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Welcome Project History Large Truck Study - Late ‘80s Large Truck Study - Late ‘80s Drive System Investigation Drive System Investigation - Mechanical.

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Presentation on theme: "Welcome Project History Large Truck Study - Late ‘80s Large Truck Study - Late ‘80s Drive System Investigation Drive System Investigation - Mechanical."— Presentation transcript:

1

2 Welcome

3 Project History Large Truck Study - Late ‘80s Large Truck Study - Late ‘80s Drive System Investigation Drive System Investigation - Mechanical - Direct Current (DC) - Alternating Current (AC) North American Locomotive Development North American Locomotive Development Project Start-up - Late ‘92 Project Start-up - Late ‘92 Prototype - Early ‘95 Prototype - Early ‘95 Field Test - ‘96 Field Test - ‘96 Market Introduction - September ‘96 Market Introduction - September ‘96

4 Development Goals Development Goals Increased Productivity Increased Productivity Decreased O&O Costs Decreased O&O Costs Better Performance Better Performance - Speed-on-grade - Maximum Speed - Continuous Gradeability - Retarding Capability - Horsepower Utilization Across Speed Range Improved Driveability Improved Driveability

5 Big Is Better Philosophy OK If? Infrastructure Can Support: Infrastructure Can Support: - Haul Road Width - Service Bays - Maintenance Handling Equipment - Crusher Capacity - Shovel Match

6 Big Is Better Philosophy OK If? Cost Per Ton is Reduced Cost Per Ton is Reduced - Higher Production - Fewer Trucks - Better Reliability & Availability

7 930E

8 930E Specifications Conventional Configuration Conventional Configuration - Rigid Frame/Single Engine/Two Axles/Six Tires Approximately 50’L X26’WX24’H Approximately 50’L X26’WX24’H 1,059,000 pound Gross Vehicle Weight 1,059,000 pound Gross Vehicle Weight 400,000+ pound Empty Vehicle Weight 400,000+ pound Empty Vehicle Weight 320 Short Ton Payload 320 Short Ton Payload 40 mph Maximum Speed 40 mph Maximum Speed 50/90 R 57 Tire Size 50/90 R 57 Tire Size Oil-cooled Service Brakes Oil-cooled Service Brakes 2700 hp DDC 16V4000 Engine 2700 hp DDC 16V4000 Engine AC Drive System AC Drive System

9 AC Electric Truck Performance High speed High speed Deep pit capacity Deep pit capacity High efficiency/ high horsepower utilization High efficiency/ high horsepower utilization Superior retarding Superior retarding Long component life Long component life

10 320 Ton Componentry MTU/DDC 16V4000 engine MTU/DDC 16V4000 engine G.E. drive system G.E. drive system - GTA-34 alternator - GDY-85 motorized wheel - AC traction torque regulation Bridgestone 50/90 R57 VELS tires Bridgestone 50/90 R57 VELS tires

11 930E Systems

12 Drive System

13 Engine

14 Specifications Make and modelMTU/DDC 16V4000 FuelDiesel Number of cylinders16 Operating cycle4 Cycle Rated brake power2700 hp (2014 kW) @ 1900 rpm Flywheel power2500 hp (1865 kW) @ 1900 rpm Weight (dry)15,419 lb (6994 kg)

15 320 Ton Capacity 20-30% more than 240 ton trucks 20-30% more than 240 ton trucks Up to 10% lower cost per ton Up to 10% lower cost per ton

16 Braking System Electric retarding 5400 hp (4026 kW) Electric retarding 5400 hp (4026 kW) Oil-cooled, multiple disc service brakes Oil-cooled, multiple disc service brakes

17 Economics Fuel savings Fuel savings Time cost control Time cost control Maintenance cost advantage Maintenance cost advantage - Lowest life-cycle cost per ton

18 Reliability Advantage UNI-ECS electronic control UNI-ECS electronic control 5-10% fuel economy improvement 5-10% fuel economy improvement 12,000+ hours to overhaul 12,000+ hours to overhaul

