Mining Shovel Overcrowd Prevention via Axial Force Monitoring

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Conventional mining shovels face damage due to excessive crowding and swing forces, which can cause boom jack conditions and torsion forces, leading to component damage and inefficiencies in material handling.

Innovation Solution

The implementation of an overcrowd prevention system and swing abuse prevention system using sensors to monitor axial, displacement, and loading forces, with a control module that adjusts and limits the applied forces to prevent damage, including audible and visual warnings for operators.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If operators apply excessive crowding force to fill the dipper assembly, then the dipper is filled more quickly, but damage occurs to the dipper assembly or other components of the mining shovel

Engineering Contradiction:

Improvedipper filling speedVSAvoidcomponent durability

Core Design Contradiction:

ProductivityVSStrength

Solution Approach 1:

The system uses sensors to continuously monitor axial force at the boom assembly and provides real-time feedback to the control module. When the monitored force approaches or exceeds the threshold, the control module automatically reduces the crowding force, creating a closed-loop control system that prevents damage while maintaining efficient operation

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The control module dynamically adjusts the crowding force parameter based on monitored conditions. When excessive force is detected, the system changes the force parameter from high (excessive) to low (controlled), preventing damage while allowing high productivity during normal operation

Inventive Principle:

Principle #35Parameter changes

2Productivity

If operators apply excessive crowding force, then the dipper is forced into the bank more effectively, but a boom jack condition occurs where the boom pivots and jacks away from the ground

Engineering Contradiction:

Improvematerial loading efficiencyVSAvoidboom stability

Core Design Contradiction:

ProductivityVSStability of the object's composition

Solution Approach 1:

The sensor system continuously monitors axial force at the boom assembly and provides real-time feedback. When force levels indicate potential boom jack conditions, the control module automatically adjusts the crowding force to maintain boom stability while preserving loading efficiency

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The system applies preliminary control by monitoring force levels before they reach dangerous thresholds. The control module proactively reduces crowding force when sensors detect approaching threshold values, preventing boom jack conditions before they occur

Inventive Principle:

Principle #9Preliminary anti-action

3Productivity

If operators swing the dipper assembly before it is sufficiently free of the bank, then the unloading process is accelerated, but torsion force or compressive loading force damages the mining shovel

Engineering Contradiction:

Improveunloading speedVSAvoidstructural integrity

Core Design Contradiction:

ProductivityVSStrength

Solution Approach 1:

The system monitors axial force and displacement to detect when the dipper is sufficiently free of the bank. Real-time feedback allows the control module to enable swing motion only when safe, accelerating unloading while preventing torsion damage

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The system performs preliminary monitoring of dipper position and force levels before allowing swing motion. This preliminary action ensures the dipper is sufficiently free of the bank before unloading begins, preventing structural damage while maintaining efficient unloading

Inventive Principle:

Principle #10Preliminary action

4Reliability

If a conventional crowd force control with a fixed threshold is used, then excessive force above the threshold is limited, but damage can still occur from applied force below the specified threshold

Engineering Contradiction:

Improveforce control protectionVSAvoidsub-threshold damage risk

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The system replaces the static fixed threshold with a dynamic monitoring approach. Sensors continuously measure axial force and displacement, allowing the control module to adaptively adjust force limits based on real-time conditions, preventing both above-threshold and below-threshold damage

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The patent replaces conventional mechanical force control with an electronic sensing and control system. Load cells and displacement sensors provide precise measurement, while the control module implements sophisticated force management that detects and prevents damage from both excessive and sub-threshold forces

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS9169615B2Control systems for a mining vehicle

Publication Date: 2015.10.27 CATERPILLAR GLOBAL MINING LLC

AI summary

A mining shovel includes a dipper assembly comprising a dipper arm coupled to a dipper, a boom assembly configured to support the dipper assembly, and an overcrowd prevention system including one or more sensors configured to monitor an axial force. The mining shovel also includes a swing abuse prevention system, including one or more sensors configured to monitor one or more compound loading forces, and one or more sensors configured to monitor a torsion loading force. The mining shovel also includes a control module configured to receive signals from the sensors, and to control at least the crowding force applied to the dipper.