BUCKET LIP AND BUCKET FOR MACHINE HAVING SEGMENTED INTEGRAL BEAM

Abstract

A bucket lip for a bucket in a machine includes an elongate one-piece casting including a forward lip edge and a plurality of mounting stations arranged along the forward lip edge. A lower lip side forms a segmented integral bean between the forward lip edge and a back lip edge, having a first outboard segment extending laterally inward from a first lateral edge, a second outboard segment extending laterally inward from a second lateral edge, and a plurality of inboard segments connecting between the first outboard segment and the second outboard segment. The bucket lip is configured for enhanced strength, optimized weight, and installation of a wear package.

Description

TECHNICAL FIELD

The present disclosure relates generally to a bucket lip, and more particularly to a bucket lip in a bucket lip assembly having a segmented integral beam.

BACKGROUND

Many different types of heavy-duty machinery are known throughout the world for use in material handling, construction, demolition, forestry, and mining, for example. Such machines are typically equipped with an implement system, commonly hydraulically actuated, including a bucket that captures material to be lifted and dumped. In mining applications, it is common for such machines to be built quite large and robust, with large bucket capacities configured for capturing, lifting, and dumping enormous amounts of material at a working face of a mine.

Operating conditions in such applications can be extremely harsh, with the material captured and moved being heavy, hard, abrasive, and sometimes needing to be broken apart by action of the bucket. One type of mining machine widely deployed in the field is generally known as a hydraulic mining shovel and includes a large bucket mounted to a boom assembly and operated to capture, lift, and dump blasted material at the working face of a mine. Buckets in such applications are often built, sometimes on-site, from multiple different parts including a so-called bucket lip that is arranged at a forward edge of the bucket. Such bucket lips are typically equipped with various protective structures, often replaceable, including edge shrouds, wing shrouds, and various wear plates, as well as ground-engaging tip structures for penetrating the blasted material to be moved. In modern hydraulic mining shovels and similar equipment, the bucket lip and attachments can be among the more complex components of the machine.

Due to the demands placed upon such machines the bucket components are typically built quite robust, often necessitating their being quite heavy, difficult to manufacture and/or install, or having other shortcomings. While efforts are sometimes made to reduce bucket or bucket lip weight, or optimize still other characteristics, the art provides ample room for improvements and development of alternatives to known strategies. One bucket lip is known from U.S. Pat. No. 9,404,240B2 to Kunz.

SUMMARY

In one aspect, a bucket lip includes an elongate one-piece casting including an upper lip side having an upper lip surface extending in a lateral direction between a first lateral edge and a second lateral edge, and in a fore-aft direction between a forward lip edge and a back lip edge, and a lower lip side. The bucket lip further includes a plurality of mounting stations arranged along the forward lip edge. The lower lip side forms a segmented integral beam between the forward lip edge and the back lip edge. The segmented integral beam includes a first outboard segment extending laterally inward from the first lateral edge, a second outboard segment extending laterally inward from the second lateral edge, and a plurality of inboard segments connecting between the first outboard segment and the second outboard segment.

In another aspect, a bucket lip includes an elongate one-piece casting having an upper lip side, a lower lip side, a first lateral edge, a second lateral edge, a forward lip edge, and a back lip edge. The lower lip side forms a segmented integral beam between the forward lip edge and the back lip edge. The segmented integral beam includes a first outboard segment, a second outboard segment, and a plurality of inboard segments together forming a stepped profile relative to the first outboard segment and the second outboard segment. The bucket lip further includes a plurality of weight-reduction pockets formed between the segmented integral beam and the back lip edge.

In still another aspect, a bucket for a machine includes a bucket body, and a bucket lip attached to the bucket body. The bucket lip includes an upper lip side and a lower lip side, a first lateral edge and a second lateral edge, and a segmented integral beam extending upon the lower lip side between the first lateral edge and the second lateral edge. The segmented integral beam includes a plurality of beam segments each including an exposed lower surface and forming a beam profile that is centrally stepped-up and centrally stepped-forward.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a diagrammatic view of a machine, according to one embodiment;

FIG. 2 is a diagrammatic view, in perspective, of a bucket lip, according to one embodiment;

FIG. 3 is another diagrammatic view of a bucket lip as in FIG. 2 showing a lower side thereof;

FIG. 4 is an elevational view of the lower side of the bucket lip as in FIGS. 2 and 3;

FIG. 5 is a sectioned side diagrammatic view of a bucket lip, according to one embodiment and illustrating a profile in comparison to a known bucket lip profile;

