Patent Description:
In many current applications, dippers are used on heavy equipment such as electric rope shovels and the like. These dippers may become worn or cracked due to the harsh environment in which they are used. Also, the digging performance for these dippers may depend on the type of material being moved.

In particular, oilsands applications are known to require maintenance on dippers due to heel wear and digging performance has proven to be less than desirable. In order to replace the dipper, the dipper must be removed from the machine with worn components being replaced. Alternatively, a whole new dipper is required. This requires undesirable extended downtime for the machine and added cost for the new dipper component(s).

Various dipper configurations are known in the art including the dipper configuration disclosed in <CIT>. The '<NUM> patent discloses a dipper for a mining shovel that includes a back wall, a first side wall extending from the back wall, a second side wall extending from the back wall, a front wall disposed opposite the back wall and extending between the first and second side walls, and a dipper door pivotally coupled to a bottom end of the dipper. The dipper door is movable between a latched and an unlatched position relative to the dipper. The dipper door is angled relative to the front wall at an acute angle when the dipper door is in the latched position.

However, nothing in the '<NUM> patent addresses digging performance or preventing heel wear of a dipper in abrasive environment such as an oilsands application.

<CIT> describes a bucket shape which reduces the wear of the heel portion of the bucket by using a multiple radius to define the shape and profile.

Accordingly, there is a need to develop a dipper that has a better digging performance, and less heel wear than has heretofore been devised.

A dipper lip according to the present disclosure comprises a first side wing, a second side wing, a rear attachment portion that spans from the first side wing and the second side wing, and a front shovel portion that extends from the first side wing to the second side wing. The dipper lip defines a midplane disposed between the first side wing, and the second side wing. Also, the front shovel portion defines a top shovel surface, while the rear attachment portion forms a top rear surface. The top shovel surface forms an obtuse angle with the top rear surface in the midplane.

A dipper according to the present disclosure comprises a top wall, a first side wall extending from the top wall, a second side wall extending from the top wall, a bottom floor extending from the first side wall to the second side wall, and a dipper lip as described above.

The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate several embodiments of the disclosure and together with the description, serve to explain the principles of the disclosure. In the drawings:.

Reference will now be made in detail to embodiments of the disclosure, examples of which are illustrated in the accompanying drawings. In some cases, a reference number will be indicated in this specification and the drawings will show the reference number followed by a letter for example, 100a, 100b etc. It is to be understood that the use of letters immediately after a reference number indicates that these features are similarly shaped and have similar function as is often the case when geometry is mirrored about a plane of symmetry. For ease of explanation in this specification, letters will often not be included herein but may be shown in the drawings to indicate duplications of features discussed within this written specification.

Various embodiments of the present disclosure include a dipper lip or a dipper that may use various angles to reduce heel wear and/or improve digging performance in abrasive environments such as oilsands applications.

Referring to <FIG>, there is shown a machine <NUM> having a carbody102 (which may include a turntable <NUM>) with a track system including a first track chain 104a and a second track chain 104b positioned at opposite sides of carbody102. Machine <NUM> is shown in the context of an electric rope shovel having an operator cab <NUM>, a boom <NUM>, a lower end <NUM> of the boom <NUM> (also called a boom foot), an upper end <NUM> of the boom <NUM> (also called a boom point), tension cables <NUM>, a gantry tension member <NUM>, a gantry compression member <NUM>, a sheave <NUM> rotatably mounted on the upper end <NUM> of the boom <NUM>, a dipper <NUM>, a dipper door <NUM> pivotally coupled to the dipper <NUM>, a hoist rope <NUM>, a winch drum (not shown), and a dipper handle <NUM>. An electric motor controls the winch drum, causing the lowering or raising of the boom, dipper, and upward and downward movement of the dipper handle relative to the boom.

Tracks 104a and 104b are part of a machine undercarriage <NUM> coupled with carbody <NUM> in a conventional manner. Each of tracks 104a and 104b include a plurality of coupled together track shoes forming endless loops extending about a plurality of rotatable elements. In a typical design, an idler <NUM> and a drive sprocket <NUM> will be associated with each of tracks 104a and 104b and mounted to a track roller frame <NUM>. A plurality of track rollers <NUM> may also be mounted to roller frame <NUM>, and are associated with each of tracks 104a and 104b to support machine <NUM> and guide tracks 104a and 104b in desired paths, as further described herein. One or more carrier rollers <NUM> (or track sliders as will be discussed momentarily herein) may also be associated with each of tracks 104a and 104b to support and guide the tracks opposite rollers <NUM> during operation.

