MODULAR DIGGING ATTACHMENT

CROSS-REFERENCE TO RELATED APPLICATION

[0001]This application claims priority to co-pending U.S. Provisional Patent Application No. 63/665,922, filed Jun. 28, 2024, the entire disclosure of which is hereby incorporated herein by reference.

FIELD

[0002]The present disclosure relates to the field of mining machines, and more particularly to a mining shovel having a dipper.

BACKGROUND

[0003]Typical power shovels or excavators use a digging attachment (e.g., a bucket or dipper) to scoop earthen material from horizontal and/or vertical surfaces. A power shovel may include a boom, and the digging attachment is supported for movement on the boom via a crowd mechanism. Once the earthen material is received within the digging attachment, the digging attachment may be moved to another location for transfer of the material and the material may be discharged, for example, into a dump truck, onto a conveyor, or onto a pile.

SUMMARY

[0004]The present disclosure relates to digging attachments, and more specifically to a dipper for a rope shovel.

[0005]In one independent aspect, provided herein is an assembly for a dipper of an industrial excavating machine. The assembly includes a first housing portion including a first housing opening at a first housing end, a second housing portion including a second housing opening at a second housing end, and an intermediate portion positionable between the first housing portion and the second housing portion. The intermediate portion includes a first open end that is positionable proximate the first housing end and a second open end that is positionable proximate the second housing end. The first housing portion is selectively couplable to the second housing portion to define a cavity of the dipper having a first volume. The intermediate portion is selectively couplable to each of the first housing portion and the second housing portion to define the cavity of the dipper having a second volume that is greater than the first volume.

[0006]In some aspects, the intermediate portion is configured to be one of a plurality of intermediate portions, each of the intermediate portions having a different length corresponding to a different volume of the cavity.

[0007]In some aspects, a profile of the first open end of the intermediate portion complements a profile of the first housing opening. In some aspects, a profile of the second open end of the intermediate portion complements a profile of the second housing opening.

[0008]In some aspects, the profiles of the first housing opening, the second housing opening, the first open end of the intermediate portion, and the second open end of the intermediate portion are substantially the same.

[0009]In some aspects, the profiles of the first housing opening, the second housing opening, the first open end of the intermediate portion, and the second open end include cross-sectional shapes. In some aspects, the cavity has a substantially continuous cross-sectional shape between the first housing opening, the first and second open ends of the intermediate portion, and the second housing opening.

[0010]In some aspects, the first housing portion includes a material receiving opening of the dipper opposite the first housing opening. In some aspects, the second housing portion includes a material discharging opening of the dipper opposite the second housing opening.

[0011]In some aspects, the length of the intermediate portion is between about four inches to about four feet. In some aspects, the different lengths of the plurality of intermediate portions vary between about four inches to about four feet.

[0012]In some aspects, the intermediate portion is a unitary piece.

[0013]In some aspects, the intermediate portion includes a plurality of interconnectable segments that are positionable between the first housing portion and the second housing portion.

[0014]In some aspects, the intermediate portion is couplable to the first housing portion and to the second housing portion via welding.

[0015]In some aspects, the intermediate portion is couplable to the first housing portion and to the second housing portion via fasteners.

[0016]In some aspects, the first housing portion includes a material receiving opening and a connector configured to be coupled to a hoist rope.

[0017]In some aspects, the assembly includes a door pivotably couplable to the second housing portion to selectively close a material discharging opening.

[0018]In some aspects, the first housing portion includes a plurality of first connectors and the second housing portion includes a plurality of second connectors, each of the first connectors and the second connectors configured to be coupled to an arm of an industrial excavating machine. In some aspects, at least one of the first connectors and/or at least one of the second connectors is configured to be coupled to the arm via a pitch brace. In some aspects, the first housing portion includes a digging edge positioned adjacent a material receiving opening, and the first connectors are positioned on an opposite side of the first housing portion relative to the digging edge.

[0019]In another independent aspect, provided herein is a digging attachment defining a cavity for receiving material therein. The digging attachment includes a first housing portion including a first housing surface and a first housing opening, a second housing portion including a second housing surface and a second housing opening, and an intermediate portion positioned between the first housing portion and the second housing portion. The intermediate portion extends between a first intermediate surface at a first open end of the intermediate portion and a second intermediate surface at a second open end of the intermediate portion. The first intermediate surface is positioned proximate the first housing surface and the second intermediate surface positioned proximate the second housing surface. A profile of the first open end of the intermediate portion complements a profile of the first housing opening. A profile of the second open end of the intermediate portion complements a profile of the second housing opening. The first housing portion, the second housing portion, and the intermediate portion cooperatively define the cavity. A volume of the cavity is determined based on a length of the intermediate portion. The first housing portion is configured to be directly coupled to the second housing portion and indirectly coupled to the second housing portion via the intermediate portion.

[0020]In some aspects, the intermediate portion is configured to be one of a plurality of intermediate portions, each of the intermediate portions having a different length corresponding to a different volume of the cavity.

[0021]In some aspects, the profiles of the first housing opening, the second housing opening, the first open end of the intermediate portion, and the second open end of the intermediate portion are substantially the same.

[0022]In some aspects, the cavity has a substantially continuous cross-sectional shape between the first housing opening, the first and second open ends of the intermediate portion, and the second housing opening.

[0023]In some aspects, the first housing portion includes a material receiving opening of the digging attachment. In some aspects, the second housing portion includes a material discharging opening of the digging attachment. In some aspects, the first housing surface is opposite the material receiving opening and the second housing surface is opposite the material discharging opening.

[0024]In some aspects, the length of the intermediate portion is between about four inches to about four feet. In some aspects, the different lengths of the plurality of intermediate portions vary between about four inches to about four feet.

[0025]In some aspects, the intermediate portion is attached to the first housing portion and to the second housing portion via welding.

