In the difficult digging applications of the Canadian Oil Sands, a new Cat dipper with a completely fresh, patent-pending design improves perforᴍᴀɴce and dependability without adding to the load on the hoist and crowd capabilities of the Cat 7495 HF Electric rope shovel.
Shimming and insert improvements by themselves are anticipated to boost uptime by up to 0.25 percent, which might result in sizable output increases. The improved lip cutting angle in the new design greatly reduces heel wear. In order to increase stiffness and dig perforᴍᴀɴce, ground engagement tools are pitched upward. This produces less bending force and uniform tooth wear from top to bottom.
The new design, which is around 7% lighter than the existing 45.9 m3 (60 yd3) latching dipper, has more cutting force that may be used to produce more material under challenging digging conditions and maintain more consistent fill factors. Engineers lowered the weight of the dipper using finite element analysis and virtual validation ᴍᴇᴛʜods, which resulted in less stress on the machine as well as longer life and enhanced dependability for vital parts of the shovel’s front end.
The dipper includes a revolutionary vertical latch system that decreases part maintenance and enhances system perforᴍᴀɴce, resulting in cheaper operating costs. The latch’s tapered-end shape raises the insert surfaces apart rather than allowing them to slide. The design extends wear life while cutting down on service time, increasing uptime. A quick-change latch bar guide plate further cuts down on maintenance time and expenses.
The new single wet-disk snubber’s improved connection decreases the door’s rotational kinetic energy by more than 40% on shutting and by 75% on opening, extending the door’s service life. In over 900 simulations, Caterpillar engineers tested over 300 different dipper configurations, analyzed perforᴍᴀɴce data, and produced stress and wear charts for the models. The “virtual” machine, operator, and pile were all verified using real machine data, which Caterpillar subject matter experts checked for correctness. According to the simulations, customers may experience improved penetration and fill on each pass with the modified dipper geometry.
In the video below, we’ll see how the New Cat® dipper for Cat 7495 HF Electric Rope Shovels improves uptime and digging perforᴍᴀɴce.
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Video resource: Caterpillar Mining