Welcome
Project History
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Large Truck Study - Late ‘80s
Drive System Investigation
- Mechanical
- Direct Current (DC)
- Alternating Current (AC)
North American Locomotive Development
Project Start-up - Late ‘92
Prototype - Early ‘95
Field Test - ‘96
Market Introduction - September ‘96
Development Goals
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Increased Productivity
Decreased O&O Costs
Better Performance
- Speed-on-grade
- Maximum Speed
- Continuous Gradeability
- Retarding Capability
- Horsepower Utilization Across
Speed Range
Improved Driveability
Big Is Better Philosophy
OK If?
• Infrastructure Can Support:
- Haul Road Width
- Service Bays
- Maintenance Handling Equipment
- Crusher Capacity
- Shovel Match
Big Is Better Philosophy
OK If?
• Cost Per Ton is Reduced
- Higher Production
- Fewer Trucks
- Better Reliability & Availability
930E
930E Specifications
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Conventional Configuration
- Rigid Frame/Single Engine/Two Axles/Six Tires
Approximately 50’L X26’WX24’H
1,059,000 pound Gross Vehicle Weight
400,000+ pound Empty Vehicle Weight
320 Short Ton Payload
40 mph Maximum Speed
50/90 R 57 Tire Size
Oil-cooled Service Brakes
2700 hp DDC 16V4000 Engine
AC Drive System
AC Electric Truck Performance
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High speed
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Superior retarding
Deep pit capacity
High efficiency/
high horsepower
utilization
Long component
life
320 Ton Componentry
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MTU/DDC 16V4000
engine
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G.E. drive system
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GTA-34 alternator
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AC traction torque
regulation
GDY-85 motorized
wheel
Bridgestone 50/90
R57 VELS tires
930E Systems
Drive System
Engine
Specifications
Make and model
Fuel
Number of cylinders
Operating cycle
Rated brake power
Flywheel power
Weight (dry)
MTU/DDC 16V4000
Diesel
16
4 Cycle
2700 hp (2014 kW) @ 1900 rpm
2500 hp (1865 kW) @ 1900 rpm
15,419 lb (6994 kg)
320 Ton Capacity
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20-30% more
than
240 ton trucks
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Up to 10% lower
cost per ton
Braking System
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Electric retarding
5400 hp (4026 kW)
•
Oil-cooled,
multiple
disc service
brakes
Economics
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Fuel savings
Time cost control
Maintenance cost
advantage
- Lowest life-cycle
cost per ton
Reliability Advantage
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UNI-ECS electronic
control
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5-10% fuel economy
improvement
•
12,000+ hours
to overhaul
Main Alternator Cutaway
Control Cabinet
Alternator 3-phase Voltage
Measuring Module
Inverter Phase
Module 1 + or -
Link Voltage
Measuring
Module
Control
Panel
Chopper GTO
Phase Module
1 and 2
Inverter Phase
Modules 2 + or -
Electrical Interface Cabinet
Truck Control
Interface
Circuit
Breakers/Switches
Lincoln Lube
System Timer
Engine Drive
System
Diode Board
Relay Boards
G.E. GDY-85 Electric Wheel
AC Drive System
Blower
Motorized
Wheels
Controls
Pumps
Alternator
Retarding
Grids
Engine
AC Control System
IGBT Aux.
Inverter
D.I.D.
Truck
Control
Interface
(TCI)
Serial
Comm.
Link
Propulsion
System
Controller
(PSC)
Blower
Cooling
Air
Inverters
#1
#2
Rectifier
Alt.
Retarding Power Circuit
BM1
Inverter
M1
Inverter
M2
BM2
Chopper
Module
1
RP1
RP2
RP3
Chopper
Module
2
Gradeability Comparison in Retarding
930E vs Cat 793C
Grade in Percent
15
930E GVW = 1,059,000 lb
930E
793C GVW = 830,000 lb
930E
10
793C
Cont.
3-min
5
Continuous
mph
km/h
0
0
0
5
5
10
15
20
25
30
35
40
45
10 15 20 25 30 35 40 45 50 55 60 65 70
Speed
Cooling
AC Drive
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Induction motors no commutator,
no brushes
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Integral outboard
planetary final
drive
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Proven GTA-34
traction alternator
Electric Retard Advantage
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High-density air
cooled grids
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5400 hp (4028 kW)
3-minute retarding
effort
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3300 hp (2460 kW)
continuous retarding
effort
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0.7 sec propel-toretard transition time
KMS
Quality Confirmation Attitude
Past Practice -
Design, Release, Produce. . .
hope for the best in the field
Current Practice - Design, Test, Re-design,
Re-test, Produce
. . . know what the field
results will be
KMS Joint Technology Projects
930E
D575A
USA
H655S
Japan
Germany
Modular
Mining
Vital Signs
Monitoring
Quality Confirmation Activity
Application of K.E.S. Techniques
Advanced technology, full butt-welded box sectional laddertype frame with integral ROPS supports, integral front
bumper, rear tubular
cross members,
steel castings at all
critical stress
transition zones,
rugged continuous
horsecollar.
