Cab Contained Electrical System Conserves Machine Space & Manufacturing Costs
Opportunity:
The OEM approached GS Global Resources looking for a cab redesign that could not only have a more efficient electrical set up but could also improve operator safety and experience and incorporate more innovative controls. Their original cab design for a mining wheel loader had all of its electrical wiring housed in a large, standalone, stainless steel box. GSGR relocating that wiring and integrating it into the cab itself would be very beneficial for the OEM.
Solution:
First and foremost, our engineering team successfully moved all of the wiring originally held within the standalone box to an enclosed section at the rear of the cab. This not only eliminated the cost of that separate structure, but also eliminated the need for numerous interconnecting cables. Furthermore, the additional real estate on the machine freed up by removing the steel electrical box was then reallocated to an essential cooling cabinet. This cabinet had a much sleeker design and was much more accessible for servicing than the previous solution. Overall, these external changes created a more cohesive machine layout and appearance with the entire electrical system seamlessly integrated into the cab itself.
The electrical updates also allowed our engineering team to design a more efficient HVAC system. Originally placed in the back of the cab, the HVAC system required external ducts to get air to the operator. The new design moved the HVAC system closer to the operator in the front of the cab, eliminating the need for external ductwork and reducing environmental impact. Additionally, we programmed a new MD4 display in the cab to include HVAC control, improving accessibility and control by the operator. This also eliminated the machine’s outdated control panel and utilized a more innovative solution.
Along with the added display, our engineers took many other steps to improve the overall efficiency of the cab’s control system. The new MD4 display could also be used to access new diagnostics capabilities, allowing operators to proactively avoid machine issues, and resulting downtime. The new control system also utilized CAN-based MRFM fuses and relays, further improving the operator’s ability to monitor machine health and status.
Finally, we also created a more ergonomic operator control station by reorganizing the cab’s controls and adding a few new features. Originally, controls were located on the lower dashboard and above the windshield, forcing operators to completely stop their task to utilize them. In order to maintain all the current functions and improve their placement, GSGR engineers designed an ergonomic armrest assembly, consolidating all of the controls and making them much more accessible to the operator. Also, a high priority for the OEM was to improve operator warning relating to safety, as the original cab had a simple red and amber dashboard light. In the new design, a detailed, programmable LED indicator panel was installed above the windshield, more directly in the operator’s sight line, improving overall safety.
Result:
- All electrical wiring is seamlessly integrated into the rear of the cab, reducing manufacturing costs and creating space for other essential machine controls.
- Improved operator safety and experience through a more comfortable, efficient, and ergonomic control station, as well as increased operator visibility by removing previous center console controls and going to a dual windshield wiper system.
- Updated components that are CAN based, giving the operator additional diagnostic capabilities.
