Otr Mining & Earth Mover Wheels
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Transcript of Otr Mining & Earth Mover Wheels
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MINING AND MINING AND EARTHMOVER EARTHMOVER
WHEELSWHEELS
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PRODUCTS & SERVICESPRODUCTS & SERVICESI UNDERGROUND & SURFACE MINING
WHEELS FROM 10” TO 63”
II REPAIRS OF UNDERGROUND & SURFACE MINING WHEELS FROM 15” TO 63”
IIIINSPECTION & CERTIFICATION PROGRAMS FOR UNDERGROUND & OPEN PIT MINING WHEELS FROM 15”TO 63”
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SECTION I SECTION I UNDERGROUND & SURFACE UNDERGROUND & SURFACE
MINING WHEELSMINING WHEELSOTR WHEEL OFFERS A WIDE VARIETY OF MINING WHEELS FROM 15” TO 63” IN STANDARD AND HEAVY DUTY DESIGNS FOR ANY MINING APPLICATION
WE ALSO OFFER CUSTOM DESIGNED WHEELS FOR SPECIFIC CUSTOMER REQUIREMENTS
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PRODUCT LINEPRODUCT LINE
HEAVY DUTY UNDERGROUND MINING WHEELS
GFM HEAVY DUTY LARGE DIAMETER MINING WHEELS
GFM QUICK CHANGE HAUL TRUCK RIMS AND WHEELS
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HEAVY DUTY UNDERGROUND HEAVY DUTY UNDERGROUND MINING WHEELSMINING WHEELS
OTR’s Heavy Duty Underground Mining (UGM) Wheels Are Manufactured From Seamless Forged & Fully Machined Sections To Ensure Maximum Performance And Fatigue Life.
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HEAVY DUTY UNDERGROUND HEAVY DUTY UNDERGROUND MINING WHEELSMINING WHEELS
••Available In 10Available In 10””,15,15””, 20, 20”” And 24And 24”” DiametersDiameters
••Standard Lock Ring Or Tapered Lock Ring Designs AvailableStandard Lock Ring Or Tapered Lock Ring Designs Available
••Wheels Can Be Customized To Fit Any ApplicationWheels Can Be Customized To Fit Any Application
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GFM HEAVY DUTY LARGE GFM HEAVY DUTY LARGE DIAMETER MINING WHEELSDIAMETER MINING WHEELS
Our GFM Large Diameter Surface Mining Wheels Are Available In Up To 63” Diameter And Are Manufactured From Fully Machined Forged HSLA Steel To Ensure Maximum Fatigue Life And Are Backed By Our 20,000 Standard Warranty.
GFM Wheels Are Available In The Following Designs
••GFMEGFME - 100% COMPATIBLE WITH TITAN, RIMEX MES, AND TOPY EU
••GFMTGFMT - 100% COMPATIBLE WITH RIMEX TSR DESIGN
••GFMWGFMW - 100% COMPATIBLE WITH TOPY 63” WTR (Wedge Type) DESIGN
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GFME STANDARD DESIGNGFME STANDARD DESIGN
FORGED AND FULLY MACHINED SECTIONS MADE FORM HSLA STEEL100% COMPATIBLE WITH STANDARD DESIGNS IN THE MARKET TODAY FROM OTHER MANUFACTURERS100% UT TESTING ON CIRCUMFERENCIAL WELDSSTANDARD 20,000 HOUR WARRANTY
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GFME QUICK CHANGE GFME QUICK CHANGE DESIGNDESIGN
FORGED AND FULLY MACHINED SECTIONS MADE FORM HSLA STEELDESIGNED TO BE 100% COMPATIBLE WITH STANDARD DESIGNS IN THE MARKET TODAY FROM OTHER MANUFACTURERS100% UT TESTING ON CIRCUMFERENCIAL WELDSSTANDARD 20,000 HOUR WARRANTY
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GFME QUICK CHANGE GFME QUICK CHANGE DESIGNDESIGN
