CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to U.S. Provisional Application No. 61/605,505, filed March 1, 2012, the entire contents of which are incorporated herein by reference.

FIELD OF THE INVENTION

[0002] The present invention relates to lubrication of an industrial machine, and in particular to automatic lubrication of one or more structural elements of an industrial machine.

BACKGROUND OF THE INVENTION

[0003] Industrial machines, such as electric rope or power shovels, draglines, etc., are used to execute digging operations to remove material from a bank of a mine. During that process, the machines employ various large mechanical components (e.g., a boom, a boom handle, a dipper, a dipper door, etc.). The industrial machines further include a variety of structural elements (e.g., pins, bearings, bushings, etc.) that connect the various mechanical components and linkages of the machines. Typically, the structural elements are not lubricated during the operation of the industrial machine, which increases the wear on these elements and decreases the longevity of the industrial machine and its structures. For example, in an electric shovel, without lubrication, bearings cannot be installed in a dipper bail, which leads to decreased pin life.

[0004] Current designs for structural elements are also dictated by bearing stresses for un- lubricated joints, which are based upon the presumption that operators do not lubricate the structural elements of the machine. This presumption leads to decreased allowable design stresses for the structural elements.

[0005] In those instances where the structural elements are lubricated, the operator typically must first stop the operation of the machine prior to lubricating the structural elements, which decreases the productivity of the machine and is also dangerous for the operator. Current lubrication systems include manual lubrication systems, or electro-chemical systems that operate well in a warmer weather, but are ineffective in a colder climate.

SUMMARY

[0006] In accordance with one construction, an automatic lubrication system includes a reservoir configured to be coupled to an industrial machine component, a lubricant line coupled to the reservoir, and a mechanism coupled to the reservoir, the mechanism configured to exact a volume of lubricant from the reservoir based solely on movement of the industrial machine component.

[0007] In accordance with another construction, an automatic lubrication system for lubricating a structural element associated with both a first industrial machine component and a second industrial machine component includes a reservoir coupled to one of the first and second industrial machine components, and a mechanism coupled to the reservoir, wherein relative movement between the first and second industrial components causes movement of the mechanism such that a volume of lubricant is discharged from the reservoir.

[0008] In accordance with another construction, a method of automatically lubricating a structural element on an industrial machine includes coupling an automatic lubrication system to an industrial machine component, the automatic lubrication system including a mechanism configured to move in response to movement of the industrial machine component, moving the industrial machine component so as to trigger movement of the mechanism, and automatically delivering an amount of lubrication to a structural element in response to movement of the mechanism.

[0009] Other aspects of the invention will become apparent by consideration of the detailed description and accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0010] FIG. 1 illustrates an industrial machine according to one construction of the invention, including a dipper, the industrial machine including a plurality of structural elements benefitting from automatic lubrication.

[0011] FIG. 2 illustrates a dipper according to another construction of the invention, the dipper including a plurality of structural elements benefitting from automatic lubrication.

[0012] FIGS. 3-7 illustrate a dipper according to another construction of the invention, the dipper including a plurality of structural elements benefitting from automatic lubrication.

[0013] FIG. 8 illustrates an automatic lubrication system according to one construction of the invention.

[0014] FIG. 9 illustrates an automatic lubrication system according to another construction of the invention.

[0015] FIG. 10 illustrates an automatic lubrication system according to another construction of the invention.

[0016] FIG. 11 is a schematic image illustrating the automatic lubrication systems of FIGS. 8-10 coupled to various industrial machine components and providing lubrication to various industrial machine structural elements.

[0017] Before any constructions of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other constructions and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. DETAILED DESCRIPTION

[0018] FIGS. 1-7 illustrate various structural elements that benefit from the automatic lubrication systems described herein. While a shovel and dippers are illustrated, the automatic lubrication systems described herein are applicable to a variety of different industrial machines and industrial machine mechanical components.

