Wear cap for bucket lip having rail channels and bucket lip assembly with same

Abstract

A wear cap (44) in a bucket lip (22) in a bucket lip assembly (36) for a machine (10) includes a cap plate (54), and each of a first sidewall (64) and a second sidewall (66) downwardly dependent from the cap plate. A wear cap mounting space (68) is defined laterally between a first sidewall (64) and a second sidewall (66), and each of the first sidewall and the second sidewall includes a protrusion extending inwardly so as to define a rail channel (74, 76) for mounting the wear cap between the respective protrusion and the wear cap lower surface (62). The wear cap can be installed and retained solely by way of engagement with the rails on a bucket lip and interlocks with an adjacent coupler (38).

Description

[0001] Description

[0002] WEAR CAP FOR BUCKET LIP HAVING RAIL CHANNELS AND BUCKET LIP ASSEMBLY WITH SAME

[0003] Technical Field

[0004] The present disclosure relates generally to protective structures for a bucket lip in a machine, and more particularly to a wear cap for shielding areas of a bucket lip during service.

[0005] Background

[0006] Many different types of heavy-duty machinery are known throughout the world for use in material handling, construction, demolition, forestry, and mining, for example. Such machines are typically equipped with an implement system, commonly hydraulically actuated, including a bucket that captures material to be lifted and dumped. In mining applications, it is common for such machines to be built quite large and robust, with large bucket capacities configured for capturing, lifting, and dumping enormous amounts of material at a working face of a mine.

[0007] Operating conditions in such applications can be extremely harsh, with the material captured and moved being heavy, hard, abrasive, and sometimes needing to be broken apart by action of the bucket. One type of mining machine widely deployed in the field is generally known as a hydraulic mining shovel and includes a large bucket mounted to a boom assembly and operated to capture, lift, and dump blasted material at the working face of a mine. Buckets in such applications are often built, sometimes on-site, from multiple different parts including a so-called bucket lip that is arranged at a forward edge of the bucket. Such bucket lips are typically equipped with various protective structures, often replaceable, including edge shrouds, wing shrouds, wear caps, and various wear plates, as well as ground-engaging tip structures for penetrating the material. In modern hydraulic mining shovels and similar equipment, the bucket lip and attachments can be among the more complex components of the machine.

[0008] Due to the demands placed upon such machines the bucket components are typically built quite robust, often necessitating their being quite heavy, difficult to manufacture and / or install, or having other shortcomings. A bucket lip may also be equipped with multiple interrelated attachments in contact with one another and the bucket lip itself, creating challenges as to managing loads, fitment of parts, servicing and replacement schedules, and still others. The art provides ample room for improvements and development of alternatives to known strategies. One bucket lip is known from United States Patent No. 9404240B2 to Kunz.

[0009] Summary

[0010] In one aspect, a wear cap for a bucket lip includes a cap plate having a wear cap upper surface extending from a wear cap forward edge to a wear cap back edge, and a wear cap lower surface. The wear cap further includes a first sidewall and a second sidewall each downwardly depending from the cap plate. A wear cap mounting space is defined laterally between the first sidewall and the second sidewall, and extends vertically to the wear cap lower surface. The first sidewall and the second sidewall include a first protrusion and a second protrusion, respectively, each extending inwardly at a location that is longitudinally between the wear cap forward edge and the wear cap back edge. A first rail channel and a second rail channel, each in communication with the wear cap mounting space, are defined, respectively, between the first protrusion and the second protrusion and the wear cap lower surface.

[0011] In another aspect, a wear cap for a bucket lip includes a cap plate having a wear cap upper surface extending from a wear cap forward edge to a wear cap back edge, and a wear cap lower surface. The wear cap further includes a first sidewall and a second sidewall each downwardly dependent from a cap plate and including a first protrusion and a second protrusion, respectively, each extending inwardly so as to form a first rail channel and a second rail channel for hooking the wear cap to rails formed by a mounting station of a bucket lip. The first sidewall and the second sidewall further include a first sidewall tip and a second sidewall tip, respectively, each forward projecting, for hooking the wear cap under a coupler mounted upon the mounting station of the bucket lip.

[0012] In still another aspect, a bucket lip assembly includes an elongate bucket lip having a bucket lip upper surface, a bucket lip forward edge, and a plurality of mounting stations arranged along the bucket lip forward edge. Each of the plurality of mounting stations includes a mounting station upper surface vertically below the bucket lip upper surface, and each of a first rail and a second rail laterally outward of the mounting station upper surface. The bucket lip assembly further includes a wear cap installed on one of the plurality of mounting stations and including a cap plate, and each of a first sidewall and a second sidewall downwardly depending from the cap plate. The first sidewall and the second sidewall include, respectively, a first protrusion and a second protrusion each extending inwardly and forming a first rail channel and a second rail channel hooking the wear cap to the respective first rail and the second rail.

