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Design and Prototyping a Mechanical Wheel for Mine Trucks

Mohammadi, Abolfazl | 2024

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  1. Type of Document: M.Sc. Thesis
  2. Language: Farsi
  3. Document No: 57808 (08)
  4. University: Sharif University of Technology
  5. Department: Mechanical Engineering
  6. Advisor(s): Durali, Mohammad; Saadat Foomani, Mahmood
  7. Abstract:
  8. Due to the excessive failures of tires used on mining trucks, which lead to significant economic and environmental damages, mine operators are seeking replacements for them. The ASW mechanical wheel, introduced by the American company Global Air Cylinder Wheel, is recognized as the most well-known alternative to pneumatic tires for mining trucks. Although this company has been active since 2004, it has not yet released a commercial product. This study examines the structural, behavioral, and operational characteristics of the mechanical wheel and its impact on the performance of mining trucks. The structure of the mechanical wheel consists of a set of hydro-pneumatic actuators that connect a metal rim to a rigid outer metal ring. The research also provides a detailed investigation into the simulation, construction, and performance testing of these hydro-pneumatic actuators, which are the key components of the mechanical wheel. According to the data obtained from finite element analysis, the outer ring is considered to be rigid with a thickness of 50 mm. To create an optimal contact surface between the wheel and the road, polyurethane coatings with a thickness of 150 mm are used. To prevent contact between the ring and the outer ring, the damping and stiffness of the actuators used in the mechanical wheel of the mining trucks are set at 40 kN.s/m and 1 MN/m, respectively. Based on the scaling performed according to a quarter-scale model of the vehicle, the damping and stiffness of the actuator sample should be 144,596 N/m and 4,724 N.s/m, respectively. Calculations indicate that an actuator with a piston diameter of 100 mm, a rod diameter of 80 mm, and an initial gas pressure of 4.9 bar can provide these values. Therefore, an actuator with the specified characteristics was designed and constructed, and its performance was evaluated using the SAF 250 axial fatigue testing machine at a frequency of 1 Hz with an amplitude of 8.2 mm. According to the test results, the fabricated actuator meets the required damping and stiffness for use in the mechanical wheel; thus, the construction of the mechanical wheel is technically and engineering-wise feasible. However, its high weight (approximately 4.5 tons) and the high production cost have hindered the commercialization of this product
  9. Keywords:
  10. Tire ; Mechanical Wheel ; Mine Truck ; Hydropneumatic Actuator ; Design and Prototyping

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