Limiting protection device and control method for bucket opening mechanism of electric shovel
By combining wireless limit switches and electric shovel controllers, the torque of the bucket-opening motor is automatically adjusted, solving the impact and pulling problem of the bucket-opening mechanism in traditional electric shovels, extending service life, improving operational safety and efficiency, and supporting intelligent upgrades.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-12-30
- Publication Date
- 2026-04-03
AI Technical Summary
Traditional electric shovels rely on the operator to manually judge and stop the bucket opening mechanism after the bucket door is fully opened. This causes the bucket opening rope and motor to be subjected to continuous impact, which shortens the service life and increases the probability of failure.
The maximum stroke of the sliding component is detected by a wireless limit switch, which generates a trigger signal. The output torque of the bucket motor is automatically adjusted through a wireless receiver and electric shovel controller to avoid ineffective pulling and impact.
It accurately captures the maximum stroke of the sliding component, reduces component fatigue wear, lowers the probability of failure, improves operational safety and efficiency, and supports intelligent and automated upgrades.
Smart Images
Figure CN121781641A_ABST
Abstract
Description
Technical Field
[0001] This application belongs to the field of mining electric shovel technology, and particularly relates to a limit protection device and control method for the bucket opening mechanism of an electric shovel. Background Technology
[0002] In heavy-duty operations such as mining, electric shovels are core loading equipment, and the stable operation of their bucket opening mechanism directly affects operational efficiency and equipment maintenance costs. Traditional electric shovels rely on manual operation by the driver: when the driver issues the bucket opening command, the bucket opening motor will continuously output a large torque, which pulls the sliding component through the bucket opening rope to drive the bucket door to open; after the bucket door is fully open, the driver needs to manually judge the bucket opening status and stop the command. If the driver's operation is not timely or the judgment is incorrect, the bucket opening motor will still maintain a large torque output.
[0003] This traditional operating mode has many technical pain points: First, after the bucket gate is opened, it reaches the effective travel limit. At this time, the continuous high torque of the motor will cause the bucket opening rope to be ineffectively taut and subjected to impact pulling. Over time, this will accelerate the fatigue wear of the bucket opening rope and shorten its service life. Second, the continuous high torque output will continuously impact the bucket opening motor itself, various connecting devices and bearings, etc., aggravating component wear, increasing the probability of equipment failure and maintenance costs. Summary of the Invention
[0004] To address some or all of the technical problems existing in the prior art, this application provides a limit protection device and control method for the electric shovel bucket opening mechanism.
[0005] This application provides a limit protection device and control method for the bucket opening mechanism of an electric shovel, including a wireless limit switch. A bucket opening lifting beam is fixedly connected to the side of the bucket gate of the electric shovel. A sliding member is slidably connected inside the bucket opening lifting beam. The sliding member is fixedly connected to the bucket opening rope of the electric shovel. The wireless limit switch is located below the bucket opening lifting beam and installed on the bucket gate. The trigger end of the wireless limit switch extends into the bucket opening lifting beam and is located at the end of the sliding path of the sliding member. It is used to detect the stroke state of the sliding member. When the sliding member slides to the maximum stroke, a trigger signal is generated.
[0006] Preferably, the bucket is located at the front end of the electric shovel's arm, and the bucket gate is rotatably connected to the bottom of the bucket.
[0007] Preferably, it also includes a wireless receiving device, which is installed inside the electric shovel shed and is used to receive the trigger signal of the wireless limit switch.
[0008] Preferably, it also includes an electric shovel controller, which is installed inside the electric shovel shed and is electrically connected to the wireless receiver.
[0009] Preferably, the trigger end of the wireless limit switch is a swing arm, which extends into the bucket lifting beam.
[0010] Preferably, the wireless limit switch is detachably and fixedly connected to the gate by bolts.
[0011] A limit control method for the bucket opening mechanism of an electric shovel includes the following steps: S1. The electric shovel controller controls the bucket opening motor to output heavy-duty driving torque, which drives the sliding parts to slide in a direction along the sliding channel of the bucket opening lifting beam through the bucket opening rope, thereby driving the bucket door at the bottom of the bucket to open. S2. When the slider reaches its maximum travel, the end of the slider contacts the trigger end of the wireless limit switch, triggering the generation of a wireless trigger signal. S3. The wireless receiving device receives the wireless trigger signal, converts it into an electrical signal that the electric shovel controller can recognize, and then transmits it to the electric shovel controller. S4. The electric shovel controller executes control logic based on the electrical signal, cuts off the bucket opening command, and adjusts the output torque of the bucket opening motor to a low-load maintaining torque to prevent the bucket opening rope from being stretched ineffectively.
