Title of Invention

METHOD AND APPARATUS FOR MONITORING A LOAD CONDITION OF A DRAGLINE OR ELECTRIC SHOVEL

Abstract Method of monitoring a load condition of a dragline (1) or an electric shovel, the dragline comprising a boom (4), a bucket (8), a hoist rope (10) from which the bucket is suspended from the boom, and a drag rope (18) for dragging the bucket, the boom extending substantially along a boom axis (BA) in its normal, unstressed state, characterized in that it comprises the step of using technical means (26, 28; 42; 46; 48; 60-70; 76, 80; 82; GPS1-GPS-3; 96, 98) to produce alignment data indicative of the lateral alignment, with respect to the plane containing said boom axis (BA), of at least one of the following dragline components (i) the hoist rope (10), (ii) the drag rope (18), (iii) the boom (4), (iv) the bucket (8), and determining said lateral alignment.
Full Text Method and apparatus for monitoring a load
condition of a dragline or electric shovel
The present invention relates to draglines and
electric shovels, such as used in open cast (or open cut)
mining, and more particularly to a method and apparatus for
monitoring their boom load conditions. In what follows,
the teachings are given for a dragline, it being understood
that they apply mutatis mutandis to an electric shovel. A
dragline is a piece of machinery used for scooping ground
material by means of a bucket suspended from a boom.
Figure 1 is a simplified diagram of a classical
dragline 1. It comprises a base unit 2, a boom 4 having a
proximal end 4a depending from the base unit and a distal
end 4b fitted, with a pulley (also known as a sheave wheel)
6, from which a bucket 8 is suspended by a metal (steel)
cable, referred to hereafter as a hoist rope 10. The base
unit 2 comprises an elevated structure 12 for passing the
hoist rope 10 to the pulley 6. In the example, this
structure includes a mast 14 at the front portion (seen
from the pulley) and stays 16, from which the hoist rope 10
connects to a drive point in the base unit 2. The hoist
rope is thereby driven from a motor drive in the base unit
to raise and lower the bucket 8 as required. The boom 4
can be driven to swing in an azimuthal (horizontal) plane
by an electric swing motor, and thereafter blocked at a set
azimuth. In the example, the swing axis SW passes through
the base unit 2, the latter being mounted on rotary
platform.
The bucket 8 is pulled towards base unit 2
substantially along the ground (horizontal) plane by
another metal (steel) cable, referred to hereafter as a
drag rope 18, to carry out the scooping action. The drag

rope 18 is attached at one end 18a to anchoring points 8a,
8b of the bucket, so that bucket's opening 8c is kept
horizontal and facing the base unit 2. The other end of
the drag rope is connected to an electrically-driven winch
(not shown) within the base unit 2.
In operation, the distal end 4b of boom 4 is
initially positioned over the zone where material 20 is to
be scooped, typically 70-100m above the ground. The hoist
rope 10 is initially adjusted to suspend the bucket 8
vertically (dotted lines) with its opening 8c confronting
piled material 20 to be scooped. The drag rope 18 is then
driven to exert a tractive force TF which drags the bucket
along the ground plane, thereby picking up material 20
through the opening 8c. At the same time, the portion of
the hoist rope 10 hanging from the pulley 6 is lengthened
to maintain the bucket suspended following along the
horizontal path of the ground. After the bucket has been
dragged over a certain distance, filled, and lifted at some
distance above the ground by hoist rope, the boom 4 is
swung to place the bucket over a dumping zone.
The bucket is then arranged to drop the material, e.g.
by tilting the bucket using an appropriate mechanism.
The dragline constitutes a large scale structure,
with a boom length of 80 metres or more and a bucket
capacity of up to 250 tonnes. The forces exerted on the
boom 4 result from a combination of the tractive force TF
exerted by the drag rope 18 and the suspending force SF
exerted on the hoist rope 10. In particular, the hoist
rope transfers a very high load to the boom, notably during
the hoisting phases for lifting and during swinging of the
boom.
Under ideal operating conditions, the bucket 8, hoist;
rope 10 and drag rope 18 are maintained in azimuthal

alignment with the principal axis of the boom BA (boom
axis), i.e. the boom, hoist rope and drag rope are kept
substantially in the same general plane, in alignment with
the horizontal projection of the boom, as shown in figure 2.
These alignments should ideally be maintained as the bucket
8 is pulled and the hoist rope 10 thereby subtends an
evolving angle α (figure 1) with the vertical in the
vertical plane containing the boom 4 . In this way, the
forces TF and SF on the boom are coplanar with the boom and
exert a compressive force on its structure. In particular,
the lateral stress LS on the boom, which would exert a
lateral bending moment, is zero under those ideal
conditions.
To meet the load demands, the boom 4 constitutes a
complex mechanical structure made of steel, typically as a
trellis box frame. The boom is a major limiting factor in
the production rate of the dragline.
If the boom is overloaded, it will crack and cause
downtime on the machine. If it is badly overloaded, it
will cause complete failure of the structure. This is a
major safety issue within a mine and can result in a fatal
accident.
The boom 4 is usually specified for operation under
these idealised working conditions, notably as regards its
safe working load limits. With a proper control of the
stresses within the boom structure, it would be possible to
allow for a controlled overload of the dragline. This
would give an improvement in output for a very low extra
cost. Savings in terms of work efficiency under these
circumstances can be typically on the order of hundreds of
thousands of dollars per year per dragline.
It is known in the art to equip the boom with strain
gauges at critical points to provide the dragline operator

with a computer display showing stress-related parameters.
This method, however, has the disadvantage of requiring
rather complex calculations based on the boom structure
characteristics, which may vary from one dragline to
another.
The present invention is based on considering the real
working conditions, and more particularly the observation
that the aforementioned ideal coplanar alignment conditions
of the boom 4 with the hoist rope 10 and/or the drag rope
18 and/or the bucket 8 are not always maintained.
Indeed, the bucket 8 can be dragged, and then hoisted,
while it is out of alignment with the plane of the boom
axis BA. This can arise since, even if the bucket's stable
equilibrium point is in alignment with the boom axis when
placed on the ground, it does not always advance smoothly
when being dragged. For instance, the bucket can slide
sideways on a slanted ground profile or the swing motors of
the dragline can be activated while the bucket still has
ground contact. Both - and other - effects can take the
bucket some distance to one side or the other of the boom
axis. This misalignment is a key issue notably during the
hoisting and swinging phases for emptying the bucket 8.
This situation is illustrated schematically in figures
3a, 3b and 3c, which illustrate respectively a laterally
misaligned bucket 8 and hoist rope 10 during the scooping
operation (bucket along -the ground), during a bucket
hoisting operation, and a boom/bucket swing operation. As
shown in figure 3a, the hoist rope 10 is laterally
misaligned by an angle (3 with respect to the vertical
alignment of the boom axis BA. The force SF on that hoist
rope thus creates on the boom 4 a lateral stress LS
proportional to SF * sin β. When the hoist rope is raising
the bucket and subsequently swinging it to a dumping point,

