Cable Armoring System

Abstract

A novel cable construction provided an armored covering over a cable containing high-strength synthetic filaments. The synthetic cable is provided with a strong and tough termination where it attaches to heavy machinery, such as mining machinery. An external armoring is then provided for a desired portion of the cable (up to the entire length of the cable). A collar is preferably provided to seal the end of the armoring portion to a cable jacket (where a cable jacket is present).

Claims

1. A mining machine for scooping material, comprising: a. a cab; b. a boom extending to a point sheave; c. a bucket assembly; d. a lift rope extending from said bucket assembly over said point sheave and to said cab, said lift rope being wrapped around a hoist drum; e. said lift rope configured to cycle between a low position in which said bucket assembly is in a low position and a high position in which said bucket assembly is in a high position; f. said lift rope including a wire rope portion wrapped around said hoist drum and extending out to a wire rope junction, and a synthetic portion extending from said wire rope junction over said point sheave to proximate said bucket assembly; g. wherein said wire rope junction lies between said hoist drum and said point sheave when said bucket assembly is in said low position and said high position; and h. cable armoring on said lift tope, extending from proximate said bucket assembly up to a level below said point sheave when said bucket assembly is in said high position.

2. (canceled)

3. A mining machine as recited in claim 1, further comprising: a. a dragline rope configured to pull said bucket assembly toward said cab; b. a portion of said dragline rope being wrapped around a dragline drum; c. said dragline rope including a wire rope portion wrapped around said dragline drum and a synthetic portion attached to said bucket assembly; and d. said wire rope portion of said dragline rope being joined to said synthetic portion of said dragline rope by a dragline junction.

4. The mining machine as recited in claim 1, wherein said cable armoring comprises fiber-reinforced rubber.

5. The mining machine as recited in claim 1, further comprising a collar sealing an upper end of said cable armoring.

6. The mining machine as recited in claim 1, wherein said point sheave is powered.

7. The mining machine as recited in claim 1, further comprising a spray nozzle configured to clean said lift rope before it passes over said point sheave.

8. The mining machine as recited in claim 1, further comprising a brush assembly configured to clean said lift rope before it passes over said point sheave.

Description

BRIEF DESCRIPTION OF DRAWINGS

[0033] FIG. 1 is a perspective view showing a prior art dragline bucket and its associated lifting and dumping rigging.

[0034] FIG. 2 is a perspective view, showing the assembly of FIG. 1 from a different vantage point.

[0035] FIG. 3 is a perspective view, showing a prior art power shovel.

[0036] FIG. 4 is a perspective view, showing another type of prior art power shovel.

[0037] FIG. 5 is a detailed perspective view, showing an exemplary attachment between a prior art dipper rope and a dipper.

[0038] FIG. 6 is a perspective view, showing another exemplary attachment between a prior art dipper rope and a yoke.

[0039] FIG. 7 is a sectional elevation view, showing additional details of the prior art attachment depicted in FIG. 6.

[0040] FIG. 8 is a perspective view, showing a connection to a yoke using the present invention.

[0041] FIG. 9 is a sectional elevation view, showing additional details of the configuration of FIG. 8.

[0042] FIG. 10 is a sectional view showing an exemplary construction of a tensile member made according to the present invention.

[0043] FIG. 11 is a perspective view, showing a connection to a yoke using the present invention.

[0044] FIG. 12 is an elevation view, showing another embodiment of the present invention.

[0045] FIG. 13 is a sectional elevation view, showing an exemplary prior art top sheave.

[0046] FIG. 14 is an elevation view, showing another embodiment of the present invention.

[0047] FIG. 15 is an elevation view, showing a prior art dragline crane.

[0048] FIG. 16 is a perspective view, showing the region of the point sheave for the crane of FIG. 15.

[0049] FIG. 17 is an exploded perspective view, showing an inspection region for a bridge support rope on a dragline crane.

[0050] FIG. 18 is a perspective view, showing components of a termination for a multi-stranded rope.

