AU2022204434A1 - A dump truck tray - Google Patents

Abstract

A flexible dump truck tray for a dump truck comprising: a floor, a front wall and at least two side walls which are connected together and can receive and contain a payload of material and a canopy extending forwardly from the front wall to shield a cab of the dump truck during loading of material into the tray, the canopy being configured for canopy locking, i.e. to support a part of the payload, the canopy having a concave shape defining a cavity for receiving the part of the payload, and the canopy and the remainder of the tray being configured so that when the tray is loaded the centre of gravity of the payload is forward of the location it would have been without cavity loading and there is a more even load distribution over the forward and rear axles of the dump truck. 6/11 110 118 110 118114 130 116 134 120 136 132 Figure 8 11 132 124a 128 124b Figure 9

Description

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Figure 9

A DUMP TRUCK TRAY TECHNICAL FIELD

The present invention relates to a dump truck tray.

Specifically, although by no means exclusively, the present invention relates to a dump truck tray suitable for transporting low-density mined material such as coal.

The present invention also relates to a dump truck comprising a dump tray according to the invention.

BACKGROUND ART

Dump trucks are commonly used at mine sites to transport a material (such as coal, iron ore, copper ore and gold etc.) from one area of a mine site to another.

Dump trucks typically comprise a vehicle chassis, with wheels and a power plant, and a truck tray that defines a recess for holding material. The truck tray typically comprises a rigid structural frame made of box sections of steel with steel plates rigidly joined to the rigid structural frame so as to form surfaces of the tray. The truck tray may also include rubber linings positioned on inner surfaces of the tray to absorb impact energy from falling material.

A problem associated with truck trays of the above description, is that the amount of material that can be transported is limited by the size of the recess. This is specifically an issue for low density mined material such as coal. Due to the low density of coal, the volume of coal that equates to the maximum payload of the vehicle is greater than the volume of the dump truck tray recess.

18827220_1 (GHMatters) P118530.AU 23/06/22

In an attempt to solve the above problem, mine operators have experimented with piling a payload of coal in the dump truck tray above the height of the walls of the tray. However, this can alter the centre of gravity of the payload which may result in stability issues of the dump truck and maintenance issues due to uneven wear on components such as tires, brakes and suspension.

Another problem is that the tray, due to its rigidity, is not very effective at absorbing impact energy from falling material. It is known to position rubber linings or linings of other resilient impact absorbing material on inner surfaces of the tray to improve impact absorption. However, the rubber and other linings add to the overall weight of the truck which detracts from its maximum payload. Furthermore, the rubber and other linings often need replacement, adding to the maintenance costs and vehicle downtime of the truck tray.

It is desirable to ameliorate one or more of the above described problems or to at least provide an alternative to known dump truck trays.

SUMMARY OF THE DISCLOSURE

The invention provides a flexible dump truck tray for a dump truck comprising: a floor, a front wall and at least two side walls which are connected together and can receive and contain a payload of material and a canopy extending forwardly from the front wall to shield a cab of the dump truck during loading of material into the tray, the canopy being configured for canopy loading, i.e. to support a part of the payload, the canopy having a concave shape defining a cavity for receiving the part of the payload, and the canopy and the remainder of the tray being configured so that when the tray is loaded the

18827220_1 (GHMatters) P118530.AU 23/06/22 centre of gravity of the payload is forward of the location it would have been without cavity loading and there is a more even load distribution over the forward and rear axles of the dump truck.

The term "concave" should be given its ordinary meaning of having an outline or surface that curves inwards and downwards when viewed from above.

The term "flexible" is understood herein to mean that the tray is capable of deforming elastically when it is subject to loading and/or unloading of material. A flexible tray has a different structure to that of a rigid tray which is configured to withstand loading with material without deformation of the tray.

Rigid trays typically use box sections of steel to form a rigid structural frame, have steel plates rigidly joined to the rigid structural frame to form the surfaces of the rigid trays and may optionally include rubber linings positioned on inner surfaces of the tray. Rigid trays are not designed to elastically deform when subjected to loading and/or unloading of material because they are designed with high stiffness to resist elastic deformation. The rubber linings merely dampen and absorb the shock and vibration of loading and/or unloading the material so as to lessen the amount of shock and vibration transferred to the rigid structural frame and steel plates.

