BelAZ mining dump trucks – BelAZ-7540V, BelAZ-75473, BelAZ-7555E, BelAZ-75131, BelAZ-75170, BelAZ-75306, BelAZ-75600

Design features and scope of application

So, a distinctive feature of the BelAZ-75131 truck and similar heavy equipment from Belarus is the use of an electromechanical transmission. Simply put, to create traction, this technique uses not the torque of an internal combustion engine, but electric motors integrated into the wheels.

A powerful, monster-like diesel engine is needed, with this design, to power the generator that produces current for these traction electric motors. Thus, the BelAZ-75131 electromechanical transmission includes the following components: a traction generator, two electric motor wheels (gearboxes assembled with traction motors), a block of dynamic braking resistors, a control cabinet; sets of ventilation and additional equipment.

Specifically, the 75131st BelAZ uses an electromechanical AC-DC transmission of its own production. And some other BelAZ dump trucks of a similar design are equipped with imported equipment from General Electric, as well as from the St. Petersburg enterprise Elektrosila.

The purpose of the quarry heavyweight BelAZ-75131 is the same as that of its brothers: it is the transportation of loose rocks along the technological paths of quarries and open-pit mining. Including in areas with the most difficult and unfavorable climatic conditions.

The technical capabilities of the BelAZ-75131 also make it possible to successfully operate it in large construction projects of large industrial and hydraulic facilities; during the construction of large-scale trunk lines, in the technological workshops of giant processing plants.

Hydraulic system

The hydraulics of the BELAZ-75131 model is a combined system of tipping, brake and steering mechanisms. The lifting of the body involves an axial piston variable displacement oil pump and 3-stage telescopic cylinders (one stage double-acting).

About the history of the BelAZ-75131 model

Over the seven decades of its operation, the Belarusian Automobile Plant in Zhodino has produced 120 thousand units of powerful and heavy-duty equipment, and foreign analogues of these models are rare. The first heavy trucks manufactured within the plant’s walls were the famous “quarter truck” - MAZ-525, with a load capacity of 25 tons, as well as the forty-ton MAZ-530.

The plant began producing mining dump trucks under the BelAZ brand in 1961, and the first model of its own brand was the BelAZ-540, with a load capacity of 27 tons. By the beginning of the 80s, the company produced six thousand heavy dump trucks annually, and this accounted for 50 percent of the global production of this equipment. BelAZ trucks have been repeatedly awarded medals at the most prestigious international exhibitions; were exported to more than five dozen countries on the planet.

The main entrance of the Belarusian Automobile Plant.

Since the early 80s, the Belarusian Automobile Plant, relying on its enormous experience, has successfully implemented a number of bold projects to create super-heavy dump trucks with a carrying capacity of 200 and 280 tons. Without stopping, as we know, on these impressive achievements. With these unique developments, BelAZ has confidently declared itself throughout the world, clearly demonstrating what Soviet engineering is capable of.

The BelAZ-75131, a real hero with a payload capacity of 130 tons, with a new progressive development - an electromechanical transmission, also received worldwide recognition.

Technical characteristics of BelAZ-75131

These mining dump trucks with a carrying capacity of 130 - 136 tons are designed for transporting rock mass and bulk cargo in open-pit mining along technological roads in various climatic conditions. At the customer's request, machines can be equipped with a centralized lubrication system, air conditioning, automatic fire extinguishing system, and weighing device. The greatest efficiency is achieved when working in conjunction with excavators and loaders with a bucket capacity of 20 m3

What is the car - so are the numbers

Its overall dimensions and weight indicators speak very clearly and eloquently about the scale of this heroic truck. And also the volumes of working fluids: the fuel tank holds 1900 liters of diesel fuel. Engine oil - 195 liters. Antifreeze in the cooling system is 410 liters. The volume of the hydraulic system is 510 liters.

BelAZ-75131 diagram.

Other indicators are:

• Length – 11.5 meters; Width – 6.4 meters; Height – 5.9 meters.
• Curb vehicle weight – 107.1 tons; The gross vehicle weight is 243.1 tons.
• Load capacity – 130 tons (for a dump truck with bias tires); 136 tons (for a dump truck with radial tires).
• Body volume – 104 cubic meters.
• Loading height – 4.8 meters.
• Wheelbase - 5.3 meters.
• Large clearance – 600 mm.
• The power of the traction generator (GSN-500 / SGD-89/38) is 1000 kW.
• Traction motor power (EK-420/TED-6/EK-590) – 420/520/590 kW.
• Tire size – 33.00 R51. (“BelShina”); tire pressure – 7 atmospheres.

