DESC:TECHNICAL FIELD
The present invention generally relates to the field of Mechanical engineering. More particularly, the present disclosure relates to four post operator safety structure for protecting the operator and reducing noise of vehicle, adapted to be positioned around the seat of the operator in the cabin of a vehicle.
BACKGROUND
A motor grader, also known as a road grader, is a heavy-duty construction machine that is used to level and grade a variety of surfaces, such as roads, parking lots, and construction sites. Motor graders are commonly used in the construction and maintenance of roads and highways, as well as in the construction of airports, parking lots, and other large construction projects. Motor graders are typically operated by skilled operators who are trained to use the machine safely and efficiently.
As with any heavy equipment, operator safety is of utmost importance when operating a motor grader. Motor grader roll-overs and falls are serious safety hazards that can result in severe injuries or even fatalities. Motor graders are often used on sloping terrain or uneven ground, which can increase the risk of a roll-over or fall. Operating a motor grader at high speeds can increase the risk of a roll-over or fall, particularly when making sharp turns. Improper loading of the ripper can cause the machine to become unbalanced and increase the risk of a roll-over or fall.
Roll Over Protection Structures (ROPS) are typically designed to provide structural support and protection for the operator in case of a rollover accident. ROPS may add weight and bulk to the equipment, which can affect the overall noise level generated by the machinery.
Therefore, there is a need in the state of art for a safety device to protect operators of motor grader from the fall or roll over and also minimize the noise level of the motor grader.

SUMMARY
In one aspect of the present disclosure, a four-post operator safety structure for protecting the operator and reducing the noise, adapted to be positioned around the seat of the operator in the cabin of a vehicle is provided. The four-post operator safety structure comprises a bottom frame which is mounted on the ground by a plurality of roll pins, a plurality of vertical mounts mounted at four corners of said bottom frame at lower end, a top frame connecting said vertical mounts at the upper end and a top crossbeam, a pair of intermediate longitudinal mounts positioned on bottom frame at front end and rear end at an intermediate position between said first end and second end, a middle frame positioned horizontally or at an angle between top frame and bottom frame adapted to connect vertical mounts along the first end and the second end and partially on front end and rear end, a plurality of gussets and a plurality of cross beams.
In some aspects of the present disclosure, the rectangular bottom frame, plurality of vertical mounts, top frame, middle frame and a pair of intermediate longitudinal mounts comprises of high strength tubes filled with Poly Urethane foam to reduce impact and noise.
In some aspects of the present disclosure, the cross beams are mounted diagonally between the bottom frame and the middle frame.
In some aspects of the present disclosure, the gussets are positioned at a plurality of positions on the four-post operator safety structure to provide strength to the structure.
BRIEF DESCRIPTION OF DRAWINGS
The accompanying drawings, which are incorporated in and constitute a part of this specification, show certain aspects of the subject matter disclosed herein and, together with the description, help explain some of the principles associated with the disclosed implementations. In the drawing,
Figure 1 illustrates a four-post operator safety structure for heavy motor grader application, in accordance with an aspect of the present disclosure;
Figure 2 illustrates an integrated cabin with roll overprotective structure (ROPS) on heavy motor grader, in accordance with an aspect of the present disclosure;
Figure 3 illustrates 3D model of four post operator safety structure for heavy motor grader application, in accordance with an aspect of the present disclosure; and
Figure 4 illustrates cross section of the main ROPS structural items filled with polyurethane foam, in accordance with an aspect of the present disclosure.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Various embodiments of the disclosure are discussed in detail below. While specific implementations are discussed, it should be understood that this is done for illustration purposes only. A person skilled in the relevant art will recognize that other components and configurations may be used without parting from the spirit and scope of the disclosure. Thus, the following description and drawings are illustrative and are not to be construed as limiting. Numerous specific details are described to provide a thorough understanding of the disclosure. However, in certain instances, known details are not described in order to avoid obscuring the description.
References to one or an embodiment in the present disclosure can be references to the same embodiment or any embodiment; and, such references mean at least one of the embodiments.
