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How Safety [in numbers] is EngineeredHow Safety [in numbers] is Engineered into Truck Bodies
Josh SwankJosh SwankPhilippi-Hagenbuch, Inc.
©.2009 Philippi-Hagenbuch, Inc
Numbers?
1. Factors that Destroy2 Ground Clearance at Full Dump2. Ground Clearance at Full Dump3. Width and how it relates to loading4. Body Weight4. Body Weight5. Loader Reach6. Construction | Superstructure| p7. Material Angles of Repose | Material Density8. Rated Capacity | Loading Factors
©.2009 Philippi-Hagenbuch, Inc
p y | g
Body Floor
©.2009 Philippi-Hagenbuch, Inc
Factors that Destroy
1. Abrasive wear2. Mass impact2. Mass impact3. Projectile impact4 Haul cycle frequency4. Haul cycle frequency5. Type and size of loading equipment6 Body inside width relative to load centering / impact6. Body inside width relative to load centering / impact7. Dump site / tail chute damage8 Loading equipment damage
©.2009 Philippi-Hagenbuch, Inc
8. Loading equipment damage
Abrasive Wear
• Body components that come in contact with hauled material
• Strength of steel / abrasion resistant• Must be built to withstand thinning over time• Minimize sidewall abrasion
• Tapering body sides allow better load release
©.2009 Philippi-Hagenbuch, Inc
Mass Impact
• Occurs when truck is loaded in two to three passes– 240 ton truck loaded with (3) 80 t – 120 t / pass
• Body floor support structure is key
©.2009 Philippi-Hagenbuch, Inc
Mass & Projectile Impact
• Sharp material projectile impact occurs with:– Sharp– Large– Chunky
materials
• Creates an “armor piercing” situation• Steel should be a derivative of steel armor platep• Mass impact affects whole truck / body vibration
that is a safety concern for truck drivers
©.2009 Philippi-Hagenbuch, Inc
Mass & Projectile Impact
©.2009 Philippi-Hagenbuch, Inc
Mass & Projectile Impact
• Reduced material discharge height directly relates to whole truck / body vibration
• Pass after pass, load after load, vibration can affect the human body
©.2009 Philippi-Hagenbuch, Inc
Haul Cycle Frequency
• More loads dropped, hauled and dumped by truck body, the more stress the body incurs
• What does 20,000 hours of body life mean?– Is it 5 loads / an hour = 100,000 loads– Is it 1 load / an hour = 20,000 loads
• Body must be bult to withstand number of loading / dumping cycles it will be subjected to, just just the number of hours in operation
©.2009 Philippi-Hagenbuch, Inc
Type and Size of Loading Equip.
Three main types of loading equipment:– Cable Shovel– Hydraulic Shovel– Front End Loader
©.2009 Philippi-Hagenbuch, Inc
Cable Shovel
• Large cable shovels (80 – 120 ton bucket capacities) incur:• Higher loading impacts• Less favorable load placement
• Bodies are often loaded off-center• Potentially causes body twist
©.2009 Philippi-Hagenbuch, Inc
Hydraulic Shovel
• Load is often closer to center• Material drop (projectile impact) remains similar
between cable and hydraulic shovels
©.2009 Philippi-Hagenbuch, Inc
Front End Loader
• Typically drop material further than cable or hydraulic shovels
• Causes greater impact to body side and often adversely impacts body life
©.2009 Philippi-Hagenbuch, Inc
Body Inside Width
• Wider bodies provide easier loading target• Allows cable and hydraulic shovels to place
material into center of bodies• Material impact decreases the closer to the floor
the material is discharged• Loading equipment damage is minimized where
ibl ith th t l di i t / t kpossible with the correct loading equipment / truck match
©.2009 Philippi-Hagenbuch, Inc
Body Loading – Narrow Body
©.2009 Philippi-Hagenbuch, Inc
Narrow bodies are harder to load and often have poor load placement
Wider bodies are easier to load and achieve proper load placement
Body Loading – Wider Body
©.2009 Philippi-Hagenbuch, Inc
Weight
• Body weight directly relates to the amount of material being hauled
• Floor thickness: 51% - 59%• Body Sides: 14% - 21%Body Sides: 14% - 21%• Front Slope: 10% - 12%
C 6% 10%• Canopy: 6% - 10%• Other: 6% - 9%
©.2009 Philippi-Hagenbuch, Inc
Body dump / tail chute damage
• Highest practical tail chute dump clearance needed
• Two ways of achieving:1. Body design – floor configuration2. Angle of body floor dump to release material
from the truck body (typically 45° floor angle at f ll d )full dump)
©.2009 Philippi-Hagenbuch, Inc
Dump Clearance
©.2009 Philippi-Hagenbuch, Inc
Loading Equipment Damage
• When there is a loading equipment / truck mismatch, damage to body sides, and loader b k tbucket
• Results in costly maintenance and unnecessary equipment downtimeequipment downtime
©.2009 Philippi-Hagenbuch, Inc
Combating these Factors
• Body Design is Key– User buy-in
• Discuss expectations in advance• Design and build to the end user’s expectations
– Know the application and design accordingly– Correctly size the body– Use the correct materials for the job– Quality welding consumables is imperative
©.2009 Philippi-Hagenbuch, Inc
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Body Weight
• Understanding end user’s expectations can help determine the weight of a body– 1 load an hour or 5 loads and hour?– Projected / intended body life– Abrasiveness of material being hauled– Loading tool / potential projectile impact
©.2009 Philippi-Hagenbuch, Inc
Loader Reach
• Type of loader affects overall width of body• Body should be designed for load to be centered• Truck & Body / Loader mismatch can affect
productivity• Important to know make/model of loader with
options prior to beginning body design
©.2009 Philippi-Hagenbuch, Inc
Construction | Superstructure
• Reinforced body superstructure imperative to support load in body, regardless of type of body
• A solid superstructure is the foundation of any body• What value is there in a floor with no natural
?seems?– Less cracking and breaking of steel– Longer body floor life– Less maintenance / downtime
©.2009 Philippi-Hagenbuch, Inc
Body Sizing
• Why are Material Densities and Angles of Repose important?
