Interchangeable wear plates

Abstract

A replaceable wear plate is provided. The wear member (500, 500a) includes a body defining an exterior (508, 508a) having an outer periphery (510, 510a), an interior opening (502) having an at least partially polygonal inner periphery (504), and at least one fastener-receiving hole (512, 512a) extending from the exterior (508, 508a) to the interior opening (502). The exterior (508, 508a) is free of any large openings to limit the risk of material being jammed.

Description

[Technical Field]

[0001] FIELD OF THE DISCLOSURE The present disclosure relates generally to wear members, and more particularly to wear members that can be assembled to a mounting base. [Background technology]

[0002] For example, many earthmoving machines, such as loaders, excavators, hydraulic mining shovels, cable shovels, bucket wheels, and draglines, are equipped with tooling for moving material (e.g., for digging material out of the ground). These tooling is often subject to extreme wear due to the abrasion and impacts experienced when moving material. To mitigate wear, replaceable wear members are attached to the tooling and engage the material being moved.

[0003] U.S. Patent No. 5,937,549 (Patent '549) to Bender et al. describes an assembly system for removably attaching a wear member to a parent member. According to Patent '549, the assembly system includes a mounting base welded to one side of the parent member. The assembly system also includes a wear member, which is mechanically assembled to the single surface of the parent member by sliding the wear member over the mounting base and engaging cooperating engagement elements. Once the wear member is slid over the mounting base, Patent '549 describes using a removable retainer to hold the wear member in place. The wear member can be replaced by removing the retainer and sliding the wear member off the base, thereby disengaging the cooperating mounting elements.

[0004] The assembly system of the '549 patent can provide certain advantages in some applications. However, it may have certain disadvantages. For example, in wear member applications where wear on multiple non-parallel (e.g., perpendicular) surfaces of a tool must be mitigated, it may be difficult and / or costly to use the assembly system of the '549 patent. The disclosed embodiments can help solve this and other problems.

[0005] Also, the wear members may be located in different portions of the work tool (e.g., bucket, dipper, etc.). The amount and type of wear imparted to the outer wear members may differ from the amount and type of wear imparted to the inner wear members. For example, an inner wear member located inside a bucket or dipper may experience more severe wear or may become clogged with material that makes removal of the wear members of the attachment system difficult.

[0006] U.S. Patent No. 6,041,529 A discloses a wear runner assembly that is assembled to the surface of an excavating bucket and functions to protect a portion of the surface from wear during use of the bucket. The assembly includes a base member, a wear runner member, a pair of bolts, and a pair of conical lock nuts. The base member is welded to the surface and has a pair of undercut slots that capture and retain the bolt heads, with the bolt bodies extending outwardly across the surface and beyond the exterior of the base member. The wear runner members are mounted on the base member by moving the wear runner member across the surface toward the base member so that the outwardly protruding bolt body portions enter and are recessed into a pair of openings formed through the bolt bodies. Also, the protrusions on the base member are complementary received within the recesses formed in the wear runner member. Finally, a conical lock nut is threaded onto the bolt bodies recessed within the openings in the wear runner member, releasably holding the wear runner member on the base member. The interlock between the protrusion of the base member and the recess of the wear runner member prevents operating loads imposed on the assembly from moving the wear runner member relative to the base member parallel to the protective surface, thereby preventing the bolt from being sheared by such operating loads.

[0007] However, the protrusions on the base member are subject to operating loads and are susceptible to shear and other damage, which requires a stronger system. Summary of the Invention

[0008] A wear member mounting system according to an embodiment of the present disclosure may include a mounting base including an at least partially polygonal periphery, an inner weld-receiving hole, and at least one dovetail slot. The wear member mounting system may further include a wear member defining an opening having an at least partially polygonal inner periphery configured to cooperate with the at least partially polygonal periphery of the mounting base, and at least one dovetail fastener subassembly including a dovetail member including a body configured to at least partially complementarily fill the at least one dovetail slot. The fastener-receiving opening extending through the body defines a circular portion and a non-circular portion.

[0009] A wear member according to one embodiment of the present disclosure may include a body defining an exterior having an outer periphery, an interior opening having an at least partially polygonal inner periphery, and at least one fastener-receiving hole extending from the outer periphery to the interior opening.

[0010] A dovetail fastener subassembly according to one embodiment of the present disclosure includes a dovetail member including a body having an at least partially pyramidal configuration, the body defining a fastener-receiving opening extending therethrough that defines a surface of rotation and a non-rotational surface.

[0011] A mounting plate according to one embodiment of the present disclosure may include a plate body defining a plate length, a plate width, and a plate thickness that is less than the plate length and the plate width. The plate body may further define an internal dovetail slot, an external dovetail slot, a T-slot communicating with the internal dovetail slot and partially defining the internal dovetail slot, and an elongated slot disposed between the T-slot and the external dovetail slot in a direction parallel to the plate length. A pair of pry slots may be provided on either side of the external dovetail slot in a direction parallel to the plate width, and an elongated pry slot may be provided adjacent the internal dovetail slot in a direction parallel to the plate length. [Brief explanation of the drawings]

[0012] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate several embodiments of the present disclosure and, together with the description, serve to explain the principles of the disclosure. [Figure 1] FIG. 1 is a perspective view of a plurality of exemplary disclosed wear member systems mounted on a tool. [Figure 2] 2 is an enlarged perspective view of a portion of the wear member system of FIG. 1. [Figure 3] FIG. 3 is a perspective view of one of the wear member systems of FIGS. 1 and 2. [Figure 4] 4 is a perspective view of an exemplary disclosed mounting base of the wear member system of FIG. 3. [Figure 5] 4 is a perspective view of the mounting base of FIG. 3 from another angle. FIG. [Figure 6] FIG. 6 is a top view of the mounting base of FIGS. 4 and 5. [Figure 7] FIG. 7 is a bottom view of the mounting base of FIGS. 4 to 6. [Figure 8] FIG. 8 is a rear view of the mounting base of FIGS. 4 to 7. [Figure 9] FIG. 9 is a front view of the mounting base of FIGS. 4 to 8. [Figure 10] FIG. 10 is a right side view of the mounting base of FIGS. [Figure 11] FIG. 11 is a left side view of the mounting base of FIGS. [Figure 12] FIG. 3 is a front view of another exemplary disclosed mounting base of one of the wear member systems of FIGS. 1 and 2. [Figure 13] 4 is a perspective view of an exemplary disclosed wear member of the wear member system of FIG. 3. [Figure 14] FIG. 14 is a perspective view of the wear member of FIG. 13 from another angle. [Figure 15] FIG. 15 is a top view of the wear member of FIGS. [Figure 16] FIG. 16 is a bottom view of the wear member of FIGS. [Figure 17] FIG. 17 is a rear view of the wear member of FIGS. [Figure 18]FIG. 18 is a front view of the wear member of FIGS. [Figure 19] FIG. 19 is a right side view of the wear member of FIGS. [Figure 20] FIG. 20 is a left side view of the wear member of FIGS. [Figure 21] 4 is a perspective view of an exemplary disclosed retainer of the wear member system of FIG. 3. [Figure 22] FIG. 4 is a perspective view of an exemplary disclosed plug of the wear member system of FIG. 3. [Figure 23] 4A-4D are side views of the wear member system of FIG. 3 in various states of assembly. [Figure 24] 4A-4D are side views of the wear member system of FIG. 3 in various states of assembly. [Figure 25] 4A-4D are side views of the wear member system of FIG. 3 in various states of assembly. [Figure 26] FIG. 10 is a perspective view of another exemplary disclosed wear member system. [Figure 27] 27 is a perspective view of an exemplary disclosed mounting base of the wear member system of FIG. 26. [Figure 28] FIG. 27 is a perspective view of an exemplary disclosed wear member of the wear member system of FIG. 26. [Figure 29] 1 illustrates a machine in which a work tool such as a dipper having a wear member, a wear member system, and a mounting base configured in accordance with various embodiments of the present disclosure may be used. [Figure 30] FIG. 1 is a perspective view of a power tool in the form of a dipper having a plurality of wear members assembled to its interior bottom surface according to various embodiments of the present disclosure. [Figure 31] FIG. 1 is an exploded view of a wear member system (also called a wear member mounting assembly) including a mounting base assembly according to one embodiment of the present disclosure. [Figure 32] FIG. 32 is an exploded view of the mounting base assembly of FIG. 31 including a pair of dovetail subassemblies. [Figure 33] FIG. 33 is a perspective view of the dovetail fastener subassembly of FIG. 32, including dovetail members, bolts (e.g., M20 bolts), nuts, etc. [Figure 34] FIG. 34 is a top view of the dovetail member of FIG. 33. [Figure 35] FIG. 32 is a top view of the wear member system of FIG. 31 shown in an assembled state. [Figure 36] FIG. 36 is a bottom view of the wear member system of FIG. 35. [Figure 37] 37 is a cross-sectional view of the wear member system taken along line 37-37 of FIG. 35. [Figure 38] FIG. 38 is a cross-sectional view of the wear member system taken along line 38-38 of FIG. 35. [Figure 39] FIG. 36 is a top view of another embodiment of the wear member system shown assembled (e.g., a smaller design than that shown in FIG. 35, which may use M16 bolts instead of M20 bolts). [Figure 40] FIG. 40 is a bottom view of the wear member system of FIG. 39. [Figure 41] FIG. 41 is a cross-sectional view of the wear member system taken along line 41-41 of FIG. 39. [Figure 42] FIG. 42 is a cross-sectional view of the wear member system taken along line 42-42 of FIG. 39. [Figure 43] FIG. 43 is a perspective view of a dovetail fastener subassembly (capable of using M16 bolts) used in the wear member system of FIGS. [Figure 44] FIG. 44 is a top view of the dovetail member of FIG. 43. [Figure 45] FIG. 1 is a partial cross-sectional view of a fastener joint that may be used with various embodiments discussed herein. [Figure 46] FIG. 37 is a bottom perspective view of the wear member of FIG. 36 with the mounting plate and dovetail fastener subassembly removed to show the configuration of its bottom slot. DETAILED DESCRIPTION OF THE INVENTION

