Patent Description:
In mining and construction, wear parts are commonly provided along the digging edge of excavating equipment such as buckets for dragline machines, cable shovels, face shovels, hydraulic excavators, bucket wheel excavators, and the like. The wear parts protect the underlying equipment from undue wear and, in some cases, also perform other functions such as breaking up the ground ahead of the digging edge. During use, the wear parts typically encounter heavy loading and highly abrasive conditions. As a result, they must be periodically replaced.

These wear parts usually comprise two or more components such as a base that is secured to the digging edge, and a wear member that mounts on the base to engage the ground. The wear member tends to wear out more quickly and is typically replaced a number of times before the base (which can also be a replaceable wear member) must also be repaired or replaced. One example of such a wear part is an excavating tooth that is attached to the lip of a bucket for an excavating machine. A tooth typically includes an adapter secured to the lip of a bucket and a point attached to the adapter to initiate contact with the ground. A pin or other kind of lock is used to secure the point to the adapter.

Often the wear parts are used on earth working equipment operated in remote locations. Getting new wear parts to the remote locations and installed on the earth working equipment can be difficult. For example, in a mining environment, the wear parts needing replacement may be on earth working equipment that cannot be easily moved to a maintenance facility when routine maintenance is required. Because of this, the wear parts are generally replaced while the earth working equipment is in the field. When the wear parts are replaced in the field, the environment in which the wear parts need to be replaced may be subjected to extreme environments. For example, the temperature may be extremely cold (e.g., freezing) or extremely hot, it may be snowing, sleeting, raining, or windy and the ground may be muddy, un-level, and/or unstable. In addition, the environment may be dusty which can pose health risks to operators. Thus the environment in which the wear parts must be replaced is varied and the environment is often difficult and/or unpredictable.

These wear parts are heavy and cannot be easily lifted by the installer, this increases the difficulty of replacing the wear parts. New wear parts are typically designed with cast lifting eyes integrally connected to the wear parts. A rigging system is attached to the lifting eyes to assist in lifting the wear parts during installation. However, the installer can still be in potential risk if the rigging arrangements are unsecure and slip or create pinch points. The installer maneuvers the wear part onto the excavating equipment. Once the wear part is fit on the excavating equipment the wear part is secured in place. Various methods known in the industry may be used to secure the wear parts in place. For example, the wear parts may be secured or locked to the excavating equipment with the use, e.g., of welds, bolts, wedges, or threaded members. The locking mechanisms require the installer to come in close proximity to the wear parts before the wear part is secured. Regardless of whether the wear part is attached to the rigging system at the time of installation, the potential for the wear part to separate from the excavating equipment and fall or swing prior to implementing the locking mechanism places the installer in potential risk.

As the wear parts contact the material to be excavated the integral lifting eyes are worn away leaving no way to gain an attachment point on the worn wear part. To remove the worn wear part some operators simply let the parts fall to the ground when the lock is removed, or use a hammer to knock the wear part from the base if fines prevent the release of the components. The uncontrolled falling of the wear part and the use of a hammer subject the operators to risks. Moreover, the operators are still left with needing to remove the wear parts from the ground to a discard pile or bin. Another common way to remove the worn wear parts is with a complex rigging arrangement using chains, straps, or other mechanisms to secure the wear part. However, during removal, the installer can still be in potential risk if the rigging arrangements are unsecure and slip or create pinch points. Additionally rigging arrangements that require chains, straps, or other mechanisms to go under the worn wear parts can be problematic when rigging is removed. Once the wear part is moved to the discard pile the rigging arrangements may be under the wear part requiring the operator roll or move the worn wear part to remove the rigging arrangement. The potential for the wear part to pinch or otherwise harm the operator as the heavy piece is rolled or moved off of the rigging arrangement places the operator in potential risk. Another alternative way to maneuver the worn wear part is to weld a lifting ring onto the part. This is not desirable because mobile welding equipment is needed at the machine site. In addition, wear parts tend to be composed of very hard steel which requires a careful and time consuming process to achieve a high quality weld. If there is a poor weld the lifting eye may be separated from the wear part causing uncontrolled movement of the wear part which becomes a potential risk to the installer.

<CIT> discloses a mining system including dredger cuttertooth manipulator comprising two robotic tools handlers for removing of worn tooth from a dredger cutterhead, and for replacing the removed tooth with the new tooth. The manipulator is fitted to dredger shape, is it two robotic tooth handlers being mounted on opposite sides of a cutter platform of the dredger ship for the cutterhead to be hoisted into a position between the two robotic tooth handlers for tooth manipulation.

<CIT> B teaches a tire changing apparatus adapted to be mounted on a ficpi for use in changing or repairing extremely large tires off the type frequently weighting several thousand pounds.

<CIT> is the reference teaching the features of the preamble of claim <NUM>.

Taking the teaching of this above prior art reference into consideration, the problem, at the origin of the instant case that the applicant wanted to solve, was to ease the replacement of wear members mounted on the earth working equipment.

To this end, the invention related to a mining system according to claim <NUM>.

It should be pointed out that <CIT> only discloses a gripping tool formed in the shape of an excavator bucket tooth, that there is no hint in <CIT> that the auxiliary tool could be configured to release a retainer and that, whereas <CIT> teaches a lock for holding a tooth which is dismounted by using a commonly used ratchet wrench, there is no hint to include such a wrench in an auxiliary tool for holding a wear member as disclosed in <CIT>.

In the preferred embodiment, the mobile base of the mining system is a service vehicle, wheeled service station or tracked service station drivable to a desired location for removing the wear member.

In accordance with another aspect of the invention, a tool includes a manipulator and a controller to remove and/or install a wear member on earth working equipment. In one preferred construction, an operator uses a user input device to remotely control the manipulator. In another preferred construction, the controller uses programmable logic to complete portions or all of the removal and/or installation process without an operator. In one preferred construction, the manipulator is a servo-electric manipulator. In another preferred construction, the manipulator is a hydraulic manipulator. In another preferred construction, the manipulator is pneumatic.

In accordance with another aspect of the invention, a tool is secured in a fixed location and earth working equipment is brought to the tool when wear parts need replacement. This allows earth working equipment that can easily be moved from one location to another to be brought to a maintenance facility where the environment can more easily be controlled.

In accordance with another aspect of the invention, a tool references a database to identify what type of wear parts are currently installed on excavating equipment. In one preferred construction, the tool references the database remotely. In other constructions, the data for the database can be provided by, e.g., elements on the equipment (such as bar codes, QR codes, transmittors, etc.), wear identification devices on the equipment, mobile data collection devices, the tool or other devices, within the controller on the tool, manually inputted by a user, etc..

In accordance with another aspect of the invention, a tool receives information from an encoding element attached to excavating equipment. The encoded mechanism may include information on the bucket serial number, the capacity of the bucket, the excavating machine that the bucket is installed on, and the type of wear parts currently installed on the excavating equipment. In one preferred construction, the encoding element is a Radio-Frequency Identification (RFID). In another preferred construction, the encoding element is a barcode. In another preferred construction, the barcode is a Quick Response (QR) Code. In another preferred construction, the encoding element is located on an excavating bucket.

In accordance with another aspect of the invention, a tool receives information from a wear part monitoring unit to identify what type of wear parts are currently installed on excavating equipment. The wear part monitoring unit is a system to monitor the health of wear parts on the excavating equipment.

In accordance with another aspect of the invention, a tool receives information from a wear part monitoring unit to identify what wear parts need replacement on an excavating machine.

In accordance with another aspect of the invention, a tool receives information from sensors of a wear part monitoring unit to assist the tool in locating the wear parts needing replacement and assist the tool when installing the new wear parts on the earth working equipment.

In accordance with another aspect of the invention, a tool communicates with a database to record information about a process completed by the tool. In one preferred construction the tool communicates at least one of: i) the time and date that the wear parts were removed and replaced, ii) how long the change-out of the wear parts took, iii) machine the wear parts were installed on, iv) type of wear parts replaced and installed, v) torque needed to remove a securement mechanism holding the wear part to the earth moving equipment, vi) torque used to install securement mechanism to hold the wear part to the earth moving equipment, and vii) the geographic location of where the wear parts were replaced.