• How does the material I carry affect the rated capacity of my truck body?
% S• Why is my body holding 15% less than the SAE rated capacity?
©.2009 Philippi-Hagenbuch, Inc
Body Sizing
•Bodies are typically sized using the SAE 2:1 Heap•Recently in conversations with a Marketing Manager and a Sales Development Manager of two different OEMs, the validity of this standard came into questionquestion.
©.2009 Philippi-Hagenbuch, Inc
Body Sizing
Off-Highway Truck Payload is determined by:– Density of material– Body volume
©.2009 Philippi-Hagenbuch, Inc
Body Sizing
• The SAE Standard does not define an effective body volume, but does define two (2) different load
tiratings:– Struck– Heaped
©.2009 Philippi-Hagenbuch, Inc
Body Sizing
SAE Struck Capacity“To measure the struck capacity of an off-highway t k b d l ff th d f fftruck body you close off the open rear-end of an off-highway truck body starting at the rear edge of the floor plate with a theoretical line drawn upward at afloor plate with a theoretical line drawn upward at a 1:1 slope to the water line or top of the body sides.” (45°)Copyright 2000 Society of Automotive Engineers, Inc.
©.2009 Philippi-Hagenbuch, Inc
Boundaries of the struck volume
Planes defined by the intermediate or discharge edges
©.2009 Philippi-Hagenbuch, Inc
SAE Struck Capacity
No material can be carried at aNo material can be carried at a 1:1 slope.
©.2009 Philippi-Hagenbuch, Inc
Typical Angles of Repose
ANGLES OF REPOSE OF VARIOUS MATERIALS
MATERIAL
Angle between horizontal and slope of heaped pile
Ratio DegreesMATERIAL Ratio Degrees
Coal, Industrial 1.4:1 35
Common earth Dry 2.8:1 20
Moist 2.1:1 25
Wet 2.1:1 25
Gravel Round to angular 1 7:1 30g 1.7:1 30
Sand & clay 2.8:1 20
Sand Dry 2.8:1 20
©.2009 Philippi-Hagenbuch, Inc
Moist 1.8:1 30
Wet 2.8:1 20Source: an OEM Manufacturer’s Handbook
Body Sizing
The SAE struck rating gis bogus, but what
about heaped rating?p g
©.2009 Philippi-Hagenbuch, Inc
Body Sizing
SAE 2:1 Heap Rating:
“3.3.1 Heaped capacity of a dumper or trailer body shall be the sum of the struck volume and the top volume enclosed by the four planes at a slope of two horizontal to one verticalby the four planes at a slope of two horizontal to one vertical (2:1) extending inward and upward from the mean lines of the sides and end plates or load-carrying extensions thereofthereof.For bodies with open ends or sides, the 2:1 slope for heaped capacity shall start from the top of the 1:1 slope
©.2009 Philippi-Hagenbuch, Inc
p p y p pwhich determines struck volume”
SAE Standard:
©.2009 Philippi-Hagenbuch, Inc
Body Sizing
What about a load with 2 different material slopes?
Whoever heard of the same material having two different slopes?
©.2009 Philippi-Hagenbuch, Inc
Body Sizing
See 4.4.2 SAE 2:1 Heap
See 4.4.2
See
4.4.2
See 4.4.2
Whoever heard of a load looking like the
©.2009 Philippi-Hagenbuch, Inc
roof of a house??
