Patent Publication Number: US-2022213663-A1

Title: Work machine dipper with improved dig and payload performance

Description:
TECHNICAL FIELD 
     The present disclosure generally relates to a work machine and, more particularly, relates to a dipper for a work a machine. 
     BACKGROUND 
     Excavating shovel dippers or buckets are used in construction to scoop earthen material from horizontal or vertical surfaces. Dippers can be mounted, via a mounting bracket, to work machines like electric rope shovels or excavators. A conventional electric rope shovel has a boom, a dipper handle pivotally connected to a mid-point of the boom, and the dipper pivotally connected at one end of the dipper handle. A cable extends over a pulley at a distal end of the boom and terminates at the end of the dipper handle supporting the dipper. The cable is reeled in or spooled out on a hoist drum being powered by electric, hydraulic, and/or mechanical motors to selectively raise and lower the dipper. The dipper is normally provided with sharp teeth to provide a digging action against the surface being worked and further includes a cavity for collecting the earthen materials to be removed. Once the earther material is received within the dipper, the dipper is usually discharged into a dump truck, onto a conveyor, or merely onto a pile. 
     Once complexity function in dipper performance is dictated by the environment in which the electric rope shovel is operating. For example, oil sands have proven to be particularly detrimental to dipper performance giving the hard-digging condition found with Devonian geology. Current dippers cannot penetrate well, last long, or fill dump trucks in relatively few passes. 
     U.S. Pat. No. 5,063,694 describes an excavating dipper for use with power shovels that is fabricated from steel plate and is formed having a separable bottom body member. The plate members forming the side and bottom cavity walls of the bottom body member are reinforced by longitudinal and transverse girth ribs. 
     While effective, there remains a need for improved dipper designs for work machines used in high wear applications, such as construction and mining. 
     SUMMARY 
     In accordance with one aspect of the present disclosure, a dipper for a work machine is disclosed. The dipper may have a front cavity wall forming an inlet which defines a vertical inlet plane, a rear cavity wall opposite the front cavity wall forming an outlet which defines an outlet plane, a top cavity wall extending between front and rear cavity walls defining a horizontal top plane, a bottom cavity wall opposite the top cavity wall defining a bottom plane, and two side cavity walls connected between the top cavity wall and the bottom cavity wall. The two side cavity walls may further extend between the front and rear cavity wall. The outlet plane may be angled relative to the inlet plane, the bottom pane may be angled relative to the top plane, and the outlet plane is perpendicular to the bottom plane. 
     In accordance with another aspect of the present disclosure, a work machine is disclosed. The work machine may include a base supported on a ground surface, a revolving frame connected to the base that is rotatable about an axis, a boom that is pivotally connected to the revolving frame, a boom handle that is pivotally connected to the boom, and a dipper coupled to the boom handle. The dipper may have a front cavity wall forming an inlet which defines a vertical inlet plane, a rear cavity wall opposite the front cavity wall forming an outlet which defines an outlet plane, a top cavity wall extending between front and rear cavity walls defining a horizontal top plane, a bottom cavity wall opposite the top cavity wall defining a bottom plane, and two side cavity walls connected between the top cavity wall and the bottom cavity wall. The two side cavity walls may further extend between the front and rear cavity wall. The outlet plane may be angled relative to the inlet plane, the bottom plane may be angled relative to the top plane, and the outlet plane is perpendicular to the bottom plane. 
     In accordance with a further aspect of the present disclosure, a method of making a dipper is disclosed. The method may include providing a front cavity wall that defines an inlet which may itself define a vertical inlet plane, positioning a rear cavity wall which may define an outlet, opposite the front cavity wall, and extending a top cavity wall defining a horizontal top plane between the front cavity wall and the rear cavity wall. The method may further include extending a bottom cavity wall, defining a bottom plane, opposite the top cavity wall before connecting two side cavity walls between the top cavity wall and the bottom cavity wall. The two side cavity walls may further extend between the front cavity wall and the rear cavity wall. The outlet plane may be angled relative to the inlet plane, the bottom plane may be angled relative to the top plane, and the outlet plane may be perpendicular to the bottom plane. The method further including connecting a lip to a bottom surface of each of the two side cavity walls and a front surface of the bottom cavity wall, the lip extending outwardly from the inlet in a direction away from the outlet, and the lip having an inner surface which may define a lip plane that may be parallel with the horizontal top plane. 
     These and other aspects and features of the present disclosure will be more readily understood when read in conjunction with the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a diagrammatic illustration of a work machine having a dipper. 