[0051] FIG. 19 is a sectional elevation view, showing components of a termination for a multi-stranded rope.

[0052] FIG. 20 is a perspective view, showing a driven point sheave on a dragline crane.

[0053] FIG. 21 is a sectional elevation view, showing a point sheave with a sacrificial insert.

[0054] FIG. 22 is a sectional view, showing a multi-stranded rope with strand jackets and an overall jacket.

[0055] FIG. 23 is a perspective view, showing the use of cable armoring proximate a point sheave.

[0056] FIG. 24 is an elevation view showing a dragline crane incorporating instrument units and various rope junctions.

[0057] FIG. 25 is a perspective view, showing the addition of an elongation measurement device on a bridge support rope.

REFERENCE NUMERALS IN THE DRAWINGS

[0058] 10 dragline bucket assembly [0059] 12 hoist socket [0060] 14 lift rope [0061] 16 upper hoist chain [0062] 18 spreader bar [0063] 20 lower hoist chain [0064] 22 lift trunnion [0065] 24 bucket [0066] 26 dump rope [0067] 28 dump block [0068] 30 drag chain [0069] 32 arch [0070] 34 drag socket [0071] 36 dragline rope [0072] 38 top rail [0073] 40 drag chain hitch [0074] 42 upper hoist assembly [0075] 44 lower hoist assembly [0076] 48 yoke [0077] 50 point sheave [0078] 52 cab [0079] 54 A frame [0080] 56 mast [0081] 58 boom [0082] 60 hoist drum [0083] 62 dragline drum [0084] 64 deflection sheave [0085] 66 deflection sheave [0086] 68 bridge support rope [0087] 70 termination [0088] 72 bend restrictor [0089] 74 bend restrictor half [0090] 76 jacket [0091] 78 jacket clamp [0092] 80 bolt flange [0093] 82 clamp receiver [0094] 84 inspection region [0095] 86 bolt flange [0096] 88 mounting hole [0097] 90 threaded receiver [0098] 92 bolt [0099] 94 band clamp [0100] 96 collector [0101] 98 anchor [0102] 100 strand [0103] 102 attachment features [0104] 104 cable [0105] 106 flange [0106] 108 drive motor [0107] 110 reduction gear [0108] 112 encoder [0109] 114 control unit [0110] 116 nozzle [0111] 118 power shovel [0112] 120 boom [0113] 122 dipper arm [0114] 124 bucket [0115] 126 floor [0116] 128 yoke [0117] 130 trunnion [0118] 132 dipper rope [0119] 134 boom rope [0120] 136 loop [0121] 138 collar [0122] 140 passage [0123] 142 termination [0124] 144 attachment fixture [0125] 146 cable armoring [0126] 148 collar [0127] 150 jacketed cable [0128] 152 cavity [0129] 154 potted region [0130] 156 interlock [0131] 158 interlock [0132] 159 O-ring [0133] 160 stranded core [0134] 162 jacket [0135] 164 gap [0136] 165 strap [0137] 168 top sheave [0138] 169 cab [0139] 170 turntable [0140] 172 track [0141] 174 A-frame [0142] 178 hoist rigging [0143] 190 sheave [0144] 192 pivot joint [0145] 194 saddle [0146] 196 bolt hole [0147] 198 shoulder [0148] 200 retainer [0149] 202 bolt [0150] 204 coupler [0151] 206 wire rope [0152] 208 helical groove [0153] 210 brush assembly [0154] 212 insert [0155] 214 strand jacket [0156] 216 bases instrument unit [0157] 218 mid-span instrument unit [0158] 220 tip instrument unit [0159] 222 lift rope junction [0160] 224 dragline junction [0161] 226 wire rope junction

DESCRIPTION OF EMBODIMENTS

[0162] FIG. 8 shows one approach to using a synthetic cable for the rigging on a dragline or a power shovel. FIG. 8 shows the example of a power shovel. Jacketed cables 150 each include a synthetic filament core surrounded by an encapsulating jacket. The jacket organizes the cable and provides protection from external contaminants and from sunlight. However, it is not nearly durable enough to withstand the harsh environment near the dipper bucket on its own. Cable armoring 146 is added near the dipper. In this example, the armoring extends up the cable until it reaches a portion of the cable which must pass over top sheave 168. Each cable passes over the top sheave as the bucket is raised and lowered. When the bucket is raised to its maximum height, the armoring in this example stops just short of the top sheave.