19 Main Alternator Cutaway

20 Control Cabinet Inverter Phase Modules 2 + or - Link Voltage MeasuringModule Chopper GTO Phase Module 1 and 2 Alternator 3-phase Voltage Measuring Module Inverter Phase Module 1 + or - ControlPanel

21 Electrical Interface Cabinet Diode Board Truck Control Interface Engine Drive System CircuitBreakers/Switches Relay Boards Lincoln Lube System Timer

22 G.E. GDY-85 Electric Wheel

23

24 AC Drive System Motorized Wheels Controls Pumps Alternator Engine Retarding Grids Blower

25 AC Control System IGBT Aux. Inverter Propulsion System Controller (PSC) Inverters #1#2 Rectifier Truck Control Interface (TCI) D.I.D. Alt. Cooling Air Blower Serial Comm. Link

26 Retarding Power Circuit M1 M2 Inverter Inverter ChopperModule2ChopperModule1 RP1RP2RP3 BM1 BM2

27 Gradeability Comparison in Retarding 930E vs Cat 793C 0 5 1015 Speed 051015202530354045 Grade in Percent 30 05101540455560702025355065 mph km/h 930E GVW = 1,059,000 lb 793C GVW = 830,000 lb 3-min3-min Cont.Cont. ContinuousContinuous 930E930E793C930E930E793C

28 Cooling

29

30 AC Drive Induction motors - no commutator, no brushes Induction motors - no commutator, no brushes Integral outboard planetary final drive Integral outboard planetary final drive Proven GTA-34 traction alternator Proven GTA-34 traction alternator

31 Electric Retard Advantage High-density air cooled grids High-density air cooled grids 5400 hp (4028 kW) 3-minute retarding effort 5400 hp (4028 kW) 3-minute retarding effort 3300 hp (2460 kW) continuous retarding effort 3300 hp (2460 kW) continuous retarding effort 0.7 sec propel-to- retard transition time 0.7 sec propel-to- retard transition time

32 KMS Quality Confirmation Attitude Past Practice -Design, Release, Produce... hope for the best in the field Current Practice - Design, Test, Re-design, Re-test, Produce... know what the field results will be

33 USA Germany Japan KMS Joint Technology Projects Vital Signs Monitoring D575A 930E H655S ModularMining

34 Quality Confirmation Activity Application of K.E.S. Techniques

35 Frame Advanced technology, full butt-welded box sectional ladder- type frame with integral ROPS supports, integral front bumper, rear tubular cross members, steel castings at all critical stress transition zones, rugged continuous horsecollar.

36 Frame Specs Rail width12” (305 mm) Rail width12” (305 mm) Rail depth34” (864 mm) Rail depth34” (864 mm) Top and bottom plate thickness1.77” (45 mm) Top and bottom plate thickness1.77” (45 mm) Side plate thickness0.98” (25 mm) Side plate thickness0.98” (25 mm) Plate material 70,000 psi (482.3 mPa) tensile strength steel Casting material 90,000 psi (620.1 mPa) tensile strength steel

37 Fabricated Rails 12” (305 mm) 34” (864 mm) Top / Bottom Bar 1.77” (45 mm).98” (25 mm) Outside / Inside Sidesheet

38 Frame Rail Ultrasonic Inspected By Model Date and Unit Length of Rejected Indications (in) Length of Rejected Indications (mm) 50804572 4064 3556 3048 2540 2032 1574 1016 508 0

39 Brake System

40 Service Brakes 2500 psi (17 229 kPa)

41 Service Brakes Oil cooled, hydraulic-actuated, multiple disc brakes at each wheel. Traction system wheel slip/slide control. Max. service apply pressure........ 2500 psi (17 229 kPa) Total friction area per brake........ 15,038 in 3 (97 025 cm 3 )

