Modeling Tire Wear and Driver Behaviour in Open Pit Haulage Operations ExtendSIM Software • Dynamic modeling of real-world processes • Uses building blocks to explore processing steps • Benefits • Easy to use • Inexpensive • MS-Windows environment • Handles both Discrete and Deterministic Models Discrete and Deterministic • Discrete Events • Probabilistic method • Maintenance, Loading, Dumping • Deterministic • First Principles • Truck movement – Fuel consumption – Tire temperature • Fuzzy Models (A.I.) • Road conditions (rolling resistance and traction) • Tire wear • Driver behaviour (velocity, acceleration, reaction time) Fuzzy Road Conditions • Rolling Resistance varies from 2.5% to 3.5% • Traction varies from 0.44 to 0.55 • Value depends on schedule for grader and water truck and rain/snow intensity/duration Rolling Resistance Fuzzy Model Conventional Approach to Tire Wear • • • • All tire suppliers use the TKPS (TMPS) method Tonnes-Kilometers per Hour Actually, this is simply an Alarm System If TKPH is exceeded on a real-time basis, the truck is prevented from operating in 5th gear to restrict velocity • A better method would be to monitor tire temperature and pressure in real time Real-time Measurement of Tire Temperature • • • • External chassis-mounted IR temperature sensor Temperature sensor embedded in tire tread External sensor subject to ambient conditions (shade/sun) Embedded sensor can wirelessly send data to on-board computer Tire Temperature Decline (until Ttire = Tatm) • Dynamic calculation every 100 msec • Tire load and speed determine temperature change • Temperature drop by ambient heat loss: ΔTd = (Tatm – Ttire)·e-kd t where ΔTd = temperature decline (°C) Tatm Ttire kd t = ambient temperature (°C) = current tire temperature(°C) = heat transfer coefficient (1.6 x 10-4) = time step (seconds) Tire Temperature (continued) • Temperature increase due to load and velocity: ΔTi = KT(1 – e-kit) – ΔTd where ΔTd = temperature increase (°C) KT = 8.344 x 10-3(P + GMW)V ki = 6.836 x 10-7(P + GMW)V2 t = time step (seconds) ΔTd = temperature decline (°C) P = payload (tonnes) GMW = gross machine weight + fuel (tonnes) Tire Temperature Change Tire temperature cycles (14.7% idle time) Velocities = 16 kph loaded / 32 kph empty Tire temperature cycles (9.3% idle time) Velocities = 16 kph loaded / 32 kph empty Tire temperature cycles (9.3% idle time) Velocities = 19 kph loaded / 38 kph empty Wear rate as a function of tire temperature Tire wear rate reported by Miller Rubber Co. in 1928 Popular Mechanics, (1928). Burning 'em Up, June, 49(6), p.938-942. (Miller Rubber Co. graph, p.940) Wear rate as a function of tire temperature Tire wear rate reported by Miller Rubber Co. in 1928 Popular Mechanics, (1928). Burning 'em Up, June, 49(6), p.938-942. (Miller Rubber Co. graph, p.940) Wear rate as a function of tire temperature Wear Rate = 21.699V2e-7,106/RT + 11,931Ve-8,621/RT There are two terms in the equation: First term relates to Energy flow through the tire Second term relates to force (momentum of tire) Scale-up to a Haulage Truck tire Miller Tire Calculated wear rate = 0.274 mm / 10,000 km @ 15 kph and 45 °C Calculated wear rate = 0.528 mm / 10,000 km @ 25 kph and 45 °C Estimated Load (Miller tire) = 2.44 kg/cm2 Load (CAT793) - full = 4.44 kg/cm2 Load (CAT793) - empty = 2.00 kg/cm2 Load ratio = 1.82 Load ratio = 0.82 Tire surface element contact ratio = 1.22 Road surface condition ratio = 12.5 CAT 793D Travelling fully-loaded = 0.274 x 1.82 x 1.22 x 12.5 = 7.61 mm / 10,000 km Travelling empty = 0.528 x 0.82 x 1.22 x 12.5 = 6.69 mm / 10,000 km Validation from Real Tire Wear Data CAT 793D Travelling fully-loaded = 7.61 mm / 10,000 km Travelling empty = 6.69 mm / 10,000 km Average = 7.15 mm / 10,000 km Calculated Tread Depth Change = 7.15 x 11 = 78.7 mm Mine Data Typical Tread Depth Change at scrap = 75 mm for ~ 110,000 km (5,500 hrs) Error = 4.9% Assumed Maximum Wear Rate = 10 mm / 10,000 km Fuzzy Tire Wear Model (mm/10,000 km) Payload Velocity Moderate Normal Low Moderate Empty Zero Zero Slow Lowest Fast Normal Very Fast High Small Zero Lowest Low Moderate Normal High Quarter Zero Low Moderate Moderate Normal High Half Zero Low Moderate Normal High Very-High Three-quarters Zero Low Moderate Normal High Very-High Full Zero Moderate Normal High Very-High Very-High Over Full Zero Moderate Normal High Very-High Maximum Three main factors: payload, speed, tire temperature Additional factors: tire pressure, road conditions, tire rotation Tire Wear Model based on Fuzzy Logic Calibration factors: maximum tire wear rate = 10 mm / 10,000 km maximum velocity = 35 kph maximum payload = 440 tonnes (average = 219 tonnes) Driver Behaviour Sub-Model Behaviour Criteria • • • • • Driving Speed Acceleration Braking Reaction Time Lateral Position Control • Many factors –gender, energy level, age, health, family and personal issues, tiredness, skill level, time since training, personality, time in shift, time in work period • Too many variables and far too complex to validate Driver Behaviour – Aggressiveness Factor Driver Behaviour – Set Points (average) Driver Type Passive Normal Aggressive Autonomous Velocity (kph) Acceleration Reaction Time Loaded Empty (m/s2) (msec) 12 22 0.31 400 ± 100 15 26 0.42 300 ± 100 18 30 0.70 250 ± 50 13 23 0.42 100 ± 0 Driver Behaviour – Aggressiveness Factor Stability Aggressiveness Factor Aggressiveness Highly Stable Little Change Highly Variable Passive -1.00 to -0.80 -1.00 to -0.50 -1.00 to -0.20 Normal -0.10 to +0.10 -0.25 to +0.25 -0.40 to +0.40 Aggressive +0.80 to +1.00 +0.50 to +1.00 +0.20 to +1.00 Driver Behaviour - 1 km modeled test drive