earth moving machine

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Earthmoving Machine

Design Evolution

19th Mechanical Engineering Safety Seminar

NSW Dept. of Primary Industry

Olympic Park, Homebush

Hayden Jones

Caterpillar Global Mining


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What drives changing technologies?

?

Evolving Regulations

Competitive Challenge

Manpower Skill Levels

Technology Advances

Safety Enhancements


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A Question of Balance?

Varying Customer

Requirements

Business Needs

International & Regional

Regulations


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EMESRT Group

1 Access & Egress

2 Working at Heights3 Noise

4 Whole Body Vibration

5 Fire

6 Dust

7 Isolat ion of Energy (inc. parking)

8 Visibi li ty/Col lision Detection &Avoidance

9 Machine stability / slope indication

10 Guarding

11 Displays & Controls (inc. labeling)

12 Tyres & Rims

13 Manual Materials Handling

14 Work postures

15 Confined space

Earth Moving Equipment

Safety Round Table(EMESRT)

BHP Billiton, Xstrata, Rio Tinto, Anglo American, Vale,

Barrick, Newmont, Freeport McMoRan

EMESRT engagement with OEMs paves the way for earthmoving equipmentthat ensures the safety and well-being of operators and maintainers.


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Caterpillar Safety Compliance

In Iron Safety Audit

On-machine compliance reviews by EMESRT memberswritten into Caterpillar Safety Design Guidelines.

Unprecedented customer access to new machine designs

during the development phases.


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EMESRT Design Philosophies

1 Access & Egress

2 Working at Heights

3 Noise4 Whole Body Vibration

5 Fire

6 Dust

7 Isolation of Energy (inc. parking)

8 Visibili ty/Collision Detection &Avoidance


10 Guarding


12 Tyres & Rims


14 Work postures

15 Confined space

15 areas of concern 8 areas given priority

1 Access & Egress

2 Working at Heights

3 Noise4 Whole Body Vibration

5 Fire

6 Dust

7 Isolation of Energy (inc. parking)

8 Visibili ty/Collision Detection &Avoidance


10 Guarding


12 Tyres & Rims


14 Work postures

15 Confined space


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Access Systems - OHT

Improved LadderRear Access

600 mm Wide

Access to Cab

Stairways

Eliminated Step

Down to Catwalk

Improved Secondary

Egress

Access to therear of the cab

Optional factorypowered access

ladder

F-series Mining Trucks


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Access Systems - OHT

785

797

789

793 795

CAT standard

Off-side ground access

EMESRT Option

Cab side ground access

Encourages lightvehicles to park on the

cab side of the truck

In development for allnew LOHT models

Customer demand

signal required for

release


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Rear Access Egress System (RAES)

Replaces LH lower platform ladder Lifts & lowers operator or service

technician to stairwell platform

Other improvementsAccess on both sides of machine

Kickrails

600 mm wide stairways Roading Fenders to reduce mud

build-up on stairs

Access SystemsWheel Loaders

993K Wheel Loader


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Corporate 6 Sigma project Safety & Design Guides updated for

tie-off location requirements

Implemented into 2008 NPI programs(New Product Introduction)

Safety Harness Tie-off Pointswhen working at heights cannot be avoided

Working at Heights - OHT


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Reduced need for Working at Heights

Working at Heights

793D

793F

Ground Level Service

& Sight Gauges

Batteries now located

in Front Bumper

No PM Service items

on RH deck of F-seriestrucks


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Rear Medium

Range

Rear Shor t Range

Side Medium

Range

Side Medium

Range

Front Medium

Range

Front ShortRange

Collision Detection & Avoidance

Caterpillar Integrated Object Detection System

50 - 60% of accidents reported by mine sites are due to poor

visibility at low speeds (data from various companies and MSHA).

An effective object detection is expected to eliminate a significant

number of these incidents.


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The system consists of:

An interactive display in the cab

Medium Range Radar front & rear

(~ 30 metre range)

Short Range Radar front, rear & sides

(~ 7 metre range)

Cameras on all 4 sides of the machine

A vision only system will also be

available, upgradeable to full object

detection system

Expected availability - Sept 09



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Visual alert if object enters caution alarm zone (5 20 metres)

Audible alert if object remains inside 5 metre critical alarm zone in

direction of machines intended path if the operator engages gear and

hasnt acknowledged alarm to full screen view.


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Electro-Hydraulic Controls

Electrical sensor input

(commonly joystick)

Solenoid controlled hydraulic

valves

Unmatched control and

precision

. a foundational technology

for machine design


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1997

1997 STIC Steer Released on 994

1998 2007


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1997

1998 E/H Implement Control D11R

1998 2007


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1997

Numerous Models

1998 2007


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1997 1998 2007

M Series Graders


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Some of Caterpillars

smaller machines

are also designedwith EH controls


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Electro-Hydraulic Controls M Series

Safety Benefits of E/H Controls

Visibility

Intuitive operation

Operator Fatigue

H-Series

M-Series


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Electro-Hydraulic Controls M Series

Fatigue 78% Arm Movement Reduction


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Today:

Integration withMachine Control &

Guidance Technology

Operator Assistance

Features

Future:

Foundation for Remote

Control / Automation

Programs

Electro-Hydraulic Automation

blade tilt angle

Angle SensorAngle Sensor

main fall angle

AccuGrade DisplayRotation Sensor

Circle Rotation

blade tilt angle

Angle Sensor

blade tilt angle

Angle SensorAngle Sensor

main fall angle

Angle Sensor

main fall angle

AccuGrade DisplayRotation Sensor

Circle Rotation

Rotation Sensor

Circle Rotation


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Off Machine Earthmoving Development

Caterpillar recognises that safetywithin the earthmoving industry

extends beyond what can be builtinto machines:


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Basic Safety Information PPE, Warning Labels

Service Technician Safety

Toolbox Talks

Safety Videos

Machine Operation / Safety Walkaround Inspections

Maintenance Checklists

Pre-start, Operating Tips

One Safe Source for all CATSafety-related media

Launch of Safety.CAT.com

Safety.cat.com


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Machine Simulators

Wheel Loader

Off Highway Truck

Motor Grader


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The D7E Track-Type Tractor

The culmination of many innovative technologies

AC Electric Drive Enhanced operator visibility

Reduced cab noise levels

Greater powertrain efficiency

Reduced fuel consumption and

emissions

Reduced maintenancerequirements

Higher productivity

Reduced operating cost

Sustainable Machine Development

D7E Video


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Thank You

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