eh3500ac presentation.ppt
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Richard Schloss
Paddy OLoughlin
Untung Prihardiyanto
Feriwan Sinatra
Welcome to Australia
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HITACHI HITACHI EH3500AC EH3500AC
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Truck History
1!" #ol$o ac%uires &lark'(ichigan) owner o* +uclid
1, H&( -uys ./0 interest in +uclid
1 H&( -uys into ,/0 interest) R./ is introduced
1! 2e$elo3ment o* R.!/A& 3rototy3e) H&( ac%uires !/0 interest
1 4ntroduced the R.!/A&
./// +H15// is launched) through this year all model names change to+H models) ending the long run o* the R and &H designation that
accom3anied the Payload in U6S6 tons) #ol$o interest reduces to /0 at the
end o* this year
.//7 +H"/// is introduced) esta-lished the 8lo-al (ining &enter 98(&:
.//, +uclid'Hitachi Hea$y +%ui3ment -ecomes Hitachi &onstruction
Truck (anu*acturing Ltd6
.// +H5"/'7 and +H11//'7 are introduced
.//5 +H15//'7) +H7"// ; +H"/// A& 44 948
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(echanical 2ri$e)(echanical 2ri$e)
• +H15// 91// mt:
2& +lectric 2ri$e Trucks)2& +lectric 2ri$e Trucks)
• +H7/// 91"/ mt:
A& +lectric 2ri$e)A& +lectric 2ri$e)
• +H+H77"//"// 91/ mt:91/ mt:
• +H,"// 9.!/ mt:
• +H"/// 971" mt:
Hitachi Rigid Dump Truck RangeHitachi Rigid Dump Truck Range
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Dump Truck Series98(W .7/ m't o$er:
(echanical 2ri$e +lectric 2ri$e) 2& +lectric 2ri$e) A&
(a=imum 8ross (achine Weight 9 m'ton:
EH3000 EH4500 EH5000
785C 789C 793C 797B
HD1500-5 630E 730E 830E 930E-3
MT3300AC MT3700B TMT260AC MT5500
MT3600B
T252 T262 TI 272 T282
500 550 600250 300 450350 400
EH3500 EH4000
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• Cummins QSK50 Tier 2 compliant engine• 1,491 kW SA !1995, "ross ngine #utput
• $ig%est retar&ing per'ormance in it(s class
• A&)ance& AC &ri)e s*stem allo+s lo+ maintenance
time an& cost
• Super &ri)ing per'ormance an& %ig%
e-cient c*cle time
• 1.5 tonne /a a*loa&
• 3005 or 426905 T*res
• 325,000 kg "/W
• St& 7o&* Capacit*
1104 m3 SA 281
• Trolle* option a)ailale
• ,.1 k : 1500 /
;/a Tor
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1. Development, Manufacturing• Transferred to Japan from USA & Canada• ig! relia"ilit# Japanese parts and components• $ntegrated development, manufacturing tec!nolog# and
know-how of !#draulic e%cavators. 'ngine
・Cummins T$'( $$ )))!p*. T#res
・*+.))(+, -/)(+-. AC drive s#stem ・itac!i AC s#stem from 0' DC s#stem. rame design Structure upgrades
Major Changes on EH3500:Major Changes on EH3500:
(a?or &hanges on +H7"//(a?or &hanges on +H7"//
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(aker @omatsu &AT
4tem Unit +H7"//A& +H7"// 57/+ 5!&
(anu*acture '' &ummins &ummins &ummins &AT
(odel '' S@"/ @.///+ @.///+ 7"1<Out3ut98ross: kW 1,. 1,. 1,. 1,15
2is3lacement L "/67 "/67 "/67 6/
(anu*acture '' Hitachi 8+ 8+ &at
2ri$e System '' A& 2& 2& echanica
(odel '' '' State='7 State='7 ABT
T i r
e
SiCe '' 756//'R"5 756//'R"5 756//'R"5 756//'R"5
&a3acity SA+ .D1Hea3ed m7
11/6, 11"61 11/6 1/,65
Width mm 577/ 577/ 5."/ ,/
(a=6 8(W m6ton 7."6/ 7.,67 7.,67 7156"
E(W m6ton 17"6" 1716/ 17!6/ 1,/6"
(a=6 Payload m6ton 1!6" 1767 1!67 1556/
(a=6 S3eed kmBh " ""6, ""65 ",6,
8rada-ility
Full Loaded
0 ."6. .,6. .,6. ."65
(a=6 Retarding Angle9Full Load 0 1"67 116 116 1,6
(a=6 Retarding S3eed
1/0、
7 、
kmBh 75 7 7 7/
(a=6 Height mm / 75/ ."/ 1"/
(a=6 Width mm 51/ 55// 5",/ 55,(a=6 Length mm 17"// 1..,/ 1.!7/ 1.155 2
i m
e n s
W e i g h t
P e r * o r m a n
2 r i $ e S
Hitachi
+ n g
i n e
< o d
S3eci*ication &om3arisonS3eci*ication &om3arison
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o pe r a t i n g %
o u r s
DC System
Contactor Tip eplacement 2,500 %rs
Traction /otor 7rus% eplacement 2,500 %rsCommutator Turn > ?n&ercut ,500 %rs
W%eel /otor #)er%auls 25,000 %rs
AC System
,500 %rs @ C%oppers )s Contactor
