Dipper Lip

Abstract

The dipper lip (300) includes a first side wing (310), a second side wing (310a), a rear bucket mounting portion (306) spanning the first side wing (310) and the second side wing (310a), and a front shovel portion (302) extending from the first side wing (310) to the second side wing (310a). The front shovel portion (302) defines an upper shovel face (314) and the rear bucket mounting portion (306) forms an upper aft face (316). The upper shovel face (314) forms an obtuse angle (318) with the upper aft face (316) at the midplane (312) of the dipper lip (300).

Description

[Technical Field]

[0001] The present disclosure relates to dippers for use in construction and mining machinery, etc. In particular, the present disclosure relates to dippers suitable for use in oil sands applications. [Background technology]

[0002] In many current applications, dippers are used on heavy machinery such as electric rope shovels. These dippers are used in harsh environments and can be subject to wear and tear. Also, the digging performance of these dippers can vary depending on the type of material being moved.

[0003] In oil sands applications in particular, heel wear is known to require dipper maintenance and can result in less-than-desirable drilling performance. Replacing a dipper requires removing it from the machine and replacing the worn components, or an entirely new dipper is required, which requires undesirable extended machine downtime and the added cost of the new dipper component(s).

[0004] Various dipper configurations are known in the art, including the dipper configuration disclosed in U.S. Patent No. 9,809,947. The '947 patent discloses a dipper for a mining shovel including a rear wall, a first side wall extending from the rear wall, a second side wall extending from the rear wall, a front wall disposed opposite the rear wall and extending between the first and second side walls, and a dipper door pivotally coupled to a lower end of the dipper. The dipper door is movable relative to the dipper between a latched position and an unlatched position. When the dipper door is in the latched position, the dipper door is inclined at an acute angle relative to the front wall.

[0005] However, the '947 patent is silent about the digging performance of the dipper or the prevention of heel wear in abrasive environments such as oil sands applications.

[0006] Therefore, there is a need to develop a dipper that has better digging performance and less heel wear than those previously devised. Summary of the Invention

[0007] A dipper according to one embodiment of the present disclosure may include a top wall, a first side wall extending from the top wall, a second side wall extending from the top wall, a bottom floor extending from the first side wall to the second side wall, and a dipper lip including a front shovel portion. In a midplane perpendicular to the top wall and the bottom floor, the front shovel portion may form an exterior angle with the bottom floor that is greater than 187.5 degrees.

[0008] A dipper according to another embodiment of the present disclosure may include a top wall, a first side wall extending from the top wall, a second side wall extending from the top wall, and a bottom floor extending from the first side wall to the second side wall. In a midplane perpendicular to the top wall and the bottom floor, the bottom floor may form a first acute angle with the top wall in a range of 5.0 degrees to 15.0 degrees such that the dipper forms a mouth that narrows toward the rear of the dipper.

[0009] A dipper lip according to yet another embodiment of the present disclosure may include a first side wing, a second side wing, a rear mounting portion spanning the first and second side wings, and a front shovel portion extending from the first side wing to the second side wing. The dipper lip may define a central plane disposed between the first and second side wings. The front shovel portion defines an upper shovel surface, and the rear bucket mounting portion forms an upper rear surface. The upper shovel surface may form an obtuse angle with the upper rear surface of the central plane.

[0010] A dipper according to one embodiment of the present disclosure may include a top wall, a first side wall extending from the top wall, a second side wall extending from the top wall, a bottom floor extending from the first side wall to the second side wall, a dipper lip including a front shovel portion, and a tip attached to the front shovel portion. In a midplane perpendicular to the top wall and the bottom floor, the tip may define a bisector with the top wall that forms an acute angle in the range of 3.0 degrees to 7.0 degrees. [Brief explanation of the drawings]

[0011] [Figure 1] FIG. 1 is a perspective view of a machine such as an electric rope shovel having a dipper that may use a dipper lip configured in accordance with various embodiments of the present disclosure. [Figure 2] FIG. 2 is a perspective view of the dipper of FIG. 1 removed from the machine. [Figure 3] FIG. 3 is a side cross-sectional view of the dipper of FIG. 2. [Figure 4] FIG. 4 is an enlarged detail view of the joint formed by the dipper lip and bottom plate of the dipper of FIG. 3. [Figure 5] FIG. 4 is a top view of the dipper lip of the dipper of FIGS. 2 and 3 in isolation. [Figure 6] FIG. 7 is a front view of the dipper lip of FIG. 6. [Figure 7] 7 is a side cross-sectional view of the dipper lip taken along line 7-7 of FIG. 6. DETAILED DESCRIPTION OF THE INVENTION

