ACARP ACARP ACARP ACARP
Open Cut

Intelligent Dumper & Hauler Suspension Systems (IDHSS)

Open Cut » Health and Safety

Published: February 97Project Number: C4013

Get ReportAuthor: Peter French | Birrana Engineering

The objective of this project  was to produce a prototype retrofit suspension upgrade package for dumpers and haulers which would allow the suspension characteristics to be optimised according to the load state of the vehicle.  The primary aims of the project were to reduce jarring and vibration at the operator's seat in order to reduce vibration related operator injuries, and to increase operator alertness by reducing vibration induced fatigue.  Chassis stresses and dynamic tyre/haul road forces are also predicted to decrease, which is anticipated to be beneficial to chassis and tyre life and result in a reduction in haul-road distress.

Results of computer simulation modelling previously conducted in project C3103 were extremely promising, however during subsequent field trials the suspension of an instrumented dumper did not behave entirely as expected. This was attributed to friction locking of the "sliding pillar" front suspension struts. Modelling conducted up until this point had not considered strut friction.

 Method

The current project was focused largely on determining the effect of strut friction on suspension performance and operator vibration.

Computer models incorporating strut bearing and seal friction were created in order to determine the effect of strut friction on operator vibration. Additional studies were made to determine sensitivity to damping levels as strut stiffness and friction were varied.

The revised simulation models predicted significant improvements in operator ride would be achievable with the IDHSS concept, however reducing strut friction would be essential for the benefits of the IDHSS to be reealised.

As friction reduces, damping levels were predicted to become of increasing importance. Options for low frction bearings and seals were researched, and prototype bearing and seals were designed, manufactured and tested.

A pair of front struts were upgraded and retrofitted with prototype IDHSS kits and were fitted to a Cat 776 coal hauler prime mover at BHP Mitsui Moura Mine for Prototype trials.

Static friction levels of the prototype strut bearings were unfortunately found to be insufficiently low, and the predicted reduction in operator vibration levels could not be achieved because the prototype IDHSS struts were still friction locking.

Overcoming strut friction to allow the benefits of the IDHSS concept to be realised is believed achievable, and further work to achieve the project objectives is continuing.

 Conclusions & Recommendations

The majority of objectives for the project have been met.

There is a clear understanding of the effect of friction on operator vibration, and revised simulation modelling and analysis have indicated that the IDHSS concept combined with a reduction in front sliding pillar strut friction should significantly improve hauler and dumper suspension performance and reduce op-erator vibration levels.

Although most aspects of the prototype struts were successful, static friction levels of the bearings used in the struts did not meet expectations, and the reduction in friction levels achieved in the prototype struts was inade-quate to realise the benefit of the IDHSS concept during the field trials.
We remain confident that the IDHSS concept will be successful. The results of the computer simulation were extremely encouraging, with the potential for a significant reduction in operator vibration being predicted.

Future work is proposed to achieve superior suspension control and minimise or eliminate static friction within the struts. It is believed simple active suspension control will produce the maximum reduction in operator vi-bration exposure and best achieve the objectives of the IDHSS concept.

Underground

Health and safety, productivity and environment initiatives.

Recently Completed Projects

C33029Review Longwall Face Ventilation To Mitigate Goaf Gas Emissions Onto Walkways And Tailgate End

As longwall mining increasingly targets deeper coal seams, managing ...

C29009Control Of Transient Touch Voltages During Switching

There have been an increasing number of electric shock incidents rep...

C29025Effectiveness Of Shotcrete In Underground Coal Mines

The primary objective of this project is to quantify the effectivene...

Underground

Open Cut

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

Open Cut

Coal Preparation

Maximising throughput and yield while minimising costs and emissions.

Recently Completed Projects

C33057Foreign Contaminants Detection On Conveyor Belts Using Digital Imaging Processing Techniques And Coal Penetrating Sensors

This project was initiated to tackle the ongoing issue of foreign co...

C29061Improving Flotation With A Combined Method

This project aimed to develop and assess a method combining the use ...

C33053Improving Centrifugal Dewatering Via Modelling And Analysis

The aim of the project was to develop a model for screen bowl centri...

Coal Preparation

Technical Market Support

Market acceptance and emphasising the advantages of Australian coals.

Recently Completed Projects

C34059Coke Reactivity With CO2 And H2O And Impacts On Coke Microstructure And Gas Diffusion

With the global shift to low-carbon ironmaking, partial substitution...

C34055Factors Underpinning The Gasification Reactivity Of Coke RMDC And IMDC With CO2

It is well known that the gasification reactivity of metallurgical c...

C33066Washability And Distribution Of Sulfur And Trace Elements For Different Size And Density Fractions Of Raw Coals

Based on the hypothesis that the levels of sulfur and other toxic tr...

Technical Market Support

Mine Site Greenhouse Gas Mitigation

Mitigating greenhouse gas emissions from the production of coal.

Recently Completed Projects

C34066Safe Operation Of Catalytic Reactors For The Oxidation Of VAM Operating Under Abnormal Reaction Conditions

The catalyst Pd/TS-1 has shown excellent activity in oxidising venti...

C28076Selective Absorption Of Methane By Ionic Liquids (SAMIL)

This third and final stage of this project was the culmination of a ...

C29069Low-Cost Catalyst Materials For Effective VAM Catalytic Oxidation

Application of ventilation air methane (VAM) thermal oxidiser requir...

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