[0026]In some aspects, the intermediate portion is attached to the first housing portion and to the second housing portion via fasteners.

[0027]In some aspects, the intermediate portion is a unitary piece.

[0028]In some aspects, the intermediate portion includes a plurality of interconnected segments positioned between the first housing portion and the second housing portion.

[0029]In some aspects, the first housing portion includes a material receiving opening and a connector configured to be coupled to a hoist rope.

[0030]In some aspects, the digging attachment includes a door pivotably coupled to the second housing portion to selectively close a material discharging opening.

[0031]In some aspects, the first housing portion includes a plurality of first connectors and the second housing portion includes a plurality of second connectors, each of the first connectors and the second connectors configured to be coupled to an arm of an industrial excavating machine. In some aspects, at least one of the first connectors and/or at least one of the second connectors is configured to be coupled to the arm via a pitch brace. In some aspects, the first housing portion includes a digging edge positioned adjacent a material receiving opening, and the first connectors are positioned on an opposite side of the first housing portion relative to the digging edge.

[0032]In another independent aspect, provided herein is an industrial excavating machine including a boom, an arm supported for movement relative to the boom, and a digging attachment coupled to the arm, the digging attachment supported by a hoist rope extending over an end of the boom. The digging attachment defines a cavity for receiving material therein. The digging attachment includes a first housing portion including a first housing surface and a first housing opening, a second housing portion including a second housing surface and a second housing opening, and an intermediate portion positioned between the first housing portion and the second housing portion. The intermediate portion extends between a first intermediate surface at a first open end of the intermediate portion and a second intermediate surface at a second open end of the intermediate portion. The first intermediate surface is positioned proximate the first housing surface and the second intermediate surface positioned proximate the second housing surface. A profile of the first open end of the intermediate portion complements a profile of the first housing opening. A profile of the second open end of the intermediate portion complements a profile of the second housing opening. The first housing portion, the second housing portion, and the intermediate portion cooperatively define the cavity. A volume of the cavity is determined based on a length of the intermediate portion. The first housing portion is configured to be directly coupled to the second housing portion and indirectly coupled to the second housing portion via the intermediate portion.

[0033]In some aspects, the intermediate portion is configured to be one of a plurality of intermediate portions, each of the intermediate portions having a different length corresponding to a different volume of the cavity.

[0034]In another independent aspect, provided herein is a method for assembling a digging attachment. The method includes: selecting an intermediate portion from a plurality of intermediate portions, each of the intermediate portions having a different length; positioning the selected intermediate portion between a first housing portion and a second housing portion; and securing the selected intermediate portion to the first housing portion and to the second housing portion. The first housing portion, the second housing portion, and the selected intermediate portion cooperatively define a cavity of the digging attachment for receiving material therein. The cavity has a volume that is determined by the length of the selected intermediate portion.

[0035]In some aspects, the cavity has a substantially continuous profile between the first housing portion, the intermediate portion, and the second housing portion.

[0036]In some aspects, the cavity has a substantially continuous cross-sectional shape between the first housing portion, the intermediate portion, and the second housing portion.

[0037]In some aspects, securing the selected intermediate portion to the first housing portion and to the second housing portion includes attaching the selected intermediate portion to the first housing portion and to the second housing portion using fasteners.

[0038]In some aspects, securing the selected intermediate portion to the first housing portion and to the second housing portion includes welding the selected intermediate portion to the first housing portion and to the second housing portion.

[0039]In some aspects, positioning the selected intermediate portion between the first housing portion and the second housing portion includes positioning a unitary intermediate portion between the first housing portion and the second housing portion, and the unitary intermediate portion is secured to each of the first housing portion and the second housing portion.

[0040]In some aspects, positioning the selected intermediate portion between the first housing portion and the second housing portion includes positioning a plurality of segments of the selected intermediate portion in series between the first housing portion and the second housing portion. In some aspects, the method further comprises: connecting the plurality of segments of the intermediate portion together; securing a first segment of the plurality of segments to the first housing portion; and securing a second segment of the plurality of segments to the second housing portion.

[0041]In some aspects, the length of the selected intermediate portion is between about four inches to about four feet. In some aspects, the different lengths of the plurality of intermediate portions vary between about four inches to about four feet.

[0042]In some aspects, the method includes coupling a door to the second housing portion, the door being pivotable relative to the second housing portion to selectively close a material discharging opening.

[0043]Other aspects of the disclosure will become apparent by consideration of the detailed description and accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0044]FIG. 1 is a side view of a mining shovel.

[0045]FIG. 2 is a perspective view of a dipper.

[0046]FIG. 3 is a side view of the dipper of FIG. 2.

[0047]FIG. 4 is an exploded view of modular components of the dipper of FIG. 2.

[0048]FIG. 5 is a side view of the dipper of FIG. 2 in an assembled state and coupled to a handle.

[0049]FIG. 6A is a side view of a dipper including a first intermediate portion or belt having a first length.

[0050]FIG. 6B is a side view of a dipper including a second intermediate portion or belt having a second length.

[0051]FIG. 7A is a section view of a portion of a first housing, a second housing, and intermediate portion of the dipper of FIG. 2, according to one embodiment.

[0052]FIG. 7B is another section view of a portion of a first housing, a second housing, and the intermediate portion of the dipper of FIG. 2.

[0053]FIG. 8 is a section view of a first housing, a second housing, and an intermediate portion of a dipper, according to another embodiment.

[0054]FIG. 9 is a section view of a first housing, a second housing, and an intermediate portion of a dipper, according to another embodiment.

[0055]FIG. 10 is a section view of a first housing, a second housing, and an intermediate portion of a dipper, according to another embodiment.

[0056]FIG. 11 is a side view of a dipper according to another embodiment.

[0057]FIG. 12 is a side view of a dipper according to another embodiment.

[0058]FIG. 13 is an isolated view of a segmented intermediate portion of a dipper.