In accordance with another aspect of the invention, a tool determines the orientation and location of a wear part on excavating equipment needing replacement using sensors. The sensors allow the tool to know the location and orientation of the wear parts even when the earth working equipment may be located on un-level ground and the wear parts have various orientations relative to the ground. In one preferred construction, the sensors are passive. In another preferred construction, the sensors are active. In another preferred construction, the sensors are chosen from a group including receivers, transmitters, and/or digital sensors. In another preferred construction, Global Positioning System (GPS) receivers are used to locate the wear part. In another preferred construction, electromagnetic wave receivers and transmitters are used to locate the wear part needing replacement. In a preferred construction the electromagnetic waves have a wavelength greater than the visible spectrum (e.g., infrared, microwave, or Radio Frequency [RF]). In another preferred construction, mechanical wave receivers and transmitters are used to locate the wear part needing replacement. In a preferred construction the mechanical waves are in the ultrasonic spectrum. In another preferred construction, laser receivers and transmitters are used to locate the wear part needing replacement. In one preferred construction, a digital inclinometer unit and a digital compass are used to determine the orientation and location of the wear part needing replacement. In one preferred construction, a camera and vision recognition software are used to identify the excavating equipment and determine the orientation and location of the wear part needing replacement.

In accordance with another aspect of the invention, a tool uses an automated or semi-automated process for removing and installing a wear part from excavating equipment operates autonomously and is also capable of being operated by an operator with a user input device. Allowing the automated tool to be operated by the operator allows other functions of the automated process to operate more efficiently. In addition the user input device allows the automated process to continue should the automated tool encounter an error. In one preferred construction, the user input device has haptic, visual, or audible feedback. In one preferred construction, the user input device is a joystick. In another preferred construction, the user input device is an operator physically (e.g., with their hands) guiding the manipulator to the desired positions. In another preferred construction, the user input device is a wearable user interface.

In accordance with another aspect of the invention, a tool is automated to determine if a wear part is appropriately oriented for removal by obtaining the wear part orientation and location from a digital sensor. In one preferred construction, a digital inclinometer unit is used to determine the tilt of the wear parts needing replacement. In one preferred construction, a camera and vision recognition software are used to identify the excavating equipment and determine if the wear part needing replacement is appropriately oriented for removal.

In accordance with another aspect of the invention, a tool includes a plurality of arms that are used to secure at least two opposing sides of the wear member. In one preferred construction, the multi-arm tool has at least two arms. In another preferred construction, the multi-arm tool has at least three arms. Two arms contact the sides of the wear member and one arm contacts the bottom of the wear member to secure the wear member to the tool.

In accordance with another aspect of the invention, a tool includes two or more auxiliary tools (or sub-tools) that are combined into a single multi-purpose tool. In one preferred construction, a first auxiliary tool secures the wear member and a second auxiliary tool removes the securement mechanism or retainer holding the wear member to the base.

In accordance with another aspect of the invention, a tool includes a manipulator provided with an auxiliary tool (or sub-tool) that has an adjustment mechanism so that the tool can be adjusted without adjusting the orientation of the manipulator.

A magnetic strap may be used to ensure that a wear part to be replaced does not prematurely become disengaged from excavating equipment. In one preferred construction, the magnetic strap utilizes at least one air actuated permanent magnet.

The tool may include two auxiliary tools to remove and install a wear part, a first auxiliary tool to secure the wear part from falling and a second auxiliary tool to engage and disengage the wear part from a base. In a preferred construction, the first and second auxiliary tools are both supported by manipulators.

The manipulator may have two arms used to remove and install a wear part, a first arm to secure the wear part from falling and a second arm to engage and disengage the wear part from a base.

The tool may be automated and use multiple auxiliary tools to perform an automated process for removing and installing wear parts secured to excavating equipment.

In accordance with another aspect of the invention, the tool uses an adjustable multi-jaw gripper to secure a wear part from falling off of a base attached to excavating equipment.

In accordance with another aspect of the invention, a cartridge fits around a wear part and secures the wear part for removal. In one preferred construction, the cartridge is secured to an automated tool. In another preferred construction, the cartridge is secured to a tool that requires an operator to maneuver the cartridge. In another preferred construction, the wear parts needing replacement are brought to the cartridge.

In accordance with another aspect of the invention, the cartridge is used for shipping, storing, installing, and removing a wear part.

In accordance with another aspect of the invention, the cartridge has at least one attachment mechanism for lifting the cartridge, for rotating the cartridge, for pulling the cartridge, or for pushing the cartridge. An attachment mechanism that can be lifted, pulled, or pushed allows a wear part secured within the cartridge to be installed and removed from a base secured to excavating equipment.

In accordance with another aspect of the invention, the tool uses pressurized fluid to remove fines from a wear part. In one preferred construction, pressurized air with or without suspended abrasive grains is used to remove fines. In another preferred construction, pressurized liquid is used to remove fines.

In accordance with another aspect of the invention, the tool uses a vibrator to remove fines from a wear part. In one preferred construction, the vibrator is secured to the wear part with at least one electromagnet, electrically re-polarized permanent magnet, or air actuated permanent magnet. In one preferred construction, the vibrator is isolated from the tool so that the vibrations do not negatively affect the tool.

In accordance with another aspect of the invention, a tool secures a gripping piece to a securement mechanism, such as a hammerless retainer, and uses the newly attached piece to remove the securement mechanism from the wear part. In one preferred construction, the tool uses a stud, a stud welder and a pneumatic wrench or hydraulic wrench to remove the securement mechanism.

In accordance with another aspect of the invention, a tool uses force control and a tool that matches an opening in a retainer to locate, create a positive engagement with the retainer, remove, and install the retainer.

A tool may use a cutter to remove the retainer. In one preferred construction, the cutter is an arc cutter. In another preferred construction, the cutter is a waterjet cutter. In another preferred construction the cutter is spun in a circle to remove the retainer. In another preferred construction, only a portion of the retainer is cut. In another preferred construction, the entire retainer is completely cut away. In another preferred construction, the cutter is an electric air arc torch. In another preferred construction, the cutter is a laser.

In accordance with another aspect of the invention, a tool uses a magnet to remove the retainer from a wear part and dispose of the retainer in a disposal stall. In one preferred construction, the magnet is an air actuated permanent magnet, electromagnet, or electrically re-polarized permanent magnet.

In accordance with another aspect of the invention, a tool uses a vacuum to create a positive engagement with the retainer to remove the retainer from a wear part and dispose of the wear part in a disposal stall.

In accordance with another aspect of the invention, a tool secures at least one new piece to the worn wear part and uses the newly attached piece to remove the wear part from the base. In one preferred construction, the tool uses a stud welder to attach the new piece to the worn wear part.

In accordance with another aspect of the invention, a tool uses a vibrator to initially disengage a wear part from a base secured to excavating equipment.

In accordance with another aspect of the invention, a tool uses a magnet to remove a wear part from a base and dispose of the wear part in a disposal stall. In one preferred construction, the magnet is an air actuated permanent magnet.

In accordance with another aspect of the invention, a tool uses a multi-jaw gripper to remove a wear part from a base and dispose of the wear part in a disposal stall.

In accordance with another aspect of the invention, a disposal stall has fixtures for supporting wear parts so that each wear part is maintained in a fixed location.

In accordance with another aspect of the invention, each replacement wear member is maintained in a fixed location and orientation on a pallet so that the tool can locate the new wear part and properly orient the part for installation.

In accordance with another aspect of the invention, a tool is automated and verifies a new wear part is fully seated on a base by comparing the current location of the retainer on the new wear part with the previously established location of the securement mechanism on the worn wear member.

In accordance with another aspect of the invention, a tool is automated and has been programmed with the geometry of a wear part being installed and has been programmed with where to place a retainer on the wear part.

The application also relates to a process according to claim <NUM> for removing a wear member from an earth working equipment used in a mining system according to claim <NUM>.

Preferably, said process is arranged for moving a retainer that secures a wear member to earth working equipment in a mine to a release position, and moving an auxiliary tool into proximity with the retainer to engage and release the retainer to permit removal of the wear member.

To gain an improved understanding of the advantages and features of the invention, reference may be made to the following descriptive matter and accompanying figures that describe and illustrate various configurations and concepts related to the invention.

Further advantages, features and potential applications of the present invention may be gathered from the description which follows, in conjunction with the embodiments illustrated in the drawings.