FIG. 6 is a sectioned side diagrammatic view through a bucket lip assembly, according to one embodiment;

FIG. 7 is a diagrammatic view showing a bucket lip assembly with an installed wear package, according to one embodiment;

FIG. 8 is a diagrammatic view showing a shroud installed on a bucket lip, according to one embodiment;

FIG. 9 is a sectioned side diagrammatic view of a shroud installed on a bucket lip, as in FIG. 8;

FIG. 10 is a diagrammatic view showing a shroud station of a bucket lip, according to one embodiment;

FIG. 11 is a sectioned view, in perspective, of a shroud station as in FIG. 10;

FIG. 12 is another sectioned view of a shroud station of a bucket lip, according to one embodiment;

FIG. 13 is another sectioned view of a shroud station of a bucket lip, according to one embodiment;

FIG. 14 is a front view of a bucket lip including a lip wing, according to one embodiment;

FIG. 15 is a diagrammatic view in perspective, of a bucket lip including a lip wing, according to one embodiment;

FIG. 16 is another diagrammatic view of a bucket lip including a lip wing, according to one embodiment;

FIG. 17 is yet another diagrammatic view of a bucket lip including a lip wing, according to one embodiment;

FIG. 18 is a diagrammatic view of a bucket assembly, according to one embodiment;

FIG. 19 is a top view of a bucket lip assembly, according to one embodiment;

FIG. 20 is a sectioned side view of a coupler station of a bucket lip, according to one embodiment;

FIG. 21 is a diagrammatic view of a coupler station of a bucket lip, according to one embodiment;

FIG. 22 is another diagrammatic view of a coupler station of a bucket lip, according to one embodiment;

FIG. 23 is yet another diagrammatic view of a coupler station of a bucket lip, according to one embodiment;

FIG. 24 is yet another diagrammatic view of a coupler station of a bucket lip, according to one embodiment;

FIG. 25 is a sectioned side diagrammatic view of a coupler station of a bucket lip, according to one embodiment;

FIG. 26 is a top view of a coupler station of a bucket lip, according to one embodiment;

FIG. 27 is a sectioned side diagrammatic view of a bucket lip assembly, according to one embodiment;

FIG. 28 is a sectioned side diagrammatic view of a coupler station including a wear cap retention feature, according to one embodiment;

FIG. 29 is a diagrammatic view, in perspective, of a coupler station as in FIG. 28;

FIG. 30 is an enlarged view showing features of the coupler station as in FIG. 28;

FIG. 31 is a sectioned side diagrammatic view of a bucket lip assembly, according to one embodiment;

FIG. 32 is a sectioned side diagrammatic view of a coupler station of a bucket lip, according to one embodiment; and

FIG. 33 is another diagrammatic view, in perspective, of a coupler station as in FIG. 32.

DETAILED DESCRIPTION

Referring to FIG. 1, there is shown a machine 10 according to one embodiment. Machine 10 includes a frame 12 supported upon ground-engaging elements 14, for example, two parallel endless ground-engaging tracks. Machine 10 also includes a hydraulically actuated implement system 16 including a boom assembly 18 and a bucket 20. An operator cab or station 26 may be supported upon frame 12 as shown. In the illustrated embodiment, machine 10 is a hydraulic mining shovel commonly applied to capture, lift, and dump material at the working face of a mine. Other machine types and/or service applications are nevertheless within the scope of the present disclosure. Moreover, while bucket 20 is shown attached in a forward or front arrangement, embodiments are contemplated where bucket 20 is reversed and arranged similarly to certain backhoe or excavator machines. Bucket 20 includes a bucket body 21 conventionally formed of a plurality of attached bucket body panels or pieces, and a forwardly positioned bucket lip 22. A plurality of ground penetrating tips 24 or the like may be supported on bucket lip 22.

Referring also now to FIGS. 2 and 3, there are shown additional features of bucket lip 22 in further detail. Bucket lip 22 may include an elongate one-piece casting 28, cast from a suitable metallic material such as an iron or a steel, including various alloys. In a practical implementation, casting 28 includes all of the features illustrated in FIG. 2 as cast-in features, although it will be appreciated that machining of as-cast surfaces may be performed to produce a final bucket lip suitable for installation and service in a bucket lip assembly or bucket assembly as further discussed herein. In some embodiments, certain of the features of bucket lip 22 might be produced separately and attached to a primary bucket lip structure such as by welding. The term “casting” is used herein to refer to bucket lip 22 and, at times, interchangeably with the terms “bucket lip” or “body,” all in reference to the monolithic piece of material that is one principle subject of the present disclosure.

