F-Series Training 795F AC Participants Copy 810
F-Series Training 795F AC Participants Copy 810
F-Series Training 795F AC Participants Copy 810
2
Safety
• 795F AC Walkaround
– Hardhat
– Safety Boots
– Safety Glasses
• Keep Hydrated
930E-4SE
Unit Rig
SF31904 SF32601
Short Tons 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250 260 270 280 290 300 310 3200 330 340 350 360 370 380 390 400 410 420
Metric Tons 100 109 1188 127 136 145 154 163 172 181 191 200 209 218 2277 236 245 254 263 272 281 290 299 308 318 327 336 345 354 363 372 381
3
Overview of Coverage
C175-16 Engine
Power Inverter – Mitsubishi Electric Collaboration
Power inverter:
Collaboration with Mitsubishi Electric
Specification 795F AC
Engine C175 –16
Power (HP) 3400
•Enhanced Visibility
Attachments
•WAVS (Camera)
•CIODS (Camera +
Radar)
Operator Controls
Secondary Egress
• Powered Stair
Attachment
• Flat & Open Deck 600 mm Wide
Access to Cab
Eliminated
Step Down to
Catwalk
Access / Egress
• Service platforms
• Propel & Starter
lockout
• Fewer service
areas Engine Service Platform
C175-16 Engine
Cooling air
duct
Blower &
Hydraulic
Motor
Driveshaft
Generator
Wheel motors
Braking; Retarding; and Control – #1 Differentiator
•2 – Retarder Lever
•3 – Retarding Speed
Control Toggle
•4 - Automatic Retarder
Control (ARC) – On/Off
Switch
Retarder Lever Operation
0% 100%
Retarder Lever
Electric Retarding
(rear wheels)
Service Brakes
(front wheels)
Service Brakes
(rear wheels)
Note: actual front/rear split varies
793 MD based on payload weight
Service Brakes
(front wheels)
Service Brakes
(rear wheels)
Retarder Lever Operation
0% 100%
Retarder Lever
Electric Retarding
(rear wheels)
Service Brakes
(front wheels)
Service Brakes
(rear wheels)
Note: actual front/rear split varies
793 MD based on payload weight
Service Brakes
(front wheels)
Service Brakes
(rear wheels)
ARC Operation
0% 100%
ARC Demand
Electric Retarding
(rear wheels)
Service Brakes
(front wheels)
Service Brakes
(rear wheels)
Note: actual front/rear split varies
793 MD based on payload weight
Service Brakes
(front wheels)
Service Brakes
(rear wheels)
ARC Operation
0% 100%
ARC Demand
Electric Retarding
(rear wheels)
Service Brakes
(front wheels)
Service Brakes
(rear wheels)
Note: actual front/rear split varies
793 MD based on payload weight
Service Brakes
(front wheels)
Service Brakes
(rear wheels)
Traction Control System
(TCS)
Operation
793F 795F AC
• Operates in propel only • Operates in propel and electric
retard
• Uses the rear brakes to limit • Limits wheel slips and slides
speed differences between by reducing electrical torque to
rear wheels each motor independently
Brake
Brake
Speed sensors
Right wheel
speed
Left wheel
speed
time
795F AC Traction Control
Rectifiers
Power converter
Engine Alt. Speed sensors
Power converter
M
Right wheel
speed
Left wheel
speed
time
Performance: Caterpillar C175 Engine
New Engine Family
• 5.3 liters displacement per cylinder:
C-175 x 16 / 85L
• High Pressure Fuel System
• Cross Flow Design
• ACERT Technology
• Tier II EPA Emissions Compliant using
ACERT Technology with ATAAC
Benefits
• Power Increase
• Lower Owning & Operating Costs
• Improved Fuel Consumption
• Improved Serviceability
• Increased Service Life
C175 3500B
Performance Study at KUCC
Speed Trap 4
2855 ft 8.3%
Speed Trap 3
866 ft 8.32%
Wheeler Trailer
Truck Shop
Speed Trap 2
743 ft 8.22%
Speed Trap 1
719 ft 9.78%
S97
Actual Study Cycle - Profile
6800
BC07
6700
6600
6500
6400
Approx.8.3%
Distance
6300
6200
6100 Approx.8.3%
6000
5900
Approx.10.0%
5800
5700 S97
0 2000 4000 6000 8000 10000 12000 14000
Elevation
Scale Truck and Tray Scan
Speed on Grade Results
793D 795F AC
tons/cycle 254 342
tons/hr 321 440
Performance: 795F AC Operator Comments
• Quiet
– No ear protection
required
• Smooth
• Braking and
Retarding are
Great
– Effortless
– Can sit back in
the seat while
retarding
Operator Comments
Safety Performance
• Ground Level Access: Fluid Levels • 345 ton Payload
and Filters • 7.0–7.5 mph @12% effective grade
• Platforms: for Working at Heights • Blended Four-Corner Retarding
• Visibility: HID, WAVES, CIODS • Traction Control
• Access/Egress: 600mm stairs, PAS • GVW within Tire Specs
• Blended Four Corner Retarding • Quiet Cab (76dBa)
• Traction Control • Mine Specific Design Bodies
Serviceability Reliability
• Modular Power Train: Lower R&I • Rear mounted Generator
• Ground Level; Platforms • Continuous Rear Axle Filtration
• Ground Level (Bumper) Service • Fewer external hoses
Center, LOTO, Batteries • Component Diagnostics On-Board
• 1000 hour filter life • Operator Advisor / Test Features
• Turbos: good access • Frame – casting and mild steel
• Drain Plugs; SOS Ports
795F AC Virtual Walk Around
