BelAZ Mining dump truck 75570 - technical specifications and description

7557 series overview

Quarry dump trucks are designed to transport rock mass in a loosened state along technological roads in open-pit mining operations with different climatic conditions. They can be used in the construction of large industrial and hydraulic structures, in the construction of highway complexes, as well as in technological departments of processing industry enterprises. Depending on the specific weight of the cargo being transported, the greatest efficiency is achieved when operating with excavators or loaders with buckets of the following capacity: 12.5 - 18 m3.

BelAZ in the world of mining dump trucks

To date, the Belarusian Automobile Plant has created a large family of mining dump trucks, consisting of twenty models and covering seven classes of load capacity (l/p): 30, 45, 55...60, 90, 130...136, 200...220 and 320 tons. Load capacity dump trucks 7540 series - 30 t, 7545 and 7547 series - 45 t, 7555 series - 55...60 t, 7557 series - 90 t, 7513 series - 130...136 t, 7530 series - 200...220 t, 7560 series - 320 t The largest number of models is in classes with a load capacity from 30 to 55...60 tons. In classes with a load capacity of 90 tons or more, there are one or two models. All dump trucks are created according to a single classic layout with a front-mounted engine unit, a rear-mounted dump body, have a rigid frame and rear drive wheels with dual tires. BelAZ dump trucks are equipped with diesel engines from three manufacturers: Yaroslavl Motor, Cummins and Deutz. YaMZ engines are used in dump trucks with a capacity of 30 and 45 tons. These are mainly 12-cylinder V-shaped engines of the YaMZ-240 and YaMZ-8401 series. In the same load capacity classes, dump trucks can be equipped with 6-cylinder in-line Cummins engines of the QSM11, QSX15, KTA19 series and 8-cylinder V-shaped Deutz engines of the BF BM 1015 series. Dump trucks with a payload of 55...60 tons and above are equipped with engines Cummins: 6-cylinder in-line with a working volume of 19 l (dump trucks with a capacity of 55...60 t), 12-cylinder V-shaped with a working volume of 30 l (dump trucks with a lifting capacity of 90 t), 12- and 16-cylinder V-shaped with a working volume with a volume of 45 and 50 l (dump trucks with a capacity of 130...136 t), a 16-cylinder V-shaped with a working volume of 60 l (dump trucks with a capacity of 200...220 t) and an 18-cylinder V-shaped with a working volume of 78 l for a dump truck /p 320 t. Dump trucks with a payload of 30...90 t use hydromechanical transmissions with electrohydraulic control and a hydrodynamic retarder. Transmissions are equipped with semi-automatic speed control systems. The BelAZ-75570 model with a capacity of 90 tons is equipped with an automatic speed control system. These transmissions are equipped with gearboxes of three sizes, having 3, 5 and 6 forward gears and, respectively, 1, 2 and 1 reverse gear. 7540 series dump trucks are equipped with 3/1 gear transmissions, 7540, 7545 and 7547 series dump trucks are equipped with 5/2 gear transmissions, and 7555 and 7557 series dump trucks are equipped with 6/1 gear transmissions. All hydromechanical transmissions have complex single-stage torque converters with fluid coupling mode ( transmissions with a number of gears of 3/1), with automatic locking (transmissions with a number of gears of 5/2 and 6/1). The 7557 Series dump truck can be equipped with an Allison hydromechanical transmission. The rear drive axles include a single-stage bevel final drive, a four-pinion differential and planetary wheel drives. The front axle is steerable, the beam has a tubular section. Suspension of the front axle and drive axle of dependent type on hydropneumatic (oil and nitrogen) cylinders. Hydrostatic steering with emergency power source. The service brakes have a separate drive; on dump trucks of the 7540 and 7547 series – drum brakes with pneumatic drive; on dump trucks of the 7545 and 7557 series - oil-cooled multi-disc for the rear axle and dry disc for the front axle; on dump trucks of the 7555 series - dry disk. Parking brakes are installed on the drive shaft of the main drive: shoe brakes on dump trucks of the 7540, 7547 and 7555 series and disc brakes on dump trucks of the 7545 and 7557 series. Retarder brakes on machines of the 7540 and 7547 series are hydrodynamic with electrical control, installed on the drive shaft of the gearbox; The 7545 and 7557 series dump trucks use multi-disc oil-cooled rear wheel brakes, and the 7555 series dump trucks use an electrically controlled hydrodynamic brake with an accelerated response