Another feature of this vehicle: the load between the axles is divided as 33 x 67 (for a loaded dump truck). It is not divided equally, with such a significant difference - because it is much more important to divide the weight between the wheels (tires), and not the axles, of which there are 4 at the rear (in the rear there are twin wheels), and in front, accordingly, there are only two wheels.

Engine BelAZ-75131

BelAZ trucks of this model are equipped with an imported Cummins engine, Cummins KTA50-S brand. This is an ultra-powerful V-shaped 16-cylinder diesel engine with a volume of 50.3 liters and a power of 1,623 horsepower (1,195 kW). Engine with direct fuel injection; with gas turbine supercharging; intermediate cooling of charge air.

The torque of this engine, at 1500 rpm, is 6292 Nm. The cylinder diameter of the Cummins KTA50-S diesel engine is 159 mm, and the piston stroke is 190 mm. To start this engine, not an electric, but a pneumatic starter, created by the plant’s specialists, is used.

The Cummins KTA50-S diesel engine is equipped with electronic control and a switchable central cooling system impeller to ensure high power density and, accordingly, stable truck speed on inclines, as well as high fuel efficiency. The specific fuel consumption of the engine, at its rated power, is 208 g/kW h.

BelAZ-75131 looks truly monumental.

Air purification is carried out by three-stage filters with dry-type elements. Exhaust gases are released through the dump truck body. The lubrication system is circulating, under pressure, “with a wet sump”. The cooling system is liquid, single-circuit, with a forced circulation system. The voltage in the electrical system is 24V.

To ensure stable engine starting in low temperature conditions, BelAZ-75131 mining dump trucks are equipped with a pre-heater for engine coolant and fuel (EH). This facilitates its start-up and promotes stable operation in the harsh conditions of the Far North, Siberia, and the Far East. BelAZ-75131 of the tropical version is not equipped with PZDs.

Chassis, suspension of the BelAZ-75131 truck

BelAZ-75131 is a rear-wheel drive truck. There are two traction electric motors in its design - for each of the drive wheels. In fact, the wheel and the motor are a single whole, and this entire assembly is therefore called an electric motor-wheel. The main components of this unit are a traction electric motor; gearbox; brake hub, speed limit sensor.

The electric motor-wheels are bolted to the rear axle housing. And the crankcase, through a central hinge, a transverse rod and suspension cylinders, is connected to the frame. Thus, the rear suspension of the BelAZ-75131 is dependent (however, it is unlikely to introduce a multi-link here). Suspension - trailing arms with a central hinge.

Those structural elements that are called shock absorbers in a regular car are made in the form of cylinders. These cylinders are gas-oil and are piston-type air springs combined with hydraulic shock absorbers. Nitrogen gas and shock-absorbing liquid are used as the working fluid.

The front suspension is also dependent; the steering knuckles of the front beam are secured to the beam using pins. Shock absorber cylinders are also present in the front suspension, but they are not interchangeable and differ in size. The piston stroke of these pneumohydraulic cylinders is – front: 320 mm; rear – 290 mm.

The suspension of the BelAZ-75131 dump truck is pneumohydraulic, with built-in hydraulic shock absorbers. In combination with the dependent guide vane system, it provides excellent smoothness, high productivity, technical speed, stability against lateral rolls, durability of the main components of the dump truck and fairly comfortable working conditions for its driver.

The supporting parts and gears of motor-wheel gearboxes are made of high-grade alloy steel using the most advanced technologies. The kinematic scheme used in the design allows torque to be transmitted to the wheel hubs simultaneously by the first and second rows of the gearbox, and to make maximum use of the space inside the wheel rim.

This allows you to reduce the loads acting on the gearboxes and helps to increase its service life. The gearbox uses design solutions that eliminate the influence of deformations that occur during operation on the operation of the gears and bearings of the gearbox. Which, to a large extent, strengthens its reliability and durability.

Transmission

As already noted, BelAZ-75131 is the founder of a family of mining dump trucks with an electromechanical transmission. It is stepless, perfectly combining power and speed characteristics. The drive system parameters are optimized by the control system algorithm.

The BelAZ electromechanical transmission includes an AC-DC electric drive with a traction generator, two traction motors, electric motor-wheel gearboxes, control devices, a microprocessor control system and monitoring devices. The motor-wheel gearbox is two-stage, with spur gears. Gear ratio – 30.36.

BelAZ-75131 at coal mines in Kuzbass.

No gear shifting is required, and there is a smooth change in power as the truck moves along the route. Thanks to the introduction of an electromechanical transmission, operating costs were reduced to almost a minimum, and productivity during transportation was significantly increased. The design of the electromechanical transmission does not contain parts and assemblies that may be subject to mechanical wear.