6A @ AC n&uction /otor6A @ AC n&uction /otor30,000 %rs
A& $ 2& Scheduled (aintenanceA& $ 2& Scheduled (aintenance
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+lectric 2ri$e (anu*acturers+lectric 2ri$e (anu*acturers
Limited
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Net Sales : 8,191,572 M \ (68,150 M US$)
Employees : 339,572
Hitachi GlobalHitachi Global
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48
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Human 4nter*ace
.///h3
&ho33er 17//kW .
T(
8ear ;
Wheel
8ear ;
Wheel
4n$erter !//k#A
T(Recti*ier 17,/kW
./kW
./kW4n$erter
!//k#A
/k#A9au=6:
2iesel+ngine
1"//k#A9main:
8 8
( &on$erter&ontroller
8ridResistance
."kW=,
A& 2ri$eSystem
2ri$e (otor
9A& (otor:
&ontrol &a-inet
8rid
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1. High Efficiency Water Cooling
2. Pressurized Enclosed Structure
to prevent from dust
3. e! ".#$% &'()
$nsulated 0ate 2ipolar Transistor
1 - ) m m 1 / )
m m
-,))3 4 /))A Class
A& 2ri$e System &ontrol &a-inetA& 2ri$e System &ontrol &a-inet
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5!eel Motor Cooling an
Control Ca"inet
6converters7
Alternator Cooling an
0rid 2o%
5!eel Motor
CA2
Alternator) 2ri$e (otor &ooling SystemAlternator) 2ri$e (otor &ooling System
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• 4 parallel circuit gri& o
• etar&ing per'ormance is capale o' operating +it% onl* 3resistor a'ter 1 resistor 'ailure
• $ig% e-cienc* cooling 'an minimums t%e re
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AC Motor Driving
→ 8o Commutator on fan motor
→ Audi"le noise reduction
→ (apid fan start9up in response to t!e retard pedal
→ :ost9cooling operation for t!e resistors
0rid(esistor M
1));3A
6main7
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Function 2escri3tion
(otor &ontrolBRetarder &ontrol
#ector &ontrol Current control of induction motor
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0
2000
4000
6000
8000
10000
12000
14000
16000
1800020000
0 5 10 15 20 25 30 35 40 45 50Vehicle Speed (km/h)
M o t o ! o " # e
( $ ・ m )
600k% 650k% &00k% 'ct#l !o"#e ( 0 5&*6+)'ct#l !o"#e ( &1*4 12,*4+)
ct#l !o"#e ( 12,*4 142*4+) Set !o"#e
600k%
650k%
&00k%
Set !o"#e
$ncreased tor?ue due to output control
6Unused au%iliar# output7
A& 2ri$e Out3ut &ontrol Per*ormance &ur$esA& 2ri$e Out3ut &ontrol Per*ormance &ur$es
A& 2& Ri ll 2 tA& 2& Ri ll 2 t
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/
1/
./
7/
,/
"/
/
5/
!/
/
/ 1/ ./ 7/ ,/ "/ /S3eed 9kmBh:
9 =
1 )
/ / /
k g :
/
1/
./
7/
,/
"/
/
/ 1/ ./ 7/ ,/ "/ /S3eed 9kmBh:
9 =
1 ) /
/ /
k g
:
(im :ull Tor?ue 'lectric (etarding Tor?ue
AC@ Maintaining t!e "ra;e tor?ue
at lo= ve!icle speed
'*))AC
'*))DC
'*))AC
'*))DC
AC@ $ncrease of rim pull
A& $ 2& ' Rim3ull 2ataA& $ 2& ' Rim3ull 2ata
A& 2 i Ri ll &h tA& 2 i Ri ll &h t
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A& 2ri$e ' Rim3ull &hartA& 2ri$e ' Rim3ull &hart
A& 2 i Ri ll 9R t d &h t:A& 2 i Ri ll 9R t d &h t:
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A& 2ri$e ' Rim3ull 9Retard &hart:A& 2ri$e ' Rim3ull 9Retard &hart:
FF 2 i &h2 i &h
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FrameFrame 2esign &hanges2esign &hanges
4ntegrated
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(AM' ST('SS A8AS$S
Trailing Arms ;Trailing Arms ; SS3indles3indles
FrameFrame
Frame Stress AnalysisFrame Stress Analysis
+H7"//A& < d 2 i+H7"//A&
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+H7"//A&
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Reduced Gear oil heating
Reduction in Spline Wear
Eliminate center-shaft seal leakage
Eew Wheel (otor Reduction 8ear Eew Wheel (otor Reduction 8ear
#ehicle +lectronic &ontrol System#ehicle +lectronic &ontrol System
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-
ngine Speed Setting
Alternator Control
Motor Speed Control
Vehicle Speed
Moto!empet#e
M
Failure process
Auto Cruise Control
.