[0013] 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 numerals will be used throughout the drawings to refer to the same or similar parts. In some cases, reference numerals will be shown herein and in the drawings followed by a letter, e.g., 100a, 100b, etc. It will be understood that the use of a letter immediately following a reference numeral indicates that these features are similarly shaped and have similar functions, as is often the case when geometric shapes are mirrored about a plane of symmetry. For ease of description herein, letters are not typically included herein, but may be shown in the accompanying drawings to indicate overlapping features described herein.

[0014] 1-2 illustrate an exemplary wear member system 14 attached to a tool 12. For example, the tool 12 may be a bucket (shown in FIG. 1), a blade, a shovel, a crusher, a grapple, or a ripper, an earthmoving machine (e.g., a loader, an excavator, a hydraulic mining shovel, a cable shovel, a bucket wheel, a dragline, or another type of earthmoving machine). The tool 12 may be used to move material (e.g., to dig material out of the ground). The wear member system 14 may be assembled to heels 15, 17 of the tool 12 to mitigate wear due to abrasion and impacts experienced by the heels 15, 17 when moving material.

[0015] 3, each wear member system 14 may include a mounting base 22, a wear member 16, a retainer 24, and a plug 26. The mounting base 22 may be configured to be assembled to (e.g., fixed to) the first and second faces 18, 20 (see FIGS. 1-2 ) of the tool 12. The wear member 16 may be configured to be removably coupled to the tool 12 via the mounting base 22. The retainer 24 may be configured to maintain the mounting member 16 coupled to the mounting base 22 when in the mounted position, and the plug 26 may be configured to protect the retainer 24.

[0016] 4-11 show an exemplary mounting base 22 from various angles. As shown, the mounting base 22 may include a generally planar first base portion 28 extending along a longitudinal direction 30. The mounting base 22 may further include a generally planar second base portion 44 extendable from the first base portion 28 in a direction generally perpendicular to the first base portion 28, shown as a vertical direction 46.

[0017] The first base portion 28 may be generally rectangular and may have an inwardly facing surface 32 configured to be assembled to the tool 12. The first base portion 28 may further have an outwardly facing surface 34 opposite the inwardly facing surface 32. Additionally, the first base portion may have a pair of opposing sides 36, 38 extending generally parallel to the longitudinal direction 30. The first base portion may also have a pair of opposing ends, a first end 40 and a second end 42, extending in a direction generally perpendicular to the longitudinal direction 30, indicated as the latitudinal direction 57.

[0018] 4-7, the first base portion 28 may define a first opening 60 that may be configured to receive a portion of the wear member 16 and the retainer 24 (see FIG. 3). The first opening 60 may extend along the vertical direction 46 from the outward-facing surface 34 through the first base portion 28 to the inward-facing surface 32. The first opening 60 may be completely filled by the first base portion 28. The first opening 60 may include a cutout portion 64 that receives a portion of the wear member 16 and a generally rectangular portion 62 adjacent to the cutout portion 64 that receives the retainer 24. Other shapes are also contemplated for the portion 62 of the first opening 60. The portion 62 may be, for example, square, circular, oval, trapezoidal, or other shape. Regardless of its shape, it may be located in the center of the first base portion 28 along the longitudinal direction 30 of the first base portion 28. The cutout portion 64 may be located between the rectangular portion 62 and the first end 40.

[0019] The rectangular portion 62 of the first opening 60 may have a surface 66 facing the cutout portion 64 and a pair of opposing ends 68, 70 extending parallel to the longitudinal direction 30. The opposing ends 68, 70 may include a pair of opposing flanges 72, 74 extending inward from lower regions of the ends 68, 70 and adjacent the outwardly facing surface 34. The opposing flanges 72, 74 may be configured to facilitate retention of the retainer 24 when the retainer 24 is attached to the rectangular portion 62 of the first opening 60.

[0020] As used herein, the term "recessed shape" is intended to cover an opening having a generally flat bottom surface and angled, generally flat sides connecting the bottom surface. Alternatively, the sides may have some degree of curvature, if desired. The cutout shape 64 of the first opening 60 may be defined by opposing angled surfaces 76, 78 that converge as they extend from the inward-facing surface 32 to the outward-facing surface 34. As a result of the convergence, the perimeter 77 of the portion 64 defined by the surfaces 76, 78 at the inward-facing surface 32 may be greater than the perimeter 75 of the portion 64 defined by the surfaces 76, 78 at the outward-facing surface 34. As shown, the surfaces 76, 78 may be symmetrical with respect to the vertical direction 46. For example, the two surfaces 76, 78 may extend at an angle β of approximately 45 degrees relative to the vertical direction 46. Alternatively, the two surfaces 76, 78 may extend at another angle relative to the vertical direction 46. Alternatively, surfaces 76, 78 may be asymmetric with respect to vertical direction 46 and may extend at different angles relative to vertical direction 46. Also, cutout feature 64 may have a generally isosceles trapezoidal shape when viewed along an axis of first base portion 28 that is generally perpendicular to second base portion 44. Angled surfaces 76, 78 may at least partially define perimeters 77, 75 of cutout feature 64 on inwardly facing surface 32 and outwardly facing surface 34, respectively. Cutout feature 64 of first opening 60 may be configured such that the perimeter of cutout feature 64 is smaller on outwardly facing surface 34 than on inwardly facing surface 32.

