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2013 Predicting Wear and Temperature of Autonomous Haulage Truck Tires
2013 Predicting Wear and Temperature of Autonomous Haulage Truck Tires
Abstract: Driverless haulage trucks have recently been developed for open pit mines. To predict the
benefits of an Autonomous Haulage Truck (AHT) system, a deterministic/stochastic model has been
created to compare an AHT fleet with a manual system by estimaing benchmarked Key Performance
Indicators (KPIs) such as productivity, safety, breakdown frequencies, maintenance and labor costs, fuel
consumption, tire wear, and cycle times. The goal of this paper is to describe the sub-model developed to
predict tire wear of an AHT that functions within a virtual 24/7 open pit mine operating with 9 trucks and
2 shovels to move ore to a crusher and waste rock to a dump.
Keywords: Autonomous Haulage Trucks, tire wear, tire temperature, simulation, modeling.
Tire temperature increases due to friction of the tread with years, tire manufacturers have been rather secretive about
the road surface as well as the cyclic flexing of the sidewalls these relationships. Undoubtedly, considerable improvement
as the tire rotates. The higher the velocity, the faster that heat in tire construction and rubber compounds since 1928 has
enters the tire through the surface and sidewall flexing affected these relationships, but little sharing of the data in a
increases leading to over-heating. Temperature is affected by useful form has been forth-coming. Table 1 lists the Miller
both load and velocity, while the ambient temperature is tire data as reported. The units of wear were reported per
important in affecting the rate of cool-down (heat transfer 1,000 miles but the depth measurement unit was not given. It
from the tire to atmosphere). The rate of cool-down increases has been assumed the data are in mils/1,000 miles.
with temperature difference between the tire and the
atmosphere so as the atmosphere cools at night, the rate of Table 1. Data extracted from Miller Rubber Company.
heat transfer from a hot tire increases which can cause tire
temperature to decline rapidly. Original Data - Miller Rubber Company mil/1,000 miles
Temperature °F
With an AHT, the number of cycles per day should increase. Velocity ± mph
Currently at the selected mine used to validate this model, 40 60 80 100
each truck averages about 21 cycles per day (equivalent to a 0 0 0 0 0
daily production rate of about 4,520 tonnes). An AHT should 5 0.14 0.21 0.32 0.46
deliver about 26 loads per day - an increase of about 1,100 10 0.4 0.62 0.94 1.38
tonnes (~24%) of added production. The question is: "Does
this additional intense activity lead to higher tire temperatures 20 1.01 1.61 2.47 3.67
that impact negatively on tire wear?" Evidence to date 30 1.72 2.77 4.29 6.44
suggests that a lower velocity (14 kph loaded, 23 kph empty) 40 2.58 4.19 6.53 9.85
of an AHT relative to a manually-operated truck (15 kph 50 3.62 5.89 9.22 13.96
loaded, 25 kph empty) will compensate for the increased
55 4.21 6.87 10.74 16.28
activity (more operating time and less idling).
60 4.87 7.94 12.44 18.88
1.1 Manufacturer and User Methods to Control Temperature
*Load (weight of vehicle) assumed as 2268 kg (5,000 lb), i.e., 567 kg/ tire.
All tire manufacturers recommend that haul truck operators
maintain driving conditions below a rating term known as Fig. 1 shows the same data converted into SI units and re-
TMPH (or TKPH) assigned to each tire type. TMPH = Tons- plotted to show the equations for each temperature in a form
Mile-Per-Hour while TKPH is Tonnes-Kilometer-Per-Hour. that can be used to gain a better understanding of how a tire
The conventional TKPH calculation gives very little real wears as a function of velocity and temperature.
sense of the temperature conditions. It serves merely as an
alarm (Joseph, 2012). If drivers appear to be exceeding this
rating on a regular basis, the 5th gear on their vehicle may be
disabled to prevent excessive speed. The calculation can be
done automatically by a Vehicle Monitoring System, but
relies on data that may not be of high quality (time duration
issues) and it is rarely applied accurately in a dynamic way.
The use of tire temperature sensors is now becoming more
prevalent and will likely preclude this approach in the future.
