Patent Application
20150191890
The present disclosure relates to a system and a method to operate an implement of a machine, and more specifically to the system and the method to operate the implement of a rope shovel.
Rope shovels typically include an implement, such as a dipper, for receiving material from a loading position and unloading the material at an unloading position. The unloading position may be a hopper of a crushing machine. During unloading of the material from the dipper, the door of the dipper may be unlocked to provide an exit for the material to fall from the dipper. When the door of the dipper is unlocked, the door may swing freely about a pivotal coupling provided between the door and the dipper. During the swinging movement, the door may hit against the hopper. Further, after the unloading of the material is finished, the dipper may be moved away from the unloading position towards the loading position for another dump cycle. During this time, the freely swinging door of the dipper may again hit against the hopper. This contact between the door and the hopper is undesirable and may cause damage to the door and/or the hopper.
U.S. Published Application Number 2012/0263566 discloses 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 instances, the controller provides feedback to assist the operator in traveling along the ideal path to the hopper. In some instances, the controller restricts the dipper motion such that the operator is not able to deviate beyond certain limits of the ideal path. In some instances, the controller automatically controls the movement of the dipper to reach the hopper.
In one aspect of the present disclosure, an implement system for a machine is provided. The implement system includes an implement having a door. The door is selectively locked to the implement. The implement system also includes a crowd mechanism configured to move the implement along a first direction. The implement system further includes a hoist mechanism configured to move the implement along a second direction. The implement system includes a controller communicably coupled to the hoist mechanism and the crowd mechanism. The controller is configured to receive a signal indicative of unlocking the door from the implement. The controller is also configured to actuate the crowd mechanism to move the implement along the first direction. The controller is further configured to actuate the hoist mechanism to move the implement along the second direction.
In another aspect of the present disclosure, a method for operating an implement of a machine is provided. The method includes receiving an operator input indicative of unlocking a door of the implement. The method further includes actuating a crowd mechanism to move the implement along a first direction. The method also includes actuating a hoist mechanism to move the implement along a second direction.
In yet another aspect of the present disclosure, a rope shovel is provided. The rope shovel includes a frame. The rope shovel also includes a boom extending from the frame. The rope shovel further includes a hoist mechanism provided on the boom. The rope shovel includes a crowd mechanism extending from the boom. The rope shovel also includes a dipper coupled to the crowd mechanism and the hoist mechanism. The dipper includes a body and a door pivotally coupled to the body. The door is selectively locked to the body. The crowd mechanism is configured to move the dipper along a first direction relative to the frame. The hoist mechanism is configured to move the dipper along a second direction relative to the frame. The rope shovel includes a controller communicably coupled to the hoist mechanism and the crowd mechanism. The controller is configured to receive a signal indicative of unlocking the door from the dipper. The controller is also configured to actuate the crowd mechanism to move the dipper along the first direction. The controller is further configured to actuate the hoist mechanism to move the dipper along the second direction.
Other features and aspects of this disclosure will be apparent from the following description and the accompanying drawings.
Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or the like parts. Referring to
The rope shovel 100 includes a frame 110. The frame 110 is configured to mount and/or support various components of the rope shovel 100. The frame 110 is also configured to swing about a swing axis S-S relative to tracks 112 to move the rope shovel 100 from the loading position 402 to the unloading position 102. The rope shovel 100 includes ground engaging members, such as the tracks 112 coupled to the frame 110. The tracks 112 are configured to propel the rope shovel 100 forward or backward on ground. The tracks 112 are also configured to turn the rope shovel 100 by varying a speed and/or a direction of each of the tracks 112 relative to each other.