[0013] Brief Description of Drawings

[0014] Fig. l is a side diagrammatic view of a machine, according to one embodiment;

[0015] Fig. 2 is a diagrammatic view of a bucket lip, according to one embodiment;

[0016] Fig. 3 is a diagrammatic view of a bucket lip assembly, according to one embodiment;

[0017] Fig. 4 is a diagrammatic view of an assembly of a wear cap, coupler, and tip, according to one embodiment;

[0018] Fig. 5 is a diagrammatic view of an assembly of a wear cap, coupler, and tip, according to another embodiment,

[0019] Fig. 6 is a sectioned side diagrammatic view of a bucket assembly, according to one embodiment; Fig. 7 is a diagrammatic view of a mounting station, according to one embodiment;

[0020] Fig. 8 is a diagrammatic view of an assembly of a wear cap and a coupler, according to one embodiment;

[0021] Fig. 9 is a perspective view of a wear cap, according to one embodiment;

[0022] Fig. 10 is a perspective view of a wear cap, according to one embodiment; and

[0023] Fig. 11 is a side diagrammatic view of portions of a bucket lip assembly, according to one embodiment.

[0024] Detailed Description

[0025] Referring to Fig. 1, there is shown a machine 10 according to one embodiment. Machine 10 includes a frame 12 supported upon ground-engaging elements 14, for example, two parallel, endless ground-engaging tracks. Machine 10 also includes a hydraulically actuated implement system 16. Implement system 16 includes a boom assembly 18 and a bucket 20. An operating cab or station (not numbered) may be supported upon frame 12. In the illustrated embodiment, machine 10 is a hydraulic mining shovel commonly employed to capture, lift, and dump material at the working face of a mine. Alternative machine types and / or service applications are within the scope of the present disclosure. Bucket 20 is shown attached in a forward or front arrangement, however, in an alternative, bucket 20 could be reversed from the configuration illustrated and arranged similarity to certain backhoe or excavator applications. Bucket 20 includes a forwardly positioned bucket lip 22.

[0026] Referring also now to Fig. 2, bucket lip 22 may include an elongate one-piece casting 24. Casting 24 may be formed as a single cast piece of a suitable metallic material, such as an iron or a steel. Elongate casting or bucket lip body 24 may include an upper surface 26 extending laterally between a first lateral wing 28 and a second lateral wing 30. In a practical implementation, first lateral wing 28 and second lateral wing 30 can be attached such as by welding to a plurality of bucket panels or body pieces to form forward constructed bucket 20. Elongate body 24 also includes a plurality of mounting stations arranged along a bucket lip forward edge 35. The plurality of mounting stations may include a plurality of coupler stations 32 in an alternating arrangement with a plurality of shroud stations 34, forwardly positioned upon elongate body 24 and potentially arranged in a variety of staggered fore-aft positions and / or a forwardly biased arrangement, such that centrally located coupler stations 34 and centrally located shroud stations are positioned relatively more forward than coupler stations and shroud stations closer to first and second lateral wings 28 and 30.

[0027] Referring also now to Fig. 3, there is shown a view of a bucket lip assembly 36 showing a plurality of edge shrouds 42 installed on bucket lip 22 in an alternating arrangement with a plurality of couplers 38. Couplers 38 are attached to a respective plurality of tips 40. Bucket lip assembly 36 also includes a plurality of wear caps 44 installed upon bucket lip 22, each at least partially upon a respective one of coupler stations 32, and interlocking with couplers 38.

[0028] It will be appreciated that during operation of machine 10 with bucket assembly 36 installed in bucket 20, tips 40 can penetrate material to assist in capturing material to be lifted and dumped, and also potentially breaking apart pieces of the material. As bucket lip assembly 36 penetrates material, for example, blasted material at the working face of a mine, the coarse, hard material can tend to flow across tips 40, couplers 38, shrouds 42, and wear caps 44. Relatively fine particles of material can be forced into crevices, cracks, gaps, between and amongst components of bucket lip assembly 36. Material can also subject components of bucket lip assembly 36 to significant wear. As will be further apparent from the following description, bucket lip assembly 36 and components thereof can be structured for advantageous limitation to intrusion of material into undesired locations, promoting a desirable flow of material to optimize wear patterns and locations, including protecting bucket lip 22 from undesired wear during service. Referring also now to Fig. 4, there is shown an example arrangement and design of an assembly of coupler 38, tip 40, and wear cap 44. Wear cap 44 may be configured for both lateral interlocking and vertical interlocking with coupler 38 as further discussed here. Coupler 38 may be vertically symmetrical and can be flipped over to engage with wear cap 44 and tip 40 in an arrangement substantially identical to that shown in Fig. 4. Fig. 5 illustrates another example assembly of coupler 38, tip 40, and a wear cap 144. In the Fig. 5 embodiment wear cap 144 laterally interlocks with coupler 38 but does not vertically interlock with coupler 38.