Casting 28 includes an upper lip side 30 having an upper lip surface 40 extending in a lateral direction between a first lateral edge 42 and a second lateral edge 44. Upper lip surface 40 further extends in a fore-aft direction between a forward lip edge 46 and a back lip edge 48. Casting 28 also includes a lower lip side 50 generally opposite to upper lip side 30. Description and discussion herein of directions such as forward, back or rearward, vertically, horizontally, above, below, laterally, and generally analogous directional indicators will be understood conventionally in reference to the described lateral, fore-aft, upper, lower, up, down, and other directional indicators used to describe the various listed features of casting 28.

Bucket lip 22 further includes a plurality of mounting stations arranged along forward lip edge 46. The plurality of mounting stations 52 may include a plurality of coupler stations 52 in an alternating arrangement with a plurality of shroud stations 54, as further discussed herein. The term “mounting station” can thus be understood to refer to either or both of coupler stations 52 and shroud stations 54 which are used, respectively, for attaching couplers and shrouds to bucket lip 22, again as further discussed herein. Upper lip side 30 can be further understood to extend laterally between a first lip wing 56 projecting upward at a location adjacent to first lateral edge 42, and a second lip wing 58 projecting upward at a location adjacent to second lateral edge 44.

Lower lip side 50 further forms a segmented integral beam 60 between forward lip edge 46 and back lip edge 48. Segmented integral beam 60 is configured to provide enhanced structural strength as compared to certain known bucket lip strategies without unduly adding weight. It will be also be apparent from the drawings that segmented integral beam 60 includes a plurality of planar lower beam surfaces (not numbered) facing generally downward, as depicted in FIG. 3. Integral beam 60 further includes a first outboard segment 62 extending laterally inward from first lateral edge 42, and a second outboard segment 64 extending laterally inward from second lateral edge 44. First outboard segment 62 and second outboard segment 64 may define a common, substantially horizontal plane.

Integral beam 60 also includes a plurality of inboard segments connecting between first outboard segment 62 and second outboard segment 64. In the illustrated embodiment, the plurality of inboard segments include a central segment 66, two angular segments 68 extending laterally outward of central segment 66, two horizontal segments 70 extending laterally outward of respective angular segments 64, and two angular segments 72 extending laterally outward of respective horizontal segments 70 to first outboard segment 62 and second outboard segment 64.

It should further be appreciated that a variety of different geometries, including a variety of different relative lengths and/or angular orientations among the respective beam segments, as well as a variable total length of integral beam 60 are contemplated within the scope of the present disclosure. In a practical implementation, at least some of the plurality of inboard segments are angularly oriented relative to first outboard segment 60 and second outboard segment 62.

As illustrated, integral beam 60 may include a total of nine beam segments. Other embodiments, for example, where integral beam 60 is relatively shorter, might include fewer beam segments such as five or seven. A relatively longer embodiment might include greater than seven segments in integral beam 60, for example nine. In a typical implementation, integral beam includes two outboard segments and a central segment, with a variable number of additional inboard segments connecting between the central segment and the respective outboard segments. Central segment 66 is typically oriented parallel to outboard segments 62 and 64. Inboard segments 70 may also be oriented parallel to outboard segments 62 and 64.

It can also be appreciated from the drawings that integral beam 60 is set back (spaced fore-aft) from forward lip edge 36 and set forward (spaced fore-aft) from back lip edge 48. The plurality of inboard segments 66, 68, 70, 72 formed a stepped beam profile relative to first outboard segment 60 and second outboard segment 62. It can further be appreciated that the stepped beam profile is centrally stepped-forward from outboard segments 62 and 64 to central segment 66, and also centrally stepped-up from outboard segments 62 and 64 to central segment 66. Centrally stepped-up means that the profile of integral beam 60 is relatively higher in the middle, and centrally stepped-forward means that integral beam 60 is relatively more forward in the middle.

Referring also now to FIG. 4, casting 28 further defines a lip lateral width dimension 74. Lower lip side 50 may further form a first minor beam 76 and a second minor beam 78 each connecting between integral beam 60 and back lip edge 48, extending in the fore-aft direction. As also shown in FIG. 4, a first weight reduction pocket 80 may be formed between first outboard segment 62 and first minor beam 76, and a second weight reduction pocket 82 may be formed between second outboard segment 64 and second minor beam 78. A third weight reduction pocket 84 may be formed laterally between first minor beam 76 and second minor beam 78, and fore-aft between integral beam 60 and back lip edge 48.