Unlike rigid dump truck trays, flexible dump truck trays do not comprise a rigid frame made from substantial beams, typically box sections of steel, and steel plates rigidly joined thereto. In contrast, a flexible dump tray comprises curved surfaces and a lighter framework than the beam structure of rigid dump truck trays. In this manner, the great moments of inertia which are achieved with

18827220_1 (GHMatters) P118530.AU 23/06/22 curved surfaces eliminate or allow obviating to a great extent the use of beams as main resistive elements. Because the dump tray requires fewer beams and an overall lighter framework, the resulting dump tray is lighter than a conventional rigid dump tray.

In other words, flexible dump truck trays are generally lighter than rigid dump truck trays of an equivalent size. This is because rigid trays require a larger mass of steel in order to provide its structural rigidity.

Furthermore, the curved surfaces of the tray increase its resistance to impacts generated during the activities of loading and unloading materials. This is because the curved shape distributes in a uniform manner the strains generated by the impact of the materials during said activities. As such, a flexible dump truck tray has a greater elasticity than a conventional rigid dump truck tray, which avoids the concentration of strains that would otherwise damage the tray and increase the frequency of maintenance required.

In other words, flexible dump truck trays have improved impact energy absorption characteristics over rigid dump truck trays due to their ability to elastically deform when subjected to loading and/or unloading of material.

Furthermore, the curved surfaces make it possible to increase the discharge speeds of materials. This is due to the lack of corners in which material would otherwise collect and adhere, for example as hang-up.

It has been found by the applicant that a combination of (a) a concave-shaped canopy; and (b) a flexible dump truck tray, can significantly increase the payload of the dump truck tray, particularly when transporting low density mined

18827220_1 (GHMatters) P118530.AU 23/06/22 material, such as coal, and can improve the weight distribution above vehicle axes.

The concave-shaped canopy creates additional volume for holding mined material. As such, the truck tray can be safely loaded with mined material, above the height of the walls of the tray, up to and onto the canopy. This is known as "canopy loading".

The concave-shaped canopy may comprise a concave wall that defines the cavity for receiving the part of the payload.

The canopy wall may have any suitable radius of curvature. By way of example, the radius of curvature may be 14-16m.

The concave wall may be formed from any suitable material. Typically, the concave wall is formed from steel.

The concave-shaped canopy may be concave in a direction transverse to a longitudinal extent of the dump truck tray.

Providing the truck tray with a concave-shaped canopy that is configured (i.e. shaped and sized) to define a cavity for receiving the part of the payload means that, when the tray is loaded, the centre of gravity of the payload is forward of the location it would have been without cavity loading and there is a more even load distribution over the forward and rear axles of the dump truck. This is an advantage of the invention.

Suitably, the truck tray with the concave canopy is shaped and sized so as to provide an axle split in a range of 35 40% of the total load on the front axle and 60-65% of the total load on the rear axle.

The truck tray may comprise a frame made from a plurality

18827220_1 (GHMatters) P118530.AU 23/06/22 of structural elements, such as box-sections, I-beams, T beams or L-beams or a combination of two or more of these structural elements that are connected together to form the frame.

The plurality of structural elements may comprise a transversal canopy beam that extends transversely across the canopy.

The transversal canopy beam may be curved to conform to the shape of the concave-shaped canopy.

The transversal canopy beam may project into the cavity such that it defines a freeboard measurement, for example to indicate to an excavator operator where to fill the tray up to. The transversal canopy beam may also define a forward stop for material contained therein.

The plurality of structural elements may comprise two lateral canopy beams which define opposed sides of the canopy.

The transversal canopy beam may be connected to the lateral canopy beams. The connection may be made by welding or bolting.

The frame may also include a bracing member, for example in the form of a bolster plate, connected to an upper section of the front wall and to a rearward section of the canopy for further supporting the canopy.

