Beruflich Dokumente
Kultur Dokumente
Fleets
2012 Dr. B. C. Paul
Note This presentation demonstrates fleet sizing using Caterpillars FPC program
and includes screen shots from the program. Credit is given to Caterpillar for the
program and interfaces. Caterpillar has produced helps and directions for using the
program which of course have common subject material with these slides. These
slides also draw on earlier work done by the author.
What Is FPC?
Hours Worked
Some Possibilities
Of course that will end the idea that three 8 hour shifts = 24 hours
If they are 8 hour shifts you might get 14 or 15 hours not 16 with
hot seat change outs
Day-Light hours
My Assumption
Cat FPC
More on FPC
What Is Bunching?
Operator Efficiency
Note!
Each fleet has a name you give it and a description you or your team use to keep
Straight what you are doing.
Availability Considerations
90 to 95%
Some people rent fleets and simply pay a cost per ton
Cat maintains and usually guarantees around 95%
availability
Interesting note I am
Holding out on inputting
My number of trucks
And cost data till I get
An idea of how many
I need.
If you fill a truck with less than 3 passes you cant get the
load distributed youll kill the suspension system in the
truck
If you take too many passes to fill the truck will spend a
large part of its cycle time sitting to be loaded.
Guidelines exist as to what tends to be workable
A Material Caution
Our Worst
It will be 4 passes
179 / 4 = 44.75 cubic yards
44.75 / 56 = 0.8 well within range for our expected digging
Note at the very end the fill factor must match a loaded
truck with an integer number of dipper passes
If I wanted to try
More than one
Fleet I could
Select Add New
Fleet and then
Pick my 793
Matched to a 5700
Why am I bypassing?
Other Support
In this tab I will describe the road that my trucks must travel to deliver their ore or waste
Loads.
Input My Information
I will need to identify the length of the segment, the grade resistance,
A rolling resistance, a speed limit (if needed), and a description (which
Comes in very handy during later review)
Starting
Stopping
Major Turns
What is Major?
My Haulage Profile
Other Forces
Rolling Resistance
Grade Resistance in %
Now what about the grade resistance what is positive and what is
Negative?
Standard Convention
A positive resistance resists motion
A negative resistance favors motion
If I just reverse
Directions I can
Click Mirror
Haul Road (and
It reverses route)
Since we have only entered one of each this is not to big a choice. If youve entered more
Than one route or truck fleet you could have quite a few choices.
The select process is really two tear. The select tab lets you create a subset of cases to work
With. Ultimately FPC can only do one case at a time the second select picks one from the
Sublist we created. (Again my one truck one road combo is boring).
Unloading
Tailgate
The truck dumps pulling forward and spreading load
behind it.
May or may not require a total stop of the truck
Truck is moving forward and avoids backing manuver
Truck ends its unload cycle already in motion
My Case
The times that come up on the list are for smaller loaders doing single truck
Loading under ideal conditions.
Getting My Number
This is the time it takes one truck to pull away and then another to move in and
Spot and be ready to load. For larger trucks this is more like 1 minute rather than
0.7
This leads to what is the First Bucket Dump?
It is assumed that during the lag time when one truck is pulling out and another
Pulling in that the loader is getting a scoop of material ready. When the truck is
Positioned only the short time to dump the dipper is involved.
Simple
Truck doesnt have to back tires into the
rockiest areas
The shovel faces armor of the tracks into
the dig face
Shovel operator has optimized view of
truck bed target
More Disadvantages
Cab
Shovel
Tru
ck
Side Effect
First Bucket Dump now takes the full cycle
time since the loader did not have a time break
while trucks backed in.
Another Impact
Your Right
FPC was designed assuming all trucks use
single truck loading
They left a loop-hole large enough to allow it to
do something else.
More Disadvantages
Advantages
Disadvantages
Multilevel Loading
FPC Handling
Drive By Loading
Lie tell FPC you have a loader with a load cycle time of 0.05
minutes
Tell it your loaders first bucket is also 0.05
(When you do enter cost tell FPC your one loader that
is as fast as 5 loaders also costs as much as 5 loaders)
When you count your loaders at the end of the computer run
multiply the number of loaders by 5
Tandom Loading
Solution Lie
It takes about 0.7 to 1 minute to spot the truck
Cut the time savings from the zero time second bucket
off of the spotting time.
Illustrative Case
Loading Height
21 5 to get over the side of a Cat
793
Commentary on Loading
Point
Tip on a Frustration
The default number
Of trucks FPC tries
Is 1 to 4.
I wanted 1 to 10.
I typed in the 10
And nothing
Happened.
I had to click in
Another field to make
The change take.
Look at Results
Things I see #1 I can reach 9 million tpy with just one loader
#2 I need 4 of 5 trucks
#3 My production per truck keeps going up fairly linearly suggests that I
am not really over-trucking my loader
I am going to the fleet input tab and using the Tmph Limit field.
Interesting to note that its the front tires that take the worst load (these tires are
Not double like those in back)
Then We Adjust
A real operator never operates the truck and mechanical theoretical maximum and
A real operator does not work an 8 hour shift with no breaks (remember the 84%
Shift efficiency). Assume this allows some tire cooling and we are at 82% of
Tire capacity. We wont blow out the tires.
(if the temperature is 120 or 140 for long periods of time we would have to reduce
The tire rating. If we ran a driverless truck we might also have an issue).
Operating Costs
Fuel
Tires
Lubricants
Repair
Operators
We get
About
17 gallons/hr
Our truck is
A 777
We assumed
$2.0/gal.
17*$2=
$34/hr
Undercarriage is a dozer
Or tracked machine
Thing 0 here
Repair Reserve Next
Lets do Tires
Next
This resource is
Available online for
Students or by
Subscription fee for
Commercial users.
Production Truck
Drivers getting
About $15.6
Comment on Estimating
Input My Knowns
I already scheduled
2772 hrs per year
With 80% availability
In my example
9
1
0.09
1
0.09
10
1600000
0
0
0
0
0
Interest Rate
Number of Compounding Periods/Year
Period interest rate (as a decimal)
Number of Payments/Year
Payment Interest Rate (as a decimal)
Years for Loan Payoff
Loan Amount
Down Payment Required
Set Up Fees
Set Up Fees Rolled into Loan
Points Up Front
Points Rolled into Loan
249312.1
249312.8
893121.7
0
Payment Amount
Final Payment Amount
Interest Paid
Fees Paid
Debt
1600000
1494688
1379898
1254776
1118394
969737.6
807701.8
631082.9
438568.3
228727.3
0
0
Interest
144000
134521.9
124190.8
112929.9
100655.5
87276.38
72693.17
56797.46
39471.14
20585.46
0
0
Payment
249312.1
249312.1
249312.1
249312.1
249312.1
249312.1
249312.1
249312.1
249312.1
249312.8
0
0
Principal
105312.1
114790.2
125121.3
136382.2
148656.6
162035.7
176618.9
192514.6
209841
228727.3
0
0
Probability of Available
It treats the entire truck and loader fleet as one
entity each.
Ie if the trucks are 90% available then the entire
truck fleet is available 90% of the time and the entire
fleet is down 10% of the time.
If loaders are 90% available then all loaders work
90% of the time and all loaders are down 10% of the
time
The Impact