Abstract:
An apparatus and method for connecting a mining dump bucket to a set of drag chains and a set of dump ropes is provided. A metallic nugget is fused to a drag rope. The metallic nugget is then inserted into a novel coupler or socket attached to a dump bucket. Also provided is a set of frustoconical wedges adjacent the nugget and a frustoconical receiver used to secure the rope to the coupler or socket.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
   This application claims priority to U.S. Provisional Application Ser. No. 60/562,432 filed Apr. 14, 2004, entitled “Termination on a Wire Rope Formed from Exothermic Metallic Material or Liquid Adhesives.” 

   FIELD OF THE INVENTION 
   The present invention relates to an apparatus and method for terminating a wire rope and connecting it to various pieces of equipment. In a preferred embodiment, the termination is used in association with a dump bucket or socket in the field of mining. 
   BACKGROUND OF THE INVENTION 
   Methods for forming wire terminations and connections are taught in U.S. Pat. No. 6,170,145 to Lucas, U.S. Pat. No. 6,035,692 to Lucas; U.S. Pat. No. 2,151,032 to Jensen, U.S. Pat. No. 6,156,975 to Roose, U.S. Pat. No. 5,499,448 to Tournier, U.S. Pat. No. 3,844,601 to Rochester, U.S. Pat. No. 2,038,535 to Brenizer, Campbell U.S. Patent Publication No. 2004/0093714, Gloaguen U.S. Patent Publication No. 2004/0121658 and Fujiwara U.S. Patent Publication No. 2002/0162683. 
   A need has existed for a wire rope termination made by a fast process resulting in a light-weight, heavy duty termination. A further need has existed for connecting wire rope terminations to mining and other equipment quickly and safely. For example, for connecting to mining rigging, such as a dragline bucket rigging for open pit mining or operations in other industries. A further need has existed for a method to create wire rope terminations which result in great strength. The present invention meets these needs. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     In the detailed description of the preferred embodiments presented below, reference is made to the accompanying drawings. 
       FIG. 1  depicts an exploded isometric view of the apparatus used in the method for making a termination for a wire rope using an exothermic metallic material. 
       FIG. 2  depicts an isometric view of the apparatus used in the method. 
       FIG. 3  depicts a front view of the assembled apparatus used in the method. 
       FIG. 4  depicts a cross-sectional side view of the assembled apparatus used in the method. 
       FIG. 5  depicts a perspective view of a socket usable with the termination. 
       FIG. 6   a  is a cutaway plan view of an alternate embodiment of a socket usable with the termination. 
       FIG. 6   b  depicts a side view of an alternate embodiment of a socket usable with the termination. 
       FIG. 7  depicts an isometric view of an alternate embodiment of a socket usable with the termination. 
       FIG. 8   a  depicts a side view of two frustoconical wedges usable with the socket of the present invention. 
       FIG. 8   b  depicts a plan view of three frustoconical wedges used with the termination of the present invention. 
       FIG. 9   a  depicts an isometric assembly view of a wire rope, termination, several frustoconical wedges and a socket. 
       FIG. 9   b  represents an isometric partially assembled assembly view of a wire rope, termination, several frustoconical wedges and a socket. 
       FIG. 9   c  represents an isometric partially assembled view of a termination, socket and wire rope. 
       FIG. 10  depicts a mining system employing the wire rope termination 
   

   The present embodiments are detailed below with reference to the listed Figures. 
   DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
   Before explaining the present embodiments in detail, it is to be understood that the embodiments are not limited to the particular descriptions and that the embodiments can be practiced or carried out in various ways. 
   The invention relates to a method for making terminations on wire rope for use on dragline buckets, or similar earth relocating components. 
   The termination described herein is made by a labor saving process for use with mining equipment. The termination for wire rope is lighter than conventional terminations used on drag lines in the mining industry, but has the same or greater strength. 
   The couplers for wire rope for the mining industry must be capable of sustaining a large break force. The coupler of the present invention weighs appreciably less than similarly sized wire ropes with typical couplers, up to or exceeding 50% less. For example, a current style coupler could weigh 6000 pounds for a 4-⅜ inch diameter wire rope. In contrast certain embodiments of the invention utilize a coupler weighing only about 1500-2800 pounds for the same diameter wire rope. In the preferred embodiment, the terminations are for use with wire ropes with a diameter between 4 inches and 7 inches. The terminations will work equally well with smaller and larger diameter wire rope. Typical wire ropes are made of steel, alloys of steel and combinations thereof. The wire rope can be a single strand rope or a multi-strand rope. 
