Bucyrus has introduced its next generation rope shovel – the Bucyrus 495HR2 (pronounced 495HR Super 2). This combines the company’s rope shovel technology and engineering innovation, producing what Bucyrus believes to be the world’s most advanced electric rope shovel. It includes innovations such as the HydraCrowdTM, LatchFreeTM dipper system, AC-IGBT electrics and enhanced propel power, along with a new operator’s cab and a bold new shovel appearance.
One feature of the rope shovel is an enhanced propel system, garnering, according to Bucyrus, a 12% 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 oil sands and wet digging environments. It provides the necessary power boost to manoeuvre the machine in tough digging situations, avoiding downtime associated with ground-lodged shovels. The upgraded propel power system comes standard on the new rope shovel and can also be retrofitted to existing Bucyrus 495HR/HF rope shovels.
The 495HR2 includes two of the most recent Bucyrus front-end innovations, the LatchFree dipper system and the HydraCrowd. The LatchFree system cuts down on render latch assembly downtime, by replacing the latch assembly with a strong steel link, removing the critical latch components from the harsh conditions of the lower dipper door.
HydraCrowd provides instantaneous, highly responsive control with smooth vibration-free operation, and negates the heavy inertial loading of rack and pinion style crowd systems by locating the hydraulic power pack on the machinery house deck. Shovel downtime associated with unplanned interferences is minimised, translating to greater reliability and productivity. Furthermore, major maintenance for the cylinder is scheduled to occur every 24 months.
AC electrics have become a staple of the company’s electric rope shovel range. The 495HR2‘s AC-IGBT drive system offers the same reliable programmable logic controller providing immediate fault identification, condition monitoring, and troubleshooting tools. These integrated systems provide the platform for AccessDirectTM, Bucyrus’s remote diagnostics package that allows shovel monitoring from any remote location across the globe, decreasing the time to assess, diagnose, and repair a shovel.
The newly designed, patent-pending station and cab was the result of a two-year, $1 million plus R&D project, including industrial research, ‘voice of customer’ field surveys, partnership with a leading ergonomics expert, and collaborative workshops with customers from around the globe. Bucyrus design engineers incorporated an ergonomic, fully adjustable and isolated operator’s seat as the focal-point of the new cab design. The operator’s seat includes infinitely variable armrests and a fully pneumatic suspension system with an integrated air compressor.
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.
Safety is enhanced by the cab’s dual access/egress doors located on the right and rear sides of the cab. The rear entry/exit and single-level floor facilitate unimpeded stretcher access to the operator station, as well as ease of entry and exit, in the case of an emergency. In conjunction with the single level floor, the efficient cab layout and spacious interior facilitates easy access to storage areas and work stations, as well as safe movement about the cab.
The operator’s station has been repositioned to offer unobstructed vertical line-of-sight extending from the crawler tracks to the point sheave. Superior right-hand and blind-side visibility is also attained from the seat repositioning. Lastly, overhead video monitors with closed circuit cameras have been installed on the machine allowing for greater situational awareness during digging, haul truck spotting, and propelling.