Focusing now on FIG. 5, integral beam 60 may define a horizontal plane 86. Lower lip side 50 may form a forward pocket surface 88 of third weight reduction pocket 84, oriented at an angle 90 to horizontal plane 86. In an implementation, angle 90 may range from 35° to 70°. FIG. 5 also illustrates a known contour 91 of a known bucket lip. It can be seen that lip 22 includes additional material at the subject location in comparison to a bucket lip having known contour 91, providing for improved strength and reinforcement. A thickness 93 can also be understood to be defined between known contour 91 and one of shroud stations 54. Certain known bucket lips may have a thickness analogous to thickness 93. An analogously defined thickness of bucket lip 22 according to the present disclosure may be at least twice that of thickness 93.

Returning to FIG. 4, an edge-pocket distance 92 may be defined between each of first lateral edge 42 and first weight reduction pocket 80, and between second lateral edge 44 and second weight reduction pocket 82. In a practical implementation, edge-pocket distance 92 may be from 15% to 25% of lip lateral lip dimension 74. FIG. 4 also illustrates an edge-beam distance 94 defined between each of first lateral edge 42 and first minor beam 76, and between second lateral edge 44 and second minor beam 78. In a practical implementation, edge-beam distance 94 may be from 30% to 40% of lip lateral lip dimension 74. FIG. 4 further illustrates the plurality of mounting stations, and in combination with other drawings, it will be appreciated that coupler stations 52 are in an alternating arrangement with shroud stations 54 laterally between first lip wing 56 and second lip wing 58. Mounting stations or coupler stations 52 may define a width dimension 96. Each of first minor beam 76 and second minor beam 78 may define a beam width dimension 98 that is at least 50% of width dimension 96.

Referring also now to FIG. 6, there are shown additional parts installed on bucket lip 22 in a bucket assembly 100. Bucket assembly 100 includes a shroud 102 installed upon a shroud station 54, a coupler 104 installed upon a coupler station 52, and a tip 106 installed upon the respective coupler 104. A wear cap 108 is also installed rearward of and vertically above coupler 104. In some embodiments, some or all of shroud 102, coupler 104, tip 106, and wear cap 108 may be releasably mounted according to known retention techniques. Some or all of shroud 102, coupler 104, tip 106, and wear cap 108 might also be mounted and secured via welding, or a combination of welding and releasable attachment strategies.

Referring now also to FIG. 7, there is shown bucket lip assembly 100 including the attached parts as in FIG. 6 but also including an attached wear package 110. Wear package 110 may include a plurality of wear plates 111 of a number and size configured for fitting one-to-one upon the beam segments of integral beam 60. In the illustrated embodiment, wear plates 111 include a total of nine wear plates installed on each of the respective segments of integral beam 60. Wear plates 111 may be welded to planar lower surfaces of the respective beam segments of integral beam 60, and may be replaceable during field service of bucket lip 22, and well as wear caps, shrouds, couplers, and tips being replaceable during field service.

Turning now to FIG. 8, there is shown again a shroud 102 installed upon a shroud station 54 in bucket lip 22 and positioned laterally between two coupler stations 52. As noted above, casting 28 may include a plurality of shroud stations 54 along forward lip edge 46. Referring also to FIGS. 9-13, each of shroud stations 54 may include a top surface 210 recessed relative to upper lip surface 40, a bottom surface 212, and a forward-facing shroud contact surface 214. Each of shroud stations 54 may further include a beveled transition surface 216 extending between the respective top surface 210 and the respective forward-facing contact surface 214. Beveled transition surface 216, together with the respective top surface 210, may form an aquiline profile. As can also be noted from the drawings, beveled transition surface 216 may slope angularly downward from top surface 210 to forward-facing contact surface 214. Depicted in FIG. 12 is an obtuse angle 218 defined by beveled transition surface 216 and top surface 210. Beveled transition surface 16 may define an acute angle 220 with forward-facing shroud contact surface 214. It can also be appreciated that a running length of beveled transition surface 216, from top surface 210 to shroud contact surface 214, may be greater than 10%, for example greater that 25%, of a running length of top surface 210. The “running lengths” include lengths of the respective surfaces as shown in profile in FIGS. 12 and 13.

Shroud contact surface 214 may be vertically oriented. A vertical plane 222 is defined parallel to shroud contact surface 214, and a horizontal plane 224 is defined normal to vertical plane 222. In a practical implementation, at least one of top surface 210 or bottom surface 212 slopes relative to horizontal plane 224. In the illustrated embodiment, top surface 210 slopes downward relative to horizontal plane 224 in a direction of shroud contact surface 214, and bottom surface 212 slopes upward relative to horizontal plane 224 in a direction of shroud contact surface 214. Each of top surface 210 and bottom surface 212 may define a respective draft angle 226 and 228 to horizontal plane 224. Draft angles 226 and 228 may each be from 3° to 10° in some embodiments, assisting in installation and removal of a shroud upon shroud station 54.