'lteto
Auto Retarding Control
#ehicle &onditionBFailure 2is3lay
ngine Speed Control
Hydraulic System Control
ie Moto
Drive Limit Signal
Hydraulic
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AC Drive S#stem Monitor Screen
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ailure (eport Screen
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4nde3endent Trailing Arm4nde3endent Trailing Arm
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IncreaseIncrease in tyre andin tyre andcomponent lifecomponent life
EasierEasier MaintenanceMaintenance
SuperiorSuperior speedspeed
in turnin turn
First-rateFirst-rate rideride
FewerFewer lubricationlubrication
pointspoints ExcellentExcellent stabilitystability
OperatorOperator comfortcomfort
Coupled withCoupled with NEOCONNEOCON ride strutsride struts
4nde3endent Trailing Arm4nde3endent Trailing Arm
E+O&OE STRUTSE+O&OE STRUTS
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ACCU9T(AC independent trailing arm
front suspension =it! 8'ECE8 ride struts
set t!e industr# standard in off9!ig!=a#
suspension
NEOCONNEOCON ride strutsabsorb more energy than
rubber or nitrogen oil!
E+O&OE STRUTSE+O&OE STRUTS
+H7"//A& Front Sus3ension+H7"//A& Front Sus3ension
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+H7"//A& Front Sus3ension+H7"//A& Front Sus3ension
True Ackerman SteeringTrue Ackerman Steering
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True Ac;erman steering decreases
tire =ear less steering error.ess error t!roug!out t!e entire
turning range.
$ntersection of front tire inner and
outer steer angle =it! center line
of rear a%le.
True Ackerman SteeringTrue Ackerman Steering
+H7"//A& Hoist &ontrol+H7"//A& Hoist &ontrol
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+H7"//A& Hoist &ontrol+H7"//A& Hoist &ontrol
Hydraulic System 4m3ro$ementsHydraulic System 4m3ro$ements
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+ngine
Hoist &ircuit
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+ngine
Hoist &ircuit
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DUM: 2ED
Hydraulic TankHydraulic Tank
+H7"//A& Load Weigh System+H7"//A& Load Weigh System
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+H7"//A& Load Weigh System+H7"//A& Load Weigh System
Automatic &ruise ; Retard &ontrolAutomatic &ruise ; Retard &ontrol
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Automatic Retarding &ontrolKeep vehicle downhill speedconstant & lower than set speed
Automatic &ruising &ontrolKeep vehicle speed constant in set speed
Automatic &ruise ; Retard &ontrolAutomatic &ruise ; Retard &ontrol
Anti'Sli3 &ontrolAnti'Sli3 &ontrol
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Slip and slide
(educe tor?ue of =!ic! rotates faster.8ote@ =!en slip or slide "ot! tire, ve!icle speed detection mig!t not correct
2ump
Anti Sli3 &ontrolAnti Sli3 &ontrol
Anti'Roll -ack Anti'Roll -ack 6uture Eption76uture Eption7
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(elease service "ra;e:ress service "ra;e :ress accelerator
S!ift lever or=ardB
F 1m
Anti Roll -ack 6uture Eption76 p 7
&ummins S@"/ Tier . +ngine&ummins S@"/ Tier . +ngine
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• Bull* compliant to A Tier 2/#$
emission le)els• Suppl*ing t%e in&ustr* +it%8
cleaner, greener >
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Same O3tionsD
• an Drives
• Alternators
• l#=!eels
• Eil :ans
• Au%. Drives
• ilters
• :relu"
• Centinel
• 'liminator
• 't!er inGection
8o c!ange in air
inlet connections
8o c!ange in
mounting
locations
8o c!ange in
Gac;et =ater
inlet outlet
connections
8o c!ange in
e%!aust outlet
connections
Retains the same installation en$elo3e as the @TA"/B@.///+
5/0 3arts num-er commonality
3irtuall# identical
dimensions
g g
S@"/ Tier . &om3lianceS@"/ Tier . &om3liance
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./// .//1 .//. .//7 .//, .//" .// .//5 .//! .// ./1/ ./11 ./1.
