EH3500AC Presentation.ppt

8/17/2019 EH3500AC Presentation.ppt

1/69

Richard Schloss

Paddy OLoughlin

Untung Prihardiyanto

Feriwan Sinatra

Welcome to Australia


2/69

HITACHI HITACHI EH3500AC EH3500AC


3/69

Truck History

1!" #ol$o ac%uires &lark'(ichigan) owner o* +uclid

1, H&( -uys ./0 interest in +uclid

1 H&( -uys into ,/0 interest) R./ is introduced

1! 2e$elo3ment o* R.!/A& 3rototy3e) H&( ac%uires !/0 interest

1 4ntroduced the R.!/A&

./// +H15// is launched) through this year all model names change to+H models) ending the long run o* the R and &H designation that

accom3anied the Payload in U6S6 tons) #ol$o interest reduces to /0 at the

end o* this year

.//7 +H"/// is introduced) esta-lished the 8lo-al (ining &enter 98(&:

.//, +uclid'Hitachi Hea$y +%ui3ment -ecomes Hitachi &onstruction

Truck (anu*acturing Ltd6

.// +H5"/'7 and +H11//'7 are introduced

.//5 +H15//'7) +H7"// ; +H"/// A& 44 948


4/69

(echanical 2ri$e)(echanical 2ri$e)

• +H15// 91// mt:

2& +lectric 2ri$e Trucks)2& +lectric 2ri$e Trucks)

• +H7/// 91"/ mt:

A& +lectric 2ri$e)A& +lectric 2ri$e)

• +H+H77"//"// 91/ mt:91/ mt:

• +H,"// 9.!/ mt:

• +H"/// 971" mt:

Hitachi Rigid Dump Truck RangeHitachi Rigid Dump Truck Range


5/69

Dump Truck Series98(W .7/ m't o$er:

(echanical 2ri$e +lectric 2ri$e) 2& +lectric 2ri$e) A&

(a=imum 8ross (achine Weight 9 m'ton:

EH3000 EH4500 EH5000

785C 789C 793C 797B

HD1500-5 630E 730E 830E 930E-3

MT3300AC MT3700B TMT260AC MT5500

MT3600B

T252 T262 TI 272 T282

500 550 600250 300 450350 400

EH3500 EH4000


6/69

• Cummins QSK50 Tier 2 compliant engine• 1,491 kW SA !1995, "ross ngine #utput

• $ig%est retar&ing per'ormance in it(s class

• A&)ance& AC &ri)e s*stem allo+s lo+ maintenance

time an& cost

• Super &ri)ing per'ormance an& %ig%

e-cient c*cle time

• 1.5 tonne /a a*loa&

• 3005 or 426905 T*res

• 325,000 kg "/W

• St& 7o&* Capacit*

1104 m3 SA 281

• Trolle* option a)ailale

• ,.1 k : 1500 /

;/a Tor


7/69

1. Development, Manufacturing• Transferred to Japan from USA & Canada• ig! relia"ilit# Japanese parts and components• $ntegrated development, manufacturing tec!nolog# and

know-how of !#draulic e%cavators. 'ngine

・Cummins T$'( $$ )))!p*. T#res

・*+.))(+, -/)(+-. AC drive s#stem ・itac!i AC s#stem from 0' DC s#stem. rame design Structure upgrades

Major Changes on EH3500:Major Changes on EH3500:

(a?or &hanges on +H7"//(a?or &hanges on +H7"//


8/69

(aker @omatsu &AT

4tem Unit +H7"//A& +H7"// 57/+ 5!&

(anu*acture '' &ummins &ummins &ummins &AT

(odel '' S@"/ @.///+ @.///+ 7"1<Out3ut98ross: kW 1,. 1,. 1,. 1,15

2is3lacement L "/67 "/67 "/67 6/

(anu*acture '' Hitachi 8+ 8+ &at

2ri$e System '' A& 2& 2& echanica

(odel '' '' State='7 State='7 ABT

T i r

e

SiCe '' 756//'R"5 756//'R"5 756//'R"5 756//'R"5

&a3acity SA+ .D1Hea3ed m7

11/6, 11"61 11/6 1/,65

Width mm 577/ 577/ 5."/ ,/

(a=6 8(W m6ton 7."6/ 7.,67 7.,67 7156"

E(W m6ton 17"6" 1716/ 17!6/ 1,/6"

