Design Optimization of Lightweight Mining Truck Trays
Project Scope
- Optimize design for lightweight mining truck trays
- Client required trays to last for 24,000 working hours but faced warranty
issues due to cracks
Business Challenges
- Strengthening trays while staying within weight limits
- Ensuring retrofit flexibility for existing trays and compatibility with new
builds
ARi’s Solutions
- Reinforced side walls of the tray design to enhance durability and prevent
cracks - Applied the optimized design to lightweight trays with payload capacities
ranging from 120m³ to 160m³ - Optimized the endcap design for compatibility with both retrofit and new
trays - Analyzed material properties and stress points to balance strength and
weight within specified limits - Collaborated with the client to ensure the design met operational
requirements and safety standards - Prepared a comprehensive manufacturing package, including 362 parts and
assembly drawings, ensuring efficient production
ARi’s Value Proposition
- Improved tray durability, eliminating crack-related warranty claims and
extending lifespan to 24,000 hours - Reduced maintenance and replacement costs through a robust, lightweight
design - Enabled retrofit compatibility, minimizing investment in new equipment
- Delivered high-quality output within a tight timeline, strengthening customer
trust and satisfaction
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https://www.arigs.com/wp-content/uploads/2025/11/Design-Optimization-of-Lightweight-Mining-Truck-Trays.pdf