Article citation information:
Hong, T.D.,
Thai, H.T. Research and design of multi-directional dumping construction in
trucks. Scientific
Journal of Silesian University of Technology. Series Transport.
2023, 119, 5-18. ISSN: 0209-3324. DOI: https://doi.org/10.20858/sjsutst.2023.119.1.
Thong Duc HONG[1],
Hiep Thanh THAI[2]
RESEARCH AND DESIGN OF MULTI-DIRECTIONAL DUMPING CONSTRUCTION IN TRUCKS
Summary. In the
current transportation industry, especially transporting coal, sand, heavy
stone, construction waste, etc., dump trucks occupy a critical position. Most
traditional dump trucks can only dump goods vertically, so their
manoeuvrability is not high. Especially in tight spaces such as construction
sites, it causes many difficulties for loading and unloading traditional dump
trucks, which takes a lot of time and effort for the driver. In this paper, we
have mainly focused on solving the above difficulties. Hence a
multi-dimensional dump truck model was designed. The hydraulic motor actuated
by the directional valve rotates the container on the required side. This
design aims to improve the features and performance of dump trucks compared to
existing conventional vehicles. This concept will save operating costs &
energy consumption, which leads to increased efficient working. In this study,
the dump truck can rotate 1800 in both directions through a hydraulic motor and
gearbox linked with slewing bearing.
Keywords: multi-dimensional
dump truck, three-axis modern trailer, three direction dropping dumper
1. INTRODUCTION
In today's industry, dump trucks are an
indispensable means of transportation for any construction site. One of the
problems raised is that setting the dump location of the vehicle in the desired
direction to dump the material consumes too much time and energy and
additionally limited working space poses challenges for efficient unloading of
goods.
The reality is that there is a need for a dump
truck that can dump materials in any desired direction. A multi-directional
dump truck can be helpful for workers in material transfer, construction sites,
garbage collection, gravel and sand material etc. It can also reduce vehicle
power and fuel consumption when dumping it in multiple directions.
Multi-directional dump trucks also take less time than dump trucks to do the
same volume work. Trucks, dump trucks, and tippers are used to transport bulk
materials from one place to another at the construction site in the mines or in
the storage yards to fulfil the actual requirements of the site. Suppose
someone with experience can understand the site conditions and available space
in mines and on the construction site. It is tough to unload bulk material at
the proper location. The trucker will have difficulty adjusting the dump truck,
which takes considerable time, and effort to unload loose material.
As we all know, dump trucks are mainly used for
loading and unloading bulk materials on construction sites, mines, and
warehouses. The usual system available is the unloading of the material at the
rear. We propose a new multidimensional dump truck with a 3D Solidworks model
to solve the above difficulties. It is also a field that has received a lot of
research attention.
Many scientists have studied the problem of
multidimensional dump trucks. Deshmukh et al. [1] present a design that could
unload the materials in three ways. This option was used for the ball socket
joint to unload the material in the left or right direction and use the hydraulic
cylinder on the backing side. For the container to move in three movements, the
solution of this paper using a spherical joint is quite suitable. However, a
pin must be used to fix one side of the ball joint when pouring on the left or
the right. Prasath et al. [2] used an optional hydraulic cylinder and jacking
mechanism to unload the trailer in three axes without external force. This
option used a directional valve to activate the hydraulic cylinder. Along with
the arrangement of suitable knee joints on the trailer and the linkage of the
hydraulic cylinder, they could unload the trailer in three axes. The study of
this design makes loading and unloading materials easy, saving time and effort
for the driver. Rani. [3] proposed a plan for a dumper that can unload in any
direction desired. This option used a pneumatic cylinder and sprocket
mechanism. The pneumatic cylinder is responsible for lifting the container to
dump the material, and the sprocket mechanism rotates the container to the
desired pouring position. With this design, the vehicle can operate in limited
working spaces and have applications in more than three directions. Pal et al.
