Professional Documents
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Body+Program (Sólo Lectura)
Body+Program (Sólo Lectura)
Body+Program (Sólo Lectura)
Overview
April 2009
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Meeting Agenda
• Engineering
– Design
– Analysis
• Products & Applications
– MSDII Body
– X Body
– Dual Slope Body
– Gateless Coal Body
• Mine Specific Design
– “FACLT”
– Mine site profile
• Manufacturing
– Shipping Configurations
– Quality & control
• Body Maintenance Program
– Inspection Tools/Forms
– Best Practices
• Summary
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TRUCK BODY ENGINEERING
Design & Analysis
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S ystems S tructural A nalysis /
V irtual P roduct E nvironment
SSA/VPE
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Truck System Simulations
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PRODUCTS & APPLICATIONS
MSDII Body, X Body, Gateless Coal Body, & Dual Slope Body
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Applications
Lightweight
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Light Weight Body - Applications
*797 & 795 are the exception – see 797 MSDII section
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785-793 MSDII Body – Feature Overview
10mm
frontwall
8mm
8mm
8mm
floor rib
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785-793 MSDII Body Size Options
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Front to Rear Body Flare
7265 mm
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Structural Advantage
8mm
• Floating sidewall
• 6mm wrapper eliminates the
need for under utilized
sections of 8mm sidewall &
16mm floor
• Maintains durability 16mm
• Efficient use of steel (weight)
16mm
6mm
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Body Exhaust Heat
Exhaust
• Highly cohesive applications Outlet
• Carry back reduction system
• Hot surface improves material flow
• Targets problem areas CATERPILLAR:
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Alternative Body Exhaust Heat Views
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Pivot Area and Hoist Brackets
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785-789 MSDII Body – Feature Overview
5mm
8mm
8mm
10mm
16mm
8mm
8mm
floor rib
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Front to Rear Body Flare
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Structural Advantage
8mm
• Floating sidewall
• 6mm wrapper eliminates the
need for under utilized
sections of 8mm sidewall &
16mm floor
• Maintains durability 16mm
• Efficient use of steel (weight)
16mm
6mm
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Body Exhaust Heat
Exhaust
Outlet
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Pivot Area and Hoist Brackets
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797F & 795F AC MSDII Body – Feature Overview
5mm
10mm
14mm 10mm
20mm
10mm
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Body Exhaust Heat
Exhaust
Outlets
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Understructure Gussets & Rib Coverage
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Body – Chassis Guards
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Lifting Options & Loading Target
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MSDII Half-Life Study
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MSDII Half-Life Study
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MSDII Body Locations 2003-2008
850
140
650 50 330
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Heavy Duty - Applications
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785 – 793 X Body – Feature Overview
5mm
8mm
12mm
16mm
Top Rail
20mm Cross Section
12mm
8mm
floor rib
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785-793 X Body Size Options
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Body Exhaust Heat
Exhaust
Outlet
• Highly cohesive applications
• Carry back reduction system
• Hot surface improves material flow
• Targets problem areas CATERPILLAR:
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Alternative Body Exhaust Heat Views
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Understructure Gussets & Rib Coverage
• Internal and external gussets optimize stress distribution
• Minimizes impact damage to floor
• Analyzed and tested for optimal floor rib coverage
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Pivot Area and Hoist Brackets
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Guards, Lifting Points, & Loading Target
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793 Payload & Volume Advantage
Volume Constraints -
Dual Slope - NOT enough capacity to attain target payload with material densities less than 2830 lbs/lcy (1.68 tonne/lcm)
X Body - Will achieve target payload for material density 2630 lbs/lcy (1.56 tonne/lcm) and greater
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789 Payload & Volume Advantage
Volume Constraints -
Dual Slope - NOT enough capacity to attain target payload with material densities less than 2900 lbs/lcy (1.72 tonne/lcm)