The unique design of tracks 104a and 104b and the overall track and undercarriage system of which they are a part are contemplated to enable machine <NUM> to operate in certain environments such as oilsands. While use in the machine environment of an electric roper shovel and dipper is emphasized herein, it should be understood that machine <NUM> might comprise a different type of machine. For instance, track-type tractors or even half-track machines are contemplated herein. Further still, machine <NUM> might consist of a conveyor or other type of machine wherein tracks are used for purposes other than as ground engaging elements. Also, the machine might be some type of hydraulic shovel, bulldozer, excavator, back hoe, etc..

The dipper <NUM> is suspended from the boom <NUM> by the hoist rope <NUM>. The hoist rope <NUM> is wrapped over the sheave <NUM> and attached to the dipper <NUM> at a bail <NUM>. The hoist rope <NUM> is anchored to the winch drum (not shown). The winch drum is driven by at least one electric motor (not shown) that incorporates a transmission unit (not shown). As the winch drum rotates, the hoist rope <NUM> is paid out to lower the dipper <NUM> or pulled in to raise the dipper <NUM>. The dipper handle <NUM> is also coupled to the dipper <NUM>. The dipper handle <NUM> is slidably supported in the saddle block <NUM>, and the saddle block <NUM> is pivotally mounted to the boom <NUM> at the shipper shaft (not clearly shown). The dipper handle <NUM> includes a rack and tooth formation thereon that engages a drive pinion (not shown) mounted in the saddle block <NUM>. The drive pinion is driven by an electric motor and transmission unit (not shown) to extend or retract the dipper handle <NUM> relative to the saddle block <NUM>.

An electrical power source (not shown) is mounted to the carbody102 to provide power to a hoist electric motor (not shown) for driving the hoist drum, one or more crowd electric motors (not shown) for driving the crowd transmission unit, and one or more swing electric motors (not shown) for turning the turntable <NUM>. In some cases, one electric motor powers all of the moving components of the shovel. Each of the crowd, hoist, and swing motors is driven by its own motor controller, or is alternatively driven in response to control signals from a controller (not clearly shown).

The track chains 104a and 104b are considered to be well suited for work in hard underfoot conditions. To this end, the track chains 104a and 104b may be "high ground pressure" tracks, each having track members durable enough to support a relatively large weight of machine <NUM>. Each of track shoe members has a footprint defined in part by front and back edges, and also defined in part by outboard edges and inboard edges. Each of track shoe members may further include a ground contact area that is equal to its footprint, or less than its footprint only to an extent that adjacent track shoes overlap one another or due to voids disposed on the bottom surface of the track shoe member. Other configurations of the track shoes and track chain assemblies are possible in other embodiments of the present disclosure.

Looking at <FIG> and <FIG>, a dipper bucket according to an embodiment of the present disclosure may comprise a top wall <NUM>, a first side wall <NUM> extending from the top wall <NUM>, a second side wall 206a extending from the top wall <NUM>, and a bottom floor <NUM> extending from the first side wall <NUM> to the second side wall 206a. A dipper lip <NUM> may be attached to the bottom floor as well as the side walls. The dipper lip <NUM> may include a front shovel portion <NUM> (may also be referred to as a front scoop portion). In some embodiments, this front shovel portion may be essentially horizontal when the top wall is horizontal, improving digging performance.

In a midplane <NUM> (may also be a plane of symmetry) that is perpendicular to the top wall <NUM> and the bottom floor <NUM>, the front shovel portion <NUM> may form an external angle <NUM> (i.e., this angle is located outside of the dipper) with the bottom floor <NUM> that is greater than <NUM> degrees. For example, this angle may range from <NUM> degrees to <NUM> degrees (e.g., may actually be about <NUM> degrees to <NUM> degrees) in some embodiments. Providing this angle may reduce the wear on the heel <NUM> of the dipper. Other angular ranges are possible in other embodiments of the present disclosure.

Also, the dipper lip <NUM> includes a rear attachment portion <NUM> (so called since this part of the lip is a rear portion used to attach the lip to the dipper) that forms a first oblique angle <NUM> with the front shovel portion <NUM>. Similarly, the rear attachment portion <NUM> of the dipper lip <NUM> may form a second oblique angle <NUM> with the bottom floor <NUM> of the dipper. The first oblique angle may have a slightly different value than the second oblique angle, but not necessarily so.

As best seen in <FIG> the top wall <NUM> of the dipper, and the front shovel portion <NUM> of the lip are substantially parallel with each other (i.e., +/- <NUM> degrees), while the rear edge <NUM> of the first or the second side wall of the dipper may be substantially perpendicular to the bottom floor <NUM> of the dipper (i.e., +/-<NUM> degrees), but not necessarily so.

Another embodiment of the dipper <NUM>, may be described as follows with continued reference to <FIG> and <FIG>. In the midplane <NUM>, (i.e., the sectioned plane shown in <FIG>), the bottom floor <NUM> may form a first acute angle <NUM> (may be the same as the heel angle) with the top wall <NUM> that ranges from <NUM> degrees to <NUM> degrees in some embodiments such that the dipper <NUM> forms a mouth (see dotted lines <NUM>) that narrows toward a rear of the dipper <NUM>.

