How Safety [in numbers] is Engineered into Truck Bodies

Josh Swank Philippi-Hagenbuch, Inc.

.2009 Philippi-Hagenbuch, Inc

Numbers?
1. 2. 2 3. 4. 5. 6. 7. 8. Factors that Destroy Ground Clearance at Full Dump Width and how it relates to loading Body Weight Loader Reach Construction | Superstructure p Material Angles of Repose | Material Density Rated Capacity | Loading Factors p y g

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Body Floor

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Factors that Destroy

1. 2. 3. 4. 4 5. 6. 6 7. 8. 8 Abrasive wear Mass impact Projectile impact Haul cycle frequency Type and size of loading equipment Body inside width relative to load centering / impact Dump site / tail chute damage Loading equipment damage

.2009 Philippi-Hagenbuch, Inc

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

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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

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Mass & Projectile Impact

Sharp material projectile impact occurs with: Sharp Large materials Chunky Creates an armor piercing situation p Steel should be a derivative of steel armor plate Mass impact affects whole truck / body vibration that is a safety concern for truck drivers
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Mass & Projectile Impact

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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

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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

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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

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Hydraulic Shovel
Load is often closer to center Material drop (projectile impact) remains similar between cable and hydraulic shovels

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Front End Loader

Typically drop material further than cable or hydraulic shovels Causes greater impact to body side and often adversely impacts body life

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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 possible with th correct l di equipment / t k ibl ith the t loading i t truck match

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Body Loading Narrow Body

Narrow bodies are harder to load and often have poor load placement
.2009 Philippi-Hagenbuch, Inc

Wider bodies are easier to load and achieve proper load placement

Body Loading Wider Body

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Weight

Body weight directly relates to the amount of material being hauled Floor thickness: 51% - 59% Body Sides: 14% - 21% Front Slope: 10% - 12% C 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 configuration 2. Angle of body floor dump to release material from the truck body (typically 45 floor angle at full dump) f ll d )

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Dump Clearance

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Loading Equipment Damage

When there is a loading equipment / truck mismatch, damage to body sides, and loader bucket b k t Results in costly maintenance and unnecessary equipment downtime

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Combating these Factors

Body Design is Key User buy-in
Discuss expectations in advance Design and build to the end users 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
.2009 Philippi-Hagenbuch, Inc

Body Weight
Understanding end users 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? Why is my body holding 15% less than the S % 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 question. question

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

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Body Sizing
The SAE Standard does not define an effective body volume, but does define two (2) different load ratings: ti Struck Heaped

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Body Sizing
SAE Struck Capacity To measure the struck capacity of an off-highway truck b d t k body you close off th open rear-end of an offl ff the d f ff highway truck body starting at the rear edge of the floor 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.

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Boundaries of the struck volume

Planes defined by the intermediate or discharge edges

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SAE Struck Capacity

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

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Typical Angles of Repose

ANGLES OF REPOSE OF VARIOUS MATERIALS Angle between horizontal and slope of heaped pile MATERIAL Coal, Industrial Common earth Dry Moist Wet Gravel g Round to angular Sand & clay Sand Dry Moist Wet
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Ratio 1.4:1 2.8:1 2.1:1 2.1:1 1.7:1 1 7:1 2.8:1 2.8:1 1.8:1 2.8:1

Degrees 35 20 25 25 30 20 20 30 20
Source: an OEM Manufacturers Handbook

Body Sizing

The SAE struck rating g is bogus, but what p g about heaped rating?

.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 vertical (2:1) extending inward and upward from the mean lines of the sides and end plates or load-carrying extensions thereof. thereof For bodies with open ends or sides, the 2:1 slope for p p y p p heaped capacity shall start from the top of the 1:1 slope which determines struck volume
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SAE Standard:

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Body Sizing
What about a load with 2 different material slopes?

Whoever heard of the same material having two different slopes?

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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??

.2009 Philippi-Hagenbuch, Inc

Body Sizing
One manufacturer states: In their spec sheets, SAE Heap overrates the capacity by 5-6% and is not achievable in practice by:

5 - 6%
.2009 Philippi-Hagenbuch, Inc

Body Sizing
Another manufacturer: For many years, [we] rated our bodies using a 2:1 field heap which assumed a 2 1 h fi ld h hi h d 2:1 heap f from all points ll i t around the body.

.2009 Philippi-Hagenbuch, Inc

Body Sizing
How can you determine a truck bodys effective load?
Taking the same truck body, one can easily arrive at 10 different load ratings. From 20.7 yd3 to 35.6 35 6 yd3
.2009 Philippi-Hagenbuch, Inc

Body Sizing

How can this bogus rating be overcome??

.2009 Philippi-Hagenbuch, Inc

Body Sizing

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

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Body Sizing
A conical load in a body

Material naturally flows to a cone in a body.

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Body Sizing
Typical Truck Load

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Body Sizing

Patent Pending

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Body Sizing What did we find out?

THERE IS NO ONE SINGLE ANGLE OF REPOSE FOR A LOAD OF MATERIAL

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Hauled Material Angles of Repose

Location Australia Australia Australia A t li Chile USA USA USA USA
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Mine Coal Coal Gold G ld Copper Coal Copper Iron Iron

Material Hauled Overburden Overburden Waste O W t & Ore Waste & Ore Overburden Waste & Ore Waste & Ore Waste & Ore

Front Angle 24 21 26 18 24 29 29 29

Rear Angle 28 31 26 30 31 31 31 34

Side Angle 34 33 33 32 24 24 33 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
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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

5.59%
overloaded

INCORRECT

13.48% 13 48%
overloaded

REALLY WRONG!

This diagram shows how the three load profiles (Load Profiled 2:1 heap P fil d, 2 1 h from all points and SAE 2:1 heap) impact the center of gravity.

.2009 Philippi-Hagenbuch, Inc

Our experience shows

The SAE 2:1 Heap overrates a truck body by as little as

7%
to as much as

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

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Properly Sized & Balanced Load

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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 chassis Body width assists in loader operators in loading body 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

How Safety In Numbers Adds Up

Knowing the density of the material being hauled lets the body manufacturer accurately design the body for its intended b d f it i t d d use Knowing what the actual capacity of the load is, and profiling the load accurately cuts down on unneeded steel, and maximizes payload

.2009 Philippi-Hagenbuch, Inc

Presented By:

Josh Swank
Sales Manager Philippi Hagenbuch, Philippi-Hagenbuch, Inc. 7424 W. Plank Road , Peoria, Illinois 61604 (309) 6979200 jj jjswank@philsystems.com @ y
.2009 Philippi-Hagenbuch, Inc