WEAR ASSEMBLY REMOVAL AND INSTALLATION

• US 20150107075A1
• Filed: 10/21/2014
• Published: 04/23/2015
• Est. Priority Date: 10/21/2013
• Status: Active Grant

• Current Assignee: ESCO Group LLC (WEIR Group PLC)
• Original Assignee: ESCO Corporation (WEIR Group PLC)
• Inventors: CLARKE, ROD, CARPENTER, RYAN J., COWGILL, NOAH, FINLEY, TAYLOR M., BLOMBERG, JOSEPH E., CARPENTER, CHRISTOPHER M., BEWLEY, ERIC L.
• Granted Patent: US 11,015,324 B2
• Time in Patent Office: Days
• US Class Current: 29/402.08
• CPC Class Codes: B23P 19/033 using vibration
• CPC Class Codes: B25J 11/00 Manipulators not otherwise provided for
• CPC Class Codes: B25J 15/0066 with different types of end effectors, e.g. gripper and welding gun B25J15/0057 and B25J15/0061 take precedence
• CPC Class Codes: B25J 15/0608 with magnetic holding means
• CPC Class Codes: E02F 5/02 for digging trenches or ditches machines for making foundation slots E02F3/205, E02F3/475 take precedence; agricultural ploughs for working ridges A01B13/02
• CPC Class Codes: E02F 9/2816 Mountings therefor
• CPC Class Codes: E02F 9/2833 Retaining means, e.g. pins
• CPC Class Codes: E02F 9/2891 Tools for assembling or disassembling
• CPC Class Codes: Y10T 29/4973 Replacing of defective part
• CPC Class Codes: Y10T 29/53013 Computer input
• CPC Class Codes: Y10T 29/53478 with magazine supply
• CPC Class Codes: Y10T 29/53974 having means to permit support movement while work is thereon

Abstract

A process and tool for installing and removing various kinds of wear parts used with earth working equipment. The process and tool allows the operator to remove and install the wear parts at a safe distance so that the operator is physically remote from the potential risks of the removal and installation process. The tool may be manually operated via an operator or the tool may be a semi-automated or fully automated.

Claims

1. A tool comprising at least one auxiliary tool to hold a wear member mounted on earth working equipment, at least one manipulator movably supporting the at least one auxiliary tool, wherein the at least one manipulator and the at least one auxiliary tool cooperate to remove the wear member from the earth working equipment, a controller to direct the movements of the at least one auxiliary tool and at least one manipulator, and a mobile base to move the tool from a first location to the earth working equipment with the wear member.

2. A tool in accordance with claim 1 wherein the mobile base is a service vehicle drivable to a desired location for removing the wear member from the earth working equipment.

3. A tool in accordance with claim 1 wherein the mobile base is a wheeled service station movable to a desired location for removing the wear member from the earth working equipment.

4. A tool in accordance with claim 1 wherein the mobile base is a tracked service station movable to a desired location for removing the wear member from the earth working equipment.

5. A tool in accordance with claim 1 including a database to provide the controller with information about at least one of i) the earth working equipment, ii) the wear members on the earth working equipment, and iii) the wear members that need replacement.

6. A tool in accordance with claim 1 including an input device for receiving data regarding the earth working equipment to be used by the controller.

7. A tool comprising at least one auxiliary tool for holding a wear member mounted on earth working equipment, at least one manipulator movably supporting the at least one auxiliary tool, an input device for receiving data regarding the earth working equipment and storing the data in a database, and a controller operating the at least one auxiliary tool and the at least one manipulator to hold and remove the wear member from the earth working equipment based at least partially on the data received by the input device.

8. A tool in accordance with claim 7 wherein the database provides the tool with information about at least one of:

i) the earth working equipment, ii) the wear members on the earth working equipment, and iii) the wear members that need replacement.

9. A tool in accordance with any one of claim 7 wherein the controller records the database details based on processes previously completed by the tool.

10. A tool in accordance with any one of claim 7 including a device for accessing the database remotely.

11. A tool in accordance with any one of claim 7 including an encoding element for providing data for the database.

12. A tool in accordance with claim 11 wherein the encoding element is an RFID.

13. A tool in accordance with claim 11 wherein the encoding element is a barcode.

14. A tool in accordance with claim 13 wherein the barcode is a QR Code.

15. A tool in accordance with claim 7 wherein the input device receives information from a wear part monitoring unit on the earth working equipment.