[0059]FIG. 14 is a section view of a first housing, a second housing, and an intermediate portion of a dipper, according to another embodiment.

[0060]FIG. 15 is a section view of a first housing, a second housing, and an intermediate portion of a dipper, according to another embodiment.

[0061]FIG. 16 is an example method for assembling a digging attachment.

[0062]Corresponding reference numerals used throughout the drawings indicate corresponding features, elements, and components.

DETAILED DESCRIPTION

[0063]Before any embodiments are explained in detail, it is to be understood that the embodiments are not limited to the details of the configuration and arrangement of components set forth in the following description or illustrated in the accompanying drawings. The embodiments are capable of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein are for the purpose of description and should not be regarded as limiting. When introducing elements of various embodiments of the present disclosure, the articles “a,” “an,” and “the” are intended to mean that there are one or more of the elements. The use of “including,” “comprising,” or “having” and variations thereof are meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Unless specified or limited otherwise, the terms “mounted,” “connected,” “supported,” and “coupled” and variations thereof are used broadly and encompass both direct and indirect mountings, connections, supports, and couplings. References to “one embodiment” or “an embodiment” of the present disclosure are not intended to be interpreted as excluding the existence of additional embodiments that also incorporate the recited features.

[0064]Relative terminology, such as, for example, “about,” “approximately,” “substantially,” and the like, used in connection with a quantity or condition would be understood by those of ordinary skill to be inclusive of the stated value and has the meaning dictated by the context (for example, the term includes at least the degree of error associated with the measurement accuracy, tolerances (for example, manufacturing, assembly, use, and the like) associated with the particular value, and the like). Such terminology should also be considered as disclosing the range defined by the absolute values of the two endpoints. For example, the expression “from about 2 to about 4” also discloses the range “from 2 to 4.” The relative terminology may refer to plus or minus a percentage (for example, 1%, 5%, 10%, or more) of an indicated value.

[0065]Functionality described herein as being performed by one component may be performed by multiple components in a distributed manner. Likewise, functionality performed by multiple components may be consolidated and performed by a single component. Similarly, a component described as performing particular functionality may also perform additional functionality not described herein. For example, a device or structure that is “configured” in a certain way is configured in at least that way but may also be configured in ways that are not explicitly listed.

[0066]FIG. 1 illustrates an industrial excavating machine such as a rope shovel 1 including a base 2, a boom 3, an elongate member (e.g., an arm or handle) 62, and a digging attachment or dipper 10. The base 2 includes a lower portion supported by traction elements (e.g., crawlers 5) and an upper portion or rotating frame supported for rotation relative to the lower portion (e.g., about an axis).

[0067]The boom 3 includes a first end 6 coupled to the rotating frame, and a second end 7 opposite the first end 6. Boom sheaves 8 are supported adjacent the second end 7 of the boom 3. The boom 3 may be pivotable relative to the base 2 about the first end 6. In some embodiments, a support structure (e.g., a gantry) may be coupled between the base 2 and the boom 3 and may limit pivoting movement of the boom 3 relative to the base 2. In the illustrated embodiment, saddle blocks 9 and a shipper shaft 11 are supported on the boom 3 between the first end 6 and the second end 7.

[0068]The elongate member (e.g., arm or handle) 62 is movably coupled to the boom 3 and includes a first end and a second end. In the illustrated embodiment, the handle 62 is supported for translational and rotational movement relative to the boom 3 by the shipper shaft 11 and the saddle blocks 9. In the illustrated embodiment, the dipper 10 is fixed to the second end of the handle 62. In other embodiments, the handle 62 may be constructed in a different manner and/or may be supported with respect to the boom 3 in a different manner. For example, the handle or stick may be a telescoping member that is pivotally connected to the boom by a yoke, and the handle/stick may be driven to extend and retract by actuation of one or more fluid cylinders or ropes. In some embodiments, the handle and dipper may be supported for movement relative to the boom via a crowd mechanism that may include a crowd pinion supported on the boom, and a crowd rack positioned on the handle that pivots about the pinion and moves translationally along the pinion.

[0069]The dipper 10 may include a digging edge having teeth 26 to engage and break apart material from a surface or structure being worked. The dipper 10 may also include a cavity for receiving or collecting the material therein.

[0070]The shovel 1 further includes a hoist system for reeling in and paying out a hoist cable or hoist rope 13. The hoist system may include a drum about which a portion of the rope 13 is wrapped. The rope 13 is secured between the drum and the dipper 10, passing over the boom sheaves 8. A tensile force or hoist force is exerted in the rope 13, which extends from the drum, around the boom sheave 8, and ultimately to the dipper 10. The dipper 10 is raised or lowered relative to the boom sheave 8 as the rope 13 is reeled in or paid out, respectively.

[0071]As shown in FIG. 2, the dipper 10 includes a first or upper housing 20, a second or lower housing portion 40, and an intermediate portion or belt 12 located between the upper housing portion 20 and lower housing portion 40. The first housing portion 20 and the second housing portion 40 may also be referred to as a first or upper housing and a second or lower housing, respectively. The upper housing 20, the lower housing 40, and the intermediate portion 12 may partially enclose a material cavity 25 of the dipper 10. The intermediate portion 12 can be secured between or coupled to each of the upper housing 20 and the lower housing 40. In some embodiments, the intermediate portion 12 may be welded to the upper housing 20 and the lower housing 40. In some embodiments, the intermediate portion 12 may be attached to the upper housing 20 and the lower housing 40 via fasteners (e.g., bolts, nuts, rivets, huck bolts, or the like).

