NEW INNOVATIVE VISION FOR LARGE MINE HAULAGE
In surface mines all over the world the haulage of overburden and minerals hasn’t changed much in decades. Current Large Haul Trucks have severe limits when it comes to traction and operating distances.
Nature has creating many problems for these vehicles, torrential rain in the tropics together with ultra low temperatures, snow and ice in far North, both accounting for at least eight percent loss of production simply because current Large Haul Trucks can’t operate safely and effectively under these conditions.
Additionally other important equipment like loading shovels and secondary equipment like loaders and dozers as well as the main processing plant are also down due to the very fact that the primary haulage system isn’t operating.
In order to overcome this production loss and to obtain additional cost savings ETF developed a new and innovative vision to the future of large haulage:
ETF’s truck haulage concept
This concept manages four important technical issues:
1. 95 % technical availability
2. 12 % Higher utilization
3. Smart power & reduced tyre usage
4. Less accidents
1. 95 % technical availability
In order to obtain a higher technical availability the Repair & Maintenance times must be reduced. ETF reached this goal firstly in order to make a repair friendly design of its vehicles. In other words, the truck is designed with the eyes of the mechanic who ultimately will at some point have to repair it.
Secondly, components which take time are engineered in such a way that they can be exchanged in fifteen minutes! This means that the repairs can be carried out in the workshop without the pressure from the operation management and the truck can return quickly into full productive operation.
Finally, the ETF adapted F-1 pit-stop system. All the ETF trucks are equipped with a wireless information system. As soon as the operator gets a message on the cab display that a technical problem has occurred, the wireless system transmits the same message to the workshop. The technician will then have time to prepare the necessary (exchange) parts and associated equipment necessary to effectively carry out the repair.
2. 12 % Higher utilization
The most significant item to increase machine utilization is that all ETF trucks are equipped as standard with a unique All-Wheel-Drive propulsion system. Full production can continue in the rain or snow which generates an average of eight percent increased production. Depending on the mine size this can accumulate to increased revenues of millions of dollars per year.
Another important item is the
elimination of checks during shift change. (Tyre pressure, oil, water, cleaning of mirrors, lights etc.)
ETF reached this by:
- Central Tyre Inflation System which, in real time, measures and adjusts the tyre pressure.
- Automatic oil level check and refill system
- Cameras instead of conventional mirrors
- Even equipping all the main lighting and cameras with a washing facility
Normally the shift change time would take say twenty minutes, with a 3-shift mine operation this could save an hour in twenty-four, which equates into another 4 % increase in productivity!
3. Smart power & tyre usage
In most applications Large Haul Trucks are operated for 50% of their operating time empty so you don’t need the engines to work at maximum power. Therefore ETF uses a multiple engine configuration. During empty haul only one or two engines are providing power, during a loaded condition on very neutral inclines three engines will power up and only when hauling on grade will all four engines be required. By just incorporating this power management system saves approx 25 % in total power costs, fuel, component wear and machine repair costs.
For the same reasons there is no need for all the tyres to be in contact with the road during empty hauls. Two axle lines are automatically lifted when the vehicle is empty, this saves approx tyre costs and increases the time before overhaul of the axles and associated components. The Central Tyre Inflation System also enables automatic lifting of an axle in case of a flat tyre. This saves the total-loss of tyres in case the operator reacts too late.
Each engine and tyre can be exchanged within 15 minutes each. A full wheel group of two wheels takes 60 minutes.
4. Less accidents
Accidents are a great concern for the mine management. Loss of life and equipment are often occurring. ETF truly believes that this can be at least seriously reduced or even totally prevented with the right equipment. It all starts with the performance of the operator. Neither cost nor effort should be saved in order to give him or her right tools to carry out the job. At the first place the working environment, the cabin, must be designed in such a way that fatigue is prevented. ETF reaches this goal by standard:
1. Providing a superb comfortable cabin with:
a. Enhanced ergonomics to reduce back pain
b. Unique HVAC system which really cools and heats under severe conditions
c. Ventilated and heated seats
2. Providing best in class all round vision with:
a. Full cabin glazing with wipers and washers on all sides
b. 4 camera's for front, side and rear view
c. Cornering lights (Xenon) with washers controlled by steering input for optimal operator vision lighting
up curves.
3. Providing state-of-the-art safety systems:
a. ABS and Traction control
b. Electronic stability control
c. Optic Security System
d. Sleep Deterrent System
e. Collision Warning System
4. Providing optimal training facilities with:
a. Trainer’s seat with a separate (demountable) steering wheel with brake controls which can
if necessary override the operator.
b. Trainee’s seat
All these technical measures will result in reduced fatigue, optimal operator performance and less accidents.
ETF’s haulage concept generates:
95 % technical availability
12 % increased productivity
47 % savings of tyre costs
25 % savings of power costs
Fewer accidents
Collectively results in the lowest costs per ton in the industry.