16. A tool in accordance with claim 7 including at least one sensor to determine a location and orientation of the wear member to be removed.

17. A tool in accordance with claim 16 wherein the at least one senor includes a passive sensor.

18. A tool in accordance with claim 16 wherein the at least one sensor includes an active sensor.

19. A tool in accordance with any one of claim 16 wherein the at least one sensor is chosen from a group consisting of receivers, transmitters, and digital sensors.

20. A tool in accordance with any one of claim 16 wherein the at least one sensor includes a GPS receiver.

21. A tool in accordance with any one of claim 16 wherein the at least one sensor includes an electromagnetic wave receiver and an electromagnetic wave transmitter.

22. A tool in accordance with claim 21 wherein the electromagnetic wave receiver and the electromagnetic wave transmitter have a wavelength greater than the visible spectrum.

23. A tool in accordance with claim 21 wherein the wavelength falls within a range that classifies the wavelength as an infrared wavelength.

24. A tool in accordance with claim 21 wherein the wavelength falls within a range that classifies the wavelength as a microwave wavelength.

25. A tool in accordance with claim 21 wherein the wavelength falls within a range that classifies the wavelength as an RF wavelength.

26. A tool in accordance with claim 16 wherein the at least one sensor includes a mechanical wave receiver and a mechanical wave transmitter.

27. A tool in accordance with claim 26 wherein the mechanical wave transmitter transmits mechanical waves in an ultrasonic spectrum.

28. A tool in accordance with claim 16 wherein the at least one sensor includes a laser receiver and a laser transmitter.

29. A tool in accordance with claim 16 wherein the at least one sensor includes a digital inclinometer and a digital compass.

30. A tool in accordance with claim 16 wherein the sensor is at least one camera.

31. A tool in accordance with claim 7 wherein the at least one auxiliary tool includes first and second arms to contact opposite sides of the wear member.

32. A tool in accordance with claim 31 wherein the at least one auxiliary tool includes a third arm that contacts a surface of the wear member generally perpendicular to the first and second arms.

33. A tool in accordance with claim 7 wherein the at least one auxiliary tool uses a multi-jaw gripper to contact the wear member.

34. A tool in accordance with claim 7 wherein the at least one auxiliary tool includes a cartridge that is placed around the wear member to hold the wear part when removed.

35. A tool in accordance with claim 7 wherein the at least one auxiliary tool and the at least one manipulator are operable by the controller to secure a gripping piece to the wear member and engage the gripping piece on the wear member to disengage the wear member from the earth working equipment.

36. A tool in accordance with claim 35 wherein the gripping piece is a stud and the at least one auxiliary tool includes a stud welder to attach the gripping piece.

37. A tool in accordance with claim 7 wherein the at least one auxiliary tool includes a magnet to disengage the wear member from the earth working equipment.

38. A tool comprising a cartridge adapted to receive and hold a wear member mounted on earth working equipment, a manipulator movably supporting the cartridge, and a controller operating the manipulator to install the wear member in the cartridge and removing the cartridge with the wear member from the earth working equipment.

39. A tool in accordance with claim 38 including a magazine containing a plurality of said cartridges each for receiving a wear member mounted on the earth working equipment.

40. A tool comprising at least one auxiliary tool to secure a gripping member to a wear member mounted on earth working equipment and to grip the attached gripping member, at least one manipulator movably supporting the at least one auxiliary tool, and a controller operating the at least one manipulator and the at least one auxiliary tool to secure the gripping member to the wear member, to grip the gripping tool and to pull the wear member from the earth working equipment.

41. A tool in accordance with claim 40 wherein the at least one auxiliary tool and the at least one manipulator are operable by the controller to release a retainer holding the wear member to the earth working equipment so that the tool can remove the wear member from the earth working equipment.

42. A tool comprising at least one auxiliary tool to release a hammerless retainer securing a wear member to earth working equipment, at least one manipulator movably supporting the at least one auxiliary tool, and a controller operating the at least one auxiliary tool and the at least one manipulator.