42 Parking Brakes Multiple disc Multiple disc Spring-applied, hydraulically released Spring-applied, hydraulically released

43 Wheel Brake Locks Switch-activated Switch-activated Rear brake only Rear brake only 2000 psi 2000 psi

44 Electric Dynamic Retarder

45 SAE = 331 ftActual = 188 ft Actual SAE J1473 58% Brake Codes Safe and Reliable Service Brakes

46 Emergency Braking Tests Truck 101 GVW = 1,023,200 lb (464,124 kg) -- EVW = 430,800 lb (195,411 kg) LoadedLoadedEmptyEmpty on8.7%on8.7% LevelGradeLevelGrade Bumper to58’9”81’5”Did notDid not bumper(17.9 m)(24.8 m)runrun Skid43’7”65’4”Did notDid not (11.8 m)(19.9 m)runrun Radar23 mph25.5 mph gun(37 k\m/h)(41 km/h)

47 Body All-welded steel flat floor body with horizontal bolsters and full canopy. Left and right canopy spill guards, eyebrows, rear wheel rock ejectors, body tilt cable, and rubber mounts on frame are standard. Pivot exhaust heating optional. Struck capacity Heaped capacity Loading height 182 yd 3 (139 m 3 ) 241 yd 3 (184 m 3 ) 21’11” (6.68 m)

48 Canopy Sheet & Bolster 0.19” (5 mm) 100,000 psi (690 mPa) Front Sheet 0.35” (9 mm) 400 BHN Nominal Floor Sheet 0.63” (16 mm) 400 BHN Nominal Side Sheet 0.31” (8 mm) 400 BHN Nominal Bolster 0.31” (8 mm) 100,000 psi (690 mPa) tensile strength steel

49 Heated Exhaust

50 930E & 830E Body Impact Plate

51

52 Cab Advanced Analog Operator Environment with integral 4-post ROPS/FOPS structure (meets J1040 Apr88), adjustable Isringhausen seat w/ lumbar, passenger seat, R-12 insulation, thermopane windows, tilt steering wheel, electric windshield wipers w/ washer, tinted safety glass, Komatsu Payload Weighing System, 55,000 Btu/hr heater and defroster, 21,600 Btu/hr air conditioning (HFC-134 refrigerant).

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61 Hydraulic System

62 Hydraulic Tank Hydraulic System 350 U.S. gal (1325 L)

63 Hydraulic Pumps Hoist & Brake Cooling Pump Tandem gear-type with output of 270 gpm (870 liters/min) at 1900 rpm and 2500 psi (17 240 kPa) Steering & Brake Pump Pressure-compensating piston with output of 60 gpm (227 liters/min) at 1900 rpm and 2750 psi (18 961 kPa)

64 Steering Steering Cylinder Bore diameter 6.50” Rod diameter 3.00” Stroke27.29” Extended74.41” Retracted47.12” Accumulator Bore 8.00” Length85.75” Working Pressure27.50 psi

65 Steering Diameter Maneuverability 97’4” (24.72 m) Turning Circle 930E

66 SAE Steering Course Steering meets SAE J1511 standards A = 1.10 x the tire track circle or 14 m, whichever is larger. B = 1.75 x the tire track circle or 22 m, whichever is larger. C = 2.00 x the maximum axle spacing or 15 m, whichever is smaller. Corridor 1 Corridor 3 Corridor 2 Corridor 4 Finish 1 Finish 2 Start 1 Start 2 1.25 x max width over tires 5 x max width over tires 25 m 40 m 30 m 20 m 10 m C C B A

67 Suspensions

68 Front Suspension Maximum stroke 12.92” (328 mm) Maximum stroke 12.92” (328 mm) Long length bearing Long length bearing Forged rod and housing Forged rod and housing Large cast mounts Large cast mounts