[4] rated dump trucks in three directions dropping dumpers. The reasons for
this evaluation are attributed
to problems encountered during material unloading in confined areas at
construction sites or situations where the process of material dismantling is
time-consuming. Therefore,
this study evaluates the previous solutions for multidimensional dump trucks,
which improve existing conventional vehicles. It helps prevent traffic
congestion because dump trucks work quickly and efficiently. Hence, this option
can save material unloading time and operating costs. Patel et al. [5]
introduced a three-way tipper mechanism. This tipper can unload the materials
in three directions without needing external force. This design is used for
ball-socket joints and pneumatic cylinders to unload goods on the back, right,
or left sides. The mechanism is designed to lift the tipper to unload the
material in three directions. This project helps to unload goods safely,
quickly, and effectively. It will be easier to dump goods in a limited area.
Khilari et al. [6] and Shinde et al. [7] presented a design using the direction
control valves, activating the hydraulic cylinder's ram and lifting the trailer
cabin on the required side. Shashidar et al. [8] used the worm screw and worm
wheel to rotate the trolley to a suitable unloading position and lift it by the
hydraulic cylinder. Toke et al. [9] studied the unloading process in three axes
with the help of locking arrangement and the pneumatic system. The direction
control valve was used to control the flow direction of the pneumatic cylinder.
2. MULTI-DIMENSIONAL DUMP TRUCK DESIGN
We
pose the problem of the method of dumping materials in a relatively narrow
space, making it difficult to put the vehicle in the appropriate pouring
position. Therefore, to solve the above problem, we offer a design plan for a
dump truck that can quickly rotate the container in many different directions
to dump materials. With this option, we use a hydraulic motor, reducer, and
slew drive to rotate the container and lift the container using a telescopic
cylinder. The chassis truck in our design is Kamaz 65115 [10]. The hydraulic
pump is driven from the power take-off of the chassis truck and supplies oil to
the telescopic cylinder and the hydraulic motor. The oil from the hydraulic
pump will be connected to the direction valve. Through this valve, we can
control the lifting and rotary of the container by the requirements set forth.
Most of the studies on multidimensional dumpers used mechanical links, which
have many advantages over traditional dump trucks. However, they also make it
difficult to unload horizontal goods or can only be loaded and unloaded in
three dimensions. Our research not only saves the installation of quick-release
pins compared to the studied multidimensional dump trucks, but also can be
dumped in more than three directions to improve the working efficiency of the
vehicle.
2.1. Modern multi-directional
dumping
The complex assemblies of the
multidimensional dump truck are arranged as shown in Fig. 1. The hydraulic
cylinder is responsible for lifting and lowering the dump truck, and the
slewing bearing combines with the hydraulic motor and the reducer to reduce the
load. Rotate the barrel to the desired pour position.
Fig. 1. General layout diagram of
modern multi-directional
The proposed design model of the
dump truck with its components is listed below:
|
1 |
Slew drive bearing |
2 |
Dumping container |
|
3 |
Hydraulic oil tank |
4 |
Directional control valve |
|
5 |
Hydraulic cylinder |
6 |
Control panel |
|
7 |
Power take-off |
8 |
Propeller shaft |
|
9 |
Hydraulic pump |
10 |
Hydraulic motor |
|
11 |
Gearbox |
12 |
Sub-frame |
Fig. 2 shows the distance from the
center of gravity of components such as the lifting cylinder, subframe,
hydraulic oil tank, bearing etc., to the centerline of the rear axle assembly
(ROH line) in the direction of longitudinal and height of the vehicle design.
Fig. 2. The
weight’s center of gravity position
The general layout parameters of the
design vehicle's mass, including the chassis truck, the subframe, the
container, the lifting cylinder, Slew bearing and linkage base, pay-load and
trucker, are shown in Table I.
Tab.
1
Dump truck axle weight distributions
|
Components |
Total weight (kg) |
Front axle (kg) |
Rear axle (kg) |
|
Chassis ( |
7725 |
4030 |
3695 |
|
Sub-frame ( |
350 |
100 |
250 |
|
Container ( |
1680 |
200 |
1480 |
|
Cylinder ( |
200 |
140 |
60 |
|
Slew bearing and linkage
base ( |
750 |
100 |
650 |
|
Hydraulic oil tank ( |
100 |
50 |
50 |
|
Trucker ( |
195 |
195 |
0 |
|
Pay-load ( |
13000 |
1285 |
11715 |
|
No-load ( |
10805 |
4620 |
6185 |
|
Full-load ( |
24000 |
6100 |
17900 |
2.2. Calculation of hydraulic
cylinder
Fig. 3 describes the moving process
from horizontal state to the vertical state driven by a telescopic hydraulic
cylinder, the lifting angle of the container is
If the container is to be lifted
when, the moment generated by the hydraulic cylinder must be greater than the
resisting moment caused by the weight of the mass components for the center of
rotation K.