[0021] As shown in FIGS. 4-11 , the first base portion 28 may further include a plurality of load pads 86 configured to contact the tool 12 and the wear member 16. The load pads 86 may be configured to transfer loads from the wear member 16 to the mounting base portion 22 and the tool 12 in a direction generally perpendicular to the planar first base portion 28, a direction generally perpendicular to the planar second base portion 44, and a direction generally parallel to the planar first base portion 28 and the planar second base portion 44. The load pads 86 may include protrusions on the first base portion 28. The protrusions may be formed by ridges surrounding the surface of the first base portion 28. The ridges on the surface of the first base portion 28 may extend to a substantially flat outer surface, so that the protrusions are substantially platform-shaped. The outer surface of the load pad 86 may be configured with ridges corresponding to the corresponding (e.g., generally parallel) surfaces of the inward-facing surface 32, the outward-facing surface 34, the side surfaces 36, 38, and the second end 42. For example, the outer surface of the load pad 86, which is generally parallel to the inward-facing surface 32, may form part of the inward-facing surface 32 and may be referred to herein as the inward-facing surface 32. The load pad 86 may be located at a corner of the first base portion 28 or configured to substantially surround at least a portion of the corner of the first base portion 28. The load pad 86 may be elevated from its respective surface, for example, a distance of between about 0.5 mm and about 4 mm. The load pad 86 that rises from and forms part of the inward-facing surface 32 may be configured to contact the first surface 18. When the wear member 16 is connected to the mounting base 22 (e.g., in the mounted position), the load pads 86 that rise from the outward-facing surface 34, the side surfaces 36, 38, and the second end 42 may be configured to contact the wear member 16.

[0022] The second base portion 44 may extend from the second end 42 of the first base portion 28. The second base portion 44 may have an inwardly facing surface 48 configured to be assembled to the tool 12. The second base portion 44 may further have an outwardly facing surface 50 opposite the inwardly facing surface 48. The second base portion 44 may further have a pair of opposing side surfaces 52, 54 extending from the first base portion 28. The second base portion 44 may further have a pair of opposing ends, i.e., a lower end 56 and an upper end 58, extending in a direction generally perpendicular to the longitudinal direction 30.

[0023] The second base portion 44 may further have a protrusion 59 extending from an upper end portion 58 in a direction generally parallel to the first base portion 28. The first base portion 28, the second base portion 44, and the protrusion 59 may form a generally L-shaped mounting base as shown in Fig. 11. As shown in Figs. 4 to 11, the edges and corners of the mounting base 22 may be rounded or rounded to reduce stress.

[0024] In some embodiments, the mounting base 22 may be welded to the tool 12. To facilitate such welding, a weld opening 80 may be formed in the base 22 to receive weld material, and the first end 40 and top end 58 of each of the base portions 28, 44 may include a chamfered surface for receiving the weld material. For example, the weld opening 80 may be generally oval and formed in the first base portion 28 between the rectangular portion 62 of the first opening 60 and the second end 42. Alternatively, the weld opening 80 may be another shape and may be formed in the second base portion 44 or another portion of the first base portion 28. In other embodiments, the weld opening may be formed in the first and second base portions 28, 44.

[0025] At first end 40, first base portion 28 may have a first chamfer 82 configured to receive weld material for assembling first base portion 28 to first surface 18 of tool 12. First chamfer 82 may extend from inwardly facing surface 32 away from the end of tool 12 when inwardly facing surface 32 is assembled to tool 12. First chamfer 82 may extend along first end 40 for less than the entire length of first end 40.

[0026] At the upper end 58, the second base portion 44 may have a second chamfered surface 84 configured to receive weld material for assembling the second base portion 44 to the second surface 20 of the tool 12. The second chamfered surface 84 may extend from the inwardly facing surface 48 away from the end of the tool 12 when the inwardly facing surface 48 is assembled to the tool 12. As shown in FIG. 1 , the second chamfered surface 84 may be located at the end of the protrusion 59. The second chamfered surface 84 may extend along the upper end 58 for less than the entire length of the upper end 58. The combination of the weld opening 80, the first chamfered surface 82, and the second chamfered surface 84 may form a three-point weld between the mounting base 22 and the tool 12.

[0027] 4-5 and 8-9, the side surfaces 52, 54 of the second base portion 44 may be configured to be disposed from the side surfaces 36, 38 of the first base portion 28. The side surfaces 52, 54 may be configured to converge as they extend from the first base portion 28. As shown, the side surfaces 52, 54 may be symmetrical about the vertical direction 46. For example, the side surfaces 52, 54 may extend at an angle α of approximately 3 degrees relative to the vertical direction 46. In other words, the width of the second base portion 44 at the upper end 58 in the latitudinal direction 57 may be narrower than the width of the second base portion 44 at the lower end 56. As shown in FIGS. 4-5 and 8-9, the transitions from the inward surface 32 to the side surfaces 52, 54 at the second end 42 and the lower end 56 may be filleted to reduce stress.

[0028] According to one embodiment, as shown in FIGS. 4-11 , the inwardly facing surface 32 of the first base portion 28, including the outer surface of the load pad 86 that forms part of the inwardly facing surface 32, may be concave, having a radius of curvature. The radius of curvature of the inwardly facing surface 32, including the outer surface of the load pad 86 that forms part of the inwardly facing surface 32, may generally correspond to the radius of curvature of the first surface 18 at the heels 15, 17 of the tool 12. The respective radii of curvature of the two surfaces may facilitate a flush fit between the inwardly facing surface 32 and the outer surface of the load pad 86 that forms part of the first surface 18. The concave inwardly facing surface 32 may have a radius of curvature between about 400 mm and about 800 mm. In some embodiments, the radius of curvature may be between about 500 mm and about 700 mm. For example, the radius of curvature may be about 600 mm. Other radii of curvature are also contemplated. In another embodiment, as shown in FIG. 12 , the inwardly facing surface 32 of the first base portion 28 may be substantially flat. A mounting base 22 having a flat inwardly facing surface 32 may be used on the first side 18 of the tool 12, which is correspondingly flat to facilitate flush mating of the surfaces. The mounting base 22 shown in FIG. 12 may otherwise be identical to the mounting base 22 shown in FIGS. 4-11, except for the different radius of curvature of the inwardly facing surface 32.

[0029] The size of the mounting base 22 may be varied to accommodate different sizes of tools 12. While the dimensions of the mounting base 22 can be varied dimensionally, the ratio of the various dimensions may remain approximately the same despite changes in the overall dimensions of the mounting base 22 and the corresponding wear member system 14. Referring to FIG. 8 , the ratio of the maximum width 146 of the first base portion 28 to the maximum width 148 of the second base portion 44 at the top end 58 in a direction parallel to both the first base portion 28 and the second base portion 44 may be between about 1.5 and about 2.5. In some embodiments, this ratio may be between about 1.75 and about 2.25. For example, the ratio may be about 2. This ratio range may be beneficial because making the second base portion 44 smaller than the first base portion 28 may reduce the weight and cost of the mounting base 22. However, the second base portion 44 needs to be large enough to maintain the overall structural integrity of the mounting base 22.

[0030] 10 , the ratio of the maximum length 150 of the first base portion 28 in a direction generally perpendicular to the second base portion 44 to the maximum height 152 of the second base portion 44 in a direction generally perpendicular to the first base portion 28 may be between about 1.5 and about 2.0. In some embodiments, this ratio may be between about 1.7 and about 1.8. In other embodiments, this ratio may be between about 1.75 and about 1.78. For example, this ratio may be about 1.77. This ratio range may be beneficial because it may provide a mounting base 22 that is appropriately sized relative to the size of the tool 12 and does not require the installation and replacement of the wear member 16 to be problematic in size and weight.

[0031] 9 , the ratio of the width 154 of the first chamfered surface 82 to the width 156 of the second chamfered surface 84 along a direction parallel to the first base portion 28 and the second base portion 44 may be between about 2.0 and about 3.0. In some embodiments, this ratio may be between about 2.25 and about 2.75. For example, this ratio may be on the order of 2.5. To ensure that the mounting base 22 is adequately secured to the tool 12, it is beneficial to maximize the length of the chamfered surface.

[0032] 13-20 show an exemplary wear member 16 from various angles. As shown, the wear member 16 may include a first generally planar wear member portion 88 extending in the longitudinal direction 30. The wear member 16 may further include a second generally planar wear member portion 90 that may extend from the first wear member portion 88 in a direction generally perpendicular to the first wear member portion 88.

[0033] The first wear member portion 88 may be generally rectangular and may have a first inwardly facing surface 89. The first wear member portion 88 may further have a wear surface 94 opposite the inwardly facing surface 89. As shown in FIG. 1 , the thickness of the first wear member portion 88 in a direction extending parallel to the second wear member portion 90 may decrease as the first wear member portion 88 extends from the second wear member portion 90. The first wear member portion 88 may define a second opening 102 that may be configured to extend through the retainer 24 (see FIG. 3 ). The second opening 102 may extend along the vertical direction 46 from the wear surface 94 through the first wear member portion 88 to the inwardly facing surface 89. The second opening 102 may also be substantially rectangular.

