Otr Wheel Engineering - Wheel inspection program 2012

Wheel Safety, Maintenance and Inspection

HISTORY

• Heavy equipment over the years have been scrapped or sold as surplus.

• Many useable parts or spares, such as wheel assemblies remained in the inventory.

• Rim failures began to be noticed in 1990’s.

• Rims from the late 1960’s and 1970’s were still in the inventory.

Plan to Reduce Rim Failures

• Remove all rims manufactured prior to 1985, immediately!

• Visually inspect all rims, before returning to service.

• Identify all rims by manufacturer (design).

• Stamp serial number and track all rims.

• Begin NDE testing and maintenance program.

Why Track and Maintain Rims?

There is no such thing as a SMALL Accident

when it comes to Rim Failure!

The Hazard Defined

26.5 x 25 tire at 90 psi has

373,650 ft/lbs of stored energy.

For example, released “instantly” it packs the

power equal to move a 200 Lb man

1,868 feet in one direction.

The bigger the tire and wheel –

the more stored potential energy!

27.00R49 tire at 102 psi has

1,309,800 ft/lbs of stored energy. Which is

equal to moving a 200 Lb man

6,549 feet in one direction. (Note: All stored energy calculations courtesy of Goodyear Tire OTR Engineering Department, August 2009)





The bigger the tire and wheel –

the more stored potential energy!





59/80R63 tire at 102 psi has




Wheel I.D. location

Rim Brand

Valve Hole

Cross Section of Rim

Rim Brand

Valve Hole

Rim Brand

Front View of Rim

•All rims are branded directly in line with the valve hole. On rims that

have the centre plate in the mid section of the wheel the front brand # is

stamped onto the inner part of the gutter section. In the case that a rim

has a centre plate flush to the top the brand is directly stamped on the

face of the plate.

•Inspect wheel and wheel components for any defects

•Any rims without brand #’s automatically are sent out for a complete inspection (if requested by customer)

•No tire is to be mounted on a wheel that has not been branded (if requested by customer)

•All wheels with brand #’s must be verified in the Rim Tracking System ( Contact North Shore) to see if an annual inspection is required (if requested by customer)

Responsibilities – Tire Shop

• Field/ Tire Shop Inspection

• Preliminary Inspection –

– Visual inspection of rim assemblies should be done every time it comes in to your shop

– All rim base(s) which have been dismounted prior to their annual Nondestructive Evaluation (NDE) inspection shall be visually inspected for defects

Points to Consider • Hardware is considered as consumable product.

• Hardware is defined as:

• Bead Seat Bands

• Rim Flanges

• Locking Rings.

• Hardware, which is suspected of having defects or distortion, shall be discarded.

• All hardware shall be inspected by Field and Tire Shop Personnel prior to its' reuse.

Visual Rim Inspection Criteria

• Gutter section • Back section • Puller nuts • Stud holes • Bolting plate weld • Rim base welds • General condition • Rim Components

(lockring, flange and beadseat)

• Run flat • Check last NDE

Lock Rings Sprung / Stretched

Good

Locking Ring - The locking ring shall be visually inspected for wear,

“sprung”, corrosion, flat spots, ovality and warping misalignment

(sprung).

Gutter Inspection Go-No Go

gauge

Lock ring

groove

•Lock ring grooves are inspected using a go no go gauge for wear & damage

Worn Lockring Groove

Non-consistent lock ring groove

Back Section/Bead Seat Inspection

Go – No Go gauges

Bead Seat Band - The bead seat band shall be visually inspected for

cracks, wear or corrosion in the area in contact with the locking

ring flange, rim base or any weld. A wire brush may be used to

clean the dirt prior to the use of the Go No go gauge. (See below)

Worn Back Section

Worn out flange mating surface

Lock Ring groove problems Washed out lock ring

grooves

Stress fatigue fractures

Caused by: Friction welding

(Fretting, Galling)

Aggregate

Corrosion

Great reasons for doing a safety inspection of the rim

Non Pressure

Zone –

Extreme Danger

Pressure

Zone

Rim Components Proper Improper

OTR can provide charts to match rim components to ensure the

proper hardware is put on to the right rim base.

Hardware Worn Side ring Good Side Ring

When conducting a visual inspection, do not only look for cracks and damage

But also look at the hardware to make sure you will achieve optimal tire

performance.

Stud Holes

Elongated or worn stud holes can lead to improper torque, which in

turn can lead to the wheel coming off the piece of equipment. This

can be repaired by re-facing or re-placing the center plate.

elongated

Damaged Gutter Section

Run Flat

•Visually inspect all wheels and wheel components

•Track rims with database

•Issue a report for each individual wheel

•MPI test wheels when needed (annually or when damaged)

•Repair or replace any wheel or wheel component when needed

Responsibilities – OTR

Tire Size 21.00x25

When this wheel failed it killed 1 mechanic and seriously injured

the second. The crack on this wheel was in the lock ring groove

above the pressure zone.

Tire Size 17.50x25

This tire was aired with the lock ring not seated properly and

when the lock ring let go there was enough force in this tire

that it pulled the axle out of the housing.

Tire Size 10.00x15

Tire flew 50 ft from the machine when the wheel failed

Rim Tracking

• All wheels inspected are stamped (branded), recorded and tracked in our database.

Rim Tracking

The Rim Tracking software allows us to track the number of wheel assemblies

held by each customer, where they are located, (ie, at the site, out for repair etc)

and what repairs have been done to date.

Rim Tracking

Each wheel is assigned a specific number. This way we can track the repairs done

on each wheel along with the cost of the repairs, and issue a detailed report to our

customers when requested.

Criteria For MPI Testing

• Test all rims within one year of service to determine warranty claims and annually thereafter.

• Test any rim prior to major repairs (centre plate change, reface).

• Visual damage (run flat, rim impact).

Shot Blasting

• The next stage of inspection requires the wheel to be sent out to be shot blasted to remove all rust, scale & paint.

MPI (magnetic particle) Inspection

• After the wheel is shot blasted & passes visual & gauge inspection it is MPI tested for fatigue cracks that are not clearly visible.

Refinishing - Paint Line

• Once the wheel has passed inspection it is repainted to OEM or Customer preferred colors.

Thank you

From your partners in safety and Service

OTR Wheel Engineering, Inc.

Business

Otr Wheel Engineering - Wheel inspection program 2012