Post on 28-Dec-2015
TYRE LIFE MANAGEMENT SYSTEM
GROUP – I
ALLU NARENDRANATHANSHUL MISHRAASHISH KUMAR PATLEASTHA TIWARINEELANJAY SAHAPALLAVI DANGERITWIK PANDEY
INTRODUCTION
1. Technical terms associated
2. Tyre repair methods
3. Operators role
4. Data analysis
5. Tyre management software
TERMS ASSOCIATED WITH TYRES
1.Tyre Type
2.Tyre width
3.Wheel Diameter
4.Load Index
5.Speed Rating
6.Side Wall
7.Bead
8.Carcass play
9.Crown Plies
10.Tread
TYPES OF TYRES
Tyres are classified into two types. They are
1.Tube Tyres2.Tubeless Tyres
Based on the principle of construction tyres are classified into 1.Radial Tyres2.Bias Tyres
In NMDC Tubeless Tyres are used in Heavy Earth Machinery like Dumpers, Loaders, Wheel Dozers.
THE RADIAL TYRES
The casing made of single ply of steel cords.
The crown isconsolidated by a beltmade up of several piles.
TYRE REPAIR METHODS
There are three methods used during the tyre repair.
These are
1. Plug method
2. Filler method
3. Patch method
Bridgestone India Limited is against the recommendation of patch method.
Still the method is preferred in the project when compared to the other two methods.
EFFECTIVE TYRE USE
In order to permit the effective utilization of tyres, selection should be done properly according to the operating conditions and the type of vehicle on which they are intended for use and then mounted, used and maintained properly.
FACTOR PERSON RESPONSIBLE
1.Correct inflation pressure Tyre mechanic
2.Specified load Operator
3.Prescribed vehicle speed Operator
4. Full Haul road maintenance
Hall road operator staff.
TYRE INFLATION PRESSURE
Tyre serviceability depends upon the inflation pressure and maintaining the inflation pressure depends upon the tyre staff and tyre incharge. According to the operating conditions tyre inflation pressure is recommended by the tyre manufacturer .
Ex:85 Ton Dumper (27×R49) tyre1. Cold inflation pressure - 100 Psi2. Hot inflation pressure - 110 Psi
Cut, Burst
Measure the cut depth
Inspect the Air pressure
Serviceable
Rock pierce in the rubber
Remove the object.
Repair if necessary.
Inspect the Air pressure.
Serviceable
Swelling Tyre
Not repairable and the Tyre has to be scrapped.
Non-Serviceable
Rubber Chunks Out
Improve Road conditions
Rotate or Reverse Tyres
Avoid rough driving
Serviceable
Minor or severe cracks
Continue to use
Ensure adequate pressure
Inspect
Serviceable
Tyre burst from shock or cutting.
Scrap TyreUn Serviceable
SPECIFIC SPEED
The speed of the vehicle depends upon the operator. For the economical use of the tyres the tyre speed should be kept within the permissible limits so that the tyre life can be extended.Phenomenon Resulting damage
1.Higher heat generation inside tyre.
Heat damage.
2.Increased abrupt braking. Chipping and bead damage.
3. Obstacles in the road Cutting, cut burst and bead damage
4. Sharp cornering Irregular wear, quick abrasion and bead damage.
WHEEL ALIGNMENT
Proper alignment is necessary for perfect wheel control , uniform tyre wear and safety. When vibrations and vehicle pulling to one side or the tyre is wearing unevenly the vehicle alignment is to be checked. Steering, suspension components, wheel assembly is to be checked instead of charging only the suspension cylinder when the above cases occur. Tyre rotation pattern should be as per the manufactures considerations otherwise uneven wear happens on the tyres.
CORRECT LOADING
Avoid unbalanced loads.
Protect tyres from falling stones during loading.
When loading with a shovel, keep the prescribed rate of loading and considering the weight distribution aspect also.
REPAIRING AND RETREADING
1. Only cut and cracked tyres are repairable.2. Tyres for possible retreading must have
more tread left than that on the normally worn out tyres for protecting the casing.
3. An overhead casing is a poor prospect for retreading.
4. Tyres damaged by heat and bursting as well as damaged on the bead can neither be repaired nor can be retreaded.
TYRE ABRASION
The degree of tyre abrasion is measured by comparing the groove depth of the used tyre to the new tyre. The difference will indicate the rate of wearing.
