As I described in the title bumper as a heart of an open cast mines because it is mainly responsible for production capacity and achievable output of that mines. Let's get details of bumper.
What is a dumper?
It is a tyre mounted vehicle with a body mounted on chassis and an operator cabin. The body can be
lifted or opened hydraulically for unloading of the material inside the body. This is a common term used for a wide variety of configuration of trucks used for transporting material. The payload capacity ranges from 10 ton trucks used mainly for
construction purposes and small private mines to 400 ton trucks which are mainly off road vehicles and are used exclusively in mines for carrying of overburden or ore. The smaller versions can be used both on road and off road; whereas the higher
versions are exclusively used for off road transportation only.
What is payload?
It is the capacity of the equipment for which the customer is paying i.e. we say a truck has payload capacity of 10 ton. This means when I purchase this truck I expect it to carry 10 ton of material and I am ready to pay for this 10 ton truck.
What is on road & off road?
On road means when a vehicle is running on public road and is bound to follow the common traffic rules with other vehicles plying on the road. Off
road means a vehicle is running on a non public road, i.e. private road. This private road may be inside a mine or in a construction site. Moreover
the road width may be non standard type and may be designed exclusively to suit the vehicles plying
on it. Also the traffic rules may be different in off roads in a particular mine.
How does a dumper functions?
This is basically a truck which is meant for carrying material over a distance. The capacity changes with
application and requirement. A dumper is wheel mounted equipment, with an operator cabin and a body which carries the material. In primitive models the body had to be lifted manually but nowadays all dumpers have hydraulic body lifting
mechanism. All dumpers have an engine as a prime mover. Then there will be transmission system, differential and final drive. There will also be a hydraulic system for body lifting function and steering function.
What is the power flow system in a dumper?
The prime mover is an engine. Then there will be a clutch or torque converter from which power flows
to gear box or transmission. The output of transmission goes to differential through a propeller shaft. Then there will be hub or final
drive on which tyres will be mounted.
What are the basic systems in a dumper?
A dumper has the following systems -
1. Power transmission system – consisting of Engine, torque converter, transmission, propel
shaft, differential and final drive.
2. Hydraulic system – consisting of Hydraulic pumps, control valves, Hydraulic cylinders (for body lifting and steering), Hydraulic tank and
Steering orbitrol.
3. Pneumatic system – consisting of air compressor, air tank, auto drain valve, unloader valve, brake treadle valve (for brake actuation) and accelerator pedal (in case of pneumatic cylinder for engine acceleration).
4. Electrical system – consisting of battery, circuit breakers or fuses, solenoid coils, resistance, relays, sensors, meters/ gauges,
starter, alternator, ammeter, switches, bulbs, head light, turning indicators, wiper, fan,
horn, reverse horn, brake light.
5. Brake system – consisting of
What is the function of engine?
It is the prime mover i.e. engine is the source of mechanical energy required to move the dumper.
The engine burns fuel to convert it to mechanical energy. Since dumper is moving equipment no motor can be used as a prime mover.
What is torque converter?
Torque converter is basically a fluid coupling between engine and transmission. This is used in case of vehicles equipped with automatic transmissions. The main function is to allow engine and transmission to run at different speeds and at the same time transfer power. It serves the
function of a clutch in case of vehicles with manual transmission or gear box.
What is clutch?
It is a mechanical device in between engine and gear box. The main function is smooth transmission
of power from engine to gear box. In a vehicle engine is constantly rotating but wheels are not rotating continuously. Also the speed of the wheels changes according to the gear selected. The clutch serves the purpose of connecting a rotating device to a non-rotating or partially rotating device. Thus there will be smooth power transfer without any
jerk.
What is gear box?
It is a unit which allows the operator to select different speed of the vehicle according to road and load conditions. This speed selection is
necessary because an engine gives maximum output in terms of horsepower and torque in a limited
range of rpm. Thus selection of gear in gear box allows the operator to get maximum output from the engine at minimum fuel consumption. This gear
changing is achieved by locking and unlocking different sets of gears.
What is transmission?
By the word transmission we loosely mean automatic transmission. Technically speaking a gear
box is a manual transmission. In automatic transmission also the basic functions of gear box is carried out, i.e. changing of output speed with
respect to fixed input speed. In automatic transmission there are planetary gears which serve the purpose of speed reduction. Unlike manual transmission there is no locking and unlocking of gears, instead here all gears are in mesh, but there are clutches to engage and disengage a particular gear combination.
What is differential?
It is basically a gear box, specially designed to transfer power from transmission to wheels while the wheels are rotating at different speeds. Whenever a vehicle is moving straight both side wheels are rotating at same rpm, whereas in a turning the inner wheel takes a shorter path than
the outer wheel. A differential helps in achieving these different speeds of the wheels while also transferring power at the same time. A differential always transfers same torque to both the wheels. The single output of transmission is distributed to both side wheels at equal ratio or different ratio as per requirement.
What is final drive?
Final drive is again a set of gears meant for reducing the speed and increasing the torque on wheels. This serves as the last in the chain of speed reduction form engine to the wheels. The wheels are directly mounted on the outer housing of this
gear box. This transmits the power form differential to the wheels. This unit may not be available in smaller versions of dumpers. After differential there will be an axle and wheel.
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