BENEFITS OF OUR GFME QUICK CHANGE DESIGN
REDUCE TIRE CHANGE AND ROTATION TIMES BY UP TO 60%ELIMINATES THE NEED TO DEMOUNT THE OUTSIDE DUAL WHEEL TO CHANGE INSIDE TIREDECREASES DOWNTIME AND INCREASES PRODUCTIVITY FOR HAUL TRUCKSELIMINATES THE NEED TO USE ADAPTER RINGS ON OUTSIDE DUAL WHEELSFULLY COMPATIBLE WITH STANDARD WHEEL COMPONENTS
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GFME QUICK CHANGE DESIGNGFME QUICK CHANGE DESIGN
80 minutes165 minutesTOTAL TIME
0152ND RETORQUE
0151ST RETORQUE
55REMOVE JACKS
010TORQUE NUTS
1010INFLATE OUTSIDE TIRE
010TIGHTEN NUTS WITH IMPACT GUN
010INSTALL NUTS ONTO BOLTS
55INSTALL OUTSIDE WHEEL & TIRE ON HUB
010DEMOUNT & MOUNT OUTSIDE TIRE ON WHEEL
1010INFLATE INSIDE TIRE
55INSTALL INSIDE TIRE
55CLEAN & INSPECT HUBS
55REMOVE INSIDE TIRE
55REMOVE OUTSIDE TIRE & WHEEL
015REMOVE NUTS - OUTER WHEEL
2020DEFLATE INSIDE & OUTSIDE TIRES
1010JACKING
Avg. Minutes using OTR GFM Quick Change wheels
Avg. Minutes using standard 5 piece wheelsTask
The data below is based on changing tires (rotating) off of positions 3 & 4 on a Cat 793C dump truck in Northern Chile. The table below shows a comparison between a standard horizontal tire
change process versus a vertical tire change process using OTR QUICK CHANGE WHEELS.
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GFME QUICK CHANGE DESIGNGFME QUICK CHANGE DESIGNSavings in Minutes when using GFM Quick
Change Wheels vs Standard Wheels
52%Time Savings Percentage
85 MINUTES
Time Savings In Minutes
80 MINUTES
Total Time Using OTR GFM Quick Change Wheels
165 MINUTES
Total Time Using Standard Wheels
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GFMT TAPER DESIGNGFMT TAPER DESIGN
GFMT STYLE WHEEL COMPATIBLE WITH RIMEX TSRSAFETY LIP INCORPORATED IN BACK SECTION AND BEAD SEAT BAND.ALSO AVAILABLE IN QUICK CHANGE DESIGN100% UT TESTING ON CIRCUMFERENCIAL WELDSSTANDARD 20,000 HOUR WARRANTY
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GFMW TAPER DESIGNGFMW TAPER DESIGN
GFMW 63” WHEELS FEATURE A TAPER LOCK DESIGN TO ELIMINATE INDEXING OF THE WHEEL COMPONENTSALL GFMW WHEELS ARE 100% COMPATIBLE WITH THE TOPY WTR (WEDGE TYPE) DESIGN.100% UT TESTING ON CIRCUMFERENCIAL WELDSSTANDARD 20,000 HOUR WARRANTY
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KOMATSU 930E 63KOMATSU 930E 63”” WHEELSWHEELS
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OUR 63OUR 63”” 930E2, 930E3 & 930E4 WHEELS 930E2, 930E3 & 930E4 WHEELS CURRENTLY RUNNING AT;CURRENTLY RUNNING AT;
Codelco Chuquicamata – ChileCodelco Radomiro Tomic – ChileBHP Escondida – ChileMinera Los Bronces – ChileMinera Pelambre - ChileSouthern Peru Copper Cuajone Mine – PeruSouthern Peru Copper Toquepala Mine – PeruMinera Collahuasi – ChileFreeport Mine – IndonesiaMinera Gaby - Chile
KOMATSU 930E 63KOMATSU 930E 63”” WHEELSWHEELS
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SECTION IISECTION II
RIM AND WHEEL REPAIRS
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RIM AND WHEEL REPAIRSRIM AND WHEEL REPAIRS
Why Repair Rims and Wheels?
