7th BALKANMINE CONGRESS – Proceedings, Prijedor 2017

DOI: 10.7251/BMC170702241S

MEASURING THE WEIGHT OF THE LOAD OF CARREER DUMPERS

Stiliyan STANKOW1, Galin VAYOV1

1
NOAC EOOD, Sofia, e-mail: stan@noac.bi, zgalin@noac.biz

ABSTRACT

Using GPS dispatch systems in the past two decades was obtained very accurate data on the times and
distances covered. For a complete picture of loading and transportation it is necessary to obtain as
accurate data of weight of mine masses. In most cases it is calculated with statistical methods, using
the average load and realized haulages. The article describes the design, the mathematical model, the
implementation problems and the results, obtained by installing scales on dump trucks working in real
time, including during loading.

1. INTRODUCTION

Tasks, solved by dumper scales according to the frequency of encounters by the authors in the
different mines are as follows. They are roughly ranked by importance for managers and
mining engineers.
1. Control of overload and underload of dumpers
2. Report of the mine production - there is no other way to be measured in tons. The
volumes could be measured by surveyors, but the specific weight varies considerably.
Also daily weights results help the surveyors for "incremental" reports
3. Operator productivity report
4. Machine productivity report - excavators, dumpers, FWL
5. Dosing of productions – concentrate, fractions
6. Determining the number of haulages
7. Creating realistic load standards
8. Creating multidimensional models of fuel consumption
9. Shock absorbers monitoring

2. TYPE OF SCALES

Various ways to measure the weight of dumper load have been proposed and implemented.
These are listed according to the frequency of encounter in the different mines.
1. On-board scales that measure the pressure in the basket lift cylinders. It has an
advantage over the shock absorbers scales for easier installation and maintenance
because it uses only one pressure sensor instead of 4. It is a disadvantage that the
result is obtained only on dump, there is no information to shovel operator during the
loading.

241
 7th BALKANMINE CONGRESS – Proceedings, Prijedor 2017

2. On-board scales that measure the pressure of the dampers. Most common, with the
most accurate measurement. Hard to install and maintain. Allows load control,
damping control, road quality control, adherence of masses and other additional
features. Most ample signal information.
3. FWL scales - often used for dosing fractions and concentrate.
4. scales on excavators. Hard to mount, difficult to maintain. The solution is different for
rope and hydraulic excavators. Problem is the measurement of rope excavators and
draglines. Hydraulic excavators are a little easier to measure. FWL's are used rarely to
load heavy dumpers.
5. weighbridges. A costly solution. Very uncommon for dumpers over 40 t. Can not
control the loading. Leads to an increase of the distance and time of the haulages.
6. belt scales in the hopper of the primary crusher. It is difficult to separate the individual
dumpers, and impossible to control the load or overload. The accuracy of the
measurement is low, some of the material remains on the walls of the hopper. It can
not be used to measure other masses except ore. Could be used to control on-board
scales.

Scales on shock absorbers are available from many manufacturers - Belaz, Caterpillar,
Komatsu, Hitachi. Those scales are:
1. difficult to maintenance,
2. have a dissimilar data format,
3. remote access to data are rarely offered,
4. have different tare procedures, if any,
5. they are options and are rarely ordered.

In most manufacturers solutions, the indication from the scale to the excavator operator is by
lamps that ignite when load reach some level, typically up to 95%, from 95% to 105%, over
105%. Disadvantages is one-time setting of the load limit.
The scales, presented in the article have the following advantages:
1. works under a slope in -7°÷+7°
2. remote access to data. Indications are in front of the driver, the excavator operator and
the dispatcher
3. shows the weight in real-time on a side display
4. visual control of the load from managers and engineers managers without need of
computers, tablets and other tools.
5. there is embedded control of shock absorbers
6. allows dosing of the last bucket

Mathematical model

The equation of vertical damping reactions (spring model) includes the equation:
2*Rf + 2*Rz = G + Gp (1)
kp *Sp + kz * Sz = G + Gp
G = kp *Sp + kz * Sz – Gp

242
 7th BALKANMINE CONGRESS – Proceedings, Prijedor 2017

The reaction of the two bridges balances the weight of the load and the weight of the
overhead masses. It is assumed that the two bridges are balanced, the shock absorbers on one
bridge are the same, and the sum of the shock absorbers reactions of each bridge is constant at
a slope along the longitudinal axis.

Model variables

Gp weight of the overweight masses, t

Rf front shock absorber's response, t. Directs perpendicular to the ground.
Rf rear shock absorber's response, t
Sp sum of the pressures in the front dampers, measured parameter, bar
Sz sum of the pressures in the rear dampers, measurable parameter, bar
Gi calculated weight on the "spring model", only from the damping reactions. No
correction for inclination angle entered, t
G measured weight with correction for inclination
α angle between the chassis and the horizon. Measured by inclinometer, degrees
lz arm of the shock absorber's to the beginning of the coordinate system (center of
mass), meters. Some virtual point defined by the rear axle lever.
lp arm of the front damper, meters. It is considered to be just above the axle of the
front axle due to the constructional design.
lt The arm of the load, m
Mt moment of load, ton-meters
Mf moment of the front shock absorbers
Mr moment of the rear dampers
kp coefficient of the front dampers - the response of the shock absorber to the
pressure, t/m². It is considered to be linear. There is a time dependency. It is fully
set about 10 seconds after a stop or start. Friction is neglected
kz coefficient of rear dampers. Average value determined by the rear axle lever.