   The terminations are made using the equipment of  FIG. 1 . In a first embodiment, the termination  10  is formed on the end of a wire rope  15  using an exothermic metallic material. In an alternative embodiment, a liquid adhesive can be used to make the termination for the wire rope. The termination formed from the liquid adhesive has additional safety advantages as the termination can be made without heat in the field, preventing burns to workers, which is a much needed benefit. 
   For terminations made using the exothermic metallic material, one end of the wire rope is inserted into a mold  25 .  FIG. 1  depicts the mold  25  as a two part mold with a top part  25   a  and a bottom part  25   b , but a one piece mold can also be used. For large diameter wire ropes, a three piece mold may be used. In this embodiment, the top half of the mold is segmented along the axis of the wire rope opening  27 . For extremely large diameter ropes, a several piece mold may be used. 
   The pieces of mold  25  are held together with toggle-type latches (not shown) spaced around the periphery of the mold. In the preferred embodiment, using two pieces for the mold, there are four latches, two on each side. For the preferred embodiment where the mold is made in three pieces, six latches are used, two on each side and two on the top to hold the top two pieces of the top section of the mold together. The latches are placed so that leakage of molten metal between the seams of the pieces of the mold and down the access of the wire rope is minimized or preferably prevented. 
   The mold has a mold opening  35 . The mold opening can be rectangular, but an elliptical shape or round shape or other shape can be used. The opening should have a diameter that is adequate to permit molten metal to flow into the mold. 
   The mold has a cavity formed with two connected chambers, a wire rope opening  27  and a termination cavity  28 . Wire rope opening  27  is cylindrical and formed to the diameter of the wire rope. Termination cavity  28  in the preferred embodiment is also cylindrical having a diameter approximately two inches greater than the diameter of wire rope  15 . The dimensions of the termination cavity are a matter of design choice. In the preferred embodiment of a termination cavity for a 4½-inch diameter wire rope, the cavity is 7¾ inches in diameter and 4 inches long 
   The termination cavity can have a conical, cylindrical, or even rectangular shape. The cavity dictates the resultant shape of the termination. For example, the termination can include a hole perpendicular to the axis of the wire rope form or form a particular shape for connection to other equipment dependent on the shape of the termination cavity. 
   The external shape of the mold can be any functional shape but is preferably rectangular. The overall external dimensions of the mold of a preferred embodiment are between about 6 inches and about 20 inches; 10 inches is a preferred example. The width of the mold of a preferred embodiment can range from about 6 to about 16 inches; 8 inches is a preferred example. The length of a preferred embodiment can range from about 8 to about 24 inches; 12 inches is a preferred example. 
   The mold is preferably made of graphite or other materials that are very heat resistant. 
     FIG. 2  shows an isometric view of wire rope  15  inserted into mold  25 .  FIG. 2  also shows a crucible  45 , baffle  47  and baffle opening  51 . 
     FIG. 3  shows a front view of baffle  47  and crucible  45  with the mold  25  and a preferable circular opening for engaging the wire rope. 
     FIG. 4  depicts a cross-sectional view of the mold, crucible and wire rope. 
   The crucible provides a reaction chamber for the exothermic material. The crucible dimensions preferably coincide with or are slightly larger than the dimensions of the mold. The dimensions of the crucible of a preferred embodiment are between 10 and 18 inches in height (preferably 12 inches), between 10 and 20 inches in width (preferably 14.5 inches), and between 10 and 30 inches in length (preferably 15 inches). In the preferred embodiment, the walls of the crucible are one inch thick. The floor of the crucible is angled to assist the molten metal flowing out of the crucible through crucible opening  50 . The crucible can have a cylindrical shape, a rectangular shape, but generally it is hollow to receive material. The crucible opening has a shape that can be rectangular, ellipsoid, or another usable shape for flowing molten metal into the crucible. The crucible is preferably made of graphite or a heat resistant material that will not deform in the presence of high heat. 