Mining Wheels are subject to harsh conditions and many times fail long before reaching the usage life due in most cases to poor work conditions and/or maintenance. Mining wheels that have failed before reaching there usage life in one area or section of the rim/wheel and are in good condition in the other areas are usually good candidates for repair. By repairing the damaged section of the Rim/Wheel, the user can save an average of 50% of the cost of a new Rim/Wheel By repairing, the overall cost per hour will also be reduced vsbuying a new Rim/WheelIn short, we can assist our customers in reducing overall rim/wheel costs by as much as 50% as our company has done throughout the world for over 20 years In Canada, Chile, Peru, Brazil and South Africa.
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RIM AND WHEEL REPAIRSRIM AND WHEEL REPAIRS
Repair Process For Rims And Wheels At OTR Wheel Engineering Inc.
1. On-Site Visual Inspection To Determine Eligibility Of Rim/Wheel Or Parts For Repair.
2. In House Non Destructive Testing (NDT) Of Rim/Wheel Or Part To Ensure Wheel Can Be Repaired.
3. Inspection And Evaluation Report Based On Internal Inspection Criteria Sent To The Customer For Approval. Report Includes Recommendations To Repair Or Scrap Part.
4. Customer Rejects Repair Or Accepts By Sending Purchase Order Or Work Order.
5. Rim/Wheel Is Repaired According To Our Internal Repair Procedure And Internal Repair Manual
6. Repaired Rim/Wheel Goes To Quality Control To Ensure All Specs Are Within Tolerance Of Original Specs.
7. Final QC & NDT Report Are Generated
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INSPECTION REPORTINSPECTION REPORT
RIM AND WHEEL REPAIRSRIM AND WHEEL REPAIRS
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INTERNAL INSPECTION CRITERIA FOR RIMS INTERNAL INSPECTION CRITERIA FOR RIMS AND WHEELSAND WHEELS
RIM AND WHEEL REPAIRSRIM AND WHEEL REPAIRS
RIMS AND WHEELS ARE INSPECTED
USING OUR INTERNAL INSPECTION CRITERIA
WHICH WE HAVE DEVELOPED IN
CONJUCTION WITH END USERS AND
OVER 20 YEARS OF EXPERIENCE IN
REPAIRING RIMS AND WHEELS.
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RIM AND WHEEL INSPECTION MANUALRIM AND WHEEL INSPECTION MANUAL
RIM AND WHEEL REPAIRSRIM AND WHEEL REPAIRS
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NDT CERTIFICATE NDT CERTIFICATE
RIM AND WHEEL REPAIRSRIM AND WHEEL REPAIRS
ALL CRITICAL AREAS ARE
INSPECTED USING NON DESTRUCTIVE
MAGNETIC PARTICLE TESTING
BY A CERTIFIED TECHNICIAN IN OUR
QUALITY DEPARTMENT
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INTERNAL REPAIR PROCEDUREINTERNAL REPAIR PROCEDURE
RIM AND WHEEL REPAIRSRIM AND WHEEL REPAIRS
REPAIRS OR RIMS AND WHEELS ARE PERFORMED
ACCORDING TO OUR INTERNAL DOCUMENTED REPAIR PROCEDURE TO
ENSURE CONSISTENCY IN OUR PROCESSES.
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FINAL QUALITY CONTROL REPORTFINAL QUALITY CONTROL REPORT
RIM AND WHEEL REPAIRSRIM AND WHEEL REPAIRS
ALL REPAIRED RIMS AND WHEELS ARE INSPECTED BEFORE AND AFTER THE REPAIR PROCESS. OUR
FINAL QUALITY CONTROL REPORT ENSURES
COMPLETE TRACEABILITY AND THAT ALL CRITICAL
SPECS ARE WITHIN TOLERANCE FOR EVERY
RIM OR WHEEL REPAIRED BY OTR WHEEL
ENGINEERING INC.
