Virtual Prototype Simulation of Truck Vibrations in High-Impact Shovel Loading Operations

The deployment of large machinery for low cost, bulk surface mine production operations has resulted in High-Impact Shovel Loading Operations (HISLO). In extreme cases, shovels load large dump trucks with 100ton (or more) passes generating high-impact forces under gravity. HISLO generates high-frequency shockwaves that cause severe truck vibrations exposing operators to Whole Body Vibrations (WBV). These extreme conditions may limit operators’ performance and further impact the overall system performance. Furthermore, the WBV levels in such cases may exceed the recommended International Standards Organization (ISO) limits resulting in long-term lower-back disorders and other health problems. There is a need for fundamental and applied research to determine HISLO vibration levels, their comparisons to ISO 2631[1-4]limits and the safety of operators under these conditions. This paper pioneers in studying and analyzing this vibration problem using virtual prototyping techniques. The truck virtual prototype allows sever scenarios to be investigated efficiently and cut solution and optimization time period without abusing the machine and compromising operator’s health and safety by physically conducting such scenarios. A3D virtual prototype truck model is built and simulated for HISLO in the MSC. ADAMS environment. The multi-degree of freedom (DOF) model is solved for displacement, velocity and acceleration of its various critical components. This 3D virtual prototype provides a solid foundation for truck vibrations and operator’s health in extremely sever conditions.