JOURNAL OF LOW FREQUENCY NOISE, VIBRATION AND ACTIVE CONTROL

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Experimental Evaluation of Whole Body Vibration exposure from Tracked Excavators with Hydraulic Breaker Attachment in Rock Breaking operations
Alphin.M.S, K.Sankaranarayanasamy and S.P .Sivapirakasam Department of Mechanical Engineering, National Institute of Technology, Tiruchirapalli -620 015, Tamilnadu, India. E-mail: alphin@aol.in Received 4th March 2010

ABSTRACT Ever expanding technological growth has led to an increase in the use of tracked excavators for construction, demolition, material handling, rock breaking etc. Excavator operators are exposed to a variety of risk factors that may lead to health problems. A major health hazard among operators is whole-body vibration. Human response to vibration is very complex and nonlinear. Whole Body Vibration in the range of 2 to 30 Hz corresponds to most of the resonant responses of various organs and parts of the human body. The objective of this paper is to assess whole body vibration for the tracked excavator with hydraulic breaker. The job safety analysis conducted through questionnaires for different industrial vehicle operators revealed the presence of a health risk among the operators in rock breaking machinery. To quantify the level of vibration, field tests are performed on four tracked excavators with hydraulic breaker attachments in two different work locations. Accelerometer, a real-time signal conditioning / processing and PULSE data acquisition software are used for vibration measurement. The frequency of vibration exposure is observed to be between 6.8 and 12 Hz. Acceleration levels measured were in the range of 0.87 -2.2 m/s2 for a tracked excavator operator with breaker. The total vibration exposure calculated was between 0.621 and 1.932 m/s2. The vibration dose value recorded was 17.6 -62.72 m/s1.75 . Whole body vibration exposure of the breaker operator was much higher and lies beyond the upper limit as given in ISO 2631-1. The ranges of vibration parameters measured were concomitant with frequent lower back pain, other muscular-skeletal injuries like leg pain etc which are prevalent among these operators. Keywords: whole body vibration, tracked excavator, ergonomics, Industrial health.

1. INTRODUCTION Whole body vibration (WBV) can affect comfort, performance and health. Its effects depend on the magnitude of the waveform and the exposure time for the occupant. Hence quantifying WBV by experimental investigation is of current interest. Whole body vibration exposure and ergonomical risk factors are significant for acceleration of more than 0.5 m/s2 with industrial drivers according to epidemiological studies [1].There is strong evidence of increase in lumbar problems due to workers being exposed to WBV [2]. Acceleration in the range between 0.30.45 m/s2 is the ergonomic standard suggested for industrial vehicles with frequencies mostly between 1-5Hz and for an 8 hours operating day. The dynamics of vehicle axle and occupant suspension systems can be redesigned in order to achieve the limits [3]. A level of 0.5m/s2 was repeatedly quoted in many studies for

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Experimental Evaluation of Whole Body Vibration exposed from Tracked Excavators with Hydraulic Breaker Attachment in Rock Breaking operation the relationship between whole body vibration and low back disorder [4]. High lateral and low vertical vibration is also prevalent in railway wagons leading to low back disorders [5]. The highest levels of vertical vibration are found in off-road vehicles and forklifts [6], [7]. The International standard ISO 2631-1[8] for exposure assessment, shows a health caution zone between 0.450.8 m/s2 for 8 hours exposure. This implies that there are certain health risks for the limit value of 1.15 m/s2, for workers exposed according to the evaluation method suggested by EU Directives [9]. The objective of this paper is to conduct Field measurements for whole body vibration in tracked excavators with breaker by using a standard vibration measurement system, and the data obtained such as magnitude of acceleration, root mean square acceleration and peak acceleration are quantified from time domain and spectral analysis signatures. Vibration Dose Value (VDV) and daily exposure are calculated and interpreted with the international standards for predicting the health risk. 2. STUDY ENVIRONMENT The Field trials for WBV analysis were conducted at Valvanthannkottai, Trichy District, India (Fig. 1). The study was necessitated because an earlier survey through questionnaires revealed that drivers of excavators with hydraulic breaker attachments (Fig.2) are suffering chronic problems of lower back pain and other musculo-skeletal injuries. The drivers seats used are of conventional type with no no soecial attachments for vibration suppression. Excavator drivers operate on an eight-hour shift. At the rock breaking operation, even though the normal shift period is 8 hours, the drivers often have extended exposure periods of up to 12 hours, with overtime work included. This results not only in longer periods of exposure, with increased vibration dose, but also reduced time for physical recovery, repair and recuperation. Most of the workers are staying near to the workplace where they lack basic facilities.

