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    Zhao 2012

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    Zhao 2012

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    amir sadighi
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    zhao2012

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    Zhao 2012

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    of 5

    Applied Mechanics and Materials Vol.

    233 (2012) pp 328-331 Online: 2012-11-29


    © (2012) Trans Tech Publications, Switzerland
    doi:10.4028/www.scientific.net/AMM.233.328

    The Optimization Design of Brake System in Mine Dump Truck


    Jingyi Zhao1,a,Chunhui Zhang1,b, Rui Guo1,c, Decai Han1,2,d,
    and Yongchang Wang1,e
    1
    Hebei Province Key Laboratory of Heavy Machinery Fluid Power Transmission and Control,
    Yanshan University, Qinhuangdao 066004, China
    2
    Environmental Management College of China, Qinhuangdao 066004, China
    a
    [email protected], [email protected], [email protected]
    d
    [email protected], [email protected],

    Keywords: Mine Dump Truck;Brake Distance;Optimization;Field Test;Practical Significance

    Abstract. Based on the introduction of the mine dump truck brake system principle, the influencing
    factors of the brake performance are already analyzed.In order to further reduce the brake distance to
    meet the requirements of actual use,the improvement plan is presented for brake system optimization
    and the field test is made.The results show that it reduces the brake action time effectively and
    improves the brake performance. It has a great practical significance.

    Intorduction
    The off-highway mine dump truck is special equipment used to transport coal mine or sand in field
    site such as large open pit mines or water projects.The appearance and structure of the mine dump
    truck is shown in Fig.1.Because of the heavy weight,high speed and more curve and slope road in
    mining area, the flexible and reliable performance of turning or braking are requested especially the
    brake performance when the truck is driving in high speed [1] .

    Fig. 1 The appearance and structure of the Fig.2 The principle diagram of the
    mine dump truck brake system
    The brake performance of the mine dump truck is evaluated by three factors such as brake efficiency,
    [ 2]
    brake performance of constant qualitative and directional stability when braking .At present many
    scholars and researchers optimize the distribution of brake force to make wheels and the ground

    All rights reserved. No part of contents of this paper may be reproduced or transmitted in any form or by any means without the written permission of Trans
    Tech Publications, www.ttp.net. (ID: 149.171.67.164, University of New South Wales, Sydney, Australia-04/07/15,18:01:36)
    Applied Mechanics and Materials Vol. 233 329

    adhesive condition be full used so as to avoid the influence of the truck stability of the front and rear
    [3]
    wheels locking .This article is intended for the condition requirements of mine dump truck to
    design the full hydraulic brake system which can satisfy the distribution requirements of brake force
    and the optimization design is made from the point of view of improving the brake performance. It
    has been found that this method improves the brake performance to some extent which provides new
    ideas and methods for brake system design.

    The principle of brake system


    In order to meet the requirement of the security for mine dump truck.The brake way of the truck is
    divided into service brake,parking brake,emergency brake,lock brake,retarder brake.When the truck
    is travelling, service brake is often used,so in this paper it is focused on. The principle diagram of the
    brake system is shown in Fig.2.
    The truck powers and the engine starts, the pump1 starts up with the stand-by pressure.At this time
    the system pressure signal feeds back to the load sensing control port then the pump charges for the
    accumulator 6 with maximum displacement.When the pressure of accumulator 6 reaches the set
    valve of unloading valve 5,the valve is opened and the load singnal is unloading.Meanwhile the
    accum ulator 6 finishes it’s charging process.
    The driver operates the brake pedal valve 9 to brake the truck according to the road conditions and
    traveling speed ,then the accumulator provides pressure and flow rate for the brake as emergency
    power supply after braking several times.The system pressure reduce to eighty percent of the set
    value of the unloading valve,the valve will be closed then the pump continue to charge for the
    accumulator un til reaching the set value and so circulates.The set value of the unloading valve 5
    determines the maximum presure of system charging,and the set value of the pedal valve determines
    the distribution of brake force [ 4] .
    The optimization analysis of brake performance
    Brake performance refers to the ability of the truck speed reduces quickly until parking.The index of
    assessing the brake efficiency is brake distance and brake deceleration.In the process of truck brake,
    brake time is divided into four stages,such as the action time in response after the driver see the signal,
    continuous brake time and release brake time [5] .It is shown in Fig.3.
    a

    a b

    Fig.3 The analysis of brake process Fig.4 Redundant pressure manifold


    t 1 -the driver's response time t 2 - duration of brake( ta as the time to eliminate the clearance of the
    brake, tb as the time to establish the pressure) t 3 -last action time, t 4 -brake release time.
    Brake distance generally refers to start trample brake pedal to completely stop the truck.In the phase
    of taking effect of the brake, the distance estimates as follows:
    During the time of t2 ,the brake distance is:
    1
    s2 = v0 ta + v0 tb − amax tb 2 (1)
    6
    During the last action time,the brake distance is:
    v2 vt a t2
    s3 = 0 − 0 b + max b (2)
    2amax 2 8
    330 Fluid Dynamic and Mechanical & Electrical Control Engineering

    In Eq. 1 and Eq. 2, v0 as starting speed, amax as brake deceleration.


    so the total distance is :
    t v2 a t2
    s = s2 + s3 = (ta + b )v0 + 0 − max b (3)
    2 2amax 24
    amax tb 2
    Because the tb is very small, is omitted and convert speed into km/h, above equation can be
    24
    expressed as:
    1 t v0 2
    s= (ta + b )v0 + (4)
    3.6 2 25.92amax
    From Eq.4,it can be concluded that if the largest brake deceleration amax and initial brake speed v0 are
    confirmed,the shorter of the time ta or tb , the smaller of the brake distance s . So measures shoud be
    taken to reduce action time.