the full weight BW of the suspended bucket and payload is
applied to the distal end of the boom, with a consequently
large lateral force component SF.
The risk of dangerous levels of lateral force LF is
both of material damage to the boom and its fixtures, e.g.
the mast 14 and stays 16 of the elevated structure 12 and
to personnel operating in the vicinity should the boom
become damaged or break. It is to be noted that a dragline
boom 4 is of considerable cost to repair or replace, owing
to its large size and special construction, and moreover
the downtime on a dragline is also very costly in terms of
lost production.
In view of the foregoing, the present invention seeks
to assess the alignment/misalignment conditions of the boom,
ropes and bucket, enabling to have at disposal critical
information about the out of plane forces being applied to
the dragline structure, or equivalently on an electric
shovel.
The present invention offers a method and apparatus
for automatically monitoring that the aforementioned
alignment conditions with the plane of the boom axis, or
equivalently on an alignment axis of an electric shovel.
More particularly, the invention provides, according
to a first object, a method of monitoring a load condition
of a dragline or an electric shovel, the dragline
comprising a boom, a bucket, a hoist rope from which the
bucket is suspended from the boom, and a drag rope for
dragging the bucket, the boom extending substantially along
a boom axis in its normal, unstressed state,
characterised in that it comprises the step of:
using technical means to produce alignment data
indicative of the alignment, with respect to the plane

containing said boom axis, of at least one of the following
dragline components:
i) the hoist rope,
ii) the drag rope,
iii) the boom,
iv) the bucket.
Optional aspects are presented as follows.
The method can be implemented as a method of
controlling a load condition of a dragline or electric
shovel, by further comprising a step of controlling the
aforementioned load condition of the dragline or electric
shovel on the basis of the alignment data.
The alignment data can be inputted to a man-machine
interface, e.g. a display device, whereby the controlling
step is performed via a human operator.
The alignment data can be inputted to automated
control means for controlling at least one of:
i) the drive motor(s) of the hoist rope,
ii) the drive motor(s) of the drag rope,
iii) the drive motor(s) of the boom, for swinging
the boom,
to perform the controlling step.
The controlling step can be performed substantially in
real time using a feedback of the alignment data.
The controlling step can be performed in a combined
manner by a human operator via a man-machine interface and
by automated control means.
The controlling step can comprises authorising a
controlled overload of the dragline or electric shovel,
notably when controlling a maximum structure stress thereon,
as a function of the alignment data.
The method can be implemented with a boom having a
specified maximum load limit, wherein the controlling step

can comprise authorising a controlled overload of the boom
above that specified load limit as a function of the
alignment data.
In one embodiment the information on the
alignment/misalignment is fed into the dragline or electric
shovel control system to automate the response to a thus-
detected overload condition, and to control the maximum
structure stress. In this way, the controls can be slowed
or otherwise modified intelligently to ensure that there is
no excessive stress (dangerous level of stress) while
applying a controlled overload above standard
manufacturers' limits.
The technical means can be used to produce the
alignment data as quantitative data indicative of an amount
of misalignment in at least one aforementioned dragline
component.
The alignment data can be obtained by measurement on a
pulley along which the hoist rope passes to hang from a
distal end of the boom.
The pulley can be configured to sway (i.e. tilt or
lean sideways) in response to a lateral stress from the
hoist rope, and the alignment data can be obtained by
determining the amount of sway of the pulley.
The alignment data can be obtained by measuring a
lateral stress exerted on the pulley, e.g. by strain gauge
means on the pulley structure.
The alignment data can be obtained by physical contact
with at least one aforementioned dragline component.
The method can comprise physically engaging the hoist
rope with an angular or linear displacement sensor device.
The alignment data can be obtained by detecting a
lateral deflection of the boom from the boom axis.

The lateral deflection can be detected by producing
an optical beam from a source attached to the boom,
preferably at or near a distal end, and detecting a
displacement of the beam spot where it impinges a target.
The alignment data can be obtained by imaging at
least one dragline component.
The method can comprise imaging the hoist rope using
camera means.
The alignment data can be obtained by analysing
coordinate data from GPS receiver means, at least one GPS
receiver being positioned on the boom.
The alignment data can be obtained by surveying
techniques, to determine coordinate evolutions of a portion
of the boom susceptible of deflecting laterally with
respect to its boom axis.
The method can comprise surveying a target
substantially at the distal end of the boom using a
surveying device, preferably a self-tracking total station
placed at a known reference point on the dragline.
According to a second aspect, the invention relates to
an apparatus for monitoring a load condition of a dragline:
or an electric shovel, the dragline comprising a boom, a
bucket, a hoist rope from which the bucket is suspended
from the boom, and a drag rope for dragging the bucket, the
boom extending substantially along a boom axis in its
normal, unstressed state,
characterised in that it comprises means for
producing alignment data indicative of the alignment, with
respect to the plane containing the boom axis, of at least
one of the following dragline components:
i) the hoist rope,
ii) the drag rope,
iii) the boom,

iv) the bucket.
The optional aspects presented above in the context of
the method according to the first object can be applied
mutatis mutandis to the apparatus according to the second
object.
The alignment data can be used to assess/control loads
on any component of the dragline or electric shovel, e.g.
the boom 4, the mast 14, stays 16, drag and hoist ropes 8,
18, bucket 8, fixtures, mounts, the platform, axles, etc.
The invention and its advantages shall be better
understood from reading the following description of the
preferred embodiments, given purely as non-limiting
examples, with reference to the appended accompanying drawings in which:
figure 1, already described, is a simplified
diagram of a dragline,
figure 2, already described, is a simplified
diagram showing the correct, on-axis, alignment of the
bucket with respect to the boom axis,
figure 3a, already described, is a simplified
diagram showing a situation in which the bucket is
misaligned with respect to the boom axis, during a dragging
phase,
figure 3b, already described, is a simplified
diagram showing a situation in which the bucket is
misaligned with respect to the boom axis, during a bucket
hoisting phase,
figure 3c, already described, is a simplified
diagram showing a situation in which the bucket is
misaligned with respect to the boom axis, during a boom
swinging phase,
figure 4 is a schematic front view of a pulley
mechanism at the distal end of the boom, having a pulley
axle adapted to tilt to accommodate for a swaying motion,

- figure 5 is a schematic front view of the pulley
mechanism of figure 4 equipped with non-contacting sensing
devices to measure the amount of sway, i.e. tilt in the
pulley axle, and functional units to exploit that data, in
accordance with a first embodiment of the invention,
- figure 6 is a schematic front view of the pulley
mechanism of figure 4 equipped with contacting sensing
devices associated with a rotation sensor to measure the
amount of sway (tilt) in the pulley axle, and functional
units to exploit that data, in accordance with a first
variant of the first embodiment,
- figure 7 is a schematic front view of a pulley with
a fixed (non-swaying) axle at the distal end of the boom,
and strain gauges applied at different points of the pulley
and axle to determine a lateral stress in accordance with a
second embodiment,
figure 8 is a schematic side view showing the
distal end of the boom and the hoist rope, equipped with an
angular rotation sensor device mechanically coupled to the
hoist rope, in accordance with a third embodiment of the
invention,
- figure 9 is a schematic plan view of the mechanical
sensor arrangement of figure 8, also showing associated
functional units exploiting the sensor signals,
- figure 10, is a schematic plan view of a dragline
equipped with a laser and camera means for detecting a
lateral boom deflection, in accordance with a fourth
embodiment of the invention,
figure 11, is a schematic front view of the
dragline equipped with a video camera arranged to image the
hoist rope, in accordance with a fifth embodiment of the
invention,

