Novamine KIMBO Dump Body Exchange System
The KIMBO Dump Body Exchange System from Novamine
Novamine develop engineering solutions to optimize maintenance aspects in large, opencast mining operations. 13 years of development have lead to the KIMBO Dump Body Exchange system for large haul trucks and off-highway trucks.
The current situation
Around the world, haul truck dump bodies are normally exchanged by means of one or two cranes. this brings with it a number of problems:
- Availability of cranes
- Availability of riggers
- Long turn around times – averaging around 33 hours
- High labour requirements – averaging 9 workers
- Work has to be interrupted during adverse climatic conditions – elevated wind speeds.
- Large suspended loads present a safety hazard
The KIMBO Solution
The KIMBO Dump Body Exchange System switched the approach from suspended load to supported load. The system consists of 6 independently adjustable, hydraulic lifting columns. These are positioned to form two work zones dedicated to the rapid dismounting and mounting of the dump body. The sequence is as follows:
REMOVE THE DUMP BODY FROM LOWBOY TRUCK – WORK ZONE 1
Lowboy truck is placed in the center of the working area of the KIMBO Dump Body Exchange System. Then the columns move forward to the dump body and the column arms move close to the dump body till a no-pressure contact is attained.
PLACE THE DUMP BODY ON MOBILE SUPPORTS
Once the four columns are in place, the dump body is lifted so that the lowboy truck can travel or move out. Then the dump body is lowered and positioned on the four mechanical adjustable-height stands.
POSITION MINE TRUCK WITH OLD DUMP BODY – WORK ZONE 2
The truck with the worn out or old dump body is centered in the KIMBO Exchange System working area. Reference marks on the ground work as guides in this process. Then, the center columns are rotated 180° to mine truck position.
POSITION KIMBO COLUMNS TO LIFT OLD DUMP BODY
The four columns move horizontally towards the dump body till a no-pressure contact is attained, and the arms are positioned on the dump body by means of vertical movements.
LIFT DUMP BODY TO DISMOUNTING FROM MINE TRUCK
The dump body is lifted until the pins can be removed and once the dump body load is supported by the columns, the mine truck moves out of the working area.
PLACE OLD DUMP BODY ON MOBILE SUPPORTS
Then the dump body is lowered and positioned on the four mechanical adjustable-height stands via the wireless remote control. Later, the central columns are rotated to lift the repaired/new dump body that will be mounted on the truck.
MOUNT NEW DUMP BODY ON MINE TRUCK – WORK ZONE 1
Then, the reverse process is started with the dump body mounting on mine truck. The dump body is lifted using the four columns to allow removal of the mobile mechanical stands. Later, the mine truck is positioned in the center of the KIMBO Dump Body Exchange System and under the dump body, and then the operator lowers the dump body for mounting on the mine truck. Once the new or repaired dump body is mounted on the truck, it is ready to return to production.
DUMP BODY MOUNTING ON LOWBOY TRUCK – WORK ZONE 2
Finally, the central columns are rotated 180o towards the worn out dump body and at the same time the lowboy truck is positioned in the KIMBO working area to mount the dump body and take it to the repair shop.
?ADVANTAGES OF THE KIMBO DUMP BODY EXCHANGE SYSTEM
|Description||Conventional Dump Body Exchange||KIMBO Dump Body Exchange System|
|Health & Safety||Higher risk of accidents||Helps drastically mitigate risk|
|Methodology||Suspended load approach||Supported load approach|
|Number of operators||Up to 9 operators||3 Operators – Increased productivity|
|Replacement time||33 hrs.||1.5 – 3 hrs. Decreases workers’ exposure under Supported load. Increased equipment availability|
|Body & Truck maintenance||Maintenance process is not simultaneous||Simultaneous maintenance is possible|
|Weather conditions||Work is interrupted with wind gusts over 35 km/hr.||Work is not interrupted. Work is continuous|
|Dump body lifting||Two cranes||No cranes required|
|Lowboy waiting costs||Lowboy & associated equipment hire||Additional costs (parking) eliminated|