X Body - Will achieve target payload for material density 2600 lbs/lcy (1.54 tonne/lcm) and greater
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785 Payload & Volume Advantage
Volume Constraints -
Dual Slope - NOT enough capacity to attain target payload with material densities less than 2950 lbs/lcy (1.75 tonne/lcm)
X Body - Will achieve target payload for material density 2650 lbs/lcy (1.57 tonne/lcm) and greater
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785 – 789 DS Body – Feature Overview
5mm
8mm
12mm
14mm
20mm
12mm
floor rib
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Body Exhaust Heat
Exhaust
• Highly cohesive applications Outlet
• Carry back reduction system
• Hot surface improves material flow
• Targets problem areas CATERPILLAR:
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Alternative Body Exhaust Heat Views
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Understructure & Rib Coverage
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8 Degree ”V” Floor & 16 Degree Ducktail
• V-shaped floor…
• Maintains low center of gravity
• Reduces shock from loading
• Ducktail improves load retention
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Guards, Lifting Points, & Loading Target
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New Canopy Design Alternative View
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Gateless Coal Body
• Tailgates cause…
– Damage & downtime
– Additional weight (payload reduction)
– Maintenance costs
– CG (center of gravity) problems
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Gateless Coal Body Field Performance
Payload Summary*
Average Payload (Tonne)
# of loads 29 15 9 5
100
95
90
91 6 ton advantage
85
tons 85
80
75
tons 73
70 tons
All Loads Gateless Coal Body Dual Slope + 610mm Dual Slope + 610mm
sideboards + Philippi tail gate sideboards + 381mm tail
extension
Load Distribution
Empty Loaded
Front Rear Front Rear
45.6% 54.4% 33.1% 66.9%
Body
777F 785C/D 789C 793F 797F
Type
MSDII
Coming
X Body Soon
(2010)
Dual
Slope
Gateless
Coal
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TRUCK BODY MANUFACTURING
General Overview
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Steel Inventory (prior to first operations)
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Plate Cleaning Machine
Plate cleaning - steel shot (multiple impeller machine) prior to first operations
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Plate Cutting (first operations)
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Forming Press
6.2 m (20 ft), 750 ton press brake 6 m (19.8 ft ), 2000 ton press brake
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Welder Qualification
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End Over End Weld Station
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Side Over Side Weld Station
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Shipping
Shipping configurations
• Single piece shipping arrangement
• Multi-piece shipping options
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Caterpillar Body Manufacturing
Design
Raw Material
Manufacturing
Shipping
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F.A.C.LT Available: MSDII & X Bodies
Impact & wear protection that maximizes body life & performance
F ragmentation
A brasion
C ohesion
L oading
T ool
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FACLT & Body Liner Segmentation
L1 L1
L2 L1 L2
L4 L3 L4
L5 L3 L5
L8 L8
L7 L 11 L 13 L 11 L7
L9 L6 L6 L9
L 12 L 14 L 12
L 10 L 10
L 15
L 15
L 15
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Material Fragmentation
Large rocks
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“FACLT” - Fragmentation
• Golf balls
• Baseballs
• Footballs (soccer)
• Basketballs
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“FACLT” - Fragmentation
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Fragmentation – Liner Placement
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“FACLT” - Abrasion
Wear Protection
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Wear Indicators
Tip Life
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Abrasion – Liner Placement
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Cohesion
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Material Cohesion is a problem…
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CURVED FRONTWALL TRANSITION
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Caterpillar Body Liner Options - Types
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Loading Tools
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Body Application Form
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Body Application Form Cont…
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TRUCK BODY MAINTENANCE
Tools & Best Practices
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Truck Body Maintenance
• Tools
– Body inspection forms
– Body inspection checklist
– Body wear map & spread sheet
– Body maintenance guidelines
– Body inspection images/examples
• Best practices
– WNGM - 50,000hr body care &
maintenance program
– “Bed on Wheels” maintenance program