The rope shovel 100 includes a boom 114 extending from and coupled to the frame 110. The rope shovel 100 also includes a crowd mechanism 116 extending from the boom 114. The crowd mechanism 116 includes a handle 117 and a dipper 108 coupled to the handle 117. In the embodiment of
The rope shovel 100 includes a hoist mechanism 120 provided on the boom 114. The hoist mechanism 120 includes a winch (not shown), a pulley 122 and a hoist cable 124. The hoist cable 124 is connected to the winch at one end. Further, the hoist cable 124 extends over the pulley 122 and is connected to the dipper 108 at the other end. Based on a rotation of the winch, the cable retracts or extends relative to the winch. Accordingly, the hoist mechanism 120 is configured to raise or lower the dipper 108 along a second direction 126 relative to the frame 110. The hoist mechanism 120 includes one or more hoist sensors (not shown). The hoist sensor is configured to generate a signal indicative of a position and/or movement of the hoist mechanism 120 relative to the frame 110. The hoist sensor may include any one or a combination of, but not limited to, an inclinometer, an accelerometer, a proximity sensor and a gyroscope. It should be noted that an orientation of the first direction 118 and the second direction 126 may change based on a position of the crowd mechanism 116 and the hoist mechanism 120.
The dipper 108 of the rope shovel 100 includes a body 128 and a door 130 pivotally coupled to the body 128. The dipper 108 is configured to receive the material and dump the material at the unloading position 102 based on an operation of the door 130. The rope shovel 100 includes a dipper trip mechanism 132 coupled to the door 130 of the dipper 108. The dipper trip mechanism 132 is configured to operate the door 130 of the dipper 108. The dipper trip mechanism 132 includes a trip motor 134 and a trip cable 136 extending between the trip motor 134 and the door 130. More specifically, the trip cable 136 is coupled to a locking mechanism (not shown) of the door 130. The locking mechanism is configured to selectively lock the door 130 to the body 128 of the dipper 108. The locking mechanism may be any locking mechanism known in the art, such as a latch bar and lever arrangement and so on. Based on an operation of the trip motor 134, the trip cable 136 retracts and actuates the locking mechanism. Based on an actuation of the locking mechanism, the door 130 is unlocked to dump the material at the unloading position 102. The dipper trip mechanism 132 includes one or more dipper sensors (not shown). The dipper sensor is configured to generate a signal indicative of unlocking of the door 130.
The rope shovel 100 includes an operator cabin 138 provided on the frame 110. Referring to
In another embodiment, the input device 202 may be any other device including, but not limited to, switches, buttons, knobs, pedals and levers. Further, the push button 206 may be independent of the joystick 204 and may be provided at any other location different from the joystick 204. The input device 202 may be configured to receive an operator input indicative of operating and/or controlling the operation of various components and system of the rope shovel 100 including, but not limited to, the tracks 112, the crowd mechanism 116, the hoist mechanism 120 and the dipper trip mechanism 132.
The operator cabin 138 also includes a feedback device 208. The feedback device 208 is configured to provide information to the operator about a status of the rope shovel 100 and other systems communicating with the rope shovel 100, such as the hopper 104, the crushing machine 106 and so on. The feedback device 208 may include any one or a combination of, but not limited to, a display device such as a liquid crystal display, light emitting diodes or other illumination device, a heads-up display, a speaker for audible feedback such as a beep, a spoken message and so on, a tactile feedback device such as a vibration device configured to provide vibration to an operator seat or the input devices 202, or any other feedback device known in the art.
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Based on the received signal indicative of unlocking the door 130, the controller 140 may be configured to actuate the crowd mechanism 116 to extend or retract the dipper 108 along the first direction 118. Further, based on the received signal indicative of unlocking the door 130, the controller 140 may be configured to actuate the hoist mechanism 120 to raise or lower the dipper 108 along the second direction 126. It should be noted that the hoist mechanism 120 and the crowd mechanism 116 may be actuated simultaneously or may be actuated sequentially in any order by the controller 140 as per system design and requirements.
