Profiled design process (Philippi-Hagenbuch process)

Truck bodies
Engineered to a specific mine parameters

True angle of repose +

Mine parameters
Geometric Design Modelación

Finite
Element
Analysis
Final Custom Product

Customer
requirements

Center of Gravity
Location
1 2

Volumetric analysis
Photometric studies load cone formation

MINERAL:
- Average Density

- Size and/or Granularity

- Degree and/or percentage of humidity

- Fill coefficient and type of loading

- Load distribution angle and formation

of the load cone

- Geological condition of the ground

and its inclinations
3 4

Centre of gravity
and axle distribution

5 6
Adverse haul conditions on bodies – rack tell-tale OEM Simulators – how real are they?

7 8

Evaluating material movement in a body - dumping Impact loading with successive passes – g level analysis?

9 10

Starting the custom body design process - site visit Part of the design model process

• Truck body profile required by end user

• What are the application conditions?
• Data collection:
• Load shapes
• Vibrated angle of repose of material

11 12
Design features Design features

• Payload increases over standard

• A one piece main pivot
bodies due to the reduction in assembly ensures a
body weight from the elimination
of excess and redundant steel proper alignment and
• Maintenance costs lowered due provides a smooth fit-up
to elimination of replacement
liners
• Canopy design protects operator
and haul truck from potential
material overflow
• AR plate and a reinforced
structure

13 14

Body add-ons Tailgate design

• Liners and impact plates

• Fenders or rock deflectors
• Eyebrows
• Rock knockers
• Mud flaps

15 16

Final Design

2 piece construction

17 18
Body Types

Dual Slope

Flat Floor

Mine Specific Design II Performance Plus

19 20

Body Liners Arcoplate

Smooth Plate for

cohesive materials

Zipper Grid for

semi-cohesive materials

Rock Box for dry and

non-cohesive materials

Mechanically Attached Wear

Plate System (MAWPS)
for all mining conditions
Hang-Up on After Installation
Plastic Liner of Arcoplate
21 22

Arcoplate

Suspended
Rubber Dump Body
(SDB Series)

Hang-Up on QT Steel After Installation

Truck Body of Arcoplate
23 24
 Duratray - Benefits Impact absorbtion

- Maintenance Free
- Double Wear Performance
(compare with 500 BHN Steel)

- Elimination of Carry Back

(Hang up of sticky material)

- Oversized Rocks
Impact absorption
- Reduction of Loading Shock

- Reduction of Loading noise

25 26

Maintenance: 30,000 hours? Body Application Cycle

Load Haul Dump

27 28

Wheel Loader Wheel Loader

Know the material

• Operator controls dumping impact
• Place material vs. dumping

Simulated impact loading

effect on the body

29 30
Electric Rope Shovels Electric Rope Shovel

Load Placement
• Correct load placement shown here

Evidence of previous
instances of forward
loading on the canopy

31 32

Loading Impact Damage Impact Damage Signatures

• Dropping the load vs. placing

Floor under rib is permanently bowed due

Need to remove the REC from canopy to material being dropped into the body

Material impact on the canopy

created a deformation at the rib

33 34

Poor Load Position Canopy Loading

• Parking on the face creates a racking situation • Unsafe practice

• Imparts racking forces on body and chassis • Body damage
• Load measuring system is compromised • Truck overloading
• Improper weight distribution
• Unnecessary stress on forward structures

35 36
Off-Center Loading Potholes

• Shifts truck’s center of gravity • Potholes cause severe racking

of body and truck
• Aggravates racking situations
• Overloads one side of frame

37 38

Soft / Wet Areas Poor Dump Practices

• Remove wet/soft spots completely and • Body bulldozing

refill vs. trying to maintain
• Dumping into an existing pile
• Not lowering body prior to
moving forward

39 40

Body Bulldozing Dump Considerations

• Pulling through berm after dumping • Poor dumping practices can result in
serious body damage

41 42
Dump Considerations Carry-back

• Pulling truck forward with body up

Carry-back

Stresses in the main rails as a result of body

contact with pile or berm during dumping

43 44

Body Wear Analysis Loading Durability

45 46