[0072]In the illustrated embodiment, the dipper 10 is assembled from a plurality of components (e.g., the upper housing 20 and the lower housing 40) that are separately manufactured and joined together via one or more intermediate structures (e.g., the intermediate portion 12). The intermediate portion 12 may be a unitary piece or structure or may include a plurality of interconnected pieces or segments (see FIGS. 12 and 13). The intermediate portion 12 may be selected from a plurality of intermediate portions that are each configured to be positioned between and secured to the upper housing 20 and the lower housing 40. The intermediate portions may each have a different size, e.g., length. The same components (e.g., the upper housing 20 and the lower housing 40) may be used to assemble dippers of various sizes by changing the intermediate portion used. For example, each of the intermediate portions may have a different length corresponding to a different volume (e.g., cubic yardage) of the cavity, such that utilizing intermediate portions of different lengths also alters the volume (e.g., cubic yardage) of the cavity.

[0073]In some embodiments, the upper housing 20 and the lower housing 40 may be configured to be directly coupled to each other (e.g., fasteners or welding) as well as indirectly coupled to each other via the intermediate portion 12. In particular, the upper housing 20 and the lower housing 40 may be selectively coupled together without the intermediate portion 12 positioned therebetween, or the upper housing 20 and the lower housing 40 may be selectively coupled via the intermediate portion 12 positioned therebetween. In this way, in some embodiments, the intermediate portion 12 may be included or omitted to adjust the volume of the cavity.

[0074]The upper housing 20, the lower housing 40, and the intermediate portion 12 may each have a length (measured in the X-axis direction of FIG. 2), a height (measured in the Y-axis direction of FIG. 2), and a width (measured in the Z-axis direction of FIG. 2). The lengths of the upper housing 20, the lower housing 40, and the intermediate portion 12 may vary, and the intermediate portion 12 can have different lengths to change the size of the cavity 25. The upper housing 20, the lower housing 40, and the intermediate portion 12 may otherwise have similar dimensions, shapes, or profiles across at least a portion of their respective lengths. For example, for at least a portion of their respective lengths, a width of each of the upper housing 20, the lower housing 40, and the intermediate portion 12 may be substantially the same. In some embodiments, for at least a portion of their respective lengths, a height of each of the upper housing 20, the lower housing 40, and the intermediate portion 12 may be substantially the same. In some embodiments, the upper housing 20 has a height and width profile that complements a height and width profile of the intermediate portion 12 along the respective lengths of the upper housing and the intermediate portion that are proximate one another. In some embodiments, the lower housing 40 has a height and width profile that complements a height and width profile of the intermediate portion 12 along the respective lengths of the lower housing and the intermediate portion that are proximate one another. In some embodiments, the intermediate portion 12 has a substantially continuous height and width profile along its length such that the cavity 25 has a substantially continuous height and width profile (or cross-sectional shape when viewed from the X-direction of FIG. 2) along at least a portion of its length extending between the upper housing 20, the lower housing 40, and the intermediate portion 12. A “substantially continuous” profile may be temporarily interrupted, e.g., by gaps, without deviating from the scope of this phrase.

[0075]In some embodiments, the upper housing 20 may have a length of approximately eight feet, the lower housing 40 may have a length of approximately eight feet, and the intermediate portion 12 may have a length of between about four inches to about four feet. For example, the intermediate portion 12 may be one of a plurality of intermediate portions each have a different length between about four inches to about four feet. In some embodiments, the width of each of the upper housing 20, the lower housing 40, and the intermediate 12 may be fourteen feet. In some embodiments, the height of each of the upper housing 20, the lower housing 40, and the intermediate portion 12 may be eighteen feet. The plurality of intermediate portions may each have substantially the same height and width; in some embodiments, the plurality of intermediate portions may have nearly identical features except for the different lengths. The volume of the cavity 25 may be determined based on the length of the intermediate portion. For example, the intermediate portion 12 may have a length of either about six inches or about four feet. Accordingly, a 78 cubic yard dipper and a 68 cubic yard dipper may be assembled from the same upper and lower housings 20, 40 by using a differently sized intermediate portion. In addition, the components of the dipper 10 may be separately transported to a mine site to be connected and assembled locally.

[0076]Referring to FIG. 4, the upper housing 20 includes a first wall or front wall 28, a second wall or back wall 30 with a first set of connectors 36, a first side wall 32 (e.g., a left side wall), and a second side wall 34 (e.g., a right side wall) partially enclosing an inner cavity. In the illustrated embodiment, the cross-sectional shape of the upper housing 20 has a substantially rectangular profile. In some embodiments, the transitions between each of the planar portions of the walls 28, 30, 32, 34 may be rounded or arcuate. The upper housing 20 may be open at both ends 22, 23 such that the inner cavity extends through the walls 28, 30, 32, 34. A first open end 22 of the upper housing 20 defines a material receiving opening. A second open end 23 of the upper housing 20 faces the intermediate portion 12. A lip 24 is positioned adjacent the first end 22 and extends along the front wall 28, as well as partially along the left side wall 32 and the right side wall 34. The lip 24 may protrude in a direction substantially parallel with the front wall 28, as well as the portions of the left side wall 32 and the right side wall 34. Teeth 26 (FIG. 3) may be coupled to the lip 24 to provide a digging action against the surface being worked.

[0077]The lower housing 40 includes a first wall or front wall 42, a second wall or back wall 44 with a second set of connectors 52, a first side wall 46 (e.g., a right side wall), and a second side wall 48 (e.g., a left side wall) partially enclosing an inner cavity. In the illustrated embodiment, the cross-sectional shape of the lower housing 40 has a substantially rectangular profile. In some embodiments, the transitions between each of the planar portions of the walls 42, 44, 46, 48 may be rounded or arcuate. The lower housing 40 may be open at both ends 57, 58 such that the inner cavity extends through the walls 42, 44, 46, 48. A first open end 57 of the lower housing 40 faces the intermediate portion 12. A second open end 58 of the lower housing 40 defines a material discharging opening. A dipper door 15 (FIG. 1) may be coupled to the dipper (e.g., to the lower housing 40) for pivoting movement. The door 15 may be releasably secured (e.g., via a latch) to the second end 58 to selectively close the material discharging opening. When released, the weight of the dipper door 15 and any material contained within the dipper 10 causes the dipper door 15 to pivot away from the second end 58, and the material falls through the material discharging opening due to gravity.

