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Payload Meter 3 Frequently Asked Questions August 2003

Payload Meter 3 Frequently Asked Questions…

What is Payload Meter 3?

Payload meter 3 is a small electronics box that measures the payload in off-
highway mining trucks from Komatsu.

How does it work?

Payload meter 3 monitors the pressures in the front and rear suspensions of the
truck. It uses these values to calculate the empty and loaded sprung-weight of the
truck to determine the payload being carried.

Does it calculate GVW?

No. The payload meter 3 does not calculate gross vehicle weight. The system
can only measure the "sprung-weight" supported by the suspensions. Items like
the tires, spindles and drive case are below the suspensions and are not included
in payload meter's calculations.

Does it work?
Yes, historically there are over 200 units running with the PLM III since 2001.
Of those units, scale tests from several mine sites have confirmed the accuracy.

Will it be reliable?
Yes, see above. The number of connectors has be significantly reduced. The
wiring uses a new, heavy duty industrial cable and ring terminal connections for
durability an easy diagnostics.

How accurate is it?

The payload meter 3 is designed to calculate the payload with a 1% repeatability.

What if the calculated payload doesn't match the in-ground scales?

Individual differences between pressure sensors and PLM3 circuit boards can
consistently shift the payload calculation. Because of these effects, any particular
truck may be consistently up to 7% off in payload calculations. However,
because of the repeatability of the payload meter 3 system, this systematic error
can be compensated.

How many loads will it record in memory?

Up to 5208 loads can be stored in memory. When the memory is full, the oldest
745 loads are erased from memory and the PLM3 continues to record haul cycles
without error or fault.

Will PLM3 work with Modular Mining?

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Payload Meter 3 Frequently Asked Questions August 2003

Yes. PLM3 has a second communications port dedicated to mine management

systems like Modular's Dispatch. In addition, the PLM3 has two CAN ports that
will be used in future vehicle monitoring systems.

How does payload meter 3 calculate payload.

Each haul cycle begins when the body comes down from the last haul cycle.
PLM3 determines that the truck is empty and begins a new empty truck tare
calculation for the haul cycle. While driving to the shovel, the payload makes a
series of calculations based on the pressures in the suspensions and the geometry
of the truck. After loading, the meter waits for the truck to travel 160 meters to
transmit an early estimate of the payload and then starts the final load calculation.
Once the load is dumped, the payload meter records the final payload calculation
and transmits the entire haul cycle data to mine management systems like
Modular Mining.

Does the payload meter calculate a new empty truck tare for every haul cycle?
Yes. This can affect the results from scale tests. The payload meter 3 is designed
to measure what is actually being hauled and dumped each haul cycle. A typical
scale test will only use 2 or 3 empty truck weights as an average empty truck
weight. This misses carry-back material. A detailed scale test of the payload
meter 3 must record the empty truck weight for each payload to accurately gauge
the performance of the system.

What data does payload meter 3 record for each haul cycle?
Carry-back from the last haul cycle is recorded as well as start time for the haul
cycle. While empty, payload meter records the travel distance, empty running
and empty stopped times as well as maximum speed and time when it occurred.
The same data is collected while the truck is loaded. Payload meter records the
number of swingloads as well as the loading and dumping times. For each haul
cycle the peak positive and negative frame torques are calculated. The peak
payload calculation and when it occurred is also part of each haul cycle record.
The operator's id number can also be recorded for each haul cycle. The tire-ton-
mph is calculated for each front and the combined rear tires. Also during each
haul cycle, the suspension pressures are monitored to determine the charge status
and warn when a flat suspension is detected. Finally, the PLM III can be used in
conjunction w/ Modular Mining to measure the relative road roughness of the
haul road and identify areas where maintenance is required.

What does the system look like?

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Payload Meter 3 Frequently Asked Questions August 2003

Load Lights
red
Pitch Inclinometer amber
2.6vdc = 0° green
24 vdc User Switch
-103mV/°
momentary NO
up = SELECT
down = SET
Suspension
Pressure Sensor L R
4000psi F F
4-20ma

Speedometer/
L R Load Display
R R

Payload RS232 - Comm 1

Meter 3

Data Port - Cab

Download Data
Configure PLM
Body Up Sensor
Troubleshoot
24vdc = down
open circuit = up

TCI - 70%
Brake Lock
TCI - Loaded
ground = on
TCI - Overloaded
open circuit = off

CAN port 1
CAN port 2

GE Speed RS232 - Comm 2

frequency input
from speedometer

Scoreboard

Power Laptop PC
Battery Power Download Data
Keyswitch Sense Configure PLM
Troubleshoot
Optional Scoreboard* and Dispatch System

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Payload Meter 3 Frequently Asked Questions August 2003

What does the black box look like and where does
it mount?
The PLM3 mounts on the back wall of the
cab and is covered by a metal panel.

How do I connect my computer to the PLM3?

The PLM3 system uses the same connector as
the PLM2 system. This connector is mounted
on the panel that covers the PLM3.

How does the operator read the payload? Where

is the operator display?
The operator display uses a
new dual
speedometer/display gauge.
The operator can see the two
most important pieces of
information speed and
payload.

Can the operator input their id

number? Can the operator
change the setup of the PLM3?
The operator can see the total
tons hauled and the number
of haul cycles for their shift.
They can also input their id
number and have it recorded
with the haul cycles for their
shift. All of this is done
through a switch on the
dashboard. This switch can
also be used to display the
suspension pressures and
inclinometer value. This
switch cannot change any of
the operating parameters of
the PLM3. This switch can
be pressed all day long
without changing how the
PLM3 functions.

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Payload Meter 3 Frequently Asked Questions August 2003

Where can PLM3 troubleshooting be done?

All the PLM3 wiring comes to a central junction box mounted on the side of the
brake cabinet dedicated to PLM3 wiring. The wiring for the sensors comes of the
junction box, through a conduit over the left tire and out to the individual
connection boxes for each sensor.

junction box

conduit

wiring to the
rest of the
sensors and Left Sensor
lights junction box

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Payload Meter 3 Frequently Asked Questions August 2003

Can I use the PLM2 sensors on the PLM3 system?

No. Because of the traveling method for calculation, the sensors used need a
broader dynamic range than the PLM2 system. The PLM3 sensors are also
current loop sensors and will be more immune to electronic damage.

Does the PLM3 use the same software as the PLM2 for downloading?
No. Completely new "Payload Data Manger" program for Windows has been
written to take advantage of the new features of the PLM3 system.

How does the download software work?

The information is downloaded from the payload meter into a central database on
the laptop. The entire fleet of trucks as an operation would be downloaded into 1
database.

Does the software make graphs?

This data can be analyzed and graphed for each truck, model of truck, date range
or shift time. These queries can be used to produce graphs, reports and export
data.

Can I use this data in my spreadsheet programs like Excel or Lotus 123?
Yes, it is very easy to query the database and export the data in ".CSV" format
that can be used in spreadsheet applications. Data can also be stored in a
compressed ".ZIP" format for archiving or transmission via email.

Does the new PC software work with the PLM2 or PLM1?

Not at this time.

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