[0012] Reference will now be made in detail to embodiments of the present disclosure, examples of which are illustrated in the accompanying drawings. Wherever possible, the same reference numbers will be used in the drawings to refer to the same or similar parts. In some cases, where reference numbers are shown herein, the drawings will show the reference numbers followed by an alphabetical letter, e.g., 100a, 100b, etc. It should be understood that the use of an alphabetical letter immediately following a reference number indicates that these features have similar shapes and similar functions, as is often the case when geometric shapes surround a symmetrical planar mirror image. For ease of description herein, alphabetical letters are often not included herein, but may be shown in the drawings to indicate overlapping features described herein.

[0013] Various embodiments of the present disclosure include a dipper lip or dipper that can use various angles to reduce heel wear and / or improve drilling performance in abrasive environments such as oil sands applications.

[0014] 1 , a machine 100 is shown having a body 102 (which may include a turntable 108) with a track system including a first track chain 104 a and a second track chain 104 b disposed on opposite sides of the body 102. The machine 100 is shown in association with an electric rope shovel having a cab 106, a boom 110, a lower end 112 of the boom 110 (also referred to as the boom foot), an upper end 114 of the boom 110 (also referred to as the boom point), tension cables 116, a gantry tension member 118, a gantry compression member 120, a pulley 122 rotatably mounted to the upper end 114 of the boom 110, a dipper 200, a dipper door 202 pivotally connected to the dipper 200, hoist ropes 128, a winch drum (not shown), and a dipper handle 130. An electric motor controls the winch drum, causing the boom, the dipper, and the dipper handle to move up and down relative to the boom.

[0015] Tracks 104a and 104b are part of a machine chassis 132 that is coupled to carbody 102 in a conventional manner. Each of tracks 104a and 104b includes a plurality of track shoes coupled together to form an endless loop extending around a plurality of rotatable elements. In a typical design, an idler 134 and a drive sprocket 136 are associated with each of tracks 104a and 104b and mounted to a track roller frame 138. As described further herein, a plurality of track rollers 140 may also be mounted to roller frame 138 and associated with each of tracks 104a and 104b to support machine 100 and guide tracks 104a and 104b along a desired path. One or more carrier rollers 142 (or track sliders, described briefly herein) may also be associated with each of tracks 104a and 104b to support and guide the track opposite roller 140 during operation.

[0016] The unique design of tracks 104a and 104b, and the overall track and undercarriage system of which they are a part, is contemplated to enable machine 100 to operate in a particular environment, such as oil sands. While the use of electric roper shovels and dippers in a machine environment is emphasized herein, it should be understood that machine 100 can comprise different types of machines. For example, track-type tractors and even half-track machines are also contemplated herein. Additionally, machine 100 may comprise a conveyor or other type of machine in which the tracks are used for purposes other than ground-engaging elements. Additionally, machine 100 could be some type of hydraulic excavator, bulldozer, excavator, backhoe, etc.

[0017] The dipper 200 is suspended from the boom 110 by a hoist rope 128. The hoist rope 128 is wound around a sheave 122 and attached to the dipper 200 by a bail 144. The hoist rope 128 is secured to a winch drum (not shown). The winch drum is driven by at least one electric motor (not shown) incorporating a transmission unit (not shown). As the winch drum rotates, the hoist rope 128 either pays out to lower the dipper 200 or retracts to raise the dipper 200. A dipper handle 130 is also coupled to the dipper 200. The dipper handle 130 is slidably supported within a saddle block 146, which is pivotally attached to the boom 110 by a dipper shaft (not explicitly shown). The dipper handle 130 includes a rack and tooth structure thereon that engages with a drive pinion (not shown) attached to the saddle block 146. The drive pinion is driven by an electric motor and transmission unit (not shown) to retract and retract the dipper handle 130 relative to the saddle block 146 .

[0018] A power source (not shown) is mounted to the carbody 102 and provides power to a hoist electric motor (not shown) for driving the hoist drum, one or more crowd electric motors (not shown) for driving the crowd transfer unit, and one or more swing electric motors (not shown) for rotating the turntable 108. In some cases, one electric motor provides power to all moving components of the excavator. Each of the crowd motors, hoist motors, and swing motors is driven by its own motor controller or in response to control signals from a controller (not explicitly shown).