Mean tread depth is to be calculated. Depth guage is used for this purpose. Depth guage positioning differs in lug pattern and traction pattern.
SHOVEL OPERATOR ROLE IN TYRE MAINTAINANCE
1. Avoid bucket spillage
2. Centering the load in the dumper
3. Avoid overloading
DUMPER OPERATOR ROLE IN TYRE MAINTAINANCE
1. Slow down on sharp turns.2. Avoid backing of rocks at shovel and dump
areas.3. Analysis of cut tyres indicate the tyres are
damaged during 9:00 PM to 5:00 AM mainly due to the poor visibility and inadequate lightning.
4. Keep the wind shields, rearview mirrors and headlights clean for good visibility.
5. Running on improperly inflated tyres should be avoided.
DOZER OPERATOR ROLE IN TYRE MAINTAINANCE
1. Spillage from the end of blades in road dump areas to be avoided.
2. Avoid exposure of rocks while crating the haul roads which can damage the tyres.
3. Wheel dozer operators can perform very valuable service in reducing tyre cuts by avoiding wheel spins as it cut treads.
MOTOR GRADER OPERATOR ROLE IN TYRE MAINTAINANCE
1. Good grading to remove all the rocks from the haulage roads.
2. Never leave high windrows which contain rocks if dumpers must cross them.
3. Haulage road must be without dips because dips in haul roads with 30 KMPH speed of haulage dumpers can increase the dynamic load by 1.5 to 3 times the tyre load rating.
WATER SPRINKLER OPERATOR ROLE IN TYRE MAINTAINANCE
1. Avoid over watering, because it exposes rocks in the haulage road creating tyre cutting conditions. Wet rubber cuts up to 50% easier than the dry.
2. Avoid slick surfaces because the dumper operators can lose vehicle control from skids, wheel spin and ineffective braking.
AVERAGE NEW TYRE LIFE (IN HOURS) TYRE SIZE 21.00R35 (Water Sprinkler)
TYRE SIZE 27.00R49 (Dumper)
TYRE SIZE 18.00 R25 (Motor Grader)
MAKE 2008-09
2009-10 2010-11 2011-12
MRF 3000 3195 2700 NA
BRIDGESTONE 3815 4005 NA NA
GOODYEAR 2800 NA NA NA
MAKE 2008-09
2009-10 2010-11 2011-12
MICHELIN 5270 6034 5550 4776
BRIDGESTONE 6056 5467 5457 5890
GOODYEAR 6522 NA NA 5770
MAKE 2010-11 2011-12
JK TYRE 2112 2300
AVERAGE LIFE COMPARISION OF NEW AND RETREADED TYRES(2011-12)
SIZE 27.00×49 (Dumper)
SIZE 35/65-35 (Front End Loader)
MAKE AVG LIFE(NEW)
AVG LIFE(RETREADED)
MICHELIN 4776 5597
BRIDGESTONE 5890 4817
MAKE AVG LIFE(NEW) AVG LIFE(RETREADED)
BRIDGESTONE 4528 8919
ANALYSIS OF TYRE DAMAGE
Reason for removal 2008-09 2009-10 2010-11 2011-12
Side wall cut 17.02% 16.67% 65% 44.4%
Burst 31.91% 50% 35% 11.11%
Inner ply separation 29.79% 16.67% 0 37.03%
Outer ply cut 21.28% 16.67% 0 7.4%
BREAKDOWN DISTRIBUTION
2008-09
2009-10
2010-11
2011-12
0
10
20
30
40
50
60
70
Sidewall cutBurstInner ply sepera-tionOuter ply sepera-tion
Perc
en
tag
e d
istr
ibu
tion
TYRE LIFE MANAGEMENT SOFTWARE
Tyre life management software helps in managing tyre status and tyre performance reports.
Advantages:1. Tyre report can be made in the required
format like according to the make wise, size wise or tyre type (new or retreaded)
2. HMR updating option will be there for the Tyres of each particular dumper.
CONCLUSION
Implement the kaizen improvement techniques.
Maintaining proper inflation pressure. Operators role. Tyre life management software.