The present invention pertains to a tool and a process for removing and installing various kinds of wear parts for earth working equipment including, for example, excavating equipment and ground conveying equipment. Excavating equipment is intended as a general term to refer to any of a variety of excavating machines used in mining, construction and other activities, and which, for example, include dragline machines, cable shovels, face shovels, hydraulic excavators, and dredge cutters. Excavating equipment also refers to the ground-engaging components of these machines such as the bucket, blade, or the cutter head. Ground conveying equipment is also intended as a general term to refer to a variety of equipment that is used to convey earthen material and which, for example, includes chutes and mining truck beds. The present invention is suited for removing and installing wear parts of excavating equipment in the form of, for example, excavating teeth and shrouds. Additionally, certain aspects of the present invention are also suited for removing and installing a wear surface in the form of, for example, runners. For convenience of discussion, the wear part removal and installation process is discussed in terms of replacing a point on a mining excavator. However, the removal and installation process may be used with other wear parts used with earth working equipment.

Relative terms such as front, rear, top, bottom and the like are used for convenience of discussion. The terms front or forward are generally used to indicate the usual direction of travel during use (e.g., while digging), and upper or top are generally used as a reference to the surface over which the material passes when, for example, it is gathered into the bucket. Nevertheless, it is recognized that in the operation of various earth working machines the wear assemblies may be oriented in various ways and move in all kinds of directions during use.

A mining excavator <NUM> is equipped with a bucket <NUM> for gathering earthen material during digging (<FIG>). The bucket <NUM> has a lip <NUM> that is the digging edge of the bucket <NUM> (<FIG> and <FIG>). The digging edge is that portion of the equipment that leads the contact with the ground. Tooth assemblies and shrouds are often secured to the digging edge to protect the edge and break up the ground ahead of the lip. Multiple tooth assemblies <NUM> and shrouds <NUM>, such as disclosed in <CIT> may be attached to lip <NUM> of bucket <NUM> (<FIG> and <FIG>). The illustrated tooth <NUM> includes an adapter <NUM> welded (or otherwise secured) to lip <NUM>, an intermediate adapter <NUM> mounted on adapter <NUM>, and a point (also called a tip) <NUM> mounted on base <NUM>. While one tooth construction <NUM> is shown, other tooth arrangements are possible. Point <NUM> includes a rearwardly-opening cavity to receive nose <NUM>, and a front end <NUM> to penetrate the ground. A securement mechanism, typically called a retainer, pin or lock <NUM>, is used to secure wear member <NUM> to base <NUM>, and base <NUM> to nose <NUM> (<FIG> and <FIG>), though different locks could be used to secure point <NUM> and base <NUM>. In this application, point <NUM> is typically referred to as the wear member and intermediate adapter <NUM> as the base. Nevertheless, intermediate adapter <NUM> and adapter <NUM> are wear members as well. For example, when intermediate adapter <NUM> needs replacement, it can be referred to as the wear member and adapter <NUM> as the base. Similarly, when adapter <NUM> needs replacement, it can be referred to as the wear member and lip <NUM> as the base. During the life of the bucket, the wear members <NUM>, <NUM>, <NUM> are usually replaced a number of times.

<FIG> illustrates the steps to a process for removing and installing worn wear members <NUM> on an excavating bucket <NUM>. The process may be accomplished by an installer/operator or the process may be a semi-automated process (i.e., various steps within the process may be automated) or a fully automated process. Variations in the process exist. For example, it may be desirable to replace more than one wear member at a time and it may be desirable to first remove all of the wear members before installing the new wear members.

In accordance with the invention, a tool <NUM> is used to remove and install wear members <NUM> (<FIG>). The tool <NUM> is brought to the excavating equipment <NUM> needing maintenance so that the wear parts may be replaced even when the earth working equipment is in a remote location and the wear parts must be replaced in the field. The tool <NUM>, for example, may be a service vehicle <NUM> as a mobile base with at least one manipulator <NUM> and at least one controller <NUM> such as a Central Processing Unit (CPU) with programmable logic. The controller can be a single CPU or a combination of CPUs located, for example, in the auxiliary tools, manipulators and/or service vehicle. The controllers can be in a remote location or, as described below, can be manually operated or partially manually operated. The service vehicle <NUM> may also be equipped with outrigger stabilizers <NUM>, a power source <NUM>, a manipulator platform <NUM>, storage stalls or pallets <NUM>, and auxiliary tools or sub-tools <NUM> to be used in conjunction with the manipulator <NUM>. The service vehicle is wheeled so that it can easily be moved from one location to another. In an alternative embodiment not shown, the service vehicle may have tracks or may have wheels and tracks. The service vehicle <NUM> is driven to the mining excavator <NUM> by an operator located within the service vehicle <NUM>. Alternatively, the service vehicle <NUM> may be driven to the mining excavator <NUM> normally or remotely via a user input device. For example, the service vehicle <NUM> may be remotely driven with a joystick (not shown) and cameras (not shown) located on the service vehicle <NUM>. In another alternative, the service vehicle <NUM> may be fully automated and programmed to drive to the mining excavator <NUM> needing wear members <NUM> replaced.

The service vehicle <NUM> is driven close enough to the excavator bucket <NUM> so that the manipulator <NUM> is able to reach the wear members <NUM> on the bucket <NUM>. Once in position the hydraulic outrigger stabilizers <NUM> are lowered to provide a stable platform for the manipulator <NUM>. The manipulator platform <NUM> may be located on the service vehicle <NUM> low enough so that the manipulator <NUM> is able to reach the wear members <NUM> when the bucket <NUM> is set on the ground. In some cases, the excavator operator may need to adjust the bucket <NUM> so that the bucket <NUM> is tilted up or prop the bucket <NUM> on a platform <NUM> so that the manipulator <NUM> is able to reach the wear members <NUM> when the manipulator <NUM> is located on the service vehicle <NUM> (<FIG>). Service vehicle <NUM> may be equipped with a lift (not shown), turntable and/or translating assemblies to lower, turn and/or move the manipulator <NUM> so that the manipulator <NUM> is able to reach the wear members <NUM> on the bucket <NUM>.

The manipulator <NUM> and auxiliary tools <NUM> may be powered from a number of power sources. For example, the manipulator <NUM> and auxiliary tools <NUM> may be powered via the service vehicle, a generator, or batteries.

The manipulator platform <NUM> may be equipped with rails (not shown) for the manipulator <NUM> to slide towards the front of the service vehicle <NUM>, towards the rear of the service vehicle <NUM>, and/or towards either side of the service vehicle <NUM>. Commercially available chains, hydraulic actuators, or electric actuators (driving a rack and pinion or ball screw) (not shown) may be connected to the manipulator <NUM> to move the manipulator <NUM> along the rails.

The storage stalls or pallets <NUM> on the service vehicle <NUM> may be a part of the manipulator platform <NUM>, integrated with the service vehicle <NUM>, or may be detachable from the service vehicle <NUM> so that all of the wear members <NUM> are loaded onto the service vehicle <NUM> in the storage stalls <NUM> prior to the service vehicle <NUM> being deployed to the field (<FIG>, <FIG>). The storage stalls <NUM> may be equipped with fixtures or jigs <NUM> to support the wear members <NUM> so that each wear member <NUM> has a fixed orientation and location relative to the manipulator <NUM> once installed on the service vehicle <NUM>.

The manipulator <NUM> may be custom built or may be a commercial off-the-shelf servo-electric manipulator or a commercial off-the-shelf hydraulic manipulator, or a commercial off-the-shelf pneumatic manipulator. The manipulator <NUM> may have integrated force sensing or may be equipped with an aftermarket off-the-shelf force sensing device. Examples of manipulators <NUM> that may be used include, but are not limited to, a Fanuc m-900ia-<NUM> servo-electric robot with integrated force sensing, an ABB IRB <NUM>-<NUM> servo-electric robot equipped with an ATI aftermarket Force/Torque Sensor, a Motoman HP500D servo-electric robot equipped with an ATI aftermarket Force/Torque Sensor, or a Vulcan Action <NUM> hydraulic manipulator.

The service vehicle <NUM> may be equipped with one or more of a variety of auxiliary tools <NUM> usable to remove and/or install wear members <NUM>. The auxiliary tools <NUM> are preferably located in a fixed location relative to the manipulator <NUM>. The manipulator <NUM> may be equipped with an industry standard tool changer <NUM> to allow the manipulator <NUM> to quickly change from one auxiliary tool to another auxiliary tool to perform various functions of the removal and installation process. The tool changer <NUM> has a first side <NUM> that connects to the manipulator <NUM> and a second side <NUM> that connects to the auxiliary tool <NUM> (<FIG>). The two sides <NUM> and <NUM> of the tool changer <NUM> are coupled together when in use and decoupled when not in use. For example, the manipulator <NUM> may be equipped with an ATI Robotic Tool Changer. The various types of auxiliary tools <NUM> the service vehicle <NUM> may be equipped with are discussed in detail below. The manipulator may also concurrently support multiple auxiliary tools <NUM>.

