Tag Archives: Product Link Elite

Cat improves efficiency and cost per tonne with 7495 mining shovel upgrades

Caterpillar has updated its 7495 and 7495 HF electric rope shovels with the result being an up to 10% increase in operating efficiency.

Drawing from more than a century of rope shovel innovation, the 2021 Cat® 7495 and 7495 HF Electric Rope Shovels (ERS) combine multiple standard feature upgrades to improve machine productivity, while component enhancements, increased frame durability and improved serviceability help reduce cost per tonne of material moved by as much as 15%.

Dan Wyatt, ERS Product Value Stream Manager, said: “Consistently, our customers tell us machine availability and productivity are primary contributors to their operation’s success. From the full adaptive control system for HydraCrowd™ to more innovative technology and data security, the advances made to the 2021 electric rope shovels reflect our commitment to meeting their needs.

“Many of these improvements are compatible with shovels in the field, so customers can realise these gains through upgrades to their existing fleets as well as new machine purchases.”

A new propel gear case for the 7495 and 7495 HF models nearly doubles the life of propel gear cases in some extreme operating conditions, Cat claims. Precise adjustments to gearing geometry and advancements in tooth hardening enhance gear case durability and productivity. The result is lower total cost of ownership of as much as $8/h when the drive system is replaced at one scheduled time.

Additionally, an ecology drain simplifies oil draining and enables kidney-loop flushing, which reduces abrasion-causing contaminants and oil change frequency.

Updates to the 7495 AC electric drive system deliver greater reliability, improved maintenance access, enhanced safety, and expanded high altitude and temperature capabilities, the company says. A liquid-cooled motion regulator cabinet efficiently dissipates heat generated by electrical components and enables operation at -40°C to +50°C and altitudes as high as 5,250 m without derating.

A faster propel transfer switch cuts lag time by 75% to improve productivity, while common motors in multiple applications means fewer parts to stock, improved parts availability and simplified maintenance, Cat says.

A reconfiguration of the crawler carriage allows drive shaft and tumbler replacement from the outboard side without removing the propel transmission. This slashes maintenance time by days while enhancing safety, Cat says. With this design, thrust loads are evenly distributed on large, tapered roller bearings rather than bronze thrust plates, increasing durability to align with 25,000-hour planned rebuilds, even in harsh environments.

Stress from every load passes through the shovel’s swing rack. This is where an enhanced design includes a single-piece rail casting that eliminates vertical segment cracks to increase durability. The rail provides a uniform path for roller movement, preventing rollers from coming loose and creating irregular wear patterns. The upgraded third rail improves access for inspection and retightening, in addition to providing added support to the thrust rail during operation. New swing girder bushings and girder-to-chassis shim designs offer improved access, reducing service time.

“All major rope shovel structures are built with high-strength steel and rugged castings, joined and thermally stress relieved to deliver reliable operation in harsh mining conditions,” Cat says. “Full penetration, profiled and ground welds are made at critical junctures, and MT, UT and X-ray inspections ensure weld quality. Structures are stress-relieved to prevent cracking, and white painted interiors facilitate inspection.”

Both the 7495 and 7495 HF ERS models now offer a full Cat bill of materials, streamlining the parts ordering process and improving parts availability, the company says.

Technology increases efficiency

Both the 7495 and 7495 HF come standard with Product Link Elite™, which transmits critical machine operating data such as utilisation, location and condition via cellular or site internet connection. Added router functionality helps to protect data security. Advanced productivity tools within Product Link Elite enable a cycle segmentation algorithm, and the combined data allows for advanced analysis of productivity, Cat says.

When linked with the available Cat MineStar™ Fleet, real-time machine tracking produces a comprehensive overview of all equipment assets to assist with fleet management and productivity.

Providing real-time feedback to improve loading efficiency, available MineStar Terrain uses guidance technology and an in-cab display to deliver precise dipper position guidance. Optional MineStar Health delivers critical event-based machine condition and operating data, while its advanced diagnostic and analytic tools improve service efficiency, the company says.

