Abstract: Systems and methods for operating a mining machine with respect to a geofence. One system includes an electronic processor configured to determine a first virtual operation zone positioned around the mobile industrial machine, where the first virtual operation zone is a dynamic area around the mobile industrial machine. The electronic processor is also configured to modify a parameter of the first virtual operation zone.

Abstract: Systems, methods, and devices are provided for controlling the operation of an industrial machine (e.g., a drill) based on a determined attribute of a pipe. A sensor is configured to generate an output signal related to a characteristic of the pipe. The characteristic of the pipe can be the presence or absence of a pipe, a weight of the pipe, etc. A controller receives the output signal from the sensor and determines an attribute of the pipe based on the output signal from the sensor. The controller is then configured to control the industrial machine or take a control action based on the attribute of the pipe.

Abstract: A system for detecting a potential collision between an object and a mining machine, the system comprising: a sensor, a first strobe light and a second strobe light, and an electronic processor configured to identify a virtual perimeter around at least a portion of the mining machine, identify a plurality of collision zones, the plurality of collision zones including at least one immediate collision zone and at least one potential collision zone, receive a signal from a sensor indicating detection of the object in one of the plurality of collision zones, determine, based on the signal, whether the object is in the immediate collision zone or the potential collision zone, generate, in response to determining that the object is in the potential collision zone, a first indication, and generate, in response to determining that the object is in the immediate collision zone, a second indication different than the first indication.

Abstract: A replaceable guide rail for a crawler includes a base that has a flange. The replaceable guide rail further includes a hole extending laterally through the flange that is configured to receive a fastener to secure a portion of the crawler to the flange, a guide member extending along the centerline and being configured to contact a track portion of the crawler and be worn down during movement of the track portion over the guide member, and a wear indicator positioned in the guide member configured to indicate whether the guide rail is in condition for replacement. The guide member has a thickness that is reduced as the guide member is worn down. The wear indicator is covered while the thickness is in a first range of thickness, and the wear indicator is exposed while the thickness is in a second range of thickness.

Abstract: A vibration monitoring system for a mining machine, the mining machine including a plurality of movable components and one or more motor operatively coupled to the plurality of movable components. The system including a plurality of sensors, each of the plurality of sensors positioned at one of a plurality of measurement points on at least one of the movable component of the industrial machine, and an electronic processor coupled to the plurality of sensors and configured to receive a signal including a parameter related to a motion of the at least one moveable component, identify a steady state of the industrial machine based, at least in part, on the parameter meeting a predetermined criteria, receive, from the plurality of sensors, a plurality of vibration data sets, and select a vibration data subset from the plurality of vibration data sets corresponding to the steady state of the industrial machine.

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: A tooling system includes a dipper having a lip with a plurality of apertures, the apertures extending at least partially through the lip. The tooling system also includes a modular adapter configured to be inserted partially into one of the apertures along an axis of insertion. The adapter is configured to be releasably coupled to the lip. The adapter includes a first portion configured to extend into the aperture, and a second portion configured to extend out of the aperture. The tooling system also includes a locking system including a fastener configured to extend at least partially into the aperture and couple to the adapter to the lip.

Abstract: Systems, methods, and devices are provided for controlling the operation of an industrial machine (e.g., a drill) based on a determined attribute of a pipe. A sensor is configured to generate an output signal related to a characteristic of the pipe. The characteristic of the pipe can be the presence or absence of a pipe, a weight of the pipe, etc. A controller receives the output signal from the sensor and determines an attribute of the pipe based on the output signal from the sensor. The controller is then configured to control the industrial machine or take a control action based on the attribute of the pipe.

Abstract: A ground engaging tool locking system includes a pin having a first, proximal head region and a second, distal end region spaced from the first, proximal head region along an axis. The pin includes a groove located between the first, proximal head region and the second, distal end region. A biasing element is disposed at least partially within the groove.

Abstract: Embodiments described herein provide an industrial machine that includes one or more indicators mounted to an external portion of the industrial machine. The one or more indicators are configured to provide an indication to an individual external to the industrial machine that a proximity detection system has detected his or her presence external to the industrial machine. The one or more indicators are controlled to provide the indication to the individual using, for example, different colors of light, different intensities of light, or activation of different indicators.