In an alternative embodiment (<FIG>), a service station <NUM> is equipped with a power source <NUM>, at least one controller <NUM> in the form of a CPU with programmable logic, at least one manipulator <NUM>, storage stalls <NUM>, and auxiliary tools <NUM> to be used in conjunction with the manipulator <NUM>. The service station <NUM> is similar in many ways to service vehicle <NUM> with many of the same benefits and purposes. The following discussion focuses on the differences and does not repeat all the similarities that apply to service station <NUM>. A mining excavator <NUM> is brought to the service station <NUM> and located close enough to the manipulator <NUM> so that the manipulator <NUM> is able to reach the wear members <NUM> on the bucket <NUM>. As with the service vehicle <NUM>, the service station <NUM> may be equipped with rails (not shown) for the manipulator <NUM> to slide back and forth on. The manipulator <NUM> and auxiliary tools <NUM> in the service station <NUM> may be powered from a number of power sources <NUM>. For example, the manipulator <NUM> and auxiliary tools <NUM> may be powered via a generator, batteries, or powered by an existing power system. Service station <NUM> is preferably located in a convenient location for the earth working tools to approach and for operators to access. Nevertheless, the service station can be located in the field and can include a mobile base such as a trailer to be moved to different locations.

Once the service vehicle <NUM> is in position relative to the excavating bucket <NUM> or the excavating bucket <NUM> is in position relative to the service station <NUM> the type of wear members <NUM> on the bucket <NUM> are identified. The wear members <NUM> on the bucket <NUM> may be identified by an operator manually entering the information into the controller <NUM>. The operator may input a specific identifier related to the excavating equipment <NUM>, and controller <NUM> uses the identifier to references a database of wear members <NUM> on the identified excavating equipment <NUM>.

In an alternative embodiment, an operator or the manipulator <NUM> may have an auxiliary tool to pull information from a database regarding the state of the wear parts. The database may be accessed by an encoding element <NUM> located on the excavating equipment <NUM>, preferably on a protected area. The encoding element <NUM> may, for example, be located on the back of the bucket <NUM> (<FIG>) or on the earth working machine operating the bucket (not shown). The encoding element may be, for example, an RFID, barcode, or QR Code. In an alternative embodiment not shown, the auxiliary tool may pull information from a mobile data collection device. The encoded mechanism <NUM> or database may store, for example, the bucket serial number, the capacity of the bucket, the machine the bucket is installed on, the part number for the bucket, and type of wear members <NUM> currently installed on the bucket <NUM>. The data is then input into the controller <NUM>. The controller <NUM> with an external Programmable Logic Controller (PLC) (not shown) or an external PC (not shown) may perform a check to ensure that the wear members <NUM> to be installed are compatible with the bucket <NUM>.

In yet another alternative embodiment, the controller <NUM> may pull the type of wear members <NUM> currently installed on the bucket <NUM> from a bucket health monitoring unit (not shown). The bucket health monitoring unit may be a system that monitors and stores the current wear characteristics of each wear member <NUM> on the bucket <NUM> and gives an alert when a wear member <NUM> is about to be worn past a minimum wear profile for the wear member <NUM>. The alert may be sent wirelessly to equipment operators and to wireless devices when the wear members <NUM> on the excavating equipment <NUM> need maintenance. In order to determine the minimum wear profile of each wear member <NUM> on the bucket, the health monitoring unit may reference a database with various wear profiles for various types of wear members <NUM>. Various aspects of the bucket health monitoring unit may be, for example, accomplished by the Tooth-Wear Monitoring system sold by Motion Metrics or similar bucket health monitoring units or from a mobile data collection device.

In addition to assisting in determining what type of wear members <NUM> are currently installed on the bucket <NUM>, the bucket health monitoring system may also be able to communicate other information to the tool <NUM>. The communication between the bucket health monitoring system and the tool <NUM> may be wireless or through a cable. The bucket health monitoring system may communicate, for example, the specific wear member(s) <NUM> that are worn such that the wear member(s) <NUM> should be replaced prior to the next maintenance window. The bucket health monitoring system may assist the tool in providing feedback to the tool during the installation and removal process. For example, the bucket health monitoring system may provide information from its sensors (e.g., cameras, accelerometers) to assist the tool in locating and securing the worn wear part and installing a new wear part on the base of the excavating equipment.

In the invention, the tool can communicate with the database of the bucket health monitoring system or another separate database to record information about the installation and removal process. The tool can communicate with, for example, at least one of: i) the time and date that the wear parts were removed and replaced, ii) how long the change-out of the wear parts took, iii) machine the wear parts were installed on, iv) type of wear parts replaced and installed, v) torque needed to remove a securement mechanism holding the wear part to the earth moving equipment, vi) torque used to install securement mechanism to hold the wear part to the earth moving equipment, and vii) the geographic location of where the wear parts were replaced.

If the mining excavator <NUM> is not equipped with a bucket health monitoring unit, an operator may look at the current wear characteristics of each of the wear members <NUM> and manually input into the controller <NUM> which wear members <NUM> need replacement. The controller <NUM>, e.g., a CPU, an external PLC, or an external PC, may also transmit information to wireless devices regarding which wear members <NUM> are being replaced. If no wear members <NUM> need to be replaced the controller <NUM> can be programmed to not continue the removal and installation process.

If one or more wear members <NUM> need replacement, the controller <NUM> can determine the location of the wear member <NUM> with respect to the manipulator <NUM>. The bucket <NUM> and service vehicle <NUM> or service station <NUM> may be equipped with sensors so that the orientation and location of the wear parts may be determined regardless of the wear parts orientation to the ground. The sensors may be active or passive sensors and may be, for example, receivers, transmitters, and digital sensors. The bucket <NUM> may have the receivers, transmitters, and digital sensors permanently installed on the bucket <NUM> or the sensors may be placed on the bucket <NUM> by an operator prior to the removal and installation process. For example, the bucket <NUM> may have at least one GPS receiver <NUM> and the service vehicle <NUM> or service station <NUM> may also have at least three GPS receivers <NUM> (<FIG>). Additional digital sensors, for example an inclinometer unit <NUM> and/or a compass <NUM>, may be located on a surface of the bucket with a calibrated starting angle so that the controller <NUM> can determine the orientation and location of the bucket <NUM> relative to the service vehicle <NUM> or service station <NUM>. The calibrated starting angle may be, for example, a flat surface of the bucket <NUM> (e.g., when the bucket <NUM> is resting on level ground). The controller <NUM> may have a bucket and wear member geometry database to assist in locating the wear members <NUM> on the bucket <NUM>. The controller <NUM> may determine where to maneuver the manipulator <NUM> based on the tilt angle of the bucket <NUM>, the locations of the service vehicle <NUM> and bucket <NUM> determined from the GPS receivers <NUM>, and location of the wear member <NUM> determined from the bucket and wear member geometry database. In another embodiment, both the bucket <NUM> and the service vehicle <NUM> or service station <NUM> may have electromagnetic wave receivers and/or transmitters, mechanical wave receivers and/or transmitters, or laser receivers and/or transmitters instead of GPS receivers <NUM>. The electromagnetic waves may, for example, have a wavelength greater than the visible spectrum (e.g., infrared, microwave, or Radio Frequency). The mechanical waves may, for example, have a wavelength in the ultrasonic spectrum. The receivers and transmitters may be similar to those used in the Nikon iGPS system or in the iTrack's Local Positioning System.

As shown in <FIG> and <FIG>, the location of the wear member in space relative to the manipulator may be determined using a camera <NUM>, vision recognition software, and bucket/wear member geometry. For example, the manipulator may be equipped with one or more cameras <NUM> and the, (e.g., a CPU, an external PLC, or an external PC) may be equipped with vision recognition software. The manipulator may be spun, rotated, or maneuvered up, down, or in a circle until the vision recognition software identifies the excavating equipment, the bucket, or the wear member. Once the vision recognition software identifies the excavating equipment, the bucket, or the wear member, the controller may determine the orientation and location of the bucket. The manipulator can then be maneuvered closer to the bucket or wear member until the vision recognition software identified a unique feature on the bucket or wear member. The unique feature may be, for example, unique cast surfaces, a uniquely designed weld-on plate, or a unique pattern of hardfacing. The unique feature would preferably be located in a place where it would not wear completely away. The unique feature would preferably have a pattern on the wear member or bucket so that the controller may determine the direction the bucket or wear member is oriented. The manipulator can be driven to the unique feature and a home position on the bucket or wear member would be established. Based on the established home position and bucket/wear member geometry, the manipulator may be maneuvered to various positions needed to remove and/or install wear members on the bucket.