As also noted above, beveled transition surface 216 defines acute angle 220 with shroud contact surface 214. In reference to plane 222, parallel to shroud contact surface 214, angle 220 may be from 35° to 65°. FIG. 13 further illustrates a vertical beam height 230 defined by casting 28, extending from a bottommost part of integral beam 60 to upper lip surface 40. Shroud contact surface 214 may define a vertical blunt height 232 that is from 30% to 50% of vertical beam height 230. Focusing on FIGS. 10 and 11, each of shroud stations 54 may include sidewalls 234 extending upwardly from the respective top surface 210. Together with top surface 210, sidewalls 234 may form a bathtub profile having as a bathtub bottom top surface 210.

Focusing on FIG. 9, there is shown a shroud 102 installed upon shroud station 54 and secured to a shroud boss 235 attached to top surface 210 such as by welding. Shroud 102 may form an installation pocket 236 fitted over forward lip edge 46 upon shroud station 54 and having a plurality of internal pocket surfaces 238. Pocket surfaces 238 may be in alignment, respectively, with top surface 210, beveled transition surface 216, shroud contact surface 214, and bottom surface 212. During service some or all of pocket surfaces 238 may contact surfaces of shroud station 54 depending upon factors such as the direction of loads upon shroud and/or wear and/or deformation of shroud 102 or shroud station 54. For example, it is contemplated that contact between shroud 102 and shroud contact surface 214, or other surfaces of shroud station 54, might or might not occur when shroud 102 is first installed and machine 10 begins operating. Over time, loading of shroud 102 may cause hard contact with shroud station 54 to occur.

Turning now to FIGS. 14-17, there are shown additional features of lip wing 58. First lip wing 56 projects upward upon casting 28 at a location adjacent to first lateral edge 42. Second lip wing 58 projects upward at a location adjacent to second lateral edge 44. It will be appreciated lip wings 56 and 58 will typically be mirror images of one another. Thus, description and illustration of only lip wing 58 will be understood to refer by way of analogy to lip wing 56. Lip wing 58 includes an outboard transition surface 310 defining a smaller radius of curvature, and an inboard transition surface 312 defining a larger radius of curvature and transitioning to upper lip surface 40. It will also be appreciated that lip wing 58 is laterally asymmetric, balancing factors relating to available surface area for welding and/or shroud attachment, with strength.

Lip wing 58 further includes a planar outboard surface 314 located above the respective outboard transition surface 310, and a planar inboard surface 316 located above the respective inboard transition surface 312. It will be appreciated that the present description focusing on lip wing 58 is understood to refer by way of analogy to first lip wing 56. Each of planar outboard surface 314 and planar inboard surface 316 may be vertically oriented. A height 318 of planar outboard surface 315 may be about twice a height 320 of planar inboard surface 316 or greater. It should be understood that as used herein the term “about,” and like relative terms, is understood to mean approximately or generally, as would be understood by a person or ordinary skill in the art applying a routine understanding of approximation. For example, “about twice” may be understood in the context of conventional rounding, thus from 1.5 times to 2.4 times. Depending upon context, other art-recognized understandings of approximation, such as within measurement error, might be applied.

Inboard transition surface 312 may extend from planar inboard surface 316 to upper lip surface 40. The larger radius of curvature defined by inboard transition surface 312 may include a compound radius of curvature. As shown in FIG. 16, the compound radius of curvature may include a larger upper radius defined by an upper curved surface 322 of inboard transition surface 312, and a smaller lower radius defined by a lower curved surface 324 of inboard transition surface 312. The smaller radius of curvature of outboard transition surface 310 may about equal in size to the smaller lower radius defined by curved lower surface 324 of inboard transition surface 312.

Also in a practical implementation, the larger upper radius defined by surface 322 may range from 225 millimeters to 375 millimeters. The smaller radius defined by lower surface 322 may range from 75 millimeters to 125 millimeters. As also shown in FIG. 17, inboard transition surface 312 may further include a back corner surface 330. Back corner surface 330 may define a corner radius of curvature from 60 millimeters to 100 millimeters.