mode, mounted on the drive shaft of the gearbox. On dump trucks with lifting capacity from 130 to 320 tons, two types of electromechanical transmissions are used: for the 7513 and 7530 series - AC-DC with a traction generator and two traction electric motors with motor-wheel gearboxes; for series 7560 – alternating current. This category of dump trucks is characterized by a rigid connection of the traction alternator to the engine, installation of traction electric motors in the hubs of the motor-wheels, and the use of double-row planetary wheel gearboxes at the motor-wheels. Hydrostatic steering with flow amplifier from a variable displacement pump (emergency drive from a pneumatic hydraulic accumulator). The service brakes are dry disc brakes with separate hydraulic drive. Combined type dump truck hydraulic system for steering, body tipping system and brakes. Considering the standard-size range of these dump trucks, it can be established that the growth of the selected range of load-carrying capacities, i.e., the transition from a small class to a neighboring one, occurs mainly with a factor of 1.5. The exception is the ratio between the second (g/c 45 t) and third (g/c 60 t) classes, for which the growth coefficient is 1.33. Obviously, this is due to the technical characteristics of the corresponding mining excavators, the capacity of the main buckets of which should ensure optimal loading of dump trucks in 4...6 working cycles. Analysis of specific indicators, which include specific material consumption (the ratio of the operating weight of the dump truck to engine power, kg/kW), energy saturation (the ratio of engine power to the total weight of the dump truck, kW/t) and a coefficient expressed as the ratio of the nominal hydraulic capacity of the dump truck to its operating weight, showed the following. The average values ​​of the specific material consumption of dump trucks included in the 30, 45 and 55...60 t capacity classes are approximately the same and range from 78...80 kg/kW. With the growth of the load class, the average values ​​of the specific material consumption of machines tend to increase and amount to about 88…90 kg/kW (l/p 130 and 200…220 t) and 92 kg/kW (l/p 320 t). The exception in this series is the model 75570 dump truck with a capacity of 90 tons; its figure is 97 kg/kW. We see a similar trend when assessing the level of energy saturation, which for dump trucks with a capacity of up to 90 tons is on average 5.4 kW/t and gradually decreases with an increase in the class of capacity up to 5 kW/t (with a capacity of 130...136 tons) and up to 4.7...4.8 kW/t for dump trucks with a capacity of 200 tons and above. As for the coefficient that evaluates the ratio of the load capacity to the operating weight of a dump truck, for all classes of dump trucks this ratio fluctuates on average within the range of 1.33...1.37, and for dump trucks with a payload of 90 and 130 tons this coefficient is lower and amounts to 1.18 …1.20. In addition to the Belarusian Automobile Plant, the following companies produce mining dump trucks in the world: • Mogilev Automobile Plant, which is now owned by BelAZ and produces the MoAZ-75054 dump truck with a capacity of 25 tons; • Caterpillar, which has mastered the production of 11 models of mining dump trucks with a capacity of 36...345 tons; • Komatsu, whose standard range of mining dump trucks includes 12 models with a payload from 25 to 291 tons; • Hitachi Construction Truck Manufacturing, Ltd., which produces a series of EH dump trucks of 13 models with payloads from 32.6 to 318 tons; • Terex company, it produces 14 models of mining dump trucks with a capacity from 31.7 to 326 tons; • Liebherr, it has 4 models of high-capacity mining dump trucks - from 180 to 360 tons; • Italian Astra, produces two models of small mining dump trucks with a capacity of 28 and 32 tons; Recently, information has appeared that the Norwegian company Aveling Barford has mastered the production of a mining dump truck with a capacity of 42 tons. The Italian company Perlini has created a family of mining dump trucks of five models with a capacity from 30 to 95 tons. The American company Kress has retained the production of a coal dump truck 200CII with a capacity of 220 tons. The most complete lines of mining dump trucks are from BelAZ, Terex, Hitachi, Komatsu and Caterpillar. Comparing the structure of the standard size ranges of mining dump trucks of the BelAZ Production Association and the leading foreign companies Caterpillar, Komatsu, Hitachi and Terex, we can conclude that the type of BelAZ dump trucks is practically not inferior to the types of these companies.

