Design and Development of the EJC88XLP
Introduction:
In Mid 2001, Sandvik Mining and Construction (SMC) recognized a need for mechanization
in the platinum mines of South Africa. This need had developed as a result
of a reduced labor force in the mines. Mechanization of the mines was to
increase over the next several years, and SMC proposed to the major platinum
mine owners a unique total mining package (later to become known as “Project
1.1”) consisting of a drill, bolter and loader, which would be sized
to operate in a 1.1meter (43 inches) narrow-reef platinum mining operation.
The Loader design became the responsibility of “EJC Mining Equipment”,
Burlington, Ontario, (A division of SMC).
First Team Meeting:
At the first meeting of the design team of “Project 1.1” the then
president of EJC Burlington, Lorne Massel, directed all present to crouch
under the table. He explained that the height of the tabletop represented
that of the roof of the mine. Our task was to design and produce a loader
low enough to fit into this restricted environment. This realistic demonstration
enabled us to recognize the challenge of producing such a vehicle.
Machine specifications:
o Diesel Powered
o Hydrostatic drive on all 4 wheels
o Articulated and oscillating center hinge
o Machine to have electronic controls and a diagnostic system based on the
Parker IQAN System.
o Machine to fit into a mine of Maximum 1.1meter high.
Design Concept:
In October 2001 the design project began, and the loader model was designated
as the EJC88XLP. The number “88” represented the maximum height
of the vehicle in centimeters (approximately the height of a man’s
hip joint to the ground). It was decided this project would be completely
designed, modeled, and processed using “Unigraphics 3D software”.
A simple design concept model was created in Unigraphics (UG). It was assessed
and analyzed to see if it adhered to the design parameters of the specification.
The machine model was subsequently divided into various modules for design
purposes, which were assigned to different members of the team. The “Top
down method” was used to construct the master model. This allowed the
entire family tree structure to be created in the “Assembly Navigator” before
any actual modeling commenced. Concurrent Engineering is essential for this
type of project, and UG was the best tool to achieve a successful result.
Unigraphic modules used during the design process were Drafting, Modeling,
Assemblies, Advanced Assemblies and Sheet metal. Ergonomics:
Operator comfort was an important issue. An extensive ergonomic study of the
operator’s compartment was therefore performed. Several solid model
proposals were created and a full-sized cardboard mock-up was assembled
to study and produce a compartment that was both comfortable and practical
for the operator. (Figs 2 & 3)
The results indicated that to comply with the required height restrictions,
an operator would need to lie on his back with his head supported and slightly
raised. Allowances also had to be made for the operator’s safety helmet
and emergency breathing apparatus.
As the design progressed reviews and status meetings were held frequently.
At these sessions the various design iterations were critiqued, and improvements
were suggested and noted for later implementation.
Master Model:
By early 2002 the design was finalized, and the “Master Model” was
frozen (Fig 4).
Engineering detail drawings and assemblies were created and passed over to
our Manufacturing Support department for processing.
Manufacturing Processes:
At EJC, all manufacturing processes are handled by the “Manufacturing
support” department. Parts are processed using two types of Unigraphic
Bundles. One is a “Manufacturing” bundle and the other is a “Machine
Manufacturing” bundle. Each bundle contains various UG modules such
as Fabrication, Nesting (Burn geometry), Sheet Metal, Cam Base, Milling,
etc. All the modules have been completely customized to suit EJC manufacturing
applications and methods.
Parts can be processed from design to manufacture.
Personnel on the shop floor can access the released drawings from their
workstations at any time, eliminating
the need for paper prints.
Completed Prototype:
By using Unigraphic’s “Master model” principle to address
any fit and assembly concerns relating to the prototype vehicle prior to manufacture,
problems were resolved quickly, and assembly time was significantly reduced.
The finished prototype machine was finally completed and rolled out of the
building under its own power in September 2002.
Conclusion:
It took eleven short months from the initial design of the structure, power
train, electrical system, diagnostic components, wheel-drive systems and
much more to the final production of the EJC88XLP.
Presently there are 20 machines in service in South Africa.
The design of this machine has subsequently won two prestigious awards.
•
Sandvik’s “Wilhelm Haglund Gold Medal for Product Development”.
This medal is awarded yearly to a particular division of Sandvik for an
outstanding achievement in product development.
•
OACETT’s “2003 Outstanding Technical Achievement award”. 
For further information on this machine and others in the EJC product line,
go to web site
www.ejc.sandvik.com
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