In the invention, the location of the wear member <NUM> in space relative to the manipulator <NUM> may be input by an operator using a user input device (i.e., a controller <NUM>) to maneuver the manipulator <NUM> to a specific position on the wear member <NUM>. In this example, the controller <NUM> is a user input device such as, for example, a joystick or wearable user interface (not shown). Alternatively, an operator can physically (e.g., with their hands) guide the manipulator <NUM>. For example, the operator may maneuver the manipulator <NUM> so that the manipulator <NUM> is directly over the securement mechanism <NUM> between the wear member <NUM> and the base <NUM> on the excavating equipment <NUM> so that the controller <NUM> is programmed with the wear member <NUM> location and orientation relative to the manipulator. The operator is preferably remote, i.e., located a safe distance away, from the wear member <NUM> and the manipulator. If the operator is located in a position where they cannot physically see the wear member <NUM>, the manipulator <NUM> and service vehicle <NUM> or service station <NUM> may be equipped with cameras <NUM> (<FIG> and <FIG>) to assist in visually maneuvering the manipulator <NUM> to the worn wear member <NUM>. The user input device, may also have haptic, visual, or audible feedback to provide information from the manipulator <NUM>. The feedback, for example, may be a vibration, a visual light, or an audible sound. Feedback, for example, may be given to an operator when the manipulator touches an object.

To ensure that the wear member <NUM> does not prematurely disengage from the excavating equipment <NUM>, the bucket <NUM> may be tilted upwards so that the wear member <NUM> is at an angle for gravity to keep the worn wear member <NUM> in place on the base <NUM>. An inclinometer unit <NUM> located on a surface of the bucket with a calibrated starting angle. The surface of the bucket may be, for example, a flat surface of the bucket <NUM> (e.g., when the bucket <NUM> is resting on level ground). The inclinometer unit <NUM> may wirelessly transmit to the controller <NUM> the current orientation of the bucket <NUM> so that the controller <NUM> can determine when the bucket <NUM> is in a safe orientation for gravity to keep the worn wear member <NUM> in place after the securement mechanism <NUM> is removed (<FIG>). Alternatively, a light or other audio, visual, or haptic feedback (not shown) may indicate to the operator when the bucket <NUM> is at a safe orientation to continue the removal process.

In the invention, the auxiliary tool, preferably in the form of a multi-arm tool <NUM>, may secure the wear member on two or more sides of the wear member <NUM> (<FIG> and <FIG>). In the illustrated example, auxiliary tool <NUM> has three arms, one arm 191a that contacts the bottom of the wear member <NUM> and two arms 191b and 191c that contact the sides of the wear member <NUM>, although the multi-arm tool <NUM> could be provided with more than three arms or fewer than three arms. In addition, the multi-arm tool <NUM> may grip any two opposing surfaces on the wear member (e.g., the arms may grip the top and bottom of the wear member, the arms may grip the sides of the wear member and the top of the wear member, or the arms may grip the top and bottom and the sides of the wear member). Each arm 191a-191c can be opened and shut so that the side arms 191b and 191c move from side to side and move closer and farther apart from each other and the bottom arm 191a moves up and down. The arms may be moved via a motor or may be moved hydraulically. The arms 191a-191c are spaced far enough apart so that when the arms are in the open position the wear member fits within the opening provided by the arms and are likewise spaced close enough to each other so that when the wear member is within the opening the arms fully contact and engage the wear member. Each arm 191a-191c additionally may have an adjustable surface <NUM> to contact the wear member <NUM>. Adjustable surface <NUM> allows the arms 191a-191c to better contact the varying surfaces of the wear member. In addition the adjustable surface <NUM> allows the arms 191a-191c to better contact a worn wear member.

The multi-arm tool <NUM> can be combined with a second auxiliary tool in the form of a removal tool <NUM> to create a combined tool <NUM> that both secures the wear member <NUM> and that can remove the securement mechanism from the wear member <NUM>. This operation can also be accomplished by a single auxiliary tool with multiple capabilities. In the illustrated embodiment, the removal tool <NUM> is provided with an adjustment mechanism <NUM> that only adjust the position of the removal tool <NUM> without adjusting the overall position of the manipulator <NUM> (i.e., the manipulator has fine control). Although the adjustment mechanism <NUM> is only shown in the embodiment shown in <FIG> and <FIG>, the adjustment mechanism <NUM> may be applied to any of the various auxiliary tools <NUM> used in the removal and installation process. The adjustment mechanism <NUM> provides the removal tool <NUM> with two or more degrees of freedom so that the removal tool <NUM> can move from side to side and up and down without adjusting the position of the manipulator arm <NUM>. The removal tool <NUM> is shown as having a hex tool <NUM>, though other tools are possible, to remove the securement mechanism. Combining the multi-arm tool <NUM> with the removal tool <NUM> allows one tool <NUM> to be used to remove the worn wear member and install the new wear member. An auxiliary tool in the form of a combined tool <NUM> may combine any of the various auxiliary tools <NUM> that secures the wear member and any of the various auxiliary tools <NUM> that removes and installs the securement mechanism from the wear member. In addition the auxiliary tool as a combined tool <NUM> may combine more than two auxiliary tools together (e.g., the combined tool may have an auxiliary tool to secure the wear member, an auxiliary tool to remove fines, and an auxiliary tool to remove the securement mechanism).

A magnetic strap <NUM> may secure the wear member to the base (<FIG>). The magnetic strap <NUM> may be made of at least one air actuated permanent magnet <NUM>. At least one air actuated permanent magnet <NUM> may be secured to the worn wear member <NUM> and another air actuated permanent magnet <NUM> may be secured to the base <NUM> and both of the air actuated permanent magnets <NUM> may be secured to each other, for example, with a metal strap <NUM>. The magnetic strap <NUM> may be applied manually or may be applied with the manipulator <NUM>. The air actuated permanent magnets <NUM> may, for example, be Optimag Pneumatic Lifting Magnets, SAV <NUM> NEO-AIR <NUM> magnets, SCHUNK Lifting Magnets MHM-P, or similar commercially available air actuated permanent magnets.

Two (or more) manipulators <NUM> (not shown) may be used. A first manipulator can be used to secure the wear member <NUM> from falling and a second manipulator can be used to disengage the wear member <NUM> from the excavator (not shown). The first manipulator may use a tool such as an air actuated permanent magnet <NUM> to secure the wear member <NUM> (<FIG>). The controller <NUM> drives the manipulator <NUM> and the air actuated permanent magnet <NUM> to the programmed location X just above the wear member <NUM>. Next, the manipulator <NUM> and air actuated permanent magnet <NUM> can be driven further toward the wear member <NUM> until the force feedback on the manipulator <NUM> registers a spike in force. The air actuated permanent magnet <NUM> can then be engaged to secure the wear member <NUM>.