In one embodiment, the controller 140 may be configured to actuate the crowd mechanism 116 to extend or retract the dipper 108 by a first predetermined distance along the first direction 118. Further, based on the received signal indicative of unlocking the door 130, the controller 140 may be configured to actuate the hoist mechanism 120 to raise or lower the dipper 108 by a second predetermined distance along the second direction 126. The first and second predetermined distances are along the first direction 118 and the second direction 126, respectively. The dipper 108 may therefore move by a third predetermined distance along a third direction 702. The third predetermined distance and the third direction 702 may be obtained by a vector addition of the first and second predetermined distances along the first and second directions 118, 126, respectively. An effective displacement of the dipper 108 may be therefore indicated by the third predetermined distance and the third direction 702. The effective displacement of the dipper 108 may prevent the door 130 from contacting the hopper 104 during the unloading of the material.
The controller 140 may be configured to estimate the predetermined distances in different ways. In one embodiment, the controller 140 may be configured to refer to a pre-calibrated reference map stored in a database (not shown) or an internal memory of the controller 140. The reference map may include pre-calibrated data corresponding to the predetermined distances. In another embodiment, the controller 140 may be configured to compute the predetermined distances based on a predetermined mathematical equation. This, mathematical equation may include a multiple polynomial regression model, a physics based model, a neural network model or any other model or algorithm known in the art.
In another embodiment, the controller 140 is configured to stop the actuation of the hoist mechanism 120 based on the operator input. Also, the controller 140 is configured to stop the actuation of the crowd mechanism 116 based on the operator input. In such an embodiment, the controller 140 may be configured to start the actuation of the hoist mechanism 120 and the crowd mechanism 116 based on a first operator input such as pressing and retaining the push button 206 in pressed position. Based on a pressed duration of the push button 206, the controller 140 may be configured to continue the actuation of the hoist mechanism 120 and the crowd mechanism 116. Further, as the push button 206 is released, the controller 140 may be configured to stop the actuation of the hoist mechanism 120 and the crowd mechanism 116 such that the releasing of the push button 206 may be a second operator input. In another exemplary embodiment, the controller 140 may be configured to start the actuation of the hoist mechanism 120 and the crowd mechanism 116 based on the first operator input such as pressing and releasing of the push button 206. Further, as the push button 206 is again pressed and released to provide the second operator input to the controller 140, the controller 140 may be configured to stop the actuation of the hoist mechanism 120 and the crowd mechanism 116.
It should be noted that the signals indicative of the actuation and the stopping of the hoist mechanism 120 and the crowd mechanism 116 may be provided to the controller 140 by the single push button 206. In another embodiment, the signals indicative of the actuation and the stopping of the hoist mechanism 120 and the crowd mechanism 116 may be provided to the controller 140 by different push buttons (not shown) configured to operate the hoist mechanism 120 and the crowd mechanism 116 independently and/or separately.
In yet another embodiment, the controller 140 may be configured to receive a signal indicative of the unloading position 102. Accordingly, the hopper 104 and/or the crushing machine 106 may include a positioning device (not shown) such as a global and/or satellite positioning module, an optical camera, a three dimensional laser scanner and so on. The positioning device may be communicably coupled to the controller 140. The positioning device may be configured to generate signals indicative of the unloading position 102. Based on the received signals, the controller 140 may be configured to determine a distance of movement for raising or lowering the hoist mechanism 120 relative to the unloading position 102. Based on the received signals, the controller 140 may also be configured to determine a distance of movement for extending or retracting the crowd mechanism 116 relative to the unloading position 102.
The controller 140 may be configured to determine the distances of movement of the hoist mechanism 120 and the crowd mechanism 116 in different ways. In one embodiment, the controller 140 may be configured to refer to a pre-calibrated reference map stored in a database (not shown) or an internal memory of the controller 140. The reference map may include pre-calibrated data corresponding to the distances of movement of the hoist mechanism 120 and the crowd mechanism 116. In another embodiment, the controller 140 may be configured to compute the distances of movement of the hoist mechanism 120 and the crowd mechanism 116 based on a predetermined mathematical equation. This, mathematical equation may include a multiple polynomial regression model, a physics based model, a neural network model or any other model or algorithm known in the art.