- figure 12a is a schematic side view of a dragline
illustrating a variant of the fifth embodiment in which a
camera is arranged to image with a plunging view,
figure 12b is a schematic front view of the
dragline in accordance with the first variant of figure 12a,
also showing the imaged scene from the camera,
- figure 13 is a schematic plan view of a dragline
equipped with GPS receivers for detecting a lateral boom
deflection, in accordance with a sixth embodiment of the
invention,
- figure 14 is a schematic plan view of a dragline
equipped with a surveying device and target respectively on
the base unit and distal end of the boom, for detecting a
lateral deflection of the boom, in accordance with a
seventh embodiment of the invention, and
- figure 15 is a simplified block diagram showing the
principle of a feedback control of a motor drive for the
hoist rope and/or drag rope, and/or boom swing, based on
the alignment information acquired in accordance with the
invention, and applicable to any of the embodiments.
The description of the preferred embodiments is based
on the dragline already described with reference to figures
1 to 3 inclusive. These figures and their description are
not repeated for the sake of conciseness. The teachings
can be transposed to an electric shovel.
In what follows, the terms lateral misalignment (or
more succinctly misalignment), or angle of misalignment,
are referenced with respect to the plane containing the
axis BA of the boom 4 in its normal, straight (undeflected)
condition. Unless otherwise stated, the boom axis BA
refers to the theoretical axis with no lateral distortion.
For the hoist rope 10, the lateral misalignment is
assessed as an angle (3 on a vertical plane, transverse to

the boom axis BA, subtended by the hoist rope with respect;
to the vertical.
For the drag rope 18, the lateral misalignment is
assessed as an angle on a horizontal plane, subtended by
the drag rope with the projection of the boom axis BA on
that horizontal plane.
For the boom itself, the lateral misalignment
expresses a distortion of the boom in a lateral direction,
causing the distal end 4b of the boom to be laterally
displaced in a horizontal plane with respect to its
alignment along the (normal) boom axis BA.
The following embodiments of the invention describe a
number of different means for detecting one or more among
the following conditions:
i) a lateral flexing of the boom 4,
ii) a line, or lines, of force having at least a
component causing a lateral stress LS on the boom,
iii) a lateral misalignment of the hoist rope 10,
bucket 8 or of the drag rope 18 with respect to the boom
axis BA.
These means can be mechanical, and/or
optical/electrooptical, and/or radiofrequency, and and/or
other.
The information is used for assessing and controlling
the load conditions on the boom 4, and/or any other
component of the dragline, such as the mast 14, stays 16,
elevated structure 12 components, anchoring points,
linkages, the mounting platform, bearings, fixtures, etc.
First are described embodiments which use the pulley
6 suspending the hoist rope 10 at the distal end 4b of the
boom 4 as the means for detecting a lateral stress/lateral
misalignment of the hoist rope.

Figure 4 illustrates a type of pulley mechanism
sometimes used in draglines, in which the pulley 6 is
mounted on bearings 22 which allow some controlled swaying,
i.e. tilting movement of pulley axle 24. In the figure,
the pulley axle 24 is also shown in a tilted position
(dotted lines) in response to the hoist rope 10 being
laterally misaligned. The swaying force is transmitted by
the hoist rope pressing on one of the inner sidewalls of
the pulley's guiding groove. Assuming that the general
plane of the pulley 6 sways to follow exactly the angle of
the hoist rope's misalignment, the corresponding angular
offset (3 of the pulley axle 24 when thus tilted is equal to
the angle of the rope's misalignment.
Figure 5 shows a first embodiment based on the pulley
mechanism of figure 4, in which the swaying motion of the
pulley and pulley axle is determined by distance measuring
sensors. In the example, two distance measuring sensors
26a and 26b are provided on the surface portions of the
bearing casing that confront respective outer side faces 6a,
6b of the pulley. The sensors 26a, 26b are arranged to
measure the distance, respectively L1 and L2, from their
location to a respective outer side face 6a, 6b of the
pulley, this distance being measured along a direction
parallel to the unswayed pulley axle 24, i.e. perpendicular
to the pulley outer side faces when unswayed. The sensors
26a, 26b can be of any known suitable technology, e.g.
optical (such as laser based) or acoustic, comprising an
optical/acoustic source and a sensor analysing the returned
laser/acoustic signal to derive the distance measurements
S1, S2.
The sensors 26a and 26b are mounted symmetrically
such that when the hoist rope 10 is aligned with the boom
axis, the distances L1 and L2 measured by the sensors 26a

and 26b are the same. Differences between the distances L1
and L2 measured by the sensors therefore express the angle
of inclination (swaying) of the pulley 6, which itself
corresponds substantially to the angle of misalignment β of
the hoist rope. The values of L1 and L2 are supplied to an
angular offset calculator 28, which calculates values of
the angle (3 from the relative values of L1 and L2. The
output of this calculator 28 is supplied to a boom strain
evaluation unit 30, which is programmed to output a boom
strain value in response to the angle (3, e.g. from a
mathematical model or look-up tables, taking into account
the forces exerted on the hoist and drag ropes. The boom
strain value is then supplied to the controller (s) 32 for
the drive motor(s) of one or several of the different motor
drives of the dragline. The latter can be the motor drive
for hoist rope 10, the motor drive for the drag rope 18 and
the motor drive for the boom swing. In this way, the motor
drive(s) can perform a real-time feedback control of the
dragline operating parameters to keep the boom stress under
proper control, and optionally record the load values for
servicing purposes. The controller(s) can be programmed to
allow controlled overloads (beyond manufacturer's
prescribed limits) of the dragline structure for maximum
work output, while remaining below the thresholds of
structural damage. The overload can e.g. be controlled to
be temporary. The allowed degree of overload can also take
into account such factors as: whether the dragline is in a
dragging, hoisting or boom swing phase, rope tension values,
the elevation angle of the boom, oscillations in the rope
or boom, wind speed, state of the boom (e.g. whether
repaired) etc. The drive can be controlled in real time in
response to the alignment/misalignment information to adapt
the drive speed or acceleration accordingly, notably by a

reduction in acceleration or speed as a function of
load/overload, or to stop the drive.
It will be appreciated that the controller (s) 32 can
also be suitably programmed to control the motor drive
directly in response to the values L1 and L2, i.e. without
recourse to the angular offset calculator 28 and/or boom
strain evaluation unit 30. In the example, the output of
the boom strain evaluation unit 30 is also sent to a man-
machine interface 34. The latter is a personal computer
type of apparatus with a data display screen placed on
board the operator's cabin 2b. The computer comprises
software and firmware modules arranged to process the
output from the boom strain evaluation unit 30 and produce
in real time, in response, a synthesised diagram of the
boom and with a representation of its distortion along a
reference scale, possibly with other data, such as the
estimated stress, load on the ropes, position of the bucket,
duration of the lateral stress, suggested actions, etc. In
addition, or alternatively, the data can sent to an audio
and/or visible alarm, alerting the operator of a lateral
stress beyond a determined threshold.
Figure 6 shows a first variant of the first embodiment,
also based on the pulley mechanism of figure 4, in which
the swaying motion of the pulley 6 is measured by a
rotation sensor 36 having a rotary disk 38. The disk is
provided with encoded indicia 40 readable by an optical
sensor of the rotation sensor 36. The optical sensor can be
implemented using a CCD or an LED, according to known
technology. The rotation sensor 36 delivers a signal
indicating the instant angular position of a reference
point on the disk 38. That point can be set to coincide
with the angular position of the assembly 52, 54 when the
hoist rope 10 when it is aligned with the boom axis BA.

