Saddle Block Shimming Gap Control for Power Shovel Gear Protection
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Solution Overview
Problem
Current maintenance routines for power shovels rely on visual inspection and assumptions for determining the saddle block shimming gap, leading to inaccurate adjustments and increased wear, which results in poor performance and potential gear damage due to increased friction and shock loads.
Innovation Solution
A control system using sensor data and linear calculations to determine the saddle angle and saddle angle gap, allowing for precise measurement of the saddle block shimming gap, enabling timely adjustments and reducing maintenance downtime.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If visual inspection and standard assumptions are used to determine saddle block shimming gap, then maintenance routine is simple, but measurement precision is poor leading to inaccurate adjustments
Solution Approach 1:
The patent replaces visual inspection and manual measurement with an automated sensor-based measurement system. Sensors mounted on the shovel boom and saddle block automatically detect the shimming gap through optical or electronic means, substituting mechanical measurement tools and human visual assessment with automated detection technology.
Solution Approach 2:
The system implements continuous feedback by automatically monitoring the saddle block shimming gap through sensors and providing real-time data to the control system. This feedback loop enables precise measurement and automatic adjustment warnings, replacing subjective visual inspection with objective, quantifiable data.
2Object-affected harmful factors
If saddle blocks are connected too close to the handle, then friction increases, but gap size must be controlled to prevent shock loads
Solution Approach 1:
The system dynamically adjusts and monitors the shimming gap to maintain optimal values during operation. By continuously measuring the gap and comparing it against predetermined thresholds, the system ensures the gap remains within the optimal range that balances friction reduction with shock load prevention.
Solution Approach 2:
The patent changes the physical parameter of the shimming gap to an optimized value through automated measurement and adjustment. The system determines the precise gap distance and adjusts it to fall within the optimal range (0.125-0.5 inches), transforming the gap from a fixed or estimated value to a precisely controlled parameter.
3Object-affected harmful factors
If gap between saddle blocks and handle increases, then friction decreases, but shock loads and gear damage increase
Solution Approach 1:
The system provides continuous feedback on the shimming gap through automated sensors, enabling real-time monitoring of the gap between saddle blocks and handle. This feedback mechanism prevents excessive gap development by alerting operators before shock loads and gear damage occur.
Solution Approach 2:
The patent replaces manual gap assessment with automated sensor-based detection that precisely measures the shimming gap. This substitution eliminates the need for visual inspection and provides accurate, objective data on gap size, preventing gear damage through early detection of excessive gaps.
Data Source
AI summary
A method of controlling the operation of an industrial machine. The industrial machine includes a boom, a dipper handle attached to the boom, a saddle block pivotally mounted to the boom at a pivot point, and a computer having a controller. The method comprises processing, with the controller, data received from a saddle angle sensor, determining, with the controller, a saddle angle and a saddle angle gap using the data from the saddle angle sensor, determining, with the controller, a height of the dipper handle. The method further comprises determining, with the controller, a height of the saddle block, determining, with the controller, a saddle gap radius, and determining, with the controller, a saddle block shimming gap by comparing the saddle gap radius with the height of the handle.