Thesis Análisis de fallas y defectos críticos en tolva de camión minero Komatsu
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Date
2020-09
Authors
Journal Title
Journal ISSN
Volume Title
Program
DEPARTAMENTO DE INGENIERÍA MECÁNICA. INGENIERÍA CIVIL MECÁNICA
Campus
Campus San Joaquín, Santiago
Abstract
El camión tolva es un camión rígido fuera de carretera diseñado específicamente para el uso en minería de alta producción y entornos de construcción de servicio pesado. La tolva, corresponde al cuerpo superior, y cumple la función de contener el material extraído en la minería para su transporte, por lo que debe ser capaz de resistir tanto impactos en el proceso de llenado, como también resistir las fuerzas dinámicas y de desgaste debido al transporte y descarga de material. Existen diversos problemas que se generan en la operación de tolvas en camiones mineros Komatsu, entre algunos, está el hecho de que las tolvas fallan de forma prematura, lo que afecta directamente la productividad de la mina y el desempeño de la tolva que se requiere para una correcta operación en las faenas mineras. El objetivo de este trabajo es realizar un análisis de fallas y defectos críticos de la tolva de camión minero Komatsu modelo 930E, para posteriormente efectuar propuestas de mejoras al diseño y a los procesos de fabricación de la tolva. El primer paso consiste en la elaboración de un catálogo de fallas y defectos de la tolva. Para esto, se identifican y se registran los defectos presentes en la tolva que se generan en el proceso de producción. Una vez identificados y registrados cada uno de los defectos que se presentan en la tolva durante su proceso de producción, se efectúa la identificación de las causas de falla de la tolva mediante determinación analítica, para lo cual se emplea la metodología de árbol de falla. De esta manera, se distinguen las causas que provocan la falla funcional: Error en diseño, Manejo inadecuado del producto y No calidad del producto. Estas causas que provocan la falla funcional, son ramificadas hasta identificar los eventos básicos que las generan.
The haul truck is a rigid off-road truck designed specifically for use in high production mining and heavy-duty construction environments. The hopper, corresponds to the upper body and it fulfills the function of containing the material extracted in mining for transport, so it must be able to withstand both impacts in the filling process, as well as withstand the dynamic and wear forces due to the transport and unloading of the material. There are several problems that multiply in the operation of hoppers in Komatsu mining trucks, among others, it is that hoppers fail prematurely, which directly affects the productivity of the mine and the performance of the hopper that is required for a correct operation in mining operations. The objective of this work is to perform a failure and critical defect analysis of the Komatsu model 930E mining truck hopper, for subsequent consequences of improvements to the design and manufacturing processes of the hopper. The first step consists of preparing a catalog of faults and defects of the hopper. For this, the defects present in the hopper that occur in the production process are identified and recorded. Once each one of the defects that occur in the hopper during its production process has been identified and registered, the causes of failure of the hopper are identified through analytical analysis, for which the fault tree methodology is used. In this way, it distinguishes the causes that cause the operational failure: Errors of design, Inadequate handling of the product and non-quality of products. These causes that may bring about functional failure are branched until the basic events that generates it are identified.After the identification of the hopper failure causes, the defects and the causes that provokes the non-quality of the parts that make up the hopper are identified individually and as a final assembly. These defects are detected in each of the stages of the production process. The determination and identification of the defects and their causes is carried out by analytical determination, in which the fault tree analysis methodology is applied. In this way, they distinguish the defects and their causes that provokes non-quality in the parts that make up the hopper: welding defects, material defects, preparation process defects and assembly defects, which are branched until identifying the basic events that those generated.
The haul truck is a rigid off-road truck designed specifically for use in high production mining and heavy-duty construction environments. The hopper, corresponds to the upper body and it fulfills the function of containing the material extracted in mining for transport, so it must be able to withstand both impacts in the filling process, as well as withstand the dynamic and wear forces due to the transport and unloading of the material. There are several problems that multiply in the operation of hoppers in Komatsu mining trucks, among others, it is that hoppers fail prematurely, which directly affects the productivity of the mine and the performance of the hopper that is required for a correct operation in mining operations. The objective of this work is to perform a failure and critical defect analysis of the Komatsu model 930E mining truck hopper, for subsequent consequences of improvements to the design and manufacturing processes of the hopper. The first step consists of preparing a catalog of faults and defects of the hopper. For this, the defects present in the hopper that occur in the production process are identified and recorded. Once each one of the defects that occur in the hopper during its production process has been identified and registered, the causes of failure of the hopper are identified through analytical analysis, for which the fault tree methodology is used. In this way, it distinguishes the causes that cause the operational failure: Errors of design, Inadequate handling of the product and non-quality of products. These causes that may bring about functional failure are branched until the basic events that generates it are identified.After the identification of the hopper failure causes, the defects and the causes that provokes the non-quality of the parts that make up the hopper are identified individually and as a final assembly. These defects are detected in each of the stages of the production process. The determination and identification of the defects and their causes is carried out by analytical determination, in which the fault tree analysis methodology is applied. In this way, they distinguish the defects and their causes that provokes non-quality in the parts that make up the hopper: welding defects, material defects, preparation process defects and assembly defects, which are branched until identifying the basic events that those generated.
Description
Keywords
CAMIONES, MAQUINARIA MINERA, MAQUINARIA TRANSPORTADORA