The plurality of structural elements may comprise a longitudinal floor beam which extends along a length of an underside of the floor. In some embodiments, the longitudinal floor beam may extend partway along a length of the tray. In such an embodiment, a plurality of longitudinal floor beams of this type may be arranged end

18827220_1 (GHMatters) P118530.AU 23/06/22 to-end to extend along a full length of the tray. In this arrangement, a spacing may be provided between adjacent ends of the longitudinal floor beams.

However, it is also envisaged that a single longitudinal floor beam may extend the full length of the tray.

The longitudinal floor beam may be curved.

The plurality of structural elements may comprise a plurality of transversal floor beams which extend transversely across the underside of the floor. Each transversal floor beam may be curved.

The transversal floor beams may intersect with the longitudinal floor beam.

The transversal and longitudinal floor beams may support the floor.

At least one of the floor, front wall, side walls and canopy may comprise structural steel plates.

The structural steel plates may be joined, for example welded or bolted, to the transversal and longitudinal floor beams.

The structural steel plates may be made from HARDOX@.

At least one of the floor, front wall and side walls may be curved.

The floor may comprise a forward portion and a rear portion, the rear portion of the floor being angled upwardly with respect to the front portion of the floor.

The angle may be between 1 and 20 degrees, preferably

18827220_1 (GHMatters) P118530.AU 23/06/22 between 5 and 15 degrees, most preferably between 5 and 10 degrees.

The invention also provides a dump truck that includes the above-described dump tray.

BRIEF DESCRIPTION OF THE DRAWINGS

Notwithstanding any other forms which may fall within the scope of the dump truck tray as set forth in the Summary of the Disclosure, a specific embodiment will now be described, by way of example only, with reference to the accompanying drawings in which:

Figure 1 is a rear facing, top perspective view of a dump truck tray according to an embodiment of the present invention;

Figure 2 is a rear facing, bottom perspective view of the dump truck tray shown in Figure 1;

Figure 3 is a side view of the dump truck tray shown in Figure 1;

Figure 3A is an enlarged view of the canopy shown in Figure 3;

Figure 4 is a top view of the dump truck tray shown in Figure 1;

Figure 5 is a bottom view of the dump truck tray shown in Figure 1;

Figure 6 is a front view of the dump truck tray shown in Figure 1;

Figure 7 is a rear view of the dump truck tray shown in

18827220_1 (GHMatters) P118530.AU 23/06/22

Figure 1;

Figure 8 is a rear facing, top perspective view of a dump truck tray according to another embodiment of the present invention;

Figure 9 is a rear facing, bottom perspective view of the dump truck tray shown in Figure 8;

Figure 10 is a side view of the dump truck tray shown in Figure 8;

Figure 10A is an enlarged view of the canopy shown in Figure 10;

Figure 11 is a front facing, bottom perspective view of the dump truck tray shown in Figure 8;

Figure 12 is a front facing, top perspective view of the truck tray shown in Figure 8;

Figure 13 is a bottom view of the truck tray shown in Figure 8;

Figure 14 is a top view of the truck tray shown in Figure 8;

Figure 15 is a front view of the dump truck tray shown in Figure 8; and

Figure 16 is a rear view of the dump truck tray shown in Figure 8.

DETAILED DESCRIPTION OF SPECIFIC EMBODIMENTS

Figures 1 to 7 show a dump truck tray 10 according to a first embodiment of the present invention.

18827220_1 (GHMatters) P118530.AU 23/06/22

The dump truck tray 10 comprises a floor 12, a front wall 14, at least two side walls 16 and a canopy 18 which are connected together and can receive and contain a payload of material.

The floor 12 and the canopy 18 are concave in a direction transverse to a longitudinal extent of the dump truck tray 10.

The floor 12 has a radius of curvature of 14-16m.

The canopy 18 has a radius of curvature of 14-16m.