[0163] In this example each cable is terminated into a heavy steel piece (attachment fixture 144). This creates a suitable termination 142 on the end of each cable. Each attachment fixture 144 is made of steel and is quite durable. These are connected to yoke 128 using steel pins. Cable armoring 146 covers and protects the jacketed cables 150 from the point each cable emerges from its respective termination up to a collar 148.

[0164] Collar 148 provides a protective seal between the jacketed cable and its cable armoring. It prevents the ingress of dust, fine debris, liquids, and other contaminants. The collar may be of a split configuration that is clamped in place using transverse bolts.

[0165] FIG. 9 shows a sectional elevation view through one cable assembly. In this version attachment fixture 144 includes a cavity 152. A length of cable filaments are potted into this cavity to form potted region 154. This creates a mechanical interlock between the end of jacketed cable 150 and attachment fixture 144.

[0166] A single potted region is shown. In reality, multiple potted connections may be made between individual filament groupings and attachment fixture 144. This type of design is described in detail in my co-pending U.S. application Ser. No. 14/693,811, which is hereby incorporated by reference.

[0167] Cable armoring 146 is added over the outside perimeter of jacketed cable 150. The cable armoring is preferably a very tough and cut-resistant material. A good example is fiber-reinforced rubber. Interlock 156 is provided between the lower end of the cable armoring and the attachment fixture. Interlock 158 is also provided between the upper end of the cable armoring and the lower end of collar 148.

[0168] Collar 148 seals around the jacketed cable. O-ring 159 is preferably provided to make a positive seal between the collar and jacketed cable 150. This prevents the ingress of dust, water, and other contaminants. Although no gap is shown between the exterior of the jacket and the interior of the cable armoring a significant gap may in fact be present in many applications. In those instances it may be necessary to connect the armoring to the attachment fixture using a split clamping ring attached by transverse bolts. A second split clamping ring may be used at the top of the cable armoring as well.

[0169] FIG. 10 shows a cross-section through a jacketed cable with an armoring layer added. Stranded cores 160 comprises the high-strength synthetic filaments (some conventional steel wires may also be included). Jacket 162 fits tightly around this core. Cable armoring 146 is a thick and tough layer. As stated previously, it may be made of a natural or synthetic rubber reinforced by another material such as steel wires or fiberglass. It may also be made of a flexible urethane. In this example, gap 146 is provided between the interior of the cable armoring and the exterior of the jacket in this example. This gap allows the cable to bend and flex without chafing against the interior of the armor layer. The gap may be filled by another material such as a woven cloth layer.

[0170] FIG. 11 shows an alternate embodiment for attaching the inventive cable to yoke 128 of a power shovel. In this instance four separate synthetic cables are used. Each pair of synthetic cables is terminated to a steel strap 165. The steel strap passes through passage 140 to connect to the yoke and thereby connect to the bucket assembly.

[0171] FIG. 12 shows still another embodiment of the present invention that is configured for use with a yoke assembly such as depicted in FIGS. 6 and 7. Wire rope 206 is a length of conventional steel strands formed into a loop to pass around saddle 194 (depicted in FIG. 6) and over shoulder 198. Returning to FIG. 12. Couplers 204 connected jacketed synthetic cable 150 to wire rope 206. As an example, each coupler may contain a potted termination to the synthetic cable on one side and a spelter type socket attaching to the wire rope on the other.