Dump truck frame and body; complex of special equipment

The frame on the BelAZ-75131 is welded, made of high-strength low-alloy steel, using cast-welded elements in areas of greatest load. The longitudinal spars are box-shaped, of variable height, connected to each other by special cross members.

The body is a classic BelAZ, bucket type, welded. It is equipped with a protective visor and a heating system with engine exhaust gases. The body is equipped with a device for mechanical locking in the raised position, stone bumpers and stone ejectors.

In the basic configuration, BelAZ-75131 is equipped with the following systems:

• combined fire extinguishing with remote activation and a subsystem on the rear axle (SKP-M);
• centralized lubrication (CSL);
• heating and air conditioning;
• load and fuel control (SKZiT);
• video review;
• telemetric – tire pressure monitoring (SKT);
• alarm when approaching a high-voltage line (USPVL).

Steering and braking control BelAZ-75131; hydraulic system

The steering of the BelAZ-75131 dump truck is hydraulic volumetric, with two circuits. Naturally, no human, or even heroic, strength is enough to turn the wheels of a dump truck if the engine stops. That is why, to ensure safety, three pneumatic accumulators are installed in the hydraulic steering system, which are designed to ensure correct operation of the dump truck’s steering in various emergency situations.

The brake mechanisms on all wheels of the BelAZ-75131 dump truck are disc brakes equipped with a hydraulic drive. In principle, like conventional cars. However, this is not quite true. After all, in order to press the brake pads to the discs in a passenger car, the effort of the foot and some help from a vacuum booster will be enough (and many citizens remember well the times when this device did not exist).

Such ease is not available to a heavy mining dump truck, so instead of a foot, the pressure is created by a pump, and the pedal only meters the force. Otherwise, the design of the brake control is standard, like that of ordinary cars. There are also two separate circuits and automatic adjustment of the gap between the discs and pads. The brake discs are located on the shafts of the traction motors.

Conventional brakes cannot tame such a monster. (Stepnoy coal mine, Chernogorsk, Republic of Khakassia).

In addition to these traditional brakes, the BelAZ-75131 is also equipped with an auxiliary electrodynamic brake. In it, braking is performed by the same wheels-electric motors. At the same time, when braking, they begin to work in generator mode.

The use of an electrodynamic braking system significantly reduces the mechanical wear of the friction materials of the brake linings. It also provides effective deceleration throughout the entire speed range, down to zero speed. Allows you to switch from traction with full traction torque to deceleration with full braking torque in less than a second. In general, the BelAZ-75131 brake system complies with international safety standards STB ISO 3450.

The hydraulic system of the BelAZ-75131 mining dump truck is a combined hydraulic system of steering, brakes and tipping mechanism. This design solution allowed the hydraulic drive to be unified; and the number of hydraulic units in its composition should be reduced.

The use of adjustable pumps with automatic unloaders helps reduce power losses in the drive and ensure the necessary oil cooling in a wide variety of climatic zones and natural conditions. Without the use of cooling radiators! The hydraulic system quickly raises and lowers the cargo platform: in 20 seconds it raises the body, and in 18 it lowers it down.

Cabin BelAZ-75131

The area on which the driver’s cabin is located is called the deck on BelAZ vehicles. To get there, you need to climb quite high up the stairs: almost four meters. And the first thing you can see on the deck is a special control cabinet. It contains all the control mechanisms for the electromechanical transmission. The “turret” in front of it is the top of the expansion tank. Behind it are the elements of the hydraulic system.

Entrance to the cabin from the deck of the dump truck.

The BelAZ-75131 cabin is equipped with a safety cage and fully complies with the European “ROPS” safety standard. This standard is quite complex, in addition to the mandatory safety cage, it also contains quite a lot of other requirements, but BelAZ strictly follows it. Thanks to this, in addition to the Russian Federation, Belarusian dump trucks are exported to many countries, including those where it is impossible to do without this certification.

Cabin interior of BelAZ-75131.

The cabin door opens in an unusual way; from the point of view of a conventional car, it opens in the opposite direction. The driver's seat is quite comfortable; it is air-sprung; the additional chair is ordinary. If necessary, it can be folded very quickly and easily. At the same time, you will get a comfortable table next to the driver’s seat. Convenient, for example, for eating. At first superficial glance, the car's controls look ordinary: the usual speedometer, tachometer, three pedals, and gearshift lever. But, of course, there are significant differences.

For example, the third pedal (in addition to the gas and brake) is not a clutch, but an electrodynamic brake. The BelAZ-75131 does not have a gearbox at all. Therefore, there is no “speed” shift lever here either and cannot be. In its place is a selector for selecting the operating mode of the electromechanical transmission. It's called a reverser switch.