   A separator  55  is disposed over the crucible opening  50 . The purpose of the separator is to keep the exothermic metallic material separate from the mold until ignition of the exothermic metallic material. Typically, separator  55  is a mild steel material; however, any sacrificial material can be used. In a preferred embodiment, the separator has a width between 2 inches and 6 inches in width and a length between 4 inches and 8 inches with a thickness that can range in a corresponding manner. In a preferred embodiment, the thickness of the separator is 10 gauge. 
   The terminations are made using an exothermic metallic material  40  that is placed into the crucible. The exothermic metallic material is preferably a powdered metallic material. Examples of usable powdered metals include aluminum, copper, tin, alloys of aluminum and alloys of copper, oxides of these metals, particularly including copper oxide. The material can be granules, a powder, or small metal chips. Different sizes of granules, powder or small metal chips can be used in the same crucible. In the preferred embodiment, the material is provided in two phases. The first phase has a fine granularity to promote ease of ignition. The second phase has a coarse granularity to slow burning of the material and provide for adequate bulk to sustain the reaction. In the preferred embodiment, the first phase has granules of approximately 1/100 of an inch in diameter and the second phase granules have the size of approximately 1/10 an inch in diameter. In the preferred embodiment, the exothermic metallic material is sold under the trademark “Cad Weld”, available from ERICO, Inc. of Solom, Ohio. 
   A baffle  47  is inserted over the crucible  45  to contain the heat and direct any resulting vapors out a baffle opening  51 . The baffle is preferably the same of similar shape to that of the crucible. The baffle is preferably made from steel plate. As shown in  FIG. 4 , the baffle  47  has at least one internal baffle  61  for deflecting the heat and hot reaction gasses from the crucible. 
   In a preferred embodiment, the baffle can have a length ranging between 11 inches to 31 inches, a width ranging between 11 inches to 21 inches, and a height ranging between 11 inches to 19 inches in length. The preferred dimensions are 16 inches in length, 15 inches in width, and 18 inches in height. The preferred thickness of the baffle is 10 gauge. 
   The process of making a termination in the preferred embodiment begins by clamping the mold together by closing the appropriate toggle clamps. Crucible  45  and baffle  47  are then appropriately assembled. Assembly requires insertion of separator  55  in between crucible  45  and termination cavity  28 . Crucible  45  and mold  25  must be positioned so that ducted communication, through separator  55  is achieved. 
   In the preferred embodiment, the end of wire rope  20  is cleaned before the termination is formed. The cleaning step can be performed by any normal means of cleaning a substance. The preferred methods for cleaning are either by using a torch, by using chemicals to remove dirt, and combinations thereof. 
   After cleaning, wire rope  15  is inserted into wire rope opening  27  far enough to extend into termination cavity  28 . In the preferred embodiment of the method, the wire rope is extended approximately two thirds of the width of termination cavity  28 . 
   Exothermic metallic material  40  is then added to crucible  45  in at least one phase. When additional phases of exothermic metallic material  40  are desired in crucible  45 , the bulk phases are added first and allowed to settle. The fine phases are then added and allowed to settle. 
   The exothermic metallic material  40  is kindled in the crucible  45 . The exothermic metallic material  40  can be kindled using a striker, a torch, a flame, or other similar heat sources, and combinations thereof. Once kindled, the exothermic metallic material  40  burns very hot and very fast. The exothermic metallic material forms a ductile and malleable material and liquefies the separator  55  forming a molten material  60 . 
   Molten material  60  flows into mold  25  through mold opening  35  and comes into contact with end  20  of wire rope  15 . Molten material  60  is of such a temperature that is partially melts and fuses to the wire rope. Molten material  60  takes the form of mold  25  around end  20  forming termination  10 . 
   Molten material  60  is allowed to cool which in the preferred embodiment can take approximately 15 minutes. Crucible  45  and baffle  47  are then removed from mold  25 . Mold  25  is then separated into pieces by disconnecting the latches which hold the pieces of the mold together. If the mold is a single piece, it may need to be broken away from the termination. In cooling, exothermic material  60  slightly contracts, allowing the pieces of the mold to be removed easily. 