As can further be seen from the drawings, and in particular FIGS. 15 and 16, each of first lip wing 56 and second lip wing 58 includes a front surface 326. Front surface 326 may slope back and upwardly away from forward lip edge 46, in a rearward direction. Front surface 326 may have a curved profile 328 matched in part to curvatures of each of outboard transition surface 310 and inboard transition surface 312. Explained differently, front surface 326 may define a radius size, at locations vertically aligning with both outboard transition surface 310 and curved lower surface 324 of inboard transition surface 312, that is equal to that of the smaller radius defined by those respective surfaces. Thus, it can be appreciated that the smaller radius defined by lower surface 324 may be understood as continuously wrapping laterally and forwardly around lip wing 58, in at least some embodiments.

Referring also now to FIG. 18, there is shown bucket lip 22 in a bucket lip assembly 338. Each of first lip wing 56 and second lip wing 58 may have a base section 334 attached to upper lip surface 40, and a bucket wing attachment section 336 extending upwardly from the respective base section 334. Each respective bucket wing attachment section 336 may include an outboard boss-mounting surface 314, corresponding to outboard surface 314, that is planar. Bucket assembly 338 also includes a bucket side wing 330 attached to lip wing 58 such as by welding. It will be appreciated that lip wing 56 will be analogously attached to a bucket side wing. A first wing shroud boss 342 may be attached to surface 314, and a second wing shroud boss 344 may be attached to bucket wing 340. Shrouds for protecting lip wing 58 and bucket side wing 340 may be attached to the respective bosses 342 and 344.

Base section 334 can also be seen to be laterally asymmetric about a midplane 332. In a practical implementation, the plurality of mounting stations of bucket lip 22 includes a first endmost station adjacent to first lateral edge 42, and a second endmost station adjacent to second lateral edge 44, including the mounting station 52 shown in FIGS. 14-18. Each of first lip wing 56 and second lip wing 58 may be intersected by the vertical midplane defined by the respective endmost mounting station, as illustrated in FIG. 14. Midplane 332 may bisect lip wing 58 between surfaces 314 and 316 in some embodiments.

Referring now to FIGS. 19-26, there are shown additional features of an example one of coupler stations 52. FIG. 19 shows a top view of couplers 104 installed on coupler stations 52 of bucket lip 22, and each equipped with an attached tip 106. Wear caps 108 are also shown positioned above and back of couplers 104. Each coupler station 52 may include a base portion 410 projecting from forward lip edge 46, and a nose portion 412 projecting from the respective base portion 410 and extending to a nose end surface 314. Base portion 410 may include at least one coupler-loading shoulder 416 stepped-off from the respective nose portion 412. The at least one coupler-loading shoulder 416 may form a plurality of up load support surfaces 418, a plurality of down load support surfaces 420, and a plurality of side load support surfaces 421, oriented, respectively, for reacting up, down, and side loads on an attached coupler.

In the illustrated embodiment, the at least one coupler-loading shoulder 416, hereinafter referred to in the singular, includes a continuous shoulder, stepped-off from a first lateral side 422, a second lateral side 424, and a bottom side 426 of the respective nose portion 412. Coupler loading shoulder 416 may thus extend along each of first lateral side 422, second lateral side 424, and bottom side 426. Coupler loading shoulder 416 may have a varying contour that forms the various load support surfaces, including in a practical implementation up load support surfaces 418 that slope downward and down load support surfaces 420 that slope upward, upon each of the respective first lateral side 422 and second lateral side 424. Coupler loading shoulder 416 may also form a plurality of bucket lip edge load support surfaces 428 each transitioning between one of the plurality of up load support surface 418 and one of the plurality of down load support surfaces 420.

Focusing on FIG. 20, nose portion 412 may define a plane 430 of upper-lower symmetry. Edge load support surfaces 428 may define a second plane 432 oriented normal to plane 430. In an implementation, each of up load support surfaces 418 and down load support surfaces 420 may be angularly oriented to both plane of upper-lower symmetry 430 and second plane 432. Side load support surfaces 421 may each include both a lateral component and a forward component to their orientation, as shown in FIG. 21. Side load support surfaces 421 may be within a vertical footprint of the respective nose portion 412.

Focusing on FIG. 25, each of up load support surfaces 418 may define an angle 434 to second plane 442 that is from 45° to 75°. Each of down load support surfaces 420 may define an angle 436 to second plane 432 that is also from 45° to 75°.

Focusing on FIG. 26, each respective nose portion 412 may define a nose length dimension 438. Shoulder 416 may define a support depth dimension 430 that is from 10% to 15% of nose length dimension 438.