The dump truck tray 10 comprises a plurality of structural elements that are connected together to form the frame. The structural elements include: (a) a pair of lateral canopy beams 20 which define opposed sides of the canopy 18 and support the sides of the canopy 18; (b) a curved transversal canopy beam 22 that intersects and is connected at opposite ends to the lateral canopy beams 20 and further supports the canopy 18, with the same curvature as the canopy 18; (c) a bracing member in the form of a bolster plate 15 (see Figure 5) connected to an upper section of the front wall 14 and to a rearward section of the canopy 18 further supporting the canopy 18; (d) a first pair of longitudinal floor beams 24a which extend along a length of an underside of the floor 12, from the front wall 14 to a middle section of the floor 12; (e) a second pair of longitudinal floor beams 24b which extend along a length of an underside of the floor 12, from the middle section of the

18827220_1 (GHMatters) P118530.AU 23/06/22 floor towards the rear of the dump truck tray 10; and (f) a plurality of (five) curved transversal floor beams 26 which extend transversely across the underside of the floor 12. Each transversal floor beam 26 intersects and is connected to the respective longitudinal floor beams 24a, 24b.

The plurality of structural elements are connected together via bolts. Any suitable connection system can be used.

Curved steel plates made from made from HARDOX@ are welded to the plurality of structural elements to form the floor 12, the front wall 14, the side walls 16 and the canopy 18.

The longitudinal and transversal floor beams 24a, 24b, 26 support the floor 12 and the lateral canopy beams 20 and the curved transversal canopy beam 22 support the canopy 18.

The floor 12 comprises a forward portion and a rear portion, the rear portion of the floor 12 is angled upwardly with respect to the front portion of the floor 12 at an angle of between 50 and 100.

The canopy 18 extends forwardly from the front wall 14 to shield a cab of the dump truck during loading of material.

The canopy 18 has a concave shape, as best shown in Figure 3A. The concave shape defines a cavity for receiving the part of the payload.

The canopy 18 and the remainder of the tray 10 are configured so that when the tray 10 is loaded the centre of gravity of the payload is above a middle section of the

18827220_1 (GHMatters) P118530.AU 23/06/22 dump truck between forward and rear axles of the dump truck.

Suitably, the concave canopy makes it possible to position the payload so as to provide an acceptable axle split of 1/3 of the total load on the front axle and 2/3 of the total load on the rear axle of the dump truck.

The bolster plate 15 acts as a bracing member between the front wall 14 and the canopy 18. The bolster plate extends at an angle between 20° and 500, preferably 40°, relative to the front wall 14 and the canopy 18. As such, it can be appreciated that the bolster plate 15 experiences a component of the horizontal and vertical forces applied to the front wall 14 and canopy 18, thus distributing the load.

Attached to the underside of the longitudinal floor beams 24b are mounting portions 28 which are configured to be attached to corresponding mounting portions on a dump truck chassis via a pivotable connection. The mounting portions 28 comprise a bracket with an aperture through which a locking pin can be inserted. Once secured, the dump truck tray 10 is pivotable relative to the dump truck chassis to be able to tip the load therefrom.

Each side wall 16 comprises a pair of apertures, also known as lifting points 30. The lifting points 30 allow cables to be threaded therethrough in order for the dump truck tray 10 to be lifted using a crane.

Figures 8 to 16 show a dump truck tray 110 according to a second embodiment of the present invention. The dump truck tray 110 has the same features as the dump truck tray 10 but with the reference numbers starting with the prefix 1.

18827220_1 (GHMatters) P118530.AU 23/06/22

The dump truck tray 110 has additional auxiliary features which will be described in the sections that follow.

The dump truck tray 110 comprises mud flaps 132 which are pivotably attached to an underside surface of the floor 112.

The dump truck tray 110 also comprises a side deflector 134 and an exhaust deflector 136.

The side deflector 134 is cantilevered from the lateral canopy beams 120. The side deflector 134 is intended to provide additional protection to the area adjacent the doors of the cab, i.e. to shield the side windows of the cab from falling rocks.

The exhaust deflector 136 is cantilevered from the front wall 114. The exhaust deflector 136 is intended to provide additional protection to the exhaust manifold, i.e. to shield the exhaust manifold from falling rocks.

Whilst the embodiments described in this specification show longitudinal floor beams 24a, 24b, 124a, 124b which extend part way along a length of the tray, it is also envisaged that a single longitudinal floor beam may extend the full length of the tray.

In the context of this application, terms such as "front" and "rear" are given in reference to the part of the dump tray that is being raised in order to tip/empty the dump tray. For example, the 'front' of the dump tray may be considered as being the part of the dump tray which is raised the most and the 'rear' of the dump tray may be considered as being the part of the dump tray which is raised the least.