Abstract: A support system is provided for a gear case of a rope shovel. The gear case supports a gear drive configured to drive rotation of a hoist drum, and the gear case includes a first end, a second end, and a longitudinal axis extending between the first end and the second end. The support system includes: a coupling for securing the gear case against translational movement relative to a rotating frame, the coupling oriented orthogonally to the longitudinal axis and configured to engage the rotating frame and a portion of the gear case; and a support member configured to be coupled to the rotating frame of the rope shovel and supporting the gear case, the support member permitting translational movement of the gear case relative to the rotating frame to accommodate flexing of the rotating frame.

Abstract: A hoist rope connector for a rope shovel includes a link extending between a first end and a second end. A rope attachment member is positioned adjacent the first end and configured to engage a hoist rope. A spherical coupling is positioned adjacent the second end and configured to be coupled to a dipper. The spherical coupling permits rotational movement between the second end and the dipper in multiple directions.

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: Embodiments described herein provide systems and methods for preventing and mitigating collisions between components of an industrial machine. The industrial machine includes an electronic controller, having an electronic processor and a memory, that is configured to receive dipper position data indicative of a position of the dipper and determine a distance between the dipper and tracks of the industrial machine based on the dipper position data. The electronic controller is further configured to set a motion command limit for a dipper motion based on the distance, the dipper motion being selected from a group of a swing motion, a crowd motion, and a hoist motion and control the dipper motion according to a dipper motion command limited by the motion command limit.

Abstract: A mining machine includes a frame having a guide rail, the guide rail having a central portion. The mining machine also includes a shoe having a recessed area that defines a roller path, the shoe further having a drive lug, wherein the central portion of the guide rail is configured to be disposed within the recessed area. The mining machine also includes a cutting tool coupled to the frame and positioned such that the cutting tool is configured to abrasively remove material from the drive lug as the drive lug passes by the cutting tool.

Abstract: Embodiments described herein provide systems and methods for generating a three-dimensional virtual track model. This track model may be used, for example, in collision prevention and mitigation systems and methods, such as those described herein, and in other collision prevention and mitigation systems and other mining systems using virtual track models. In some embodiments, the systems and methods described herein provide a simplified modeling process that enables quick, accurate modeling of tracks of a mining machine that can account for custom tracks that vary in size depending on the particular mining machine.

Abstract: Systems and methods for operating a mining machine with respect to a geofence. One system includes an electronic processor configured to determine a first virtual operation zone positioned around the mobile industrial machine, where the first virtual operation zone is a dynamic area around the mobile industrial machine. The electronic processor is also configured to modify a parameter of the first virtual operation zone.

Abstract: A method of determining a payload mass, the method comprising receiving rope data indicative of the rope force from the rope force sensor, receive position data indicative of the current shovel position from the one or more position sensors, determine a payload mass based on the rope force, the current shovel position, and a defined relationship between a kinetic energy of the mining shovel, a potential energy of the mining shovel, one or more degrees of freedom of the mining shovel, and one or more forces experienced by the mining shovel, and provide the payload mass to a display device associated with the mining shovel.

Abstract: A mining machine includes a base having two drive tracks configured to rest on a ground surface and to move the mining machine along a first direction. The drive tracks each have a length along the first direction between a front end of the drive track and a rear end of the drive track. The mining machine further includes a carbody that extends between the two drive tracks, a turntable coupled to the carbody that defines an axis of rotation, and a stabilizer appendage coupled to the carbody. The stabilizer appendage extends forward from the carbody along the first direction and includes a roller or plate to contact the ground surface and provide stabilizing support during a digging operation. The axis of rotation is positioned closer to the front end of the drive tracks than the rear end of the drive tracks.

Abstract: Systems, methods, and devices for controlling the operation of an industrial machine (e.g., a drill) based on a determined attribute of a pipe. A sensor is configured to generate an output signal related to a characteristic of the pipe. The characteristic of the pipe can be the presence or absence of a pipe, a weight of the pipe, etc. A controller receives the output signal from the sensor and determines an attribute of the pipe based on the output signal from the sensor. In some embodiments, the attribute of the pipe is a wall thickness of the pipe. In some embodiments, the controller determines the wall thickness of the pipe based on a difference between an initial weight for the pipe and a current or present weight of the pipe. In some embodiments, the controller determines the wall thickness of the pipe based on a difference between an initial diameter of the pipe and a current or present diameter of the pipe.