Developing Haulage Profiles(Part of Getting the Truck Cycle Time)

©Dr. B. C. Paul 2000 revised 2008Note – The instructor prepared the basic steps and methods in these

slides from prevailing industrial practices, and widelyAvailable handbooks and manufactures recommendations. The

program includes screen shots from the FPC program developed by Caterpillar Equipment Company. Data input

Methods shown are obviously geared to that program.

Next We Check Cycle Times to Determine How Many Trucks are

Needed To date our 10 trucks is based on a

cycle time out of thin air. To make things more solid we

need to trace out the route, figure how fast the trucks can cover it

Add any fixed cycle time elements to the moving cycle

First Step to Address this is to Identify the route

Part 1 - Divide the Haulroad into segments with similar characteristics

Part 2 - Determine Peak Vehicle Speed Performance on Segments• Check for Traction Requirements

Part 3 - Adjust Peak to Average Speeds

Continued

Part 4 - Total Up Draft Cycle Time Part 5 - Check for Tire Overheating Part 6 - Calculate Draft Fleet Match Part 7 - Check for Bunching and

Adjust

Continued

Part 8 - Calculate Fleet Economics Part 9 - Compare Fleets and Make

Selection

Dividing Haulage Profile

Road Segments Divide When• There is a major change in grade

(slope)• There is a major change in underfoot

conditions• There is a major change in vehicle

operating considerations• Starting• Stopping• Major Turns

What is Major?

Depends in part on what you are doing• Computer Methods favor greater

detail• Hand methods favor more moderation

Good intuitive Check is whether sustained enough to change vehicle speed

Example Haulage Profile

Producing 5 million tons a year of Limestone from a Quarry

Returning Truck• 550 feet level from gyratory crusher• down 400 foot 10% ramp• 40 feet flat at an interchange• down 400 foot 10% ramp• 3900 foot level on bench to Load

Haulage Profile

Point to Note - the 3900 foot approached a load area• May need to break the final approach

for speed restriction• Could also add a more drastic

adjustment for average speed Truck Loads Loops 2900 foot level on bench

• Same point on breaking start

Rest of Profile

400 feet up 10% ramp after a hard turn

40 feet on level through interchange

400 feet up 10% ramp 550 feet level to gyratory crusher Dump into Gyratory

Lets Input that into FPC

I will pick theHaulage Road Tab

Program complainsThat I have not yetDone costs for myEquipment(Thank you but IDon’t want to doThat until later)

Input My Haul Course Identification

Real mines haveMultiple courses –Only my exampleHas just one

Give a description

Make a decision onWhether a fasterTruck can pass aSlower one.

A Passing Question

Caterpillar has done a lot of time studies

Program assigns more than possible speed characteristic to a truck• Mimics full simulation of moving

trucks• It needs to know what to do if a truck

catches up

This is the Screen Where I Have to Tell the Program

About My MaterialsOf course I have beenChecking trucks andGuessing aboutMatches all along butThe program needsTo be able to checkAs it calculatesproduction

I can type in my densities or click select materialAnd use Cat’s built in materials table.

Pick Broken Limestone

This is actually theSame table I wasUsing all along

Pick and click ok

Now All I Need is to Fill In My Tonnage

Note that this featureWould let me mineDifferent parts ofMy total material fromDifferent benchesAccessed byDifferent haul routes.

Now I’m Ready for My Haulage Route

I need to decideWhether to do aLoaded haul orEmpty return first

In my description IStarted with an emptyReturn so I will doThat here as well.

Start My Input

I know my firstSegment is

550 feet

On a 0% grade

Away from the crusher

Type in the Rest of the Empty Return Haulage Profile

Now click radioButton to start inputOf loaded haul

Note that if I need toInsert a segment IMissed or delete oneI put in by mistakeThat I have buttonsFor that purpose.

The Mirror Option

Sometimes haul andReturn are overSame roads inOpposite directions.I can instantly inputAn opposite returnRoute with the mirrorOption.

Type in the Rest of the Haulage Profile for Loaded

TruckNote at this pointI have input

Distance

Grade of the road(measured as a %)

A description ofWhat the roadSegment is. (helpsKeep things organized)