Abstract: Methods for monitoring a machine are described. In one aspect, a method includes receiving information on a plurality of events associated with the machine, determining a severity value for at least one event of the plurality of events, the severity value based on at least one of a safety value, a hierarchy value, a time-to-repair value, and a cost-of-repair value, and outputting an alert includes the severity value if the severity value exceeds a predetermined threshold associated with the at least one event. Systems and machine-readable media are also described.

Abstract: Systems, methods, devices, and computer readable media for controlling the operation of an industrial machine including one or more components. A method of controlling the industrial machine includes determining a position of at least one of the one or more components of the industrial machine during a digging operation, determining a hoist bail pull setting based on the position of the at least one of the one or more components and a relationship between component position and hoist bail pull, and setting a level of hoist bail pull to the hoist bail pull setting. The level of hoist bail pull early in the digging operation is greater than the level of hoist bail pull later in the digging operation.

Abstract: A drill rig includes a base, a drill tower extending from the base, a drill pipe coupled to and supported by the drill tower, and a driving mechanism coupled to the drill tower that moves the drill pipe relative to the drill tower. The driving mechanism includes a rack and a plurality of pinions that engage the rack. The drill rig also includes an adjustment mechanism coupled to the driving mechanism, the adjustment mechanism including a plurality of rollers and an adjustment component that moves the plurality of rollers simultaneously toward the pinions to contact the rack.

Abstract: A mining shovel includes a boom and a transmission unit coupled to the boom. The transmission unit includes an outer housing, an internal motor housing disposed within the outer housing, and a venting system coupled to the outer housing to direct air through both the outer housing and the internal motor housing.

Abstract: A dipper door trip assembly includes a dipper, a dipper door pivotally coupled to the dipper, a linkage assembly including a sliding latch bar disposed at least partially in the dipper door, and a latch keeper coupled to the dipper. The latch keeper includes a roller that engages and disengages the latch bar.

Abstract: Systems and methods for synchronizing time between multiple systems on a mining machine. The system includes a programmable logic controller (PLC) for controlling the mining machine and for transmitting a time to synchronize computer subsystems on the machine. The PLC includes a system clock that is programmed to operate on local time. A battery pack is connected to the PLC to allow the system clock to function continuously, even when the machine is turned off. Computer subsystems request and receive time updates from the PLC. A local time on each computer subsystem is determined based on the time update received from the PLC. Each computer subsystem includes a time zone parameter set to Coordinated Universal Time (UTC) and a Daylight Saving Time (DST) parameter that is disabled. Accordingly, the local time on each computer subsystem is set to the time update value received from the PLC.

Abstract: A mining machine having a control system for operating the mining machine, the control system having a vibration monitor. The mining machine comprising a mining machine, a sensor sensing vibration of a component of the mining machine, and a vibration module. The vibration module determining when the mining machine is moving in a predetermined cycle, obtaining vibration sensor data from the sensor based on determining that the mining machine is moving in a predetermined cycle, processing the vibration sensor data to generate processed vibration data, and outputting the processed vibration data.

Abstract: An industrial machine and a method of controlling an industrial machine, the industrial machine including a dipper supported by a dipper handle. The method may include determining an operating phase of the industrial machine, in a first operating phase of the industrial machine, limiting, with at least one controller, a reach of the dipper handle, and in a second operating phase of the industrial machine, enabling, with the at least one controller, an extended reach of the dipper handle greater than the reach in the first operating phase. The industrial machine may include at least one controller configured to determine an operating phase of the industrial machine, in a first operating phase of the industrial machine, limit a reach of the dipper handle, and, in a second operating phase of the industrial machine, enable an extended reach of the dipper handle greater than the reach in the first operating phase.

Abstract: A mining machine includes a boom, a handle coupled to the boom, a dipper coupled to the handle, and a dipper door pivotally coupled to the dipper. The mining shovel also includes a dipper door trip assembly including a trip motor coupled to the boom, a trip drum coupled to the handle, a linkage assembly coupled to the dipper door, a first actuation element extending directly from the trip motor to the trip drum, and a second actuation element extending directly from the trip drum to the linkage assembly.

Abstract: An industrial machine that includes a dipper, a hoist drum, a wire rope connected between the hoist drum and the dipper, a hoist motor, a sensor, and a controller. The sensor generates a signal related to a number of wire wraps of the wire rope around the hoist drum, which is received by the controller. The controller determines, based on the signal from the sensor, the number of wire wraps around the hoist drum. If the controller determines that there are an insufficient number of dead wraps around the hoist drum, the controller sets one or more parameters of the hoist motor. The controller sets each of the one or more parameters of the hoist motor to a value that is lower than a normal operational value for the parameter.

