A super-sized rope shovel development from Bucyrus

By Anthony Donovan
With innovations like the HydraCrowd (TM) and the LatchFree (TM) Dipper System, coupled with the efficiency of AC IGBT electrics and enhanced propel power, the rope shovel’s safety, reliability, and productivity bypasses that of its predecessors.
Headlining the design improvements of the 495HR² is a newly designed, patent-pending operator’s station and cab. A two-year, $1 million plus research and development project provided the foundation from which the cab design emerged.
Bucyrus design engineers, armed with insight into the aspects most desired by Bucyrus customers, set-out to develop a cab that delivers more comfort, added safety, greater reliability and enhanced productivity.
Predicated upon the principle that a comfortable operator is a productive operator, Bucyrus design engineers incorporated an ergonomic, fully adjustable and isolated operator’s seat as the focal-point of the new cab design. The leather bound operator’s seat includes infinitely variable armrests and a fully pneumatic suspension system with an integrated air compressor. The armrests can float with the operator’s arms during operation, facilitating unimpeded armrest movement towards the body, away from the body, and into resting positions on the operator’s legs.
Recognising that vibration and noise have a tiring effect on operators, meticulous efforts were taken to minimise cab vibration and noise, further enhancing the overall comfort of the newly designed operator’s cab. Structurally, the cab is bolstered by an extended machine house underneath for improved stability. In addition, the cab is mounted on shock-absorbing rubber isolators, reducing the vibration imposed on the cab, and most importantly the shovel operator, during machine operation. Rattle-free cabinet and closet door fasteners ensure a quiet work environment, and drawers with a patented dual latching system won’t open unexpectedly during shovel operation. Lastly, all cab walls are adequately insulated for internal and external sound dampening.

Increased propel power
Another feature of the rope shovel is an enhanced propel system, garnering a 12 per cent increase in maximum propel torque. This system was designed to combat propel challenges encountered in the mine environment, most notably in the soft footing found in oilsands and wet digging environments. It provides the necessary power boost to maneuver the machine in tough digging situations, avoiding downtime associated with ground-lodged shovels.
The increase in maximum propel torque was achieved through the design of a new, larger planetary gear case. When coupled with the highly reliable AC variable speed propel motor it supplies increased power to move this massive machine with ease. The propel motor is mounted to an angled motor base to increase clearance under the motor, further improving the reliability of the components by moving them away from the pit floor.