[0019] FIG. 1 illustrates a mining shovel 10 that includes a mobile base 15, drive tracks 20, a turntable 25, a revolving frame 30, a boom 35, a lower end 40 (also called a boom foot), tension cables 50, a gantry tension member 55, a gantry compression member 60, a dipper 65 including a dipper body 70 and a dipper door 72, a bail 73, a hoist rope 75, a winch drum 80, an electric motor 82, a dipper handle 85, a saddle block 90, a pivot point 95 (e.g., a shipper shaft), a transmission unit 100 (also called a crowd drive), a bail pin 105, a dipper door pin 110, and a boom point pin 115.

[0020] The mobile base 15 is supported by the drive tracks 20. The mobile base 15 supports the turntable 25 and the revolving frame 30. The turntable 25 is capable of 360-degrees of rotation relative to the mobile base 15. The boom 35 is pivotally connected at the lower end 40 to the revolving frame 30. The boom 35 is held in an upwardly and outwardly extending relation to the deck by the tension cables 50, which are anchored to the gantry tension member 55 and the gantry compression member 60. The gantry compression member 60 is rigidly mounted on the revolving frame 30, and a sheave 45 is rotatably mounted on the upper end of the boom 35.

[0021] The dipper body 70 is suspended from the boom 35 by the hoist ropes 75. The hoist rope 75 is wrapped over the sheave 45 and coupled to the dipper body 70 at the bail 73. The hoist rope 75 is anchored to the winch drum 80 of the revolving frame 30. The winch drum 80 is driven by the electric motor 82 that incorporates a transmission unit (not shown). As the winch drum 80 rotates, the hoist rope 75 is paid out to lower the dipper body 70 or pulled in to raise the dipper body 70. The dipper handle 85 is also rigidly coupled to the dipper body 70. The dipper handle 85 is slidably supported in the saddle block 90, and the saddle block 90 is pivotally mounted to the boom 35 at the pivot point 95. The dipper handle 85 includes a rack tooth formation thereon that engages a drive pinion (not shown) mounted in the saddle block 90. The drive pinion is driven by an electric motor and the transmission unit 100 to extend or retract the dipper handle 85 relative to the saddle block 90.

[0022] An electrical power source (not shown) is mounted to the revolving frame 30 to provide power to the electric motor 82 for driving the winch drum 80, one or more crowd electric motors (not shown) for driving the crowd transmission unit 100, and one or more swing electric motors (now shown) for turning the turntable 25. Each of the crowd, hoist, and swing motors is driven by its own motor controller or drive in response to control signals from a controller (not shown).

[0023] The controller is electrically and/or communicatively coupled to a variety of modules or components of the shovel 10. Specifically, the controller is coupled to one or more sensors (not shown), a user interface (not shown), one or more hoist motors and hoist motor drives (not shown), one or more crowd motors and crowd motor drives (not shown), and one or more swing motors and swing motor drives (not shown). The controller includes combinations of hardware and software that are operable to, among other things, control the operation of the power shovel 10, the dipper handle 85, the dipper body 70, etc., monitor the operation of the shovel 10, etc. The sensors include position sensors, velocity sensors, acceleration sensors, an inclinometer, and one or more motor field modules.

[0024] The controller includes a plurality of electrical and electronic components (not shown) that provide power, operational control, and protection to the components and modules within the controller and/or shovel 10. Specifically, the controller includes, among other things, a processing unit (e.g., a microprocessor, a microcontroller, or another suitable programmable device), a memory, input units, and output units. The processor of the controller sends control signals to control the operations of the shovel 10. Specifically, the controller monitors and/or controls, among others, the digging, dumping, hoisting, crowding, and swinging operations of the shovel 10.

[0025] The dipper body 70 is coupled to the hoist rope 75 via the bail 73. When the shovel 10 is ready to be unloaded, the operator positions the dipper body 70 over an unloading zone (e.g., vehicle, conveyor, etc.) and opens the door 72 to unload the collected material. This frequent movement of the shovel 10 wears out the structural elements of the bail 73 and the dipper body 70.

[0026] Structural elements of mining shovel 10 that benefit from lubrication include at least the bail pins 105, the dipper door pin 110, equalizer pins (not shown), as well as any latching componentry that may be provided on the dipper 70 or mining shovel 10.