The rotary disk 38 of the sensor is joined to the
proximal end 42a of rigid stem 42, whose distal end 42b is
arranged to be resiliently biased firmly against the outer
face of a flange 6a of the pulley 6 to follow its lateral
displacement. The distal end 42b contacts the pulley near
the circumference and at a point vertically above or below
the pulley axle 24 for maximum translational movement for a
given angle of tilt, i.e. sway. Accordingly, the stem 42
causes the rotary disk 38 to turn as a function of pulley's
swaying motion from its central position (the latter is
illustrated in dotted lines). The rotation signal from the
sensor 36 is sent to an angular offset angle detector 44,
similar to offset calculator 28, calibrated to produce an
indication of the misalignment angle β in response to the
evolution of rotation sensor output as the pulley tilts.
Preferably, a concentric groove (not shown) is
provided on the side face 6a of the pulley to receive and
guide the distal end 42b of the stem, allowing it to
maintain a fixed radial position with respect to the
pulley's axle 24, while allowing the pulley to rotate
freely.
In the example, stem is generally straight up to the
distal end 42b, at the region of which it has a bend
portion 42c to place the contact point with the pulley
entering from the side. The proximal end 42a of the stem
is laterally displaced from the pulley. This configuration
of the stem and its positioning allows to follow the
swaying motion of the pulley without interfering with the
passage of the rope 10.
Alternatively, the stem 42 can be made to divide into
two branches at the distal end, forming a fork embracing
the pulley with sufficient free space around the sides to
accommodate for its tilting motion as it sways. The free

ends of the fork are turned inwardly to contact a
respective outer face of the pulley flanges 6a and 6b,
again preferable near their circumference and above or
below the pulley axle to convert the pulley's swaying or
swinging motion into a substantial angular displacement of
the stem.
Depending on the dragline, the response of the pulley
bearing 22, and its operating conditions, the angle of
deflection determined by the rotation sensor 36 may not
correspond to the actual misalignment angle (3 of the rope.
In this case, an experimentally-determined scaling or
correction factor may be used in the angular offset
detector 44.
Likewise, a similar correction factor can be applied
in the embodiment of figure 5 if the swaying angle of the
tilted pulley does not properly match the hoist rope's
angle of misalignment.
In a further a variant, the rotary sensor and stem can
be replaced by a feeler device, such as a spring loaded
plunger projecting inwardly from the bearing housing and
impinging one of the faces 6a or 6b of the pulley. Each
plunger is associated to a sensor measuring its projection,
corresponding to the distance L1 or L2 (cf. figure 4) to
determine the amount of sway in the pulley, based on the
known value of L1 when there is no sway in the pulley.
This variant can also be implemented with two feeler
devices operating on opposite side faces 6a and 6b of the
pulley, in a manner analogous to the embodiment of figure 5,
so delivering the two distance values L1 and L2.
Conversely, the embodiment of figure 5 could be
implemented with just one sensor device 26a or 26b laser
beam, using the fact that the value of L1/L2 or L2/L1 when
the pulley is unswayed (not deflected) is a known constant.

In a second embodiment, the pulley mechanism can also
be used as a point of measurement of lateral stress on the
boom 4 even if it not designed to allow the above-described
swaying motion of the pulley 6 and axle 24. In this case,
the measurement can be effected by means of one or several
strain gauges, as illustrated in figure 7.
As shown in the example of figure 7, strain gauges 46
can be placed on the outer side faces of the flanges 6a, 6b
of the pulley 6 and/or on the pulley axle 24. The gauges
are connected to a calculation unit (not shown) where the
detected distortion is converted to a lateral stress LS
value on the boom. This conversion can be established on
the basis of prestored conversion tables obtained
empirically from test data, or from mathematical modelling.
Figure 8 illustrates schematically a third embodiment
of the invention, in which the alignment/misalignment of
the drag rope 10 is also detected by mechanical means 48.
These comprise a short sleeve 50, or alternatively a ring,
surrounding the drag rope 10, and by which lateral
deflections of the rope are detected by angle sensors. The
sleeve 50 is connected to the underside of the boom 4 by a
mechanical assembly comprising two arms 52, 54 which are
mutually articulated to allow the sleeve 50 to follow the
variations of the rope angle a in the vertical longitudinal
plane as the bucket 8 is dragged (cf. figure 1). The
lengths of the arms 52, 54 are set to allow the sleeve 50
to follow the full amplitude of the evolutions of the angle
α of the hoist rope 10, without impeding the movement of
the latter. The arm assembly 52, 54 is rigid in the
lateral direction, i.e. in the direction of lateral stress
LS, and joins to a rotary sensor within a housing 56 fixed
to the boom 4.

As shown in figure 9, arm 54 of the assembly is
attached to a rotary sensor disk 38 comprising encoded
indicia 40 readable by an optical sensor device 36,
analogous to the sensor 36 of figure 6, and which can also
be implemented using a CCD or a LED, according to known
technology. The sensor 36 delivers a signal indicating the
instant angular position of a reference point on the disk.
That point can be set to coincide with the angular position
of the assembly 52, 54 when the hoist rope 10 is aligned
with the boom axis BA. The output from the sensor is pre-
processed by an angular offset calculator 28, which
produces the value of the deflection angle (3 of the rope as
the disk 38 is caused to rotate by the arm assembly 52, 54.
The calculator 28 is similar to the one of figure 4
used to express the rope angle (3. This angle value is
inputted to a boom strain evaluation unit 30 which is also
fed with the values of the loads on the ropes 10 and 18 to
produce monitoring and alarm information to a man-machine
interface 34. The latter is substantially the same as in
the first embodiment, producing equivalent PC display data
and audio/visual alarms signals as described above. The
boom strain evaluation unit 30 also delivers signals to one
or several motor drive controls 32 for real time automated
control of the dragline load parameters, as described above,
notably allowing a controlled overload.
To minimise interference with the natural movement of
the rope 10, the inside of the sleeve 50 is equipped with a
set of four rollers 58 whose axes are along respective
sides of a square. The rollers surround the rope 10, and
each one has a concave profile to follow its contour.
In variants of this second embodiment, the rotatior.
angle sensor can be replaced by a linear displacement

sensor, with appropriate adaptation of the linkages to the
hoist rope 10, or drag rope 18.
Figure 10 illustrates a fourth embodiment of the:
invention based on an optical laser 60 fixedly mounted on
the distal end 4b of the boom, shown here in a plan view.
The laser 60 is powered to generate a laser beam 62 which
impinges on a target zone 64 provided on the front face 2a
(line I-I) of the base unit 2, where it creates a
detectable beam spot 65. The laser is positionally
referenced so that its beam 62 is aligned to follow the
boom axis BA when the boom is in its normal state, with no
lateral distortion. The beam spot 65 in this case impinges
at a point along a vertical line where the proximal end 4a
of the boom is centred. The vertical position of the spot
depends on the inclination of the boom. Its lateral
position along the target zone 64 depends on a lateral
distortion of the boom 4: as the boom experiences a lateral
stress, its distal end 4b is deflected in the direction of
stress, and the laser 60 fixed at that point is no longer
directing the beam spot 65' on the vertical centreline, as
shown in dotted lines. The displacement SD of the beam
spot 65' from the vertical centreline expresses the amount
of lateral distortion, and provides a sensitive measurement
of that parameter by the virtue of the considerable optical
lever effect.
The target zone 64 is monitored by a video camera 66
mounted on the base unit 2 by means of a forwardly
projecting bracket 68. The raw signal from the camera is
supplied to a video signal processor unit 70 which
emphasises the image of the beam spot 65, 65' . The output
from the processor unit 70 is supplied for display on a
monitor 72 located at the dragline's control cabin 2b,
where it acts as a man-machine interface for monitoring the