43. A tool in accordance with claim 42 wherein the at least one auxiliary tool and the at least one manipulator are operable to remove the retainer from the wear member to release the retainer.

44. A tool in accordance with claim 42 wherein the at least one auxiliary tool and the at least one manipulator are operable by the controller to secure a gripping piece to the retainer, grip the gripping piece and thereby release the retainer.

45. A tool in accordance with claim 42 wherein the at least one auxiliary tool and the at least one manipulator are operable to unscrew at least a portion of the retainer to release the retainer.

46. A tool in accordance with claim 42 wherein the at least one auxiliary tool is operable by the controller to drive the retainer to the release position.

47. A tool in accordance with claim 42 wherein the at least one auxiliary tool includes a magnet for release of the retainer.

48. A tool in accordance with claim 42 wherein the at least one auxiliary tool includes a vacuum to release the retainer.

49. A tool in accordance with claim 42 wherein the at least one auxiliary tool and the at least one manipulator are operable to cut out at least a portion of the retainer to release the retainer.

50. A tool in accordance with claim 49 wherein the cutter is one of a group consisting of an arc cutter, a waterjet cutter an electric air arc torch, and a laser.

51. A tool in accordance with claim 42 wherein the at least one auxiliary tool spins in a generally variable, circular motion to engage the retainer.

52. A tool in accordance with claim 51 wherein the at least one auxiliary tool includes a pneumatic wrench to release the retainer.

53. A tool in accordance with claim 51 wherein the at least one auxiliary tool includes a hydraulic wrench to release the retainer.

54. A tool in accordance with claim 42 wherein the at least one auxiliary tool includes a nozzle to spray pressurized fluid to remove fines from the retainer.

55. A tool in accordance with claim 42 wherein the at least one auxiliary tool includes a nozzle to spray pressurized fluid to remove fines from the wear member.

56. A tool in accordance with claim 54 wherein the nozzle sprays pressurized air to remove the fines.

57. A tool in accordance with claim 54 wherein the nozzle sprays pressurized liquid to remove the fines.

58. A tool in accordance with claim 56 wherein the nozzle sprays abrasive grains with the pressurized fluid to remove the fines.

59. The tool in accordance with claim 42 wherein the at least one auxiliary tool includes a vibrator to remove fines from the wear member prior to disengaging the wear member from the earth working equipment.

60. A tool in accordance with claim 59 including an air actuated permanent magnet to secure the vibrator to the wear member.

61. A tool in accordance with claim 42 including a disposal stall for receiving the wear member after removal from the earth working equipment.

62. A tool in accordance with claim 42 including fixtures for supporting the wear member after removal from the earth working equipment.

63. A tool in accordance with claim 42 wherein the at least one auxiliary tool and the at least one manipulator are operable by the controller to install a replacement wear member in place of the removed wear member.

64. A tool comprising a single manipulator, at least one auxiliary tool supported by the manipulator to hold and move a first wear member on the earth working equipment and to hold and move a second wear member at a stowage location, and a controller operating the manipulator and the at least one auxiliary tool to remove the first wear member from a base on the earth working equipment and to install the second wear member on the base.

65. A tool in accordance with claim 64 wherein the controller is programmable with the geometry of the replacement wear member and with where to place a retainer in the replacement wear member to secure the wear member to the earth working equipment.

66. A tool in accordance with claim 64 including a fixture to maintain the replacement wear member in a fixed location and orientation on the tool until the replacement wear member is held by the at least one auxiliary tool to be mounted on the earth working equipment.

67. A tool in accordance with claim 64 wherein the at least one auxiliary tool verifies that the replacement wear member is fully installed on the earth working equipment by comparing a location of a retainer in the replacement wear member with a previously established location of a retainer on the removed wear member.

68. A tool in accordance with claim 64 wherein the at least one auxiliary tool includes camera to verify that the replacement wear member is fully installed on the earth working equipment by performing a visual check.