[0027] FIG. 2 illustrates a different construction of a dipper 265 including a dipper body 270 and a dipper door 272 pivotally coupled to the dipper body 270 about a dipper door pin 310. The Dipper 265 includes a snubber 274 for dampening rotation of the dipper door 272. The dipper door 272 pivots between a closed position (shown in dashed lines in FIG. 2) and an opened position (shown in solid lines in FIG. 2). The snubber 274 includes a housing 276 and an arm 278 that is pivotally supported by the housing 276 about a snubber pin 284. The movement of the dipper door 272 between the opened and closed positions pivots the arm 278 relative to the housing 276. The snubber 274 dampens the movement of the arm 278, which in turn dampens the motion of the dipper door 272. The dipper door pin 310 is located below the snubber 274.

[0028] Structural elements of the dipper 265 that benefit from lubrication include at least the snubber pin 284 and the dipper door pin 310, as well as any latching componentry that may be provided on door 272.

[0029] FIGS. 3-7 illustrate yet a different construction of a dipper 465 including a dipper body 470 and a dipper door 472 pivotally coupled to the dipper body 470 about a dipper door pin 510. The dipper body 470 includes a latch receiving opening 486.

[0030] With reference to FIGS. 4, 6, and 7, in order to keep the dipper door 472 closed until it is desired to open the door 472 to drop the dipper's contents, the dipper door 472 includes an impact actuated latch 488 in the form of a jaw having a "C" shape. The latch jaw 488 is pivotally and rotatably mounted on the dipper door 472 for rotation between a door-opened position and a door-closed position. [0031] With reference to FIGS 5-7, a portion of the dipper body 470 is shown. The dipper body includes the receiving opening 486 and a dipper striker bar 492. As illustrated in FIG. 6, the latch jaw 488 is configured to engage the dipper striker bar 492 in a door-closed position.

[0032] As illustrated in FIGS. 6 and 7, the dipper 465 includes a locking mechanism 524 on the dipper door 472. The locking mechanism 524 includes a primary locking mechanism 560 including a bar 564 pivotally coupled at pin 566 to the door 472, and another connecting bar 568 pivotally coupled to and extending between each of the bar 564 at pin 567 and the latch jaw 488 at pin 569. The latch jaw 488 is pivotally coupled to the door 472 at pin 571. A hold open mechanism 522 biases the latch jaw 488 into its open position, and is in the form of a tension springs 523 coupled between the bar 564 and the connecting bar 568. When locking the locking mechanism 524, the pin 566 travels through the springs 523, which helps to drive the latch jaw 488 into a locked position and hold the latch jaw 488 closed.

[0033] As illustrated in FIGS. 6 and 7, the locking mechanism 524 further includes a secondary latch 594 engaged with bar 564, and a plunger 602 that engages the secondary latch 594. In operation, the latch jaw 488 is held in a latched position by the secondary latch 594 that holds onto the primary locking mechanism 560 until the operator trips the secondary latch 594.

[0034] Structural elements of the dipper 465 that benefit from lubrication include at least the dipper door pin 510, the dipper striker bar 492, the plunger 602, the pin 566, and the pin 569.

[0035] While a particular latching mechanism for a dipper 465 is illustrated in FIGS. 6 and 7, various other types of dippers and dipper latching mechanisms also benefit from lubrication, including various standard industry dipper latch doors and latch-free doors. Components in industry dipper latch doors and latch-free doors that benefit from lubrication include, but are not limited to, ends of rotatable cross shafts, crank pins, actuators, lug pins, pivot pins, lever arms, links, and apertures for receiving such components.

[0036] FIG. 8 illustrates an automatic lubrication system 700 according to one construction of the invention, for use with the shovel and dippers described above, or with other industrial machines. The lubrication system 700 includes a reservoir 702, a plunger 705 disposed in the reservoir 702 and coupled to a spring 707. A mechanism 715 (a lever in the illustrated construction) is coupled to the reservoir 702, and pistons 710 coupled to the mechanism 715. The mechanism 715 includes a weight 720 coupled to a distal end. Four lubricant lines 725 are fluidly connected to the reservoir 702. The mechanism 715 is configured to exact a volume of lubricant 701 (e.g. oil, grease, or other lubricant) from the reservoir 702 based solely on movement of an industrial machine component.