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FULLY MACHINED FORGED SECTIONS USED FULLY MACHINED FORGED SECTIONS USED FOR REPAIRSFOR REPAIRS
RIM AND WHEEL REPAIRSRIM AND WHEEL REPAIRS
OTR WHEEL USES FULLY MACHINED FORGED
SECTIONS MADE FROM HSLA STEEL FOR RIM
SECTION REPLACEMENT (REPAIRS). THESE
SECTIONS AND PROCESSES USED IN
REPAIRING WHEELS ARE IDENTICAL TO THAT OF
NEW WHEEL MANUFACTURING
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RIM AND WHEEL REPAIRSRIM AND WHEEL REPAIRS
SUBMERGED ARC WELDINGSUBMERGED ARC WELDINGALL SECTIONS REPLACED ON RIMS AND WHEELS ARE WELDED USING
SUBMERGED ARC WELDING PROCEDURE AS USED IN THE
MANUFCTURING PROCESS FOR NEW RIMS AND WHEELS
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WHEEL SAFETY, MAINTENANCE AND
INSPECTION
SECTION IIISECTION III
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HISTORYHISTORY
Heavy equipment over the years have been scrapped or sold as surplus.Many useable parts or spares, such as wheel assemblies remained in the inventory.Rim failures began to be noticed in 1990’s.Rims from the late 1960’s and 1970’s were still in the inventory.
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PLAN TO REDUCE RIM FAILURESPLAN TO REDUCE RIM FAILURES
Remove all rims manufactured prior to 1985, immediately.Visually inspect all rims, before returning to service.Identify all rims by manufacturer (design).Number and track all rims.Begin NDE testing and maintenance program.
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WHY TRACK AND MAINTAIN RIMS?WHY TRACK AND MAINTAIN RIMS?
A 26.5 x 25 tire at 90 psi has 373,650 ft/lbs of stored energy. Which is
Equal to moving a 200 Lb man 1868 feet in one direction.
There is no such thing as a SMALLACCIDENT when it comes to Rim Failure!
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WHEEL I.D. LOCATIONWHEEL I.D. LOCATION
Rim Brand
Valve Hole
Cross Section of Rim
Rim Brand
Valve Hole
Rim Brand
Front View of Rim
•All rims are branded directly in line with the valve hole. On rims that have the centre plate in the mid section of the wheel the front brand # is stamped onto the inner part of the gutter section. In the case that a rim has a centre plate flush to the top the brand is directly stamped on the face of the plate.
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•Inspect wheel and wheel components for any defects •Any rims without brand #’s automatically are sent out for a complete inspection (if requested by customer)•No tire is to be mounted on a wheel that has not been branded (if requested by customer)•All wheels with brand #’s must be verified in the Rim Tracking System ( Contact OTR Wheel) to see if an annual inspection is required (if requested by customer)
RESPONSIBILITIES RESPONSIBILITIES –– TIRE SHOPTIRE SHOP
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Preliminary Inspection– Visual inspection of rim assemblies should
be done every time it comes in to your shop– All rim bases which have been dismounted
prior to their annual Nondestructive Evaluation (NDE) inspection shall be visually inspected for defects
FIELD / TIRE SHOP INSPECTIONFIELD / TIRE SHOP INSPECTION
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POINTS TO CONSIDERPOINTS TO CONSIDER
Hardware is considered as consumable product.Hardware is defined as:Bead Seat BandsRim FlangesLock Rings. Hardware, which is suspected of having defects or distortion, shall be discarded. All hardware shall be inspected by Field and Tire Shop Personnel prior to its' reuse.
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VISUAL RIM INSPECTION CRITERIAVISUAL RIM INSPECTION CRITERIAGutter sectionBack section Puller nutsStud holesBolting plate weldRim base weldsGeneral conditionRim Components (lockring, flange and beadseat)Run flat Check last NDE
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Lock RingsLock Rings
Sprung / Stretched Good
Lock Ring - The lock ring shall be visually inspected for wear, “sprung”, corrosion, flat spots, ovality and warping misalignment (sprung).