[0172] Cable armoring 146 is provided over a length of the cable in proximity to the dipper. Collar 148 seals the armoring to jacketed cable 150 at the point of termination for the cable armoring. Cable armoring 146 is likewise sealed to coupler 204 on its opposite end.

[0173] In some embodiments the cable armoring will extend from the dipper attachment up and over the top sheaves. In other instances, a separate length of cable armoring may be provide in the vicinity of the top sheaves.

[0174] Returning again to FIG. 13, the reader will recall how each top sheave includes a helical groove 208 configured to guide the cable's path as it is reeled in and payed off. FIG. 14 depicts an embodiment in which a length of armoring has been provided to cover the section of the cable that passes around the top sheave. Cable armoring 146 exists between two collars 148 on an intermediate portion of jacketed cable 150 (rather than a portion proximate an end of cable 150).

[0175] Having provided a disclosure of the invention and some of its applications, the following additional principles should also be known:

[0176] 1. The inventive methods and hardware has been described with respect to two examples of mining machinery—power shovels and dragline cranes. However, the invention is applicable to other forms of mining machinery and beyond the mining industry as well. As an example, the invention is applicable to any field where armoring of a flexible tensile member is desirable.

[0177] 2. The armor layer or layers may be made removable over some or all of the tensile member's length. This may be done to facilitate inspection of the underlying synthetic core components.

[0178] 3. Some “grip” engagement between the core and the armor layer will be desirable in some circumstances. As an example, the inward facing surface of the armor layer could be given a gripping texture (ribs or helical grooves) so that the armor layer does not slip with respect to the core in a region where the tensile member passes over a sheave. In such a situation surface shearing forces are preferably transmitted from the armor layer to the core layer in order to prevent the armor layer slipping like a sock. It is also possible to provide outward facing gripping surfaces on the core layer or on the jacket material surrounding the core layer.

[0179] 4. Another type of gripping feature between the core and the armor layer can be cross-stitching or some form of adhesive.

[0180] 5. It is desirable to provide an armor layer that indicates a breach or other significant damage to the protection it affords. As a first example the armor material may include a brightly colored layer covered by a dark layer. A gouge or a split then becomes visible as a bright portion against a dark background. For embodiments in which the armor layer is sealed to a termination at both ends of a tensile member, a brightly dyed fluid can be placed between the armor layer and the core layer. This bright fluid will seep out of any breach in the armor layer and indicate a problem.

[0181] 6. An armor layer may be provided on an intermediate portion of the tensile member rather than proximate the ends. As one example, an armor layer may be provided for a region of the tensile member that passes back and forth over a top sheave.

[0182] 7. An armor layer may be provided on a length of core that is passed around a spliced termination (such as a large thimble-type device) and woven back into itself. The armor layer could cover the terminated portion and the woven portion.

[0183] It is helpful to consider the application of the present inventive hardware to prior art heavy equipment. FIG. 15 shows a prior art dragline crane. Cab 52 is mounted on walking shoes that slowly move the machine from one location to the next. A turntable is provided so that the cab can swivel.

[0184] Boom 58 is pivotally mounted to the cab. It extends for a large distance. For very large machines the boom may be as long as 100 meters. Mast 56 extends upward as shown. Multiple bridge support ropes 68 maintain the boom's position. A first group of bridge support ropes connects the top of mast 56 to the tip of boom 58. A second group of bridge support ropes 68 connect the top of mast 56 to A-frame 54 on the cab.

[0185] Bucket assembly 10 actually does the digging and scooping. The weight of the bucket (and its contents) is supported by lift rope 14 (which may be two or more ropes rigged in parallel). Lift rope 14 passes over point sheave 50 and back to hoist drum 60 within the cab. Deflection sheaves 64,66 redirect the path of the hoist rope as needed. Dragline rope 36 pulls the bucket toward the cab. It is reeled in and paid out by dragline drum 62.

