Elphinstone underground support solutions

ELPHINSTONE, located in Tasmania’s north west, are leaders in the innovation and design of underground mining support vehicles.

The company has recently developed and released six new vehicles for this unique and demanding environment and the first production units are already on their way to North America, South America, Russia, Africa, Asia and Australia.

There are two fundamental platforms, with specialised underground attachments for different applications.

The first is the WR820 series – a 20t base platform – and the other is the WR810 series – a 10t platform.

The WR820 Series currently comprises a water cannon, an agitator (in 8m3 or 10m3) and a water tank.

The WR810 Series currently comprises a scissor lift, a 6m3 agitator and a fuel and lube truck.

The Elphinstone engineering, research and development division has an extensive program to develop new configurations for other applications and to complement the existing range.

Engines and power trains

At the heart of both platforms are CAT engines – world-renowned for their smooth torque delivery, reliability, fuel efficiency, readily available parts and product support.

The WR810 Series vehicles are equipped with CAT’s C7.1 ACERT engine, which meets Tier 3 EPA regulations.

The engine delivers 158kW (214hp) net and 922Nm of torque from its 7.1-litres of displacement, at 1400rpm.

Due to their extra payload capacities, the WR820 Series machines are fitted with CAT’s C11 ACERT engine, which delivers 239kW (321hp) net and 1430Nm of torque from its 11.15-litres of displacement, at 1300rpm.

By the end of 2019 there will be a new CAT Tier 4 Final engine for the WR810 platform.

Countries with strict engine emission levels will benefit from this option.

All of the engines feature CAT’s proprietary ACERT technology and their ADEM A4 control module to control the common rail fuel injection solenoids and achieve emission requirements through controlled combustion, rather than via exhaust gas recirculation.

This higher level of fuel control throughout the combustion cycle not only improves emissions but translates directly into lower fuel consumption as the engines are simply working more efficiently and using less fuel.

Literally boosting each engine’s performance is a turbocharger, fitted with a computer controlled wastegate that allows higher boost pressures to be brought in earlier in the rev range to increase useable bottom-end torque.

Backing up that power in the WR810s is a five-speed (three-speed reverse) transmission fitted with a lock-up torque converter.

The WR820s are fitted with a six-speed (single speed reverse) power shift transmission, also with a lock-up converter which stops converter slip under certain load and rpm conditions (such as empty return), when torque multiplication is not required, to increase road speed and reduce fuel consumption.

Serviceability

Downtime during service and maintenance is dramatically reduced on all Elphinstone vehicles through some clever engineering and design features incorporated with service personnel in mind.

Large, hinged engine enclosure doors make servicing easy and fast, as do removable floor and side plates.

Quick-change air filters and 500-hour oil service intervals also reduce downtime and keep machines in operation longer for greater productivity.

A centralised onboard service centre includes fast fill and evacuation points and points to take uncontaminated fluid samples for analysis.

The 24V electrical system features colour-coded wiring circuits with individual circuit breakers.

All wiring is double-insulated, sealed to keep out dirt and moisture and covered with fire-resistant material.

An on-board diagnostic system continuously checks all critical machine functions for early warning and fast fault finding, with all data recorded for analysis.

Maintenance, technical assistance and access to spare parts is simplified through the worldwide Caterpillar dealer network and the Elphinstone product support team.

Safety

Safety is one of the most important aspects of any piece of machinery employed in the mining world.

All WR810 and WR820 vehicles feature anti-skid deck surfaces; three-point access to cab and machine; retractable seat belt; steering frame lock; hinged belly guards; ceramic coated exhaust manifold and turbine housing; triple insulated battery cables; fuel water separators made of non-flammable material; firewalls and heatshields; machine interlocks; a centralised isolation point (engine disconnect switch, starter isolation switch, jump start receptacle and fire system activation if fitted); and an optional integrated fire suppression system.

Integrated into the operator station is a ROPS/ FOPS (Roll-Over Protective Structure), ISO 3471:2008, (Falling Object Protective Structure) ISO 3449:2005 that offers protection to the operator.

Operator station

In addition to the safety features mentioned, the operator stations can be optioned as fully enclosed and climate controlled if required.

Various seat options are available from a mechanical suspension seat to an active suspension seat for premium operator comfort.

The WR810 operator cabin has been designed to seat three people in comfort and with exceptional visibility.

Operator training is simpler and safer with the trainer positioned next to the operator.

In the working environment, a three-seater cabin allows for the complete crew to go collectively rather than deploying an additional light vehicle for personnel transport.

The transmission control for forward, reverse and gear range is conveniently located for the operator’s right hand.

The machine controls are ergonomically designed and positioned allowing the operator to control machine functions with minimal effort, resulting in greater concentration on vehicle operation, with reduced operator fatigue.

An engine protection system is fitted that will shut down the engine if low engine oil pressure, low coolant level or coolant over-temperature conditions are experienced.

Conveniently located and easy-to see gauges and displays make monitoring machine systems as simple as possible.

The system continuously provides critical machine data and a three-level warning system alerts the operator of any abnormal conditions.

Grade control

Elphinstone identified an opportunity to expand its growing range of underground support vehicles by including a haul road maintenance vehicle, based on the Caterpillar 120K and 120M surface grader platforms.

The key role of the underground grader is to create a safe, consistent access throughout the underground tunnel network, ensuring all production, support and light vehicles can move freely in a safe and controlled manner with optimal efficiency.

The added benefit is the improvement to the production equipment tyre life due to well-maintained haul roads.

Elphinstone initially acquired the IP for the UG20M and UG20K underground graders from Ground Force, before further refining and customising these existing platforms to ensure compliance and performance in the harsh and demanding underground environment.

In addition to Elphinstone’s leading operator safety and ergonomics features, a robust rear guard is installed to provide rear protection to the machine itself and the front of the machine features a counterweight for machine balance.

Operation and manoeuvrability are enhanced via an optional shortened gooseneck frame and mouldboard resulting in improved turning radius with the standard articulation features of the grader.

Mouldboard lift cylinders and exhaust have been redesigned to a low-profile configuration.