Body Sizing
One manufacturer states:
In their spec sheets, SAE Heap overrates the capacity by 5-6% and is not achievable in practice by:capacity by 5-6% and is not achievable in practice by:
5 6%5 - 6%©.2009 Philippi-Hagenbuch, Inc
Body Sizing
Another manufacturer:
“For many years, [we] rated our bodies using a 2:1 fi ld h hi h d 2 1 h f ll i tfield heap which assumed a 2:1 heap from all points
around the body.”
©.2009 Philippi-Hagenbuch, Inc
Body Sizing
How can you determine a truck body’s effective load?
Taking the sameTaking the same truck body, one can easily arrive at 10
different load ratings. From 20.7 yd3 to
35 6 yd3
©.2009 Philippi-Hagenbuch, Inc
35.6 yd
Body Sizing
How can this “bogus” rating be overcome??
©.2009 Philippi-Hagenbuch, Inc
Body Sizing
Any material dumped makes a cone, or a conical loadconical load.
©.2009 Philippi-Hagenbuch, Inc
Body Sizing
A conical load in a body
©.2009 Philippi-Hagenbuch, Inc
Material naturally flows to a cone in a body.
Body Sizing
Typical Truck Load
©.2009 Philippi-Hagenbuch, Inc
Body Sizing
©.2009 Philippi-Hagenbuch, Inc
Patent Pending
Body Sizing
What did we find out?
THERE IS NO ONE SINGLE ANGLE OF REPOSETHERE IS NO ONE SINGLE ANGLE OF REPOSE FOR A LOAD OF MATERIAL
©.2009 Philippi-Hagenbuch, Inc
Hauled Material Angles of Repose
Location Mine Material Hauled Front Angle
Rear Angle
Side Angle
Australia Coal Overburden 24° 28° 34°
Australia Coal Overburden 21° 31° 33°
A t li G ld W t & O 26° 26° 33°Australia Gold Waste & Ore 26 26 33
Chile Copper Waste & Ore 18° 30° 32°
USA Coal Overburden 24° 31° 24°USA Coal Overburden 24 31 24
USA Copper Waste & Ore 29° 31° 24°
USA Iron Waste & Ore 29° 31° 33°
©.2009 Philippi-Hagenbuch, Inc
USA Iron Waste & Ore 29° 34° 34°
Angles of Repose
©.2009 Philippi-Hagenbuch, Inc
Body Sizing
When making body choices, know the differences between:
• Profiled Load®
• 2:1 field heap• SAE 2:1 Heap
©.2009 Philippi-Hagenbuch, Inc
Loading Factors
Factors Ignored -– Body corner voids
• Material loading from a chute forms conical shape • Voids will occur in the four body corners unless
material is “spoon-filled” into dump body– Loading equipment
• With trends towards 2-plus pass loading, little control exists over how material is placed in truck body
©.2009 Philippi-Hagenbuch, Inc
body
Loading Factors
Bodies designed for the loading equipment?– Shovel loaded requires wider body– Front End loader requires longer body– Minimizes need for loading to spill point
©.2009 Philippi-Hagenbuch, Inc
CORRECT
This diagram showsINCORRECT5.59% overloaded This diagram shows
how the three load profiles (Load
P fil d® 2 1 h
overloaded
Profiled®, 2:1 heap from all points and
SAE 2:1 heap) impactREALLY WRONG!13 48% SAE 2:1 heap) impact
the center of gravity.WRONG!13.48%
overloaded
©.2009 Philippi-Hagenbuch, Inc
Our experience shows…
The SAE 2:1 Heap overrates a truck bodyby as little asby as little as
7%to as much as
7%
18%18%
©.2009 Philippi-Hagenbuch, Inc
Dump Clearance
• Body design – floor configuration• Angle of body floor dump to release material from
truck body– 45o floor angle at full dump is usually sufficient
©.2009 Philippi-Hagenbuch, Inc
Properly Sized & Balanced Load
©.2009 Philippi-Hagenbuch, Inc
How Safety In Numbers Adds Up
• Ground clearance is a factor in safe body life and operation
• Proper body weight to load ratio keeps the Center of Gravity low, and the load distributed correctly on chassischassis
• Body width assists in loader operators in loading body safely and correctly each and every loadbody safely and correctly each and every load
• Wider bodies = less whole body / truck vibration which is safer for the truck operator
©.2009 Philippi-Hagenbuch, Inc
which is safer for the truck operator
How Safety In Numbers Adds Up
• Knowing the density of the material being hauled lets the body manufacturer accurately design the b d f it i t d dbody for its intended use
• Knowing what the actual capacity of the load is, and profiling the load accurately cuts down onand profiling the load accurately cuts down on unneeded steel, and maximizes payload
©.2009 Philippi-Hagenbuch, Inc
Presented By:
Josh SwankSales Manager
Philippi-Hagenbuch, Inc.Philippi Hagenbuch, Inc.7424 W. Plank RoadPeoria, Illinois 61604 ,
(309) 697–9200jjswank@philsystems.com
©.2009 Philippi-Hagenbuch, Inc
jj @ y
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