The present disclosure is directed to a construction machine and, more particularly, to a construction machine having a synthetic rope arrangement.
Power shovels and draglines are in a category of construction machines that are used to remove large amounts of overburden and ore during a mining operation. The power shovels typically include a boom, a dipper handle pivotally connected to a mid-point of the boom, and a shovel bucket (also known as a dipper) pivotally connected to one end of the dipper handle. Cables extend from a hoist drum over a pulley at a distal end of the boom to an end of the dipper handle supporting the dipper. The cables are reeled in or spooled out by electric, hydraulic, and/or mechanical motors connected to the hoist drum to selectively raise and lower the dipper. The draglines typically include a mast or tri-structure, a boom, and a bucket assembly connected by hoist cables and drag cables. The hoist cables extend from the top of a dragline housing to the end of the boom, and further down to the bucket assembly. Drag cables extend from a front base of the dragline house to the bucket assembly. These cables are reeled in or spooled out by electric and/or mechanical motors connected to the hoist drum and drag drum to selectively raise and lower the bucket assembly.
In most power shovels and draglines, the cables are connected to the drums by way of anchors mounted to an outer surface of the drum. In particular, a cylindrical collar or ferrule is brazed to an end of each cable. The anchors are then welded around their perimeters to the outer surface of the drum, and the ferrule of each cable is placed within a corresponding anchor. The cables extend through the anchors to wrap around the drum. An exemplary hoist drum is disclosed in DE Patent 10 2005 004 0816 that issued to Schneider et al. on Aug. 10, 2006.
Although conventional cables used in construction machines may be acceptable in some applications, the cables can also be problematic. For example, the cables must be replaced frequently because of limited bending fatigue resistance. Because the cables are heavy and stiff, replacement can be difficult, time consuming, and expensive. In addition, as the cables abrade, strands of the ropes can break and create snag hazards. Further, the cables have a very large bending radius that require large drums and sheaves on the machine.
The construction machine and synthetic rope arrangement of the present disclosure solve one or more of the problems set forth above and/or other problems in the art.
In one aspect, the present disclosure is directed to a synthetic rope arrangement for a construction machine. The synthetic rope arrangement may include a synthetic rope with an end, and an anchor having an opening formed therein to receive the end of the synthetic rope. The anchor may be removably connectable to the construction machine. The synthetic rope arrangement may also include a stop coupled to the end of the synthetic rope and configured to inhibit the end of the synthetic rope from passing through the anchor.
In another aspect, the present disclosure is directed to a method of connecting a synthetic rope to a construction machine. The method may include passing an end of the synthetic rope through an anchor, and coupling a stop to the end of the synthetic rope to inhibit the synthetic rope from slipping through the anchor. The method may further include connecting the anchor to the construction machine.
In yet another aspect, the present disclosure is directed to a construction machine. The construction machine may include a base, and a tool operatively connected to the base. The construction machine may also include a drum mounted to the base, a motor configured to drive the drum, and a synthetic rope arrangement operatively connecting the drum to the tool. The synthetic rope arrangement may have a synthetic rope with a first end and a second end, a first anchor having an opening formed therein to receive the first end of the synthetic rope, and a second anchor having an opening formed therein to receive the second end of the synthetic rope.
The first anchor may be removably connectable to the drum, and the second anchor may be removably connectable to the tool. The synthetic rope arrangement may also have at least one stop coupled to each of the first and second ends of the synthetic rope and configured to inhibit the first and second ends of the synthetic rope from passing through the first and second anchors.
Crawler 12 may be a structural unit that supports movements of machine 10. In the disclosed exemplary application, crawler 12 is itself movable, having one or more traction devices such as feet, tracks, and/or wheels that are driven to propel machine 10 over a work surface 26. In other applications, however, crawler 12 may be replaced with a stationary platform configured for direct engagement with work surface 26.
Base 14 may pivot relative to crawler 12 about a vertical axis 28. As base 14 is pivoted about axis 28, attached gantry 16, boom 18, dipper handle 20, tool 22, and/or arrangements 24 may likewise pivot to change a radial engagement angle of tool 22 with work surface 26. Base 14 may house, among other things, a power source (e.g., a combustion engine) 30 and an internal drum (e.g., a hoist drum, a drag drum, etc.) 32 that is driven by power source 30.
Gantry 16 may be a structural frame, for example a general A-shaped frame, which is configured to anchor one or more of arrangements 24 to base 14. Gantry 16 may extend from base 14 in a vertical direction away from crawler 12. Gantry 16 may be located rearward of boom 18 relative to tool 22 and, in the disclosed exemplary embodiment, fixed in a single orientation and position. Portions of arrangement(s) 24 may extend from an apex of gantry 16 to a distal end of boom 18, thereby transferring a weight of boom 18, tool 22, and a load contained within tool 22 into base 14. These arrangement(s) 24 may generally be static.
Boom 18 may be pivotally connected at a base end to base 14, and constrained at a desired vertical angle relative to work surface 26 by one or more of arrangements 24. Additional arrangements 24 may extend from drum 32 over a pulley mechanism 34 located at the distal end of boom 18 and around a pulley mechanism 36 of tool 22. These arrangements 24 may generally be dynamic, having portions that are selectively reeled-in and spooled-out by drum 32 to affect the height and angle of tool 22 relative to work surface 26. For example, when drum 32 is driven in a first direction, the effective length of the static arrangements 24 may be shortened to cause tool 22 to rise and tilt backward away from work surface 26. In contrast, when drum 32 is driven in a second direction, the effective length of the static arrangements 24 may be lengthened to cause tool 22 to lower and tilt forward toward work surface 26.