[0078]Continuing with FIG. 4, the intermediate portion 12 includes a first wall or front wall 14, a second wall or back wall 16, a first side wall 17 (e.g., a left side wall) and a second side wall 18 (e.g., a right side wall) partially enclosing an inner cavity. In the illustrated embodiment, the cross-sectional shape of the intermediate portion 12 has a substantially rectangular profile. In some embodiments, the transitions between each of the planar portions of the walls 14, 16, 17, 18 may be rounded or arcuate. The intermediate portion 12 may be open at both ends 71, 73 such that the inner cavity extends through the walls 14, 16, 17, 18. In the illustrated embodiment, the inner cavity of the intermediate portion 12 has substantially the same cross-sectional shape as the inner cavity of the upper housing 20 and the inner cavity of the lower housing 40. In the illustrated embodiment, the inner cavity of the intermediate portion 12 has substantially the same cross-sectional shape as the material receiving opening adjacent the first end 22 and the cross-sectional shape of the material discharging opening adjacent the second end 58. In the illustrated embodiment, the intermediate portion 12 may be a unitary structure with a continuous outer edge. In some embodiments, the intermediate portion 12 may be formed from two or more pieces or segments (see FIGS. 12 and 13). In some embodiments, the two or more pieces or segments may be stacked in series, and each piece or segment may have the same height and width profile and the same or different lengths. In some embodiments, the two or more pieces or segments may be circumferentially arranged and cooperatively define the height, width, and length of the intermediate portion.

[0079]The intermediate portion 12 may be positioned between the upper housing 20 and the lower housing 40 such that a first open end 71 of the intermediate portion 12 faces the second open end 23 of the upper housing 20 and a second open end 73 of the intermediate portion 12 faces the first open end 57 of the lower housing 40. The first end 71 of the intermediate portion 12 may be secured or coupled to the second end 23 of the upper housing 20 (e.g., via welding or fasteners). The second end 73 of the intermediate portion 12 may be secured or coupled to the first end 57 of the lower housing 40 (e.g., via welding or fasteners). The opening defined by the first end 71 of the intermediate portion 12 may complement a height and width profile of (or has the same cross-sectional shape as) the opening defined by the second end 23 of the upper housing 20. Similarly, the opening defined by the second end 73 of the intermediate portion 12 may complement a height and width profile of (or has the same cross-sectional shape as) the opening defined by the first end 57 of the lower housing 40. In some embodiments, the cavity 25 (FIG. 2) of the dipper 10 may have a substantially continuous height and width profile, or a substantially continuous cross-sectional shape, between the second end 23 of the upper housing 20, the ends 71, 73 of the intermediate portion 12, and the first end 57 of the lower housing 40. The “substantially continuous” profile or cross-sectional shape may be temporarily interrupted, e.g., by gaps that exist between the intermediate portion 12 and the upper housing 20 and/or the lower housing 40, and/or by gaps that exist between segments of the intermediate portion 12, without deviating from the scope of this phrase.

[0080]As shown in FIG. 4, the upper housing 20 further includes a first housing surface 54 positioned at the second end 23 and opposite the first end 22. The lower housing 40 further includes a second housing surface 50 positioned at the first end 57 and opposite the second end 58. The intermediate portion 12 includes two end surfaces or intermediate surfaces 70a, 70b, respectively positioned at the ends 71, 73. The end surfaces 70a, 70b of the intermediate portion 12 may be separated by a distance D. During the assembly of the dipper 10, the first housing surface 54 is positioned proximate the first end surface 70a and the second housing surface 50 is positioned proximate the second end surface 70b. The first housing surface 54 may be secured or coupled to the first end surface 70a of the intermediate portion 12 (e.g., via welding or fasteners). The second housing surface 50 may be secured or coupled to the other end surface 70b of the intermediate portion 12. The housing surfaces 54, 50 may respectively mate with or abut the end surfaces 70a, 70b of the intermediate portion 12; however, in some embodiments, a gap may exist between the first housing surface 54 and the first end surface 70a and/or between the second housing surface 50 and the second end surface 70b.

[0081]In some embodiments, the housing surfaces 54, 50 may be configured to be selectively secured or coupled together or selectively secured or coupled to the respective end surfaces 70a, 70b of the intermediate portion 12. In this way, as discussed above, in some embodiments the upper housing 20 and the lower housing 40 may be configured to be directly coupled to each other with the intermediate portion 12 omitted or indirectly coupled to each other via the intermediate portion 12 positioned therebetween. The housing surfaces 54, 50 may mate with or abut one another when the housings 20, 40 are directly coupled to each other; however, in some embodiments, a gap may exist between the first housing surface 54 and the second housing surface 50 when the housings 20, 40 are directly coupled to each other. In some embodiments, the second end 23 of the upper housing 20 and the first end 57 of the lower housing 40 may have substantially the same height and width profile, or substantially the same cross-sectional shape, such that the cavity of the dipper cooperatively defined by the housing portions 20, 40 (with the intermediate portion 12 omitted) may be substantially continuous in profile or cross-sectional shape. The “substantially continuous” profile or cross-sectional shape may be temporarily interrupted, e.g., by gaps that exist between the upper housing 20 and the lower housing 40, without deviating from the scope of this phrase.