Caterpillar AC Electric Drive
Electric Drive Fundamentals
C175-16 Engine
Cooling air
duct
Blower &
Hydraulic
Motor
Driveshaft
Generator
Wheel motors
AC System Basics – Engine & Generator
• Engine / Generator
– Engine powers the generator
– Generated AC voltage is converted then
used to power wheel motors
– Excitation regulator and Inverter draw
power out of the generator
– Engine speed becomes independent of
power generated
• Available power still based on rpm
– 2-3 Megawatts can be generated
• 30-40 Trucks = Small Town
AC System Basics – DC Recitifer
3-phase AC voltage from the generator is routed to the Inverter cabinet where
it is converted to DC for use by the Inverters
Converted DC
from rectifier
AC System Basics – AC Inverter
Variable AC
from Inverter
AC System Basics – Wheel Motors
The AC voltage from the inverter is sent to the wheel motor where it’s amplitude and
frequency results in torque and speed on the motor’s driveshaft. The amount of
torque and speed is based on operator inputs
• Inner workings:
– Stator: Frame & Windings
– Rotor: Rotating component
• On AC trucks, the voltage and
frequency determine the speed and
torque of the wheel motors
AC System Basics – Retarding Grids
Electric trucks use their wheel motors for dynamic retarding, using
electric current to slow the rear wheels
• Retard Mode
– The voltage and frequency sent to the
wheel motors result in them behaving like
generators
– Generated voltage from the wheel motors
goes back into the inverter cabinet on onto
the DC Bus
– The excess voltage is then routed to
retarding grid
– Voltage is absorbed by the resistor grids
then dissipated as heat
• Similar to a big toaster
– A large cooling fan is needed to force the
heat out
’08-’09
AC Drive Train Development Drivetrain
Simulator
(HIL)
Hardware in
797 Mule Loop Prototype/Pilot
Truck Trucks
Caterpillar Technical Center
• Tucson Proving
• C175 Engine
Grounds -
• NPI intent Generator
Engineering
and Motors
2005 • Product Support &
• CAT Proprietary
Marketing
electric drive controls
• Purpose – To test • Field Development
• 797 modified w/ Electric ECM and software • Pilot truck in
• Component Validation
Drive linked to computer operation at
• Software testing and
• 3524 Engine generated component Kennecott Utah
validation
• Primary Use – Software “models” Copper.
• Continues to be utilized
• Propulsion • Production intent
into production
• Retarding Software/Controls
• Traction Control • Machine and System
• Anti-Rollback Level set ups
• Troubleshooting
AC Drivetrain Simulator
Rubber
Couplings
Motor
Inertia
Dyno Weights Alternator
C175-16 Engine
Machine
Control
Software
795F AC Performance Differentiation
Working at Heights Engine Bay, Tie Off points, Center torque tube etc.
Operator Sound 76 dba vs. 81dba
Operator Visibility WAVS, HID lighting
Hydraulic Filter Life 1000 hours vs. 500 hours
Major Component R&I Generator, WM, and FD component R&I...industry best
SERVICEABILITY
Ground Level Maintenance Filters, SOS ports, sight glasses, pressure ports
AST (HVOF) Hoist cylinders and struts
Ecology drains Filters, pans, etc.
System integration Supportability with bumper to bumper
Complexity System complexity - Hydraulics
VIMS Advisor A single source for diagnostics, all critical functions
Payload 345sT, w/ liners, 100% fuel/lubes, 4% debris, field options
Propulsion SOG (12%) 7.0-7.5 mph (11.3-12.1 kph)
Retarding SOG (-10%) 6,400hp in retarding; 19.28 mph (31.03 kph)
PERFORMANCE
Codelco – Andina
• High Altitude – 4,000 m (13,125 ft)
• Temp = -15 to 30 C
• Copper; Flat to Uphill
ERM153/154 CMS Stats
60 = World
Class
Performance
795F Availability Drivers
Engine
Mine
4.5 (20%)
6.7 (30%)
PM LPT
• Pilot long lead major components first requested 4th Qtr 2007
• Pilot parts stocking turned in Dec 2008
• All AC drive major components in Morton
• All other major components in Morton
– Engine in Schilli
• Major components / long lead items submitted Jan 15, 2010
– Included Boliden & Chile
• Revised parts stocking list completed Jan 28, 2010
– Included Boliden & Chile
• Current Activity
– Electric components updates
– Critical engine component strategy
– Weekly status report on major components
Parts Stocking – Status
• 82% of the major components and critical parts in stock (51 pn’s)
– Of these not in stock (9 pn’s), 67% can be service from factory (6 pn’s)
– Weekly reports on stocking levels and deliverables
– 1 HA Engine Ar is due December 2010
• ITTP complete
– Used on ERM153
– Revised for ERM154
– OMM – Completed
– Assembly SI final revision
– Commissioning final revision
– Power Train Electrical SO/TA/TS – Completed
– VIMS & Payload SO/TA/TS – Completed
– Schematics: Hydraulic and 24V Electrical Complete
– Frame Inspection SI