Redesign of tipper truck

Redesign of Tipper TruckSaurabh Nimsarkar

IDC IIT Bombay

Guide Prof. Ramchandran

Product Study

Product StudyUser Research

Product StudyUser ResearchDesign Direction and Brief

Product StudyUser ResearchDesign Direction and BriefForm and Function Explorations

Product StudyUser ResearchDesign Direction and BriefForm and Function ExplorationsEvaluation and Selection

Product StudyUser ResearchDesign Direction and BriefForm and Function ExplorationsEvaluation and SelectionFinal Model

Product Study

ChronologyHow it works?

Types of TippersEnvironment Study

Global Tipper TrucksIndian Tipper Trucks

Inferences Dimensional Drawing

Year 1900Graff and Hiffle

http://goo.gl/fR9846





Product Study

Year 1910Lauth Juergens

Dump Trucks By Donald F. Wood





Product Study

http://goo.gl/jTmS5t

Year 1920Crawler Tractor





Product Study


Year 1920Autocar Crica

Product Study





http://goo.gl/GyL4x3

Year 1928Model AA Dump

Truck

Product Study





http://goo.gl/nDrrxD

Year 1934Trak Truck

Product Study






Year 1951Euclid 1LLD

Product Study






Year 1952Fruehauf Side

dump

Product Study





Year 1958Autocar AP40

http://goo.gl/0F8BeM

Product Study





Loaded with dump such as sand, cement, concrete, bricks, rocks, mud, gravel, coal, asphalt

Unloading Operation

Unloaded Dump

Product Study





Dump BedFlat Bed

Hydraulics

Cabin

Frame

Product Study





Frame Configurations

Product Study





Frame

~1730 mm

*Scania Body Building Document

Product Study





Cabin Types

•Cab over Engine (CoE)•Conventional Cab •Semi forward cabs•Cab beside Engine (CbE)

Product Study





Cabin Types

Day Cab Comfort Cab Crew Cab

DAF

Volvo

Product Study





Hydraulic System

Product Study





Types of Hydraulic

Telescopic Hoist

Telescopic Dual HoistScissor HoistUnderbody Hoist

Product Study





Standard Tipper Trucks

Transfer Dump Trucks

Superdump TruckSemi trailer end dump truck

Semi trailer bottom dump truckSide Dump Truck

Product Study





Off Highway Tippers

Haul TrucksArticulated Dumpers

Product Study





Mining

Product Study





Roads and Cities

Product Study





Snow

Product Study





Rain, River and Forest

Product Study





Tipper Truck OEM’s

Ford

Freightliner

Hino Motors, Ltd.

International

Iveco

Kenworth

Mack

MAN

Mercedes-Benz

Moxy

Peterbilt

Scania

Sterling

Volvo

Wesco

Western Star

Hyundai

DAF

Isuzu

Nissan

Fiat Group

Tatra

Ashok Leyland

Force Motors

Hindustan Motors

Mahindra Navistar

Swaraj Mazda

Tata Motors

Volvo

CAT

JCB

Eicher

AMW

Bharat Benz

Scania

Product Study





VolvoFM Dumper

Product Study





Tata 1616

Product Study





Humanistic Aspects•Ergonomics•Aesthetics•Acceptability•Fit and finish•Usability

Technical Aspects•Materials •Processes•Mechanism•Performance and reliability•Usefulness

1. Ingress and Egress of Driver

2. Eye mapping and activity analysis of driver to reduce fatigue and noise

3. Signal to noise ratio for productivity

4. Driver seat comfort5. Character of the truck6. Aesthetic appeal of the

truck7. Fit and finish of the

interior 8. Usability includes how

is the operation performed in terms of

system level design.

Product Study





User Research

Observation on siteActivity Analysis

Problem IdentificationInterview and Questionnaire

Inference

Primary User – Driver Secondary User – Helper Tertiary User – Owner / Supervisor

Tertiary User buys truck on the basis of –•Cost•Productivity•Load Capacity•Efficiency

Primary User has no say in on the choice of the truck. Usability of truck is ignored!