[0186] Bridge support ropes 68 are conventionally thought of as “fixed” or “standing” rigging in that they are not reeled in and paid out (in this context such a tension member will be referred to generally as a “stay”). This does not mean, however, that they are not subjected to dynamic forces. As lift tope 14 is reeled in to lift the bucket, the tension on bridge support ropes 68 increases substantially. Once the scooping phase is done, the entire crane pivots to the dumping area. This swinging motion places lateral loads on the bridge support ropes. When the bucket is dumped the load on the bridge support ropes is suddenly and significantly reduced.

[0187] In these various motions the boom tends to bounce and sway. Bridge support ropes 368 undergo bouncing motions constantly. In some instances they will experience circular as well as lateral oscillations. The motions are best visualized as waves. Principles of superposition can produce violent motion in some instances. These violent motions are difficult to predict.

The fixed rigging for these types of heavy machines has traditionally been made from heavy wire rope. Wire rope is quite tough. It is also capable of repeated elastic deformation without significant damage. Wire rope also provides good damping characteristics. The steel wires making up the rope provide reasonable damping. In addition, as most wire ropes are helically laid, the layered helices themselves provide good damping characteristics by twisting and untwisting.

[0188] High-strength synthetic filaments offer potential advantages over the use of wire rope. These filaments have a much higher strength-to-weight ratio. If one can reduce the weight of the cable rigging in a large earth moving machine, the weight saving translates directly into additional payload. There is therefore a real incentive to use advanced synthetic filaments instead of steel wire in a tensile strength member in a large piece of equipment.

[0189] A tensile strength members must be connected to other components in order to be useful. For example, a cable used in a hoist generally includes a lifting hook on its free end. This lifting hook may be rigged to a load. The assembly of an end-fitting and the portion of the cable to which it is attached is generally called a “termination.”

[0190] A tough steel lifting hook is commonly attached to a wire rope to create a termination. A “spelter socket” is often used to create the termination. The “spelter socket” involves an expanding cavity within the end-fitting. A length of the wire rope is slipped into this cavity and the individual wires are splayed apart. A liquid potting compound is then introduced into the expanding cavity with the wires in place. The liquid potting compound transitions to a solid over time and thereby locks the wire rope into the cavity.

[0191] The potting compound used in a spelter socket is traditionally molten lead and—more recently—is more likely a high-strength epoxy. However, the term “potting compound” as used in this description means any substance which transitions from a liquid to a solid over time. Examples include molten lead, thermoplastics, and UV-cure or thermoset resins (such as two-part polyesters or epoxies). Other examples include plasters, ceramics, and cements. The term “solid” is by no means limited to an ordered crystalline structure such as found in most metals. In the context of this invention, the term “solid” means a state in which the material does not flow significantly under the influence of gravity. Thus, a soft but stable wax is yet another example of such a solid.

[0192] The prior art approaches to adding a termination to a cable are explained in detail in commonly-owned U.S. Pat. Nos. 7,237,336; 8,048,357; 8,236,219 and 8,371,015. These prior patents are hereby incorporated by reference. The prior art approaches are also explained in detail in commonly-owned U.S. patent application Ser. Nos. 13/678,664 and 15/710,692. These published pending applications are also hereby incorporated by reference.

[0193] Many different high-strength synthetic filaments are now known. Examples include DYNEEMA (ultra-high-molecular-weight polyethylene), SPECTRA (ultra-high-molecular-weight polyethylene), TECHNORA (aramid), TWARON (p-phenylene terephthalamide), KEVLAR (para-aramid synthetic fiber), VECTRAN (a fiber spun from liquid-crystal polymer), PBO (poly(p-phenylene-2,6-benzobisoxazole)), carbon fiber, and glass fiber (among many others). In general the individual filaments have a thickness that is less than that of human hair. The filaments are very strong in tension, but they are not very rigid and they are not very tough. They offer potential weight savings over traditional wire rope but they also require additional methodologies and hardware to allow them to survive in a hostile environment such as a pit mine.