A cartridge <NUM> may be used to secure the wear member <NUM> (<FIG>). The cartridge <NUM> has a top wall <NUM>, bottom wall <NUM>, and two opposing sidewalls (<NUM>, <NUM>) extending between the top wall <NUM> and the bottom wall <NUM>. Guides or locators <NUM> on the interior surface <NUM> of the cartridge <NUM> may assist in properly positioning the wear member <NUM> within the cartridge <NUM>. The locators may be an additional piece secured to one of the walls or the locator may be an integral part of one of the walls. The locators may be sensors that indicate when the wear member is properly positioned within the cartridge. The locators <NUM> may be on the interior surface <NUM> of the top wall <NUM>, the bottom wall <NUM>, the first sidewall <NUM>, the second sidewall <NUM>, or a combination thereof. In addition to the cartridge <NUM> being able to house a worn wear member <NUM> for removal, storage, and shipment; the cartridge <NUM> may also be used to house new wear members <NUM> for shipment, storage, and installation (<FIG>). However, the cartridge may only be used for housing worn wear members, or may only be used for housing new wear members. The uniform shape of the cartridge <NUM> allows the wear member <NUM> to be stored and shipped more easily. The locators <NUM> may be, for example, hollow so that studs <NUM> may be inserted into the locators <NUM>. The studs <NUM> may have a resilient member so that the studs may be pushed further into the locators when the studs <NUM> engage the wear member <NUM>. In an alternative embodiment not shown, the locators <NUM> may be resilient so that the locators engage the wear member as the wear member is inserted into the cartridge. For example, the locator may be a cutout of a part of one of the walls of the cartridge so that the cutout creates a tab that extends into the cavity of the cartridge to engage the wear member (not shown). The worn wear member <NUM> may be stud welded, or otherwise secured <NUM>, to the studs <NUM> and/or the locators <NUM> for additional support, but this is not a requirement and the studs or locators may be sufficient to hold the wear member in position. The stud weld <NUM> may be performed by an operator or may be performed using the manipulator <NUM>. The walls <NUM>, <NUM>, <NUM>, and <NUM> of the cartridge <NUM> may be provided with at least one attachment mechanism <NUM> for securing the cartridge <NUM> to a lifting device. The attachment mechanism may, for example, be a lifting eye, an air actuated permanent magnet, or one or more holes in, e.g. the sidewalls <NUM>, <NUM>. The lifting device, for example, may be a hoist or manipulator <NUM>. In an alternative embodiment, the earth moving equipment may be brought to the cartridge <NUM>. The walls <NUM>, <NUM>, <NUM>, and <NUM> of the cartridge <NUM> may have an opening <NUM> so that the securement mechanism <NUM> between the wear member <NUM> and the base <NUM> is accessible once the cartridge <NUM> is installed on the wear member <NUM>. The attachment mechanism <NUM> may also be used for lifting the cartridge <NUM>, for rotating the cartridge <NUM>, for pulling the cartridge <NUM>, or for pushing the cartridge <NUM>. An attachment mechanism <NUM> that can be lifted, pulled, or pushed allows a wear member <NUM> secured within the cartridge <NUM> to be installed and removed from the base <NUM> while being secured to the manipulator <NUM>. The cartridge <NUM> in combination with the attachment mechanism <NUM> may eliminate the need for a lifting eye on the wear member <NUM>. Eliminating the lifting eye on wear member <NUM> could minimize the manufacturing rejects of wear members <NUM>. In an alternative embodiment, at least one attachment mechanism <NUM> is provided for securing the cartridge <NUM> and at least one additional attachment mechanism <NUM> is provided for lifting, pulling, and pushing.

Multiple cartridges <NUM> and new wear members <NUM> could be housed, stored, shipped, and transported in a storage stall <NUM> from the time the wear members <NUM> leave manufacturing to the time the wear members <NUM> are installed on the excavating equipment <NUM>. Multiple cartridges <NUM> and worn wear members <NUM> could be housed, stored, shipped, and transported in a storage stall <NUM> from the time the wear members <NUM> are removed from the excavating equipment <NUM> to the time the wear members <NUM> are refurbished, reclaimed, or scrapped. In an alternative embodiment, the cartridges <NUM> may be placed within a storage stall <NUM> in a magazine formation so that when one cartridge is taken from the storage stall the remaining cartridges slide to a new location such that a new cartridge is ready for removal from the storage stall <NUM> (<FIG>). Once a cartridge <NUM> is used to remove a worn wear member <NUM>, the cartridge <NUM> with the worn wear member <NUM> may be placed back in the same storage stall <NUM> or may be placed in a different storage stall <NUM> (<FIG>).

Alternatively, one manipulator with a first arm to secure the wear member <NUM> from falling and a second arm to disengage the wear member <NUM> from the excavator may be used (not shown). The first arm may use a multi-jaw gripper <NUM> to secure the wear member <NUM> to the manipulator (<FIG>). The multi-jaw gripper <NUM> can have two outer arms <NUM> that oppose each other. Each outer arm <NUM> has a wedge <NUM> that extends from an inner surface <NUM> and along the rear surface <NUM> of each arm <NUM>. Each outer arm <NUM> has an inner wedge <NUM> that can slide along the inner surface <NUM>. A cavity <NUM> extends between the outer arm <NUM> and the inner wedge <NUM>. A sliding mechanism <NUM> is inserted into each cavity <NUM>. The sliding mechanism may be, for example, a screw, a pneumatic cylinder, or a hydraulic cylinder. Each outer arm <NUM> is secured to a support <NUM> that extends between each opposed outer arm <NUM>. A cavity <NUM> extends from one outer arm <NUM> through the support <NUM> and through the other outer arm <NUM>. A sliding mechanism <NUM> is inserted into the cavity <NUM> so that the opposing arms are able to slide together and apart. To attach the multi-jaw gripper <NUM> to a wear member <NUM> the manipulator <NUM> slides the outer arms <NUM> apart from each other and the manipulator <NUM> slides the inner wedges <NUM> away from the from the rear surface <NUM>. The manipulator places the multi-jaw gripper <NUM> over the wear member <NUM> and slides the opposed outer arms <NUM> together so that each rear surface <NUM> and each wedge <NUM> fits between the wear member <NUM> and the base <NUM>. In this position each rear surface <NUM> abuts the base <NUM> and the wedge <NUM> abuts the wear member. Next the manipulator <NUM> slides each inner wedge <NUM> towards the rear surface <NUM> until the inner wedges <NUM> abut the front end <NUM> of the wear member <NUM>. Wear member <NUM> is now secured and ready for the securement mechanism <NUM> to be removed from the wear member <NUM>.

If the mining excavator <NUM> is used in an environment that creates fines that build up between the wear member <NUM> and the base <NUM> and the area surrounding the securement mechanism <NUM>, an auxiliary tool <NUM> for dislodging the fines may be utilized. The auxiliary tool may be used manually by an operator or may be used with the manipulator <NUM>. For example, a common tool currently used in the mining industry for removing fines may be utilized. The common tool may be, for example, a pneumatic needle scaler (not shown) or may be a pressure washing system. For example, a nozzle <NUM> for a pressure washing system <NUM> may be provided that attaches to the manipulator <NUM> (<FIG>). The pressure washing system <NUM> is shown as having one nozzle <NUM>, but may have more than one nozzle <NUM>. The pressure washing system <NUM> may use a cleaning agent such as air with or without suspended abrasive grains or water to remove the fines. In an alternative embodiment, the pressure washing system <NUM> may utilize a ring nozzle <NUM> with many inwardly facing orifices <NUM> around the ring to deliver the cleaning agent (<FIG>). The ring nozzle <NUM> creates a sheet of cleaning agent around the wear member <NUM>. The ring may be provided with a securement fixture <NUM> for fixing the ring to a tool changer <NUM> (<FIG>). The manipulator <NUM> may sweep the ring nozzle <NUM> along the longitudinal axis of the wear member <NUM>. In an alternative embodiment, the pressure washing system <NUM> may utilize a frame <NUM> with a sliding carriage <NUM> mounted to the frame <NUM> (<FIG>). The sliding carriage would be able to slide back and forth along the frame <NUM> as the cleaning agent is dispersed from the nozzle <NUM> on the sliding carriage <NUM>. The frame <NUM> may be provided with a securement fixture (not shown) similar to the securement fixture <NUM> used with the ring nozzle <NUM> in <FIG>. The manipulator may sweep the frame <NUM> along the longitudinal axis of the wear member <NUM>.

A vibrator <NUM> may be used to dislodge the fines from the wear member <NUM>. For example, the manipulator <NUM> may be used to lower a vibrator <NUM> onto the worn wear member <NUM> with a winch <NUM> (<FIG>). The vibrator <NUM> is isolated so that the vibrations do not cause damage to the manipulator <NUM>. In alternative embodiments not shown, the tool may not have a winch <NUM> and the vibrator <NUM> may be isolated from the manipulator <NUM>, for example, with an air spring or a rubber bladder to ensure the vibrations do not damage the manipulator <NUM>. The vibrator <NUM> may be a CDX Explosion Proof Electric Vibrator or similar commercially available vibrators. At least one air actuated permanent magnet <NUM> may be mounted to the vibrator <NUM> with a swivel mount <NUM>. The air actuated permanent magnet <NUM> may be an Optimag Pneumatic Lifting Magnet, SAV <NUM> NEO-AIR <NUM>, SCHUNK Lifting Magnet MHM-P, or similar commercially available air actuated permanent magnet. The swivel mount <NUM> allows the air actuated permanent magnet <NUM> to orient to the wear members <NUM> outer surface.