Heavy diesel engines D-280 of the Minsk Motor Plant - on the BelAZ conveyor The Minsk Motor Plant ahead of schedule produced 10 new D-280 engines with a power of 425 hp for BelAZ. during the implementation of a joint project with OJSC Tutaevsky Motor Plant. As the general designer of BelAZ PA A. Egorov said, “BelAZ considers the D-280 engine as a good alternative to the YaMZ-240 engines currently used on mining dump trucks with a lifting capacity of 30 tons, which were developed in the early 1960s.” According to A. Egorov, the technical level of the new D-280 engine is significantly higher than the YaMZ-240. If well executed in production, it can compete with the best world samples. The first samples are performing very well. All engines purchased from MMZ have already been installed in production vehicles. The organizational and technical problems of dump truck production, which are inevitable when introducing new products, are quickly resolved. In the coming weeks, three BelAZ-7540S dump trucks will be delivered to Belarusian consumers. 7540 mining dump trucks are in good demand. At least 600 of these machines are produced and sold annually in many regions of the world. In total, BelAZ PA plans to produce about 2,080 mining dump trucks of various carrying capacities in 2008. The first dump truck with the D-280 engine was released in May 2008. Since then, it has been working in three shifts in a lime quarry in the Grodno region, its mileage has already reached 60,000 km, which corresponds to the warranty mileage. The engine performance does not give rise to any complaints. Drivers note increased vehicle dynamics, lower fuel consumption, reduced acceleration time, which increases the average speed and, as a result, improves the economic results of operation.

90-ton BELAZ with a new electric traction drive. Testing the technology of the future

OJSC BELAZ, one of the largest manufacturers of mining dump trucks in the world, supported the proposal of CJSC PTFC ZTEO to create a model with a lifting capacity of 90 tons with a synchronous electric drive of the same name.

In an effort to strengthen the position of the automobile plant's products on the global market, the company's specialists made a joint decision to develop a new type of electric drive that will improve traction and speed characteristics and increase the level of reliability of a mining dump truck with a lifting capacity of 90 tons. According to the technical specifications of OJSC BELAZ, specialists of CJSC PTFC ZTEO developed a new traction electric drive KTEP B-90.

The converted vehicle equipped with it underwent experimental testing at the transport site.

In the crowd of yellow mining dump trucks, we do not immediately find our hero. In appearance, it looks like an ordinary 90-ton BELAZ, however, as the owners of the car, transport specialists, explain to us, this is the technology of the future. The dump truck of the new century, they are sure, is a machine with an electric drive of a new type.

The dump truck that operates in Region 42 today is an experimental model.

The development team, under the patronage of a long-time partner, JSC PTFC ZTEO, installed a set of traction electrical equipment based on a synchronous single-pole electric motor with independent excitation on a vehicle already in the transport company’s fleet.

Today it is undergoing operational tests - the developers are monitoring changes in performance characteristics. The management of Region 42 and BELAZ driver Alexander Frankiv are helping them.

Alexander Frankiv, BELAZ operator Region 42 LLC

“I did my internship at a regular BELAZ, and when I came to Region 42, I immediately got behind the wheel of a car with a new AC electric drive. The difference is certainly noticeable, and I enjoy working on the converted dump truck much more. We maintain constant contact with the developers: they came to our company, and we talk on the phone regularly,” says Alexander Frankiv, showing us his iron horse.

Through the eyes of a BELAZ operator

Alexander is happy to tell us about working on an unusual dump truck. The first thing he notes is more power and traction. With a full body, the car goes uphill well.