[0037] In some constructions, the lubrication system 700 also includes a damping mechanism (not shown) that provides smooth motion of the mechanism 715 by limiting the bouncing effect of a machine component (e.g., the dipper body as the dipper digs through a bank of material).

[0038] In the illustrated construction, the reservoir 702 has a cylindrical shape. In other constructions the reservoir 700 has different forms and shapes. In some constructions, the reservoir 702 has a diameter of approximately eight inches and a length of approximately ten feet. In the illustrated construction, and with reference to FIG. 1, the lubrication system 700 is positioned in an area A on the dipper body 70. Generally, the hollow portion A is surrounded by walls of the dipper body 70, such that the hollow portion A is protected from rocks during the operation of the shovel 10. In the illustrated construction, the reservoir 702 is coupled to the walls of dipper body 70 by mechanical fasteners 711 and is filled with the lubricant 701 (e.g., 200 pounds). In other constructions, other mechanisms are used to couple the automatic lubrication system 700 to a mechanical component of the shovel 10, or other industrial machine.

[0039] The reservoir 702 includes a first end 730 and a second end 733 having an end cap 735. The first end 730 of the reservoir 700 defines an outer wall 737 and an inner wall 739. One end of the spring 707 is coupled to the inner wall 739 and the other end of the spring is coupled to the plunger 705. The spring 707 constantly applies pressure on the plunger 705, which presses the lubricant 701 inside the reservoir 702 to ensure that the lubricant is concentrated at the second end 733 of the reservoir. The end cap 735 includes four pistons 710, each of which is coupled to a corresponding lubricant line 725 extending from the second end 733 of the reservoir 702. In other constructions, the lubrication system 700 includes fewer or more pistons 710 or lubricant lines 725.

[0040] The lubrication system 700 utilizes movement of a mechanical component (e.g. the dipper body 70 as the dipper passes through a dig cycle) to capture the energy of the movement and convert that energy into energy used to transfer lubricant from the reservoir 702 to a structural element or elements. For example, in the illustrated construction in FIG. 8, when the boom handle 85 and the dipper body 70 are not moving, the mechanism 715 is positioned at approximately forty five degrees relative to the body of the reservoir 702. As the dipper body 70 begins to move and initiate a start of the dig cycle, the weight 720 moves downward due to gravity. Then, as the dipper body 70 moves through the dig cycle, the orientation of the weight 720 changes accordingly. The weight 720 pulls the mechanism 715 down, and the mechanism 715 presses the pistons 710, whereby the pistons 710 inject the lubricant 701 from the reservoir 702 into the lubricant lines 725. The lubricant lines 725 are coupled to the structural elements of the shovel 10 (e.g., the dipper door pins 110, the bail pins 105, etc.) and deliver the lubricant 701 to these structural elements during every dig cycle of the shovel 10. When the dipper body 70 is unloaded and the boom handle is ready for a new dig cycle, the plunger 705 presses the lubricant toward the second end 733 of the reservoir 702. That way, the lubrication system 700 is always "recharged" and there is a sufficient amount of lubricant to be pumped into the lubricant lines 725.

[0041] Continuous lubrication of the structural elements increases the allowable design stresses of the structural elements, thereby allowing for smaller structural elements. Further, the addition of reliable automatic lubrication allows use of bearings (e.g., in a dipper bail), which can drastically increase structural element life.