[0019] Track chains 104a and 104b are believed to be well suited for operation in challenging underfoot conditions. To this end, track chains 104a and 104b may be "high ground pressure" tracks, each having track members durable enough to support the relatively large weight of machine 100. Each of the track shoe members has a footprint defined in part by leading and trailing edges and in part by outer and inner edges. Each of the track shoe members may further include a ground contact area equal to or less than its footprint, depending only on the extent to which adjacent track shoes overlap one another or on voids disposed on the bottom surfaces of the track shoe members. Other configurations of track shoe and track chain assemblies are possible in other embodiments of the present disclosure.

[0020] 2 and 3 , a dipper bucket according to one embodiment of the present disclosure may include a top wall 204, a first side wall 206 extending from the top wall 204, a second side wall 206a extending from the top wall 204, and a bottom floor 208 extending from the first side wall 206 to the second side wall 206a. A dipper lip 300 may be attached to the bottom floor as well as the side walls. The dipper lip 300 may include a front shovel portion 302 (also referred to as a front scoop portion). In some embodiments, when the top wall is horizontal, this front shovel portion is essentially horizontal, which may improve digging performance.

[0021] In a mid-plane 210 (which may be a plane of symmetry) perpendicular to the top wall 204 and bottom floor 208, the front shovel portion 302 may form an exterior angle 304 with the bottom floor 208 that is greater than 187.5 degrees (i.e., this angle is located on the outside of the dipper). For example, in some embodiments, this angle may be in the range of 189.5 degrees to 191.5 degrees (e.g., may actually be approximately 190.0 degrees to 191.0 degrees). Providing this angle may reduce wear on the heel 305 of the dipper. Other angle ranges are possible in other embodiments of the present disclosure.

[0022] Dipper lip 300 also includes a rear attachment portion 306 (so called because this portion of the lip is the rear used to attach the lip to the dipper) that forms a first bevel angle 212 with front shovel portion 302. Similarly, rear attachment portion 306 of dipper lip 300 may form a second bevel angle 214 with dipper bottom floor 208. The first bevel angle may, but need not, have a slightly different value than the second bevel angle.

[0023] As best shown in FIG. 3, the top wall 204 of the dipper and the front shovel portion 302 of the lip are substantially parallel to one another (i.e., + / - 2.0 degrees), while the trailing edge 215 of the first or second side wall of the dipper may, but is not necessarily, substantially perpendicular to the bottom floor 208 of the dipper (i.e., + / - 2.0 degrees).

[0024] Another embodiment of the dipper 300 may be described as follows with continued reference to Figures 2 and 3. At the mid-plane 210 (i.e., the cross-section shown in Figure 3), the bottom floor 208 may, in some embodiments, form a first acute angle 216 (which may be the same as the heel angle) in the range of 5.0 degrees to 15.0 degrees with the top wall 204 such that the dipper 200 forms a mouth (see dotted line 218) that narrows toward the rear of the dipper 200.

[0025] More specifically, in some embodiments of the present disclosure, first acute angle 216 may range from 7.5 degrees to 12.5 degrees. In other embodiments of the present disclosure, first acute angle 216 may range from 9.0 degrees to 11.0 degrees (e.g., approximately 10.0 degrees). Other ranges are possible in other embodiments of the present disclosure.

[0026] As previously mentioned herein, trailing edge 215 may be defined by top wall 204, first side wall 206, and second side wall 206a. Dipper door 220 (see also FIG. 1) may be pivotally attached to the dipper at top wall 204 (e.g., rear pivot point 230 in FIGS. 2 and 3) configured to contact trailing edge 215. This may not be the case in other embodiments of the present disclosure.

[0027] The front lip (e.g., dipper lip 300) may also be attached to a dipper that includes a rear mounting portion 306 and a front shovel portion (e.g., see 302). The rear mounting portion 306 may form a first obtuse angle 222 (see FIG. 3) in the range of 175.0 degrees to less than 180.0 degrees with the bottom floor 208 on the midplane 210 of the inside of the dipper (i.e., the interior of the dipper).

[0028] More specifically, in some embodiments of the present disclosure, the first obtuse angle 222 may be in the range of 176.5 degrees to 178.5 degrees.

[0029] Similarly, in some embodiments of the present disclosure, the front shovel portion (see, e.g., 302) may form a second obtuse angle 224 in the range of 173.0 degrees to 177.0 degrees with the rear mounting portion 306 on the dipper's inner midplane 210. Any of these angle ranges may be different in other embodiments of the present disclosure.

[0030] 4, the rear attachment portion 306 of the front lip may form a joint 226 with the bottom floor 208 of the dipper. At this joint 226, the rear attachment portion includes upper and lower chamfers 308, 308a disposed at the joint, while the bottom floor may have a flat surface 228 abutting the chamfers. A fillet weld (not shown) may attach these components to one another to form a rigid joint between them.