[0029] Fig. 6 illustrates a sectioned side view of coupler 38, tip 40, and wear cap 44, as those components might appear installed on bucket lip 22. Coupler 38 may include a forwardly projecting nose portion 46 upon which tip 40 is mounted. Coupler station 32 may also be forward projecting and received in coupler 38. Coupler station 32 includes a mounting station or coupler station upper surface 48. Coupler station upper surface 48 may be spaced vertically below bucket lip upper surface 26, the significance of which will be further apparent from the following description.

[0030] Referring also now to Fig. 7, there are shown additional features of an example coupler station 32 including upper surface 48, which may be planar, and spaced vertically below bucket lip upper surface 26. Mounting station 32 may also include each of a first rail 50 and a second rail 52 positioned laterally outward of upper surface 48. Wear cap 44 may be installed upon rails 50 and 52. In one practical implementation, engagement with rails 50 and 52 enables wear cap 44 to hook onto mounting station 32 to inhibit vertical displacement of wear cap 44, and potentially limiting wear cap 44 being pushed back upon bucket lip 22. As also noted above, wear cap 44 may also be vertically interlocking and laterally interlocking with coupler 38. Wear cap 44 can be installed and retained on bucket lip 22 without welding, bolting, or any other fastening to bucket lip 22 apart from engagement with rails 50 and 52 and abutment with coupler 38. Referring also now to Figs. 8-11, there are shown other features of wear cap 44 and in further detail. Wear cap 44 may include a cap plate 54 having a wear cap upper surface 56 extending from a wear cap forward edge 58 to a wear cap back edge 60, and a wear cap lower surface 62. Wear cap 44 also includes a first sidewall 64 and a second sidewall 66 each downwardly depending from cap plate 54.

[0031] A wear cap mounting space 68 is defined laterally between first sidewall 64 and second sidewall 66, and extends vertically to wear cap lower surface 62. It will be appreciated that coupler station 32 can be received in part within wear cap mounting space 68 when wear cap 44 is installed for service on bucket lip 22. First sidewall 64 and second sidewall 66 include a first protrusion 70 and a second protrusion 72, respectively. Each of first protrusion 70 and second protrusion 72 extends inwardly at a location that is longitudinally between wear cap forward edge 58 and wear cap back edge 60. A first rail channel 74 and a second rail channel 76, each in communication with wear cap mounting space 68, are defined, respectively, between first protrusion 70 and second protrusion 72 and wear cap lower surface 62. First rail channel 74 and second rail channel 76 are configured to receive first rail 50 and second rail 52, respectively.

[0032] In an embodiment, first sidewall 64 and second sidewall 66 each include a sidewall lower edge 78 and 79, respectively, extending forward and angularly downward from cap plate 54. Sidewall lower edges 78 and 79 may be straight edges configured to abut complementary shoulders upon coupler station 32 in some embodiments. It can be appreciated that each of first sidewall 64 and second sidewall 66 may originate at a location that is longitudinally between wear cap forward edge 58 and wear cap back edge 60. First sidewall 64 and second sidewall 66 may each further include a forward projecting sidewall tip 80 and 82, respectively, for hooking wear cap 44 under coupler 38 mounted upon mounting station 32 of bucket lip 22.

[0033] Each of sidewall tips 80 and 82 may include a terminal corner. One terminal corner 84 of second sidewall 66 is shown in Fig. 10 and it will be appreciated that sidewall 64 includes an analogously defined terminal corner. Sidewall 66, and by analogy sidewall 64, may include a sidewall forward edge 85 extending upward from the respective terminal comer 84 and angularly oriented to the respective sidewall lower edge 78 and 79.