More specifically, the first acute angle <NUM> may range from <NUM> degrees to <NUM> degrees in some embodiments of the present disclosure. In other embodiments of the present disclosure, the first acute angle <NUM> may range from <NUM> degrees to <NUM> degrees (e.g., about <NUM> degrees). Other ranges are possible in other embodiments of the present disclosure.

As alluded to earlier herein, a rear edge <NUM> may be defined by the top wall <NUM>, the first sidewall <NUM>, and the second sidewall 206a. A dipper door <NUM> (see also <FIG>) may be pivotally attached to the dipper at the top wall <NUM> (e.g., at rear pivot points <NUM> in <FIG> and <FIG>) that is configured to contact the rear edge <NUM>. This may not be the case in other embodiments of the present disclosure.

A front lip (e.g., a dipper lip <NUM>) may also be attached to the dipper including a rear attachment portion <NUM>, and a front shovel portion (e.g., see <NUM>). The rear attachment portion <NUM> may form a first obtuse angle <NUM> (see <FIG>) with the bottom floor <NUM> on the midplane <NUM> inside the dipper (i.e. in the interior of the dipper) that ranges from <NUM> degrees to less than <NUM> degrees.

More particularly, the first obtuse angle <NUM> may range from <NUM> degrees to <NUM> degrees in some embodiments of the present disclosure.

Likewise, the front shovel portion (e.g., see <NUM>) may form a second obtuse angle <NUM> with the rear attachment portion <NUM> on the midplane <NUM> inside the dipper that ranges from <NUM> degrees to <NUM> degrees in some embodiments of the present disclosure. Any of these angular ranges may be different in other embodiments of the present disclosure.

Looking at <FIG>, the rear attachment portion <NUM> of the front lip may form a joint <NUM> with the bottom floor <NUM> of the dipper. At this joint <NUM>, the rear attachment portion includes a top chamfer <NUM>, and a bottom chamfer 308a disposed at the joint, while the bottom floor may have a flat surface <NUM> abutting the chamfers. Fillet welds (not shown) may attach these components together, making a rigid joint between these components.

Turning now to <FIG>, a dipper lip that may be supplied as a replacement part or as a retrofit in the field for a dipper will now be discussed.

Such a dipper lip <NUM> may comprise a first side wing <NUM>, a second side wing 310a, a rear attachment portion <NUM> that spans from the first side wing <NUM> to the second side wing 310a, and a front shovel portion (e.g., see <NUM>) that extends from the first side wing <NUM> to the second side wing 310a.

The dipper lip <NUM> may also define a midplane <NUM> (may be a plane of symmetry as shown but not always) disposed between the first side wing <NUM>, and the second side wing 310a. As best seen in <FIG>, the front shovel portion <NUM> defines a top shovel surface <NUM>, the rear attachment portion <NUM> forms a top rear surface <NUM>, and the top shovel surface <NUM> forms an obtuse angle <NUM> with the top rear surface <NUM> in the midplane <NUM>.

In some embodiments of the present disclosure, the obtuse angle <NUM> may range from <NUM> degrees to <NUM> degrees. In other embodiments of the present disclosure, the obtuse angle <NUM> may range from <NUM> degrees to <NUM> degrees (e.g., may be about <NUM> degrees).

As seen in <FIG>, the front shovel portion <NUM> is arcuately shaped in both a vertical plane <NUM> (dipping parabolic shape shown in <FIG>) and a horizontal plane <NUM> (convex arcuate shape shown in <FIG>). Other configurations are possible in one or both planes other than arcuate, etc..

In <FIG>, it can be seen that the front shovel portion <NUM> defines a plurality of vertically extending thru-apertures <NUM>, and a plurality of forwardly extending bosses <NUM>. These facilitate the attachment of adapters <NUM>, teeth <NUM>, and edge protectors <NUM> (may also be referred to as shrouds) shown in <FIG> and <FIG>. Any of these features or components may be altered or omitted, etc..

As best seen in <FIG> and <FIG>, the rear attachment portion <NUM> may define a pointed rear edge <NUM> that extends from the first side wing <NUM> to the second side wing 310a. This edge may be used to allow the dipper lip to be attached to the dipper. This feature may be omitted in other embodiments of the present disclosure.

The first side wing <NUM> or the second side wing 310a may include a top wing surface <NUM>, 330a that defines a minimum thickness <NUM>, and an overall length measured perpendicularly to the minimum thickness <NUM>. A ratio of the overall length <NUM> to the minimum thickness <NUM> may range from <NUM> to <NUM> in some embodiments of the present disclosure. In some cases, the overall length <NUM> may range from <NUM> to <NUM>. This ratio and length may provide enough of a transition between the front shovel portion and the interior of the dipper so that a digging performance improvement and a sturdy attachment are provided simultaneously.