[0012] The limit protection device and control method for the bucket-opening mechanism of the electric shovel in this application have the following advantages and positive effects: (1) By accurately capturing the maximum stroke position of the sliding part through the wireless limit switch, the control logic is triggered in time to adjust the output torque of the bucket opening motor, which completely avoids the ineffective impact pull of the bucket opening rope. At the same time, it greatly reduces the continuous impact and extra load on the core components such as the bucket opening motor, connecting device, and bearing, significantly reduces the fatigue wear and failure probability of the components, effectively extends the overall service life of the bucket opening mechanism, and reduces the frequency and cost of equipment maintenance and replacement.
[0013] (2) The trigger signal generated by the wireless limit switch provides an objective and accurate quantitative judgment basis for the completion of the bucket opening action, which gets rid of the limitations of the traditional method of relying on the driver's subjective observation and manual operation. It provides reliable basic data support for the remote operation and unmanned operation of electric shovels, helps mining equipment to achieve intelligent and automated upgrades, and improves the accuracy and efficiency of operations.
[0014] (3) By replacing manual judgment and operation with automatic control logic, the equipment overload caused by driver's untimely operation and judgment deviation is avoided, the safety hazards such as breakage caused by excessive stretching of bucket rope are reduced, and the consistency and stability of bucket opening action are ensured, the safety and continuity of mining operations are improved, and the overall operation efficiency is guaranteed. Attached Figure Description
[0015] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only applicable to a further understanding of the embodiments of this application and constitute a part of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort. In the drawings: Figure 1 This is a schematic diagram of the assembly structure of the gantry and bucket in the existing technology; Figure 2 yes Figure 1 Enlarged view of point A; Figure 3 This is a schematic diagram showing the installation position relationship between the bucket lifting beam and the wireless limit switch in this application; Figure 4 This is a schematic diagram of the sliding member of this application moving to its maximum travel to trigger the wireless limit switch.
[0016] Explanation of reference numerals in the attached figures: 1-Bucket, 2-Bucket gate, 3-Bucket opening rope, 4-Bucket opening lifting beam, 5-Sliding component, 6-Wireless limit switch, 61-Swing arm, 7-Bucket arm. Detailed Implementation
[0017] To make the objectives, technical solutions, and advantages of this application clearer, the technical solutions of this application will be clearly and completely described below in conjunction with specific embodiments and corresponding drawings. Obviously, the described embodiments are only a part of the embodiments of this application, and not all of them. All other embodiments obtained by those skilled in the art based on the embodiments of this application without creative effort are within the scope of protection of this application.
[0018] like Figures 1 to 4 As shown, the limit protection device for the bucket-opening mechanism of the electric shovel provided in this embodiment includes a wireless limit switch 6, a wireless receiver, and an electric shovel controller, as follows: Figure 1 and Figure 2As shown, the bucket 1 is located at the front end of the shovel arm 7, and the bucket gate 2 is rotatably connected to the bottom of the bucket 1. The bottom of the bucket 1 has an opening adapted to the bucket gate 2. The bucket 1 is linked to the shovel arm 7 through a transmission structure. During the loading stage, the bucket gate 2 closes the bottom of the bucket 1 to prevent ore leakage. During the unloading stage, the bucket gate 2 opens under the drive of the sliding member 5, providing a channel for the ore to fall. The bucket gate 2 of the electric shovel is fixedly connected to the side of the bucket opening beam 4. The bucket opening beam 4 has a sliding channel adapted to the sliding member 5 inside, and the sliding member 5 is slidably connected inside the bucket opening beam 4. The sliding member 5 is fixedly connected to the bucket opening rope 3 of the electric shovel. One end of the bucket opening rope 3 is connected to the winch mechanism of the bucket opening motor, and the other end of the bucket opening rope 3 is fixedly connected to the sliding member 5. The sliding member 5 can receive the tension transmitted by the bucket opening rope 3 and slide directionally along the sliding channel of the bucket opening beam 4, while simultaneously driving the bucket gate 2 to open. The bucket lifting beam 4 provides directional sliding guidance for the sliding member 5, restricts the movement trajectory of the sliding member 5, avoids deviation or jamming during the sliding process, and at the same time bears the tension transmitted by the sliding member 5 and distributes it to the bucket gate 2.
[0019] like Figure 3 and Figure 4 As shown, the wireless limit switch 6 is located below the bucket lifting beam 4 and installed on the bucket gate 2. The wireless limit switch 6 can be detachably and fixedly connected to the bucket gate 2 by bolts. The trigger end of the wireless limit switch 6 extends into the bucket lifting beam 4 and is located at the end of the sliding path of the sliding member 5. It is used to detect the stroke state of the sliding member 5. When the sliding member 5 slides to the maximum stroke, a trigger signal is generated.