[0042] FIG. 9 illustrates an automatic lubrication system 800 according to another construction of the invention, for use with the shovel and dippers described above, or with other industrial machines. The lubrication system 800 includes a reservoir 802, a plunger 805 disposed in the reservoir 802 and coupled to a threaded rod 807 (e.g., a screw in the illustrated construction) and a non-threaded rod 808. The lubrication system 800 also includes a gear reduction 810 (e.g., a pinion and a gear in the illustrated construction) coupled to a mechanism 815 (e.g., a ratchet mechanism in the illustrated construction) having a weight 820 coupled to the mechanism 815. The mechanism 815 is coupled to the reservoir 802, and a single lubricant line 825 is coupled to the reservoir 802, though other numbers of lubricant lines are also possible. The mechanism 815 is configured to exact a volume of lubricant 801 (e.g. oil, grease, or other lubricant) from the reservoir 802 based solely on movement of an industrial machine component. In the illustrated construction, the lubrication system 800 is positioned at the back area A of the dipper body 70 (FIG. 1), and the reservoir 802 is filled with the lubricant 801 (e.g., 200 pounds).

[0043] The reservoir 802 includes a first end 830 having a first end cap 832 and a second end 833 having a second end cap 835. The first end 830 defines an outer wall 837 and an inner wall 839. The gear reduction 810 is coupled to the outer wall 837 of the first end cap 832. The mechanism 815 is mechanically coupled to the gear reduction 810. One end of each of the rods

807 and 808 is coupled to the inner wall 839 of the first end cap 832 and the other ends of the rods 807 and 808 are coupled to an inner wall 841 of the second end cap 835. The rods 807 and

808 engage the plunger 805.

[0044] As the shovel 10 enters a dig cycle, gravity created during that movement moves the weight 821 at the end of the mechanism 815. As the dipper body 70 rises through the bank of material, the mechanism 815 moves downward and rotates the gear reduction 810. The gear reduction 810 turns and moves the threaded rod 807 inside the reservoir 802. The non-threaded rod 808 prevents the plunger 805 from turning, which results in linear motion of the plunger 805. As the rod 807 turns, the rod moves the plunger 805 inside the reservoir 802 forward in small incremental distances. The plunger 805 compresses the lubricant and forces it from the reservoir 802 into the lubricant line 825. The lubricant line 825 delivers lubricant to the structural elements of the shovel 10. The use of a mechanism 815 in the form of a ratchet in this construction helps to minimize the amount of grease distributed to the structural elements by limiting the effect of the bouncing impact of the dipper body as it digs. As the dipper body returns to the start of the dig cycle, the mechanism 815 returns to its starting position and the lubrication system 800 begins the lubrication process again. [0045] FIG. 10 schematically illustrates an automatic lubrication system 900 according to yet another construction of the invention, for use with the shovel and dippers described above, or with other industrial machines. The lubrication system 900 operates to lubricate one or more structural elements based on relative motion of mechanical components. For example, the illustrated lubrication system 900 in FIG. 10 provides lubrication when the shovel 10 unloads material from the dipper body. Specifically, the lubrication system 900 uses the energy created during the closing of the dipper door to operate various mechanical linkages and/or pneumatic systems in the lubrication system 900.

[0046] The lubrication system 900 includes a reservoir 902, a piston 905 coupled to the reservoir 902 and also coupled to a spring 907, a mechanism 910 (e.g., a plunger in the illustrated construction) coupled to the dipper body 70 and the piston 905, and a single lubricant line 925, though additional lubricant lines 925 are also possible. In the illustrated construction, the lubrication system 900 is positioned along a back area of the dipper body 70, such as area A described above. The reservoir 902 is filled with lubricant 901 (e.g. oil, grease, or other lubricant) and the lubricant line 925 is coupled to one or more structural elements of the shovel 10. The mechanism 910 is configured to exact an amount of lubricant 901 from the reservoir 902 based solely on relative movement between two industrial machine components.

[0047] In the illustrated construction, one end of the plunger 910 is directly coupled to the dipper body and another end of the mechanism 910 is coupled to the piston 905. In some constructions, the reservoir 902 of the system 900 is similar to the reservoir illustrated in FIG. 8, where the piston 905 and the spring 907 are positioned inside the reservoir 902. The reservoir 902 includes a first end 930 and a second end 933. The first end 930 includes a high pressure check valve 935 and the second end 933 includes a low pressure check valve 937.

