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: 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: 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: 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 generate a virtual model of an exclusionary zone located on or near the industrial machine. The electronic controller is further configured to receive dipper position data indicative of a position of the dipper and determine a distance between the dipper the exclusionary zone 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 system for detecting an obstacle within a vicinity of a mining machine and providing automated camera control. The system includes at least one proximity sensor associated with the mining machine and a camera associated with the mining machine. The system also includes an electronic processor communicatively coupled to the at least one proximity sensor and the camera. The electronic processor is configured to receive data from the at least one proximity sensor. The electronic processor is also configured to determine a location of at least one obstacle based on the data. The electronic processor is also configured to determine at least one camera parameter based on the location of the at least one obstacle and control the camera using the at least one camera parameter.

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: 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 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: 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: 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 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: 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 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: A industrial machine including a component, one or more actuators configured to control the component, an input device configured to generate a first signal corresponding to a first desired motion and a second signal corresponding to a second desired motion, and a controller. The controller is configured to receive the first signal, determine a first target vector, determine a first set of control signals, the first set of control signals related to the first desired motion, and provide the first set of control signals to the one or more actuators. The controller is also configured to receive the second signal, determine a second target vector, determine a second set of control signals based on the first target vector and the second target vector, the second set of control signals related to the second desired motion, and provide the second set of control signals to the one or more actuators.

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 system includes a first industrial machine and a second industrial machine. The system also includes a power distribution system configured to provide power to the first industrial machine and the second industrial machine. The first industrial machine includes a first power control system configured to monitor power usage of the first industrial machine, and transmit power usage information of the first industrial machine to the second industrial machine. The second industrial machine includes a second power control system configured to monitor power usage of the second industrial machine, receive the power usage information from the first industrial machine, and control power usage of the second industrial machine based on the power usage information received from the first industrial machine.

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: 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 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: 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.