User Research



Inference

Driver : AminAge : 55 yrs

Height : 1.7 mNo disability

Truck : Tata 1613Could weather, Uneven terrain Camera : Sony

dslr

User Research



Inference




dslr

Gets location of site from supervisor

Prepares to go to site

Checks oil : Transmission, brake oil,

Hydraulic, gear oil.

All oil gauge are in different position.

Operator enters the vehicle through the

door. Uses Right Hand to open the door.

Step of foot rest with right foot. Uses left

hand to hold hand grab. Gets left foot in

the cabin first.Operator sits on the chair

Helper sits beside himOperator starts the ignition

With the left hand, key on the left side

Vehicle starts on neutral gear.

If vehicle is not on neutral gear , operation

Is done with left hand.

Vehicle is started.

Operator Drives the vehicle at the site.

Along the way he changes gear and checks

in the rear mirror by moving his neck

At the work site, helper gets down the

vehicle and guides driver instructing driver

by shouting loud.

At the work site, helper gets down the

vehicle and guides driver instructing driver

by shouting loud.Transmission is set in reverse direction and

driver reverses. He often looks back and

do not use rear mirrors

Driver manoeuvres the vehicle near

the excavator . Driver stops at the

signal of helper and switch off

ignition.Driver awaits.

Excavator switches off ignition. Driver gets

out of the truck and peeks in the dump

bed. Once confirmed from excavator

operator driver starts engine.Helper gets in the cabin. Driver changes

gear and goes to the unloading site.

Helper gets down and guides driver to the

specific unloading point.Helper stops the driver and moves to the

rear of the vehicle to remove the hook at

the back for unloading.Helper signals operator.

Driver uses unloading liver by left hand

which is at left hand side of the driver

Driver also accelerates by right foot

keeping his right hand on steering.

Helper instructs driver to move front.

Driver changes gear and moves forward to

unload the truck.

User Research



Inference




dslr

Once unloaded, Driver lower the bed with

lever on left.

Helper gain fixes the hook of the bed and

get in the cabin.

Driver leaves for the next loading operation

and process repeats for around 2 hours.

After the work , operator drives back the

truck at the office site

Helper checks the vehicle and cleans it

User Research



Inference




dslr

1. Cabin was badly maintained. Instrument was not working

2. External parts which were not integrated with body were broken

3. Ingress problem because of height of vehicle4. Steering frequently causes fatigue5. Rear mirror hardly solve visibility problem6. For taking reverse, driver has to depend on

helper7. Dump bed too high for excavator8. Driver has to wait in cabin which is hot and

humid with noise, dust and vibration during loading

9. No consistent feedback of load distribution of dump

10.No feedback of unloading, Helper gives signal

User Research



Inference

What is your educational qualification?

How many years of experience you have?

Have you had any training in operation of Tipper truck? If so how many years?

What are the other vehicles you drive or have driven?

Currently working on which vehicle?

Are you the primary driver of the truck?

What are the in which environments you have previously worked?Day – Night – Cold – Fog – Rain – Snow – River – Hilly region – Forest

.How many hours you work in day, night and overtime duration?

User Research



Inference

In night shift where do you take rest or sleep?

Do you have any previous history of occupational hazard/disability or problem? Out of the following which is the most troublesome?Cabin Temperature – Noise – Dust – Vibration– Visibility issue

Out of the following which is the most troublesome? Left rear– Right rear – front leftfront right – Dump bed

How many people travel along with you while working and driving? Min/max?

Do you have any technical complaints?

Do you have any usability complaints?

Desired feature sought by driver and helper?

Out of the known trucks in the market which one is most desired? Why?

User Research



Inference

Most drivers are illiterateAll drivers haven't had any training.

