Abstract: A system and method for collecting operational vibration data for a mining machine. The method includes, receiving at least one motion command. The method further includes, controlling at least one component based on the at least one motion command. The method further includes determining, by an electronic processor, at least one predicate parameter. The method further includes determining, by the electronic processor, whether the predicate parameter is true. The method further includes, while the at least one component is being controlled based on the motion command and the at least one predicate parameter is true, receiving, from a plurality of sensors, each of the plurality of sensors positioned at one of a plurality of measurement points on the at least one component of the mining machine, a plurality of vibration data sets.

Abstract: A dipper having an inlet and an outlet. The dipper includes a front wall and an opposite back wall extending between the inlet and the outlet. The front wall has a substantially linear inner surface between the inlet and the outlet. The dipper further includes two side walls connected between the front wall and the back wall and extending between the inlet and the outlet. Further, the dipper has a lip coupled to the front wall and extending outwardly from the inlet in a direction away from the outlet, the lip having a lip inner surface arranged generally parallel with the substantially linear inner surface of the front wall.

Abstract: Systems and methods for predicting replacement of a component of an industrial machine. One system includes an electronic processor configured to determine a wear rate of the component based on a current dimension of the component and historical dimensions of the component and determine a replacement cost for the component. Determining the replacement cost includes determining a cost of downtime for replacing the component based on a time for replacing the component and a downtime cost for the industrial machine during the time for replacing the component, a material cost in replacing the component, and an operating cost of the industrial machine associated with not replacing the component. The electronic processor is also configured to determine a replacement recommendation for the component based on the wear rate, the replacement cost, and discard criteria and output the replacement recommendation.

Abstract: An equalizer for a mining machine includes an equalizer main body, an internal chamber defined by the main body configured to retain lubrication, and a bushing disposed within the internal chamber. The bushing includes an opening. The equalizer further includes a pin disposed partially in the internal chamber and extending through the opening.

Abstract: A mining machine includes a frame, a boom, an elongated member supported by a pivot element for movement relative to the boom, and a digging attachment. The boom includes a first end coupled to the frame and a second end opposite the first end. The pivot element is positioned between the first end and the second end of the boom. The hoist rope includes a portion extending over the second end of the boom. The member includes a first end, a second end, a first portion proximate the first end of the member, and a second portion positioned between the first portion and the second end of the member. At least a portion of the second portion is oriented at an angle relative to the first portion. The digging attachment is coupled to the second end of the member and is supported by the hoist rope.

Abstract: A drive assembly for a mining vehicle includes a frame, a housing coupled to the frame, and a motor positioned in the housing. The motor includes a motor frame with a first axial end and a second axial end opposite the first axial end. The drive assembly also includes a transmission that is positioned at least partially within the frame. The transmission is coupled to the motor frame at the first axial end. The drive assembly further includes a support assembly that couples the second axial end of the motor frame to the housing.

Abstract: A mobile mining machine includes a base with a deck and a counterweight box, a hoist drum supported on the deck, a motor drivably coupled to the hoist drum, a main transformer configured to supply power to the motor, an auxiliary transformer, and an electrical room coupled to the base. The main transformer and the auxiliary transformer are positioned inside the electrical room, and the electrical room contains at least one unguarded electrical connection.

Abstract: A mining machine includes a boom, a handle coupled to the boom, and a dipper coupled to the handle. The mining machine further includes a liner system coupled to the dipper. The liner system includes a first guide member and a second guide member coupled to a surface of the dipper, wherein the first and second guide members and the surface of the dipper define a channel extending along the dipper, and wherein the liner system further includes an insert disposed at least partially within the channel that is inhibited from moving away from the surface of the dipper by a portion of the first guide member.

Abstract: A system and method for preventing a run-away state of an industrial machine. Joints of the industrial machine are monitored in order to determine if the industrial machine is in danger of entering a run-away state. If a joint parameter exceeds a threshold value, which is indicative of the potential to enter a run-away state, then a force or torque limit is increased so that the industrial machine has additional force or torque to slow down the industrial machine when decelerating. This additional torque prevents the industrial machine from entering the run-away state.

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: A mining machine includes a frame, a boom coupled to the frame, a handle coupled to the frame and a dipper coupled to the handle. The handle includes an extension, and a bail is coupled directly to the extension, such that the bail is isolated from the dipper.

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 mast and rack assembly for a mining machine includes a mast and a rack assembly coupled to the mast. The rack assembly includes outer rails and rack segments disposed between the outer rails and the mast. At least one of the outer rails overlaps two of the rack segments.

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: 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 method of determining payload data of a mining machine having a bucket and a handle. The bucket and handle are rotatably coupled via a pin and an actuator. The method includes sensing, via a sensor, a force associated with the actuator, determining, via a controller, a characteristic indicative of a rotational angle of the bucket, and determining, via the controller, payload data based on the force and the characteristic.

Abstract: Methods and systems for detecting heavy machine wear. One system includes a heavy machine tooth of an industrial machine having a working end and a mounting end opposite the working end. The system also includes a wear indicator included in the tooth. The wear indicator includes a conductive tip, a conductive outer body extending along at least a length of the tooth, a conductive inner core positioned within the outer body, and insulating material positioned between the outer body and the inner core. The conductive tip is positioned between the working end of the tooth and the outer body and electrically couples the outer body and the inner core to form an electric circuit. The system also includes a transmitter included in the tooth. The transmitter transmits a state of the electric circuit.

Abstract: A modular drive system for use with an industrial machine having a gear case includes a motor system. The motor system includes a motor housing and a motor shaft disposed in the motor housing. The motor system has a first, non-drive end and a second, drive end. The modular drive system also includes a brake system coupled to the second end of the motor system, and a drive gear coupled to the motor shaft, the drive gear disposed between the first end and the brake system.

Abstract: Industrial machines and methods of operating the same. One method includes receiving, with an electronic processor, a current value of a parameter of an industrial machine during operation of the industrial machine and comparing, with the electronic processor, the current value of the parameter to a stored value of the parameter to determine whether the industrial machine is unlevel. The method also includes, when the industrial machine is unlevel, autonomously, with the electronic processor, changing a position of at least one of a plurality of jacks to level the industrial machine, wherein autonomously changing the position of at least one of the plurality of jacks includes at least one selected from a group consisting of extending the at least one of the plurality of jacks and retracting the at least one of the plurality of jacks.

Abstract: A bit changer assembly includes a bit basket actuator assembly configured to be coupled to a drill rig. The bit basket actuator assembly includes an actuator, a guiderail, and a bit basket that is movably coupled to the guiderail via actuation of the actuator. The bit changer assembly also includes a bit carousel configured to be coupled to the drill rig, such that the bit carousel is rotatably and vertically moveable relative to the drill rig.