[0020] Preferably, the trigger end of the wireless limit switch 6 is a swing arm 61, which extends into the bucket lifting beam 4. The swing arm 61 can swing flexibly around the body of the wireless limit switch 6, and the end of the swing arm 61 extends into the end of the sliding path of the slider 5, which has the function of detecting the stroke state of the slider 5. When the slider 5 slides to its maximum stroke, the end of the slider 5 contacts the swing arm 61 and pushes the swing arm 61 to swing, triggering the action of the internal mechanical structure of the switch.
[0021] Preferably, the wireless limit switch 6 can adopt a self-generating design, such as by adding a solar power generation module. The self-generating module synchronously generates a stable wireless trigger signal, eliminating the need for an external power supply. The wireless limit switch 6 is entirely encapsulated in a housing, which is dustproof, corrosion-resistant, and impact-resistant, making it suitable for harsh working conditions in mines with high dust and vibration.
[0022] The wireless receiver is installed inside the electric shovel shed to receive the trigger signal from the wireless limit switch 6. The wireless receiver can be fixed inside the front wall panel of the electric shovel shed using a mounting bracket. The wireless receiver integrates a wireless signal receiving module and a signal conversion module. By matching the wireless limit switch 6 with a preset wireless frequency band, it can quickly receive the trigger signal and convert it into an electrical signal recognizable by the electric shovel controller, achieving a stable connection with the controller.
[0023] Preferably, the wireless receiver can be equipped with a housing that is shockproof, dustproof, and waterproof.
[0024] The electric shovel controller is installed inside the shovel shed. It contains pre-stored control logic and is electrically connected to a wireless receiver. It also works in conjunction with the bucket motor's drive module, enabling it to analyze trigger signals and quickly execute control commands. It can receive and analyze trigger signals transmitted from the wireless receiver, cut off the bucket-opening command, adjust the bucket motor's output torque, and prevent ineffective stretching of the bucket rope.
[0025] This embodiment provides a limit control method for the bucket opening mechanism of an electric shovel, including the following steps: S1. The electric shovel controller controls the bucket opening motor to output heavy-duty driving torque, which drives the sliding member 5 to slide in a direction along the sliding channel of the bucket opening lifting beam 4 through the bucket opening rope 3, thereby driving the bucket door 2 at the bottom of the bucket 1 to open. S2. When the slider 5 slides to its maximum stroke, the end of the slider 5 contacts the trigger end of the wireless limit switch 6, triggering the generation of a wireless trigger signal. S3. The wireless receiver receives the wireless trigger signal, converts it into an electrical signal that the electric shovel controller can recognize, and then transmits it to the electric shovel controller. S4. The electric shovel controller executes control logic based on the electrical signal, cuts off the bucket opening command, and adjusts the output torque of the bucket opening motor to a low-load maintaining torque to prevent the bucket opening rope 3 from being stretched ineffectively.
[0026] The specific operating procedure is as follows: After the electric shovel completes loading and transporting the ore to the unloading area, the driver issues an opening command based on operational needs. This command is received by the electric shovel controller. The controller then controls the opening motor to output a preset large torque. The torque is transmitted to the opening rope 3 through the motor winch mechanism. The opening rope 3 is tightened under the traction of the winch mechanism, which in turn pulls the sliding member 5 to slide directionally along the sliding channel inside the opening beam 4. The sliding member 5 synchronously drives the bucket gate 2, causing the bucket bolt on the bucket gate 2 to gradually unlock and slowly open.
[0027] As the sliding member 5 continues to slide, when the bucket gate 2 is fully open and reaches the effective bucket opening state, the sliding member 5 slides to the end of the bucket opening lifting beam 4 (i.e., the maximum stroke position). At this time, the end of the sliding member 5 makes physical contact with the swing arm 61 of the wireless limit switch 6. The continuous thrust of the sliding member 5 drives the swing arm 61 to swing around the switch body, thereby triggering the mechanical structure inside the wireless limit switch 6. The wireless limit switch 6 synchronously generates a stable wireless trigger signal, which is transmitted to the wireless receiving device installed inside the electric shovel shed through a preset wireless frequency band.
[0028] After receiving the trigger signal, the wireless receiver quickly converts it into an electrical signal that the electric shovel controller can recognize and transmits it to the controller. Upon parsing the signal, the electric shovel controller immediately executes the preset control logic. On one hand, it temporarily cuts off the driver's bucket-opening command to prevent repeated command input due to delayed or incorrect operation. On the other hand, it rapidly adjusts the output torque of the bucket-opening motor, switching from a higher output torque to a lower load state, completely preventing ineffective tautness and impact pulling of the bucket-opening rope 3.