[0034] Wear cap forward edge 58 may further include a laterally extending coupler contact surface 86, received in a notch in coupler 38. Wear cap forward edge 58 may also include a first cutout 88 and a second cutout 90. First cutout 88 and second cutout 90 are defined, respectively, between each sidewall tip 80 and 82 and coupler contact surface 86. First cutout 88 and second cutout 90 may each extend laterally outward from coupler contact surface 86, and then vertically downward to the respective first sidewall tip 80 and second sidewall tip 82.

[0035] Focusing on Fig. 10, a wear cap width dimension 92 may be defined between first sidewall 64 and second sidewall 66. A mounting station shielding dimension 94 may be defined between wear cap upper surface 56 and each respective terminal corner 84. In an embodiment, each of first sidewall 64 and second sidewall 66 extends to a distance vertically below wear cap upper surface 56 that is at least 25% of wear cap width dimension 92. The distance vertically below, corresponding to shielding dimension 94, may be from 25% to 75% of wear cap width dimensions 92 in some embodiments.

[0036] Focusing on Fig. 9, each of first protrusion 70 and second protrusion 72 may include an upward facing rail hooking surface. A rail hooking surface 96 of protrusion 70 is visible in Fig. 9, and second protrusion 72 will be understood to include an analogous upward facing rail hooking surface. Rail hooking surface 96 may define an acute angle, opening generally in a forward direction, with the respective sidewall lower edge 78 in some embodiments. First rail channel 74 and by analogy second rail channel 76, extends to a contoured forward surface 98 transitioning between a rail channel outer wall 100 and a sidewall inner surface 102.

[0037] With continued focus on Fig. 9, but now also in specific reference to Fig. 11, wear cap lower surface 62 may form a lip contact surface 104 extending to wear cap back edge 60, and a mounting station contact surface 106 located vertically below lip contact surface 104. Lip contact surface 104 and mounting station contact surface 106 may be vertically spaced apart by way of a spacing distance 108. First rail channel 74 and second rail channel 76 may be defined, respectively, between first protrusion 70 and second protrusion 72 and mounting station contact surface 106. Lip contact surface 104 and mounting station contact surface 106 may be oriented parallel to one another and each may be planar.

[0038] Industrial Applicability

[0039] Referring now to the drawings generally, it will be recalled that mounting station upper surface 58 is spaced vertically below bucket lip upper surface 26. Wear cap 44 is configured to fit upon coupler station 32 but extend back of coupler station 32 to transition to bucket lip upper surface 26. Surfaces 104 and 106 of wear cap 44 may be configured complementary to surfaces 26 and 48 of bucket lip 26. As a result, rails 50 and 52 can be positioned lower than bucket lip upper surface 26, providing full retention of wear cap 44 at locations spaced below bucket lip upper surface 26. It will also be recalled sidewalls 64 and 66 may extend vertically downward so as to shield portions of coupler station 32. As a result, material that might otherwise impact and / or slide along exposed cast material of bucket lip 22 can be prevented from contacting much of coupler station 32. The described horizontal or lateral interlocking and the vertical interlocking of wear cap 44 with coupler 38 can assist in load management and wear cap retention, as well as minimizing gaps that might be packed with material during service.

[0040] The present description is for illustrative purposes only, and should not be construed to narrow the breadth of the present disclosure in any way. Thus, those skilled in the art will appreciate that various modifications might be made to the presently disclosed embodiments without departing from the full and fair scope and spirit of the present disclosure. Other aspects, features and advantages will be apparent upon an examination of the attached drawings and appended claims. 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 “one” or similar language is used. Also, as used herein, the terms “has,” “have,” “having,” or the like are intended to be open-ended terms. Further, the phrase “based on” is intended to mean “based, at least in part, on” unless explicitly stated otherwise.

Claims

Claims1. A wear cap (44) for a bucket lip (22) comprising: a cap plate (54) including a wear cap upper surface (56) extending from a wear cap forward edge (58) to a wear cap back edge (60), and a wear cap lower surface (62); a first sidewall (64) and a second sidewall (66) each downwardly depending from the cap plate; a wear cap mounting space (68) is defined laterally between the first sidewall and the second sidewall, and extends vertically to the wear cap lower surface; the first sidewall and the second sidewall including a first protrusion (70) and a second protrusion (72), respectively, each extending inwardly at a location that is longitudinally between the wear cap forward edge (85) and the wear cap back edge; and a first rail channel (74) and a second rail channel (76), each in communication with the wear cap mounting space, are defined, respectively, between the first protrusion and the second protrusion and the wear cap lower surface.

2. The wear cap of claim 1 wherein the first sidewall and the second sidewall each include a sidewall lower edge (78, 79) extending forward and angularly downward from the cap plate, and wherein the first sidewall and the second sidewall each include a forward projecting sidewall tip (80, 82).

