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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


p y | g

Body Floor


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


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


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


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



• Reduced material discharge height directly relates to whole truck / body vibration

• Pass after pass, load after load, vibration can affect the human body


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


Type and Size of Loading Equip.

Three main types of loading equipment:– Cable Shovel– Hydraulic Shovel– Front End Loader


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


Hydraulic Shovel

• Load is often closer to center• Material drop (projectile impact) remains similar

between cable and hydraulic shovels


Front End Loader

• Typically drop material further than cable or hydraulic shovels

• Causes greater impact to body side and often adversely impacts body life


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


Body Loading – Narrow Body


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


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%


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)


Dump Clearance


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


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


y g p

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


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


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


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?


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.


Body Sizing

Off-Highway Truck Payload is determined by:– Density of material– Body volume


Body Sizing

• The SAE Standard does not define an effective body volume, but does define two (2) different load

tiratings:– Struck– Heaped


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.


Boundaries of the struck volume

Planes defined by the intermediate or discharge edges


SAE Struck Capacity

No material can be carried at aNo material can be carried at a 1:1 slope.


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


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


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


p p y p pwhich determines struck volume”

SAE Standard:


Body Sizing

What about a load with 2 different material slopes?

Whoever heard of the same material having two different slopes?


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


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.”


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


35.6 yd

Body Sizing

How can this “bogus” rating be overcome??


Body Sizing

Any material dumped makes a cone, or a conical loadconical load.


Body Sizing

A conical load in a body


Material naturally flows to a cone in a body.

Body Sizing

Typical Truck Load


Body Sizing


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


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°


USA Iron Waste & Ore 29° 34° 34°

Angles of Repose


Body Sizing

When making body choices, know the differences between:

• Profiled Load®

• 2:1 field heap• SAE 2:1 Heap


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


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


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


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%


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


Properly Sized & Balanced Load


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


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


Presented By:

Josh SwankSales Manager

Philippi-Hagenbuch, Inc.Philippi Hagenbuch, Inc.7424 W. Plank RoadPeoria, Illinois 61604 ,

(309) 697–[email protected]


jj @ y

swank

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