Systems and methods for predicting replacement of a component of an industrial machine. One system includes an electronic processor configured to determine a wear rate of the component based on a current dimension of the component and historical dimensions of the component and determine a replacement cost for the component. Determining the replacement cost includes determining a cost of downtime for replacing the component based on a time for replacing the component and a downtime cost for the industrial machine during the time for replacing the component, a material cost in replacing the component, and an operating cost of the industrial machine associated with not replacing the component. The electronic processor is also configured to determine a replacement recommendation for the component based on the wear rate, the replacement cost, and discard criteria and output the replacement recommendation.

A method for determining stability of a vehicle having a load suspended from the vehicle is provided. The method can include obtaining measurements from a plurality of sensors positioned on the vehicle, obtaining a measurement from a vehicle accelerometer operative to determine an inclination of the vehicle, determining a position of the load suspended from the vehicle, determining a slung load of the load suspended from the vehicle, using the determined slung load and the determined position of the load suspended from the vehicle, determining tipping moments acting on the vehicle, determining righting moments acting on the vehicle and determining a tipping stability based on the determined tipping moments and determined righting moments.

An undercarriage assembly for a rope shovel comprising a crawler frame having a crawler body, a first leg and a second leg, the first leg having a first lateral crawler frame bore therethrough and the second leg having a second lateral crawler frame bore therethrough; a roller component disposed at least partially below the crawler body between the first leg and the second leg, the roller component having a lateral roller component bore therethrough; a first crawler frame bushing having a first flanged end, the first crawler frame bushing disposed in and through the first lateral crawler frame bore; a roller component bushing having a first flanged end, the roller component bushing being disposed in and through the lateral roller component bore; wherein the first flanged end of the first crawler frame bushing abuts the first flanged end of the roller component bushing.

Embodiments described herein provide systems and methods for generating a three-dimensional virtual track model. This track model may be used, for example, in collision prevention and mitigation systems and methods, such as those described herein, and in other collision prevention and mitigation systems and other mining systems using virtual track models. In some embodiments, the systems and methods described herein provide a simplified modeling process that enables quick, accurate modeling of tracks of a mining machine that can account for custom tracks that vary in size depending on the particular mining machine.

Embodiments described herein provide systems and methods for generating a three-dimensional virtual track model. This track model may be used, for example, in collision prevention and mitigation systems and methods, such as those described herein, and in other collision prevention and mitigation systems and other mining systems using virtual track models. In some embodiments, the systems and methods described herein provide a simplified modeling process that enables quick, accurate modeling of tracks of a mining machine that can account for custom tracks that vary in size depending on the particular mining machine.

Systems and methods for predicting replacement of a component of an industrial machine. One system includes an electronic processor configured to determine a wear rate of the component based on a current dimension of the component and historical dimensions of the component and determine a replacement cost for the component. Determining the replacement cost includes determining a cost of downtime for replacing the component based on a time for replacing the component and a downtime cost for the industrial machine during the time for replacing the component, a material cost in replacing the component, and an operating cost of the industrial machine associated with not replacing the component. The electronic processor is also configured to determine a replacement recommendation for the component based on the wear rate, the replacement cost, and discard criteria and output the replacement recommendation.

Embodiments described herein provide systems and methods for preventing and mitigating collisions between components of an industrial machine. The industrial machine includes an electronic controller, having an electronic processor and a memory, that is configured to receive dipper position data indicative of a position of the dipper and determine a distance between the dipper and tracks of the industrial machine based on the dipper position data. The electronic controller is further configured to set a motion command limit for a dipper motion based on the distance, the dipper motion being selected from a group of a swing motion, a crowd motion, and a hoist motion and control the dipper motion according to a dipper motion command limited by the motion command limit.

Embodiments described herein provide systems and methods for preventing and mitigating collisions between components of an industrial machine. The industrial machine includes an electronic controller, having an electronic processor and a memory, that is configured to receive dipper position data indicative of a position of the dipper and determine a distance between the dipper and tracks of the industrial machine based on the dipper position data. The electronic controller is further configured to set a motion command limit for a dipper motion based on the distance, the dipper motion being selected from a group of a swing motion, a crowd motion, and a hoist motion and control the dipper motion according to a dipper motion command limited by the motion command limit.

The present invention concerns a dipper assembly and parts thereof for use with a mining shovel. The dipper assembly includes: a dipper body having a back wall and an open dipper bottom; a dipper door pivotally coupled to the back wall of the dipper body and moveable between open and closed positions relative to the open dipper bottom; and a latch assembly for releasably securing the door in the closed position. The latch assembly includes a latch keeper and a latch member for engaging the latch keeper. The latch keeper is associated with the dipper body proximate the open dipper bottom and the latch member is coupled to the dipper door. The latch member includes at least one roller to assist the latch member in engaging and disengaging with the latch keeper and to reduce wear on the latch member.

A method for determining stability of a vehicle having a load suspended from the vehicle is provided. The method can include obtaining measurements from a plurality of sensors positioned on the vehicle, obtaining a measurement from a vehicle accelerometer operative to determine an inclination of the vehicle, determining a position of the load suspended from the vehicle, determining a slung load of the load suspended from the vehicle, using the determined slung load and the determined position of the load suspended from the vehicle, determining tipping moments acting on the vehicle, determining righting moments acting on the vehicle and determining a tipping stability based on the determined tipping moments and determined righting moments.