Calculation of the minimum thrust
force of telescopic cylinder with moment equilibrium about point K is shown as
follows:
|
|
(1) |
or
|
|
(2) |
Where
Fig. 3. Erection diagram driven by
telescopic cylinder
The required thrust force is maximum
at the starting position of the dumping container, and then decreases as the
container is raised higher [12].
The following formula can calculate
the thrust force of hydraulic cylinder:
|
|
(3) |
Where
From equation (2) (3), the minimum
diameter of the cylinder can be calculated according to the following equation:
|
|
(4) |
From formula (4), it is possible to
determine the minimum diameter of the hydraulic cylinder
Therefore, we choose the hydraulic
cylinder to lift the container, a telescopic cylinder with the parameters given
in Tab. 2.
Tab.
2
Technical specifications of hydraulic cylinder [11]
|
MODEL NO.
5.5-3-138-B00 |
||||
|
Extension |
1 |
2 |
3 |
Number of Stages: 3 |
|
Diameter |
129 |
111 |
95 |
|
|
Stroke |
1164 |
1169 |
1172 |
Total Stroke: 3505 |
|
Thrust |
258 |
196 |
142 |
Thrust based on 220 |
|
Oil |
15 |
11.2 |
8.2 |
Total Oil: 34.4 |
Besides, the maximum extension speed
is less than 0.2 m/s[11], so the lifting time of the hydraulic cylinder is more
than 17.5 seconds. Therefore, choose the lifting time of the hydraulic cylinder
to be 30 seconds.
The flow of oil supplied to
hydraulic cylinders:
|
|
(5) |
Where
Minimum hydraulic pump power for
lifting cylinder:
|
|
(6) |
2.3. Calculation of slew bearing
The slewing bearing of the
multi-directional dump truck is subjected to the equivalent axial load
Fig. 4. Diagram of force and moment components acting on slewing
bearings [14]
Therefore, the vertical load acting
on the slewing bearing are given by the following equation:
|
|
(7) |
Where
From Fig. 5, it is possible to
calculate the tilting moment on the slew bearing given by the following
formula:
|
|
(8) |
Where
When the dumping container is at the
maximum angle, the hydraulic cylinder has gone all the way, and the slewing
bearing is subject to the maximum tilting moment. The distance from the set
point of the gravity of the goods and the container to the center of the
slewing bearing is shown in Fig. 5.
The equivalent radial load is given
by the following equation:
|
|
(9) |
Where
Fig. 5. Schematic diagram of the moment acting on the slewing bearing
According to research by Yang et al.
[15] and Bokare et al. [16], the type of truck identified in this study is a
medium truck. The maximum acceleration or deceleration rate of medium trucks
The safety factors should be taken
into account in the following equations for the prevailing loads [14]:
|
|
(10) |
|
|
(11) |
Where
Tab.
3
Technical specifications of slew drive [14]
|
MODEL
NO. SP-H 0855/2-05914 |
|
|
Module |
8 |
|
Number of
teeth, wheel |
122 |
|
Number of
teeth, pinion |
15 |
|
Slew drive
gear ratio |
8.13 |
|
Overall gear
ratio incl. gearbox |
147.21 |
|
Maximum
torque |
47180 |
|
Static load
rating, radial |
1037 |
|
Static load
rating, axial |
2777 |
|
Dynamic load
rating, radial (kN) |
354 |
|
Dynamic load
rating, axial (kN) |
414 |
|
Weight, incl.
10 kg for hydraulic motor OMS125 (kg) |
289 |
Table III has given the
specifications of slewing bearing SP-H 0855, such as overall gear ratio,
maximum torque, and static load rating etc. These are the main specifications
of slewing bearings.
The radial load must satisfy the
following equation [14]:
|
|
(12) |
From equations (7) (8) (9), it is
shown that equation (12) satisfies. According to equation (10) (11), we can
calculate
Because Fig. 6 is the limit load
diagram of slewing bearing SP-H 0855/2-05914. At point (
Fig. 6.