[0194] Tensile members made predominantly from synthetic filaments are very strong in tension but weak in abrasion resistance, cut resistance, and transverse shear resistance (The word “predominantly” is used because it is known to provide hybrid cables that include both metallic components and synthetic components). This invention disclosure describes hardware and methods that are useful in adapting tensile strength members including synthetic filaments to a harsh environment. The hardware and methods are primarily directed toward synthetic cables, but the reader should bear in mind that these techniques are advantageous for traditional wire ropes in some circumstances as well.

[0195] FIG. 16 shows a detailed view of a particular area of the prior dragline crane shown in FIG. 15. The view centers on the area of point sheave 50—located near the very tip of boom 58. In this example four separate bridge support ropes 68 carry the weight of the boom and the loads imposed by lift ropes 14 (which raise and lower the bucket). The term “rope” is a traditional term used within the heavy equipment industry. In this context the term rope is a synonym for a cable or any other term referring to a tensile strength member.

[0196] Each bridge support rope is made primarily (if not fully) from high-strength synthetic filaments. Each of the four bridge support ropes ends in a termination 70. Each termination in this example is connected to the boom by a large transverse pin. Bend restrictors 72 provide a transition between the freely flexing portion of the rope and the portion that is rigidly locked within the termination. In this example, each bend restrictor 72 is approximately 3 meters long. The forces involved in such an assembly are tremendous.

[0197] FIG. 17 provides additional details concerning the cables, the terminations, and the bend restrictors employed. In the state shown in FIG. 17, inspection region 84 of the cable is fully accessible. The strands and filaments themselves are accessible, as jacket 76 (a protective sleeve covering the cable) stops at jacket clamp 78.

[0198] In order to reassemble the exploded assembly depicted in FIG. 17, the user may start by urging the two bend restrictor halves 74 together (The word “may” is used because more than one order of assembly is possible). The user then inserts the four transverse bolts 92.

[0199] Each bolt 92 passes through a hole in one bend restrictor half and threads into a threaded receiver in the opposite bend restrictor half. The hole in each restrictor half includes a counterbore with a bearing face. The head of each bolt bears against the bearing face of a counterbore as the bolt is tightened—thereby pulling the two bend restrictor halves together.

[0200] The two bend restrictor halves are properly positioned with respect to termination 70 by that face that the bolts 92 slide through bolt receiver 86 on the termination and bolt flange 80 on jacket clamp 78. A stronger connection between the termination and the bend restrictor is preferred, however. To that end, numerous bolts are passed through mounting holes 88 in the termination and into threaded receivers 90 on the bend restrictor halves. These bolts create a very strong flange-type connection.

[0201] The two bend restrictor halves are preferably made of a very tough yet somewhat elastic material. In the embodiment shown, the two halves are made of molded urethane. While urethane is indeed a tough material, the reader should bear in mind that the tension on the cable will often be enormous and the lateral flexure loads are also quite substantial. These loads will tend to buckle and separate the two bend restrictor halves.

[0202] In order to strengthen the assembly, a series of clamp receivers 82 are provided on the exterior surface of the bend restrictor halves. Each clamp receiver is a groove having a rectangular cross section. Once the two halves are united, a band clamp 94 is opened, passed around the two halves, and secured in each clamp receiver. The example shown provides enough receivers to accommodate eight band clamps 94. Once these band clamps are tightened, the assembly becomes much stronger.

[0203] The tightened assembly is placed in service and remains in service for a defined interval. Once the interval is completed, the bend restrictor must be opened to facilitate inspection of the cable. The band clamps are removed and the two bend restrictor halves are disassembled. Inspection region 84 is thereby exposed.

[0204] The cable itself is made of several individual strands that are braided, woven, or twisted together. A braided example is shown. Termination 70 typically includes a fairly complex assembly. FIG. 18 shows a perspective view of one of the internal components. An anchor 98 is attached to the end of each individual strand 100 in the cable (such as by potting). Each anchor is then attached to collector 96 using an attachment feature 102. FIG. 19 shows a sectional elevation view through termination 70 (in a simplified form). Collector 96 is mounted within the body of the termination. All the individual cable strands are connected to the collector. The collector is secured within a larger structure (in this case a loading eye that is used to connect to a transverse pin). Bend restrictor 72 attaches to the termination at flange 106. Jacket 76 extends in this example all the way to bend restrictor 72.