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GUTTER INSPECTIONGUTTER INSPECTION
Go-No Go gauge
Lock ring groove
Lock ring grooves are inspected using a Go- No go gauge for wear & damage
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WORN LOCKRING GROOVEWORN LOCKRING GROOVE
Non-consistent lock ring groove
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BACK SECTION / BEAD SEAT BACK SECTION / BEAD SEAT INSPECTIONINSPECTION
Go – No Go gauges
Bead Seat Band - The bead seat band shall be visually inspected for cracks, wear or corrosion in the area in contact with the locking ring flange, rim base or any weld. A wire brush may be used to clean the dirt prior to the use of the Go No go gauge.
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WORN BACK SECTIONWORN BACK SECTION
Worn out flange mating surface
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Washed out lock ring groovesStress fatigue fracturesCaused by:– Friction welding
(Fretting, Galling)– Aggregate– Corrosion
Great reasons for doing a safety inspection of the rim
Non PressureZone –Extreme Danger
Pressure Zone
LOCK RING GROOVE PROBLEMSLOCK RING GROOVE PROBLEMS
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RIM COMPONENTSRIM COMPONENTSProper Improper
OTR can provide charts to match rim components to ensure the proper hardware is put on to the right rim base.
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HARDWAREHARDWARE
Worn Side ring Good Side Ring
When conducting a visual inspection, do not only look for cracks and damage But also inspect the hardware to make sure you will achieve optimal tire performance.
Worn Side ringGood Side RingWorn Side ring
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BOLT HOLESBOLT HOLES
Elongated or worn bolt holes can lead to improper torque, which in turn can lead to the wheel coming off of the machine. This can be repaired by re-facing or re-placing the center plate.
Elongated
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DAMAGED GUTTER SECTIONDAMAGED GUTTER SECTION
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RUN FLATRUN FLAT
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•Visually inspect all wheels and wheel components•Track rims with database•Issue a report for each individual wheel•MPI test wheels when needed (annually or whendamaged)•Repair or replace any wheel or wheel component when needed
RESPONSIBILITIES RESPONSIBILITIES –– OTR WHEELOTR WHEEL
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2525””X15 WHEEL FAILUREX15 WHEEL FAILURE
When this wheel failed it killed 1 mechanic and seriously injuredthe second. The crack on this wheel was in the lock ring grooveabove the pressure zone.
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TIRE SIZE 17.50X25TIRE SIZE 17.50X25
This tire was aired with the lock ring not seated properly andwhen the lock ring let go there was enough force in this tire that it pulled the axle out of the housing.
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TIRE SIZE 10.00X15TIRE SIZE 10.00X15
Tire flew 50 ft from the machine when the wheel failed
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RIM TRACKINGRIM TRACKING
All wheels inspected are stamped (branded), recorded and tracked in our database.
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The Rim Tracking software allows us to track the number of wheelassemblies held by each customer, where they are located, (ie, at the site, out for repair etc) and what repairs have been done to date.
RIM TRACKINGRIM TRACKING
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Each wheel is assigned a specific number. This way we can track the repairs done on each wheel along with the cost of the repairs, and issue a detailed report to our customers when requested.
RIM TRACKINGRIM TRACKING
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CRITERIA FOR MPI TESTINGCRITERIA FOR MPI TESTING
Test all rims within one year of service to determine warranty claims and annually thereafter.Test any rim prior to major repairs (centre plate change, reface).Visual damage (run flat, rim impact).
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SHOT BLASTINGSHOT BLASTING
The next stage of inspection requires the wheel to be sent out to be shot blasted to remove all rust, scale & paint.
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MPI (MAGNETIC PARTICLE) MPI (MAGNETIC PARTICLE) INSPECTIONINSPECTION
After the wheel is shot blasted & passes visual & gauge inspection it is MPI tested for fatigue cracks that are not clearly visible.
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REFINISHING REFINISHING -- PAINT LINEPAINT LINE
Once the wheel has passed inspection it is repainted to OEM or Customer preferred colors.
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Thank youThank you
From your partners in safety and Service
OTR Wheel Engineering, Inc.