[0034] As shown in FIGS. 13-14 and 16-17, the wear surface 94 may be convex and have a radius of curvature. The radius of curvature of the wear surface 94 may generally correspond to the radius of curvature of the first surface 18 at the heel 15, 17 of the tool 12. The convex wear surface 94 may have a radius of curvature between about 500 mm and about 800 mm. In some embodiments, the radius of curvature may be between about 600 mm and about 700 mm. In some other embodiments, the radius of curvature may be between about 650 mm and about 660 mm. For example, the radius of curvature may be about 655 mm.

[0035] The second wear member portion 90 may be generally rectangular and may have a second inwardly facing surface 91 adjacent the first inwardly facing surface 89 of the first wear member portion 88. The first inwardly facing surface 89 and the second inwardly facing surface 91 of the wear member 16 may define a receiving pocket 96 configured to receive the mounting base 22. The receiving pocket 96 may be a generally rectangular concave cavity located within the first wear member portion 88 and the second wear member portion 90. As shown in FIG. 1 , the width of the receiving pocket 96 may be less than the width of the wear member 16. The first wear member portion 88 may include a portion of the receiving pocket 96 configured to receive the first base portion 28, and the second wear member portion 90 may include a portion of the receiving pocket 96 configured to receive the second base portion 44. The portion of the receiving pocket 96 defined by the first wear member portion 88 may be openable at a first end 92 facing the second wear member portion 90. In other words, the receiving pocket 96 may be open at the first end 92 of the first wear member portion 88 when viewed in the longitudinal direction.

[0036] The first inwardly facing surface 89 of the first wear member portion 88 may define a protrusion 104 adjacent a second opening 102 configured to removably connect the wear member 16 to the mounting base 22 during assembly to the tool 12. The protrusion 104 may be located between the second opening 102 and the first end 92 of the wear member 16. The protrusion 104 may have opposing engagement surfaces 106, 108 that may diverge from one another as they extend from the first inwardly facing surface 89 within the receiving pocket 96 to an upper surface 112 of the protrusion 104. As shown in FIG. 18 , the engagement surfaces 106, 108 may be symmetrical about the vertical direction 46. For example, the engagement surfaces 106, 108 may extend at an angle, e.g., approximately 45 degrees, away from the first inwardly facing surface 89 relative to the vertical direction 46. The protrusion 104 may have a generally isosceles trapezoidal shape when viewed along an axis generally perpendicular to the first wear member portion 88 of the second wear member portion 90. As shown, the joints between each engagement surface 106, 108 and the first inwardly facing surface 89 may be rounded to reduce stresses within the projection 104 and the first wear member portion 88. As shown in Figures 13-20, other joints, edges and corners of the wear member 16 may be radiused or rounded to reduce stresses.

[0037] The protrusion 104 may further have a front surface 114 and a rear surface 116 that extend from the first inward surface 89 to the top surface 112. The front surface 114 and the rear surface 116 may be substantially perpendicular to the first inward surface 89. The protrusion 104 may be configured to form a dovetail joint with the cutout feature 64 of the first opening 60. The height of the protrusion 104 may also be configured to be less than the depth of the receiving pocket 96, such that the protrusion 104 is positioned completely within the receiving pocket 96. In other words, the protrusion 104 may be configured such that no portion of the protrusion 104 extends beyond the boundaries of the receiving pocket 96.

[0038] 13-14 and 17-18, the second wear member portion 90 may have opposing side surfaces 98, 100 extending from the first wear member portion 88. The side surfaces 98, 100 are initially spaced apart and then pivotally converge toward each other as they extend from the first wear member portion 88. As shown in FIG. 17, the converging portions of the side surfaces 98, 100 may extend at an angle λ relative to the vertical direction 46. The angle λ may be between about 15 degrees and about 18 degrees. In some embodiments, the angle λ may be between about 16 degrees and about 17 degrees. For example, the angle λ may be about 16.75 degrees. In other embodiments, other angles λ may be utilized, or it may be envisioned that the side surfaces 98, 100 may be parallel.

[0039] The wear member 16 may also define one or more wear indicators 118. The wear indicators may be configured to provide an indication of when the wear member 16 should be replaced with a new wear member 16. An indication of when the wear member 16 should be replaced may be, for example, when a sufficient portion of the material of the wear member 16 has worn away to expose the mounting base 22 through one or more wear indicators 118. That is, when the mounting base 22 becomes visible through the wear member 16 at the location of one wear indicator 118, this may be an indication that the wear member 16 should be replaced.

[0040] The first wear member portion 88 may define a wear indicator 118 formed on its inwardly facing surface 89 within the receiving pocket 96 between the rectangular second opening 102 and the second end 120. The wear indicator 118 may include a recess recessed into the first wear member portion 88 from the first inwardly facing surface 89 away from the receiving pocket 96. The second wear member portion 90 may also define a wear indicator 118 formed on its second inwardly facing surface 91 in a central region of the second wear member portion 90. The wear indicator 118 formed on the second inwardly facing surface 91 may include a recess recessed into the second inwardly facing surface 91 away from the receiving pocket 96. The wear indicator 118 may be positioned away from the receiving pocket 96 to provide an indication that the wear member 16 should be replaced before wear occurs on the mounting base 22. The recess depth of the wear indicator 118 from the first inwardly facing surface 89 within the receiving pocket 96 may be between about 1 mm and about 5 mm. In other embodiments, the depth may be between about 2 mm and about 4 mm. For example, the depth may be about 3 mm.

[0041] As shown in FIGS. 13, 15, and 18, the wear indicators 118 defined by the wear member 16 may be "X"-shaped recesses. Other recess shapes are contemplated. Additional wear indicators 118 may also be formed on the wear member 16. For example, as shown in FIG. 15, the first wear member portion 88 may define circular recessed wear indicators 118 located between the rectangular second openings 102 on either side of the receiving pocket 96 and the first end 92. In yet another example, as shown in FIGS. 13 and 18, the second wear member portion 90 may define additional wear indicators 118 outside the receiving pocket 96. These additional wear indicators may be any of a variety of shapes, such as square, circular, triangular, rectangular, or other shapes. These wear indicators 118 formed outside the receiving pocket 96 may have a greater recess depth than the other wear indicators 118.

[0042] 13-15 , the wear member 16 may further include a plurality of load pads 124 configured to contact the mounting base 22. The load pads 124 may be configured to transfer load from the wear member 16 to the mounting base 22 in a direction generally perpendicular to the first wear member portion 88, a direction generally perpendicular to the second wear member portion 90, and a direction generally parallel to the first wear member portion 88 and the second wear member portion 90. The load pads 124 may include protrusions within the receiving pocket 96. The protrusions may be formed by ridges on the surface of the receiving pocket 96. The surface of the receiving pocket 96 may include a first inwardly facing surface 89, side walls 126, 128, and a second inwardly facing surface 91. The protrusions may be generally platform-shaped. The load pads 124 may be located at corners of the receiving pocket 96. The load pads 124 may be configured to correspond to and contact the load pads 86 of the mounting base 22. All of the load pads 124 upstanding from the first inwardly facing surface 89 may be substantially horizontal. All of the load pads 124 upstanding from the second inwardly facing surface 91 may be substantially horizontal. All of the load pads 124 raised on each separate side wall 126, 128 may be substantially horizontal.

[0043] The second wear member portion 90 may further have one or more bearing surfaces 130 formed by the side walls of the receiving pocket 96, as shown in FIGS. 13 and 18 . The bearing surfaces 130 may extend from the second inwardly facing surface 91 parallel to the first wear member portion 88 beyond the receiving pocket 96 defined by the first wear member portion 88. The bearing surfaces 130 are configured to contact the mounting base 86 of the first base portion 28 and the upper end 58 of the second base portion 44 when the mounting base 22 is coupled to the wear member 16. The bearing surfaces 130 may be configured to transfer a load to the mounting base 22 perpendicular to the first wear member portion 88.