         FIG. 2  is a perspective view of an exemplary dipper, in accordance with the present disclosure. 
         FIG. 3  is a left side view of the dipper of  FIG. 2 , in accordance with the present disclosure. 
         FIG. 4  is a rear view of the dipper of  FIG. 2 , in accordance with the present disclosure. 
         FIG. 5  is a front view of the dipper of  FIG. 2 , in accordance with the present disclosure. 
         FIG. 6  is a flow chart of a series of steps that may be involved in the making of a dipper, in accordance with aspects of the present disclosure. 
     
    
    
     DETAILED DESCRIPTION 
     Referring to  FIG. 1 , a dipper  1  is attached to a work machine  2 . The work machine  2  may embody a fixed or mobile machine that performs some type of operation associated with an industry such as mining, construction, farming, transportation, or any other industry known in the art. For example, the work machine  2  may be an earth moving machine such as an electric rope shovel, as shown, or a backhoe, an excavator, a dozer, a loader, a motor grader, or any other earth moving machine. Work machine  2  may include a boom handle  4  and the dipper  1  (e.g., bucket, etc.) supported by a boom  6 . The dipper  1  is coupled to the boom handle  4 , moving in more than one direction along with the boom handle  4 . The dipper  1  is configured to hold earth and other materials that are loaded into the dipper  1  by the action of the boom handle  4 . The boom handle  4  is configured to apply a force to the dipper  1 , pushing the dipper  1  into a surface  8  (shown in  FIG. 3 ) (i.e. a bank of material such as overburden, ore, or other earthen material to be mined or moved and referred to collectively as “mining material”). The dipper  1  is forced into the bank by the force of the boom handle  4 , digging into the surface  8  and filling the dipper  1  with mining material. 
     The work machine may further include a revolving frame  9  connected to and supported by a base  10 . The revolving frame  9  is rotatable about an axis (not shown) relative to the base  10  by a rotating assembly  11 . The base is supported on a ground surface  12 . The revolving frame may further include a cabin  13 , and the boom  6  being pivotally connected to the revolving frame  9 . The boom handle  4  may also be pivotally connected to the boom. 
     Although the disclosure is shown and described by way of example with reference to a work machine  2 , the disclosure is also applicable for use with any machine or vehicle that includes a dipper or bucket for digging and/or transporting material, such as excavators, etc., all of which are intended to within the scope of the disclosure. 
     Referring to  FIGS. 2-5 , the dipper  1  is shown, according to an exemplary embodiment. The dipper  1  includes a front cavity wall  14  and a rear cavity wall  16 . The front cavity wall  14  defines an inlet  18 , through which the dipper  1  is filled, and the rear cavity wall  16  defines an outlet  20 , through which the dipper  1  is emptied. The inlet  16  and the outlet  20  define a cavity  21 . As best shown in  FIG. 3 , the dipper  1  further includes a top cavity wall  22  defining a substantially horizontal top plane  23 , and a bottom cavity wall  24 , opposite the top cavity wall  22 , defining a bottom plane  25 . The bottom cavity wall  24 , in one exemplary embodiment, may be grated or lattice framed, and include a replaceable liner. The top cavity wall  22  extends between the front cavity wall  14  and the rear cavity wall  16 , and the bottom cavity wall  24  may extend from the rear cavity wall  16  in a direction towards the inlet  18 , or an inlet plane  26 . In a further exemplary embodiment, the bottom cavity wall  24  extends from the rear cavity wall  16  to the lip  27  (discussed below). The inlet  18 , as shown in its side profile in  FIG. 3 , defines the substantially vertical inlet plane  26 , and the outlet  20  defines an outlet plane  28 . A first side cavity wall  29  and an opposite second side cavity wall  30  are connected between the top cavity wall  22  and the bottom cavity wall  24  and extend between the from the front cavity wall  14  and rear cavity wall  16 . 
     In one exemplary embodiment, the cavity  21  is defined by the inlet  18  and the outlet  20 , and is further defined by the front cavity wall  14 , rear cavity wall  16 , top cavity wall  22 , bottom cavity wall  24 , and the first and second side cavity walls  29 ,  30 . In another exemplary embodiment, in a side profile of the dipper  1  as shown in  FIG. 3 , the cavity  21  is defined by the top plane  23 , bottom plane  25 , inlet plane  26 , and the outlet plane  28 . In this embodiment, the side profile shape of the cavity  21  may be a quadrilateral with no parallel sides, as the inlet plane  26  is not parallel to the outlet plane  28 , and the top plane  23  is not parallel to the bottom plane  24 . Further is this embodiment, the bottom plane  25  is perpendicular to the outlet plane  28 . 