Figure 1.

One of the Sites where field study has been done (At Vazhavanthan Kottai in Tiruchirapalli District, India)

If they complete the work allocated for the day in a shorter time, productivity increases, but it comes at the cost of increased vibration exposure levels and associated health effects. This is due to the increase in driving speeds, vibration shock loads and reduced rest periods . Tracked excavators used for rock breaking are primarily operated by means of hydraulic breaker attachments. Excavators with breaker attachments are operated for the whole working day to break the big blocks of stones to the desired size. In some cases the stones are broken directly from rock. The breaking is possible by high compression force applied with impact. The excavator has to travel on very uneven paths, filled with stones.

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Alphin.M.S, K.Sankaranarayanasamy and S.P.Sivapirakasam

Figure 2.

Tracked Excavator with Hydraulic Breaker Attachment

2.1 EVALUATION OF WHOLE BODY VIBRATION EXPOSURE In the absence of the domination by any axis of vibration, the total value vibration for a seated worker, the vibration total value (av) for the frequency-weighted accelerations (aw) of whole-body vibration is calculated as [8]

av=(kx2 awx2 + ky2awy2 + kz2 awz2)1/2

(1)

Where k = 1.4 for X and Y axes and k = 1 for Z axis. Since it is believed that the health effects of whole-body vibration are influenced by shocks or vibration peaks, ISO 2631-1 [1997] suggests using the fourth power vibration dose method instead of the second power of the acceleration time history (i.e. r.m.s.) as the basis for averaging. The fourth power vibration dose value (VDV) is expressed in meters per second to the power of 1.75 (i.e. m/s1.75).The assessment of exposure to whole-body vibration is based on the calculation of daily exposure A(8) expressed as continuous equivalent acceleration over an eight hour period, calculated as the highest (r.m.s.) value, or the highest vibration dose value (VDV) of the frequency-weighted accelerations determined on three orthogonal axes (1.4awx, 1.4awy, awz) in accordance with the International standard [8]. 2.1.1 Measuring Equipment Instrumentation used for the measurements and recording of whole-body vibrations include accelerometers (Bruel & Kjaer) and signal conditioning equipment (Bruel and Kjaer Vibration Analyzer 3560), analogue-to-digital converters (Dell Laptop) and a data analyzer (PULSE software platform). The PULSE platform is capable of measuring any type of vibration with basic tools such as FFT analysis and waterfall plots standard in all PULSE vibration solutions. Accelerometers are the most common transducers used in whole body vibration measurements, and produce an electrical output proportional to acceleration. Transducers are connected to some form of signal conditioning, to provide power to the transducer in addition to amplifying and filtering the vibration signal before it is passed to the data analyzer. The analogue to digital converter converts the conditioned, filtered, analogue voltage signal to a digital record. The data analyzer enables visual inspection of the acquired signals during measurement and provides a means of storing the signals in a useful digitized form in the computer memory. The accelerometer was placed and fixed firmly at the position where the measurement was intended to be recorded. Hardware setup in the PULSE software for data acquition system was set for the corresponding Transducer. Spectral Analysis gave the assessment from Fast Fourier Transforms (FFT) and Power Spectral Density.

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Experimental Evaluation of Whole Body Vibration exposed from Tracked Excavators with Hydraulic Breaker Attachment in Rock Breaking operation 2.1.2 Vibration Test Vibrations were measured according to the coordinate system as shown in Fig.3. Vibration which is transmitted to the body was measured from the sensor placed at the interface. Three principal areas as suggested by ISO 2632 are used for measurements which are the supporting seat surface, the seat-back and the feet. The duration of measurement was kept sufficiently long to ensure reasonable statistical precision and to ensure that the vibration is typical of the exposures which are being assessed

Figure 3.