[0082]As shown in FIG. 5, the intermediate portion 12 (or an intermediate portion 12a) is generally aligned with the material receiving opening of the dipper 10 with respect to a material cavity axis B extending between the material receiving opening and the material discharging opening. The material cavity axis B may extend in the X-axis direction. The intermediate portion 12 is generally oriented in a plane A, perpendicular to the material cavity axis B and disposed between the upper housing 20 and the lower housing 40. The plane A may extend parallel to the Y-axis and the Z-axis (FIG. 2). The interior surfaces of the upper housing 20, the lower housing 40 and intermediate portion 12 are generally aligned with one another to form, or cooperatively define, a continuous material cavity 25 (FIG. 2).

[0083]The upper housing 20, the lower housing 40 and the intermediate portion 12 can be manufactured separately and assembled at a working location (e.g., at a mine-site). After assembly, the dipper 10 may be coupled to the end of the handle 62. In some embodiments, one of the housing portions (e.g., the lower housing 40) is coupled to the handle 62 directly, and the other housing portion (e.g., the upper housing 20) is coupled to the handle 62 via an intermediate link 60 (e.g., a pitch brace). As shown in FIG. 5, the first set of connectors 36 positioned on the upper housing 20 may be coupled to the link 60, and the second set of connectors 52 positioned on the lower housing 40 may be coupled to the handle 62. Stated another way, the upper housing 20 is coupled to the lower housing 40 via the intermediate portion 12a and via the handle 62 and link 60. It will be understood that, in some embodiments, the first set of connectors 36 may be coupled directly to the handle 62 and the second set of connectors 52 may be coupled to the link 60. In the illustrated embodiment, the upper housing 20 also includes an upper coupling 66 (e.g., a bail coupling) for coupling to the hoist rope 13 (FIG. 1), for example, via a bail and/or equalizer.

[0084]As shown in FIGS. 6A and 6B, the upper housing 20 and the lower housing 40 may be coupled by one of various intermediate portions or belts, and each intermediate portion may have a different length measured in the X-axis direction. For example, intermediate portion 12a (FIG. 6A) may have a first length D1, and the intermediate portion 12 (FIG. 6B) may have a second length D2 that is different (e.g., shorter) than D1. In some embodiments, the intermediate portions may have a length between about four includes to about four feet, such as between about 0.5 feet to about four feet, and one or more additional intermediate portions may have an intermediate length. If desired, a length of the dipper 10 can be readily modified (e.g., during assembly and/or during repair or rebuild) by changing the intermediate portion 12, thereby altering the volume (in cubic yards or cuyd) of the dipper 10 depending on the application or mine site requirements.

[0085]For example, FIG. 6A illustrates a dipper 10a having a volume of about 78 cuyd, with the lower housing 40 having a length DB, the upper housing 20 having a length DT and the intermediate portion 12a having a length D1. FIG. 6B illustrates a dipper 10 having a volume of about 68 cuyd, with the lower housing 40 having a length DB, the upper housing having a length DT, and the intermediate portion 12 having a length D2. The length of the lower housing DB and the length of the upper housing DT are the same for both the dipper 10a and the dipper 10. In other words, each of the dippers 10, 10a are constructed from upper housings 20 having the same length and lower housing 40 having the same length, while the total lengths and volumes of the dippers are different due to the length of the respective intermediate portions 12, 12a. Among other things, the modular dipper permits similarly sized components (e.g., dipper door) to be utilized on a wide range of dipper sizes.

[0086]Conventional dippers for electric mining shovels are generally fabricated as a unitary structure with a movable door. However, a variety of dipper sizes may be required depending on various factors, such as the size of the associated mining shovel, mining conditions, material density, payload targets, and truck-pass matching. The manufacturing process for each dipper can be complex and can require a long lead time since the dipper bodies frequently are custom built. In contrast, the modular dipper 10 can be manufactured and assembled to accommodate any one of various sizes while using common inventory.

[0087]FIGS. 7A and 7B illustrate an exemplary connection between the upper housing 20, the intermediate portion 12, and the lower housing 40. In this embodiment, the first housing surface 54 (FIG. 4) of the upper housing 20 is welded to an associated end surface 70a (FIG. 4) of the intermediate portion 12. The second housing surface 50 (FIG. 4) of the lower housing 40 is welded to another associated end surface 70b (FIG. 4) of the intermediate portion 12. In the illustrated embodiment, the inner and outer edges of the intermediate portion 12 and the housings 20, 40 are beveled to facilitate a welded joint along the perimeter of the intermediate portion 12. The welds are applied at the seams defined between the adjacent beveled edges of the intermediate portion and each of the upper housing 20 and the lower housing 40. The intermediate portion 12 may be welded to the housing along an inner edge, an outer edge, or both the inner and outer edges.

[0088]FIG. 8 illustrates another exemplary connection between the upper housing 20, the intermediate portion 12, and the lower housing 40. In this embodiment, the upper housing 20 includes through holes 80 spaced apart along a perimeter of the first housing surface 54 (FIG. 4), and the lower housing 40 includes through holes 82 spaced apart along the perimeter of the second housing surface 50 (FIG. 4). The end surface 70a (FIG. 4) of the intermediate portion 12 adjacent the first housing surface 54 includes through holes 84, and the end surface 70b (FIG. 4) of the intermediate portion 12 adjacent the second housing surface 50 includes through holes 86. The through holes 84 are aligned with the through holes 80, and the through holes 86 are aligned with the through holes 82. The intermediate portion can be secured to the upper housing 20 and the lower housing 40 via fasteners 88, 90 (e.g., threaded bolts). In some embodiments, the fasteners 88, 90 may independently include bolts, nuts, rivets, huck bolts, or the like. In the illustrated embodiment, each fastener 88 extends through an associated pair of through holes 80, 84, and each fastener 90 extends through an associated pair of through holes 82, 86. The through holes may be evenly spaced around the respective outer edges of the upper housing 20, the lower housing 40, and intermediate portion 12. In some embodiments, the through holes may not be evenly spaced apart and may instead be selectively distributed, e.g., at regular or irregular intervals. In some embodiments, the through holes may be distributed to accommodate a difference in tensile loading across the back of the dipper 10 compared to the front of the dipper 10. The coupling of the upper housing 20, lower housing 40, and the intermediate portion 12 simplifies assembly of the dipper and provides the ability to change a dipper size by changing the intermediate portion using tools that are available on-site.