[0029] By accurately capturing the maximum travel position of the sliding component 5 through the wireless limit switch 6, the control logic is triggered in a timely manner to adjust the output torque of the bucket opening motor, which completely avoids the ineffective impact and pulling of the bucket opening rope 3. At the same time, it significantly reduces the continuous impact and additional load on core components such as the bucket opening motor, connecting device, and bearings, significantly reduces the fatigue wear and failure probability of components, effectively extends the overall service life of the bucket opening mechanism, and reduces the frequency and cost of equipment maintenance and replacement.
[0030] The trigger signal generated by the wireless limit switch 6 provides an objective and accurate quantitative basis for judging the completion of the bucket opening action, breaking away from the limitations of the traditional method that relies on the driver's subjective observation and manual operation. It provides reliable basic data support for the remote and unmanned operation of electric shovels, helping mining equipment to achieve intelligent and automated upgrades and improving the accuracy and efficiency of operations.
[0031] By replacing manual judgment and operation with automatic control logic, equipment overload caused by driver delays or judgment errors is avoided, safety hazards such as breakage caused by excessive stretching of the bucket opening rope 3 are reduced, and the consistency and stability of bucket opening actions are ensured, thereby improving the safety and continuity of mining operations and guaranteeing overall operational efficiency.
[0032] It should be noted that, unless otherwise expressly specified and limited, the term "connection" or its synonyms should be interpreted broadly in this document. For example, "connection" can be a fixed connection or a detachable connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium; it can be the internal communication of two elements or the interaction between two elements. Those skilled in the art can understand the specific meaning of the above terms in this application according to the specific circumstances. Furthermore, expressions such as "first" and "second" are merely used to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any such actual relationship or order between these entities or operations. At the same time, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. In addition, the terms "front," "rear," "left," "right," "upper," and "lower" in this document refer to the placement states shown in the accompanying drawings.
[0033] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of this application, and are not intended to limit them. Although this application has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of this application.
Claims
1. A limit protection device for the bucket-opening mechanism of an electric shovel, characterized in that, The device includes a wireless limit switch (6), an opening lifting beam (4) fixedly connected to the side of the bucket gate (2) of the electric shovel, a sliding member (5) slidably connected inside the opening lifting beam (4), the sliding member (5) being fixedly connected to the opening rope (3) of the electric shovel, the wireless limit switch (6) being located below the opening lifting beam (4) and installed on the bucket gate (2), the trigger end of the wireless limit switch (6) extending into the opening lifting beam (4) and located at the end of the sliding path of the sliding member (5), used to detect the stroke state of the sliding member (5), and generating a trigger signal when the sliding member (5) slides to the maximum stroke.
2. The limit protection device for the electric shovel bucket opening mechanism according to claim 1, characterized in that, The bucket (1) is set at the front end of the arm (7) of the electric shovel, and the bucket door (2) is rotatably connected to the bottom of the bucket (1).
3. The limit protection device for the electric shovel bucket opening mechanism according to claim 1, characterized in that, It also includes a wireless receiver, which is installed inside the electric shovel shed and is used to receive the trigger signal of the wireless limit switch (6).
4. The limit protection device for the electric shovel bucket opening mechanism according to claim 3, characterized in that, It also includes an electric shovel controller, which is installed inside the electric shovel shed and is electrically connected to the wireless receiver.
5. The limit protection device for the electric shovel bucket opening mechanism according to claim 1, characterized in that, The trigger end of the wireless limit switch (6) is a swing rod (61), which extends into the bucket lifting beam (4).
6. The limit protection device for the electric shovel bucket opening mechanism according to claim 1, characterized in that, The wireless limit switch (6) is detachably and fixedly connected to the gate (2) by bolts.
7. A limit control method for an electric shovel bucket-opening mechanism, characterized in that, The limit protection device for the bucket-opening mechanism of the electric shovel according to any one of claims 1-6 includes the following steps: S1. The electric shovel controller controls the bucket opening motor to output heavy-duty driving torque, which drives the sliding part (5) to slide in a direction along the sliding channel of the bucket opening lifting beam (4) through the bucket opening rope (3), and at the same time drives the bucket door (2) at the bottom of the bucket (1) to open. S2. When the slider (5) slides to its maximum stroke, the end of the slider (5) contacts the trigger end of the wireless limit switch (6) to generate a wireless trigger signal. S3. The wireless receiving device receives the wireless trigger signal, converts it into an electrical signal that the electric shovel controller can recognize, and then transmits it to the electric shovel controller. S4. The electric shovel controller executes control logic according to the electrical signal, cuts off the bucket opening command, and adjusts the output torque of the bucket opening motor to a low load maintaining torque to prevent the bucket opening rope (3) from being stretched ineffectively.