[0044] 3, the wear member 16 may be wider than the mounting base 22 in the latitudinal direction 57, longer than the mounting base 22 in the longitudinal direction 30, and taller than the mounting base 22 in the vertical direction 46. In other words, the wear member 16 may be configured to substantially surround the mounting base 22 when coupled in the mounting position as shown in FIG.

[0045] The size of the wear member 16 can be varied to allow the wear member 16 to fit various sizes of tools 12. Although the size of the wear member 16 can be varied, the ratio of the various sizes remains approximately the same even though the combined size of the wear member 16 and the corresponding wear member system 14 is changed.

[0046] 17 , at the upper end 121, along a direction parallel to both the first and second wear member portions 88, 90, the ratio of the maximum width 160 of the first wear member portion 88 to the maximum width 162 of the second wear member portion 90 may be between about 1 and about 2. In some embodiments, this ratio may be between about 1.25 and about 1.75. In other embodiments, this ratio may be between about 1.5 and about 1.6. For example, this ratio may be about 1.55. The width ratio may correlate with the angle λ of the converging sides 98, 100 of the second wear member portion 90. As a result of the converging sides and the width ratio, wear member systems 14 may be installed close to each other along the heel of the tool without interference issues, as shown in FIG. 2 .

[0047] 19 , the ratio of the maximum length 164 of the first wear member portion 88 along a direction generally perpendicular to the second wear member portion 90 to the maximum height 166 of the second wear member portion 90 along a direction generally perpendicular to the first wear member portion 88 may be between about 1.15 and about 1.5. In some embodiments, this ratio may be between about 1.3 and about 1.35. For example, this ratio may be about 1.32. This ratio may be correlated to the maximum length and height ratio of each of the mounting bases 22. This ratio range may be beneficial because it may provide a wear member 16 of appropriate dimensions relative to the dimensions of the tool 12, but is not so large or heavy that installation and replacement of the wear member 16 becomes problematic.

[0048] Additionally, the dimensions of the mounting base 22 relative to the wear member 16 can remain substantially constant regardless of how the overall dimensions of the wear member system 14 change. For example, with reference to FIGS. 8 and 17, the ratio of the width 160 of the first wear member portion to the width 146 of the first base portion 28 may be between about 1.15 and about 1.5. In some embodiments, this ratio may be between about 1.3 and about 1.35, such as about 1.32. Referring again to FIGS. 8 and 17, the ratio of the width 162 of the second wear member portion 90 to the width 148 of the second base portion 44 may be between about 1.55 and about 1.8. In some embodiments, this ratio may be between about 1.65 and about 1.70, such as about 1.68. With reference to FIGS. 10 and 19, the ratio of the length 164 of the first wear member portion 88 to the length 150 of the first base portion 28 may be between about 1.0 and about 1.4. In some embodiments, the ratio may be between about 1.1 and about 1.3, such as about 1.20. These ratios of wear member 16 to mounting base 22 may be beneficial to ensure that the dimensions of both mounting base 22 and wear member 16 are appropriate based on the dimensions of tool 12. Additionally, these ratios may provide an appropriate amount of material surrounding mounting base 22 so that the life expectancy of wear member 16 may be sufficiently long.

[0049] 3 and 21 , the retainer 24 may have a substantially flat, rectangular body portion 132 that may be adapted to be positioned within the rectangular portion 62 of the first opening 60. The retainer 24 may be configured to hold the wear member 16 in its mounted position on the mounting base 22 when mounted within the rectangular portion 62 of the first opening 60. The body may be constructed of steel or any suitable substantially incompressible material. The retainer 24 may further include spring portions 134 along the body 132 that may be adapted to provide sufficient end-to-end resilience to the body 132 to allow the length of the body 132 to compress when pressure is applied to the ends, but also sufficient stiffness from one side to the other so that the retainer 24 may withstand compressive loads applied laterally without significant deformation. Other retainer designs are also contemplated for maintaining the mounted position of the wear member 16. The first opening 60 and the retainer 24 may have shapes other than rectangular, for example.

[0050] 22 shows one embodiment of the plug 26. The plug 26 may have a flat base portion 136 and multiple protrusions 138 shaped to correspond to the spring portion 134 of the retainer 24, so that the protrusions 138 of the plug 26 are inserted into the spring portion 134 of the retainer 24. This may prevent soil from getting caught on the spring portion 134 when the plug 26 is inserted into the retainer 24. Without the plug 26, soil may get caught on the spring portion 134, limiting the compression of the spring portion 134 and making it difficult to remove the retainer 24.

[0051] 26-28 illustrate another embodiment of a wear member system. Wear member system 14' may be substantially similar to wear member system 14. For example, wear member system 14' may include a wear member 16', a mounting base 22', a retainer 24, and a plug 26. Mounting base 22' may be configured to be assembled (e.g., fixed) to first surface 18 and second surface 20 of tool 12. Wear member 16' may be configured to be removably coupled to mounting base 22'. Retainer 24 may be configured to hold mounting member 16 coupled to mounting base 22, and plug 26 may be configured to protect retainer 24.

[0052] As shown in FIGS. 26-28 , mounting base 22′ may be similar in many respects to mounting base 22′. However, there are distinct differences between the embodiments. For example, second base portion 44′ of mounting base 22′ may be approximately the same width as first base portion 28′ at second end 42′, but second base portion 44′ may be narrower than first base portion 28 at second end 42′. As a result of the increased width of second base portion 44′ relative to first base portion 28, the width of second chamfered surface 84′ may also be increased. The shape of receiving pocket 96′ defined by wear member 16′ may be correspondingly formed to receive the wider second base portion 44′ of mounting base 22′.

[0053] Another difference between the embodiments includes, for example, how the second base portion 44′ defines tab openings 168, 168 configured to receive the lugs 170 defined by the wear member 16′. The wear member 16 and mounting base 22 are not provided with tab openings 168 and tabs 170. As shown in FIG. 26 , the tab openings 168 may be configured to receive the tabs 170 through the second base portion 44′. The surfaces of the tabs 170 may be configured to contact corresponding surfaces of the tab openings 168 when the wear member 16′ is coupled to the mounting base 22′. The surfaces of the tab openings 168 and tabs 170 may be configured to function similarly to the load surfaces 130 of the wear member system 14. In other words, the lugs 170 may be configured to transfer loads applied to the wear member 16′ through the tab openings 168, 168 to the mounting base 22′. Loads transmitted by tab openings 168 and tabs 170 may act in vertical 46 and latitudinal 57 directions on wear member 16' on mounting base 22'.

[0054] Another example of a difference between wear member systems 14 and 14' includes the difference between the wear indicator 118 of wear member 16 and the wear indicator 118' of wear member 16'. Wear member 16' may be circular and "X" shaped, as described herein, and may include a circular wear indicator 118' formed along the sidewall of receiving pocket 96', as opposed to wear indicator 118, which may be disposed within receiving pocket 96. Additional minor differences between wear member systems 14, 14' may be discernible from the drawings. [Industrial Applicability]

[0055] The disclosed wear member system may be applied to any tool having a heel with substantially vertical first and second surfaces. Compared to prior art wear member systems, the wear member system may have various advantages. For example, the tool can be relatively easily removed and installed, regardless of the tool's size. Furthermore, a single mounting base and wear member system may be used to protect the tool's first and second surfaces. Another advantage may be based on the applicability of multiple surface wear indicators, which may provide an indication of when the wear member should be replaced.

[0056] The wear member 16 and mounting base 22 provide a quick and easy system for attaching and detaching the wear member 16 to the mounting base 22. Attachment and detachment of the wear member 16 can be accomplished without the use of special tools, requiring only a common pry bar. FIGS. 23-25 ​​show the attached wear member 16 and mounting base 22 in various assembled states. Note that the mounting base 22 may be assembled to the tool 12 by welding, as described herein. The mounting base 22 may be welded to the tool 12 along the first surface 18 at the first location 140 and the second location 142, and along the second surface 20 at the third location 144. Once the mounting base 22 is assembled to the tool 12, the mounting member 16 may be coupled to the mounting base 22 by moving the mounting member 16 in a first direction toward the mounting base 22, as shown by arrow 172 in FIG. 23 . The protrusions 104 of the wear member 16 must be substantially aligned with the rectangular portions 62 of the first openings 60 so that the protrusions 104 are inserted into the first openings 60 .