7/. ' /. HP Tier 1 Tier . Tier 7
/7 ' 5"1 HP Tier 1 Tier . Tier 7
I 5"1 HP Tier 1 Tier .
Tier ,
Tier ,
Tier ,
US +PA (o-ile
O** Highway
'mission levels 8E% /. 8E% H C
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))
G7"// Unit J.) User Test at &allideG7"// Unit J.) User Test at &allide
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))
G7"// Unit J.) User Test at &allideG7"// Unit J.) User Test at &allide
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)
G7"// Unit J.) User Test at &allideG7"// Unit J.) User Test at &allide
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2e$elo3ment test 3rogress H&AS+
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Final dri$e *ailed7 times
• Per*ormances tests ha$e -een com3leted success*ully in Fe-B.//56
• O3erational test 3rogress had -een slower than 3laned schedule due to
7 *inal dri$e *ailures and some other small 3ro-lems6
• O3erational test ha$e -een com3leted middle o* (arB.//!6
Per*ormance and relia-ility test 9H&(: H&AS+
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Per*ormance tests
I
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!e+t tem +pec me+#ed
#dmet
M7im#m +peed (km/h) $M% 56*0 3 5&*3 p++
'cceletio 0 9: 100m (+ec) $M% 1&*8 3 18*2 p++
.M% 1,*1 3 21*4 p++
;p hill +peed ,m (m) $M% 21*4 5 18*5 p++.M% 35*1 4 32*5 p++
ote+ ? $M%@143325k .M%@325000
2ri$ing 3er*ormance
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Eew Load Weigh System accuracy
Standard loading times
A$e /60
(in '/60
(a= 16,0
Une$en loading
Front side /670
Rear side 1650
Right side /6"0
Le*t side '1610
S3eci*ication MB' 76/0
Load Weigh System accuracy test
with H&( truck scale 911thBEo$.//:
H&AS+ O3eratorNs comments *or 3er*ormance
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Eperator comments !ave "een ver# positive e%cept visi"ilit# and noise in
t!e ca". T!ese items !ave "een improved during 1)))!r service.
/A35 'B Cpe(to D#e+t io00(ie
1
2
3
4
5
'ccele(tio0 Eeeli06
=et(d Eeeli06
Feeli06 #phill
(ccele(tio0
!(eli06 Eoce #phill
!(eli06 Eeeli06 (0d
+t(GilitH
Fi0e co0tol (ccele(tio0
(0d et(d
0+t#me0t p(0el i0+ide
c(G
$eI mo0ito di+pl(H
$oi+e i0 the B(G
Cpe(to i+iGilitH
1* ;0(ccept(Gle 2* CC= 3*F'= 4* .CC 5* /JB/KK/$!
H&AS+ Impo!eme"t (1) "o#se #" te %a&
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,odification
Add t!e sound attenuation
material under t!e operator ca".6Done Sep))+ at 1)))!r service7
%mprovement
-.*d2 in t!e Ca" 6I-.*d2 99 I)d27
Test result
H&AS+ Impo!eme"t (2) opeato '#s#l#ty
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.ro/lem
T!e ladder and t!e platform in front of t!e ca" "loc; visi"ilit#.
,odification
(edesign t!e ladder and t!e platform and replace.
6Done Sep))+ at 1)))!r service7
Eriginal $mproved
peat#o"al test (e&*2007 +Ma*2008 ) H&AS+
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A$aila-ility during o3erational test has -een a**ected -y 7 *inal dri$e
*ailures and small other 3ro-lems6
(ore than "0 o* down time are caused -y *inal dri$e oil leak6
H&AS+ Impo!eme"t (3) #"al #!e &ea#"- .a#l/e
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+timted c#+e oE mi Gei +#Ece Elki oE Eil die
i
de clmp
im
Foce Eom tHe 81L (Iith E#ll lod 1*5.)