Referring now to FIGS. 27-30, each of coupler stations 52 may include a top surface 510 stepped-down from upper lip surface 40. FIG. 27 illustrates bucket lip assembly 100 where it can be seen that wear cap 108 is positioned upon top surface 510. Top surface 510 is stepped-down from upper lip surface 40. Coupler station 52 further includes a wear cap retention feature 512 shown in FIGS. 28-30, protruding in at least one of an upward direction or a lateral direction relative to top surface 510. FIG. 28 illustrates a clearance or distance 514 vertically between retention feature 512 and upper lip surface 40. Retention feature 512 may have a retention feature elevation, such that retention feature 512 is flush with or vertically below upper lip surface 40. Thus, in some embodiments distance 514 might be equal to zero.

As best shown in FIG. 30, wear cap retention feature 512 may include at least one, and typically two, wear cap rails 516 that receive complementary structures such as slots or channels of an installed wear cap. Top surface 510 may be planar, and each of a first wear cap rail 516 and a second wear cap rail 516 may include a planar rail surface 518 transitioning with and coplanar with the respective top surface 510. In an implementation, a first undercut 520 may be defined between first wear cap rail 516 and a base portion 410 of the respective coupler station 52. A second undercut generally hidden from view in the drawings, will be understood to be analogously defined between a second wear cap rail 516 and base portion 410.

Undercut 520, and by way of analogy, a second undercut upon an opposite lateral side of coupler station 52, forms a wedge shape opening in a forward direction away from forward lip edge 46. Each of first wear cap rail 516 and second wear cap rail 516 may also include a leading edge 522 extending angularly back from the respective nose portion 412, and a trailing edge 523 extending in the fore-aft direction from the respective leading edge 522. An angle defined between each respective leading edge 522 and second plane 432 shown, for example, in FIG. 20 may be from 45° to 75° in some embodiments.

Turning now to FIGS. 31-33, there is shown a bucket lip assembly 600 including bucket lip 22, but additional features for wear cap installation differing from that of the embodiment shown in FIGS. 27-30. Bucket lip assembly 600 includes a coupler 604, a tip 606, and a wear cap 608. Coupler 604 is mounted on coupler station 652. Wear cap 608 forms a slot, channel, or other void 656, that receives a retention feature 654 welded onto coupler station 652. In this embodiment, wear cap retention feature 654 may include a welded-on plate 654 received in slot 656. It can be appreciated that wear cap retention feature 654 may be set forward from upper lip surface 40.

INDUSTRIAL APPLICABILITY

Referring to the drawings generally, bucket lip 22 can be installed as part of an OEM product in a bucket constructed at and shipped from a factory or constructed on-site at a mine, for instance. In other instances bucket lip 22 may be provided as an aftermarket replacement part integrated into existing buckets in the field. As will be apparent from the foregoing description, bucket lip 22 includes numerous different features, some or all of which can be implemented in any given product. Moreover, as also discussed above embodiments are contemplated wherein all of the features of bucket lip 22 discussed herein are integrated into a single casting, however embodiments are contemplated where various parts such as one or more of lip wings, mounting stations, and wear cap retention features, for example, are separately supplied and attached to a bucket lip to form an assembly.

The present description is for illustrative purposes only, and should not be construed to narrow the breadth of the present disclosure in any way. Thus, those skilled in the art will appreciate that various modifications might be made to the presently disclosed embodiments without departing from the full and fair scope and spirit of the present disclosure. Other aspects, features and advantages will be apparent upon an examination of the attached drawings and appended claims. As used herein, the articles “a” and “an” are intended to include one or more items, and may be used interchangeably with “one or more.” Where only one item is intended, the term “one” or similar language is used. Also, as used herein, the terms “has,” “have,” “having,” or the like are intended to be open-ended terms. Further, the phrase “based on” is intended to mean “based, at least in part, on” unless explicitly stated otherwise.

Claims

1. A bucket lip comprising:

an elongate one-piece casting including an upper lip side having an upper lip surface extending in a lateral direction between a first lateral edge and a second lateral edge, and in a fore-aft direction between a forward lip edge and a back lip edge, and a lower lip side;

a plurality of mounting stations arranged along the forward lip edge; and

the lower lip side forming a segmented integral beam between the forward lip edge and the back lip edge, including a first outboard segment extending laterally inward from the first lateral edge, a second outboard segment extending laterally inward from the second lateral edge, and a plurality of inboard segments connecting between the first outboard segment and the second outboard segment.

2. The bucket lip of claim 1 wherein the segmented integral beam is set back from the forward lip edge and set forward from the back lip edge, and the plurality of inboard segments form a stepped beam profile relative to the first outboard segment and the second outboard segment.

