DESIGN AND DEVELOPMENT OF 3-WAY DROPPING DUMPER
ABSTRACT
Modern 3 ways dropping dumper has been conceived by observing the difficulty in unloading
the materials. The survey in this regards in several automobile garages, revealed the facts that
mostly some difficult methods were adopted in unloading the materials from the trailer. This
paper has mainly focused on above difficulty. Hence a prototype of suitable arrangement has
been designed. The vehicles can be unloaded from the trailer in three axes without application of
any impact force. The Direction control valve which activates the ram of the hydraulic cylinder
which lifting the trailer cabin in require side. Further modifications and working limitations will
put this work in the main league of use. This concept saves time & energy which leads to
efficient working.
INTRODUCTION
A dumper is a vehicle designed for carrying bulk material, often on building sites. Dumpers are
distinguished from dump trucks by configuration: a dumper is usually an open 4-wheeled vehicle
with the load skip in front of the driver, while a dump truck has its cab in front of the load. The
skip can tip to dump the load; this is where the name "dumper" comes from. They are normally
diesel powered. A towing eye is fitted for secondary use as a site tractor. Dumpers with rubber
tracks are used in special circumstances and are popular in some countries.
Early dumpers had a payload of about a ton and were 2-wheel drive, driving on the front axle
and steered at the back wheels. The single cylinder diesel engine (sometimes made by Lister)
was started by hand cranking.
The steering wheel turned the back wheels, not front. Having neither electrics nor hydraulics
there was not much to go wrong. The skip was secured by a catch by the driver's feet. When the
catch is released, the skip tips under the weight of its contents at pivot point below, and after
being emptied is raised by hand.
Modern dumpers have payloads of up to 10000kg and usually steer by articulating at the middle
of the chassis (pivot steering).
They have multi-cylinder diesel engines, some turbocharged, electric start and hydraulics for
tipping and steering and are more expensive to make and operate. An A-frame known as a ROPS
(Roll-Over Protection) frame may be fitted over the seat to protect the driver if the dumper rolls
over. Some dumpers have FOPS (Falling Object Protection) as well. Lifting skips are available
for discharging above ground level. In the 1990s dumpers with swivel skips, which could be
rotated to tip sideways, became popular, especially for working in narrow sites such as road
works. Dumpers are the most common cause of accidents involving construction plant.
A dumper is an integral part of any construction work and hence its role is important for
completion of any constructional site. One of the problem are cited with dumper in the time and
energy for setting the huge dumper in the proper direction to dump the material it in carrying and
hence the need of the project work riser which is about 3 way dropping dumper which can dump
the material in any direction except the rental one without moving the truck in any direction.
A dump truck (or, UK, dumper truck) is a truck used for transporting loose material (such as
sand, gravel, or dirt) for construction. A typical dump truck is equipped with a hydraulically
operated open-box bed hinged at the rear, the front of which can be lifted up to allow the
contents to be deposited on the ground behind the truck at the site of delivery. In the UK and
Australia the term applies to off-road construction plant only, and the road vehicle is known as a
tipper, tipper lorry (UK) or tip truck (AU).
A small scale model has developed using light weight material i.e. plastic and hydraulically
operated piston and cylinder arrangement. This hydraulic arrangement actuates on motor driven
which makes the prototype semi automatic.
Moreover, battery drives the motor handled using a control panel which is attached with the base
model using wires / FRC cable and after that controlled by operator. A conventional dump truck
is mounted on a truck chassis and has an open dump box hydraulically operated and hinged at
the rear of the truck usually by one or more hydraulic rams that raise the dump box to unload
contents at a delivery site. These hydraulic rams are either front loaded or mounted in the
underbody and are driven from a gear box power take-off. Hydraulic rams mounted in the
underbody provide the capability of the dump body to tip the dump box on a three-way basis,
either to the left or right side or to the rear.
How a typical tipper trucks works?
The tipping mechanism is the heart of a three way tipper construction truck. Tipping mechanisms
works basically as follows:
III-A Hydraulic Cylinder
A hydraulic cylinder is placed below the body of truck longitudinally at one end of the truck, and
the piston end of the hydraulic cylinders is connected by the means of a pivot joint to the chassis
of truck.
Hydraulic Cylinder Arrengement
In the forward stroke of the cylinder, it pushes the truck body upward thus gives necessary lift
for tipping dumping. So, in the forward stroke of the cylinder, the truck is unloaded. In the return
stroke of the cylinder the body of the truck comes to its original position.
III-B Hinge Joint
The other bottom end of the body of the truck is connected by a hinged joint with the chassis.
Unloading Position
3-way tipper can overcome this problem, as it can unload material on three sides.
III-C Three Way Tipper Mechanisms
As already mentioned, a three-way tipper can unload materials in all three sides. To control the
sides of tipping one more pneumatic cylinder apart from the main hydraulic cylinder is required.
Also we require special types of hinge joints in this case.
Tipper Body
The diagram of a 3-way tipper arrangement showing the main hydraulic cylinders are placed at
four corners of the chassis (structure).Each of the four corners of the body is connected by a
cross joint with the hydraulic cylinders. The cross joint allows the joining members to tilt with
respect to two perpendicular axis.
Suppose the side of cylinder 3 & 4 is rear of the vehicle, then by operating cylinder no.1 & 2 will
cause rear tipping, operating cylinder 2 & 4 will cause left side tipping, and operating cylinder 1
& 3 will cause right side tipping. Automation of tipping will be possible by using a power pack
with PLC control or some similar kind of automation devices
WORKING PRINCIPLE
Model has constructed using various material like MDF (Medium density fiber core) hard wood
plywood, 3/16 nuts & bolts, aluminum sheet, motors (DC), gearboxes, syringes, wheel screw,
nuts, toggle switches, push buttons, battery etc. Firstly, a base chassis structure is prepared using
MDF 8mm sheet. The structure is 22 in length and 11 in width. This structure incorporates
driving motor along with steering motor. These motors are fixed with a fixed reduction radio
gearbox of 100:1 to increase torque and reduce speed of the motor. The wheel base is kept 14
while the track distance to the output slate of the gearbox which is associated with the DC motor
and gearbox assembly is fixed in the wheel hub, and it is attached with the chassis using
aluminum sheet. A steering rod connects both the wheels of truck with a steering motor.
At the end of this chassis a platform of 26 x 36 cm which are pivoted on each and off opposite
sides. So as to four Z shaped. Each two platforms are connected using a plastic syringe piston
and cylinder assembly that forms the hydraulic piston and cylinder arrangement. Hydraulic fluid
in piston and cylinder arrangement pushed and pulled using a head screw arrangement. The
proper guide ways and guide slides make the fluid to flow through gearbox and motor. This
assembly is of three sections as there are three numbers of hydraulic cylinders that operates the
trolley. This power cylinder and piston arrangement is fitted in front of the trolley. These motors
are connected to the wired remote that incorporated toggle switches and push button, by
manipulating these buttons the entire work can be demonstrated. By operating the push button,
motor actuates the piston and cylinder arrangement which pushes the hydraulic fluid to the
cylinder beneath. The trolley piston gets out and makes the trolley to tilt by operating various
cylinders; the material can be dropped in 3 ways.
Advantages
Increased moving ability :
Thus, it does not become tiresome to perform the job.
Can be used in very compact places :
Where reversing & turning of vehicle is difficult.
Accommodate on dam site working.
Saves time & energy.
Increased complexity:
It requires complex mechanism for getting desired output.
APPLICATIONS
In coal factory etc