lateral stress LS on the boom 4. The monitor 72, also
referred to as video monitor, can be a computer monitor
connected to a PC type computer. In this way, it is
amenable to display computer generated data. The
information can be complemented by markings delimiting
limits L on either side of the vertical centreline, beyond
which the flexing of the boom has attained a danger
threshold. These markings can be painted on the part of
the front 2a of the base unit that serves as the target
zone 64, or inserted electronically by the video signal
processor 70. Other markings can be provided in the same
way to indicate e.g. graduations of lateral deflection SD,
possibly in units expressing force or percentages of the
safe working limit. The contents of the display thus
comprise the above reference markings and a real-time
representation of the beam spot 65, 65'.
In this way, the operator OP observing the video
monitor 72 can use this technical information to monitor
the lateral distortion of the boom at any time and derive a
warning of damaging lateral stresses on the boom.
The output of video signal processor 70 is also
applied to a computerised evaluation unit 74 programmed to
detect automatically the position of the beam spot 65, 65'
and react accordingly. The reaction can be a warning
signal detectable by the human operator OP, or a command to
one or several of the motor drive controls 32 already
described, e.g. to reduce or halt the application of the
towing force TF on the drag rope 18 and/or the force SF on
the hoist rope 10, or again the swinging motion of the boom
4.
The evolution of the lateral position of the beam
spot can thus be exploited in an automated or human
feedback control of the dragline's operating conditions,

notably of the load applied to the drag rope and/or the
hoist rope, boom swing, as explained above.
Figure 11 illustrates a fifth embodiment of the
invention, also based on optical means, which in this case
serve to monitor the alignment of the hoist rope 10 and
bucket 8. The monitoring is obtained by a video camera 7 6
mounted on the boom 4, with the lens directed to image the
hoist rope 10 suspended from the pulley 6. The camera's
field of view is adjusted against a graticule 78 which
serves as a reference for assessing the rope's lateral
alignment/misalignment. The graticule can be physical
markings 78a on a transparent plate in front of the camera
lens, or it can be inserted electronically. In the example,
the graticule is designed to show a vertical centreline
against which the image 10I of the hoist rope 10 coincides
when in correct lateral alignment, and a set of inclined
lines converging towards the top, associated with indicia
78b to enable the operator OP to assess the degree of rope
lateral misalignment.
The video output of the camera 76 is sent to a video
signal processor 70', similar to processor 70 described
above, but optimised to enhance the visibility of the
rope's image 10I and to insert the graticule 78 when it is
created electronically. The output of the video signal
processor 70' is sent to a video monitor 72 at the
operator's cabin 2b, as in the previous embodiment, where
it displays for the operator OP the rope's image 10I and
graticule 78 (box 79). In this way, the video monitor also
provides a man-machine interface producing technical
information so as to enable the operator to assess the
rope's lateral alignment/misalignment. The video monitor
72 can be the computer monitor associated to a PC as

described with reference to the previous embodiments, or
simply a TV monitor.
The video signal processor 70' also extracts and
exploits the pixels of the rope's image 10I to derive
computer exploitable data on the rope's lateral inclination
angle (3. This data is supplied to an evaluation unit 74',
similar to evaluation unit 74 described above, adapted to
use that inclination angle data in conjunction with the
instantaneous load values applied on the drag ropes 10, 18,
supplied as input parameters. In this way, it determines
the lateral stress LS on the boom 4 and acts on the motor
drive control(s) 32 as described above to adjust in real
time the load on the ropes 10, 18 and if needs be the boom
swing dynamics accordingly.
Likewise, the operator OP can exploit the rope
inclination data with his knowledge of the instantaneous
loads applied to the ropes to assess the risk of boom
damage. As in the previous embodiment, the information
from the video signal processor 70' or evaluation unit 74'
can also be used to trigger an alarm signal detectable by
the operator when a certain risk level is detected or to
influence the respective drive motors. In certain cases it
may be beneficial to only show the derived load
characteristics data to the operator.
The camera 76 can be placed at any suitable point
along the length of the boom, based on the following
considerations: the closer it is to the pulley 6, the
closer it will be to the rope 10, and hence the better the
viewing position, while the further it is from the pulley,
the greater the absolute lateral displacement of the rope
for a given misalignment - and hence the easier to detect
that misalignment.

In a variant, a camera 80 can be arranged to view the
bucket 8 instead of the rope 10, for instance by being
placed at the front face 2a of the base unit, at a position
in vertical alignment with the proximal end 4a of the boom
4. The video signal processor 70' is then optimised to
analyse the contours of the imaged bucket and thereby
determine the lateral position of its centreline. This
variant has the advantage of placing the camera 80 at a
zone that is relatively more sheltered and stabilised, and
of using a larger object (bucket) as the imaging target,
compensating for the additional viewing distance.
Naturally, it is possible to implement both cameras
76 and 80, and possibly others, so as to provide the
operator OP/evaluation unit with multiple image data for
analysing the operating conditions.
Figures 12a and 12b illustrate another variant in
which a video camera 82 is arranged to provide a plunging
view of drag rope 10. In the example, the camera 82 is
mounted on a bracket 84 projecting from the distal end 4b
of the boom 4. The camera 82 is located forward of the
vertical from the pulley 6 and turned at an angle towards
the ground zone where the bucket 8 operates, so as to
provide a field of view as shown by the broken lines FOV.
The field of view covers both the hoist rope 10 (foreground)
and the drag rope 18 (background), as well as the bucket 8.
The vertical centreline of the camera image 86 coincides
with the vertical projection of the boom axis BA when the
boom is not deformed, and hence also with the lateral
alignment of the drag rope 18 and hoist rope 10 under
correct working conditions (figure 12b). As shown more
particularly in figure 12b, the camera 86 can thereby
detect a lateral misalignment of the hoist rope 10, drag
rope 18 and bucket 8 (representation in dotted lines) . As

in the other embodiments, the signal from the camera 82 is
processed as already described with reference to figure 11
to produce the image 86 on the operator's video monitor 72
and/or for exploitation by an evaluation unit 74'
controlling the motor drive control (s) in the manner
described above.
The camera arrangement of figures 12a and 12b can be
implemented in addition to the camera arrangements
described with reference to figure 11, providing a further
source of visual monitoring information and/or computer
data on the alignment conditions.
Figure 13 illustrates a sixth embodiment based on GPS
receivers to detect a lateral distortion of the boom 4
arising from a lateral stress LS. In the example, three
GPS receivers GPS1, GPS2 and GPS3 are positioned along the
longitudinal axis of the dragline containing the boom axis
BA. A first GPS receiver GPS1 is fixed onto base unit 2 of
the dragline, for which it constitutes a fixed reference
point. The other two receivers, GPS2 and GPS3, are fixed
respectively at the proximal and distal ends 4a and 4b of
the boom 4.
The three GPS receivers obtain their coordinate
position data from satellites S1, S2, S3, ... at frequent
intervals, say every second. They send these coordinate
position data by wire or wireless link to a GPS coordinate
comparison unit 88, where they are analysed. The GPS
coordinate comparison unit initially stores the coordinate
position data of the three GPS receivers corresponding to
the current location of the dragline and in a condition
where the boom is not submitted to a lateral stress. The
coordinate data from receivers GPS1 and GPS2, respectively
at the base unit 2 and at the proximal end 4a of the boom,
serve to determine the theoretical orientation of the boom