(a=6 Payload m6ton 1!6" 1767 1!67 1556/

(a=6 S3eed kmBh " ""6, ""65 ",6,

8rada-ility

Full Loaded

0 ."6. .,6. .,6. ."65

(a=6 Retarding Angle9Full Load 0 1"67 116 116 1,6

(a=6 Retarding S3eed

1/0、

7 、

kmBh 75 7 7 7/

(a=6 Height mm / 75/ ."/ 1"/

(a=6 Width mm 51/ 55// 5",/ 55,(a=6 Length mm 17"// 1..,/ 1.!7/ 1.155 2

i m

e n s

W e i g h t

P e r * o r m a n

2 r i $ e S

Hitachi

+ n g

i n e

< o d

S3eci*ication &om3arisonS3eci*ication &om3arison


9/69

o pe r a t i n g %

o u r s

DC System

Contactor Tip eplacement 2,500 %rs

Traction /otor 7rus% eplacement 2,500 %rsCommutator Turn > ?n&ercut ,500 %rs

W%eel /otor #)er%auls 25,000 %rs

AC System

,500 %rs @ C%oppers )s Contactor

6A @ AC n&uction /otor6A @ AC n&uction /otor30,000 %rs

A& $ 2& Scheduled (aintenanceA& $ 2& Scheduled (aintenance


10/69

+lectric 2ri$e (anu*acturers+lectric 2ri$e (anu*acturers

Limited


11/69

Net Sales : 8,191,572 M \ (68,150 M US$)

Employees : 339,572

Hitachi GlobalHitachi Global


12/69


13/69

48


14/69

Human 4nter*ace

.///h3

&ho33er 17//kW .

T(

8ear ;

Wheel

8ear ;

Wheel

4n$erter !//k#A

T(Recti*ier 17,/kW

./kW

./kW4n$erter

!//k#A

/k#A9au=6:

2iesel+ngine

1"//k#A9main:

8 8

( &on$erter&ontroller

8ridResistance

."kW=,

A& 2ri$eSystem

2ri$e (otor

9A& (otor:

&ontrol &a-inet

8rid


15/69

1. High Efficiency Water Cooling

2. Pressurized Enclosed Structure

to prevent from dust

3. e! ".#$% &'()

$nsulated 0ate 2ipolar Transistor

1 - ) m m 1 / )

m m

-,))3 4 /))A Class

A& 2ri$e System &ontrol &a-inetA& 2ri$e System &ontrol &a-inet


16/69

5!eel Motor Cooling an

Control Ca"inet

6converters7

Alternator Cooling an

0rid 2o%

5!eel Motor

CA2

Alternator) 2ri$e (otor &ooling SystemAlternator) 2ri$e (otor &ooling System


17/69

• 4 parallel circuit gri& o

• etar&ing per'ormance is capale o' operating +it% onl* 3resistor a'ter 1 resistor 'ailure

• $ig% e-cienc* cooling 'an minimums t%e re


18/69

AC Motor Driving

→ 8o Commutator on fan motor

→ Audi"le noise reduction

→ (apid fan start9up in response to t!e retard pedal

→ :ost9cooling operation for t!e resistors

0rid(esistor M

1));3A

6main7


19/69

Function 2escri3tion

(otor &ontrolBRetarder &ontrol

#ector &ontrol Current control of induction motor


20/69

0

2000

4000

6000

8000

10000

12000

14000

16000

1800020000

0 5 10 15 20 25 30 35 40 45 50Vehicle Speed (km/h)

M o t o ! o " # e

( $ ・ m )

600k% 650k% &00k% 'ct#l !o"#e （ 0 5&*6+)'ct#l !o"#e （ &1*4 12,*4+)

ct#l !o"#e （ 12,*4 142*4+) Set !o"#e

600k%

650k%

&00k%

Set !o"#e

$ncreased tor?ue due to output control

6Unused au%iliar# output7

A& 2ri$e Out3ut &ontrol Per*ormance &ur$esA& 2ri$e Out3ut &ontrol Per*ormance &ur$es

A& 2& Ri ll 2 tA& 2& Ri ll 2 t


21/69

/

1/

./

7/

,/

"/

/

5/

!/

/

/ 1/ ./ 7/ ,/ "/ /S3eed 9kmBh:

9 =

1 )

/ / /

k g :

/

1/

./

7/

,/

"/

/

/ 1/ ./ 7/ ,/ "/ /S3eed 9kmBh:

9 =

1 ) /

/ /

k g

:

(im :ull Tor?ue 'lectric (etarding Tor?ue

AC@ Maintaining t!e "ra;e tor?ue

at lo= ve!icle speed

'*))AC

'*))DC

'*))AC

'*))DC

AC@ $ncrease of rim pull

A& $ 2& ' Rim3ull 2ataA& $ 2& ' Rim3ull 2ata

A& 2 i Ri ll &h tA& 2 i Ri ll &h t


22/69

A& 2ri$e ' Rim3ull &hartA& 2ri$e ' Rim3ull &hart

A& 2 i Ri ll 9R t d &h t:A& 2 i Ri ll 9R t d &h t:


23/69

A& 2ri$e ' Rim3ull 9Retard &hart:A& 2ri$e ' Rim3ull 9Retard &hart:

FF 2 i &h2 i &h


24/69

FrameFrame 2esign &hanges2esign &hanges

4ntegrated


25/69

(AM' ST('SS A8AS$S

Trailing Arms ;Trailing Arms ; SS3indles3indles

FrameFrame

Frame Stress AnalysisFrame Stress Analysis

+H7"//A& < d 2 i+H7"//A&


26/69

+H7"//A&


27/69

Reduced Gear oil heating

Reduction in Spline Wear

Eliminate center-shaft seal leakage

Eew Wheel (otor Reduction 8ear Eew Wheel (otor Reduction 8ear

#ehicle +lectronic &ontrol System#ehicle +lectronic &ontrol System


28/69

-

ngine Speed Setting

Alternator Control

Motor Speed Control

Vehicle Speed

Moto!empet#e

M

Failure process

Auto Cruise Control

.

'lteto

Auto Retarding Control

#ehicle &onditionBFailure 2is3lay

ngine Speed Control

Hydraulic System Control

ie Moto

Drive Limit Signal

Hydraulic


29/69


30/69

AC Drive S#stem Monitor Screen


31/69

ailure (eport Screen


32/69

4nde3endent Trailing Arm4nde3endent Trailing Arm


33/69

IncreaseIncrease in tyre andin tyre andcomponent lifecomponent life

EasierEasier MaintenanceMaintenance

SuperiorSuperior speedspeed

in turnin turn

First-rateFirst-rate rideride

FewerFewer lubricationlubrication

pointspoints ExcellentExcellent stabilitystability

OperatorOperator comfortcomfort

Coupled withCoupled with NEOCONNEOCON ride strutsride struts

4nde3endent Trailing Arm4nde3endent Trailing Arm

E+O&OE STRUTSE+O&OE STRUTS


34/69

ACCU9T(AC independent trailing arm

front suspension =it! 8'ECE8 ride struts

set t!e industr# standard in off9!ig!=a#

suspension

NEOCONNEOCON ride strutsabsorb more energy than

rubber or nitrogen oil!

E+O&OE STRUTSE+O&OE STRUTS

+H7"//A& Front Sus3ension+H7"//A& Front Sus3ension


35/69

+H7"//A& Front Sus3ension+H7"//A& Front Sus3ension

True Ackerman SteeringTrue Ackerman Steering


36/69

True Ac;erman steering decreases

tire =ear less steering error.ess error t!roug!out t!e entire

turning range.

$ntersection of front tire inner and

outer steer angle =it! center line

of rear a%le.

True Ackerman SteeringTrue Ackerman Steering

+H7"//A& Hoist &ontrol+H7"//A& Hoist &ontrol


37/69

+H7"//A& Hoist &ontrol+H7"//A& Hoist &ontrol

Hydraulic System 4m3ro$ementsHydraulic System 4m3ro$ements


38/69

+ngine

Hoist &ircuit


39/69

+ngine

Hoist &ircuit


40/69

DUM: 2ED

Hydraulic TankHydraulic Tank

+H7"//A& Load Weigh System+H7"//A& Load Weigh System


41/69

+H7"//A& Load Weigh System+H7"//A& Load Weigh System

Automatic &ruise ; Retard &ontrolAutomatic &ruise ; Retard &ontrol


42/69

Automatic Retarding &ontrolKeep vehicle downhill speedconstant & lower than set speed

Automatic &ruising &ontrolKeep vehicle speed constant in set speed

Automatic &ruise ; Retard &ontrolAutomatic &ruise ; Retard &ontrol

Anti'Sli3 &ontrolAnti'Sli3 &ontrol


43/69

Slip and slide

(educe tor?ue of =!ic! rotates faster.8ote@ =!en slip or slide "ot! tire, ve!icle speed detection mig!t not correct