Reference to "one embodiment", "an embodiment", “one aspect”, “some aspects”, “an aspect” means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the disclosure. The appearances of the phrase "in one embodiment" in various places in the specification are not necessarily all referring to the same embodiment, nor are separate or alternative embodiments mutually exclusive of other embodiments. Moreover, various features are described which may be exhibited by some embodiments and not by others.
The terms used in this specification generally have their ordinary meanings in the art, within the context of the disclosure, and in the specific context where each term is used. Alternative language and synonyms may be used for any one or more of the terms discussed herein, and no special significance should be placed upon whether or not a term is elaborated or discussed herein. In some cases, synonyms for certain terms are provided.
A recital of one or more synonyms does not exclude the use of other synonyms.
The use of examples anywhere in this specification including examples of any terms discussed herein is illustrative only and is not intended to further limit the scope and meaning of the disclosure or of any example term. Likewise, the disclosure is not limited to various embodiments given in this specification. Without intent to limit the scope of the disclosure, examples of instruments, apparatus, methods and their related results according to the embodiments of the present disclosure are given below. Note that titles or subtitles may be used in the examples for convenience of a reader, which in no way should limit the scope of the disclosure. Unless otherwise defined, technical and scientific terms used herein have the meaning as commonly understood by one of ordinary skill in the art to which this disclosure pertains. In the case of conflict, the present document, including definitions will control.
Additional features and advantages of the disclosure will be set forth in the description which follows, and in part will be obvious from the description, or can be learned by practice of the herein disclosed principles. The features and advantages of the disclosure can be realized and obtained by means of the instruments and combinations particularly pointed out in the appended claims. These and other features of the disclosure will become more fully apparent from the following description and appended claims or can be learned by the practice of the principles set forth herein.
The term “operator” is referred as a person who is operating vehicle or the motor grader.
The term “four post” or “four-post” is referred as Roll Over Protection Structures (ROPS) with four vertical posts that support the structure used in heavy equipment or agricultural machinery.
As mentioned before, there is a need for technology that overcomes these drawbacks, is more compact and requires less maintenance..
The present disclosure also provides a four-post operator safety structure for protecting the operator and reducing the noise, adapted to be positioned around the seat of the operator in the cabin of a vehicle.
Operator sits in the Rollover protective structure (ROPS) integrated cabin or workstation which is positioned at above the ground level, steering and work control system are located within the cabin shell. Four Post Rollover protective structure (ROPS) is mounted with the help of suitable roll pin connections (Not shown) and mounting bracket (Not shown) are integrated part of equipment main frame. During Rollover accident, ROPS experiences impact force more than 8 times of gross vehicle weight (GVW) will get transferred on lateral position of ROPS structure. In certain cases, equipment may even experience multiple roll over consider as worst case, ROPS experiences impact force around 19.62 times of Gross Vehicle Weight (GVW) will get transferred on vertical position of ROPS structure.
Important factors in ROPS design is that rollover structure must be stiff enough to withstand the impact forces and also flexible enough to absorb the all the kinetic energy developed during the rollover accident. It is expected that any ROPS member should not enter into the operator survival space called Deflection Limiting Volume (DLV). In this invention ROPS structure main pillar has been designed using high strength square tubes to meet the requirement for heavy motor grader application and strap and combination of formed gusset. Gussets are used which act as an energy absorber and it gives more strength to the ROPS to meet required performance criteria in case of rollover accident of motor grader.
This invention has uniqueness of its design, Roll over protective structure (ROPS) main ROPS structural items no. 101,103,104,105,112,115 and 116 are filled with Poly Urethane (P.U) foam as sound absorption material, high strength square tubes forms four Post Rollover protective structure (ROPS) gives the roll over protection to operator during rollover accident against impact force during the rollover accident of Heavy Motor grader.
From Fig.1 & 3, the main ROPS structural items no. rectangular bottom frame (101), vertical mounts(103), top frame(105),middle frame(104), pair of intermediate longitudinal mounts(112), plurality of cross beams(115) and top crossbeam(116) are filled with Poly Urethane (P.U) foam as sound absorption material and also these square tubes forms Four Post Rollover protective structure (ROPS).