with respect to a fixed coordinate system as the boom axis
BA swings (axis SW, figure 1). From the coordinate data of
receivers GPS1 and GPS2, the comparison unit 88 can thus
determine by extrapolation the three-dimensional
coordinates of any point lying on the boom axis BA, under a
condition of zero lateral stress (theoretical boom axis),
and conversely can verify whether a given three-dimensional
coordinate lies on that axis or not.
In this way, it verifies whether or not the
coordinate data from third receiver GPS3, at the distal end
4b, lies on the theoretical boom axis BA. More
particularly, it assesses, by standard transformation
techniques, the amount lateral deflection of the distal end
4b of the boom from the theoretical boom axis BA, resulting
from a lateral stress LS. By a similar technique, it can
also measure, if needs be, a sag of the boom in the
vertical plane.
The calculated value of the lateral deflection of the
boom is supplied to a boom strain evaluation unit 30 as
described above, which determines the response to take as a
function of the amount of estimated lateral stress, based
on the deflection data, as well as possibly other
parameters, such as the load on the ropes 10, 18, motor
drive parameters, etc.
The response takes the form of a signal or data sent
in adapted form to a man-machine interface 34 of the type
described above.
The boom strain evaluation unit 30 can also be
adapted to supply signals to a feedback loop with the motor
drive control (s) 32 for the hoist rope, drag rope or boom
swing drive(s), as already described.
For enhanced accuracy of the GPS coordinate data, the
GPS coordinate comparison unit 88 may be connected to a

nearby land-based GPS correction signal station 92, if
available, e.g. by a radio link 94.
Another approach uses 3 GPS units distributed on the
boom, e.g. one at its proximal end, one in the middle, one
at its distal end, to assess the boom curvature as a
consequence of lateral load forces.
Figure 14 illustrates a seventh embodiment of the
invention in which a lateral deflection of the boom 4
resulting from lateral stress LS is detected by surveying
techniques. The concept uses a surveying device located at
a fixed position with respect to the base unit 2 or the
proximal end 4a, adapted to monitor the azimuthal angle of
the distal end 4b relative a reference axis, suitably the
undeflected boom axis BA.
In the example, this technique is implemented by an
auto-tracking total station 96 fixed on the base unit 2 and
positioned in alignment with the boom axis BA. The total
station 96 is trained on a target 98, such as an optical
prism or mirror, used in surveying. The auto-tracking
function of the total station 96 allows the latter to
follow automatically the movements of the distal end 4b of
the boom and to provide continuous information on the
evolution of its azimuthal angle, which is normalised to
the deflection angle of boom. The deflection angle data is
processed by a boom strain evaluation unit 30, analogous to
the one described e.g. with reference to figure 5, and
which sends signals to the motor drive control(s) 32 and/or
to a man-machine interface 34 as explained above.
Further embodiments of the invention can be
implemented by monitoring the torque on the shaft of the
swing axis SW of the boom structure (of. figure 1) . In
this case, a feedback monitor circuit can be placed in the

swing motor drive used for swinging the boom structure.
The monitor circuit can determine the turning moment on the
swing axis SW, e.g. when the bucket 8 is being dragged,
that turning moment resulting from a misalignment of the
suspending and drag ropes 8 and 18. The turning moment can
be evaluated by various techniques, e.g. by measuring the
torque to be applied by the drive motor to compensate for
that moment.
Figure 15 illustrates schematically a real-time
feedback control system 100 suitable for the motor drive of
any one of the hoist rope drive, drag rope drive, or boom
swing drive. This feedback control system, typically in
the form of a servo system, can be applied to any of the
embodiments having been described. It may, for instance,
be functionally integrated with the evaluation unit 74 or
motor drive control 32.
The system takes as input the alignment data acquired
concerning the alignment/misalignment of the boom structure
4, hoist rope 10, drag rope 18 or bucket 8, which is
assimilated to a low frequency measurement. Typically,
that data is delivered in adapted form by the boom strain
evaluation unit 30, or the evaluation unit 74, 38', or the
like. The values of the parameters evaluated, which are
indicative of lateral boom stress or a risk of lateral boom
stress, are submitted to a threshold detector 102, which
assesses whether one or several graded stress limit values
are reached. The output of the threshold detector is
applied to a first mixing input 104a of a signal mixer or
combiner 104 having a second input 104b for accepting
command drive signals from the operator OP. The operator
acts through a command interface taking into account the
alignment data produced on his man-machine interface 34.

The output of mixer/combiner 104 produces the motor
drive commands. In this example, the command is a weighted
or equal combination of inputs from both the operator and
an automated analysis of the alignment conditions. The
system can thus allow a manual override to a certain degree,
or e.g. produce automatically an operational stress limit
envelope within which the operator is free to fix the
values. In variants, the mixer 104 can be omitted,
whereby the control is entirely manual, based on the
operator's information produced on the man-machine
interface indicating the acquired alignment/misalignment
conditions, or alternatively entirely automated. In the
latter case, the alignment data is sent directly to the
motor drive (s) 32, if needs be via the threshold detector
32. The latter can be omitted in variant embodiments.
The control means 100 is in a feedback loop, with the
detection of the alignment/misalignment condition feeding
back information in real time to implement the control
performed by the motor drive command. The
alignment/misalignment data can be sampled at a suitable
frequency to ensure a real-time or quasi real time control
of the drive and load conditions.
The implementation of the command system can be based
on any suitable servo control loop using standard
engineering practice.
The operator and/or automated control may be provided
with limit stress values corresponding to maximum boom load
limits, typically standard manufacturers limits. This
maximum load data can be presented in the form of graphical
charts, or indicia on a load indication scale presented on
the man-machine interface, or it can be in the form of
stored machine readable data in look-up tables or a
database.

The experience of the human operator allows him to
determine if and when an indicated overload can be
tolerated, for instance in certain phases, or for certain
periods, taking various parameters into account.
For an automated feedback control of drive motors,
the maximum load values can be exploited similarly to
command intelligently an overload under specific programmed
conditions, taking into account other parameters, e.g.
based on fuzzy logic techniques.
In this way, the human operator and/or the automated
feedback control can control the operation of the dragline
with substantially no excessive stress while being under
conditions at - or controllably exceeding - standard
manufacturer's limits for the boom and possibly other
critical components such as the mast 14, stays 16, ropes 10,
18, bucket 8, platform, anchoring points, etc..
It will be appreciated that the above-described
alignment monitoring and human or automated control of the
hoist rope and/or drag rope and/or boomswing drive motor(s),
as a function of that monitoring, can take place at all
times or whenever judged necessary. The above-described
monitoring and human or automated control can be carried
out notably during:
- a dragging operation for loading the bucket,
- a hoisting operation for raising or lowering the
bucket,
- a swinging operation for moving the bucket to a
dumping zone,
- any other phase of operation of the dragline.
In the example of figure 15, the signals from the
mixer/combiner 104 are used to command respective motor
drive controls 32 for:

- a hoist rope motor 106, which is provided at the
base unit 2 to wind/unwind the hoist rope 10 from the base
unit 2. The command can serve here e.g. to establish the
appropriate wind/unwind speed, acceleration/deceleration,
stoppage of the hoist rope;
- a drag rope motor 108, which is provided at the base
unit 2 to wind/unwind the drag rope 18 from the base unit 2.
The command can serve here e.g. to establish the
appropriate wind/unwind speed, acceleration/deceleration,
stoppage of the drag rope; and
- a boom swing motor 110, which is provided at the
base unit 2 to swing the boom 4 laterally e.g. to position
the bucket 8 from a drag zone to a dumping zone, the
swinging being around the swing axis SW at the base unit as
shown in figure 1. The command can serve here e.g. to
establish the appropriate swing speed,
acceleration/deceleration, stoppage of the boom 4, in
either direction.
It also possible to adapt the above-described
embodiments of the invention to analyse the alignment of
the drag rope 18 and/or the bucket 8, instead of or in
addition to the alignment of the hoist rope 10.
Thus, for the embodiment of figure 11, the camera 76,
or an additional camera, may also be arranged to monitor
the alignment of the drag rope 18, e.g. by being placed at
some point along the boom 4 and directed towards the ground,
with a field of view covering the zone occupied by the drag
rope and bucket. The electronic image can be referenced
and processed in the same manner as described for the
camera image 4 6, but to determine the angle subtended by
the drag rope 18 with respect to the boom axis BA.
In a similar manner, in the embodiment of figures 12a
and 12b, the camera 50, or an additional camera, may be

arranged at some point along the boom and directed to focus
more particularly on the alignment of the drag rope 18.
Also, the embodiment of figure 9 can be implemented on
the drag rope 18 in addition to, or instead of, being
implemented on the hoist rope. The sleeve 50 would in that
case surround the drag rope 18 at some point between the
bucket 8 and the base unit 2, and be coupled to the rotary
sensor unit 56 by an adapted arm and bracket device.
The measuring/analysing devices (lasers, cameras,
sensors, GPS receivers gauges, etc.) and the functional
hardware and software units described in the above
embodiments can be powered by any suitable means (power
cable, battery pack, solar cells, etc.), and can likewise
communicate by any suitable means (wire data link, optical
data transmission, radio link, wireless communications
protocol (WiFi, Bluetooth, ...) , etc.).
From the foregoing, it will be understood that the
invention can implemented in numerous ways and with
numerous techniques, e.g. laser and optical lever,
electronic image acquisition, telemetry by radio signals,
such as GPS receivers, mechanical sensing on the rope
and/or pulley, surveying, etc.
The measurements can be of the actual lateral
distortion of the boom, the stresses applied to the boom
and their lateral force component, or the angle of
misalignment of the hoist and/or drag rope(s) with respect
to vertical projection of the boom axis, etc.
It will be apparent that the different embodiments
described accommodate for transpositions of means and/or
techniques from one embodiment to other. Also, a number
different embodiments can be implemented together in a
dragline or electric shovel to provide respective
complementary sources of alignment data.

Also, the hardware and software aspects of
embodiments can be implemented in many different equivalent
forms in addition to those described in the examples.

WE CLAIM:
1. Method of monitoring a load condition of a dragline (1) or an electric
shovel, the dragline comprising a boom (4), a bucket (8), a hoist rope (10) from
which the bucket is suspended from the boom, and a drag rope (18) for
dragging the bucket, the boom extending substantially along a boom axis (BA) in
its normal, unstressed state,
characterized in that it comprises the step of:
- using technical means (26, 28; 42; 46; 48; 60-70; 76, 80; 82; GPS1-
GPS-3; 96, 98) to produce alignment data indicative of the lateral alignment,
with respect to the plane containing said boom axis (BA), of at least one of the
following dragline components:
i) the hoist rope (10),
ii) the drag rope (18),
iii) the boom (4),
iv) the bucket (8),
and
determining said lateral alignment.

2. Method as claimed in claim 1, comprising a step of controlling (32; 34, 72,
OP) said load condition of the dragline (1) or electric shovel on the basis of said
alignment data.
3. Method as claimed in claim 2, wherein said alignment data is inputted to a
man-machine interface (34, 72), a display device (72), whereby said controlling
step is performed via a human operator (OP).
4. Method as claimed in claim 2 or 3, wherein said alignment data is inputted
to automated control means (32) for controlling at least one of:
i) the drive (106) of the hoist rope (10),
ii) the drive (106) of the drag rope (18),
iii) the drive (110) of the boom (4), for swinging the boom,
to perform said controlling step.
5. Method as claimed in any one of claims 2 to 4, wherein the controlling
step is performed substantially in real time using a feedback of said alignment
data.

6. Method as claimed in any one of claims 2 to 4, wherein said controlling
step is performed in a combined manner by a human operator (OP) via a man-
machine interface (34, 72) and by automated control means (32).
7. Method as claimed in any one of claims 2 to 6, wherein said controlling
step comprises authorizing a controlled overload of said dragline (1) or electric
shovel, notably when controlling a maximum structure stress thereon, as a
function of said alignment data.
8. Method as claimed in any one of claims 2 to 7, wherein said boom (4) has
a specified maximum load limit, and wherein said controlling step comprises
authorizing a controlled overload of the boom above said specified load limit as a
function of said alignment data.
9. Method as claimed in any one of claims 1 to 8, wherein said technical
means produce said alignment data as quantitative data indicative of an amount
of misalignment in at least one said dragline component (4, 10, 18, 8).

10. Method as claimed in any one of claims 1 to 10, wherein said alignment
data is obtained by measurement on a pulley (6) along which the hoist rope(10)
passes to hang from a distal end (4b) of the boom (4).
11. Method as claimed in claim 10, wherein said pulley (6) is configured to
sway in response to a lateral stress from the hoist rope (10), and wherein said
alignment data is obtained by determining (100a, 26b, 28; 38-36, 42, 28) the
amount of sway of said pulley.
12. Method as claimed in claim 10 or 11, wherein said alignment data is
obtained by measuring (46) a lateral stress exerted on said pulley (6).
13. Method as claimed in any one of claims 1 to 12, wherein said alignment
data is obtained by physical contact (46, 48) with at least one said dragline
component (4, 8, 10, 18).
14. Method as claimed in claim 13, comprising physically engaging (50) the
hoist rope (10) with an angular or linear displacement sensor device (56-36).

15. Method as claimed in any one of claims 1 to 14, wherein said alignment
data is obtained by detecting a lateral deflection of the boom (4) from said boom
axis (BA).
16. Method as claimed in claim 15, wherein said lateral deflection is detected
by producing an optical beam (62) from a source (60) attached to the boom (4),
preferably at or near a distal end (4b), and detecting a displacement (SD) of the
beam spot (65') where it impinges a target (64).
17. Method as claimed in any one of claims 1 to 16, wherein said alignment
data is obtained by imaging (42; 48; 50) at least one said dragline component
(4, 8, 10, 18).
18. Method as claimed in claim 17, comprising imaging the hoist rope (10)
using camera means (76, 80; 82).
19. Method as claimed in any one of claims 1 to 18, wherein said alignment
data is obtained by analyzing coordinate data from GPS receiver means (GPS1-
GPS3), at least one GPS receiver (GPS3) being positioned on said boom (4).