3. The wear cap of claim 2 wherein the sidewall tips each include a terminal corner (84), and a sidewall forward edge (85) extending upward from the respective terminal corner and angularly oriented to the respective sidewall lower edge.

4. The wear cap of any of claims 1-3 wherein the wear cap forward edge includes a laterally extending coupler contact surface (86), and a first cutout (88) and a second cutout (90) are defined, respectively, between each of the sidewall tips and the coupler contact surface.

5. The wear cap of any of claims 1-4 wherein: a wear cap width dimension is defined between the first sidewall and the second sidewall, and a mounting station shielding dimension (94) is defined between the wear cap upper surface and each respective terminal corner; and the mounting station shielding dimension is from 25% to 75% of the wear cap width dimension.

6. The wear cap of any of claims 2-5 wherein the first protrusion and the second protrusion each include an upward facing rail hooking surface (96) defining an acute angle with the respective sidewall lower edge.

7. The wear cap of any of claims 1-6 wherein the first rail channel and the second rail channel each extend to a respective contoured forward surface (98) transitioning between a rail channel outer wall (100) and a sidewall inner surface (102).

8. The wear cap of any preceding claim wherein the wear cap lower surface forms a lip contact surface (104) extending to the wear cap back edge, and a mounting station contact surface (106) located vertically below the lip contact surface.

9. The wear cap of claim 8 wherein the first rail channel and the second rail channel are defined, respectively, between the first protrusion and the second protrusion and the mounting station contact surface, andwherein the lip contact surface and the mounting station contact surface are oriented parallel to one another and each is planar.

10. A wear cap (44) for a bucket lip (22) comprising: a cap plate (54) including a wear cap upper surface (56) extending from a wear cap forward edge (58) to a wear cap back edge (60), and a wear cap lower surface (62); a first sidewall (64) and a second sidewall (66) each downwardly depending from the cap plate and including a first protrusion (70) and a second protrusion (72), respectively, each extending inwardly so as to form a first rail channel (74) and a second rail channel (76) for hooking the wear cap to rails formed by a mounting station (32, 34) of a bucket lip; and the first sidewall and the second sidewall further including a first sidewall tip (80) and a second sidewall tip (82), respectively, each forward projecting, for hooking the wear cap under a coupler (38) mounted upon the mounting station (34) of the bucket lip.

11. The wear cap of claim 10 wherein the first sidewall and the second sidewall each include a sidewall lower edge (78, 79) extending forward and angularly downward from the cap plate; and wherein the first sidewall tip and the second sidewall tip each extend to a location positioned forward of the wear cap forward edge, and a cutout (88, 90) is formed between the wear cap forward edge and each respective first sidewall tip and second sidewall tip.

12. The wear cap of claim 10 or 11 wherein a wear cap width dimension is defined between the first sidewall and the second sidewall, and each of the first sidewall and the second sidewall extends to a distance below the wear cap upper surface that is at least 25% of the wear cap width dimension.

13. The wear cap of any of claims 1-12 wherein: the wear cap lower surface (62) forms a lip contact surface (104) extending to the wear cap back edge, and a mounting station contact surface (106) located vertically below the lip contact surface; and the first rail channel and the second rail channel are defined, respectively, between the first protrusion and the second protrusion and the mounting station contact surface.

14. The wear cap of any of claims 10-13 wherein the wear cap forward edge includes a coupler contact surface (86), and each of a first cutout (88) and a second cutout (90) are defined, respectively, between the first sidewall tip and the second sidewall tip and the coupler contact surface; and wherein the first cutout and the second cutout each extend laterally outward from the coupler contact surface, and then vertically downward to the respective first sidewall tip and second sidewall tip.

15. A bucket lip assembly (36) comprising: an elongate bucket lip (22) including a bucket lip upper surface (26), a bucket lip forward edge (35), and a plurality of mounting stations (32, 34) arranged along the bucket lip forward edge; each of the plurality of mounting stations including a mounting station upper surface (26) vertically below the bucket lip upper surface, and each of a first rail (50) and a second rail (52) laterally outward of the mounting station upper surface; a wear cap (44) installed on one of the plurality of mounting stations and including a cap plate (54), and each of a first sidewall (64) and a second sidewall (66) downwardly depending from the cap plate; and the first sidewall and the second sidewall including, respectively, a first protrusion (70) and a second protrusion (72) each extending inwardly and forming a first rail channel (74) and a second rail channel (76) hooking the wear cap to the respective first rail and second rail.

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