“Trailer code has brought in the standardization in trailer design. We are providing ABS Brakes system which gives proper handing of vehicle on sudden applied brakes and other safety devices like Side and rear Under Run protection Device. We are using trailer components like axles, King Pin and Landing gears which are certified by approved agency under AIS 113 code. These tested components give longer service intervals and less breakdowns in trailer which gives hassle-free service to transporters,” briefs Mr. Nikhil Panchal, Technical Director, Vasant Fabricators Pvt. Ltd., Ahmedabad.
Excerpts of his insights follow:
Mandatory and other safety requirements
Bulkers are unfired pressure vessels which operate up to 2 BAR pressure. We provided Pressure Relief valve that operates at set pressure and releases the appropriate air quantity to maintain the bulker inside pressure within limits. Safety valves and pressure gauges used in our bulkers are of reputed brand and calibrated which ensures their effective working and accurate reading respectively. All our bulkers are tested pneumatically up to 2.6 BAR for leakages and safe site operations.
While fabricating bulker we always take care of raw material and weld joints traceability, dimension controls of components which are essential things in pressure vessels. We also provide compressor in bulker. This compressor is PTO driven through shaft. We have to make proper alignment and fitting of compressor in such way that driving shaft rotates smoothly without any jerks and knocking.
In future we will supply Auto hatch which operates from the driver’s cabin. For material loading driver has to reach top of the bulker and open the loading hatch. They don’t have safety belts or other safety equipment. This is very unsafe operation. Sometimes drivers fall from the top and get serious injuries. Auto hatch restricts driver to go on top to open the lids. This will save time for loading operation and less efforts and fatigue to drivers. This feature will be very useful where bulker is loaded 4~5 times in a day.
We provide roll over protection device for Hazardous liquids and chemical tanks.
Safety features and highlights in operations
Most accidents happen in late night and in low visibility areas. So vehicle should have alarm or warning feature if driver is continuously driving or speeding and even vehicle speed should automatically reduce and restrict to low speed at certain low visibility areas. Vehicle should have Auto braking system so that on sudden braking by any vehicle, its following vehicle can maintain the safe distance for stopping. Vehicle brake shoes replacement alarm and any electric lighting fault indication should be there so that vehicle effective braking can be done. If all electrical lights like brakes light, indicator light, etc., function properly then following vehicle driver can judge the front vehicle movement. This will avoid major accidents.
Safety apprehensions at higher road speeds
Increasing speed limits of Highways and Express highways always helps to reduce transit time but a few changes required for safe travelling at high speed.
High-speed vehicles require more effective braking. Right now most loaded trucks run at 50~60 Kmph speed if we further increase the speed of the same vehicle its brake force is not enough to stop the vehicle in shorter distance. We should use disc brakes in trailers so that at shorter distance loaded vehicle can be stopped. Even use of EBD and ABS brakes also helps for better controlling of vehicle in turnings and skidding at high speed. Wheel balancing and alignment should be accurate, this will reduce the failure of any moving parts due to vibrations and jerks at high speeds. Manufacturers should design and test their components for 140 kmph speed rating then only we can stop breakdowns or failure of such cruicial components and reduce the mishaps.
Light-weighting necessity and trend
Lightweight vehicles are always beneficial for end users who carry rated loads. We are working on weight reduction in our product for last five years. We have introduced our first range of lightweight bulkers in 2012 made from High Strength steel. These bulkers are 1.5 MT lighter than the conventional mild steel bulkers.
Generally bulkers and some chemical tankers operate at one side load. In this case lightweight product will give better fuel efficiency and tyre life. Increased tyre life will reduce the carbon footprints. By increasing the load capacity per trip end user will gain more profits and this will reimburse extra pays for lightweight vehicle within 12 months; and he will carry more load in less fleet operation so overall fuel usage will be reduced compared to conventional bulkers. This will reduce the pollution in environment.
Overall light weighting is beneficial to user in long term.
Role of advanced materials in light-weighting
High Strength steel and Aluminum – Magnesium alloys help us to reduce our product weight significantly. Both materials are useful for different applications to reduce the weight of product.
For cement and other industrial powders, we are replacing Mild Steel with High strength steel, which reduces 30% weight of product without affecting the strength of the same. Generally High Strength steel Yield strength is more than 480 MPA, which is just double than 250 MPA Yield strength of Mild Steel. Still we are reducing only 30% thickness of material so yet being lightweight, high strength bulkers have more strength than the conventional bulkers.
For Polymer and food grade industries where Stainless steel is used, we are replacing them with Al-Mg Alloys. Aluminum is 65% Lighter than stainless steel. Al-Mg Alloy with H321 tempered has YS upto 220 MPA. By increasing thickness of aluminum compare to stainless steel we are getting the same strength of product but the weight of product will be reduced by more than 50%.
Now due to increasing cost of road infrastructure government is getting strict on overload vehicle so both Al-Mg Alloys and high strength steel will play crucial roles in light weighting the vehilcle over period of time.