20. Method as claimed in any one of claims 1 to 19, wherein said alignment
data is obtained by surveying techniques (96, 98), to determine coordinate
evolutions of a portion of the boom (4) susceptible of deflecting laterally with
respect to its boom axis (BA).
21. Method as claimed in claim 20, comprising surveying a target (98)
substantially at the distal end (4b) of the boom using a surveying device,
preferably a self-tracking total station (96) placed at a known reference point on
the dragline.
22. Apparatus for monitoring a load condition of a dragline (1) or an electric
shovel, the dragline comprising a boom (4), a bucket (8), a hoist rope (10) from
which the bucket is suspended from the boom, and a drag rope (18) for
dragging the bucket, the boom extending substantially along a boom axis (BA) in
its normal, unstressed state,
characterized in that it comprises means (26, 28; 42; 46; 48; 60-70; 76,
80; 82; GPS1-GPS3; 96, 98) for producing alignment data indicative of the lateral
alignment, with respect to the plane containing said boom axis (BA), of at least
one of the following dragline components:

i) the hoist rope (10),
ii) the drag rope (18),
iii) the boom (4),
iv) the bucket (8),
and
determining said lateral alignment.
23. Apparatus as claimed in claim 22, comprising control means (32; 34, 72,
OP) for controlling said load condition of the dragline (1) or electric shovel on the
basis of said alignment data.
24. Apparatus as claimed in claim 22 or 23, comprising a man-machine
interface (34, 72), a display device (72), for receiving said alignment data.
25. Apparatus as claimed in claim 23 or 24, comprising automated control
means (32) for controlling at least one of:
i) the drive (106) of the hoist rope (10),
ii) the drive (108)of the drag rope (18),
iii) the drive (110) of the boom (4), for swinging the boom,
in response to said alignment data.

26. Apparatus as claimed in any one of claims 23 to 25, wherein said
controlling means (32; 3, 72, OP) are arranged to operate substantially in real
time using a feedback of said alignment data.
27. Apparatus as claimed in any one of claims 23 to 26, comprising means for
commanding a controlled overload of said dragline (1) or electric shovel, notably
when controlling a maximum structure stress thereon, as a function of said
alignment data.
28. Apparatus as claimed in any one of claims 23 to 27, wherein said boom
(4) has a specified maximum load limit, and wherein said controlling means (32;
34, 72, OP) comprises means for commanding a controlled overload of the boom
above said specified load limit as a function of said alignment data.
29. Apparatus as claimed in any one of claims 22 to 28, wherein said means
(26, 28; 42; 46; 48; 60-70, 80; 82; GP1-GPS3; 96, 98) for producing said
alignment data comprise means for producing quantitative data indicative of an
amount of misalignment in at least one said dragline component (4, 10, 18, 8).

30. Apparatus as claimed in any one of claims 22 to 29, wherein said means
for producing said alignment data comprise means (26, 28) for effectinq a
measurement on a pulley (6) along which the hoist rope (10) passes to hand
from a distal end (4b) of the boom (4).
31. Apparatus as claimed in claim 30, wherein said pulley (6) is configured to
sway in response to a lateral stress from the hoist rope (10), and wherein said
means for producing said alignment data comprise means (100a, 26b, 28; 38-
36, 42, 28) for determining the amount of sway of said pulley.
32. Apparatus as claimed in claim 30 or 31, wherein said means for producing
said alignment data comprise means (46) for measuring a lateral stress exerted
on said pulley (6).
33. Apparatus as claimed in any one of claims 22 to 32, wherein said means
for producing said alignment data comprises means for acquiring said alignment
data by physical contact (46, 48) with at least one said dragline component (4,
8, 10, 18).

34. Apparatus as claimed in claim 33, comprising means (50) physically
engaging the hoist rope (10) with an angular or linear displacement sensor
device (56-36).
35. Apparatus as claimed in any one of claims 22 to 34, wherein said means
for producing said alignment data comprise means for detecting a lateral
deflection of the boom (4) from said boom axis (BA).
36. Apparatus as claimed in claim 35, comprising a source (60) for generating
an optical beam (62), said source being attached to the boom (4), preferably at
or near a distal end (4b), and means (66-70) for detecting a displacement (SD)
of the beam spot (65') where it impinges a target (64).
37. Apparatus as claimed in any one of claims 22 to 36, wherein said means
for producing said alignment data comprise means (42; 48; 50) for imaging at
least one said dragline component (4, 8, 10, 18).
38. Apparatus as claimed in claim 37, comprising camera means (76, 80; 82)
for imaging the hoist rope (10).

39. Apparatus as claimed in any one of claims 22 to 38, wherein said means
for producing said alignment data comprise GPS receiver means (GPS1-GPS3), at
least one GPS receiver (GPS3) being positioned on said boom (4).
40. Apparatus as claimed in any one of claims 22 to 39, wherein said means
for producing said alignment data comprise surveying means (96, 98) for
determining coordinate evolutions of a portion of the boom (4) susceptible of
deflecting laterally with respect to its boom axis (BA).
41. Apparatus as claimed in claim 40, comprising a target (98) substantially at
the distal end (4b) of the boom, and a surveying device, preferably a self-
tracking total station (96) placed at a known reference point on the dragline and
aimed at said target.

Method of monitoring a load condition of a dragline (1) or an electric shovel, the
dragline comprising a boom (4), a bucket (8), a hoist rope (10) from which the
bucket is suspended from the boom, and a drag rope (18) for dragging the
bucket, the boom extending substantially along a boom axis (BA) in its normal,
unstressed state, characterized in that it comprises the step of using technical
means (26, 28; 42; 46; 48; 60-70; 76, 80; 82; GPS1-GPS-3; 96, 98) to produce
alignment data indicative of the lateral alignment, with respect to the plane
containing said boom axis (BA), of at least one of the following dragline
components (i) the hoist rope (10), (ii) the drag rope (18), (iii) the boom (4),
(iv) the bucket (8), and determining said lateral alignment.

Documents:

901-KOL-2005-CORRESPONDENCE.pdf

901-KOL-2005-FORM 27.pdf

901-KOL-2005-FORM-27-1.pdf

901-KOL-2005-FORM-27.pdf

901-kol-2005-granted-abstract.pdf

901-kol-2005-granted-claims.pdf

901-kol-2005-granted-correspondence.pdf

901-kol-2005-granted-description (complete).pdf

901-kol-2005-granted-drawings.pdf

901-kol-2005-granted-examination report.pdf

901-kol-2005-granted-form 1.pdf

901-kol-2005-granted-form 18.pdf

901-kol-2005-granted-form 2.pdf

901-kol-2005-granted-form 26.pdf

901-kol-2005-granted-form 3.pdf

901-kol-2005-granted-form 5.pdf

901-kol-2005-granted-reply to examination report.pdf

901-kol-2005-granted-specification.pdf

901-kol-2005-granted-translated copy of priority document.pdf


Patent Number 227802
Indian Patent Application Number 901/KOL/2005
PG Journal Number 04/2009
Publication Date 23-Jan-2009
Grant Date 20-Jan-2009
Date of Filing 30-Sep-2005
Name of Patentee LEICA GEOSYSTEMS AG.
Applicant Address HEINRICH-WILD-STRASSE, CH-9435 HEERBRUGG
Inventors:
# Inventor's Name Inventor's Address
1 BALDWIN, GEOFF 22 WENDELL STREET, NORMAN PARK, BRISBANE, QUEENSLAD, AUSTRALIA 4170
PCT International Classification Number B23Q 15/00
PCT International Application Number N/A
PCT International Filing date
PCT Conventions:
# PCT Application Number Date of Convention Priority Country
1 2004222734 2004-10-20 Australia