To disengage the retainer, or lock, <NUM> between the wear member <NUM> and the base <NUM>, the manipulator <NUM> may utilize an auxiliary tool <NUM> to attach a gripping member or piece <NUM> to the retainer <NUM>. For example, the manipulator <NUM> and an auxiliary tool <NUM> to attach gripping member <NUM> to the lock <NUM> are driven to a programmed location just above the wear member <NUM>. The programmed location may be manually input via user input device as outlined above, or may be determined via receivers and bucket geometry as outlined above. Next the manipulator <NUM> is driven further toward the wear member <NUM> along the axis of the lock <NUM> until the force feedback on the manipulator <NUM> registers a spike in force indicating that the auxiliary tool <NUM> is touching the wear lock <NUM>. The auxiliary tool <NUM> then attaches gripping piece <NUM> to the lock <NUM>. Attaching a piece to the lock <NUM> allows the manipulator <NUM> to not require precise alignment with the lock <NUM> for removal. The gripping piece may have a variety of different shapes and may be, for example, a cylindrical stud, a splined stud with a ring groove, a T-shaped stud, an L-shaped stud, or a bladed stud. The manipulator <NUM> may switch to another auxiliary tool <NUM> to remove the lock. The auxiliary tool <NUM> for attaching piece <NUM> may be, for example, a stud welder <NUM>, and the auxiliary tool <NUM> to remove the lock <NUM> may be, for example, an pneumatic or hydraulic wrench <NUM> matching the shape of the stud <NUM> (<FIG>). The gripping member <NUM> can also be attached by mechanical means. In the given example, the lock <NUM> has a threaded pin which can be released by turning the pin with the pneumatic or hydraulic wrench. Other attachments or auxiliary tools could be used for other kinds of locks. The manipulator <NUM> may switch to another auxiliary tool <NUM> and go back to the programmed location of the piece or stud <NUM> to grip the stud <NUM> and dispose of the lock <NUM> in a disposal stall <NUM> located on the service vehicle <NUM> or in the service station <NUM>.

The auxiliary tool <NUM> matching the shape of the lock opening <NUM> may be attached to the manipulator <NUM>. Force control on the manipulator <NUM> and an algorithm may be used to find the opening <NUM> in the lock <NUM>. For example, the manipulator <NUM> and a hex tool <NUM>, that matches the shape of the lock opening <NUM>, can be driven to a programmed location X just above the wear member <NUM> (<FIG>). The programmed location X may be manually input via a user input device or may be determined via receivers and bucket geometry as outlined above. Next the manipulator <NUM> is driven further toward the wear member <NUM> along the axis of the lock <NUM> until the force feedback on the manipulator <NUM> registers a spike in force indicating that the hex tool <NUM> is touching the wear member <NUM>. The manipulator <NUM> continues to move in a variable, generally circular pattern on a plane normal to a longitudinal axis of the lock <NUM> until the force drops indicating that the hex tool <NUM> is in at least partial alignment with the lock opening <NUM>. The manipulator <NUM> may rotate the hex tool <NUM> to assist in aligning the hex tool <NUM> within the lock opening <NUM>. The manipulator <NUM> continues to move in a variable, generally circular pattern on a plane normal to the longitudinal axis of the lock <NUM> until the force again drops indicating that the hex tool <NUM> is further aligned with the lock opening <NUM>. The manipulator <NUM> continues this pattern until the hex tool <NUM> is in complete alignment with the lock opening <NUM>. The manipulator <NUM> rotates the hex tool <NUM> in order to back the lock <NUM> out of opening <NUM>. If the lock <NUM> cannot be maintained within the wear member <NUM> in a release position, the manipulator <NUM> may switch to another auxiliary tool <NUM> such as a suction cup (not shown) or an air actuated permanent magnet <NUM> (<FIG>) to grip the lock <NUM> for disposal. The suction cup or air actuated permanent magnet <NUM> is driven to the programmed location X just above the lock <NUM>. Next the manipulator <NUM> is driven further toward the wear member <NUM> until the force feedback on the manipulator <NUM> registers a spike in force. The suction cup or air actuated permanent magnet <NUM> is then engaged to grab the lock <NUM> for disposal of the lock <NUM> in a disposal stall <NUM> located on the service vehicle <NUM> or in the service station <NUM>.

The manipulator <NUM> may utilize an auxiliary tool <NUM> to cut the lock <NUM>. The lock <NUM> may be completely cut up or only the parts of the lock <NUM> may be cutoff. The cutter <NUM> may be moved by the manipulator <NUM> so that the cutter <NUM> cuts an inverse frustoconical path <NUM> so that only the lock <NUM> and wear member <NUM> are cut (<FIG> and <FIG>). The base <NUM> remains uncut so that the base <NUM> does not need to be replaced. In an alternative embodiment only the lock <NUM> is cut. The inverse frustoconical motion path may, for example, converge in a key way void <NUM> of the base <NUM>. The cutter <NUM> may be an electric air arc torch, a waterjet cutter, or laser. If the entire lock <NUM> is not cut up the manipulator <NUM> may switch to another auxiliary tool <NUM>, for example a suction cup (not shown) or a magnet <NUM> (<FIG>), to remove and dispose of the lock <NUM> in a disposal stall <NUM> located on the service vehicle <NUM> or in the service station <NUM>. Other auxiliary tools to remove other kinds of retainers or locks can be used as well.

To disengage the worn wear member <NUM> from the base <NUM> the manipulator <NUM> may first utilize an auxiliary tool <NUM> to attach at least one gripping piece <NUM> to the worn wear member <NUM>. For example, the manipulator <NUM> and an auxiliary tool <NUM> to attach <NUM> to the wear member <NUM> are driven to a programmed location just above the wear member <NUM>. The programmed location may be manually input via a user input device or may be determined via receivers and bucket geometry as outlined above. Next the manipulator <NUM> is driven further toward the wear member <NUM> until the force feedback on the manipulator <NUM> registers a spike in force indicating that the auxiliary tool <NUM> is touching the wear member <NUM>. The auxiliary tool <NUM> then attaches at least one piece <NUM> to the wear member <NUM>. The auxiliary tool <NUM> may attach one piece <NUM> to each side of the wear member (<FIG>). The auxiliary tool <NUM>, for example, may be a stud welder <NUM> (<FIG>). The gripping member can also be mechanically attached to the wear member such as by clamp inserted into the lock opening or a component of the lock (e.g., an expansion clamp as sold by Pascal Corporation of Itami, Hyogo, Japan). The manipulator <NUM> may then switch to another auxiliary tool <NUM> and go back to the programmed location of the new piece(s) or stud(s) <NUM> to grip the stud(s) <NUM>. The manipulator <NUM> would pull on the stud(s) <NUM> along a longitudinal axis of the base <NUM> to pull the worn wear member <NUM> off of the base <NUM>. In an alternative embodiment, the auxiliary tool <NUM> may also attach gripping pieces <NUM> to the base <NUM> (not shown). Attaching pieces <NUM> to the base <NUM> allows the auxiliary tool <NUM> to leverage against the new pieces <NUM> on the base <NUM> and the wear member <NUM> to pull the wear member <NUM> off of the base <NUM>. The manipulator <NUM> would then dispose of the worn wear member <NUM> in a disposal stall <NUM> located on the service vehicle <NUM> or in the service station <NUM>. The disposal stall <NUM> may have fixtures or jigs (not shown) to support the worn wear member <NUM> so that the parts are maintained in a fixed location.

The worn wear member <NUM> may be disengaged from the base <NUM> by the manipulator <NUM> pulling the cartridge <NUM> or the multi-jaw gripper <NUM> along the longitudinal axis of the base <NUM>.

The worn wear member <NUM> may initially be disengaged from the base <NUM> using a vibrator <NUM>. The vibrator <NUM> may be similar to the vibrator <NUM> discussed above for removing fines (<FIG>). After the initial separation, the manipulator <NUM> may switch to another auxiliary tool <NUM>, for example, an air actuated permanent magnet <NUM> similar to the air actuated permanent magnet <NUM> used to grip the lock for disposal (<FIG>). The air actuated permanent magnet <NUM> is driven to the programmed location X just above the wear member <NUM>. Next the manipulator <NUM> is driven further toward the wear member <NUM> until the force feedback on the manipulator <NUM> registers a spike in force. The air actuated permanent magnet <NUM> is then engaged to grab the worn wear member <NUM>. The manipulator <NUM> pulls the air actuated permanent magnet <NUM> and wear member <NUM> along the longitudinal axis of the base <NUM> to back the worn wear member <NUM> off of the base <NUM> for disposal of the wear member <NUM> in a disposal stall <NUM> located on the service vehicle <NUM> or in the service station <NUM>.

