Abstract: A reel system includes a reel having a rotational axis, the reel including a plurality of ledges spaced radially from the rotational axis, the ledges defining a stepped configuration along an interior surface of the reel. The reel system also includes a first clamp having a first width and a second clamp having a second width greater than the first width, wherein the first clamp and the second clamp engage the plurality of ledges as the reel is rotated.

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 crawler assembly including a crawler frame member having a first crawler extension and a second crawler extension and an idler wheel disposed therebetween. The idler wheel defines a bore therethrough. The crawler assembly includes a shaft that extends through the bore. The shaft is fixed relative to the wheel by a tapered interference fit and rotatable relative to the first and second crawler extensions. A first side of the shaft is received by the first extension and has at least one journal bushing disposed therebetween. A second side of the shaft is received by the second extension and has a least one journal bushing disposed. A removable endcap is secured to each of the first and second sides of the shaft. A thrust surface is created at an interface between the endcaps and the journal bushings.

Abstract: A hoist system includes a drum, a motor, and a transmission. The drum includes a hollow shell, a first end, a second end, and an internal web, and defines a longitudinal axis extending between the first end and the second end. The internal web extends across an interior portion of the shell in a direction perpendicular to the longitudinal axis, thereby defining a first portion and a second portion of the shell. The motor is coupled to the first end and includes an output shaft. The transmission is driven by the motor and includes a planetary gear train positioned within the interior portion of the shell. The planetary gear train includes an input gear coupled to the motor output shaft and an output gear coupled to the internal web to rotate the drum about the longitudinal axis. The planetary gear train is positioned in a first portion of the shell.

Abstract: Controlling a digging operation of an industrial machine. The industrial machine includes a dipper, a crowd motor, and a hoist motor. The control includes determining a torque associated with the crowd motor and a torque associated with the hoist motor and determining a dig force vector for the dipper based on the torque associated with the crowd motor and the torque associated with the hoist motor. The dig force vector includes a dig force angle and a dig force magnitude. The method also includes determining a value for the dig force angle of the dig force vector, and controlling, using a processor, the dig force magnitude based on the determined value for the dig force angle. The dig force magnitude is controlled by controlling at least one of the torque associated with the crowd motor and the torque associated with the hoist motor.

Abstract: Systems and methods for detecting collisions. One system includes a processor configured to receive data from at least one sensor installed on a 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 to identify whether the plurality of planes represent a haul truck. The processor is further configured to receive a current position and a current direction of movement of a dipper of the shovel, and determine if a collision is possible between the dipper and the identified haul truck based on the plurality of planes, the current position, and the current direction of movement and without receiving any information from the haul truck. If a collision is possible, the processor is configured to alert an operator of the shovel and, optionally, augment movement of the dipper.

Abstract: A leveling system for supporting a drill assembly includes at least one hydraulic actuator and a manifold coupled to the actuator. The hydraulic actuator supports the cab relative to a support surface, and includes a first end coupled to the cab and a second end that is extendable away from the first end. The manifold is coupled to the actuator and includes a directional flow control valve, a regenerative flow valve, and at least one counterbalance valve for controlling the extension of the actuator. The counterbalance valve is in direct fluid communication with the actuator.

Abstract: Systems, methods, devices, and computer readable media for controlling a digging operation of an industrial machine. A method includes determining a hoist bail pull associated with the industrial machine, determining a crowd torque limit value for a crowd drive based on the determined hoist bail pull of the industrial machine, and setting a crowd torque limit of the crowd drive to the crowd torque limit value to limit a torque associated with a crowd motor to the crowd torque limit value.

Abstract: A dipper assembly includes a body defining an outer surface and an opening, a door pivotably coupled to the body, and a latch mechanism releasably securing the door relative to the body. The door is pivotable between a closed position in which the door is positioned adjacent the opening and an open position in which the door is positioned away from the opening. The latch mechanism includes a latchkeeper and a latch member engaging the latchkeeper. The latch member is coupled to one of the body and the door and the latchkeeper is coupled to the other of the body and the door. The latchkeeper includes an end surface and a stop member coupled to the end surface. The stop member engages the one of the body and the door when the door is in the closed position. The stop member is extendable relative to the end surface.

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: Systems, methods, devices, and computer readable media for controlling a digging operation of an industrial machine that includes a dipper and a crowd drive. A method includes determining an acceleration associated with the industrial machine, determining a crowd retract factor based on the acceleration, comparing the crowd retract factor to a threshold crowd retract factor, setting a crowd speed reference and a crowd retract torque for the crowd drive for a period of time based on the comparison of the crowd retract factor to the threshold crowd retract factor.

Abstract: A seat module for an industrial machine. The industrial machine includes a base, a body, and a cab module supporting the seat module. The seat module includes a seat, a control panel mounted on the seat, one or more monitors attached to the control panel, and a plurality of controls positioned on the control panel. The seat module also includes a controller having a processor and connected to the control panel. The controller is configured to receive information from the plurality of controls and to control the operation of the industrial machine based on the received information.

Abstract: A snubber for a mining shovel including a dipper body and a dipper door rotatably coupled to the dipper body. The snubber includes a housing having an internal wall defining a fluid-filled chamber, a shaft rotatably coupled to the housing and including a portion positioned within the chamber, a paddle positioned within the chamber, a dam positioned within the chamber, a first valve, and a second valve. Rotation of the dipper door relative to the dipper body causes rotation of the shaft relative to the housing. The paddle is coupled to the shaft such that the paddle rotates with the shaft. The dam and paddle substantially partition the internal chamber into a first portion and a second portion. The first valve controls fluid flow from the first chamber to the second chamber, and the second valve controls fluid flow from the second chamber to the first chamber.

Abstract: A method of controlling the operation of an industrial machine. The industrial machine includes a boom, a dipper handle attached to the boom, a saddle block pivotally mounted to the boom at a pivot point, and a computer having a controller. The method comprises processing, with the controller, data received from a saddle angle sensor, determining, with the controller, a saddle angle and a saddle angle gap using the data from the saddle angle sensor, determining, with the controller, a height of the dipper handle. The method further comprises determining, with the controller, a height of the saddle block, determining, with the controller, a saddle gap radius, and determining, with the controller, a saddle block shimming gap by comparing the saddle gap radius with the height of the handle.

Abstract: A sheave includes a hub defining an axis, a rim defining at least one circumferentially extending groove, and two plates oriented substantially perpendicular to the axis. Each plate is connected to the hub and to the rim, and a plurality of reinforcing tubular members extend between the plates.

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: 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 mining shovel includes a digging assembly having a generally V-shaped boom including a lower connection point for attachment to the mining shovel. A first portion of the boom extends generally upwardly from the lower connection point, and a second portion of the boom is angled with respect to and extends upwardly and forwardly from the first portion. The second portion includes a distal end defining a sheave support, and a pivot element is positioned generally at a connection area between the first portion and the second portion. The digging assembly also includes a boom attachment having a first end that is pivotally supported by the pivot element and a second end that is supported by the sheave support.

Abstract: A mining shovel adapted to dig a bank of material includes a boom having an end, a hoist rope extending over the end of the boom, an elongated member movably coupled to the boom, a dipper for engaging the bank of material, a bail assembly, and a pitch brace. The member includes a first end and a second end. The dipper is coupled to the second end of the member and includes a digging edge. The bail assembly includes a first end pivotably coupled to the dipper and a second end coupled to the hoist rope passing over the boom. The pitch brace includes a first end pivotably coupled to the bail assembly and a second end pivotably coupled to the member.

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.