In the quarry on Bolshaya Talda, where the dump truck operates, it was even given the funny nickname “Tatarsila”. In addition, Alexander confidently drives his dump truck over potholes and bumps, while other Belazi drivers try to go around them, as well as make forced stops and starts on slopes.

For the operator of special equipment, this is a fundamental point: in the area where the excavator is working, the quality of the surface is far from ideal, and maneuvering a loaded BELAZ is not so easy.

By the way, the speed has also increased - when driving on a long shoulder, the improved dump truck overtakes its iron colleagues - this is possible, among other things, due to a larger control range with constant power.

It is also convenient for Alexander to drive the updated dump truck to load because his vehicle has an intelligent anti-rollback system - there is almost always a slope at the loading site, and the vehicle rolls down when the selector is moved to position P.

For work in a quarry, this is a fundamental point: it is necessary that when the car drives up a slope, the driver can fully release the gas, while the dump truck stops smoothly and under no circumstances goes back.

Well, when the selector was in reverse, it didn’t roll forward.

Holding a loaded car is a simulator with elements of acrobatics for the driver, so the developers paid special attention to the recoil system. The solution created by the developers keeps electric motors “under current” both at near-zero speeds and when the accelerator pedal is released.

Another important point is that the operator’s work has become safer due to the improved braking system. If a standard BELAZ with such a carrying capacity has a braking power of 800-1000 kW, then on this dump truck the developers managed to increase this figure to 1250 kW.

“There are some standard options for wheeled vehicles that were not initially provided for on BELAZ vehicles. For example, ABS.

During our internship, we were taught: if the drive wheels are blocked, we need to accelerate. But on my car this problem does not happen at all.

And full-fledged cruise control has also appeared - we call it a speed stabilizer. This is also an important point, because technological roads are, most often, either mud or ice, so without such a solution the car will slip.

I also don’t encounter such a problem as “the switch was knocked out” - this is not an uncommon story for Belazians. Imagine: you’re driving a loaded car, and then you need to quickly get out of the cab and turn on the automatic machines - you don’t want to do this at all,” says Alexander.

And further…

The company's engineers add on their own: the machine is repaired less frequently than other dump trucks. She had a chance to visit the box only to repair the suspension and minor faults identified during operational tests, which were subsequently eliminated (and the converted BELAZ has been operating at the sites of Region 42 partners since January 2022). In addition, fuel consumption has decreased.

Region 42 specialists show us a control cabinet installed on the deck. Conversion technology is another feature of the machine.

The cabinet has a high degree of protection - IP67 and autonomous liquid cooling, and, as they explain to us, this ensures reliable protection of electronics from dust, moisture and stabilization of operating temperature, which is extremely important for the operating conditions of mining dump trucks.

We note that the cabinet is unusually small - lower than on standard BELAZ vehicles.

It turns out that there is a direct connection here - with this level of protection and cooling method it was possible to reduce the dimensions of the product. This is an important nuance: although it seems that the BELAZ is a huge machine, in fact, there is not much space on the deck. And the lower cabinet gives the driver greater visibility on the right.

The control cabinet is sealed, that is, it is not only not necessary to open it, but it is completely impossible. The owners of the dump truck were only happy about this turn: an entire item in the scheduled maintenance disappeared, but working with electronics is not only a labor-intensive, but also an unsafe process. Therefore, a sealed control cabinet is just what the doctor ordered.

In general, the owners do not regret that they undertook the experiment, and today they confirm that it was successful.

Connection of times

All these changes were made possible thanks to the use of a new type of electric machines. The DC motor has held its position for a long time, remaining the most commonly used drive for creating continuous motion.

Its weak point is the collector unit, working with which imposes a lot of restrictions. The asynchronous motor, which has recently been gaining momentum in popularity, does not have this drawback.

Its disadvantage is the short-circuited rotor winding, which tends to heat up, and, therefore, the problem of heat removal arises. This is what the development team set out to solve, finding a way to create a synchronous motor without a rotor winding.

Although the updated engine of the dump truck bears the marking of ZAO PTFC ZTEO, a whole team took part in creating the system.