Any of the ratios or dimensions discussed herein may be varied to be different than what has been specifically mentioned in other embodiments of the present disclosure for use in other applications.

In various embodiments of the present disclosure, the dipper lip or other components of the dipper may be made from any suitable materials, such as metal (e.g., cast iron, iron, steel, grey cast-iron, aluminum), reinforced plastic, etc. When metal such as iron or manganese steel is employed, the dipper lip or other component may be cast and machined to final dimensional tolerances.

It should be noted that the description of the dipper lip or other component may omit small blends, fillets, chamfers, etc. When the description of these features is omitted, their presence is to be ignored when interpreting this specification including the claims.

Again, for any of the embodiments discussed herein, the values of dimensions, angles, and ratios may be varied to be different than anything shown or described herein. Also, various features may be modified in configuration or omitted in various embodiments of the present disclosure, etc. Materials of the various components may also be varied as needed or desired to be different.

In practice, a dipper lip, a dipper, and/or any component thereof may be sold, manufactured, bought etc. and in the aftermarket or original equipment scenarios according to any of the embodiments discussed herein. That is to say, the machine may be sold with the dipper, and/or dipper lip, etc. according to embodiments described herein or the machine may be retrofitted, repaired, or refurbished to use any of the embodiments discussed herein. Similarly, any dipper may be retrofit or repaired using a dipper lip according to any embodiment of the present disclosure.

The inventors of the present disclosure have discovered that the embodiments disclosed herein allow the tips or teeth to be rotated up <NUM>° to provide a better the digging performance as compared to previous designs. Also, the back of the lip was rotated up <NUM>° to provide heel wear protection. With the new lip geometry, increased dig performance and virtually no heel wear are expected.

As shown in <FIG>, the tip or tooth <NUM> may define a bisector <NUM> that forms a mouth angle <NUM> with the top wall <NUM> that ranges from <NUM> degrees to <NUM> degrees (may be about <NUM> degrees) in some embodiments of the present disclosure.

These design parameters may be critical for obtaining the desired oilsands digging performance and dipper longevity.

While the arrangement is illustrated in connection with an electric rope shovel, the arrangement disclosed herein has universal applicability in various other types of machines commonly employ track systems, as opposed to wheels. The term "machine" may refer to any machine that performs some type of operation associated with an industry such as mining or construction, or any other industry known in the art. For example, the machine may be an excavator, wheel loader, cable shovel, or dragline or the like. Moreover, one or more implements may be connected to the machine. Such implements may be utilized for a variety of tasks, including, for example, lifting and loading.

For any of the embodiments discussed herein, the dipper lip or dipper may be modified to be used on other implements for other machines including other types of buckets.

As used herein, the articles "a" and "an" are intended to include one or more items, and may be used interchangeably with "one or more. " Where only one item is intended, the term "one" or similar language is used. Also, as used herein, the terms "has", "have", "having", "with" or the like are intended to be open-ended terms. Further, the phrase "based on" is intended to mean "based, at least in part, on" unless explicitly stated otherwise.

It will be apparent to those skilled in the art that various modifications and variations can be made to the embodiments of the apparatus and methods of assembly as discussed herein without departing from the scope of the invention. Other embodiments of this disclosure will be apparent to those skilled in the art from consideration of the specification and practice of the various embodiments disclosed herein. For example, some of the equipment may be constructed and function differently than what has been described herein and certain steps of any method may be omitted, performed in an order that is different than what has been specifically mentioned or in some cases performed simultaneously or in sub-steps. Furthermore, variations or modifications to certain aspects or features of various embodiments may be made to create further embodiments and features and aspects of various embodiments may be added to or substituted for other features or aspects of other embodiments in order to provide still further embodiments.

Claim 1:
A dipper lip (<NUM>) comprising:
a first side wing (<NUM>);
a second side wing (310a);
a rear bucket attachment portion (<NUM>) that spans from the first side wing (<NUM>) and the second side wing (310a); and
a front shovel portion (<NUM>) that extends from the first side wing (<NUM>) to the second side wing (310a);
wherein the dipper lip (<NUM>) defines a midplane (<NUM>) disposed between the first side wing (<NUM>), and the second side wing (310a), the front shovel portion (<NUM>) defines a top shovel surface (<NUM>), the rear bucket attachment portion (<NUM>) forms a top rear surface (<NUM>);
characterised in that the top shovel surface (<NUM>) forms an obtuse angle (<NUM>) with the top rear surface (<NUM>) in the midplane (<NUM>).