   The resultant termination  10  is lighter than conventional terminations and is typically capable of sustaining a higher break force than the wire rope. 
   A termination according to the present invention may be made using a liquid adhesive. 
   If the termination is formed using a liquid adhesive, the wire rope first end is place in a mold. A liquid adhesive is then poured into the mold  25  through the mold opening  35  covering the end of the wire rope. The liquid adhesive may need to be heated to room temperature if the method is performed in a cold climate. Examples of usable liquid adhesives include an epoxy, such as a Devcon™ aluminum epoxies from Illinois Tool Work, of Devcon, Ill. Epoxies from 3-M of Minneapolis, Minn. are also contemplated as usable herein, as well as other epoxies that are strong and bond to steel. 
   The liquid adhesive is allowed to cure in the mold  25  forming a cured termination typically capable of sustaining a higher break force than the wire rope. 
   In the preferred embodiment the formed termination is inserted into a socket. The socket has an equipment connector on one end adapted to engage mining equipment and a wire rope connector on the other end adapted to engage the termination. Of course, the termination provided by the preferred embodiments of the invention does not necessarily need to be inserted into a socket to operate and is useful by itself in other applications which do not require a socket. 
     FIG. 5  shows the wire rope with termination engaging a socket  89 . The socket has a first connector end  90  adapted to engage mining equipment; and a second connector end  80  to engage the termination  10  on wire rope  15 . First connector end  90  includes hole  92 , connector  105  and connector hole  106 . Hole  92  is sized to include a bushing  100  for connection to mining equipment. Connector hole  106  is similarly sized for connection to the mining equipment. Second connector end  80  includes an upward facing opening  95  which is sized to permit an insertion of wire rope  15  and termination  10 . 
   Socket  89  is preferably formed from ANSI 4140 steel or EN30B material. The dimensions of socket  89  are a matter of engineering choice. However, in the preferred embodiment for a wire rope of 4½ inch diameter, socket  117  is approximately 35 inches long and 13¼ inches wide. 
   Moving to  FIG. 6   a , an alternate embodiment of a socket is shown as socket  117 . Socket  117  has body  115 . In the preferred embodiment, body  115  is formed from ANSI 4140 steel or EN30B material. First connector end  113  comprises socket ear  116  and socket ear  118  which are used for connection to mining equipment. Socket ear  116  includes hole  125 . Similarly, socket ear  118  includes hole  130 . Copper alloy bushing  131  is placed in hole  125 . Similarly, copper alloy bushing  130  is placed in hole  126 . The size and composition of the bushings are a matter of engineering choice. 
   Body  115  includes ear support  135  and ear support  140 . Ear support  135  and ear support  140  strengthen body  115  to prevent spreading of the ears during operation. Guide set  120  is used during operation of the mining equipment to locate a connector (not shown) during operation. The inclusion of the ear supports and guide set are optional depending on the forces applied to the system and connection pins used in operation. 
   Body  115  includes a bore  160  opening into frustoconical bore  165 . Bore  160  is approximately the same diameter as wire rope  15 . Frustoconical bore  165  includes circumferential slots  145 ,  150  and  155 . The circumferential slots allow for lubrication of the frustoconical wedges (not yet shown). The inclusion of the circumferential slots is optional. 
   Body  115  further includes lateral opening  157 . Lateral opening  157  is sized to allow entry and exit of the termination. 
     FIG. 6   b  shows cradles  161  and  162  formed in body  115  of socket  117 . The cradles are provided in the preferred embodiment to reduce weight and are optional. 
     FIG. 7  shows alternate embodiment of the socket for the termination, socket  117 . Socket  117  includes upward connector  175  for connection to mining equipment. Upward connector  175  includes through hole  180  and bushing  185 . Socket  117  also includes sled  170 . In the preferred embodiment, sled  170  is welded to socket  117  to protect the socket and its internal pieces from the elements during mining operations. 
     FIGS. 8   a  and  8   b  show frustoconical wedges  190 ,  195  and  200 . The frustoconical wedges are designed to fit into frustoconical bore  165  and around wire rope  15 . Frustoconical wedge  190  includes surface slot  192 . Similarly, frustoconical wedge ( 195 ) includes surface slot  197  and frustoconical wedge  200  includes surface slot  202 . The surface slots are provided to allow a circular retaining tie to be applied to the frustoconical wedges to hold them together around wire rope  15  during insertion into frustoconical bore  165 . 