[0031] 5-7, a dipper lip that may be supplied as a replacement part for a dipper or as a field retrofit will be described.

[0032] Such a dipper lip 300 may include a first side wing 310, a second side wing 310a, a rear mounting portion 306 spanning from the first side wing 310 to the second side wing 310a, and a front shovel portion (see, e.g., 302) extending from the first side wing 310 to the second side wing 310a.

[0033] Dipper lip 300 may also define a midplane 312 (which may be, but is not necessarily, a plane of symmetry as shown) disposed between first side wing 310 and second side wing 310a. As best shown in FIG. 7 , forward shovel portion 302 defines an upper shovel surface 314, and rear mounting portion 306 forms an upper aft surface 316, which forms an obtuse angle 318 with upper aft surface 316 at midplane 312.

[0034] In some embodiments of the present disclosure, the obtuse angle 318 may range from 173.0 degrees to 177.0 degrees. In other embodiments of the present disclosure, the obtuse angle 318 may range from 174.0 degrees to 176.0 degrees (e.g., approximately 175.0 degrees).

[0035] As shown in Figures 5 and 6, the front shovel section 302 is arcuate in both the vertical plane 320 (inclined parabolic as shown in Figure 6) and the horizontal plane 322 (convex arc as shown in Figure 5). Other configurations in one or both planes other than arcuate are possible.

[0036] 5-7, it can be seen that the front shovel portion 302 defines a plurality of vertically extending through-holes 324 and a plurality of forwardly extending bosses 326 that facilitate the attachment of the adapter 232, teeth 234, and edge protector 236 (also called a shroud) shown in FIGS. 2 and 3. Any of these features or components may be modified or omitted.

[0037] 5 and 7, the rear attachment portion 306 may define a pointed trailing edge 328 that extends from the first side wing 310 to the second side wing 310a. This edge may be used to attach the dipper lip to the dipper. This feature may be omitted in other embodiments of the present disclosure.

[0038] The first side wing 310 or the second side wing 310a may include an upper wing surface 330, 330a that defines a minimum thickness 332 and an overall length measured perpendicular to the minimum thickness 332. In some embodiments of the present disclosure, the ratio of the overall length 334 to the minimum thickness 332 may range from 3.3 to 5.3. In some cases, the overall length 334 may range from 495.3 mm to 609.6 mm. This ratio and length provides a sufficient transition between the front shovel portion and the interior of the dipper, thereby simultaneously providing improved digging performance and sturdy mounting.

[0039] Any of the proportions or dimensions discussed herein may be modified for use in other applications other than those specifically set forth in other embodiments of the present disclosure.

[0040] In various embodiments of the present disclosure, the dipper lip or other components of the dipper may be made of any suitable material, such as metal (e.g., cast iron, iron, steel, gray cast iron, aluminum), reinforced plastic, etc. When a metal such as iron or manganese steel is used, the dipper lip or other components may be cast and machined to final dimensional tolerances.

[0041] It should be noted that the description of the dipper lip or other components may omit small blends, fillets, chamfers, etc. If the description of these features is omitted, their presence should be disregarded when interpreting this specification, including the claims.

[0042] Again, for any of the embodiments discussed herein, the dimensions, angles, and ratios may be varied from those shown or described herein. Also, in various embodiments of the present disclosure, various features may be varied in configuration or omitted. Materials of various components may also be varied as needed or desired. Industrial Applicability

[0043] Indeed, the dipper lip, dipper, and / or any components thereof may be sold, manufactured, purchased, etc. in an aftermarket or original equipment scenario according to any of the embodiments described herein. That is, a machine may be sold with a dipper and / or dipper lip, etc. according to the embodiments described herein, or the machine may be modified, repaired, or refurbished to use any of the embodiments described herein. Similarly, any dipper may be modified or repaired using a dipper lip according to any embodiment of the present disclosure.

[0044] The inventors of the present disclosure have discovered that the embodiments disclosed herein allow the tip or tooth to be rotated up 11° to provide better digging performance compared to previous designs. Additionally, the back of the lip is rotated up 10° to prevent heel wear. The new lip shape is expected to improve digging performance and virtually eliminate heel wear.

[0045] As shown in FIG. 3, the tip or tooth 234, in some embodiments of the present disclosure, may define a bisector 238 with the upper wall 204 that forms a mouth angle 240 in the range of 3.0 to 7.0 degrees (which may be approximately 5.0 degrees).

[0046] These design parameters can be important to obtain desirable oil sands drilling performance and dipper life.

