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: 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: 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: 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: The invention provides a bail for a rope shovel having a hoist rope and a dipper. The bail includes a pair of arms coupled to the dipper; and a cross-member extending between the pair of arms and being pivotably coupled to each of the arms. The cross-member includes a mounting block for coupling the hoist rope to the bail.

Abstract: An industrial machine that includes a dipper, a crowd actuation device, a hoist actuation device, a swing actuation device, one or more sensors, and a controller. The one or more sensors generate one or more signals related to a load within the dipper. The one or more signals are received by the controller. The controller determines, based on the one or more signals, whether the industrial machine is operating in an over-loaded condition by comparing a suspended load to a suspended load threshold value. If the suspended load is greater or equal to the suspended load threshold value, the controller takes an action to control the industrial machine. The action taken by the controller can include increasing, decreasing, or otherwise modifying a speed parameter or speed limit, increasing, decreasing, or otherwise modifying a force parameter, etc.

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: 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 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 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: An automatic lubrication system includes a reservoir configured to be coupled to an industrial machine component, a lubricant line coupled to the reservoir, and a mechanism coupled to the reservoir, the mechanism configured to exact an amount of lubricant from the reservoir based solely on movement of the industrial machine component.