   In the preferred embodiment, of frustoconical wedges for use with a 4½ inch wire rope, each frustoconical wedge is 8⅝ inches long and has an outer diameter of 5⅞ inches and an inner diameter of 3⅛ inches. Frustoconical wedge  190  also includes generally flat mating surface  191 , similarly, frustoconical wedge  195  has generally flat mating surface  196  and frustoconical wedge  200  has generally flat mating surface  201 . Each of the mating surfaces is designed to contact the generally flat mating surface of the termination during operation of the invention. 
     FIG. 8   b  shows that the three frustoconical wedges of the preferred embodiment are equal in size, being separated by gaps at 120 degrees. For example, gap  205  separates frustoconical wedge  190  and frustoconical wedge  195  when inserted into frustoconical bore  165 . The gaps allow for radial contraction of each frustoconical wedge toward the other frustoconical wedges toward the wire rope during operation of the invention. Gap  205  is typically ⅜ of an inch. In the preferred embodiment, there are three equally spaced and identical frustoconical wedges. However, in alternate embodiments, there can be two or more frustoconical wedges divided axially to provide compression forces to wire rope  15 . 
   In the preferred embodiment, the angle of inclination of the frustoconical wedges is about 96 degrees plus or minus 5 degrees. Of course, other angles of inclination will function according to engineering choice. 
   Each of the dimensions of the frustoconical wedges, gaps and slots can differ, depending on the size of the wire rope and the frustoconical bore. Each of the frustoconical wedges are preferably made of mild steel or an aluminum ally. 
   Turning to  FIGS. 9   a ,  9   b  and  9   c , the assembly and usage of the termination, frustoconical wedges and socket can be seen. 
     FIG. 9  shows an exploded view of socket  117 , wire rope  15  and termination  10 , as well as frustoconical wedges  190 ,  195  and  200 . In operation, wire rope  15  is threaded through bore  160  in socket  117 . Termination  10  is then formed on wire rope  15  as previously described. 
   Frustoconical wedges  190 ,  195  and  200  are then assembled onto wire rope  15  as shown in  FIG. 9   b . A circular retaining tie  169  is then fitted into the surface slots to hold the frustoconical wedges in place on the wire rope. If desired, lubrication is placed in circumferential slots  145 ,  150  and  155 . The wire rope, frustoconical wedges and termination are then pulled into socket  117 . The termination seats on mating surfaces  191 ,  196  and  202  on frustoconical wedges  190 ,  195  and  200 , respectively. In turn, the frustoconical wedges seat inside frustoconical bore  165 . 
     FIG. 9   c  shows the forces applied to wire rope  15  and socket  117  during operation. Force (F 1 ) is applied axially along the wire rope resisted by force (F 3 ) applied to through hole  125 . A lifting force (F 2 ) is then applied to hole  180  resulting in lifting and pulling of mining equipment. Force (F 2 ) and (F 3 ) are resisted by a combination of the friction on the wire rope resulting from the inward radial pressure of the frustoconical wedges on the wire rope. In turn, the inward radial pressure is created by the force (F 1 ) acting through the contact between the termination and the mating surfaces of the frustoconical wedges. As force (F 1 ) is increased, the radial pressure on the wire rope is also increased. 
     FIG. 10  depicts a mining system  1000  employing the wire rope termination that can be used with excavation equipment of various types, particularly draglines for earth moving mining equipment. The mining system  1000  utilizes wire ropes with a diameter between ¼ inches and 7 inches. The wire rope can be a single or multi-stranded and are made of steels, alloys of steel or combinations thereof. 
   In the mining system  1000 , termination  1001  is disposed on one end of dump rope  1020  as shown. Termination  1001  is engaged with dump rope socket  1002 . Dump rope socket  1002  connects to a bucket rigging device thru drag rope socket  1004 . Sockets such as those generally shown in  FIG. 5  and  FIG. 7  or any other sockets known to be compatible in the art may be used as a dump rope socket or a drag rope socket. 