Foce Eom de clmp @&1,L
ede lod
moto(i+ide)
Gek(o#t+ide)
Foce Eom tHe 81L (Iith E#ll lod 1*5.)
ede lod
deEomi
Cause of failure
N*eforming of housing +y the force from dagger clamp ma,es sever edgeload
on the rollers of +earing and damage.
Housing
(odi*ication• Rein*orce wheel housing to 3re$ent de*orming6• (odi*ied *inal dri$es were already arri$ed to Australia6
H&AS+ Impo!eme"t (3) #"al #!e .a#l/e (%o"t)
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-adial
displacement
riginal &mproved
3#/
Effect of modification !as confirmed +y
0E analysis and stress measurement !ith
actual final drive.
0E analysis !as done +y HC and other
Hitachi group engineering company.
7mple oE
F'
lH+i+
e+#lt
H&AS+ Impo!eme"t () Se!#%e ae #l 4ea
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Cause : #ring o' rake caliper +as &amage&
Action : C%ange t%e material o' #ring
$ar&ness 8 #riginal 0$s /o&iDe& .1$s
Wit%stan& pressure 8 #riginal 43/pa /o&iDe& 113/pa
ConDrmation test ;n&urance test=
105E F 21/a F 200,000c*cles Pass
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&AE
9@e'&AE:
&AE
9SA+'K17:
ard=ire
2S& Drive s#stem Controller
2# itac!i td
+&( 'ngine Controller Unit
2# Cummins
'ngine (ev.
speed
'rror information
6Multi pac;et data7'rror information
6Multi pac;et data7
Can not receive
man# data at once
&&U'42U
&ommunication
+rror
occurring =!ile receiving
additional data
42U $nformation displa# Unit
2is3lay 4n*ormation
9Payload6 +tc:
(ulti Packet dataBsec
2LU Data logger Unit
Eum-er
o* data
increased
at 1///hr Eum-er o*data
increased
at 1///hr
&ommunication error occurred a*ter 1///hr modi*ication -ecause num-er o*
data *rom &&U and 2LU to 42U increased -y changing so*t ware6
42U so*tware was u3graded to -e a-le to recei$e data and 3ro-lem was *i=ed6
&&U Main Controller Unit
H&AS+ Impo!eme"t (6) eel Moto #- temp
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Cause 8 /ain lo+er motor stops &uring truck stops ;30sec=
Action 8 C%ange t%e control program 'or main lo+er 'an so t%at t%e 'an
keeps rotating &uring loa&ing an& &umping ;10min=
A'ter mo&iDcation actual +orking &ata s%o+s ma motor temp isaroun& 110 &eg6C ;$ig% temp limit 150&eg6C=
3 &a*s &ata a'ter impro)ement
(a= (otor tem3
a33ro= 11/ deg
Air inlet tem3
a33ro= ,/ deg
H&AS+ Impo!eme"t (7) #"al #!e %ool#"- al#ty
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Original
Oil coolers *or *inal dri$es were changed to increase cooling a-ility
• SiCe o* cooler D . times a33ro=
• (aterial o* cooler D Steel Aluminum• &ooling a-ility D (ore than 1/ increased℃
4m3ro$ed
H&AS+ Impo!eme"t (8) #"al #!e %ool#"- l#"e pess/e lo
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Cause : Small metal particles stuck on c%eck )al)e 'or *pass line
Action : A&&e& oil Dlter in s*stem an& t%en ne)er %appen again
check valve
Oil flter
H&AS+ e.oma"%e %ompa#so" (e.ee"%e ata)
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:erformance stud# =as done during actual operation =it! e%actl# same !aul
road as competitorKs truc; 6same class7 .
According to t!e data of 1) c#cles, t!e fuel consumption =as +L "etter and
t!e time from loading area to dumping area =as - L s!orter t!ancompetitorKs truc;.
Actual haul road
Test and im3ro$ement Summary H&AS+
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:erformance test and operational test =as successfull# completed.
T!e results of performance tests all meets CMKs specifications.
EperatorKs comments for performance is ver# good.MaGor pro"lem t!at occurred during operational test =as final drive "earing
failures and alread# completed improvement.
Some ot!er pro"lems =ere found out during operational test and most of
t!em are "eing improved during modification period 6Mar 9 April))I7.
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