[0057] 24, the wear member 16 may initially be positioned on the mounting base 22 in an offset position such that the protrusion 104 is insertable into the rectangular portion 62 of the first opening 60 to the left of the cutout feature 64. The wear member 16 may then be slid rightward in a second direction into the mounted position, as indicated by arrow 174. Sliding the wear member 16 rightward allows the protrusion 104 to move from the rectangular portion 62 of the first opening 60 into the cutout feature 64, and the engagement surfaces 106, 108 of the protrusion 104 engage the angled surfaces 76, 78 of the cutout feature 64 in an inverse interlocking relationship. The engagement surfaces 106, 108 and the angled surfaces 76, 78 may cooperate to form a dovetail joint.

[0058] In the installed position, as shown in FIG. 25 , the rectangular portion 62 of the first opening 60 may be aligned with the rectangular second opening 102, so that the retainer 24 may be inserted into the rectangular portion 62 of the first opening 60 via the wear member 16. The retainer 24 may be inserted into the rectangular portion 62 of the first opening 60 in a third direction, as indicated by arrow 176. One end of the retainer 24 is positioned within the first opening 60 below one of the flanges 72, 74, and a prybar may be inserted into the other end of the retainer 24. By applying a moderate force to the retainer 24 with a screwdriver, the length of the retainer 24 may be sufficiently compressed so that the free end of the retainer 24 can move completely beyond the other flange and seat retainer 24 into the rectangular portion 62 of the first opening 60. The retainer 24 may prevent longitudinal movement of the mounting member 16 relative to the mounting base 22 during installation. The retainer 24 may be prevented from moving by retaining the position of the projection 104 within the notched feature 64 of the first opening 60. After the retainer 24 is installed, it may also be installed by inserting a plug 26 into the second rectangular opening 102 of the wear member 16.

[0059] The wear member 16 can be removed from the mounting base 22 by reversing the above steps. For example, the first plug 26 (if installed) can be removed. The retainer 24 can then be removed, and the wear member 16 can be slid leftward until the protrusion 104 is aligned with the rectangular portion 62 of the first opening 60. Once the protrusion 104 is aligned, the wear member 16 can be dropped from the mounting base 22. A new wear member 16 can then be installed.

[0060] Another advantage of the wear member system 14 is its versatility. The wear member system 14 may utilize only a single wear member 16 to protect the first surface 18 and a portion of the second surface 20 of the tool 12 at the heel 15 or 17. In contrast, a single-surface wear member typically requires two separate mounting bases and wear members, one for the first surface 18 and one for the second surface 20, to protect each heel of the tool. Thus, the wear member system 14 may reduce installation time and costs by protecting both surfaces with one wear member and one mounting base.

[0061] Another advantage of the wear member system 14 and wear member 16 may be one or more wear indicators 118, which may provide an indication of when the wear member 16 should be replaced. In some applications, the wear member 16 may experience different amounts of wear depending on the surface of the wear member 16. As a result, it may be beneficial to form wear indicators 118 on multiple surfaces and at multiple locations on the surface of the wear member 16 to provide wear indications at multiple locations. In some applications, it may be beneficial to periodically rotate the position of the wear member 16 on the tool 12 to achieve uniform wear of the wear members 16 and increase the life of each wear member.

[0062] 29 and 30 , a machine 200 is shown having a carbody 202 (e.g., an electric rope shovel with a dipper that may use any of the embodiments discussed herein) (which may include a turntable 208) with a track system including a first track chain 204a and a second track chain 204b located on opposite sides of the carbody 202. The machine 200 is shown in the context of an electric rope shovel having a cab 206, a boom 210, a lower end 212 of the boom 210 (also referred to as the boom foot), an upper end 214 of the boom 210 (also referred to as the boom point), tension cables 216, a gantry tension member 218, a gantry compression member 220, a sheave 222 rotatably mounted to the upper end 214 of the boom 210, a dipper 300, a dipper door 302 pivotally mounted to the dipper 300, a hoist rope 228, a winch drum (not shown), and a dipper handle 230. The motor controls the winch drum to cause the boom, dipper to be lowered or raised, and the dipper handle to be raised and lowered relative to the boom.

[0063] Tracks 204a, 204b are part of a machine chassis 232 that is conventionally coupled to carbody 202. Each track 204a, 204b includes a plurality of coupled track shoes that form an annular ring extending around a plurality of rotatable elements. In a typical design, an idler 234 and a drive sprocket 236 are associated with each of tracks 204a and 204b and mounted to a track roller frame 238. As described further herein, a plurality of track rollers 240 may also be mounted to roller frame 238 and associated with each of tracks 204a and 204b to support machine 200 and guide tracks 204a and 204b along a desired path. One or more carrier rollers 242 (or track sliders) may also be associated with each of tracks 204a and 204b to support and guide the track opposite roller 240 during operation.

[0064] The unique design of tracks 204a and 204b, and the overall track and undercarriage system of which they are a part, is contemplated to enable machine 200 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 200 can comprise different types of machines. For example, track-type tractors and even semi-track machines are also contemplated herein. Additionally, machine 200 may comprise a conveyor or other type of machine in which the tracks are used for purposes other than as ground-engaging elements. Additionally, machine 200 could be some type of hydraulic excavator, bulldozer, excavator, backhoe, etc.

[0065] The dipper 300 is suspended from the boom 210 by a hoist rope 228. The hoist rope 228 is assembled to a sheave 222 and attached to the dipper 300 by a bail 244. The hoist rope 228 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 228 either unwinds to lower the dipper 300 or retracts to raise the dipper 300. A dipper handle 230 is also coupled to the dipper 300. The dipper handle 230 is slidably supported within a saddle block 246, which is pivotally attached to the boom 210 by a dipper shaft (not explicitly shown). The dipper handle 230 includes a rack and tooth structure thereon that engages with a drive pinion (not shown) attached to the saddle block 246. The drive pinion is driven by an electric motor and transmission unit (not shown) to retract and retract the dipper handle 230 relative to the saddle block 246 .

[0066] A power source (not shown) is mounted to the carbody 202 and drives a hoist electric motor (not shown) for driving the hoist drum, one or more crowd electric motors (not shown) for driving the crowd transfer units, and one or more swing electric motors (not shown) for rotating the turntable 208. In some cases, one electric motor powers all moving components of the excavator. Each of the crowd motor, hoist motor, and swing motor is driven by its own motor controller or in response to control signals from a controller (not explicitly shown).

[0067] Track chains 204a and 204b are believed to be well suited for operation in challenging underfoot conditions. To this end, track chains 204a, 204b may be "high ground pressure" tracks durable enough to support the relatively heavy track members of machine 200. Each track shoe member has a footprint defined in part by leading and trailing edges and in part by outer and inner edges. Each track shoe member may include a contact area equal to its footprint, or a contact area less than its footprint only to the extent that adjacent track shoes overlap, or further contact area due to voids in the bottom surface of the track shoe member. Other configurations of track shoe and track chain assemblies are possible in other embodiments of the present disclosure.

[0068] It is conceivable that both the outer and inner wear members may wear and build up. Accordingly, further embodiments are described herein to limit wear and packing in harsh abrasive environments such as oil sands. However, it should be understood that these embodiments are applicable to other environments and applications as well.

[0069] Such an embodiment has a bolt-on wear member (sometimes referred to as a cover) with a dovetail fastening subassembly that replaces the dovetail on the wear member as described previously herein, allowing the wear member to fit the same mounting base. This cover can be placed directly on the base, and the cover uses all four sides of the base to bear load. This contrasts with earlier implementations in which the wear member used only three sides of the base to bear load, with a spring retainer providing load support on the fourth side. The wear member eliminates the large openings disclosed herein that allow packing to occur. Figure 30 shows multiple wear members and a wear member mounting system installed on the interior floor of a dipper.