69. A tool in accordance with claim 64 wherein the at least one manipulator includes a hydraulic manipulator.

70. A tool in accordance with claim 64 wherein the at least one manipulator includes a servo-electric manipulator.

71. A tool in accordance with claim 64 wherein the at least one manipulator includes a pneumatic manipulator.

72. A tool in accordance with claim 64 wherein the controller operates on programmable logic to fully automate the use of the tool.

73. A tool in accordance with claim 72 including a switch to convert the tool from a fully automated mode to a manual mode where the tool is operated by an operator.

74. A tool in accordance with claim 64 wherein the controller operates on programmable logic to at least partially automate the use of the tool.

75. A tool in accordance with claim 64 wherein the controller operates at least partially manually by a remote user.

76. A tool in accordance with claim 64 wherein the controller is manually operated by a remote user.

77. A tool comprising a manipulator, at least one auxiliary tool movably supported by the manipulator for holding and removing a wear member on earth working equipment, and a controller operating the manipulator and the at least one auxiliary tool at least partially manually by a remote user.

78. A tool in accordance with claim 77 wherein the controller includes a joystick.

79. A tool in accordance with claim 77 wherein the controller provides feedback to the operator.

80. A tool in accordance with claim 79 wherein the feedback is haptic.

81. A tool in accordance with claim 79 wherein the feedback is visual.

82. A tool in accordance with claim 79 wherein the feedback is audible.

83. A tool in accordance with claim 77 wherein the at least one auxiliary tool and the at least one manipulator are operable by the controller to install a replacement wear member in place of the removed wear member.

84. A tool in accordance with claim 77 wherein the at least one auxiliary tool and the at least one manipulator are operable by the controller to release a retainer holding the wear member to the earth working equipment so that the tool can remove the wear member from the earth working equipment.

85. A tool in accordance with claim 84 wherein the at least one auxiliary tool and the at least one manipulator are operable to remove the retainer from the wear member to release the retainer.

86. A tool in accordance with claim 77 wherein the at least one auxiliary tool includes a magnet to contact the wear member to secure the wear member and prevent premature disengagement from the earth working equipment during the removal process.

87. A tool in accordance with claim 86 wherein the magnet is chosen from a group consisting of air actuated permanent magnets, electrically re-polarized permanent magnets, and electromagnets.

88. A tool in accordance with claim 77 wherein the controller has error handling means to reset the tool in the event the earth moving equipment moves relative to the tool during the removal process.

89. A tool in accordance with claim 77 including a mobile base to move the tool from a first location to the earth working equipment with the wear member.

90. A mining tool to remove a wear member from earth working equipment in a mine, the mining tool comprising at least one auxiliary tool to release a retainer securing the wear member to the earth working equipment, at least one manipulator movably supporting the at least one auxiliary tool, and a controller operating the at least one auxiliary tool and the at least one manipulator.

91. A mining tool in accordance with claim 90 wherein the controller operates the at least one manipulator and the at least one auxiliary tool to engage and remove the wear member from the earth working equipment following release of the retainer.

92. A mining tool to remove a wear member from earth working equipment in a mine, the mining tool comprising at least one auxiliary tool to hold the wear member, at least one manipulator movably supporting the at least one auxiliary tool to remove the wear member from the earth working equipment, and a controller to operate at least one auxiliary tool and the at least one manipulator.

93. A mining tool in accordance with claim 92 including a mobile base to move the tool from a first location to the earth working equipment with the wear member.

94. A mining tool in accordance with claim 92 wherein the at least one auxiliary tool and the at least one manipulator are operable by the controller to install a replacement wear member in place of the removed wear member.

95. A mining tool in accordance with claim 94 wherein there is only one manipulator.

96. A mining tool in accordance with claim 92 wherein the controller operates on programmable logic to at least partially automate the use of the tool.

97. A mining tool in accordance with claim 92 wherein the controller operates at least partially manually by a remote user.

98. A cartridge to house a wear member for earth working equipment comprising a housing that has a top wall, a bottom wall, and two opposing side walls connecting the top and bottom walls, and a rear end that is generally open to allow the cartridge to be installed over the wear member.

99. A cartridge in accordance with claim 98 wherein the cartridge has interior walls and at least one locator secured to one of the said interior walls of the cartridge to assist in properly positioning the wear part within the cartridge.

