Abstract: A roller circle assembly for heavy machinery includes an upper circular rail and a lower circular rail concentrically arranged about a central axis, and tapered rollers between the upper and lower rail. Each tapered roller includes a flange having an angled and convex flange contact surface that contacts the lower rail. The lower rail and/or the upper rail can include an angled surface configured for contact with the flange contact surface. The geometry of the rollers and the lower rail are configured to reduce the stresses applied to the rollers and lower rail due to contact between the flange contact surface and the angled surface.

Abstract: An industrial machine that includes a dipper, a dipper handle, a boom, a crowd motor, a hoist motor, a swing motor, a first sensor, a second sensor, and a controller. The first sensor generates a first signal related to a dipper handle angle and the second sensor generates a second signal related to a hoist rope angle. The first signal and the second signal are received by the controller. The controller determines, based on the first and second signals, a retract torque value. The retract torque value is compared to a retract torque threshold values. If the retract torque value is greater or equal to the threshold value, the retract torque of the crowd motor is set to a maximum value. If the retract torque is less than the threshold value, the retract torque of the crowd motor is set to a default value.

Abstract: A shoe for a crawler track includes a first end, a second end, a longitudinal axis extending between the first and second ends, a roller path axis extending perpendicular to the longitudinal axis, and an intermediate portion disposed between the first and second ends. The intermediate portion includes a roller-engaging portion disposed along the roller path axis, the intermediate portion including four successive faces that form a parallelogram when viewed from a direction substantially perpendicular to the longitudinal axis, two of the four faces being disposed at an acute angle relative to the longitudinal axis.

Abstract: Methods and systems for training an operator. One system includes a computing device including a processing unit and computer-readable medium. The computer-readable medium stores a training simulator application that is configured to receive an operating command from the operator, generate a simulated working environment and a simulated wheel loader having a simulated bucket, and generate an indicator providing depth-related information to an operator relating to a position of at least a portion of the simulated wheel loader with respect to a point-of-reference within the simulated working environment. The training simulator application is further configured to output the simulated working environment and the indicator for display to the operator, and automatically modify the indicator based on a position of the simulated wheel loader with respect to the point-of-reference.

Abstract: A system and method for capturing information related to mining machine performance and making the information accessible to remote maintenance staff. The information can be used to generate alarms, determine a state of the machine, determine performance statistics for the machine, and identify problems with the machine that may require attention. The information can be provided in a state message and the data can be packaged as XML data or in a string format. The data associated with a message can be particular to the current state or context of the mining machine. That is, in the case of a rope shovel, different data may be included in a message generated in a swing state versus a message generated in a tuck state. In some instances, a message is generated when progress thresholds are satisfied, such as for each foot of drilling performed by a mining drill.

Abstract: A mining machine comprising a power monitor sensing power consumption of the mining machine during a select time period to generate power consumption data; a sensor sensing payload of the mining machine during the select time period to generate payload data; and a monitoring module. The monitoring module including computer readable media for comparing the power consumption data and the payload data to generate shovel efficiency data, and outputting the shovel efficiency data.

Abstract: A mining shovel including a base, a boom, a first member moveably coupled to the boom, a bucket, and a pivot actuator. The base includes a hoist drum for paying out and reeling in a hoist rope. The boom includes a first end coupled to the base and a second end opposite the first end. The hoist rope extends over the second end of the boom. The first member includes a first end and a second end. The bucket is pivotably coupled to the second end of the first member. The pivot actuator moves the bucket relative to the second end of the first member, and the pivot actuator includes a first end coupled to the first member.

Abstract: An industrial machine that includes a plurality of components, an identification tag reader, an actuator, and a controller. The plurality of components is installed in the industrial machine and each of the plurality of components includes an identification tag. The identification tag reader is receives a signal from each of the plurality of identification tags, and each signal received from the plurality of identification tags is specific to a respective one of the plurality of components. The controller identifies the plurality of components that is installed in the industrial machine based on the signals from each of the plurality of identification tags, compares the identified plurality of components to a predetermined list of components that are expected to be installed in the industrial machine, and modifies an operational setting of an operating parameter when the identified plurality of components does not match the predetermined list of components.

Abstract: Systems and methods for providing an overview-head view of an industrial machine, such as a shovel. One system includes at least one processor configured to receive data from at least one sensor installed on the shovel relating to the area around the shovel, identify a plurality of planes based on the data, determine if the plurality of planes are positioned in a predetermined configuration associated with a haul truck, and if the plurality of planes are positioned in the predetermined configuration, superimpose the plurality of planes on an overhead-view image of the shovel and the area.

