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The P&H 4100XPC is a large-scale electric rope shovel designed by Komatsu Mining, widely used in open-pit mining for overburden removal and ore loading. Its 56.6 m³ dipper (bucket) is one of the most critical components, directly influencing the machine's loading efficiency, structural reliability, and operational safety.
1.P&H4100XPC 56.6m³ Dipper
• High Strength & Wear Resistance
The dipper operates under severe impact and abrasive conditions. The design balances structural strength and long-term wear resistance using optimized material layouts and reinforcements.
• Structural Optimization
Finite Element Analysis (FEA) is used to perform topology optimization, reducing dead weight while maintaining sufficient load-bearing capacity and rigidity.
• Modular Assembly
Critical components such as the bottom plate, side plates, lip, and tooth adaptors are designed in a modular fashion to allow for easy maintenance and replacement, increasing equipment uptime.
2.P&H4100XPC 56.6m³ Dipper Design Parameters
Item |
Value |
Capacity (Struck) |
56.6 m³ |
Estimated Empty Weight |
65–75 tonnes |
Tooth Configuration |
5–7 replaceable cast teeth |
Material Composition |
HARDOX 450/500, A514, Q690 |
Safety Factor |
≥ 2.5 (on critical structures) |
Structural Features |
Closed box ribs, reinforced lip |
3.Manufacturing Process Workflow
Step-by-Step Process:
Step |
Operation |
Equipment |
Notes |
001 |
Material Cutting |
CNC Plasma / Waterjet |
Edge finishing required |
002 |
Part Fit-Up |
Welding jigs/table |
Dimensional pre-check after tack weld |
003 |
Segmental Welding |
FCAW / GMAW Auto |
Sequence control to avoid distortion |
004 |
Straightening / Shaping |
Hydraulic press |
Flatness ≤ 3mm per meter |
005 |
Tooth Adapter Mounting |
Fixture welding |
Alignment tolerance < 1 mm |
006 |
Trunnion Welding |
Manual + NDT |
100% UT/MT tested |
007 |
Stress Relief Heat Treat |
Local or full post weld |
Temperature rise ≤150°C/h |
008 |
Surface Prep & Paint |
Blasting + Epoxy |
Hardfacing applied post-blast |
3.P&H 4100XPC 56.6m³ Dipper Shipping
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