[0048] The lubrication system 900 utilizes movement of the dipper door as the dipper body unloads material. When the dipper door closes, the door presses the plunger 910 and the resultant energy is transferred to the plunger 910. The plunger 910 then presses the piston 905 of the lubrication system 900. The piston 905 injects lubricant 901 from the reservoir 902 into the lubricant line 925 through the low pressure check valve 937. The lubricant line 925 is coupled to structural elements of the shovel, such as the dipper door pins and the bail pins, and delivers the lubricant to these structural elements when the shovel 10 unloads material from the dipper body. The spring 907 returns the piston 905 out past the dipper body when the dipper door opens. The high pressure check valve 935 releases air from the reservoir 902 and relieves pressure if the lubricant line 925 is blocked.

[0049] In one construction, and with reference to FIG. 2, the snubber 274 is used as the mechanism 910 to suppress the excess force created by the dipper door 272. In this construction, the snubber 274 is directly coupled to the piston 905 of the lubrication system 900. The snubber 274 transfers the energy created by the dipper door 272 to operate the lubrication system 900 and to lubricate the structural elements of the shovel.

[0050] In another construction, the lubrication system 920 is coupled to a controller (not shown) of the shovel 10, or other industrial machine. The controller monitors the lubrication of the structural elements of the industrial machine by using an automatic lubrication module (not shown). For example, in some constructions the lubrication system 920 includes a sensor (not shown) positioned at the dipper door. The sensor detects the force created by closing of the dipper door (e.g. before or after the force is suppressed by the snubber 274 in the case of dipper 265) and sends information about this force to the controller. In this manner, the controller monitors the operation of the snubber 274 to ensure that energy created by the door 272 is not too excessive. Further, in some constructions the lubrication system 920 includes a sensor (not shown) positioned in the reservoir 902. This sensor monitors the level of lubricant 901 in the reservoir 902 and notifies the operator when the level is below a predetermined threshold and lubricant 901 needs to be added in the reservoir 902. In other constructions, the lubrication system 900 includes other electro-mechanical components that permit the controller to control the automatic lubrication of a structural element.

[0051] With continued reference to FIG. 10, an alternative actuating spring pump 939 is also shown. The spring pump 939 is actuated by the dipper door 72 (or, for example, by a snubber), so that as the door 72 opens/closes, a pumping motion is created that pressurizes the reservoir 902 and causes delivery of the lubricant 901 through lubricant line 925. [0052] FIG. 11 illustrates schematically how the lubrication systems 700, 800, and 900 are configured to be coupled to one of a variety of industrial machine components 1000 on an industrial machine, and are configured to provide lubrication to a variety of structural elements 1100 found on an industrial machine. The lubrication systems 700, 800, 900 are designed to automatically provide lubrication to a structural element (e.g., a pin) based solely on movement of one or more industrial machine components (e.g., a dipper, a dipper door, a boom, a boom handle, etc.).

[0053] Specifically, and with reference to FIGS. 1-7 and 11, the lubrication systems 700, 800, and/or 900 are configured to be coupled to machine components 1000 that include, but are not limited to, the dipper body 70, the dipper door 72, the boom 35, the dipper handle 85, the dipper body 270, the dipper door 272, the dipper body 470, the dipper door 472, and various dipper latching components

[0054] The lubrication systems 700, 800, and/or 900 are configured to provide lubrication to structural elements 1100 that include but are not limited to the bail pins 105, the dipper door pin 110, the snubber pin 284, the dipper door pin 310, the dipper door pin 510, the dipper striker bar 492, the plunger 602, the pin 566, and the pin 569.

[0055] The lubrication systems 700, 800 are specifically designed to be coupled to industrial machine components and to capture the motion of the machine components themselves, whereas the lubrication system 900 is specifically designed to be coupled to two industrial machine components to capture the relative motion of the two industrial machine components. In either case, the lubrication systems 700, 800, 900 advantageously use only the motion and energy of an industrial machine component(s) to initiate lubrication. Regular lubrication of the structural elements of an industrial machine decreases the wear on these elements and on a drive for the industrial machine, and increases the structural life and provides energy for the structural elements of the industrial machine.

[0056] Although the invention has been described in detail with reference to certain preferred constructions, variations and modifications exist within the scope and spirit of one or more independent aspects of the invention as described.