Equation of the balance of the moments along the longitudinal axis

The equation (1) is valid only when the dumper rests on a flat landing. Unfortunately, this
condition is almost always violated in the complicated conditions of the face. The angle of
inclination should be take into account. The slope is measured with an embedded scale
inclinometer. The inclination of the dumper chassis is measured against the horizon. The
equation is derived from the equality of the turning points.

Mf + Mt = Mr (2)
Rf * lp + G * lt = Rr * lz
Rf * lp + G * (c*G + d) * cos ((a*G + b) - α) = Rr * lz
kp *Sp * lp + G * (c*G + d) * cos ((a*G + b) - α) = kz * Sz * lz

The system of equations that is obtained is:

kp *Sp + kz *Sz - G - Gp = 0 (3)

G * (c * G + d) * cos ((a*G + b) - α) + kp *Sp * lp - kz * Sz * (lo-lp) = 0

The unknown variable is G. The variables in the equation are Sp, Sz, α - the pressure in the
dampers and the angle of inclination. The constants in the equation are lp, lz, kp, kz, a, b, c, d,
Gp. Constants are determined by regression.

243
 7th BALKANMINE CONGRESS – Proceedings, Prijedor 2017

The linear approximation

The system of equations (3) is non-linear, with trigonometric functions. The solution can be
done by the sequential approximation method with repeated calculation of trigonometric
functions. The on-board microprocessor has to solve it about 10 times per second, which
almost completely loads it. For simplicity of calculations, an approximate linear formula can
be used:
G = a * α * Gi + b * Gi + c * α + d (4)

The coefficients are determined by regression analysis. One solution for the Komatsu HD405
dumper is for example:
Gp=32.38000
kp= 0.26600 kz= 0.23900 a = 0.01295 b = 1.00256 c = 0.32862 d = 0.76812

Another solution, including determination of the kp and kz:

Gp=30.38017 kp= 0.17698 kz= 0.27460
a = 0.00880 b = 1.01032 c = 0.15980 d= 3.99950

Quadratic approximating

Even better results yield a quadratic approximation. The coefficients are based on a regression
analysis of the data at speed 0.0 - the dumper is at rest but located at a different slopes. The
free member who is taken over by Gi's value is rejected

G = е*Gi*Gi + f*α*α + a*α*Gi + b*Gi + c*α (5)

Angle α is measured in '%'. Exemplary coefficients of the Komatsu HD405 machine

polynomial:
e = 0.0003241 f = 0.0059584 a = 0.0081838 b = 0.9946782 c = 0.1636173

3. IMPLEMENTATION

The model described is realized in scales, installed on dumpers types Komatsu HD405 and
Caterpillar 771D. The board computers of the previous installed dispatch system was used.
Damping pressure sensors and side displays was added.
Depending on the condition of the dumper - loading, driving, staying, the side display shows
different data - current weight, ride load, average speed, waiting time. In addition, they are
displayed for the driver during a stop:
 fuel level
 the voltage of the battery
 the condition of the damper, etc.

244
 7th BALKANMINE CONGRESS – Proceedings, Prijedor 2017

Figure 1. Front shock absorber of CAT 771D Figure 1 Side display

sensor mounted

Figure 2. Display indications on load. Video on. Figure 3. Pressure sensors of shock absorbers
https://www.drpobox.com/s/29a6abvuu3p30i7
sgd005.avi?dl=0

4. RESULTS

On Fig 6 is shown a signal from scales – 4 cycles. Each bucket is visible. Signal from dump is
very clear and recognizable.
On Fig 6 is shown a pace of loading and signal from dispersion filter. The dispersion signal is
very strong and is used for recognition of the buckets.
On Fig 7 is shown a histogram of dumps of one dumper, mass is ore. The distribution is
almost normal, with tails to high and low values. Overloading and under-loadings are quite
probable. Approximately 25% of haulages are out of bounds -10%÷+10%. A special program
prepares a table report of load distribution for each machine, mass and operator.

245
 7th BALKANMINE CONGRESS – Proceedings, Prijedor 2017

Figure 5. Cycles of the weight signal

Figure 6. Recognition of buckets by dispersion of the signal

5. CONCLUSIONS

1. There is a significant dispersion in loading

2. In real production conditions it is impossible to achieve loading "by specifications",
although unrealistic expectations of some managers
3. nevertheless a control of loading and protection of overloading could be achieved using
scales with real-time measure and display
4. The "specification norm" must not be chased, realistic norms should be created with
realistic mean value and some acceptable range

Figure 7. Histogram of loades

246