Frame
Frame Specs
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Rail width
12” (305 mm)
Rail depth
34” (864 mm)
Top and bottom
plate thickness
1.77” (45 mm)
Side plate
thickness
0.98” (25 mm)
Plate material
Casting material
70,000 psi (482.3 mPa)
tensile strength steel
90,000 psi (620.1 mPa)
tensile strength steel
Fabricated Rails
12”
(305 mm)
.98” (25 mm)
Outside / Inside Sidesheet
34” (864 mm)
Top / Bottom Bar
1.77” (45 mm)
/2
0
/1
0
/9
6
/9
6
/6
/9
6
/3
/9
6
/9
6
2/
7/
97
4/
18
/9
6/
7
16
-2
0/
97
8/
11
/9
7
10
/1
4/
97
15
-D
ec
2/
20
/9
8
3/
27
/9
8
1/
3/
97
12
12
12
12
/2
1
200
5080
180
4572
160
4064
140
3556
120
3048
100
2540
80
2032
60
1574
40
1016
20
508
0
0
Date and Unit
Length of Rejected Indications (mm)
11
Length of Rejected Indications (in)
Frame Rail Ultrasonic Inspected By Model
Brake System
Service Brakes
2500 psi (17 229 kPa)
Service Brakes
Oil cooled, hydraulic-actuated, multiple disc brakes at
each wheel. Traction system wheel slip/slide control.
Max. service apply pressure ........ 2500 psi (17 229 kPa)
Total friction area per brake ........ 15,038 in3 (97 025 cm3)
Parking Brakes
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Multiple disc
Spring-applied,
hydraulically
released
Wheel Brake Locks
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Switch-activated
Rear brake only
2000 psi
Electric Dynamic Retarder
Brake Codes
Safe and Reliable Service Brakes
SAE = 331 ft
Actual = 188 ft
58%
Actual
SAE J1473
Emergency Braking Tests
Truck 101
GVW = 1,023,200 lb (464,124 kg) -- EVW = 430,800 lb (195,411 kg)
Loaded
on
Level
Loaded
8.7%
Grade
Empty
on
Level
Empty
8.7%
Grade
Bumper to
bumper
58’9”
(17.9 m)
81’5”
(24.8 m)
Did not
run
Did not
run
Skid
43’7”
(11.8 m)
65’4”
(19.9 m)
Did not
run
Did not
run
Radar
gun
23 mph 25.5 mph
(37 k\m/h) (41 km/h)
All-welded steel flat floor body with horizontal bolsters
and full canopy. Left and right canopy spill guards,
eyebrows, rear wheel
rock ejectors, body
tilt cable, and rubber
mounts on frame are
standard. Pivot
exhaust heating
optional.
Struck capacity
Heaped capacity
Loading height
Body
182 yd3 (139 m3)
241 yd3 (184 m3)
21’11” (6.68 m)
Canopy Sheet & Bolster
Front Sheet
0.19” (5 mm) 100,000 psi (690 mPa)
0.35” (9 mm)
400 BHN Nominal
Floor Sheet
0.63” (16 mm)
400 BHN Nominal
Side Sheet
0.31” (8 mm)
400 BHN Nominal
Bolster
0.31” (8 mm)
100,000 psi (690 mPa)
tensile strength steel
Heated Exhaust
930E & 830E Body Impact Plate
930E & 830E Body Impact Plate
Advanced Analog Operator Environment with integral 4-post
ROPS/FOPS structure (meets J1040 Apr88), adjustable
Isringhausen seat w/ lumbar, passenger seat, R-12 insulation,
thermopane windows, tilt steering wheel, electric windshield
wipers w/ washer, tinted
safety glass, Komatsu
Payload Weighing System,
55,000 Btu/hr heater and
defroster, 21,600 Btu/hr
air conditioning
(HFC-134 refrigerant).
Cab
Hydraulic System
Hydraulic Tank
Hydraulic System
350 U.S. gal (1325 L)
Hydraulic Pumps
Hoist & Brake Cooling Pump
Tandem gear-type with
output of 270 gpm
(870 liters/min) at 1900 rpm
and 2500 psi (17 240 kPa)
Steering & Brake Pump
Pressure-compensating
piston with output of 60 gpm
(227 liters/min) at 1900 rpm
and 2750 psi (18 961 kPa)
Steering
Steering Cylinder
Bore diameter
Rod diameter
Stroke
Extended
Retracted
6.50”
3.00”
27.29”
74.41”
47.12”
Accumulator
Bore
Length
Working
Pressure
8.00”
85.75”
27.50 psi
Steering Diameter
Maneuverability
97’4” (24.72 m)
Turning Circle
930E
SAE Steering Course
25 m
5 x max width over tires
B
Corridor 3
Finish 2
Finish 1
C
C
30 m
40 m
Corridor 4
Corridor 1
10 m
Corridor 2
20 m
A = 1.10 x the tire track circle or 14 m,
whichever is larger.
