse Thermal Oxidisers For VAM Abatement - CFD Modelling Of Fixed-Bed RTO Devices

The project is part of a larger multi‐phase program of study a...

C27058Technological Assessment Of A Recycle Reactor For VAM Abatement

Underground coal mining emits high volumes of methane, diluted in ve...

Mine Site Greenhouse Gas Mitigation

Low Emission Coal Use

Step-change technologies aimed at reducing greenhouse gas emissions.

Recently Completed Projects

C17060BGasification Of Australian Coals

Four Australian coals were trialled in the Siemens 5 MWth pilot scale ga...

C17060AOxyfuel Technology For Carbon Capture And Storage Critical Clean Coal Technology - Interim Support

The status of oxy-fuel technology for first-generation plant is indicate...

C18007Review Of Underground Coal Gasification

This report consists of a broad review of underground coal gasification,...

Low Emission Coal Use

Mining And The Community

The relationship between mines and the local community.

Recently Completed Projects

C16027Assessing Housing And Labour Market Impacts Of Mining Developments In Bowen Basin Communities

The focus of this ACARP-funded project has been to identify a number...

C22029Understanding And Managing Cumulative Impacts Of Coal Mining And Other Land Uses In Regions With Diversified Economies

The coal industry operates in the context of competing land-uses that sh...

C23016Approval And Planning Assessment Of Black Coal Mines In NSW And Qld: A Review Of Economic Assessment Techniques

This reports on issues surrounding economic assessment and analysis ...

Mining And The Community

NERDDC

National Energy Research,Development & Demonstration Council (NERDDC) reports - pre 1992.

Recently Completed Projects

1609-C1609Self Heating of Spoil Piles from Open Cut Coal Mines

Self Heating of Spoil Piles from Open Cut Coal Mines

1301-C1301Stress Control Methods for Optimised Development...

Stress Control Methods for Optimised Development and Extraction Operations

0033-C1356Commissioned Report: Australian Thermal Coals...

Commissioned Report: Australian Thermal Coals - An Industry Handbook

NERDDC