The standard Operator Assist – Enhanced Motion Control simplifies machine operation to promote high production while protecting the machine. This system is designed to yield more reliable crowd rope replacement schedules, full design life for hoist ropes, reduced wear on crowd brakes and longer life for hoist gear case components, according to Cat

HydraCrowd

A new adaptive control system (ACS) – a final piece of a multiphase enhancement initiative for HydraCrowd – delivers up to 25% cost savings on the ACS valve, resulting in up to 5% total cost of ownership saving for the entire system, Cat says. Lower initial costs, rebuildable elements and improved accessibility combine to reduce the time required for replacements. The new design also increases reliability without significantly changing the HydraCrowd maintenance schedule, according to Cat.

The new circulation filter employs two smaller, easily accessed filters that do not require roof panel removal for replacement. More affordable than the previous single-filter design, the new configuration also reduces replacement time, Cat says.

A new filter placed at the pump drive transmission improves filtration of the lubrication fluid, helping to extend the life and reliability of the system by reducing contaminants and decreasing wear. The new pump drive transmission filter assists in reducing unplanned maintenance events to decrease downtime.

Cat ups the ante with introduction of AD63 underground truck

Caterpillar has released a new underground articulated truck that, it says, features increased payload, advanced emissions controls, enhanced comfort and serviceability.

The new Cat® AD63, the largest underground truck in the Caterpillar product line, features a 5% increased payload and more torque for enhanced production capabilities, compared with its predecessor, the AD60. The new AD63 also can be configured to meet the strictest diesel engine emissions regulations – for both regulatory compliance and improved underground air quality, the company says.

Additional new features enhance operator ergonomics, maintenance access and safety, and data collection for machine health monitoring, according to the company.

The new model will be available in late 2020, according to the company.

The AD63 is powered by the Cat C27 diesel engine, which produces 588 kW, meets EU Stage V emission standards and is approved by CANMET for use in underground mines, the mining OEM said. The truck does not require diesel exhaust fluid (DEF) to meet these standards, with the emissions control system maintaining the ability to use diesel particulate filters, such as the Cat Wall Flow Filter, to further reduce particulate emissions.

The AD63 powertrain also features a new torque converter gear ratio to increase peak torque and improve gear retention on variable grades, according to Cat. “The optimised transmission shift strategy results in smoother uphill driving and greater operator comfort,” it said. “The new torque converter also increases rimpull when driving away from a stop.”

The AD63 engine package has extended altitude capability – from negative 3,048 m to positive 1,524 m – while the new engine cooling package maintains capabilities at high ambient temperatures. A new design and routing for cooling air, meanwhile, improves serviceability, and the radiator core has serviceable tubes for fast repairs.

In the AD63 cab, the ducted ventilation and air conditioning system gives the truck operator full control with nine adjustable louvres for comfortable cooling and efficient defogging. The HVAC system is powered by a battery electric system so it can be operated when the engine is not running, which pays off in less engine idling and lower operating costs, according to Cat.

The new cab arrangement features a forward-facing trainer seat offering increased space and comfort for the trainer, Cat says. The tilt cab feature gives maintenance personnel the ability to tilt the cab for access to the cab side of the engine for easier and faster access to components. And, outside the cab, a redesigned access ladder and fold-flat handrails enhance safety during maintenance

The new AD63 incorporates Product Link Elite™ as standard equipment to enable data collection and equipment health monitoring. “The system enables sharing data across multiple destinations, reduces gaps in data or lost data due to network issues, and has direct connectivity to Caterpillar and Cat dealers for remote support and services, such as condition monitoring,” the company said.

The AD63 also has external displays showing the weight of the truck contents to the loader operator. “Instant feedback for the loader operator enables more efficient passes and optimum truck loads,” the company said, which added that displays are on both sides of the truck.

In addition to new technology, Caterpillar has added the option of a new lightweight dump body, with 38.3 m³ capacity. The AD63 also maintains commonality with other AD60 bodies.