[0089]As shown in FIG. 9, in some constructions, a fastener 90 may extend through a first housing surface of the upper housing 20, the end surfaces 70a, 70b of the intermediate portion 12, and the second housing surface 50 of the lower housing 40. It is understood that other types of fasteners (e.g., a threaded rod) may be used in other embodiments. In the illustrated embodiment, the fastener 90 may include a bolt and a retainer (e.g., a nut). In some embodiments, drilled and/or tapped holes may be utilized.

[0090]Depending on where the assembly of the dipper is performed, welding can be performed manually or autonomously (e.g., robotically). In some embodiments, a manual or autonomous track welding operation may be performed to secure components of the dipper together. In some embodiments, shown in FIG. 10, a rail 100 may be temporarily mounted to a surface 102 of the intermediate portion 12. An autonomous (e.g., robotic) welder can be locked to the rail and may travel around a perimeter of the dipper, autonomously welding the connection of the intermediate portion 12 to the lower housing 40 and upper housing 20. The weld produced via the track welding operation may include a fillet weld, bevel weld, or groove weld. In some embodiments, the partially welded dipper can be re-positioned (for example, rotated 180 degrees about a vertical axis), and the opposite groove can also be welded in a similar manner. Such an assembly process can simplify field welding, reduce operator hours, maintain quality of the welded joint and reduce the need for lifting/repositioning the dipper when welding.

[0091]As shown in FIG. 11, an intermediate portion 110 may include two or more pieces or segments. In the illustrated embodiment, the intermediate portion 110 includes a first piece or segment 112 and a second piece or segment 114. The first segment 112 and second segment 114 may have the same or different lengths depending on the work machine, specific application, and volume requirements. An upper housing 116 may have a discontinuous rigged edge 118 or may jog over and the lip 120 may be directly connected to the second piece 114 of the intermediate portion and extend outwardly.

[0092]FIG. 12 depicts another example of a dipper 200 that includes a segmented intermediate portion 212 positioned between an upper housing 220 and the lower housing 240. In this embodiment, the segmented intermediate portion 212 includes first and second segments 214, 216 positioned in series (or stacked) between the upper housing 220 and the lower housing 240. In the illustrated embodiment, the segmented intermediate portion 212 includes two segments 214, 216; however, any number of segments can be included in the segmented intermediate portion, e.g., two segments, three segments, four segments, five segments, or more than five segments. The first segment 214 may be coupled to the upper housing 220 (e.g., via welding or fasteners). The second segment 216 may be coupled to the lower housing 240 (e.g., via welding or fasteners). The first and second segments 214, 216 may be coupled together, or interconnected, (e.g., via welding or fasteners) to join the upper housing 220 and the lower housing 240. The first and second segments 214, 216 may be coupled together before or after being coupled to the respective housings 220, 240.

[0093]The first and second segments 214, 216 may cooperatively define a length of the intermediate portion 212 (measured in the X-axis). A height and width profile, or cross-sectional shape when viewed from the X-direction, of the first segment 214 may be substantially the same as a height and width profile, or cross-sectional shape, of at least a portion of the upper housing 220. A height and width profile, or cross-sectional shape when viewed from the X-direction, of the second segment 216 may be substantially the same as a height and width profile, or cross-sectional shape, of at least a portion of the lower housing 240. In some embodiments, the first and second segments 214, 216 may have substantially the same height and width profile, or substantially the same cross-sectional shape, such that the segmented intermediate portion 212 has a substantially continuous height and width profile (or cross-sectional shape when viewed from the X-direction) along its length between the upper housing 220 and the lower housing 240. The “substantially continuous” profile or cross-sectional shape may be temporarily interrupted, e.g., by gaps between the segments 214, 216, between the first segment 214 and the upper housing 220, and/or between the second segment 216 and the lower housing 240, without deviating from the scope of this phrase.

[0094]FIG. 13 depicts another example of a segmented intermediate portion 300. The intermediate portion 300 includes a plurality of segments 302, 304, 306, 308 that cooperatively define the height, width, and length of the intermediate portion 300. In the illustrated embodiment, the intermediate portion 300 includes four segments 302, 304, 306, 308 that are arranged circumferentially and each segment defines a corner of the intermediate portion 300. In some embodiments, the intermediate portion 300 may include more or fewer segments, such as two segments, three segments, four segments, five segments, or more than five segments. The segments 302, 304, 306, 308 may be coupled together, or interconnected, via fasteners or welding for example.

[0095]The features of the segmented intermediate portions 212, 300 can be utilized in combination in some examples. For example, one or more segments 214, 216 of the intermediate portion 212 of FIG. 12 may be segmented with a plurality of segments 302, 304, 306, 308 as shown in FIG. 13.

[0096]In some embodiments, the components of a dipper (e.g., the upper housing, lower housing, and intermediate portion, or the upper and lower housing) may be assembled via both welding and mechanical means (e.g., fasteners). FIG. 14 depicts one example in which alignment or backing plates 400, 402 and fasteners 404 (e.g., bolts) can be used to align an upper housing 420 and an intermediate portion 412 of a dipper for a subsequent welding process and/or to align a lower housing 440 and the intermediate portion 412 of the dipper for a subsequent welding process. The backing plates 400, 402 may overcome challenges associated with aligning large structures such as the upper housing 420, intermediate portion 412, and lower housing 440, which may require precise alignment for welding. In this example, a first backing plate 400 is positioned proximate (e.g., in contact with) the first housing 420 and the intermediate portion 412 and a second backing plate 402 is positioned proximate (e.g., in contact with) the second housing 440 and the intermediate portion 412. Fasteners 404 are respectively inserted through the first housing 420, the intermediate portion 412, or the second housing 440 and received by the backing plates 400, 402. For example, the fasteners 404 may be inserted through oversized holes formed (e.g., burned or machined) in the first housing 420, the intermediate portion 412, and the second housing 440, and the fasteners 404 are received by corresponding holes in the backing plates 400, 402 to align the intermediate portion 412 with each of the upper housing 420 and the lower housing 440.