2. MODEL APPROACH
2.1 Effect of Velocity and Temperature on Tire Wear Rate
Fig.1. Tread Wear Data converted to SI units as a function of
The heat transfer coefficient (H) between a tire and air at a Temperature and Velocity as reported by the Miller Rubber
speed of 48 kph is generally accepted to be 57.12 W/mm2·K Company (Popular Mechanics, 1928).
(Yeow et al, 1977), (Schallamach, 1967). Some research
claims that H is dependent on velocity. In this work, it was The coefficients in the equations shown in Fig. 1 have been
decided to ignore velocity effects on H since the cool-down analysed with respect to temperature using a thermodynamic-
period during idling (i.e., zero velocity) is, perhaps, one of kinetic approach. An Arrhenius equation has been applied to
the most important elements in the analysis. Other work has each coefficient to represent the "activation energy" required
considered different heat transfer coefficients for the to wear rubber from a tire. This relationship is in Fig. 2.
circumferential heat loss and for transfer of heat between the
wheel and the air inside the tire. These details have been As can be seen, correlation of these two equations is
ignored as well. extremely high with R2 values of 0.995 in both cases. The
combined derived equation for the Miller Rubber Company
The analysis begins with the "best" available data published data (after including the gas constant R (1.9859 cal/K·mol) is
in the literature on the impact of velocity and temperature on given in Eq. 1:
tire wear (tread depth) ± a 1928 report from the Miller
Rubber Company published in Popular Mechanics. Over the Wear Rate = 21.699·V2·e-7,106/RT + 11,931·V·e-8,621/RT (1)
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(a)
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that an element of the tire surface meets the road is The average travel velocity is 20 kph and the typical tire life
significant. For the Miller data, the tire diameter is estimated to scrap is 5,500 hours. This is equivalent to a service travel
at 0.67 m, so the circumference is approximately 2 m. A distance of 110,000 km. For this distance, tire wear at 15 kph
CAT793D tire has a diameter of 3.7 m, so its circumference and fully-loaded is 83.7 mm while at 25 kph and empty, it
is 11.6 m. For a travelled distance of 1 km, a regular tire equals 73.6 mm. The overall average is 78.7 mm. Current
revolves 500 times while a CAT793D tire revolves 86 times. average final depth of wear of scrapped tires at the selected
So for each kilometre travelled, a tire element on a regular mine is reported to be 72 mm (97 (new) ± 25 (scrapped)). The
vehicle meets the road surface 5.8 times more than that of a prediction is remarkably close to the actual data.
tire element on a CAT793D truck. Countering this lower
contact frequency is the fact that the element is in contact for Other factors that should be taken into account are the road
a greater distance with a CAT793D tire than for a regular tire. and tire rolling resistance. Since the analysis deals with a
This contact percentage is 7.27% of the circumference for a "dirt" road, the frequency of trucks passing over the surface,
regular tire and 12.89% for a CAT793D truck tire, i.e., about together with maintenance practices (grading and watering),
1.77 times more contact per revolution. This yields a ratio of will affect the rolling resistance on a daily basis. Rolling
0.305 (1.77/5.8) for the CAT tire compared to a regular tire. resistance variation at the selected mine falls between 2.5 to
However, the CAT tire is much wider than a regular tire so 3.5 %, which affects the energy required to drive the truck
that must be accounted for as well. A CAT tire is 1 m in and indirectly may cause changes in tire wear rates.
width compared to a width of ~0.25 m on a regular tire. So A study done by NHTSA (2009) with tires of 16 different
the ratio of tire element contact is 1.22 (0.305/0.25) for the models with known rolling resistances and assumed traction
CAT tire compared to a regular tire. factors were subjected to dry and wet skid-trailer testing on
Road surface conditions should also be taken into account. asphalt and concrete skid pads. The study could not find any
The Miller Rubber company measurements were for an significant relationship between dry peak slide numbers and
asphalt road which is smooth and with few discontinuities. A rolling resistance. However, these tires showed a strong and
mine haulage road consists of rocks of varying sizes that significant relationship between better rolling resistance and
presents a much rougher surface that will impact negatively poor wet slide numbers. For the subset of 5 tire models
on tire wear rate. Maintenance of the road surface through subjected to on-vehicle tread wear testing, no clear
grading and watering can help maintain a more consistent relationship was found between wear rate and rolling
surface (and perhaps a slightly reduced wearing surface) but resistance. For a subset of 6 tire models, the study showed
tread wear on a mine haulage road compared to an asphalt significant amounts of wear in the indoor tread wear tests,
surface is estimated to be 10 to 15 times higher. with a trend toward higher wear for tires with low rolling
resistance. The current model in this research does not reflect
In analysing the Miller Company data, the load is assumed to these dynamic changes, but this could be included through
be 567 kg per tire. Eq. 1 can be used to determine the wear additional studies.