     The inlet  18  may have a larger width than height, forming a substantially rectangular shape that may have rounded corners. Similarly, the outlet may have a larger width than height, forming a substantially rectangular shape that may have rounded corners. The inlet  18  may have a width to height ratio of 1.8-2.2, and the outlet a width to height ratio of 2.1-2.6. A width to length body length ratio between 1.3-1.7 may exist between the top plane  23  and the inlet plane  26 . The difference in width to height ratios between the inlet and outlet  18 ,  20 , along with the 5-10 degrees angled bottom plane (discussed below), gives the cavity  21  formed between the inlet  18  and outlet  20  a funnel shape. 
     Shown in  FIG. 3 , the dipper  1  is shown in an exemplary digging configuration. A digging configuration is when the boom handle  4  is configured to apply a force to the dipper  1 , pushing the dipper  1  into the surface  8 . In this configuration, the top pane  23  is substantially parallel to the ground surface  12 . The bottom plane  25  is angled relative to the top plane  23 . In one exemplary embodiment, the bottom pane is angled 5-10 degrees relative to the plane and is angled downwards in a direction towards the inlet plane  26 , or the inlet  14 . 
     Further, the inlet plane  26 , defined by the front cavity wall  14 , may be substantially vertical, and perpendicular to the top cavity wall  22 , or the top plane  23 . The outlet plane  28 , defined by the rear cavity wall  16 , extends from the top cavity wall  22  to the bottom cavity wall  24 , and may be angled relative to the inlet plane  26 , or the front cavity wall  14  extending from the top cavity wall  22  in a direction away from the inlet plane  26 . The outlet plane  28  being perpendicular to the bottom plane  25 . 
     As shown in  FIGS. 2-3 , the dipper may further comprise the lip  27  coupled to a bottom surface  32 ,  33  of each of the first and second side cavity walls  29 ,  30  and a front surface  35  of the bottom cavity wall  24 . The lip  37  may extend outwardly in a direction away from the outlet  20  and have an inner surface  36  defining a lip plane  37 . The lip plane  37  is arranged substantially parallel with the top plane  23 . In the digging configuration shown in  FIG. 3 , the lip plane  37  may be substantially parallel with the ground surface  12 . The lip may comprise a plurality of adaptors  39 , where each adaptor of the plurality of adaptors is configured to hold a pierce digging tooth  40 . In one exemplary embodiment, the number of adaptors comprising the plurality of adaptors is between 7-10, but any number of adaptors suitable to conduct a digging operation may be used. The lip  27  may further comprise two lip protectors  41 , on opposite ends of the lip  37 , that are attach to the lip  27  and may engage with the front cavity wall  14  and extend away from the inlet  18 . 
     Best shown in  FIG. 3 , the plurality of adaptors  39  define an adaptor plane  42 . In one exemplary embodiment, the adaptor plane  42  points in an upward direction, between 5-15 degrees upwards relative to the lip plane  37 , away from the inlet  18 . In a further exemplary embodiment, the plurality of adaptors  39  can be mounted in reverse to define the adaptor plane in a downwards direction (not shown), between 5-15 degrees downwards relative to the lip plane  37 , and away from the inlet  18 . 
     The dipper  1  may further include a reinforced section  44 , as shown in  FIGS. 1-2 . This reinforced section  44  may be relatively thick such as 1 to 18 inches, and an extension of, or coupled to, the top cavity wall  22 , allowing for greater structural support of the dipper  1 . On top of the dipper  1 , connected to the reinforced section  44 , or a top surface  45  of the top cavity wall  22 , may be a first and second set of mounting brackets  46 ,  47 . The first set of mounting brackets  46  is used for connecting to the broom handle  4 , and the second set of mounting brackets  47  is for connecting to a boom lever  48 . The boom lever  48  is configured to pivot the dipper  1 , relative to the boom handle  4 , and the boom handle  4  is configured to pivot relative to the boom  6 . The boom handle  4  and the boom  6  and configured to move the dipper  1  from the digging configuration shown in  FIG. 3  to an unloading configuration (not shown), in which the dipper is rotated so that the top plane  23  is substantially perpendicular to the ground surface  12 . In this configuration a rear door  50  of the dipper  1 , will be open, and any mining materials located in the cavity  21  can flow out of the outlet  20 . 