– Body wear management best practice
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Body Inspection Forms
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Body Inspection Forms
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Body Inspection Checklist
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Body Wear Map
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Body Wear Spread Sheet
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Body Maintenance Guidelines
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Develop a Body Maintenance Program
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Body Washed & Thoroughly Examined Every PM
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Operator Walk Around Inspection
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Wear Package Maintenance
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Body Inspection
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Side Wall Structure Review
• Visual inspection indicates
– Typical rail cap condition
– Minimal impact damage
• Structure & base plate
– Good condition overall (Example MSDII Body at 20,000 hrs)
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Rock Shedders
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Canopy & Frontwall
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Canopy & Frontwall
(Example MSD II body at 10,000 hrs)
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Verify Proper Body Shimming
(Example unit at 81,135 hrs)
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Verify Proper Body Shimming
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Body Pivot Pin & Hoist Bracket
(Example MSD II body at 18,000 hrs)
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Center Floor Ribs (between main rails)
(Example MSD II body at 20,000 hrs)
– Top images
• No deformation
– Bottom image
(Example MSD II body at 10,000 hrs)
• Significant deformation
• Loading practice &
fragmentation need to
be evaluated
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Body Field Seam (weld joint)
(Example MSD II body at 20,000 hrs)
Crack highlighted by
exhaust gas
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Sidewall Plate & Liner
(Example MSD II body at 16,000 hrs)
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Floor Area (base plate & liner)
(Example MSD II body at 20,000 hrs)
– Top image
• Minimal impact damage
• Adequate for the application
– Bottom image
• Base floor plate
deformation (Example MSD II body at 10,000 hrs)
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Wear Package (rear 1/3 of the body)
(Example MSD II body at 7,000 hrs)
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Body Tail Structure Review
– Gussets intact
• Minor deformation
• Minimal berm contact
– Excellent dumping practice
• Minimal body
understructure stress &
fatigue
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Safety Cable Bracket & Cable Review
(Example MSD II body at 23,000 hrs)
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Post Inspection (What next?)
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CAT Body Repair Information
• Welding Procedure Special Instruction – REHS1841
• Operation & Maintenance Guide – AEDK0627
• Body Assembly Special Instructions (helpful reference)
• MSDII Body
• 797B – REHS0963
• 795F AC – REHS4413
• 793C/D/F – REHS2437
• 789C – REHS2777
• 785D – REHS4412 ( 785C – REHS3714)
• X Body
• 793C/D/F – REHS3713
• 789C – REHS3718
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WNGM Body Presentation
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WNGM Key Components to Bed Survival
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WNGM Key Components to Bed Survival
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MSD Body Inspection Form
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WNGM Unit 4 Most Recent Inspection
Manage Cracks
(length & time)
Manage Wear
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MSD Body Inspection Form – View 2
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WNGM Unit 4 Most Recent Inspection
Drawn in tumble
bars – managing
all onsite additions
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MSD Body Inspection Form – View 3
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WNGM Unit 4 Most Recent Inspection
New or existing
If existing – change
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MSD Body Inspection Form – View 4
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WNGM Unit 4 Most Recent Inspection
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WNGM Key Components to Bed Survival
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WNGM Key Components to Bed Survival
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WNGM Current Body Hours
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WNGM has a few operational items that help our
body life exceed normal life expectancy.
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WNGM Unit 2 – 15,014 Hours Since Rebuild
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What does WNGM’s truck body program demonstrate?