Dipper handle 20 may be pivotally connected at one end to a general midpoint of boom 18, and at an opposing end to a corner of tool 22 adjacent pulley mechanism 36 (e.g., rearward of pulley mechanism 36). In this position, dipper handle 20 may function to maintain a desired distance of tool 22 away from boom 18 and ensure that tool 22 moves through a desired arc as the effective lengths of the dynamic arrangements 24 change. In the disclosed embodiment, dipper handle 20 may be connected to boom 18 at a location closer to the base end of boom 18, although other configurations are also possible. In some configurations, dipper handle 20 may be provided with a crowd cylinder (not shown) that functions to extend or retract dipper handle 20. In this manner, the distance between tool 22 and boom 18 (as well as the arcuate trajectory of tool 22) may be adjusted. It should be noted that other linkage configurations may additionally or alternatively be used to connect base 14 to tool 22, if desired.
Drum 32 may be rotatably mounted within a pedestal 38 that is fixedly connected to base 14, and operatively connected to power source 30 via a gear train (not shown). As shown in
At least one mounting feature 52 may be recessed within outer annular surface 48 of drum body 40 and configured to receive one or more ends 53 of arrangement 24. Although the disclosed mounting feature 52 is shown as being located at an axial end of drum 32, it is contemplated that mounting feature 52 could alternatively be centered in an axial direction of body 40. And if more than one mounting feature 52 is included, the mounting features 52 may be located symmetrically around the periphery of body 40 to improve the balance of drum 32. For example, when two mounting features 52 are included, the mounting features 52 may be located opposite each other relative to body 40.
Mounting feature 52 may be a forged or cast component that is subsequently connected (e.g., bolted or welded) at a corresponding location on body 40 (e.g., within a corresponding hole or recess in body 40) of drum 32. In the disclosed example, mounting feature 52 is generally arcuate and hollow, having a pocket 54 configured to internally receive the end of arrangement 24. One or more retainers 56 may extend inward a distance at an end of pocket 54 to retain the associated arrangement end 53. In this configuration, retainers 56 may function as collars for end 53. It is contemplated that mounting feature 52 could have a different female configuration or, alternatively, a male configuration (e.g., a hook, a stud, etc.) that is configured to engage and constrain end 53 of arrangement 24, if desired. It is also contemplated that mounting feature 52 could be integrally formed with body 40. It should be noted that other ends 53 of the same or other arrangements 24 may connect to other portions of machine 10 (e.g., to base 14, to gantry 16, to boom 18, to dipper handle 20, to tool 22, etc.) in the same or in a similar way that end 53 is shown as connecting to mounting feature 52 of drum 32 in
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Rope 58 may be an ultrahigh-molecular weight polyethylene type of rope fabricated from many smaller diameter fibers. Rope 58 may have a density less than water (e.g., about 15% the density of water), with high resistance to tension fatigue, bending fatigue, ultraviolet light, and chemical erosion. Rope 58 may be more flexible than a steel cable, allowing for ease of handling, reeling by drum 32, and installation. In some embodiments, a coating 63 may be applied to rope 58. Coating 63 may be applied to only some portions (e.g., to only an end) of rope 58 or to the entire length of rope 58. Coating 63 may have a particular coloring and/or provide a particular property to rope 58. For example, when coating 63 is applied only at the end of rope 58 wrapped around drum 32, coating 63 may have a bright coloring (e.g., red or orange). In this instance, the color of coating 63 may function as a warning to the operator of machine 10 during unspooling that rope 58 is nearing a maximum unspooled length. In another example, coating 63 may increase a grip of rope 58 on outer annular surface 48, such that mounting feature 52 is required to hold less of the tension load from rope 58. In this instance, coating 63 could be made from a flexible synthetic material, such as polyurethane, polychloroprene, polyethylene, or another tribological nonmetallic materials, and may or may not have an abrasive additive (e.g., sand) distributed therein.
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It should be noted that one or more features of each of the different embodiments of end 53 may be combined, as desired. For example, any one of the different end embodiments could include spikes, nails, potting materials, back-braiding, looping, fraying, swaging, etc.
The disclosed synthetic rope arrangement may be used in any construction machine application where component longevity, reliability, cost, and ease of use are desired. The disclosed synthetic rope arrangement may be particularly applicable to rope shovels and draglines. The disclosed synthetic rope arrangement may have improved longevity and reliability due to increased abrasion and bending fatigue resistance, a lighter weight, and improved means of connection to machine 10. The disclosed synthetic rope arrangement may also require less inspection and replacement. And when the disclosed synthetic rope arrangement does require replacement, a decreased density and increased flexibility may reduce a cost and hassle of completing the replacement.
It will be apparent to those skilled in the art that various modifications and variations can be made to the disclosed synthetic rope arrangement and machine. Other embodiments will be apparent to those skilled in the art from consideration of the specification and practice of the disclosed synthetic rope arrangement and machine. It is intended that the specification and example be considered as exemplary only, with a true scope being indicated by the following claims and their equivalents.