2ump

Anti Sli3 &ontrolAnti Sli3 &ontrol

Anti'Roll -ack Anti'Roll -ack 6uture Eption76uture Eption7


44/69

(elease service "ra;e:ress service "ra;e :ress accelerator

S!ift lever or=ardB

F 1m

Anti Roll -ack 6uture Eption76 p 7

&ummins S@"/ Tier . +ngine&ummins S@"/ Tier . +ngine


45/69

• Bull* compliant to A Tier 2/#$

emission le)els• Suppl*ing t%e in&ustr* +it%8

cleaner, greener >


46/69

Same O3tionsD

• an Drives

• Alternators

• l#=!eels

• Eil :ans

• Au%. Drives

• ilters

• :relu"

• Centinel

• 'liminator

• 't!er inGection

8o c!ange in air

inlet connections

8o c!ange in

mounting

locations

8o c!ange in

Gac;et =ater

inlet outlet

connections

8o c!ange in

e%!aust outlet

connections

Retains the same installation en$elo3e as the @TA"/B@.///+

5/0 3arts num-er commonality

3irtuall# identical

dimensions

g g

S@"/ Tier . &om3lianceS@"/ Tier . &om3liance


47/69

./// .//1 .//. .//7 .//, .//" .// .//5 .//! .// ./1/ ./11 ./1.

7/. ' /. HP Tier 1 Tier . Tier 7

/7 ' 5"1 HP Tier 1 Tier . Tier 7

I 5"1 HP Tier 1 Tier .

Tier ,

Tier ,

Tier ,

US +PA (o-ile

O** Highway

'mission levels 8E% /. 8E% H C


48/69

))

G7"// Unit J.) User Test at &allideG7"// Unit J.) User Test at &allide


49/69

))



50/69

)



51/69

2e$elo3ment test 3rogress H&AS+


52/69

Final dri$e *ailed7 times

• Per*ormances tests ha$e -een com3leted success*ully in Fe-B.//56

• O3erational test 3rogress had -een slower than 3laned schedule due to

7 *inal dri$e *ailures and some other small 3ro-lems6

• O3erational test ha$e -een com3leted middle o* (arB.//!6

Per*ormance and relia-ility test 9H&(: H&AS+


53/69

Per*ormance tests

I


54/69

!e+t tem +pec me+#ed

#dmet

M7im#m +peed (km/h) $M% 56*0 3 5&*3 p++

'cceletio 0 9: 100m (+ec) $M% 1&*8 3 18*2 p++

.M% 1,*1 3 21*4 p++

;p hill +peed ,m (m) $M% 21*4 5 18*5 p++.M% 35*1 4 32*5 p++

ote+ ? $M%@143325k .M%@325000

2ri$ing 3er*ormance


55/69

Eew Load Weigh System accuracy

Standard loading times

A$e /60

(in '/60

(a= 16,0

Une$en loading

Front side /670

Rear side 1650

Right side /6"0

Le*t side '1610

S3eci*ication MB' 76/0

Load Weigh System accuracy test

with H&( truck scale 911thBEo$.//:

H&AS+ O3eratorNs comments *or 3er*ormance


56/69

Eperator comments !ave "een ver# positive e%cept visi"ilit# and noise in

t!e ca". T!ese items !ave "een improved during 1)))!r service.

/A35 'B Cpe(to D#e+t io00(ie

1

2

3

4

5

'ccele(tio0 Eeeli06

=et(d Eeeli06

Feeli06 #phill

(ccele(tio0

!(eli06 Eoce #phill

!(eli06 Eeeli06 (0d

+t(GilitH

Fi0e co0tol (ccele(tio0

(0d et(d

0+t#me0t p(0el i0+ide

c(G

$eI mo0ito di+pl(H

$oi+e i0 the B(G

Cpe(to i+iGilitH

1* ;0(ccept(Gle 2* CC= 3*F'= 4* .CC 5* /JB/KK/$!

H&AS+ Impo!eme"t (1) "o#se #" te %a&


57/69

,odification

Add t!e sound attenuation

material under t!e operator ca".6Done Sep))+ at 1)))!r service7

%mprovement

-.*d2 in t!e Ca" 6I-.*d2 99 I)d27

Test result

H&AS+ Impo!eme"t (2) opeato '#s#l#ty


58/69

.ro/lem

T!e ladder and t!e platform in front of t!e ca" "loc; visi"ilit#.

,odification

(edesign t!e ladder and t!e platform and replace.

6Done Sep))+ at 1)))!r service7

Eriginal $mproved

peat#o"al test (e&*2007 +Ma*2008 ) H&AS+


59/69

A$aila-ility during o3erational test has -een a**ected -y 7 *inal dri$e

*ailures and small other 3ro-lems6

(ore than "0 o* down time are caused -y *inal dri$e oil leak6

H&AS+ Impo!eme"t (3) #"al #!e &ea#"- .a#l/e


60/69

+timted c#+e oE mi Gei +#Ece Elki oE Eil die

i

de clmp

im

Foce Eom tHe 81L (Iith E#ll lod 1*5.)