No of User Interviewed - 7

Most driver liked other vehicle they drive other than tipper truck.

All drivers work for 8-10 hrs with excluding overtime. There is no regulation for driving and working hours.

Cabin has minimum 2 person and maximum 4 while working or driving.All driver complained about Heat and Humidity in the cabin, Mirror adjustability, Brake and steering problem. They rest and sleep outside cabin

User Research



Inference

Cabin Temperature 5Noise 3Dust 1.8Vibration 1.8Visibility 3.2

Problems Identified by User

Cabin Temper-atureNoiseDustVibrationVisibility

34%

20%12%

12%

22%

User Research



Inference

Left Rear 4.6

Right Rear 3.4

Front Left 3.2

Front Right 2.4

Dump Bed 2.6

Visibility Problems Identified by Users

Left RearRight RearFront LeftFront RightDump Bed

28%

21%20%

15%

16%

Design Direction and Brief

ObjectiveTarget user

Design DirectionsSpecification

Deliverable

Design Directions from User Research and Analysis :

Objective :

To design cabin of a tipper truck which is user centric

Target User :

Primary User i.e. Driver of the Tipper truck


Ingress and Egress should be user centric

Cabin which allows driver to sleep and rest

Design solution to make cabin more comfortable by reducing noise, heat

and vibrations.

Enhanced Visibility of Dump bed , minimize blind spots and reduce

dependence of helper




Deliverable


Unexpressed recommendations :

Bull bar or Bumper

Sun Glare Protection

Emergency Exit for safety.




Deliverable

Specification :

Existing Chassis of Tata 1613 will be used to design new semi forward cabin. Any alteration in the chassis if required will be specified.Engine, Wheelbase, Track, Tyre dimension will be same.Rear Unloading and Bed hoist mechanism will not be changed.




Deliverable

Deliverable :

Scale model of cabin 1:15

Timeline

Scania Package

Initial Explorations

Initial Explorations

Warm Up SketchesPackaging and Specifications

Layout and Form Exploration SketchesFunction Exploration

SketchesRenders

Packaging and Specifications

Exploration



SketchesRenders

Evaluation


Exploration

Manikin used is 95 Percentile Indian male – 1.77m



SketchesRenders


Exploration

Cabin for how many Person?

• From interview, 2-4 people travel in the cabin • 1 Driver , 1 Helper others 2 are workers or other

labor• Existing 1616 has seating for 3 (1+2)• Four people travelling is not recommended and

advisable in the small space.• Therefore proposed cabin design for 3 person.

Primarily for Driver and Helper and one extra passenger can be accommodated while driving.



SketchesRenders


Exploration

Will it be a day cab or sleeper cab?

• From User research, all drivers work in the night, do night shift and overtime. Fatigue is a major problem for lower productivity. All driver sleep outside the cabin or in temporary tents.

• Hence proposed solution – Sleeper cabin for Two person. Driver and helper.

• Cabin will be air-conditioned and sealed to negate dust, noise and vibration.



SketchesRenders


Exploration

Raising Floor Height



SketchesRenders


Exploration

Raising Floor/seat height



SketchesRenders


Exploration

Cabin Layout for seating and sleeping :

Indian male 95% percentile manikin was used. Dimension were

taken from Indian anthropometric dimensions for ergonomic design

practice - Debkumar Chakrabarti.

Seat width and thickness were taken from Volvo truck and were

checked for compatibility with Indian anthropometric dimension.

Volvo FH seat Dimension (519 X458 X97) mm

It was observed that Volvo seat dimension can be benchmarked for

Indian anthropometric dimension as well.

For dimensions refer page 78 of report

Exploration

Layout and Form Exploration Sketches

Exploration

Exploration

Function Exploration Sketches

Exploration

Exploration

Explorations

Renders

Renders

Renders

Exploration

Concept Evaluation

Renders

Selection

Selection

Modeling

Thank You

Redesign of tipper truck

Automotive

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