     The rear door  50 , as shown in  FIG. 5 , may be pivotally mounted to the dipper  1  by a door bracket  51  attached to the top surface  45  of the top cavity wall  22 , or the reinforced section  44 . The rear door  50  is configured to move from a closed position to an open position to open the outlet  20 , and to move from an open position to a closed position to close the outlet  20 . The rear door  50  further defining a rear door plane  52  when in the closed position. The rear door plane is angled relative to the inlet plane  26  when is the closed position. 
     The rear door may further comprise a latching mechanism  53 , as shown in  FIG. 5 , configured to lock the rear door when in the closed position. The latching mechanism  53  may be unlocked by a pull string  54 , or hydraulic cable (not shown), or electric latching mechanism with an electric wire (not shown), in order to allow the rear door  50  to be moved to the open position. The latching mechanism  53  may extend through the rear door  50  through an aperture (not shown) and may be at least partially housed inside of the cavity  21 . In order to protect the latching mechanism  53 , the latching mechanism  53  may further include a protective cover  55 , as best shown in  FIG. 4 . The protective cover  55  may have a bottom surface  56  defining a latching mechanism plane  57 , and the latching mechanism plane  57  may be substantially parallel to the bottom plane  25 . 
     INDUSTRIAL APPLICABILITY 
     In general, the teachings of the present disclosure may find applicability in many industries including, but not limited to, electric rope shovels. More specifically, the teachings of the present disclosure may find applicability in any industry using dippers, or shovels, in a digging operation, such as, but not limit to, mining, excavating, agriculture, construction, and the like. 
     Turning now to  FIG. 6 , with continued reference to  FIGS. 1-5 , a flowchart illustrating an exemplary process  100  for making a dipper  1  is disclosed. At block  100 , a front cavity wall  14  defining an inlet  18 , and the inlet  18  defining a substantially vertical inlet plane  26 , is provided. At block  104 , a rear cavity wall  16  is positioned opposite the front cavity wall  14 , the rear cavity wall  16  may define an outlet  20 , and the outlet  20  may define an outlet plane  28 . In block  106 , a top cavity wall  22  is then extended between the front cavity wall  14  and the rear cavity wall  16 . The top cavity wall may define a substantially horizontal top plane. A bottom cavity wall  24  opposite the top cavity wall  22 , in block  108 , is then extended from the rear cavity wall  16  towards the inlet  18 , and further defines a bottom plane  25 . The method may then include, at block  110 , connecting two side cavity walls  29 ,  30  between the top cavity wall  22  and the bottom cavity wall  24 , the two cavity walls  29 ,  30  may further extend between the front cavity wall  14  and the rear cavity wall  16 . 
     In the resulting dipper  1  from the process  100 , the outlet plane  28  may be angled relative to its inlet plane  26 , and the bottom plane  25  may be angled relative to the top plane  23 . Further, the outlet plane  28  may be perpendicular to its bottom plane  25 , creating a quadrilateral side profile with no parallel sides which allows for better digging without dragging the bottom of the dipper  1  when the top plane  23  is positioned parallel with a ground surface  12 . 
     The dipper&#39;s  1  inlet  18  may further have a wider width than height, allowing for a more efficient pass volume during the digging operation. Similarly, the outlet  20  may have a wider width than height, with a larger width to height ratio, along with a tapered bottom angled downwards and extending from the outlet  20  towards the inlet  18 , creating a funnel shaped cavity  21  that allows for the more efficient pass volume. The more efficient pass loading may include 3-5 pass loadings for a 400 Ton truck. 
     As shown in block  112 , the process of making the dipper  1  may further include connecting a lip  27  to a bottom surface  32 ,  33  of the side cavity walls  29 ,  30 , and a front surface  35  of the bottom cavity wall  24 . The lip  27  may define a lip plane  37  that is arranged substantially parallel with the top plane  23  of the dipper  1  during the digging operation. To improve the efficiency of the dipper  1  and allow for the more efficient pass loadings, the lip  27  may further include a plurality of adaptors  39  that are angled in an upward direction relative to the lip plane  37 . These angled adaptors allow for more efficient digging action as the adaptors each include a pierce digging tooth  40  that will cut through the mining material when the dipper  1  is rotated up and through the mining material, during the digging action, as they are pointed in the direction of travel of the dipper  1  during this maneuver. 
     While the preceding text sets forth a detailed description of numerous different embodiments, it should be understood that the legal scope of protection is defined by the words of the claims set forth at the end of this patent. The detailed description is to be construed as exemplary only and does not describe every possible embodiment since describing every possible embodiment would be impractical, if not impossible. Numerous alternative embodiments could be implemented, using either current technology or technology developed after the filing date of this patent, which would still fall within the scope of the claims defining the scope of protection.