[0070] 31-43, there are shown wear member mounting systems 400, 400a (e.g., system 400 may be larger than system 400a) constructed in accordance with two different embodiments of the present disclosure. Such wear member mounting systems 400, 400a may include a mounting base 700 (see, e.g., FIG. 32) including an at least partially polygonal perimeter 702 (other shapes of perimeter may include arcs), an internal weld-receiving opening 704 (which may have, e.g., an elongated oval groove or runway shape, although other configurations, locations, and multiples are possible), and at least one dovetail slot 706, 706a (which may be open or enlarged on a bottom surface 712). A wear member 500, 500a (see, e.g., FIGS. 31 and 40) may be configured to be assembled to the mounting base 700 by dropping it onto the mounting base instead of sliding it onto the mounting base.

[0071] To this end, the wear member 500, 500a may define in its lower surface 506, 506a an opening 502 (e.g., with reference to FIGS. 36, 40, which may be a counterbore extending only to the bottom surface to help reduce buildup) having an at least partially polygonal inner periphery 504 configured to cooperate with an at least partially polygonal outer periphery 702 of the mounting base 700. Other configurations of these boundaries are possible in other embodiments of the present disclosure.

[0072] The wear member mounting system 500, 500a may further include at least one dovetail fastener subassembly 600, 600a (see, e.g., FIGS. 1 and 2). One subassembly 600a may be smaller than the other subassemblies 600a (31, 32, 33, 34, 43, 44, etc.) and includes a dovetail member 602, 602a configured to at least partially complementarily fill at least one dovetail slot 706, 706a of the mounting base 700 and defining a fastener-receiving opening 604, 604a extending therethrough, the body having a circular portion 606, 606a and a non-circular portion 608, 608a. In some illustrated embodiments, the circular portion 606, 606a includes a cylindrical clearance hole 610, 610a (610a having a diameter of approximately 18.0 mm for receiving an M16 bolt and 610b having a diameter of approximately 22.0 mm for receiving an M20 bolt), and the non-circular portion 608, 608a may include a plurality of flat surfaces 612, 612a that are angled relative to one another. More specifically, these flat surfaces may receive the hex head of a bolt to prevent the bolt from rotating, such as during assembly.

[0073] In Figures 37 and 41, at least one dovetail slot 706, 706a includes a pair of angled sidewalls 708, and the body of the dovetail member 602, 602a may include a pair of inclined surfaces 614, 614a that cooperate with (i.e., contact or nearly contact) the angled sidewalls 708. While a 2.0 mm clearance may be provided as shown, this is not required. In other words, line-to-line designs, preload designs, and other designs are possible. The shape of these features does not necessarily have to be flat; they may be arc-shaped, such as when a pin-round or partial pin-round dovetail is used. Also, T-slot dovetails with right-angled surfaces may also be employed.

[0074] Returning to FIG. 32 , the mounting base may include a top surface 710 and a bottom surface 712 (so called because this surface is closest to the mounting surface of the work tool). At least one dovetail slot 706 may be disposed at least partially inside the polygonal perimeter 702 and communicate with a T-slot extending through the top surface 710 and bottom surface 712 of the mounting base 700. The T-slot 712 may be omitted in other embodiments of the present disclosure. Another dovetail slot 706 a may extend through the top surface 710 and bottom surface 712 and at least partially to the polygonal perimeter 702. This may not be the case in other embodiments of the present disclosure. For example, one of the dovetail slots may be omitted, or both slots may be located toward the inside of the mounting base 700, etc.

[0075] 33 and 43 show that the dovetail members 602, 602a may include rectangular pads 616, 616a extending upward from a pair of angled surfaces 614, 614a forming top surfaces 618, 618a. The pair of angled surfaces 614, 614a may also extend to bottom surfaces 620, 620a. The circular portions 606, 606a of the fastener-receiving openings 604, 604a extend from the top surfaces 618, 618a, and the non-circular portions 608, 608a of the fastener-receiving openings 604, 604a extend from the bottom surfaces 620, 620a to the circular portions 606, 606a. Specifically, the circular portion 606, 606a may include a cylindrical clearance hole 610, 610a, and the non-circular portion 608, 608a may include a plurality of flat surfaces 612, 612a that are angled relative to one another. For example, these surfaces may be configured to mate with a hex head or square head of a bolt, etc. Other configurations are possible in other embodiments of the present disclosure.

[0076] In the field, the wear member mounting system 400, 400a is typically assembled by assembling (e.g., by welding) the mounting base 700 to the surface of the work tool. The dovetail fastener subassembly(s) 600, 600a are then placed into the dovetail slot(s). If the dovetail slot includes a T-slot, the subassembly is inserted into the T-slot and slid until it reaches the dovetail slot. If the dovetail slot is peripheral, the subassembly simply slides into the dovetail slot. The wear member 500, 500a is then placed onto the mounting base, allowing the fastener to pass through its counterbore 526, 526a. The nuts 636, 636a are then tightened to secure the wear member.

[0077] If the dovetail fastener subassembly is not supplied assembled, it must first be assembled. The fastener simply needs to be inserted through the bottom of the dovetail member until its head reaches the partial countersink with a flat surface.

[0078] Indeed, the wear member, mounting base, dovetail fastener subassembly, wear member mounting system, and / or any component thereof can be sold, manufactured, purchased, etc. in an aftermarket or OEM scenario according to any embodiment described herein. That is, a machine may be sold with a dipper and / or wear member mounting system, etc. according to an embodiment described herein, or the machine may be modified, repaired, or refurbished to use any of the embodiments described herein. Similarly, any dipper or other work tool can be modified or repaired using any embodiment of the present disclosure.

[0079] For example, as shown in FIGS. 31 and 36-42, a wear member 500, 500a, which may be provided as a replacement part, may include a body defining an exterior 508, 508a having an outer periphery 510, 510a, an interior opening 502 having an at least partially polygonal inner periphery 504, and at least one fastener-receiving hole 512, 512a extending from the exterior 508a to the interior opening 502.

[0080] As shown in Figures 36 and 40, the inner periphery of the polygon is at least partially defined by a series of mating pads 514 that form a rectangular structure (which may be located at the corners of the rectangular structure and may protrude approximately 25.0 mm) having an opening depth 516 (see also Figures 38 and 42), an opening width 518, and an opening length 520. In some embodiments of the present disclosure, the ratio of opening width 518 to opening length 520 may be in the range of 0.75 to 0.90. Other ratios are possible, such as for small and large scale applications.

[0081] Specifically, the opening length 520 may range from 155.0 mm to 235.0 mm, the opening width 518 may range from 118.0 mm to 200.0 mm, and the opening depth 516 may range from 18.0 mm to 29.0 mm. Other size ranges are possible in other embodiments of the present disclosure. A pair of mating pads 514 are spaced apart along a direction parallel to the opening length by pry slots 522 (see FIGS. 36 and 42), which include angled pry surfaces 524.

[0082] With continued reference to Figures 36 and 42, as shown in Figures 36 and 42, the fastener-receiving holes 512, 512a may take the form of counterbore holes 526, 526a defining a major diameter portion defining a major diameter 528, 528a and a minor diameter portion defining a minor diameter 530, 530a. In some embodiments of the present disclosure, the ratio of the major diameter 528, 528a to the minor diameter 530, 530a may be in the range of 2.0 to 2.75. It is easier to clean the counterbore with the fastener head, if any, located within the counterbore, allowing for easier removal. This may not be the case in other embodiments of the present disclosure.

[0083] 38, fastener-receiving holes 512 define a diameter (e.g., major diameter 528) that is spaced a minimum distance 532 from outer periphery 510. In some embodiments of the present disclosure, the ratio of minimum distance 532 to diameter 528 may be within a range of 0.77 to 0.92. This ratio may balance the cleaning effectiveness just discussed with the structural integrity of the wear member. This ratio may not be necessary in some applications where cleaning or structural integrity is not required (e.g., when suitable durable materials are used).