   Referring to the socket of  FIG. 7  as an example, drag rope socket  1004  has ears  118  and bushing  185  with a hole  180 . The sockets are connected in operation by aligning the ears of the dump rope sockets  1002  with the hole of the bushing of the drag rope socket  1004 . When the three holes are aligned, a throughpin is inserted to connect the ears of the dump rope socket  1002  to the upper hole in the bushing of the drag rope socket. 
   Drag rope socket  1004  is connected to drag rope  1026  with a termination  1010 . A drag rope link  1092  connected to drag rope socket  1004  links the socket to drag chain  1085 . On the other end of drag chain  1085 , drag hitch link  1052  connects chain  1085  to drag hitch  1054 . Drag hitch  1054  is mounted to mining bucket  1088 . 
   A mirror opposite of the above is also depicted in  FIG. 10 . Termination  1030  is disposed on one end of dump rope  1022 . Termination  1030  is engaged with dump rope socket  1089 . Dump rope socket  1089  connects to a bucket rigging device thru drag rope socket  1006 . Similarly, dump rope socket  1089  connects to drag rope socket  1006  by aligning the ears of the dump rope socket  1089  to a hole in the bushing of drag rope socket  1006 . 
   Dump ropes  1020  and  1022  also have terminations  1018  and  1016  engaged with arch anchor sockets  1009  and  1008 . Arch anchor sockets  1009  and  1008  are connected to arch anchors  1058  and  1060 . Arch anchors  1058  and  1060  are mounted on arch  1066 . Arch  1066  is attached to the upper outside corners of mining bucket  1088 . In a preferred embodiment, arch  1060  is welded to mining bucket  1088 . 
   Attached to mining bucket  1088  is a trunion  1062 . Trunion  1062  has a trunion pin  1062  inserted in the trunion  1062  which allows for rotation of mining bucket  1088 . A second trunion and trunion pin are located on the opposite side of mining bucket  1088 . Trunion  1062  connects to lower hoist chain  1070 . Similarly lower hoist chain  1068  is connected to a trunion on the opposite side of mining bucket  1088 . Lower hoist chains  1068  and  1070  are connected to spreader bar  1072 . Also connected to spreader bar  1072  are upper hoist chains  1074  and  1076 . Mounted on upper hoist chains  1040  and  1042  are dump sheaves  1040  and  1042 . 
   Dump sheaves  1040  and  1042  are pulleys through which the dump ropes  1020  and  1022  are threaded. Connected at the other ends of the upper hoist chains  1040  and  1042  is a hoist rigging cluster  1085 . Hoist rigging cluster  1085  may vary significantly in design. Hoist ropes are freely connected to hoist rigging cluster  1078 . Hoist ropes  1078  typically connect to a crane used in the operation of the mining system. 
   In exemplary embodiments, the mining bucket is used for dirt or ore. In the preferred embodiment, the mining system is suspended from a crane by the hoist ropes  1078 . In operation of the mining system, the mining bucket is lowered near or set on the surface to be mined. The crane exerts a pulling force on the drag ropes which in turn pull the drag chains and the mining bucket. This process sets out to cause dirt or ore or any other materials to be collected from the surface. Once the mining bucket has collected the substances to be mined, an upward force is exerted by the crane at the hoist ropes which elevates the rear portion of the mining bucket. Simultaneously, a pulling force is exerted on the drag ropes. As the tension on the drag rope increases, the tension in the dump rope will increase resulting in the elevation of the front of the mining bucket. By increasing the elevation of the front, the collected substances are trapped in the mining bucket. Since, tension in the dump rope and its termination increases as elevation of the mining bucket is increased, frustoconical wedges are used to reduce tension. In a preferred embodiment, the elevation of the front of the mining bucket is approximately 26 degrees. 
   The mining bucket is dumped out by decreasing the force on the drag ropes which causes the tension in the dump ropes to decrease. This process subsequently lowers the front of the mining bucket and releases the contents of the bucket. The mining bucket is returned to its original mining position by releasing the tension in the hoist ropes and drag ropes. 
   The embodiments have been described in detail with particular reference to certain preferred embodiments thereof, but it will be understood that variations and modifications can be effected within the scope of the embodiments, especially to those skilled in the art.