B = 1.75 x the tire track circle or 22 m,
whichever is larger.
C = 2.00 x the maximum axle spacing
or 15 m, whichever is smaller.
Start 1
Start 2
1.25 x max width over tires
Steering meets
SAE J1511 standards
Suspensions
Front Suspension
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Maximum stroke 12.92” (328 mm)
Long length bearing
Forged rod and housing
Large cast mounts
Rear Suspension
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Variable rate hydro-pneumatic with
rebound control
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Maximum stroke - 9.0” (229 mm)
Maximum rear axle oscillation - ± 6.5°
Rear Hitch Pin
High Mounted Rear
Axle Hitch Pin
Maximum rear axle
oscillation ± 6.5°
Hoist Cylinders
Extended
169.07” pin to pin
Retracted
65.07” pin to pin
Bore diameters
1st stage
14.00”
2nd stage
11.75”
3rd stage
9.50”
All stages sealed
Quill for deceleration at
frame-standard
Stroke each stage
34.88”
Hoist
Cylinders
Rock service, tubeless, radial tires
Standard tire 50/90 R57
Tires
Tire Rating
Bridgestone 50/90 R57 VELS
Load and inflation
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165,000 lb at 102 psi
176,000 lb at 116 psi
Specifications
Specifications
30’8” 9.35 m
12’8” 3.86 m
45’9”
13.94 m
RAISED
21’11”
6.68 m
EMPTY
23’10”
7.26 m
EMPTY
4’1”
1.25 m
14’0”
4.27 m
LOADED
45°
5’11”
1.80 m
EMPTY
13’10” 4.21 m
3’1” 0.94 m
20’10” 6.35 m
50’0” 15.24 m
14’8” 4.47 m
4’7”
1.40 m
LOADED
Specifications
27’8” 8.43 m
26’0” 7.92 m
15’2”
4.62 m
7’5”
2.26 m
19’8” 5.99 m
17’2” 5.23 m
24’2 7.37 m
26’10” 8.10 m
Weight Distribution
Empty Vehicle
Front axle
Rear axle
Total (wet, 50% fuel)
Loaded Vehicle
Front axle
Rear axle
Total
lb
204,289
215,181
419,470
kg
92 664
97 604
190 268
%
48.7
51.3
lb
353,000
706,000
1,059,000
kg
160 120
320 239
480 359
%
33.3
66.7
Service Capacities
Cooling system
Crankcase *
Hydraulic system
Motor gear box (each)
Fuel
* Includes lube oil
205 U.S. gal (776 L)
58 U.S. gal (220 L)
350 U.S. gal (1325 L)
25 U.S. gal (95 L)
1200 U.S. gal (4542 L)
930E World Population
Total 100
10
67
12
11
KMS 930E AC Drive Truck
“In The Dirt”
Customer
A. T. Massey
Arco
Asarco Mission
Asarco Ray
Barrick
Chuquicamata
Fording River
Freeport
PD Chino
PD Morenci
Peabody
Peoria
Pipeline
Syncrude
100 Units
Hours
Location
10,193
W. Virginia
3,050
Wyoming
22,650
Arizona
8,389
Arizona
9,950
Nevada
11,163
Chile
13,522
Canada
18,790
Indonesia
99,580
New Mexico
235,883
Arizona
9,600
Wyoming
4,000 Peoria Proving Grounds
7,318
Nevada
30,050
Canada
484,138 Hours
Meeting the future global mining
system needs of the 21st. Century.
Thank You
For Visiting
KMS Peoria
Fuel Savings
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UNI-ECS electronics
engine control
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Separate circuit
charge air cooling
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Fluid coupling fan
drive
Fuel Savings
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Matched engine
drive system
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Engine speed
managed by AC
traction control
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Drive matched to
“sweet spots” on
fuel map
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Engine at idle
speed in retarding
Control Cabinet
AC Traction Torque Regulator
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Torque regulator
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Built in diagnostics/
diagnostics display
panel
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Fault and statistical
data recording
Wheel slip/slide
control in propel
and retard
Rims
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Standard five (5) piece
rim 32” x 57” x 6.5”
(813 mm x 1448 mm x
165 mm)
Patented Phase II New
Generation Rim
assembly with forged
center bolt flange and
62” (1575 mm) center line dual spacing
Rated at 120 psi (827 kPa) cold inflation pressure