Dipper Swing Torque Control for Shovel Impact Reduction
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Solution Overview
Problem
Industrial machines like electric rope shovels experience damage due to improper swinging of the dipper, which results in high impact speeds and stresses on components, potentially causing collisions with other objects during digging operations.
Innovation Solution
A controller monitors the dipper's operation and applies motor torque in the opposite direction to slow down the swing when high impact is detected, using processor-determined compensation methods to limit swing torque and prevent excessive acceleration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the dipper is swung at high speed to increase productivity, then the dig cycle time is reduced, but the dipper and components suffer from excessive impact and stress causing damage
Solution Approach 1:
The swing torque is made dynamically adjustable based on real-time monitoring of dipper swing speed and acceleration. The control system continuously adapts the torque application to maintain optimal swing performance while preventing excessive speeds that cause damage, resolving the contradiction between productivity and reliability
Solution Approach 2:
The system implements feedback control by monitoring dipper swing parameters (speed, acceleration) and automatically adjusting swing torque accordingly. When high swing speed is detected, the system reduces torque to prevent damage, while allowing higher torque when safe operating conditions exist, thus maintaining both productivity and component durability
2Reliability
If motor torque is applied to slow down the dipper swing and reduce impact, then component stress is reduced, but the swing speed control precision must be increased
Solution Approach 1:
The control system performs multiple functions using the same monitoring infrastructure: it monitors swing speed for productivity optimization, monitors acceleration for impact prevention, and uses both parameters for automated torque adjustment. This multi-functional approach reduces the need for separate high-precision measurement systems for each function
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution effectively reduces the impact and stress on the dipper and other components by controlling the swing speed, preventing damage from collisions and ensuring safer operation.
Implementation Method 1
The controller uses motor torque to slow the swing of the dipper when it detects high impact with the bank. In particular, the controller applies motor torque in the opposite direction of the movement of the dipper, which counteracts the speed of the dipper and decelerates the swing speed.
Data Source
AI summary
Systems and methods for compensating dipper swing control. One method includes, with at least one processor, determining a direction of compensation opposite a current swing direction of the dipper and applying the maximum available swing torque in the direction of compensation when an acceleration of the dipper is greater than a predetermined acceleration value. The method can also include determining a current state of the shovel and performing the above steps when the current state of the shovel is a swing-to-truck state or a return-to-tuck state. When the current state of the shovel is a dig-state, the method can include limiting the maximum available swing torque and allowing, with the at least one processor, swing torque to ramp up to the maximum available swing torque over a predetermined period of time when dipper is retracted to a predetermined crowd position.