Abstract: A system for controlling the operation of an industrial machine during crowd runaway conditions. The system includes a controller that monitors and compares an actual crowd system state (e.g., an actual dipper position) with a requested crowd system state (e.g., a requested dipper position from the operator). If the controller determines that the crowd system is behaving contrary to requested crowd system behavior, the controller adjusts a crowd parameter, such as a crowd motor torque, to resolve the runaway condition.

Abstract: A mining machine includes a boom having an interior chamber, a saddle block coupled to the boom, a handle slidably coupled to the saddle block, and a reel system disposed at least partially within the chamber.

Abstract: A system includes a first industrial machine and a second industrial machine. The system also includes a power distribution system configured to provide power to the first industrial machine and the second industrial machine. The first industrial machine includes a first power control system configured to monitor power usage of the first industrial machine, and transmit power usage information of the first industrial machine to the second industrial machine. The second industrial machine includes a second power control system configured to monitor power usage of the second industrial machine, receive the power usage information from the first industrial machine, and control power usage of the second industrial machine based on the power usage information received from the first industrial machine.

Abstract: A dipper for a mining shovel includes a back wall, a first side wall extending from the back wall, a second side wall extending from the back wall, a front wall disposed opposite the back wall and extending between the first and second side walls, and a dipper door pivotally coupled to a bottom end of the dipper. The dipper door is movable between a latched and an unlatched position relative to the dipper. The dipper door is angled relative to the front wall at an acute angle when the dipper door is in the latched position.

Abstract: A rope shovel has a boom and a hoist rope. The boom has a first end and a second end. The hoist rope extends over the second end of the boom. A digging assembly for the rope shovel includes a shaft, an elongated member supported for movement relative to the boom, an attachment, and a drive link. The shaft is positioned between the first end and the second end of the boom and transverse to the boom, and the shaft includes at least one pinion gear. The elongated member includes a first end and a second end. The attachment is coupled to the first end of the elongated member and is configured to be coupled to the hoist rope. The drive link includes a rack engaging the pinion gear of the transverse shaft such that rotation of the pinion gear moves the drive link and actuates the attachment.

Abstract: A shovel includes a dipper, a hoist rope supporting the dipper, and a bail assembly. The bail assembly includes a bail configured to be coupled to the dipper and an equalizer including a mounting block configured to receive a portion of the hoist rope. The bail is pivotable about a bail axis and defines a first side. The equalizer is pivotably coupled to the bail. The equalizer is pivotable about an equalizer axis that is parallel to the first side of the bail and is offset from the first side.

Abstract: A cartridge includes a body, an aperture extending through the body sized to receive a pivot pin, and a spherical bushing disposed within the body. The cartridge also includes a first internal seal disposed axially on one side of the bushing and a second internal seal disposed axially on an opposite side of the bushing. The cartridge also includes an end cap disposed at least partially within the aperture that abuts the bushing and prevents the bushing from moving axially in a first direction within the aperture.

Abstract: A crawler mechanism includes a frame, a track including a plurality of shoes coupled together and supported for movement relative to the frame along a direction of travel, a sprocket, and a guide rail. The frame includes a first end, a second end, a first side extending between the first end and the second end and proximate a support surface, and a second side. Each shoe includes an intermediate portion having a first hardness. The sprocket drives the plurality of shoes to move along the second side of the frame. The guide rail is coupled to the second side of the frame and includes a base having an outer surface and a coating bonded to the outer surface. The coating contacts the intermediate portion of the shoes as the shoes move along the second side of the frame, and the coating defines a second hardness less than the first hardness.

Abstract: Systems and methods for compensating dipper swing control. One method includes, with at least one processor, determining a direction of compensation opposite a current swing direction of the dipper and applying the maximum available swing torque in the direction of compensation when an acceleration of the dipper is greater than a predetermined acceleration value. The method can also include determining a current state of the shovel and performing the above steps when the current state of the shovel is a swing-to-truck state or a return-to-tuck state. When the current state of the shovel is a dig-state, the method can include limiting the maximum available swing torque and allowing, with the at least one processor, swing torque to ramp up to the maximum available swing torque over a predetermined period of time when dipper is retracted to a predetermined crowd position.

Abstract: A counterweight system for an industrial machine includes a body having a front end and a back end, the body defining a cavity, and a plurality of walls defining a plurality of discrete sections within the body, each discrete section having an aperture for inserting a counterweight into the cavity.