[0205] The use of advanced synthetics offer significant advantages for dragline cranes and similar machinery. There are disadvantages as well, however. Wire rope is inherently tough and can be passed over the various sheaves many times without significant damage. Synthetic rope—even when contained within a jacket—is not as tough. FIG. 20 illustrates an embodiment intended to address some of the concerns with using synthetic rope.

[0206] Lift ropes 14 in the view are made of synthetic filaments (or largely of synthetic filaments in the case of a hybrid rope). The lift ropes pass over point sheave 50. Point sheaves 50 are traditionally heavy steel structures possessing a great deal of inertia. As the lift ropes are lifted up and down by the hoist drum in the cab, they may slip of the point sheave. To address this concern the point sheave in the embodiment shown is positively driven.

[0207] Drive motor 108 drives the point sheave through reduction gear 110. Encoder 112 provides information regarding the position and rotational velocity of the point sheave. This information is fed to control unit 114, which controls the motion of drive motor 108. In one approach the motor is driven so that point sheave 50 matches the speed of the lift rope—as the lift rope is reeled in or paid off. The point sheave may also be selectively driven faster than the linear speed of the lift ropes, or slower.

[0208] A second concern with the use of synthetic ropes is the presence of heavy dust, small particulate debris, and even small stones between the lift ropes and the point sheave. These may be thrown or carried up from the region of the bucket. In the version shown a pair of spray nozzles 116 are directed toward the lift ropes. These spray high pressure water. They may be periodically activated (such as when the bucket is being lifted—or they may remain active at all times. The nozzles tend to blast dust and debris off the lift ropes before they pass over the point sheave. They also tend to cool the lift ropes.

[0209] Additional nozzles may be provided for the point sheave itself. These additional nozzles can provide cooling water for the point sheave. Temperature sensors on the sheave can be used to determine when cooling water is desirable.

[0210] In addition to the spray nozzles, the inventive embodiment can also include a mechanical cleaning element—such as brush assembly 210. Brush assembly 210 surrounds the two lift ropes. As the two lift ropes are pulled upward the brush assembly tends to remove dust and debris from the cables.

[0211] The use of synthetic ropes allows the substitution of softer and lighter materials for the various sheaves on the crane—including the point sheave. As an example, aluminum may be substituted for steel in the sheaves. The use of aluminum reduces weight and—also significantly—rotational inertia.

[0212] It is also possible to place a softer insert into the point sheave at the point of contact with the lift ropes. FIG. 21 shows an embodiment of point sheave 50 including insert 212. The point sheave itself in this example is made of metal but the insert is made of a high-strength polymer such as DELRIN. In another embodiment the point sheave is made of alloyed high-strength aluminum while the insert is made of soft aluminum.

[0213] The use of a tough “armoring layer” over the outside of a synthetic rope will be desirable in many applications for heavy machinery. FIG. 22 shows a section view through a synthetic rope. This particular rope is a braided construction including 12 separate strands 100. Each individual strand is encased within a tough strand jacket 214. The cable as a whole is encased within jacket 76. Jacket 76 is preferably a very tough material, having significant thickness.

[0214] The material and the thickness can be varied for different regions of a cable. FIG. 23 shows an example. Lift rope 114 is enclosed within a jacket 76. However, in the region reaching down from point sheave 50 tot eh dragline bucket assembly, a much thicker jacket is used. This thicker jacket is denoted as cable armoring 146.

[0215] Cable armoring 146 is not able to easily pass around the point sheave. In the position shown in FIG. 23, lift ropes 114 are shown at the maximum upward travel of the dragline bucket assembly. The reader will note how cable armoring 146 stops just below point sheave 50. The uppermost extent of cable armoring 146 is set so that it will not need to contact the point sheave during the dragline crane's operation. The lowermost extent of the cable armoring goes all the way down to the bucket assembly—since this is the most hostile part of the environment.