    The optimization and experimental verification of the brake system


    The optimization method of brake system. According to the literature 5, when meeting the
    distribution requirements of brake force,the minimum brake deceleration is as follows:
    v0
    amin = (5)
    0.5426v0 − 7.2ta − 3.6tb
    So it is very important for reduction of brake distance to improve the action time of the brake.It is
    obvious that the optimal objective is brake distance s and the optimization variables are ta and tb .
    According to the users’ specific requirements of the brake distance, optimization measures are
    taken,shown in Fig. 4.
    The parking brake switch is started to remove brake so as to make the truck be driving.At the same
    time,the pressure oil is imported in the P port and pass through the shuttle valve and get into the
    cylinder of wet disk brake from A port.This pressure which can improve response time of the brake
    deter mines the redundant pressure in the brake cylinder.When normal service brake, the present
    presure is introduced through B port and comparing with P port by the shuttle valve so as to get the
    higher pressure to act on the brake.But the set valve of check valve should be tested so as to not
    influence the truck to move.
    60
    after optimization
    50
    brake distance(m)

    before optimization
    40

    30

    20

    10

    0
    5 10 15 20 25 30 35 40 45 50
    initial brake speed(km/h)
    Fig.5 The response curve of rear brake pressure Fig.6 Brake distance curve in 3.5s pluse signal

    The experimental verification.In order to test the effect of the improved system and adopt
    corresponding measures for testing. The control oil of emergency brake is adopted to control the
    pedal valve.Through the setup program of the controller,control signal is produced to control the
    solenoid directional valve.The precise control of the pedal valve is realized.Because three brakes
    Applied Mechanics and Materials Vol. 233 331

    need to be done in the condition of emergency brake,three pulse signals can be set by controller and
    the duration of each pulse signal is set randomly as 3.5 seconds,4.2 seconds and 6 seconds.The rear
    brake pressure is shown in Fig.5 berfore and after optimization.
    50 after optimization 50 after optimization
    45 45
    before optimization before optimization
    brake distance(m)

    40

    brake distance(m)
    40
    35 35
    30 30
    25 25
    20 20
    15 15
    10 10
    5 5
    0 0
    5 10 15 20 25 30 35 40 45 50 5 10 15 20 25 30 35 40 45 50
    initial brake speed(km/h) initial brake speed(km/h)
    Fig.7 Brake distance curve in 4.2s pluse signal Fig.8 Brake distance curve in 6s pluse signal
    As can be seen from the diagram,there is excessive pressure of more or less 3 bar existing in the
    braking system.This makes the response speed of the brake improve and the action time can decrease
    0.5~1s.Return oil resistance increases when the brake releases the preasure,so the response speed
    would be decreased.But the release time will not influence brake distance.
    In order to further verify the effect after optimization,the brake distance under above set time is
    measured in good road condtion and least square method is used to fit three brake distance.The curve
    is shown in Fig.6- Fig.8.From these curves,it can be seen that if the brake time is long enough,the
    difference of the brake distance would be more and more obvious with the initial brake speed
    increasing to 50km per hour before and after the optimization.
    It is shown from the diagram above, the brake distance decreases comparing with other ways
    because the response speed is increasing and the action time of the brake is shorten after
    optimization.Besides,the process of brake finishes between 3.5s and 4.2s satisfying the performance
    and actual use requirements.

    Conclusion
    From the perspective of analysing brake performance, full hydraulic brake system is optimized by
    adding the redundant pressure manifold. The brake performance is stable through the field test.
    Because of the existing of redundant pressure, the brake response time decreases and the brake
    distance is shorten effectively.It meets the requirements of the actual working condition and it has
    practical application and reference value.

    References
    [1] WANG Jing, FENG Maolin, Multifunctional wet multiple disk brake used in the car, J. Coal
    Mine Machinery, (1999)53-54.
    [2] Yu z s. Auto theory, M.Beijing:China Machine Press,2000.
    [3] WANG Yaqing, ZHANG Daisheng, SHEN Guoqing, The optimization design and simulation
    calculation of braking force distribution of the automobi le , J.Journal of HeFei University of
    Technology, 28(2005) 1393-1396.
    [4] ZHANG Jin, The analysis of the brake core structure characteristics of full power hydraulic
    brake system, J. Mechanical Engineering & Automation, 12(2008) 9-12.
    [5] FAN Xiaobin,XIA Qunsheng, The test and simulation study of braking performance of mine
    dump truck, J.Coal Mine Machinery, 4(2009) 33-36.
    Fluid Dynamic and Mechanical & Electrical Control Engineering
    10.4028/www.scientific.net/AMM.233

    The Optimization Design of Brake System in Mine Dump Truck


    10.4028/www.scientific.net/AMM.233.328

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