Figure 3 illustrates 3D model of four post operator safety structure for heavy motor grader application, in accordance with an aspect of the present disclosure.
ROPS vertical fillers(103) are mounted at four corners of said bottom frame(101) on roll pins(114). The lateral load supporting beam 101,104 and 105 are connecting beams for ROPS and 116 is cross beam for load transfer. Roll pins (114) are mounted on the ground.
Figure 2 illustrates an integrated cabin with roll overprotective structure (ROPS) on heavy motor grader, in accordance with an aspect of the present disclosure.
Present ROPS structure is designed for Heavy Motor Grader application (65000 Kg Gross Vehicle Weight) which will be manufactured first time in India to cater to mining sector.
Figure 4 illustrates cross section of the main ROPS structural items filled with polyurethane foam.
The design novelty is, inside the ROPS square tubes are filled with Poly Urethane (P.U) foam, which acts as sound absorption material in order to reduce the noise level of integrated cab.
Present Invention is unique in nature. It offers solution for two different problems first it meets structural performance of Roll over protective structure secondly it reduce the noise level to meet standard requirement.Table-1 shows the structural requirements of the ROPS.
Table-1 (ROPS Items)
Description Quantity
Square Tube 100x100x12mm - 1843mm Length 1 No. Each
Square Tube 100x100x12mm - 1743mm Length 1 No. Each
Square Tube 60x60x3mm - 1843mm Length 1 No. Each
Square Tube 100x100x12mm – 1370 mm Length 1 No. Each
Square Tube 100x100x12mm – 1480 mm Length 1 No. Each
Square Tube 60x60x3mm - 1350mm Length 1 No
Square Tube 60x60x3mm - 1820mm Length 1 No
Square Tube 100x100x12mm - 480mm Length 1 No. Each
Mounting Plate -36mm Thick 6 Nos
Gusset 2 Nos
Gusset 4 Nos
Strap 4 Nos
Gusset 2 Nos
Strap 2 Nos
Gusset 1 No. Each
Strap 1 No. Each
Gusset 1 No. Each
Strap 1 No. Each
Strap 1 Nos
Square Tube 100x100x12mm - 1285mm Length 1 Nos
Square Tube 100x100x12mm - 1455mm 1 Nos
Gusset 16 Nos.
Gusset 4 Nos.
Gusset 4 Nos.
Gusset 2 Nos.
Gusset 2 Nos.

This invention has unique design features, that is cabin structure is integrated design of ROPS (Roll overprotective structure and FOPS (Fall over Protective structure). The design novelty is inside the ROPS square tubes are filled with Poly Urethane (P.U) foam, which acts as noise absorption material in order to reduce the noise level of integrated cabin to the claimed design level of 80dB for Heavy Motor Grader application. The items of cabin structure are 101,103,104,105,112,115 and 116 as depicted in above figure no.01& 02. The other unique features of this cabin design are,
- Higher Energy absorption capacity by robust cabin structure design.
- Occupies less space through the optimised cabin design with high strength steel.
- Improves the visibility by adopting optimum tube size at operator front view.
- Meets the ergonomic requirements by adopting the standards in core design.
- Eventually, this unique cabin design meets all claimed the design criteria.
The conceptual design was developed for 65000Kg Heavy Motor grader application and verified with calculation as per international standard-3471: 2008. “Earth-moving machinery -Roll-overprotective structures - laboratory tests and performance requirements”.
Further FEA model was developed, implicit and explicit analyses were conducted to understand the behavior of the ROPS. (Explicit analysis result not shown in this report)
Result shows that this proposed invention meets the performance criteria, in additional reduction in noise will be achieved.
ADVANTAGES:
The Proposed Roll Overprotective Structure (ROPS) for Heavy Motor Grader Application
• Provides the crush protection to the seat belted operator during an accidental roll-over of heavy Motor Grader over 65000 Kg Gross Vehicle Weight (GVW) application
• Energy absorption capacity is high. It prevents ROPS failure subjected to sudden impact forces during the rollover
• ROPS high strength square tubes items number 101,103,105,112 and 115
• Middle frame(104) and cross beam 116 are also filled with Poly Urethane (P.U) foam as noise absorption material (refer Section AA) to reduce the noise level in integrated cabin with Roll over Protective structure (ROPS) of Heavy Motor Grader.