Foce Eom de clmp @&1,L

ede lod

moto（i+ide）

Gek（o#t+ide）

Foce Eom tHe 81L (Iith E#ll lod 1*5.)

ede lod

deEomi

Cause of failure

N*eforming of housing +y the force from dagger clamp ma,es sever edgeload

on the rollers of +earing and damage.

Housing

(odi*ication• Rein*orce wheel housing to 3re$ent de*orming6• (odi*ied *inal dri$es were already arri$ed to Australia6

H&AS+ Impo!eme"t (3) #"al #!e .a#l/e (%o"t)


61/69

-adial

displacement

riginal &mproved

3#/

Effect of modification !as confirmed +y

0E analysis and stress measurement !ith

actual final drive.

0E analysis !as done +y HC and other

Hitachi group engineering company.

7mple oE

F'

lH+i+

e+#lt

H&AS+ Impo!eme"t () Se!#%e ae #l 4ea


62/69

Cause : #ring o' rake caliper +as &amage&

Action : C%ange t%e material o' #ring

$ar&ness 8 #riginal 0$s /o&iDe& .1$s

Wit%stan& pressure 8 #riginal 43/pa /o&iDe& 113/pa

ConDrmation test ;n&urance test=

105E F 21/a F 200,000c*cles Pass


63/69

&AE

9@e'&AE:

&AE

9SA+'K17:

ard=ire

2S& Drive s#stem Controller

2# itac!i td

+&( 'ngine Controller Unit

2# Cummins

'ngine (ev.

speed

'rror information

6Multi pac;et data7'rror information

6Multi pac;et data7

Can not receive

man# data at once

&&U'42U

&ommunication

+rror

occurring =!ile receiving

additional data

42U $nformation displa# Unit

2is3lay 4n*ormation

9Payload6 +tc:

(ulti Packet dataBsec

2LU Data logger Unit

Eum-er

o* data

increased

at 1///hr Eum-er o*data

increased

at 1///hr

&ommunication error occurred a*ter 1///hr modi*ication -ecause num-er o*

data *rom &&U and 2LU to 42U increased -y changing so*t ware6

42U so*tware was u3graded to -e a-le to recei$e data and 3ro-lem was *i=ed6

&&U Main Controller Unit

H&AS+ Impo!eme"t (6) eel Moto #- temp


64/69

Cause 8 /ain lo+er motor stops &uring truck stops ;30sec=

Action 8 C%ange t%e control program 'or main lo+er 'an so t%at t%e 'an

keeps rotating &uring loa&ing an& &umping ;10min=

A'ter mo&iDcation actual +orking &ata s%o+s ma motor temp isaroun& 110 &eg6C ;$ig% temp limit 150&eg6C=

3 &a*s &ata a'ter impro)ement

(a= (otor tem3

a33ro= 11/ deg

Air inlet tem3

a33ro= ,/ deg

H&AS+ Impo!eme"t (7) #"al #!e %ool#"- al#ty


65/69

Original

Oil coolers *or *inal dri$es were changed to increase cooling a-ility

• SiCe o* cooler D . times a33ro=

• (aterial o* cooler D Steel Aluminum• &ooling a-ility D (ore than 1/ increased℃

4m3ro$ed

H&AS+ Impo!eme"t (8) #"al #!e %ool#"- l#"e pess/e lo


66/69

Cause : Small metal particles stuck on c%eck )al)e 'or *pass line

Action : A&&e& oil Dlter in s*stem an& t%en ne)er %appen again

check valve

Oil flter

H&AS+ e.oma"%e %ompa#so" (e.ee"%e ata)


67/69

:erformance stud# =as done during actual operation =it! e%actl# same !aul

road as competitorKs truc; 6same class7 .

According to t!e data of 1) c#cles, t!e fuel consumption =as +L "etter and

t!e time from loading area to dumping area =as - L s!orter t!ancompetitorKs truc;.

Actual haul road

Test and im3ro$ement Summary H&AS+


68/69

:erformance test and operational test =as successfull# completed.

T!e results of performance tests all meets CMKs specifications.

EperatorKs comments for performance is ver# good.MaGor pro"lem t!at occurred during operational test =as final drive "earing

failures and alread# completed improvement.

Some ot!er pro"lems =ere found out during operational test and most of

t!em are "eing improved during modification period 6Mar 9 April))I7.


69/69

Documents

EH3500AC Presentation.ppt