69 Rear Suspension Variable rate hydro-pneumatic with rebound control Variable rate hydro-pneumatic with rebound control Maximum stroke - 9.0” (229 mm) Maximum stroke - 9.0” (229 mm) Maximum rear axle oscillation - ± 6.5° Maximum rear axle oscillation - ± 6.5°

70 Rear Hitch Pin Maximum rear axle oscillation ± 6.5° High Mounted Rear Axle Hitch Pin

71 Hoist Cylinders Extended169.07” pin to pin Retracted 65.07” pin to pin Bore diameters 1st stage 14.00” 2nd stage 11.75” 3rd stage 9.50” All stages sealed Quill for deceleration at frame-standard Stroke each stage 34.88”

72 Hoist Cylinders

73 Tires Rock service, tubeless, radial tires Standard tire 50/90 R57

74 Tire Rating Bridgestone 50/90 R57 VELS Load and inflation 165,000 lb at 102 psi 165,000 lb at 102 psi 176,000 lb at 116 psi 176,000 lb at 116 psi

75 Specifications

76 Specifications 30’8” 9.35 m12’8” 3.86 m 21’11” 6.68 m EMPTY 4’1” 1.25 m 45° 5’11” 1.80 m EMPTY 13’10” 4.21 m20’10” 6.35 m 50’0” 15.24 m 3’1” 0.94 m 14’8” 4.47 m 23’10” 7.26 m EMPTY 14’0” 4.27 m LOADED 4’7” 1.40 m LOADED 45’9” 13.94 m RAISED

77 27’8” 8.43 m 15’2” 4.62 m 19’8” 5.99 m 24’2 7.37 m 26’0” 7.92 m 7’5” 2.26 m 17’2” 5.23 m 26’10” 8.10 m Specifications

78 Weight Distribution Empty Vehicle lb kg % Front axle 204,289 92 66448.7 Rear axle 215,181 97 60451.3 Total (wet, 50% fuel) 419,470190 268 Loaded Vehicle lb kg % Front axle 353,000160 12033.3 Rear axle 706,000320 23966.7 Total1,059,000480 359

79 Service Capacities Cooling system 205 U.S. gal (776 L) Crankcase * 58 U.S. gal (220 L) Hydraulic system 350 U.S. gal (1325 L) Motor gear box (each) 25 U.S. gal (95 L) Fuel1200 U.S. gal (4542 L) * Includes lube oil

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82 930E World Population Total 100 67 12 11 10

83 KMS 930E AC Drive Truck “In The Dirt” KMS 930E AC Drive Truck “In The Dirt”

84 Meeting the future global mining system needs of the 21 st. Century.

85 Thank You For Visiting KMS Peoria

86 Fuel Savings UNI-ECS electronics engine control UNI-ECS electronics engine control Separate circuit charge air cooling Separate circuit charge air cooling Fluid coupling fan drive Fluid coupling fan drive

87 Fuel Savings Matched engine drive system Matched engine drive system Engine speed managed by AC traction control Engine speed managed by AC traction control Drive matched to “sweet spots” on fuel map Drive matched to “sweet spots” on fuel map Engine at idle speed in retarding Engine at idle speed in retarding

88 Control Cabinet AC Traction Torque Regulator Torque regulator Torque regulator Wheel slip/slide control in propel and retard Wheel slip/slide control in propel and retard Built in diagnostics/ diagnostics display panel Built in diagnostics/ diagnostics display panel Fault and statistical data recording Fault and statistical data recording

89 Rims Standard five (5) piece rim 32” x 57” x 6.5” (813 mm x 1448 mm x 165 mm) Standard five (5) piece rim 32” x 57” x 6.5” (813 mm x 1448 mm x 165 mm) Patented Phase II New Generation Rim assembly with forged center bolt flange and 62” (1575 mm) center line dual spacing Patented Phase II New Generation Rim assembly with forged center bolt flange and 62” (1575 mm) center line dual spacing Rated at 120 psi (827 kPa) cold inflation pressure Rated at 120 psi (827 kPa) cold inflation pressure

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