[0047] Although this arrangement is shown in connection with a motorized rope shovel, the arrangement disclosed herein is versatile for various other types of machines that typically employ a track system rather than wheels. The term "machine" may refer to a machine that performs some type of operation associated with industries such as mining, construction, or other industries known in the art. The machine may be, for example, an excavator, wheel loader, cable shovel, or tow line. Additionally, one or more implements may be connected to the machine. The implements may be used in a variety of operations, such as lifting and loading.

[0048] For any of the embodiments described herein, the dipper lip or dipper may be modified for use with other implements on other machines, including other types of buckets.

[0049] 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 "a" or similar term is used. Also, as used herein, the terms "has," "have," "having," "with," and the like are intended to be open-ended terms. Furthermore, the phrase "based on" is intended to mean "based at least in part on," unless otherwise specified.

[0050] It will be apparent to those skilled in the art that various modifications and variations can be made in the embodiments of the apparatus and assembly methods discussed herein without departing from the scope or spirit of the invention. Other embodiments of the present disclosure will be apparent to those skilled in the art from consideration of the specification and practice of the various embodiments disclosed herein. For example, some devices may have configurations and functions different from those described herein, and certain steps of any methods may be omitted, performed in a different order than specifically mentioned, or in some cases performed simultaneously or in substeps. Furthermore, specific aspects or features of the various embodiments may be changed or modified to create further embodiments, and features and aspects of the various embodiments may be in addition to, or substituted for, other features or aspects of other embodiments to provide still further embodiments.

[0051] It is therefore intended that the specification and examples be considered as exemplary only, with a true scope and spirit of the invention being indicated by the following claims and their equivalents.

Claims

1. A dipper lip (300), a first side wing (310); a second side wing (310a); and a rear bucket mounting portion (306) spanning the first side wing (310) and the second side wing (310a); a front shovel portion (302) extending from the first side wing (310) to the second side wing (310a); the dipper lip (300) defines a central plane (312) disposed between the first side wing (310) and the second side wing (310a), the front shovel portion (302) defines an upper shovel surface (314), the rear bucket mounting portion (306) forms an upper rear surface (316), and the upper shovel surface (314) forms an obtuse angle (318) with the upper rear surface (316) at the central plane (312); The dipper lip (300), wherein the obtuse angle (318) is in the range of 173.0 degrees to 177.0 degrees.

2. The dipper lip (300) of claim 1, wherein the obtuse angle (318) is in the range of 174.0 degrees to 175.0 degrees.

3. The dipper lip (300) of claim 1, wherein the front shovel portion (302) is arcuate in both a vertical plane (320) and a horizontal plane (322).

4. The dipper lip (300) of claim 1, wherein the front shovel portion (302) defines a plurality of vertically extending through-holes (324) and a plurality of forwardly extending bosses (326).

5. The dipper lip (300) of claim 1, wherein the rear bucket mounting portion (306) defines a pointed trailing edge (328) extending from the first side wing (310) to the second side wing (310a).

6. 2. The dipper lip (300) of claim 1, wherein the first side wing (310) or the second side wing (310a) includes an upper wing surface (330) defining a minimum thickness (332) and an overall length (334) measured perpendicular to the minimum thickness (332), wherein a ratio of the overall length (334) to the minimum thickness (332) is in the range of 3.3 to 5.

3.

7. The dipper lip (300) of claim 6, wherein the overall length (334) is in the range of 495.3 mm to 609.6 mm.

8. A dipper bucket (200), an upper wall (204); a first side wall (206) extending from the top wall (204); a second side wall (206a) extending from the top wall (204); a bottom floor (208) extending from the first side wall (206) to the second side wall (206a); a dipper lip (300) including a front shovel portion (302); In a mid-plane (312) perpendicular to the top wall (204) and the bottom floor (208), the front shovel portion (302) forms an exterior angle (304) with the bottom floor (208) that is greater than 187.5 degrees; The dipper bucket (200), wherein the exterior angle (304) is in the range of 189.5 degrees to 191.5 degrees.

9. 9. The dipper bucket of claim 8, wherein the dipper lip includes a rear bucket mounting portion that forms a first oblique angle with the front shovel portion, the rear bucket mounting portion of the dipper lip forming a second oblique angle with the bottom floor of the dipper bucket, the top wall and the front shovel portion are substantially parallel to one another, and the dipper bucket further includes a tip attached to the front shovel portion, the tip defining a bisector at the mid-plane with the top wall that forms an opening angle in the range of 3.0 degrees to 7.0 degrees.

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