Mining Goes Digital – Mueller et al. (Eds)
© 2019 Taylor & Francis Group, London, ISBN 978-0-367-33604-2
506
Comprehensive, experimental verification of the effects of the
lock-up function implementation in LHD haul trucks in the deep
underground mine
Tomasz Kaniewski
OZG Lubin, KGHM Polska Miedz SA, Lubin, Poland
Paweł Śliwiński
KGHM Polska Miedz SA, Headquarters Lubin, Poland
Justyna Hebda-Sobkowicz & Radoslaw Zimroz
Faculty of GeoEngineering, Mining and Geology, Wroclaw University of Technology, Wroclaw, Poland
ABSTRACT: Large haul trucks cooperating with wheel loaders are used on a large scale for
horizontal hauling in underground mines of KGHM Polish Copper. Most of the population
of LHD trucks are machines with a capacity of up to 25 tons produced by KGHM ZANAM.
The latest products include the TB series of trucks: CB4-20TB, CB4-24TB. These are modern machines, equipped with a monitoring system that acquires many operational parameters
according to the KGHM data acquisition standard. They are developed in close cooperation
with users. Thanks to the data from the onboard monitoring system, machines have been
equipped with the Lock-up system, which is closely related to the operation of the gearbox.
The article describes the effects analysis of the use of the “lock-up” function in the CB4 20TB
machine, based on monitoring data analysis. The Lock-up function is automatically activated by
the digital transmission controller under certain conditions. For specified operating ranges, the
gearbox mechanically blocks the hydraulic torque converter. This action improves the efficiency
of the transmission, which translates into fuel consumption, exhaust emissions, reduction of
heat emission by the converter. It improves the efficiency of engine-based braking, reducing
the load on the friction-based braking system thus prolonging the lifespan of the brakes and
the safety of the users. In the paper, the technical and economic benefits and the improvement
of machine operation safety are analyzed. They are expressed by reducing the load on braking
systems, reducing the temperature of the oil in the gearbox and reducing the fuel consumption.
1 INTRODUCTION
Mining concerns and companies that produce machine systems for mining, especially underground, face many challenges. Extreme environmental conditions, deteriorating parameters of
exploited deposits, a radical increase in the demand for mineral resources related to the development of modern technologies and the globalization of raw material markets cause huge
interest of enterprises in improving the efficiency of processes in every possible element [1–9].
Improvements in efficiency could be achieved in many ways, in this paper we consider
technical solutions only. One of such innovations recently introduced to underground mines
is lock up system installed in mobile machines such as loaders or trucks. The concept of
lock up system is well known in the automotive industry, especially in heavy duty mobile
machines. The basic tasks of lock up are to block the torque converter in order to increase
efficiency of driveline (the transmission) and/or to enable effective engine-based braking. A
typical usage of lock up system is (for efficiency increase) vehicle moving at a constant speed
on straight sections of the road or (for engine braking) heavy vehicles moving on slopes,
© 2019 Taylor & Francis Group, London, ISBN 978-0-367-33604-2
506
Comprehensive, experimental verification of the effects of the
lock-up function implementation in LHD haul trucks in the deep
underground mine
Tomasz Kaniewski
OZG Lubin, KGHM Polska Miedz SA, Lubin, Poland
Paweł Śliwiński
KGHM Polska Miedz SA, Headquarters Lubin, Poland
Justyna Hebda-Sobkowicz & Radoslaw Zimroz
Faculty of GeoEngineering, Mining and Geology, Wroclaw University of Technology, Wroclaw, Poland
ABSTRACT: Large haul trucks cooperating with wheel loaders are used on a large scale for
horizontal hauling in underground mines of KGHM Polish Copper. Most of the population
of LHD trucks are machines with a capacity of up to 25 tons produced by KGHM ZANAM.
The latest products include the TB series of trucks: CB4-20TB, CB4-24TB. These are modern machines, equipped with a monitoring system that acquires many operational parameters
according to the KGHM data acquisition standard. They are developed in close cooperation
with users. Thanks to the data from the onboard monitoring system, machines have been
equipped with the Lock-up system, which is closely related to the operation of the gearbox.
The article describes the effects analysis of the use of the “lock-up” function in the CB4 20TB
machine, based on monitoring data analysis. The Lock-up function is automatically activated by
the digital transmission controller under certain conditions. For specified operating ranges, the
gearbox mechanically blocks the hydraulic torque converter. This action improves the efficiency
of the transmission, which translates into fuel consumption, exhaust emissions, reduction of
heat emission by the converter. It improves the efficiency of engine-based braking, reducing
the load on the friction-based braking system thus prolonging the lifespan of the brakes and
the safety of the users. In the paper, the technical and economic benefits and the improvement
of machine operation safety are analyzed. They are expressed by reducing the load on braking
systems, reducing the temperature of the oil in the gearbox and reducing the fuel consumption.
1 INTRODUCTION
Mining concerns and companies that produce machine systems for mining, especially underground, face many challenges. Extreme environmental conditions, deteriorating parameters of
exploited deposits, a radical increase in the demand for mineral resources related to the development of modern technologies and the globalization of raw material markets cause huge
interest of enterprises in improving the efficiency of processes in every possible element [1–9].
Improvements in efficiency could be achieved in many ways, in this paper we consider
technical solutions only. One of such innovations recently introduced to underground mines
is lock up system installed in mobile machines such as loaders or trucks. The concept of
lock up system is well known in the automotive industry, especially in heavy duty mobile
machines. The basic tasks of lock up are to block the torque converter in order to increase
efficiency of driveline (the transmission) and/or to enable effective engine-based braking. A
typical usage of lock up system is (for efficiency increase) vehicle moving at a constant speed
on straight sections of the road or (for engine braking) heavy vehicles moving on slopes,