100. A cartridge in accordance with claim 98 wherein the cartridge includes a first chamber for receiving the wear member from the earth working equipment and a second chamber for receiving a replacement wear member to be mounted on the earth working equipment in place of the removed earth working equipment.

101. A process comprising operating a powered manipulator to move an auxiliary tool supported on the manipulator into proximity with a wear member on earth working equipment in a mine, operating the auxiliary tool to contact and hold the wear member, and operating one or more of the auxiliary tool and the manipulator to remove the wear member from the earth working equipment.

102. A process comprising operating a powered manipulator to move an auxiliary tool supported on the manipulator into proximity with a retainer securing a wear member to earth working equipment in a mine, operating the auxiliary tool to contact and hold the retainer, and operating one or more of the auxiliary tool and the manipulator to move the retainer to a release position to permit removal of the wear member from the earth working equipment.

103. A process comprising transporting a tool on a wheeled vehicle to earth working equipment, releasing a retainer securing a wear member to the earth working equipment, and removing the wear member from the earth working equipment following release of the retainer all while the operator remains remote from the wear member.

104. A process in accordance with claim 103 including installing a replacement wear member on the earth working equipment in place of the removed wear member.

105. A process in accordance with any one of claim 103 including using a controller with programmable logic to operate at least one manipulator and at least one auxiliary tool to automatically conduct at least one of the steps of the process.

106. A process in accordance with any one of claim 103 including using a user operated controller to operate at least one manipulator and at least one auxiliary tool to manually conduct at least one of the steps of the process with the user at a remote location.

107. A process in accordance with any one of claim 103 including using a controller with programmable logic to operate at least one manipulator and at least one auxiliary tool to automatically conduct all of the steps of the process.

108. A process in accordance with any one of claim 103 including using a user operated controller to operate at least one manipulator and at least one auxiliary tool to manually conduct at least one of the steps of the process with the user at a remote location.

109. A process comprising operating a powered manipulator to move an auxiliary tool supported on the manipulator into proximity with a wear member on earth working equipment, operating the auxiliary tool to hold the wear member, operating one or more of the auxiliary tool and the manipulator to remove the wear member from the earth working equipment, and using a user operated controller to operate at least one manipulator and at least one auxiliary tool to manually conduct at least one of the steps of the process with the user at a remote location.

110. A process comprising operating a powered manipulator to move an auxiliary tool supported on the manipulator into proximity with a retainer securing a wear member to earth working equipment, operating the auxiliary tool to contact and hold the retainer, operating one or more of the auxiliary tool and the manipulator to move the retainer to a release position to permit removal of the wear member from the earth working equipment, and using a user operated controller to operate at least one manipulator and at least one auxiliary tool to manually conduct at least one of the steps of the process with the user at a remote location.

111. A process for replacing a wear member mounted on earth working equipment comprising the steps of i) powering at least one auxiliary tool secured to a manipulator, ii) securing the wear member to the auxiliary tool iii) disengaging a hammerless retainer holding the wear member to a base on the excavating equipment;

iv) pulling the wear member from the base with the manipulator;

v) transporting the wear member to a disposal stall with the manipulator;

vi) disengaging the auxiliary tool from the wear member;

vii) securing a replacement wear member to the auxiliary tool;

viii) maneuvering the replacement wear member toward the excavating equipment with the manipulator;

ix) installing the replacement wear member on the base with the manipulator;

x) securing the replacement wear member to the base with a hammerless retainer; and

xi) disengaging the replacement wear member from the auxiliary tool.

112. A process for removing a wear member from earth working equipment comprising the steps of i) maneuvering a tool from a location remote to the earth working equipment to a location adjacent the earth working equipment, ii) powering an auxiliary tool secured to a manipulator on the tool, iii) securing the wear member to the auxiliary tool, and iv) disengaging the wear member from a base on the earth working equipment.

113. A process for removing a retainer securing a wear member to a base on earth working equipment, the process including the steps of i) maneuvering a tool from a location remote to the earth working equipment to a location adjacent the earth working equipment, ii) powering an auxiliary tool secured to a manipulator on the tool, iii) engaging the retainer with the auxiliary tool, and iv) disengaging the retainer from the base.