WBV measurement direction and location

From the spectra obtained for the vibration measurement maximum amplitude and the corresponding frequency were observed. R.M.S acceleration was also measured using the Pulse B&K data acquition software. The values obtained are used for further evaluation. The frequency at which the magnitude attains maximum is observed to be between 6.8-12 Hz for most of the cases measured. Crest factor which is the ratio of the peak acceleration measured will be useful to predict the presence of instantaneous Shocks.

Figure 4.

Accelerometer location during vibration field Test

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Alphin.M.S, K.Sankaranarayanasamy and S.P.Sivapirakasam

Figure 5.

Field Test set up Showing Accelerometer, Vibration Analyzer, Connectors and Laptop Table I Vibration Measurement with Rock Breaking Machinery (For a Working Period of 12hrs)
X-direction Y-direction Trial 3 2.55 7.219 1.81 19.6 1.69 6.9 1.39 22.8 1.88 38.56 2.3 24.6 1 2.22 78.53 1.43 11.2 1.27 4.969 1.39 9.3 1.07 19.28 1.41 11.3 2 1.07 11.94 1.44 9.12 1.34 5.72 1.43 8.23 1.66 6.625 1.35 12.22 3 1.44 11.94 1.91 8.45 1.30 6.03 1.26 10.2 2.20 6.063 1.68 9.56 1 1.51 6.938 1.58 15.2 1.83 16.34 1.58 17.1 3.88 8.781 2.71 15.2 Z-direction Trial 2 2.44 18.41 2.12 12.1 0.926 16.03 0.87 19.6 2.50 8.56 2.35 20.8 3 1.30 8.281 1.68 15.9 1.63 15.34 1.28 15.2 1.90 22.78 2.02 18.2

Position

Measured Parameters 1 Max. acc (m/s )

n 2

Trial 2 2.58 7.5 2.04 25.3 1.72 8.75 1.36 24.3 2.37 21.81 2.08 28.2

2.05 6.813 2.22 18.2 2.56 7.156 1.88 29.2 2.84 2.375 1.58 32.1

At floor

Frequency(Hz) RMS accn(m/s2) Crest Factor Max. accn(m/s2)

At seat operator

Frequency(Hz) RMS accn(m/s2) Crest Factor Max. accn(m/s2)

At back rest

Frequency(Hz) RMS accn(m/s2) Crest Factor

3.0 RESULT ANALYSIS 3.1 VIBRATION ANALYSIS During the rock breaking operation amplitude of acceleration, crest factor, and dominant frequencies as measured under typical working conditions are summarized in Table I. The maximum acceleration in the vertical axis was 3.88 m/s2 at 8.78 Hz for the measurement taken at backrest. But the highest magnitudes of acceleration at floor and seat operator interface were 2.56 m/s2 at 7.15 Hz and 2.58 m/s2 at 7.5 respectively at the X axis. The vibration magnitude transmitted through the floor to the leg is comparatively higher than at the seat operator interface, so it indicates that the cushion in the seat dampens the vibration transmitted from floor to seat. The operators backrest was exposed to the maximum vibration of more than 3 m/s2 in X and Z axes, Y-axis vibration exposed to the operator back was comparatively less. Vol. 29 No. 2 2010 105

Experimental Evaluation of Whole Body Vibration exposed from Tracked Excavators with Hydraulic Breaker Attachment in Rock Breaking operation In order to predict the health risk associated with the operation of rock breaker vehicle, the 8-h equivalent frequency weighted acceleration values A(8) are computed from the equation below and the values are depicted in Fig.5.

Ax (8)= 1.4 aWx Ay (8)= 1.4aWy Az (8)=

5 4 3 2 1 0

Texp T0 Texp T0 Texp T0

(2)

aWz

Acceleration (m/s2)

Trial -1 Trial -2 Trial -3 X Y Z X Y Z X Y Z

Average
LEG
BUTTOCK BACKREST

Figure 5.