Limiting load diagram for compressive loads for slew drive SP-H 0855/2-05914
[14]
It is clear that with a service
factor of
Determine the friction torque of an
unloaded slew drive [14]:
|
|
(13) |
The friction torque for a slew drive
under load can approximately be determined using the following formula [14]:
|
|
(14) |
Minimum torque on the shaft of
hydraulic motor:
|
|
(15) |
Where
Minimum power of hydraulic motor:
|
|
(16) |
Where
The flow to be supplied to the
hydraulic motor of the slewing bearing:
|
|
(17) |
The speed of the hydraulic motor is
|
|
(18) |
Therefore, we choose the hydraulic
motor OMP 40 with the specifications given in Table 4.
Tab.
4
Technical specifications of hydraulic motor [15]
|
MODEL NO. OMP 40 |
|
|
Max
speed cont |
|
|
Max pressure drop cont |
|
|
Max pressure drop peak |
|
|
Geometric
displacement |
|
|
Max oil flow cont |
|
|
Max
torque cont ( |
|
|
Max output power cont ( |
|
|
Min
speed |
|
The technical specifications of the
hydraulic motor in Table IV, such as torque and power, satisfy the calculated
values in equations (15) and (16). This hydraulic motor will transmit torque to
the slewing bearing through the gearbox.
2.4. 3D model
Fig. 7a is the state of the vehicle
moving with no-load or full-load on the road. In which, hydraulic cylinders and
slewing bearings in the initial state do not work.
The body parts of the dump truck are
important components that support the total weight of the dump truck. Fig. 7b
shows the assemblies of the dump truck. The container is lifted by a hydraulic
cylinder and rotated to the unload position using slewing bearing and hydraulic
motor. With slewing bearings and a hydraulic motor, the vehicle can be unloaded
in many desired positions quickly.
(a) Moving on the road (b)
Separation assemblies
Fig. 7. The 3D model of multidimensional dump truck
(a) Slewing bearing rotary 00 b)
Slewing bearing rotary 900 (c)
Slewing bearing rotary -900
d) Slewing bearing rotary -450 e)
Slewing bearing rotary 450
Fig. 8. The dump truck unloads according to the angle of the slewing
bearing
Unloading options are shown in Fig.
8 to help the vehicle quickly get into the position of loading and unloading
goods and become more efficient in the working process.
3. CONCLUSIONS
This paper presents the design of a
multidimensional dump truck to increase the vehicle's mobility when working.
From there, Dump trucks will save time and operating costs. Stage cylinders and
slewing bearings are calculated to satisfy allowable load limits. The
feasibility of the proposed solution has been demonstrated by building
multidimensional dump trucks using the Solidworks model and related
calculations.
With this design option, we want to
improve the flexibility and mobility of this dump truck to improve work
productivity, especially since the designed vehicle can load and unload goods
easily in different locations.
The advantage of this study is that
the dump truck can unload goods in more than 3 directions. We propose a
multidimensional option but still unloading in the rear, so the structure of
the loading container remains the same compared to the traditional dump method.
Especially with this option, the dump truck can work in limited space.
Acknowledgement:
We acknowledge the support of time
and facilities from Ho Chi Minh City University of Technology (HCMUT), VNU-HCM
for this study.
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Received 16.12.2022; accepted in
revised form 30.02.2023
Scientific Journal of Silesian University of Technology. Series
Transport is licensed under a Creative Commons Attribution 4.0
International License
[1] Department of Automotive
Engineering, Faculty of Transportation Engineering, Ho Chi Minh City University
of Technology (HCMUT), 268 Ly Thuong Kiet Street, District 10, Ho Chi Minh
City, Viet Nam. Email: hongducthong@hcmut.edu.vn. ORCID: https://orcid.org/0000-0002-8010-5851
[2] Department of Automotive Engineering,
Faculty of Transportation Engineering, Ho Chi Minh City University of
Technology (HCMUT), 268 Ly Thuong Kiet Street, District 10, Ho Chi Minh City,
Viet Nam. Email: thaithanhhiep@hcmut.edu.vn. ORCID: https://orcid.org/0000-0003-4069-9437