• High strength square tubes provides more compactness in size of Roll over Protective Structure (ROPS)
• Reduction in overall size of the ROPS leads to improve the visibility to the Operator.
• ROPS Performance meets the relevant International standard Requirements.
• This concept can be applied for other heavy off-highway machines.
• This concept can be applied for following Equipment in our company
• Motor grader variants, Dump truck variants, Dozer variants, Water sprinkler variants, Excavators, Wheel Loaders, etc

In one aspect of the present disclosure, a four-post operator safety structure for protecting the operator and reducing the noise, adapted to be positioned around the seat of the operator in the cabin of a vehicle is provided. The four-post operator safety structure comprises a bottom frame is mounted on the ground by a plurality of roll pins, a plurality of vertical mounts mounted at four corners of said bottom frame at lower end, a top frame connecting said vertical mounts at the upper end and a top crossbeam, a pair of intermediate longitudinal mounts positioned on bottom frame at front end and rear end at an intermediate position between said first end and second end, a middle frame positioned horizontally or at an angle between top frame and bottom frame adapted to connect vertical mounts along the first end and the second end and partially on front end and rear end, a plurality of gussets and a plurality of cross beams.
In some aspects of the present disclosure, the rectangular bottom frame, plurality of vertical mounts, top frame, middle frame and a pair of intermediate longitudinal mounts comprises of high strength tubes filled with Poly Urethane foam to reduce impact and noise.
In some aspects of the present disclosure, the cross beams are mounted diagonally between the bottom frame and the middle frame.
In some aspects of the present disclosure, the gussets are positioned at a plurality of positions on the four-post operator safety structure to provide strength to the structure.
The implementation set forth in the foregoing description do not represent all implementations consistent with the subject matter described herein. Instead, they are merely some examples consistent with aspects related to the described subject matter. Although a few variations have been described in detain above, other modifications or additions are possible. In particular, further features and/or variations can be provided in addition to those set forth herein. For example, the implementation described can be directed to various combinations and sub combinations of the disclosed features and/or combinations and sub combinations of the several further features disclosed above. In addition, the logic flows depicted in the accompany figures and/or described herein do not necessarily require the particular order shown, or sequential order, to achieve desirable results. Other implementations may be within the scope of the following claims.
,CLAIMS:1. A four post operator safety structure (100) for protecting the operator and reducing noise of vehicle, adapted to be positioned around the seat of the operator in the cabin of a vehicle, the said four-post operator safety structure(100) comprises:
a. a bottom frame (101) mounted on the ground by a plurality of roll pins (114);
b. a plurality of vertical mounts (103) mounted at four corners of said bottom frame (101) at lower end;
c. a top frame (105) connecting said vertical mounts at the upper end and a top crossbeam (116);
d. a pair of intermediate longitudinal mounts (112) positioned on said bottom frame (101) at front end (109) and rear end (110) at an intermediate position between said first end (107) and said second end (108);
e. a middle frame (104) positioned horizontally or at an angle between said top frame (105) and said bottom frame (101) adapted to connect vertical mounts (103) along the first end (107) and the second end (108) and partially on said front end (109) and said rear end (110);
f. a plurality of gussets (114); and
g. a plurality of cross beams (115).

2. The four-post operator safety structure (100) as claimed in claim1, wherein said rectangular bottom frame (101), said plurality of vertical mounts (103), said top frame (105), said middle frame(104), said pair of intermediate longitudinal mounts (112), said plurality of cross beams (115) and said top crossbeam (116) comprises of high strength tubes filled with Poly Urethane foam to reduce impact and noise.

3. The four-post operator safety structure (100) as claimed in claim1, wherein said cross beams (115) are mounted diagonally between said bottom frame (101) and said middle frame (104).

4. The four-post operator safety structure (100) as claimed in claim1, wherein said gussets (114) positioned at a plurality of positions on said four-post operator safety structure (100) to provide strength to structure.