rate and the ratio of the impact factors can be used to scale
the data to a CAT793D. Velocity represents Energy and 2.3 Effect of Load and Velocity on Tire Temperature
Momentum as follows: Tire temperature will increase as a tire moves along a road
Energy = (Load x Velocity2)/2 (2) surface. Heat enters the tire through the contact surface with
Momentum = (Load x Velocity) (3) the road and from the flexing of the tire sidewalls as the tire
rotates. The heat generated is a function of the energy that
Wear at 15 kph and 45 °C = 0.274 mm/10,000 km distributed
flows through each tire which is a function of the weight of
as 0.063 and 0.211 between energy and force.
the vehicle and its speed as follows:
Wear at 25 kph and 45 °C = 0.528 mm/10,000 km distributed
as 0.176 and 0.352 between energy and force. Total Energyin = (Mass x Velocity2)/2 (4)
Miller Load = 567/232 = 2.44 kg/cm2. Heat is lost from the tire through its sidewalls and
circumferential surface to the surrounding air. This heat
CAT793D Load (full) = 400,000/(6x15,000) = 4.44 kg/cm2, transfer occurs regardless of whether the truck is moving.
so load ratio is 4.44/2.44 = 1.82. The drop in temperature due to heat loss to the atmosphere is
calculated as follows:
CAT793D Load (empty) = 180,000/(6x15,000) = 2.00 kg/cm2,
û7d = (Tatm ± Ttire)·e-kdt (5)
so load ratio is 2.00/2.44 = 0.82.
where û7d = temperature decline during the time step (°C)
For a CAT793D, tire wear rates will be as follows: Tatm = temperature of the atmosphere ± current (°C)
Ttire = temperature of the tire ± current (°C)
Travelling fully-loaded at 15 kph and 45 °C = kd = heat transfer coefficient (1.6 x 10-4)
0.274*1.82*1.22*12.5 = 7.61 mm/10,000 km. t = time (seconds)
The equation to calculate temperature increase due to load
Travelling empty at 25 kph and 45 °C = and velocity is:
0.528*0.82*1.22*12.5 = 6.69 mm/10,000 km. û7i = KT(1 ± e-kit) ± û7d (6)
where û7i = temperature increase during the time step (°C)
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KT = 8.344 x 10-3(P+GVW)V Fig. 6 shows what can happen when truck velocities are
Ki = 6.836 x 10-7(P+GVW)V2 increased to 19 and 38 kph for loaded and empty conditions
t = time (seconds) respectively. Although the rise in temperature initially is
û7d = temperature decline during the time step (°C) lower, the system is unstable with the temperature continuing
P = payload (tonnes) to rise well above the danger point of 90 ºC after 9 cycles.
V = velocity (kph) Clearly, this truck will require a cool-down period.
GVW = gross vehicle weight including fuel (tonnes)
Saibel et al (1973) show that heat generation on automobile
tires have significant effects on both temperature distibution
and wear. In this study, the tire temperature of a trailer
travelling at 30 mph was measured at stopping places about 8
miles apart. Surface temperatures were measured within a
minute after stopping the trailer. The results show tire surface
temperature rises exponetially during travel achieving a
steady state temperature at the end of eight miles of travel.
One minute after stopping, the tire surface temperature began
decreasing exponentially as well from its maximum value. Fig.5. Effect of Idling Time on Tire Temperature Change
Fig. 4 depicts the dynamic temperature increase of a during the haulage cycle. Total idling time = 5 min. (14.7%).
CAT793D truck moving at a velocity of 16 kph with a full
payload of 220 tonnes (GVW = 180 tonnes) and the
temperature decline that occurs when the truck is idling
(motionless) for an atmospheric temperature of 35 °C. As can
be seen the temperature while travelling increases to a steady-
state value of 75 °C after a time interval of about one hour.
The time to decline from this value back down to ambient
conditions is a bit longer at about 90 minutes.
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