The synchronous traction generator GST-850 is truly a development of JSC PTFC ZTEO. Single-pole synchronous traction motors DVIT-320 were developed at the Federal State Budgetary Educational Institution of Higher Education "National Research University "MPEI", and the design was optimized and produced at JSC "PTFC "ZTEO".

The control cabinet (SHU B-90) is the work of NPP CYCLE PLUS LLC, and specialists from NPF Vector LLC worked on the creation of the upper level controller. As a result, KTEO was born, which has unique characteristics.

It was not for nothing that Region 42 engineers called this traction electrical equipment the technology of the future. Today, several manufacturers are working on the creation of such systems - among them there are representatives of Russia, Belarus, the USA and Europe, however, a like-pole synchronous motor and a sealed control cabinet with such an intelligent control complex have been used for the first time.

“We set ourselves the task of making a new, more advanced product. CJSC PTFC ZTEO is an asset of the Tatelektromash holding, an enterprise with a long history, and the plant specializes in the production of electrical equipment specifically for heavy-duty mining dump trucks.

Their partnership with BELAZ has been going on for many years.

And today we have assembled a whole team of professionals to not only present products that are competitive with foreign analogues, but to create an advanced solution,” said Mikhail Kotelnikov, leading engineer of SPE CYCLE PLUS LLC.

The authors based their development on a synchronous electric machine with axial excitation, the design of which was proposed by Pavel Yablochkov for a generator back in the middle of the 19th century. And today the idea of ​​the creator of “Russian Light” is gaining a second birth.

Dump truck 7558С. The first one went!

Of course, the development team wants to go further. The converted BELAZ is only a starting option: dump trucks with the new KTEO should roll off the assembly line of the Belarusian plant. And now machine number one is already ready: the 7558C modification dump truck has already been released in Zhodino and today is waiting for its owner.

Optimization of electrical parameters and control algorithms of DVIT-320 made it possible to increase the power of these engines to 370 kW. After the dump truck passes operational tests, the vehicles will be put into production.

As they say, there is no limit to perfection: on the first factory machine, the developers were able to implement several more useful options.

This is a completely unusual adaptive internal combustion engine control system.

Standard systems deliberately underload diesel - a certain amount of kilowatts is allocated for the operation of hydraulics or other systems powered by the engine.

But, explains Mikhail Kotelnikov, they do not constantly consume power, which means there are unused reserves.

The adaptive system allows you to monitor the condition of the internal combustion engine and, if possible, load it up to 98%. Due to this, the speed characteristics of the dump truck have increased.

“Thanks to the adaptive engine control system, we were able to introduce another improvement. When a standard BELAZ starts to slow down, the engine speed increases - even when driving in a straight line or moving around the pits.

We didn’t even immediately understand why such difficulties were needed. And they are needed to cool the engine. But if we have already created the ability to monitor and know the temperature of all units, such “crutches” were not needed.

We implemented a cooling system taking into account the current temperature: the engine does not increase speed unnecessarily, we save fuel,” says Mikhail Kotelnikov.

The recoil system has become even more intelligent: the developers have found the opportunity to combine its operation with a working parking brake. In this way, it was possible to reduce the heating of the traction motors.

An original solution is a brake resistor fan rotation sensor: if something is wrong, the system signals or even stops the car. The solution increases safety: when braking using hydraulics, the pads can burn out, but why do we need additional risks?

The developers talk about their iron horse with enthusiasm, rejoicing at the ideas they have implemented. The authors are making plans for the future: the 90-ton BELAZ is, of course, one of the most popular models in Russian production, but it is far from the smallest (55-ton trucks are also available) and not the largest (the record is 450 tons). Therefore, there will be enough work for the future: the creators intend to release a standard series of KTEO to equip the entire line of dump trucks of the Belarusian plant.

“The use of an AC traction electric drive in the design of a mining dump truck provides a number of advantages:

• reduction of operating costs;
• increased productivity during transportation;
• improvement of traction and dynamic qualities, wider range of operation in dynamic braking mode, which can be applied to zero speeds without a time limit;
• the ability to overcome longer slopes, the characteristics of traction mode and dynamic braking mode are significantly higher;
• increase in maximum speed to 67 km/h;
• improving the operational characteristics of the dump truck;
• reduction of time for maintenance and repair, the number of serviced units is smaller, and their service life is longer.

