Project Background
A leading mining equipment manufacturer approached XinSheng with a critical challenge: their 150-ton haul trucks were experiencing frequent overheating events in high-altitude, hot-climate mining operations. The existing cooling system was unable to cope with ambient temperatures exceeding 45°C combined with extreme dust conditions.
The Challenge
Operating Conditions
- Ambient temperatures: 40-50°C
- Altitude: 3,500m above sea level
- Dust levels: Extreme (open-pit copper mine)
- Operating hours: 20+ hours per day
- Engine power: 1,800 kW
Problems Encountered
The original cooling system suffered from:
- Rapid fin clogging due to fine dust particles
- Insufficient heat rejection at high altitude
- High fan power consumption (15% of engine power)
- Frequent maintenance requirements (every 500 hours)
Our Solution
Engineering Approach
XinSheng’s application engineering team conducted detailed analysis including:
- CFD simulation of airflow through the cooling module
- Thermal performance modeling at altitude conditions
- Fin geometry optimization for dust resistance
- Fan selection and noise optimization
Design Features
Optimized Core Design
- Wider fin spacing (10 FPI vs. standard 14 FPI) for improved cleanability
- Enhanced turbulator patterns for better heat transfer
- Single-row core arrangement for easy access
Modular Construction
- Radiator + CAC + hydraulic oil cooler in integrated module
- Quick-disconnect connections for field serviceability
- Corrosion-resistant materials and coatings
Improved Airflow
- Optimized shroud design reducing air-side pressure drop by 25%
- Variable-speed fan control integration
- Reduced recirculation with improved sealing
Results
After 12 months of field operation:
| Metric | Before | After | Improvement |
|---|---|---|---|
| Cooling Capacity | Baseline | +30% | Significant |
| Service Interval | 500 hrs | 2,000 hrs | 4x longer |
| Unplanned Downtime | Baseline | -50% | Major reduction |
| Fan Power | 15% of engine | 10% of engine | 5% savings |
Customer Testimonial
“The XinSheng cooling module has transformed our operation. We’ve seen a dramatic reduction in heat-related downtime, and our maintenance costs have dropped significantly. The engineering team’s understanding of our operating conditions was exceptional.”
— Mining Equipment OEM, Project Lead
Products Used
This project utilized the following XinSheng products:
- Modular Cooling Pack - Integrated radiator, CAC, and oil cooler assembly
- Bar & Plate Oil Cooler - High-pressure hydraulic system cooling
- Tube & Fin Engine Radiator - Primary coolant system
Applicable Industries
This solution approach is applicable to:
- Open-pit mining operations
- Quarry equipment
- Large construction machinery
- Any high-temperature, dusty environment
Next Steps
Interested in similar solutions for your application? Contact our engineering team to discuss your specific requirements.