Abstract: An industrial machine includes a frame supporting a boom, an elongated member movably coupled to the boom, an attachment, a conduit, and a reel supporting at least a portion of the conduit. The boom includes a first end coupled to the frame and a second end opposite the first end. The elongated member is movably coupled to the boom and includes a first end and a second end. The attachment is coupled to the second end of the elongated member. The conduit extends between the frame and the attachment. The reel is rotatably supported on a support shaft. The reel rotates about an axis of rotation to reel in and pay out the conduit as the elongated member moves relative to the boom.

Abstract: A mining shovel includes a base, a revolving frame coupled to the base and rotatable about an axis, a boom pivotally coupled to the revolving frame, a handle coupled to the boom, and a dipper coupled to the handle. The dipper has a dipper door, and is located at a front end of the shovel. A counterweight having a center of gravity is disposed at the rear end of the shovel to balance the shovel, and is supported by a truss structure that is coupled to the revolving frame, such that the center of gravity is disposed above the revolving frame.

Abstract: A pin retention system includes a pin having a circumferential groove disposed along the pin, and a plurality of retention elements sized to sit within the circumferential groove, each of the retention elements including a plurality of holes. The system also includes a plurality of dowels sized to slide within the holes in the retention elements.

Abstract: Systems and methods for training an operator. One system includes a computing device including a processing unit and computer-readable medium. The computer-readable medium stores a training simulator application. The training simulator application, when executed by the processing unit, is configured to (i) receive an operating command from the operator, (ii) generate a simulated working environment and a simulated shovel having a simulated dipper, the simulated shovel and the simulated dipper positioned within the simulated working environment based on the operating command, (iii) generate an indicator providing depth-related information to an operator relating to a position of the simulated dipper with respect to a point-of-reference within the simulated working environment, and (iv) output the simulated working environment and the indicator to at least one output device for display to the operator.

Abstract: A system and method for various levels of automation of a swing-to-hopper motion for a rope shovel. An operator controls a rope shovel during a dig operation to load a dipper with materials. A controller receives position data, either via operator input or sensor data, for the dipper and a hopper where the materials are to be dumped. The controller then calculates an ideal path for the dipper to travel to be positioned above the hopper to dump the contents of the dipper. In some embodiments, the controller outputs operator feedback to assist the operator in traveling along the ideal path to the hopper. In some embodiments, the controller restricts the dipper motion such that the operator is not able to deviate beyond certain limits of the ideal path. In some embodiments, the controller automatically controls the movement of the dipper to reach the hopper.

Abstract: An industrial machine that includes a dipper, a user interface, a sensor, a hoist actuator, and a controller. The user interface is operable to generate a first signal related to a requested characteristic of the industrial machine. The sensor is operable to generate a second signal related to an actual characteristic of the industrial machine. The hoist actuator has at least one operating parameter. The controller is configured to receive the first signal related to the actual characteristic, receive the second signal related to the requested characteristic, compare the requested characteristic to the actual characteristic to detect a dipper drop condition, and modify a setting of the at least one operating parameter of the hoist actuator after the dipper drop condition is detected.

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 method of controlling a digging operation of an industrial machine, the industrial machine including a dipper and an actuator. The method including determining a force associated with the actuator; determining a dig force vector for the dipper based on the force associated with the actuator, the dig force vector including a dig force angle and a dig force magnitude; determining a characteristic of the industrial machine; and controlling, using a processor, the dig force vector based on the characteristic of the industrial machine, the dig force vector being controlled by controlling at least one of the force associated with the actuator and an angle of the dipper.

Abstract: A mining machine including a brake operable to halt motion of a component of the mining machine; a first sensor operable to sense a characteristic of the brake to generate brake data; a second sensor operable to sense motion of the component of the mining machine to generate motion data; and a controller. The controller is operable to receive the brake data and the motion data, analyze the brake data and the motion data according to a brake set model and a brake release model, and output an alert in response to an issue with the analyzed brake data or the analyzed motion data.

Abstract: An industrial machine includes a frame, an elongated member, an attachment, a plurality of fluid lines, and a cartridge. The frame includes a boom and a fluid source. The elongated member is movably coupled to the boom and includes a first end and a second end. The attachment is pivotably coupled to the first end of the elongated member. The plurality of fluid lines is coupled to the second end of the elongated member and is in fluid communication with the fluid source. The cartridge is removably coupled to the elongated member. The cartridge includes a housing and a plurality of conduits supported within the housing. The conduits are in fluid communication with the plurality of lines.