Total exposure, A (8)

Health risks predicted by the standard analysis procedure were compared across the common values that were normalized to an 8-h equivalent value. Rankings (high; moderate; low) for predicting health risks were predicted for a rock breaker machinery operator based on Health Guidance Caution Zone (HCGZ) limits from total acceleration and VDV total values [8]. The vibration dose value is the cumulative dose, based on the fourth root of the fourth power of the acceleration signal with units of m/s1.75. The European directory prohibits exposure above the exposure limit value of 21 m/s1.75 VDV. If the exposure exceeds an exposure action value of 9.1 m/s1.75 VDV a programme of continual improvement was recommended for the employer to implement. VDV total calculated as suggested by the European directive standard is shown in Table II. The daily exposure (Fig. 6) is the maximum of these three values. VDV was calculated [9]. The highest value of VDVexp x, VDVexp y and VDVexp z will give the daily VDV.
70 60 VDV(m /s1.75) 50 40 30 20 10 0 X Y
LEG

Trial -1 Trial -2 Trial -3 Z X Y Z X Y Z Average

BUTTOCK BACKREST

Figure 6. 106

VDV variation 106

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Alphin.M.S, K.Sankaranarayanasamy and S.P.Sivapirakasam Table II Vibration Dose Value

Total VDV (m/s1.75) Measurement Location
Axis Trial -1 Trial -2 Trial -3 Average

Remarks

X LEG Y Z X BUTTOCK Y Z X BACKREST Y Z

62.72 40.46 31.9 53.06 39.34 31.9 44.66 39.9 54.7

57.68 40.74 42.8 38.36 40.46 17.6 58.8 38.08 47.4

51.1 54.04 33.9 39.34 35.56 25.8 64.96 47.46 40.8

57.16 45.08 36.2 43.58 38.45 25.1 56.14 41.81 47.39

Health risk is likely

Health risk is likely

Health risk is likely

Figure 7.

Acceleration Range

The measured acceleration at various positions during rock breaking shows high variation at the operators back compared to floor and seat-operator interface (Fig. 7). The maximum value of VDV obtained is 64.96 m/s1.75 at the backrest during the third trial measurement taken with a breaker. 3.2 COMFORT RATING PREDICTION The acceptable value of vibration magnitude for comfort depends on many factors which vary with each application.ISO 2631 gives approximate indications of likely reactions to various magnitude of overall vibration total values in mobile vehicles. An acceleration level less than 0.315 m/s2 is not uncomfortable, 0.315 m/s2 to 0.63 m/s2 is a little uncomfortable, 0.5 m/s2 to 1 m/s2 is fairly uncomfortable, 0.8 m/s2 to 1.6 m/s2 to 1.6 m/s2 is uncomfortable, 1.25 m/s2 to 2.5 m/s2 is very uncomfortable, greater than 2 m/s2 is extremely uncomfortable. The vibration total value of r.m.s. Vol. 29 No. 2 2010 107

Experimental Evaluation of Whole Body Vibration exposed from Tracked Excavators with Hydraulic Breaker Attachment in Rock Breaking operation acceleration, in orthogonal coordinates was calculated using Eqn. 1. and tabulated in Table III. The total vibration exposure average taken at the leg-floor interface was the highest with 3.46 m/s2 . Table III Total Exposure (for 12hrs. working period)
Total Exposure Axis
Trial -1

Measurement Location

(m/s2) A(8)
Trial -2 Trial -3 Average

Remarks

X LEG Y Z X BUTTOCK Y Z X BACKREST Y Z

3.8 2.45 1.94 3.22 2.38 1.94 2.66 2.42 3.32

3.5 2.47 2.6 2.33 2.45 1.06 3.56 2.31 2.88

3.1 3.27 2.06 2.38 2.16 1.56 3.94 2.88 2.47

3.46 2.73 2.2 2.64 2.33 1.52 3.38 2.53 2.89 Health risk is likely Health risk is likely Health risk is likely

The nature of work done by the tracked excavator would be the reason for total vibration exposure at the buttocks being less than the other two positions. the major shocks are predicted to transmit along the x axis to the occupant. Table IV Comfort analysis
Trial I awx 1.88 awy 1.39 awz 1.58 av(m/s2) 3.635 Comfort level Extremely uncomfortable Extremely uncomfortable Extremely uncomfortable

