Earthmoving Machine

Design Evolution
19
th
Mechanical Engineering Safety Seminar
NSW Dept. of Primary Industry
Olympic Park, Homebush
Hayden J ones
Caterpillar Global Mining
What drives changing technologies?
?
Evolving Regulations
Competitive Challenge
Manpower Skill Levels
Technology Advances
Safety Enhancements
A Question of Balance?
Varying Customer
Requirements
Business Needs
International & Regional
Regulations
EMESRT Group
1 Access & Egress
2 Working at Heights
3 Noise
4 Whole Body Vibration
5 Fire
6 Dust
7 Isolation of Energy (inc. parking)
8 Visibility/Collision Detection &
Avoidance
9 Machine stability / slope indication
10 Guarding
11 Displays & Controls (inc. labeling)
12 Tyres & Rims
13 Manual Materials Handling
14 Work postures
15 Confined space
Earth Moving Equipment
Safety Round Table
(EMESRT)
BHP Billiton, Xstrata, Rio Tinto, Anglo American, Vale,
Barrick, Newmont, Freeport McMoRan
EMESRT engagement with OEMs paves the way for earthmoving equipment
that ensures the safety and well-being of operators and maintainers.
Caterpillar Safety Compliance
In Iron Safety Audit
On-machine compliance reviews by EMESRT members
written into Caterpillar Safety Design Guidelines.
Unprecedented customer access to new machine designs
during the development phases.
EMESRT Design Philosophies
1 Access & Egress
2 Working at Heights
3 Noise
4 Whole Body Vibration
5 Fire
6 Dust
7 Isolation of Energy (inc. parking)
8 Visibility/Collision Detection &
Avoidance
9 Machine stability / slope indication
10 Guarding
11 Displays & Controls (inc. labeling)
12 Tyres & Rims
13 Manual Materials Handling
14 Work postures
15 Confined space
15 areas of concern8 areas given priority
1 Access & Egress
2 Working at Heights
3 Noise
4 Whole Body Vibration
5 Fire
6 Dust
7 Isolation of Energy (inc. parking)
8 Visibility/Collision Detection &
Avoidance
9 Machine stability / slope indication
10 Guarding
11 Displays & Controls (inc. labeling)
12 Tyres & Rims
13 Manual Materials Handling
14 Work postures
15 Confined space
Access Systems - OHT
Improved Ladder
Rear Access
600 mm Wide
Access to Cab
Stairways
Eliminated Step
Down to Catwalk
Improved Secondary
Egress
Access to the
rear of the cab
Optional factory
powered access
ladder
F-series Mining Trucks
Access Systems - OHT
785
797
789
793
795
CAT standard
Off-side ground access
EMESRT Option
Cab side ground access
Encourages light
vehicles to park on the
cab side of the truck
In development for all
new LOHT models
Customer demand
signal required for
release
Rear Access Egress System (RAES)
Replaces LH lower platform ladder
Lifts & lowers operator or service
technician to stairwell platform
Other improvements
Access on both sides of machine
Kickrails
600 mm wide stairways
Roading Fenders to reduce mud
build-up on stairs
Access Systems Wheel Loaders
993K Wheel Loader
Access Systems Track-type Tractors
D11T Tractor
Robust Design; cast steel hinge
Locks out of danger of damage
Hydraulic powered pivot design
Rear cab window access also
available
Corporate 6 Sigma project
Safety & Design Guides updated for
tie-off location requirements
Implemented into 2008 NPI programs
(New Product Introduction)
Safety Harness Tie-off Points
when working at heights cannot be avoided
Working at Heights - OHT
Reduced need for Working at Heights
Working at Heights
793D
793F
Ground Level Service
& Sight Gauges
Batteries now located
in Front Bumper
No PM Service items
on RH deck of F-series
trucks
Rear Medium
Range
Rear Short Range
Side Medium
Range
Side Medium
Range
Front Medium
Range
Front Short
Range
Collision Detection & Avoidance
Caterpillar Integrated Object Detection System
50 - 60% of accidents reported by mine sites are due to poor
visibility at low speeds (data from various companies and MSHA).
An effective object detection is expected to eliminate a significant
number of these incidents.
The system consists of:
An interactive display in the cab
Medium Range Radar front & rear
(~ 30 metre range)
Short Range Radar front, rear & sides
(~ 7 metre range)
Cameras on all 4 sides of the machine
A vision onlysystem will also be
available, upgradeable to full object
detection system
Expected availability - Sept 09
Collision Detection & Avoidance
Collision Detection & Avoidance
Visual alert if object enters cautionalarm zone (5 20 metres)
Audible alert if object remains inside 5 metre criticalalarm zone in
direction of machines intended path if the operator engages gear and
hasnt acknowledged alarm to full screen view.
Electro-Hydraulic Controls
Electrical sensor input
(commonly joystick)
Solenoid controlled hydraulic
valves
Unmatched control and
precision
. a foundational technology
for machine design
Electro-Hydraulic Controls
1997
1997 STIC Steer Released on 994
1998
2007
Electro-Hydraulic Controls
1997
1998 E/H Implement Control D11R
1998
2007
Electro-Hydraulic Controls
1997
Numerous Models
1998
2007
Electro-Hydraulic Controls
1997 1998
2007
M Series Graders
Electro-Hydraulic Controls
Some of Caterpillars
smaller machines
are also designed
with EH controls
Electro-Hydraulic Controls M Series
Safety Benefits of E/H Controls
Visibility
Intuitive operation
Operator Fatigue
H-Series
M-Series
Electro-Hydraulic Controls M Series
Fatigue 78% Arm Movement Reduction
Electro-Hydraulic Controls
Today:
Integration with
Machine Control &
Guidance Technology
Operator Assistance
Features
Future:
Foundation for Remote
Control / Automation
Programs
Electro-Hydraulic Automation
blade tilt angle
Angle Sensor
Angle Sensor
main fall angle
AccuGrade Display
Rotation Sensor
Circle Rotation
blade tilt angle
Angle Sensor
blade tilt angle
Angle Sensor
Angle Sensor
main fall angle
Angle Sensor
main fall angle
AccuGrade Display
Rotation Sensor
Circle Rotation
Rotation Sensor
Circle Rotation
Off Machine Earthmoving Development
Caterpillar recognises that safety
within the earthmoving industry
extends beyond what can be built
into machines:
Basic Safety Information
PPE, Warning Labels
Service Technician Safety
Toolbox Talks
Safety Videos
Machine Operation / Safety
Walkaround Inspections
Maintenance Checklists
Pre-start, Operating Tips
One Safe Source for all CAT
Safety-related media
Launch of Safety.CAT.com
Safety.cat.com
Machine Simulators
Wheel Loader
Off Highway Truck
Motor Grader
The D7E Track-Type Tractor
The culmination of many innovative technologies
AC Electric Drive
Enhanced operator visibility
Reduced cab noise levels
Greater powertrain efficiency
Reduced fuel consumption and
emissions
Reduced maintenance
requirements
Higher productivity
Reduced operating cost
Sustainable Machine Development
D7E Video
Thank You