Trying to speed up operational testing of their development, specialists from PTFC ZTEO entered into an agreement with Region-42, as a result of which the described modernized dump truck appeared. The drive (KTEO) was created with BELAZ, and the first sample of the dump truck would have been assembled at the plant in any case. The main one for us to start work on was the DVIT-320 (traction single-pole synchronous electric motor).

Today there is a dump truck with KTEO at the plant. If the operational tests are completed with a positive result and the dump truck is in demand among customers, the solution will go into production,” experts note.

e-mail zteo.ru

Sources

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Excerpt characterizing BelAZ-75570

The Cossack accompanying Nesvitsky handed over a handbag and a flask, and Nesvitsky treated the officers to pies and real doppelkümel. The officers joyfully surrounded him, some on their knees, some sitting cross-legged on the wet grass. - Yes, this Austrian prince was not a fool to build a castle here. Nice place. Why don't you eat, gentlemen? - said Nesvitsky. “I humbly thank you, prince,” answered one of the officers, enjoying talking with such an important staff official. - Beautiful place. We walked past the park itself, saw two deer, and what a wonderful house! “Look, prince,” said the other, who really wanted to take another pie, but was ashamed, and who therefore pretended that he was looking around the area, “look, our infantry have already climbed there.” Over there, in the meadow outside the village, three people are dragging something. “They will break through this palace,” he said with visible approval. “Both,” said Nesvitsky. “No, but what I would like,” he added, chewing the pie in his beautiful, moist mouth, “is to climb up there.” He pointed to a monastery with towers visible on the mountain. He smiled, his eyes narrowed and lit up. - But that would be good, gentlemen! The officers laughed. - At least scare these nuns. Italians, they say, are young. Really, I would give five years of my life! “They’re bored,” said the bolder officer, laughing. Meanwhile, the retinue officer standing in front was pointing something out to the general; the general looked through the telescope. “Well, so it is, so it is,” the general said angrily, lowering the receiver from his eyes and shrugging his shoulders, “and so it is, they will attack the crossing.” And why are they hanging around there? On the other side, the enemy and his battery were visible to the naked eye, from which milky white smoke appeared. Following the smoke, a distant shot was heard, and it was clear how our troops hurried to the crossing. Nesvitsky, puffing, stood up and, smiling, approached the general. - Would your Excellency like to have a snack? - he said. “It’s not good,” said the general, without answering him, “our people hesitated.” – Shouldn’t we go, Your Excellency? – said Nesvitsky. “Yes, please go,” said the general, repeating what had already been ordered in detail, “and tell the hussars to be the last to cross and light the bridge, as I ordered, and also to inspect the flammable materials on the bridge.” “Very good,” answered Nesvitsky. He called to the Cossack with the horse, ordered him to remove his purse and flask, and easily threw his heavy body onto the saddle. “Really, I’ll go see the nuns,” he said to the officers, who looked at him with a smile, and drove along the winding path down the mountain. - Come on, where will it go, captain, stop it! - said the general, turning to the artilleryman. - Have fun with boredom. - Servant to the guns! - the officer commanded. And a minute later the artillerymen ran out cheerfully from the fires and loaded. - First! - a command was heard. Number 1 bounced smartly. The gun rang metallic, deafening, and a grenade flew whistling over the heads of all our people under the mountain and, not reaching the enemy, showed with smoke the place of its fall and burst. The faces of the soldiers and officers brightened at this sound; everyone got up and began observing the clearly visible movements of our troops below and in front of the movements of the approaching enemy. At that very moment the sun completely came out from behind the clouds, and this beautiful sound of a single shot and the shine of the bright sun merged into one cheerful and cheerful impression. Two enemy cannonballs had already flown over the bridge, and there was a crush on the bridge. In the middle of the bridge, having dismounted from his horse, pressed with his thick body against the railing, stood Prince Nesvitsky.