[0216] FIG. 24 shows some additional embodiments of the present inventive system. The reader will note that lift rope 14 includes wire rope junction 226. Wire rope works well on the drum itself. The portion of the lift rope on hoist drum 60 and extending out to wire rope junction 226 in this embodiment is conventional wire rope. The portion of the wire rope extending from wire rope junction all the way out to the bucket assembly is made from high-strength synthetic filaments (or mostly so). However, the portion of lift tope 14 below lift rope junction 222 includes additional cable armoring for protection. Thus, the single lift rope has three distinct sections: (1) conventional wire rope around the drum and up to wire rope junction 226; (2) high-strength synthetic filaments from wire rope junction 226 to lift rope junction 222; and (3) high-strength synthetic filaments encased in cable armoring from lift rope junction 222 down to the bucket assembly.

[0217] Likewise dragline rope 36 includes dragline junction 224. Conventional wire rope can be used around dragline drum 62 and out to dragline junction 224. Outward from the dragline junction rope made from high-strength synthetic filaments (or mostly so) is used.

[0218] FIG. 24 also illustrates the inclusion of various instrument units to measure and record the motion of different parts of the structure, and stresses on different parts of the structure. It is known in the industry to include strain gauges on various portions of the boom and mast structures. These are used to measure elastic deformations and thereby gain some knowledge about the movements and forces involved. This knowledge can be used to detect operator abuse, imminent component failure, and other useful things. Strain gauges are not very accurate, however, particular with the bouncing motions of the boom and mast.

[0219] Accurate inertial measurement units have now become relatively affordable. These units now incorporate MEMS instruments for linear acceleration measuring and ring-laser-gyros for attitude measuring. An internal processor then integrates the linear acceleration information and creates a full 6 degree-of-freedom “picture” of the location and orientation of the particular inertial measurement unit.

[0220] In the embodiment of FIG. 24, base instrument unit 216 includes an inertial 645 measurement unit. It is located proximate the base of the boom. Tip instrument unit 220 contains the same instrumentation. It is mounted near point sheave 50. These two units continuously measure the position and orientation of the two ends of the boom. This information is then fed to a central processor that uses the relative position to monitor the actual motion of the boom.

[0221] As an example, if the dragline crane moves forward into an area of soft soil the entire machine will tip forward somewhat. If only the motion at the tip were available, one might conclude that the boom had experienced a substantial load. However, with the motion of the base and the tip available, a monitoring system will “know” that the tip motion is just a result of the entire machine tipping forward somewhat and not the result of a substantially increased load on the boom.

[0222] Additional instrument units may be added along the span of the boom. FIG. 24 shows the inclusion off mid-span instrument unit 218. This mid-span unit is helpful in detecting the bending of the boom in its primary bending mode (a “banana” shape). Even more mid-span instrument units can be added to detect higher-order bending modes and for other purposes. It is useful to monitor the load in things such as bridge support ropes 68. Load measurement is typically inferred by measuring elongation. However, as high-strength synthetic filaments have a very high modulus of elasticity, it can be difficult to measure load via measuring elongation.

[0223] FIG. 25 shows an embodiment of an elongation measurement unit that can be placed in a synthetic rope such as a bridge support rope 68. Each end of telescoping sleeve 228 is connected to bridge support rope 68. The two portions of the telescoping sleeve are linked by an element where elongation is easily measured. As an example, they can be linked by a steel rod. A strain gauge or gauges are then place don ten steel rod and the elongation of the steel rod is used to infer the load on the bridge support rope.

[0224] Although the preceding description contains significant detail, it should not be construed as limiting the scope of the invention but rather as providing illustrations of the preferred embodiments of the invention. Thus, the language ultimately used in the claims shall define the invention rather than the specific embodiments provided.