During unloading of the material from the dipper of the rope shovel, the door of the dipper is unlocked by actuating the dipper trip mechanism. When the door of the dipper is unlocked, the door tends to swing freely along the pivotal coupling. During the swinging movement, the door may tend to hit against the walls of the hopper. Further, after the unloading of the material is finished, the dipper is moved away from the unloading position towards the loading position for another dump cycle. During this time, the freely swinging door of the dipper may again hit against the walls of the hopper which is also undesirable. This may cause damage to the door, the locking mechanism and/or the hopper.
The present disclosure relates to a method for operating the dipper 108 of the rope shovel 100. The method may prevent contact between the door 130 and the hopper 104 during the unloading of the material. Referring to
At step 804, based on the received signal indicative of unlocking the door 130, the controller 140 actuates the hoist mechanism 120 to raise or lower the dipper 108 along the second direction 126. At step 806, based on the received signal indicative of unlocking the door 130, the controller 140 actuates the crowd mechanism 116 to extend or retract the dipper 108 along the first direction 118.
In one embodiment, the controller 140 actuates the crowd mechanism 116 to extend or retract the dipper 108 by the first predetermined distance along the first direction 118. Further, based on the received signal indicative of unlocking the door 130, the controller 140 actuates the hoist mechanism 120 to raise or lower the dipper 108 by the second predetermined distance along the second direction 126. The first and second predetermined distances are along the first direction 118 and the second direction 126, respectively. The dipper 108 therefore moves by the third predetermined distance along the third direction 702. The third predetermined distance and the third direction 702 are obtained by the vector addition of the first and second predetermined distances along the first and second directions 118, 126, respectively. The effective displacement of the dipper 108 is therefore indicated by the third predetermined distance and the third direction 702. The effective displacement of the dipper 108 prevents the door 130 from contacting the hopper 104 during the unloading of the material.
In another embodiment, the controller 140 stops the actuation of the hoist mechanism 120 based on the operator input. Further, the controller 140 stops the actuation of the crowd mechanism 116 based on the operator input. In such an embodiment, the controller 140 may be configured to start the actuation of the hoist mechanism 120 and the crowd mechanism 116 based on the first operator input such as pressing and retaining the push button 206 in pressed position. Based on the pressed duration of the push button 206, the controller 140 may be configured to continue the actuation of the hoist mechanism 120 and the crowd mechanism 116. Further, as the push button 206 is released, the controller 140 may be configured to stop the actuation of the hoist mechanism 120 and the crowd mechanism 116 such that the releasing of the push button 206 may be the second operator input. In another exemplary embodiment, the controller 140 may be configured to start the actuation of the hoist mechanism 120 and the crowd mechanism 116 based on the first operator input such as pressing and releasing of the push button 206. Further, as the push button 206 is again pressed and released to provide the second operator input to the controller 140, the controller 140 may be configured to stop the actuation of the hoist mechanism 120 and the crowd mechanism 116.
In yet another embodiment, the controller 140 receives the signal indicative of the unloading position 102 of the hopper 104. Based on the received signals, the controller 140 determines the distance of movement for raising or lowering the hoist mechanism 120 relative to the unloading position 102. Based on the received signals, the controller 140 also determines the distance of movement for extending or retracting the crowd mechanism 116 relative to the unloading position 102.
While aspects of the present disclosure have been particularly shown and described with reference to the embodiments above, it will be understood by those skilled in the art that various additional embodiments may be contemplated by the modification of the disclosed machines, systems and methods without departing from the spirit and scope of what is disclosed. Such embodiments should be understood to fall within the scope of the present disclosure as determined based upon the claims and any equivalents thereof.