II

1.36

1.43

0.87

2.89

III

1.39

1.26

1.28

2.92

Figure 8. 108

Comfort rating 108

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Alphin.M.S, K.Sankaranarayanasamy and S.P.Sivapirakasam Calculated vibration total value av was compared from [8] standard guide to assess the effects of vibration on comfort and perception under comfort reactions to vibration environments, it has been found that rock breaker operators are extremely uncomfortable from Figure 8 and the acceleration values exceed 2.5m/s2. So from the results obtained (Table IV) it is clear that tracked excavator with breaker machinery crosses the standard limit by big margin and in many cases the exposure in the y direction is higher than the vertical axis. 4. CONCLUSION Field vibration tests were conducted with tracked excavators with hydraulic attachments for WBV assessment and evaluation. The peak frequency was observed between 6.8-12 Hz for most of the vibration exposures. Acceleration measured in ranges between 0.87-2.2 m/s2, the total exposure calculated varies from 0.621 to 1.932 m/s2, Vibration dose values recorded were between 17.6 and 62.72 m/s1.75. The Crest Factor Values reveal that there are instantaneous shocks present in the exposure. The results obtained from the field study clearly prove the possibilities of frequent lower back pain and other muscular-skeletal injuries like leg pain etc. According to the calculated values, very high levels of adverse health effects were predicted for rock breaker operators. The assessment method for the effect of repeated shocks on the human body has led to an appreciation of the importance of biodynamic frequency, and peak accelerations in ergonomics and work place design. Occupational exposure to WBV and physical factors at work are important components of the multifactorial origin of physiological effects in professional mobile machinery operators. Ergonomic evaluation and design of work environment in use of tracked excavators is required. ACKNOWLEDGEMENT Authors thank for the Instrumentation facilities from the National Institute of Technology, Tiruchirapalli, India. REFERENCES 1. Bovenzi Massimo, Rui Francesca, Negro Corrao, Dagostin Flavia, Angotzi Giuliano, Bianchi Sandra, Bramanti Lia,Festa Gianluca, Gatti Silvana,Pinto Iole, Rondina Livia, Stacchini Nicola An Epidemiological Study Of Low Back Pain In Proessional Drivers, Journal Of Sound And Vibration Vol.298, 2006, pp. 515-539. 2. Lenka Gallais, Michael J. Griffin,Low Back Pain in Car Drivers:A review of studies published 1975 to 2005, Journal of Sound and Vibration, Vol 298, No.3, 2006, 499-513. Kroemer.K and E.Grandjean Fitting The Task to the Human-A Textbook of Occupational Ergonomics, Taylor and Francis, London, 1997. Bovenzi.M and C.T.J.Hulshof,An Updated Review of Epidemiologic Studies On The Relationship Between Exposure To Whole-Body Vibration And Low Back Pain (19861997). International Archives Of Occupational and Environmental Health 72, 1999, pp. 351365. Johanning E., Back disorders and health problems among subway train operators exposed to whole-body vibration. Scand J Work Environ Health,1991, 17(6), pp. 414419. Sarah Cation, Robert Jack, Michele Oliver,James P.Dickey, Natasha K.LeeShee,Six Degree of freedom whole body Vibration during Forestry Skidder Operations,International Journal of Industrial Ergonomics.Vol. 38, No.9-10, 2008, pp. 739-757.

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Experimental Evaluation of Whole Body Vibration exposed from Tracked Excavators with Hydraulic Breaker Attachment in Rock Breaking operation 7. Scarlett.A.J, J.S.Price, R.M.Stayer,Whole body vibration:Evaluation of emission and exposure levels arising from Agriculture Tractors, Journal of Terramechanics. Vol.44, No 1, 2007, pp. 65-73. International Organization for Standardization, ISO 2631/1:1997 Mechanical vibration and shock evaluation of human exposure to wholebody vibration, Part 1: General requirements, Geneva, Switzerland. European Parliament and the Council of the European Union (2002) Directive 2002/44/EC on the minimum health and safety requirements regarding the exposure of workers to the risks arising from physical agents

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