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Bed On Wheels Platform
• Safety first
– Handrails and covers
– Bed is raised to provide flat
working surface
• Efficiency
– Moveable
– Tooling stored & ready to go
– Every 1500 hours
– 8 hour shift
– Any internal repairs replace
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Entry Point Into Rear Of The Bed
• Dedicated to Bed on
Wheels Program
• Trained
• Establish & maintain core
expertise
• Creative solutions to wear
problems resulting in
extended body life
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Tooling & Supplies
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Body Wear Management - Best Practice
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Front End of The Tool
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Truck Body Crack Management Tool
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Telfer’s Wear Measurement
Data Sheet DT01 DT02 DT03 DT04 DT05 DT06 DT07 DT08 DT09 DT10 DT11 DT12 DT13 DT14 Nominal
Return to
Menu Aug-05 Nov-05 Aug-05 Aug-05 Nov-05 Jul-05 Nov-05 Jul-05 Aug-05 Sep-05 Aug-05 Nov-05 Jul-05 Jul-05
F1 10.5 10.1 9.7 10.7 10 10.7 10 7.1 9.9 10.4 10.5 10.6 10.3 10.1 12
F2 14.5 13.8 12.8 14.2 13.4 14.2 13.7 14.4 14 14 13.6 14.5 14.2 14.9 16
Substantial wear - Increase Inspections F3 10.2 10.5 9.7 10.7 9.9 10.7 9.5 10.8 9.9 10.6 10.1 10.5 10.6 11 12
F4 8.8 7.1 8.1 8.6 6.9 8.4 7.8 8.1 6.5 5.7 8.6 7.4 9 9.4 12
Excessive Wear - schedule for repairs to that area F5 12.1 10.5 12.2 11.7 10.6 13.0 11.7 12.3 9.9 11.6 11.3 10.8 12 12.1 16
F6 9.2 6.8 8 8.8 7.2 8.9 7.6 8.8 7.4 7.4 8.7 7.7 9.5 9.2 12
Highest wear in the fleet for this area F7 9 6.8 9.6 8.1 8.9 9.4 9.4 9.2 8.1 8.2 7.6 8.2 9.3 9.1 12
F8 12.7 10.8 13.2 11.8 12 11.9 11.6 11.5 11.3 12.1 10.7 12.1 13.1 13.4 16
F9 9.1 8.7 9.6 8.8 9 9.1 8.6 9.2 8.7 9 7.2 8.5 9.5 9.4 12
L1 5.6 5.3 5.4 5.5 5.6 5.6 5.5 5.6 5.5 5.5 5.4 5.6 5.3 5.8 6
L2 4.9 4.9 4.9 4.9 4.9 5.3 4.8 5.4 5.1 5.3 4.9 4.7 5.1 5.5 6
L3 10.2 4.9 7.2 4.8 5.1 10.4 10.1 7.9 9.7 10.3 5.1 5.2 10.3 7.1 12
R1 5.6 5.5 5.4 5.6 5.6 5.6 5.6 5.6 5.5 5.6 5.5 5.6 5.5 5.1 6
R2 5.2 4.6 4.6 4.8 4.4 5.1 4.8 5.4 4.8 5.1 5 4.7 5 5.7 6
R3 10.5 5 9.7 5 4.9 11.2 10.1 8.7 10.2 9.8 5.2 4.8 10.2 10.5 12
H1 11.5 11.6 11.5 11.6 11.6 11.7 11.6 11.6 11.3 11.2 11.5 11.5 11.5 11.7 12
H2 7.4 7 7.3 7.2 7.2 7.6 7.3 7.6 7.2 7.4 7.1 7.1 7.3 7.6 8
H3 11.7 11.5 11.6 11.4 11.6 11.7 11.7 11.7 11.4 11.6 11.5 11.5 11.5 11.8 12
H4 11.5 11.5 11.5 11.4 11.5 11.7 11.5 11.7 11.2 11.6 11.7 11.5 11.6 11.6 12
H5 7.3 7.3 7.3 7.3 7.3 7.4 7.4 7.6 7.5 7.4 7.2 7.1 7.3 7.5 8
H6 11.7 11.6 11.6 11.4 11.6 11.7 11 11.7 11.6 11.6 11.6 11.5 11.8 11.7 12
G2 25 19.8 28 21.2 19.7 27.9 21.4 16.1 23.1 22.7 25 26.6 16.5 12.4 41
G3 30 22.3 27.8 27.3 24.9 27.4 25.2 17.1 27.1 23.7 27 26.2 16.2 9.1 41
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CAT TRUCK BODY PROGRAM
Recap & Summary
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CAT Truck Body Program Recap
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Summary
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