3. The bucket lip of claim 2 wherein the plurality of inboard segments include a central segment oriented parallel to the first outboard segment and the second outboard segment, a first angular segment between the horizontal central segment and the first outboard segment, and a second angular segment between the horizontal central segment and the second outboard segment.

4. The bucket lip of claim 1 wherein the elongate one-piece casting defines a lip lateral width dimension, and the lower lip side further forms a first minor beam and a second minor beam each connecting between the segmented integral beam and the back lip edge.

5. The bucket lip of claim 4 wherein a first weight-reduction pocket is formed between the first outboard segment and the first minor beam, and a second weight-reduction pocket is formed between the second outboard segment and the second minor beam.

6. The bucket lip of claim 5 wherein a third weight-reduction pocket is formed laterally between the first minor beam and the second minor beam, and fore-aft between the segmented integral beam and the back lip edge.

7. The bucket lip of claim 6 wherein the segmented integral beam defines a horizontal plane, and the lower lip side forms a forward pocket surface of the third weight-reduction pocket oriented at an angle to the horizontal plane of 35 degrees to 70 degrees.

8. The bucket lip of claim 5 wherein an edge-pocket distance is defined between each of the first lateral edge and the first weight-reduction pocket and between the second lateral edge and the second weight-reduction pocket, and the edge-pocket distance is from 15% to 25% of the lip lateral width dimension.

9. The bucket lip of claim 4 wherein an edge-beam distance is defined between each of the first lateral edge and the first minor beam and between the second lateral edge and the second minor beam, and the edge-beam distance is from 30% to 40% of the lip lateral width dimension.

10. The bucket lip of claim 4 wherein the plurality of mounting stations define a width dimension, and each of the first minor beam and the second minor beam defines a beam width dimension that is at least 50% of the width dimension.

11. The bucket lip of claim 1 wherein the plurality of mounting stations includes a plurality of coupler stations and a plurality of shroud stations in an alternating arrangement laterally between a first lateral wing adjacent to the first lateral edge and a second lateral wing adjacent to the second lateral edge.

12. A bucket lip comprising:

an elongate one-piece casting including an upper lip side, a lower lip side, a first lateral edge, a second lateral edge, a forward lip edge, and a back lip edge;

the lower lip side forming a segmented integral beam between the forward lip edge and the back lip edge;

the segmented integral beam including a first outboard segment, a second outboard segment, and a plurality of inboard segments together forming a stepped profile relative to the first outboard segment and the second outboard segment; and

a plurality of weight-reduction pockets formed between the segmented integral beam and the back lip edge.

13. The bucket lip of claim 12 wherein each of the first outboard segment, the second outboard segment, and the plurality of inboard segments includes a planar lower surface.

14. The bucket lip of claim 13 wherein the segmented integral beam is set back from the forward lip edge and set forward from the back lip edge, and wherein the stepped profile is both stepped-up and stepped-forward relative to the first outboard segment and the second outboard segment.

15. The bucket lip of claim 14 further comprising an attached wear package including a plurality of wear plates attached to the segmented integral beam.

16. The bucket lip of claim 12 wherein at least some of the plurality of inboard segments are angularly oriented relative to the first outboard segment and the second outboard segment.

17. The bucket lip of claim 12 wherein the lower lip side forms a first minor beam and a second minor beam each extending between the segmented integral beam and the back lip edge.

18. The bucket lip of claim 17 wherein the plurality of inboard segments include a central segment, and the plurality of weight-reduction pockets include a first weight-reduction pocket formed between the first minor beam and the first outboard segment, a second weight-reduction pocket formed between the second minor beam and the first outboard segment, and a third weight-reduction pocket formed between the central segment and the back lip edge.

19. A bucket for a machine comprising:

a bucket body;

a bucket lip attached to the bucket body, and including an upper lip side and a lower lip side, a first lateral edge and a second lateral edge, and a segmented integral beam extending upon the lower lip side between the first lateral edge and the second lateral edge; and

the segmented integral beam including a plurality of beam segments each including an exposed lower surface and forming a beam profile that is centrally stepped-up and centrally stepped-forward.

20. The bucket of claim 19 wherein:

the segmented integral beam is set back from the forward lip edge and set forward from the back lip edge;

the segmented integral beam includes a first outboard segment, a second outboard segment, a central segment, and at least one angular segment extending between the central segment and each respective one of the first outboard segment and the second outboard segment; and

the bucket lip further includes a first minor beam extending between the segmented integral beam and the back lip edge, and a second minor beam extending between the segmented integral beam and the back lip edge.