In the context of this application, the term "inner

18827220_1 (GHMatters) P118530.AU 23/06/22 surface" is given in reference to the part of the dump tray which contacts the material.

In the context of this application, the term "outer surface" is given in reference to the part of the dump tray which is on the reverse surface to the surface of the dump tray which contacts the material.

In the claims which follow and in the preceding description of the invention, except where the context requires otherwise due to express language or necessary implication, the word "comprise" or variations such as "comprises" or "comprising" is used in an inclusive sense, i.e. to specify the presence of the stated features but not to preclude the presence or addition of further features in various embodiments of the invention.

It is to be understood that, if any prior art publication is referred to herein, such reference does not constitute an admission that the publication forms a part of the common general knowledge in the art, in Australia or any other country.

It will be understood to persons skilled in the art of the invention that many modifications may be made without departing from the spirit and scope of the invention.

18827220_1 (GHMatters) P118530.AU 23/06/22

Claims (19)

1. CLAIMS 1. A flexible dump truck tray for a dump truck comprising: a floor, a front wall and at least two side walls which are connected together and can receive and contain a payload of material and a canopy extending forwardly from the front wall to shield a cab of the dump truck during loading of material into the tray, the canopy being configured for canopy locking, i.e. to support a part of the payload, the canopy having a concave shape defining a cavity for receiving the part of the payload, and the canopy and the remainder of the tray being configured so that when the tray is loaded the centre of gravity of the payload is forward of the location it would have been without cavity loading and there is a more even load distribution over the forward and rear axles of the dump truck.
2. 2. The truck tray of claim 1, further comprising a frame made from a plurality of structural elements or a combination of two or more of these structural elements that are connected together to form the frame.
3. 3. The truck tray of claim 2, wherein the plurality of structural elements comprises a transversal canopy beam that extends transversely across the canopy.
4. 4. The truck tray of claim 3, wherein the transversal canopy beam is curved to conform to the shape of the concave-shaped canopy.
5. 5. The truck tray of claim 3 or claim 4, wherein the plurality of structural elements comprises at least two lateral beams which define opposed side of the canopy.
6. 6. The truck tray of claim 5, wherein the transversal canopy beam is connected to the lateral canopy beams.

   18827220_1 (GHMatters) P118530.AU 23/06/22
7. 7. The truck tray of any one of claims 2 to 6, wherein the frame comprises a bracing member connected to an upper section of the front wall and to a rearward section of the canopy for further supporting the canopy.
8. 8. The truck tray of any one of claims 2-7, wherein the plurality of structural elements comprises a longitudinal floor beam which extends along a length of the underside of the floor.
9. 9. The truck tray of claim 8, wherein the longitudinal floor beam extends partway along a length of the tray.
10. 10. The truck tray of claim 8, wherein the longitudinal floor beam extends along a full length of the tray.
11. 11. The truck tray of any one of claims 8-10, wherein the longitudinal floor beam is curved.
12. 12. The truck tray of any one of claims 8-11, wherein the plurality of structural elements comprises a plurality of transversal floor beams which extend transversely across the underside of the floor.
13. 13. The truck tray of claim 12, wherein each transversal floor beam is curved.
14. 14. The truck tray of claim 12 or 13, wherein the transversal floor beams intersect with the longitudinal floor beam.
15. 15. The truck tray of any one of the preceding claims, wherein at least one of the floor, front wall, side walls and canopy comprises structural steel plates.
16. 16. The truck tray of any one of the preceding claims,

    18827220_1 (GHMatters) P118530.AU 23/06/22 wherein at least one of the floor, front wall and side walls are curved.
17. 17. The truck tray of any of the preceding claims, wherein the floor comprises a forward portion and a rear portion, the rear portion of the floor being angled upwardly with respect to the front portion of the floor.
18. 18. The truck tray of claim 17, wherein the angle is between 1 and 20 degrees, preferably between 5 and 15 degrees, most preferably between 5 and 10 degrees.
19. 19. A dump truck comprising a dump tray as claimed in any one of claims 1 to 18.

    18827220_1 (GHMatters) P118530.AU 23/06/22

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