[0084] 35, 36, 39, and 40, the outer periphery 510, 510a may define an upper sloped portion 534, 534a, a pair of side recesses 536, 536a, and a bottom notch 538. Each of the pair of side recesses 536, 536a may have a footing eye 540, 540a. The outer periphery 510, 510a also defines a first protrusion 542, 542a between the upper sloped portion 534, 534a and the footing eye 540, 540a, and a second protrusion 544, 544a between the bottom notch 538 and the footing eye 540, 540a. Additionally, the wear member includes a bottom surface (or lower surface 506, 506a, see FIGS. 36 and 40) that defines a first cavity 546, 546a at the bottom surface of the first projection 542, 542a and a second cavity 548, 548a at the bottom surface of the second projection 544, 544a. These cavities help to cut out excess material, reducing costs and preventing problems associated with the casting process, such as voids, porosity, and sink marks.

[0085] Also, because the overall perimeter is not a pure rectangle or square, the wear member may be better able to grip material, facilitating bucket filling and reducing the likelihood of material becoming trapped under the wear member within the assembly structure, which may provide more effective wear protection than simply shaped wear members known to those skilled in the art.

[0086] It should be noted that the cross sections of Figures 38 and 42 may represent planes of symmetry for the wear member, and therefore various features such as those described above may, but do not necessarily, reflect these planes.

[0087] 35 and 39, it can be seen that perimeters 510 and 510a define width 550 and lengths 552 and 552a. In some embodiments of the present disclosure, the ratio of width 550 to length 552, 552a may range from 1.05 to 1.32. In this case, the length may range from 275.0 mm to 350.0 mm, the width may range from 360.0 mm to 370.0 mm, and the body may have a thickness 554 ranging from 70.0 mm to 80.0 mm (see FIG. 38). Other ratios and size ranges are possible in other embodiments of the present disclosure.

[0088] When assembled, there may be a 1.0 mm gap between the mounting plate and the sides of the opening in the wear member, and a 5.0 mm gap near the front of the assembly (in the area near bottom notch 538). These gaps are adjustable.

[0089] 33, 34, 43, and 44, a dovetail fastener subassembly 600, 600a, which may be provided in the field as an alternative or retrofit, includes a dovetail member 602, 602a including a body having an at least partially pyramidal configuration (e.g., inclined surfaces 614, 614a having flat sides 624, 624a, etc.), defining a fastener-receiving opening 604, 604a extending through the body, and defining a rotation surface 626, 626a and a non-rotation surface 628, 628a.

[0090] The subassembly may also include a bolt 630, 630a having a head 632, 632a and a shaft 634, 634a. The head 632, 632a is aligned with the non-rotating surface 628, 628a, and the shaft 634, 634a is aligned with the rotating surface 626, 626a. As a result, the bolt may pass through the dovetail member with the free end of the male threads exposed. A nut 636, 636a can be threaded onto the shaft, which is held stationary by the alignment of the head and non-rotating surface. Examples of bolts that can be used include M16 bolts and M20 bolts.

[0091] Figures 37 and 45 show typical examples of what a bolted joint may look like when assembled. Washers (638, 638a) are also provided. The stress distribution 640 in Figure 45 has been determined by the inventors to be acceptable for at least some applications.

[0092] 32 illustrates a mounting plate 700a that may be provided as a field replacement or retrofit. The mounting plate 700a may include a plate body that defines a plate length 716, a plate width 718, and a plate thickness 720 that is less than the plate length 716 and the plate width 718.

[0093] The plate body may also define an internal dovetail slot (see, e.g., 706), an external dovetail slot (see, e.g., 706a), a T-slot 714 that communicates with the internal dovetail slot and partially forms the internal dovetail slot, and an elongated slot 722 disposed between the T-slot 714 and the external dovetail slot along a direction parallel to the plate length 718.

[0094] A pair of pry slots 722 may be positioned on either side of the external dovetail slot (see, e.g., 706a) along a direction parallel to the plate width 716, and an elongated pry slot 726 may be positioned proximate to the internal dovetail slot (see, e.g., 706) along a direction parallel to the plate length 718.

[0095] 46 shows the bottom opening 502. The bottom floor 503 may be continuous, may not be flat, or may have multiple surfaces located at different levels. For example, the bottom floor 503 may include a series of mounting pads 556 (e.g., four located at each corner of the opening 502) and a pair of shallow pockets 558 (e.g., which may have a depth of 30.0 mm or less) located between a pair of mounting pads, each pocket surrounding a fastener-receiving opening or hole, and a large gap pocket 560 (e.g., which may have a depth greater than 30.0 mm) located midway through the opening 502 and separating one set of mounting pads and pockets from another set. Other configurations are possible in other embodiments of the present disclosure.

[0096] Although the device is shown in the context of an electric rope shovel, the device disclosed herein is universally applicable to various other types of machines that typically employ an endless track system rather than wheels. The term "machine" refers to any machine that performs any type of work associated with industries such as mining or construction, or other industries known in the art. For example, the machine may be an excavator, wheel loader, cable shovel, or tow line. Additionally, one or more tools may be connected to the machine. Such implements may be utilized for various tasks, such as lifting and loading.

[0097] 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 to be used, "one" or similar language 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 expressly stated otherwise.

[0098] It will be apparent to those skilled in the art that various modifications and variations may be made in the embodiments of the apparatus and assembly methods described 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 apparatus may have different configurations and functions than those described herein, and some steps of any method may be omitted, performed in a different order than specifically mentioned, or in some cases performed simultaneously or sequentially. Furthermore, some 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 added to or substituted for other features or aspects of other embodiments to provide still further embodiments.

[0099] Therefore, the specification and embodiments are 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 wear member (500, 500a) comprising: a body, the body comprising: an exterior (508, 508a) having an outer periphery (510, 510a); an interior opening (502) having an at least partially polygonal inner periphery (504); at least one fastener-receiving hole (512, 512a) extending from said exterior (508, 508a) to said interior opening (502); the at least partially polygonal inner periphery (504) is formed by a series of mating pads (514) configured to be integral with the body and forming a rectangular configuration having an opening depth (516), an opening width (518), and an opening length (520), the ratio of the opening width (518) to the opening length (520) being in the range of 0.75 to 0.90; The wear member (500, 500a) has an opening length (520) in the range of 155.0 mm to 235.0 mm, an opening width (518) in the range of 118.0 mm to 200.0 mm, and an opening depth (516) in the range of 18.0 mm to 29.0 mm, and wherein a pair of the series of mating pads (514) are separated by a pry slot (522) including an angled pry surface (524) along a direction parallel to the opening length (520).

2. 2. The wear member of claim 1, wherein the at least one fastener-receiving hole is a counterbore defining a major diameter portion defining a major diameter and a minor diameter portion defining a minor diameter, wherein a ratio of the major diameter to the minor diameter is in the range of 2.0 to 2.

5.

3. 2. The wear member of claim 1, wherein the at least one fastener-receiving hole defines a diameter spaced a minimum distance from the outer periphery, the ratio of the minimum distance to the diameter ranging from 0.77 to 0.

92.

4. 2. The wear member (500, 500a) of claim 1, wherein the outer periphery (510, 510a) defines an upper sloped portion (534, 534a), a pair of side recesses (536, 536a), and a bottom notch (538).

5. The outer periphery (510, 510a) further includes a footing eye (540, 540a) disposed in each of the pair of side recesses (536, 536a), and the outer periphery (510, 510a) includes a first protrusion (542, 542a) between the upper inclined portion (534, 534a) and the footing eye (540, 540a), and a second protrusion (542, 542a) between the bottom notch (538) and the footing eye (540, 540a).

5. The wear member (500, 500a) of claim 4, wherein the wear member (500, 500a) includes a bottom surface (506, 506a), defining a first cavity (546, 546a) in the bottom surface of the first protrusion (542, 542a) and defining a second cavity (548, 548a) in the bottom surface of the second protrusion (544, 544a).

6. 5. The wear member of claim 4, wherein the outer periphery defines a width and a length, wherein a ratio of the width to the length is in the range of 1.05 to 1.32, and the interior opening includes a bottom floor having a series of mounting pads, a pair of shallow pockets disposed between the pair of the series of mounting pads and surrounding at least one fastener-receiving hole, and a large clearance pocket disposed in a central portion of the interior opening.

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