Once the worn wear member <NUM> has been removed from the base <NUM>, fines on the base <NUM> may need to be removed prior to installing a new wear member <NUM>. Various auxiliary tools for removing fines exist and the tools may be used manually by an operator or may be used with the manipulator <NUM>. For example, a common tool currently used in the mining industry for removing fines may be utilized. The common tool may be, for example, a pneumatic needle scaler (not shown) or may be a pressure washing system <NUM> or vibrator <NUM> as previously discussed (<FIG>, <FIG>).

Each new wear member <NUM> (i.e., the wear member to be installed whether it is new or partially used) is located in a specific location on the storage stalls or pallet <NUM>. Each new wear member <NUM> may be located on a fixture or jig <NUM> in a fixed orientation (<FIG>). In an alternative embodiment, each new wear member <NUM> may be located in a cartridge <NUM> in a specific fixed orientation and position on the pallet <NUM>. Each pallet <NUM> is located in a specific fixed location relative to the manipulator <NUM>. When the base <NUM> is ready for a new wear member <NUM> to be installed the controller <NUM> can use the programmed location of the pallet <NUM> and the programmed location of the new wear member <NUM> on the pallet to maneuver the manipulator <NUM> to the new wear member <NUM>. In an alternative embodiment, an operator may use a controller in the form of a user input device (not shown) to maneuver the manipulator <NUM> to the new wear member <NUM>.

The manipulator <NUM> may use an auxiliary tool <NUM> to rigidly grip the new wear member <NUM>. The auxiliary tool <NUM> may be, for example, a custom tool <NUM> that rigidly grips a lifting eye <NUM> on the wear member <NUM> (<FIG>). The custom tool <NUM>, may for example, consist of a U-bolt <NUM> that is threaded <NUM> on both ends and is passed laterally through a lifting eye <NUM> on the wear member <NUM>, a double-wedge block <NUM> with lateral flanges <NUM> and holes <NUM> that align with the U-bolt <NUM>, and two nuts <NUM> to be threaded onto the ends of the U-bolt <NUM>. The double-wedge block <NUM> is placed over the U-bolt so that the ends of the U-bolt <NUM> enter the holes <NUM> on the double-wedge block <NUM>. The nuts <NUM> are threaded on the ends of the U-bolt <NUM> to tighten the double-wedge block <NUM> against the lifting eye <NUM>. Once the nuts <NUM> have been completely tightened the custom tool <NUM> eliminates lateral and fore/aft movement of the wear member <NUM> while lifting, orienting, and positioning the wear member <NUM>. The double-wedge block <NUM> may have a surface <NUM> for attaching a tool changer <NUM> (<FIG>) so that the custom tool <NUM> may be used with a manipulator <NUM>. In an alternative embodiment (not shown), a sandwich clamping mechanism in combination with tripod stabilizing pivot feet may be used to rigidly grip the wear member <NUM>. The pivot feet may, for example, utilizing pneumatic, hydraulic, or electric cylinders.

With the new wear member <NUM> rigidly secured to manipulator <NUM> the controller <NUM> maneuvers the new wear member <NUM> back to the programmed location of the base <NUM>. Because the manipulator <NUM> picked the wear member <NUM> up in a fixed orientation and because the custom tool maintains the wear member <NUM> in a fixed orientation the controller <NUM> can orient the wear member <NUM> to fit on the base <NUM>. The manipulator <NUM> pushes the new wear member <NUM> onto the base <NUM>. To ensure that the wear member <NUM> is fully seated on the base <NUM> the controller <NUM> compares the current location of the lock opening <NUM> on the new wear member <NUM> with the programmed removal location of the lock <NUM> on the worn wear member <NUM>. In an alternative embodiment, a visual check is performed. The visual check may be performed by an operator or may be performed by a 2D vision camera (not shown). Cameras (not shown) may be located on the manipulator <NUM> to assist the operator in the visual check.

The manipulator <NUM> may grip an attachment mechanism <NUM> on the cartridge <NUM> to lift the cartridge <NUM> from the pallet. Since the wear member <NUM> has a fixed orientation within the cartridge <NUM> and the cartridge <NUM> has a fixed orientation and location on the pallet <NUM> the controller <NUM> can rotate and orient the cartridge <NUM> and the wear member <NUM> within the cartridge <NUM> to fit on the base <NUM>. While the manipulator <NUM> is secured to the attachment mechanism <NUM>, the manipulator <NUM> pushes the new wear member <NUM> onto the base <NUM> until the wear member <NUM> is fully seated on the base <NUM>. Spring pins <NUM> may be installed in the guides or locators <NUM> within the cartridge <NUM> (<FIG>). The spring pins <NUM> may engage detents in the new wear member <NUM> to keep the wear member <NUM> in the cartridge <NUM>. The spring pins <NUM> engage the wear member <NUM> until the securement mechanism <NUM> is in place between the wear member <NUM> and the base <NUM> and at which point the spring pins <NUM> are released and the new wear member <NUM> is disengaged from the cartridge <NUM>.

Once the new wear member <NUM> is fully seated on the base <NUM> the controller <NUM> locates the new retainer <NUM>. The controller <NUM> may be programmed with the type of wear member <NUM> being installed and be programmed with the geometry of the new wear member <NUM>. Based on the programmed geometry of the wear member <NUM>, the manipulator <NUM> may determine where the retainer <NUM> needs to be located on the wear member <NUM>. If the new retainer <NUM> is integrated with the wear member <NUM> the controller <NUM> maneuvers the manipulator <NUM> to the appropriate location on the wear member <NUM>. If the retainer <NUM> is not integrated with the wear member <NUM>, the controller <NUM> maneuvers the manipulator <NUM> to the service stall <NUM>. The retainer <NUM>, like the wear member <NUM>, may be located on the pallet <NUM> in a fixed location and orientation. In an alternative embodiment, an operator may use a user input device (not shown) to maneuver the manipulator <NUM> to the retainer <NUM>.

To engage the retainer, or lock,<NUM> between the wear member <NUM> and the base <NUM>, an auxiliary tool <NUM> matching the shape of the lock opening <NUM> may be attached to the manipulator <NUM>. For example, as discussed above, force control on the manipulator <NUM> and an algorithm may be used to place the hex tool <NUM> in the lock opening <NUM> (<FIG>). Once the hex tool <NUM> is fully seated in the lock opening <NUM> the hex tool spins the lock to fully secure the wear member <NUM> to the base <NUM>. In the present example, the hex tool <NUM> can be used to drive the lock <NUM> into the lock opening <NUM> to hold the lock <NUM> in a hold position to secure the point to the base. In a wear member with an integrated lock, the lock can be in a determined location by the controller still holding the wear member on the base.

Claim 1:
A mining system including
(i) an earth working equipment (<NUM>) having at least a wear member (<NUM>) to work the ground, a base (<NUM>) supporting the wear member (<NUM>), and a retainer (<NUM>) holding the wear member (<NUM>) to the base (<NUM>), and
(ii) a tool (<NUM>), the tool (<NUM>) comprising:
- at least one auxiliary tool (<NUM>) to hold the wear member (<NUM>) mounted on the earth working equipment (<NUM>),
- a single manipulator (<NUM>) movably supporting the at least one auxiliary tool (<NUM>), wherein the manipulator (<NUM>) and the at least one auxiliary tool (<NUM>) cooperate to remove the wear member (<NUM>) from the earth working equipment (<NUM>),
- a controller (<NUM>) to direct the movements of the at least one auxiliary tool (<NUM>) and the manipulator (<NUM>),
- a mobile base (<NUM>) to move the manipulator and the at least one auxiliary tool (<NUM>) from one location to a second location close to the earth working equipment (<NUM>), wherein the tool (<NUM>) can be used throughout a mine and moved to convenient locations to accommodate the removal of wear members from earth working equipment usable in different location,
characterized in that
- the at least one auxiliary tool (<NUM>) is arranged to release the retainer (<NUM>) and
- the manipulator (<NUM>) and the at least one auxiliary tool (<NUM>) cooperate to release the retainer (<NUM>).