Cost of the BelAZ-75710 dump truck

According to a long-established tradition, the prices at which super-heavy trucks are sold to customers are not made public. In this regard, people interested in this issue can only operate with indirect, unofficial data. According to the most approximate estimates, the BelAZ-75710 costs at least ten million dollars. After all, the Siemens MMT500 electric power drive alone costs more than 2.5 million dollars. And just one Bridgestone 59/80R63 tire costs, according to the official price list of the tire concern, and excluding delivery, 40 thousand dollars. And there are eight of them in the set. In a word, what is the car, so is its cost!

But: the BelAZ work shift in the quarry lasts 23 hours a day! (On average, one hour is spent on refueling and changing drivers). The mileage over the specified 5/6-year service life accumulates to more than 500 thousand kilometers. After decommissioning, BelAZ trucks that have exhausted their service life are used to repair those dump trucks that are “in service,” which also helps reduce their cost.

In addition, BelAZ-75710 is equipped with a 360-degree video viewing system. In addition to video cameras, on all four sides of the giant dump truck there are motion sensors and special radars that record the approach of a person to the machine. Therefore, if someone hesitates in their walks next to or under the dump truck, the driver will be clearly aware of this.

BelAZ-75131 drone is already a reality!

At the end of April 2015, at the factory site, in the presence of a large number of observers and representatives of the press, the first and only unmanned mining dump truck BelAZ-75131, which had successfully passed tests, was demonstrated. This technique performed all actions flawlessly and with high accuracy.

Externally, a truck equipped with an autopilot is no different from a regular one: only the seat in the cab of a driving vehicle that raises and lowers the body is empty. Its driver sits in a completely different place and controls a multi-ton vehicle using equipment similar to modern driving simulators in DOSAAF. This BelAZ-75131 is equipped with a route analyzer that works using GPS/GLONASS systems.

This 130-ton BelAZ became the “first sign” of a bold project by designers who planned to combine work in a single quarry into a single automated process. In which one operator will be able to control the operation of several dump trucks simultaneously (from 6 to 10 units!), and in the future, an excavator too.

As noted by the director of the Belarusian Automobile Plant, Pyotr Parkhomchik, the creation in the future of such unified quarry complexes (excavator + “squad” of dump trucks) under the control of one operator will not only optimize work in quarries, but also significantly improve the working conditions of people in the industry. After all, despite all the modern solutions related to improving the microclimate in the cabins of dump trucks and excavators, installing air-sprung seats, it is still very difficult to work on this equipment even in harsh climatic conditions.

Security systems

On the Internet you can find many photographs of valiant workers in the mining industry against the backdrop of BelAZ trucks of various brands overturned in their quarries. In order to maximally protect the BelAZ-75710 from such “adventures”, for the first time in history, a stabilizer bar was used on a mining dump truck, another solution of Belarusian engineers, which can be called unique of its kind. It also protects against lateral rollover and gives a smooth ride.

Electronic scale indicators are installed on each side of the dump truck, clearly visible to the excavator operator. He sees and knows in real time how many tons of rock have already been loaded into the body. BelAZ-75710 is also equipped with a safety system in case of steering hydraulic failure. This system - pneumatic-hydraulic steering accumulators - will provide sufficient pressure to safely pull off the road to a safe place and stop. There are six of them in the BelAZ-75710 - more than in any other truck.

Reviews about the BelAZ-75131 car

You cannot find reviews of dump trucks of this brand on the Internet: there are very few of them, and their drivers, and even more so, their owners, apparently do not have the habit of sitting on forums and writing reviews. From the reviews of journalists who drove the BelAZ-75131 (only as passenger observers, only those who have undergone special training are allowed to drive!), the following conclusions can be drawn.

Driving the famous 130-ton truck.

130 or more tons of cargo “behind your back” is serious. It is impossible to pull such a loaded car out of a skid on ice or slippery ground, and there is no way to stop it quickly in an emergency. Therefore, for example, even with a 12 percent slope on the slopes, you are allowed to drive no faster than 24 kilometers per hour.

It’s amazing that a multi-ton dump truck accelerates unexpectedly quickly and smoothly, with no pauses during acceleration, thanks to a specific transmission. Only a few seconds pass, and the BelAZ-75131 already reaches its maximum speed. True, it is only 48 kilometers per hour. But this technology has completely different, highly specialized tasks.

uCrazy.ru

• Warhammer
• September 7, 2006 08:00
• 19601

This time I have prepared some background information about these wonderful machines. Well, let's start