[0097]The alignment or backing plates 400, 402 fastened to the intermediate portion 412 and the upper and lower housing 420, 440, respectively, may align the intermediate portion 412 and the housings 420, 440. The backing plates 400, 402 may also operate as a welding backup bar. When the fasteners 406 are tightened or torqued, the backing plates 400, 402 may draw the intermediate portion 412 and the respective upper and lower housing 420, 440 together, which may minimize gaps and improve alignment for welding. Once the intermediate portion 412 is aligned with the upper and lower housing 420, 440 via the backing plates 400, 402, a welding process may be performed to form welds or joints 406 at the interface between the intermediate portion 412 and the upper housing 420 and the interface between the intermediate portion 412 and the lower housing 440. As shown in FIG. 14, the backing plates 400, 402 are located at the welded interfaces behind the joints 406. In some embodiments, after the joints 406 are formed, the backing plates 400, 402 may be removed. Accordingly, the backing plates 400, 402 may be temporary support structures for the welding process that facilitate field alignment of the primary structural sections (e.g., the upper housing 420, the lower housing 440, and the intermediate portion 412). In some embodiments, the backing plates 400, 402 may be permanent supports.

[0098]FIG. 15 depicts another example in which an intermediate portion 512 of a dipper is utilized as an alignment or backing plate at each interface with an upper housing 520 and the lower housing 540. The dipper of FIG. 15 may be assembled similar to the dipper of FIG. 14, except the intermediate portion 512 is used in lieu of the backing plates 400, 402. In this example, the intermediate portion 512 is positioned offset from the upper housing 520 and the lower housing 540. As such, a face-to-face interface is formed between the intermediate portion 512 and each of the upper housing 520 and the lower housing 540. Fasteners 504 may be inserted through each interface to initially secure the intermediate portion 512 to the upper and lower housing 520, 540. A welding process may then be performed to form welds or joints 506 at the offset edges of the intermediate portion 512 and the upper housing 520 and the offset edges of the intermediate portion 512 and the lower housing 540.

[0099]FIG. 16 depicts an example of a method 600 for assembling a digging attachment, such as the dipper 10 described above. The method 600 includes selecting 602 an intermediate portion, e.g., the intermediate portion 12, from a plurality of intermediate portions, each of the intermediate portions having a different length, e.g., D1 or D2. The method 600 also includes positioning 604 the selected intermediate portion between a first housing portion, e.g., the upper housing 20, and a second housing portion, e.g., the lower housing 40. The method 600 also includes securing 606 the selected intermediate portion to the first housing portion and to the second housing portion. The first housing portion, the second housing portion, and the selected intermediate portion cooperatively define a cavity of the digging attachment for receiving material therein, and the cavity has a volume that is determined by the length of the selected intermediate portion. In some embodiments, the cavity has a substantially continuous profile between the first housing portion, the intermediate portion, and the second housing portion. For example, the cavity may have a substantially continuous cross-sectional shape between the first housing portion, the intermediate portion, and the second housing portion. Here again, gaps may exist, for example between the intermediate portion and the first housing portion and/or the second housing portion, without deviating from the “substantially continuous” profile or cross-sectional shape of the cavity.

[0100]In some embodiments, securing 606 the selected intermediate portion to the first housing portion and to the second housing portion includes attaching the selected intermediate portion to the first housing portion and to the second housing portion using fasteners (e.g., bolts, nuts, rivets, huck bolts, or the like). In some embodiments, securing 606 the selected intermediate portion to the first housing portion and to the second housing portion includes welding the selected intermediate portion to the first housing portion and to the second housing portion.

[0101]In some embodiments, positioning 604 the selected intermediate portion between the first housing portion and the second housing portion includes positioning a unitary intermediate portion between the first housing portion and the second housing portion, and the unitary intermediate portion is secured to each of the first housing portion and the second housing portion. In some embodiments, positioning 604 the selected intermediate portion between the first housing portion and the second housing portion includes positioning a plurality of segments of the selected intermediate portion in series between the first housing portion and the second housing portion. In some embodiments, the method 600 further includes connecting the plurality of segments of the intermediate portion together (e.g., via welding or fasteners), securing a first segment of the plurality of segments to the first housing portion (e.g., via welding or fasteners), and securing a second segment of the plurality of segments to the second housing portion (e.g., via welding or fasteners). The order of operations are not limited to the order described and can be performed in any suitable order. For example, the plurality of segments may be connected together before the first segment is secured to the first housing portion and/or before the second segment is secured to the second housing portion, or the first segment may be secured to the first housing portion and/or the second segment may be secured to the secured housing portion before the plurality of segments are connected together.

[0102]In some embodiments, the method may include, in lieu of the selecting 602 step, securing or directly coupling the first housing portion and the second housing portion to each other without an intermediate portion positioned therebetween. For example, the first housing portion and the second housing portion may be secured via fasteners (e.g., bolts, nuts, rivets, huck bolts, or the like). In some embodiments, the first housing portion and the second housing portion may be secured via welding.

[0103]The foregoing has been described in relation to a rope shovel. It will be apparent to one skilled in the art that the embodiments described herein could likewise be used for other industrial machines. The embodiment(s) described above and illustrated in the figures are presented by way of example only and are not intended as a limitation upon the concepts and principles of the present disclosure. As such, it will be appreciated that variations and modifications to the elements and their configuration and/or arrangement exist within the spirit and scope of one or more independent aspects as described.