HEAVY ENGINEERING AND WEAR PARTS
hardened leading-edge inserts( LEIs) installed in the lip at the adapter positions. The Nexsys LEI provides superior material properties to a standard lip alloy, specifically in terms of hardness, the company says. This hardness advantage provides a bearing area for the adapter that is 50 % harder than a new lip, and over twice as hard as a rebuilt lip. The increase in hardness better resists deformation due to repeated impacts and provides a significant improvement in lip durability, Weir claims.
In addition to a longer wearing lip, the Nexsys LEIs deliver several additional advantages. The dual-eared design of the
The Nexsys system is a next-generation lip and GET system for rope shovel dippers that significantly reduces maintenance and improves productivity
LEI provides greater stabilisation to the adapter, when compared with the single stabiliser on a traditional Whisler lip. This increased stabilisation reduces lip wear and reduces the loading that the stabilising features experience by 50 %. In addition, the Nexsys LEIs come gauge-fit from the factory, which eliminates the process of repetitive welding, gauging and grinding to achieve optimal fits, according to the company.
A hard-rock coal mine in North America trialled the new Nexsys lip system on a P & H ® 4100XPC rope shovel. Previously the mine ran the ESCO Whisler Plus system with great success over conventional Whisler style lip systems, according to Weir, yet it is always on the lookout for machine upgrades to improve the operation.
The Nexsys system operated at the mine for 15 months before requiring a lip rebuild compared with 10 months for the Whisler Plus system. In addition, the total time required for the adapter fit area rebuild was reduced from 225 hours to 31.5 hours – an 86 % improvement.
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Weir explained:“ When a lip system provides greater service life prior to requiring a rebuild, not only does the mine reduce their maintenance costs; it also improves the machine production, minimises worker exposure to the hazards associated with maintenance activities and reduces the skilled labour requirements for the mine site.”
Johnston added:“ The Nexsys system is the most advanced lip system available for rope shovels, delivering exceptional performance and durability for our customers to improve their productivity and reduce the overall cost of ownership.”
Autonomy-ready
Philippi-Hagenbuch Inc says all of its fully custom-engineered solutions can now be seamlessly integrated with autonomous haul trucks to optimise hauling operations.
The company tailors all its equipment to fit each haul truck’ s specific features. No matter which make and model of truck customers have, they can incorporate Philippi-Hagenbuch’ s upgrades to overcome hauling challenges while achieving their desired level of fleet autonomy, it claims.
Josh Swank, Philippi-Hagenbuch Chief Growth Officer, said:“ We’ re hearing more customers talk about autonomy in hauling. We want them to know whenever they decide to incorporate an autonomous truck in their operation, they can come to us to ensure their autonomous trucks reach their full potential.
“ By making every piece of our equipment autonomous-compatible, we give customers confidence that their investment will continue to deliver maximum hauling efficiency as their operations evolve.”
As is the case with traditional haul trucks, each of Philippi-Hagenbuch’ s engineeredto-order solutions will integrate seamlessly with autonomous trucks, ensuring the truck can operate how it was designed to, the company claims. Philippi-Hagenbuch equipment works harmoniously with autonomous haul trucks’ control systems without human intervention.
The company says that each Philippi- Hagenbuch solution is autonomous-ready, including:
• Autogate ® Tailgates: Philippi-Hagenbuch’ s first product in 1969 is still a go-to addition for customers who want to maximise their haul truck utilisation. Tailgates increase hauling capacity by up to 20 % while enhancing safety and extending tyre life. The increased capacity proves effective for any material – hard and rocky or liquid. When equipped on an autonomous truck, the tailgate will open and close automatically when the truck’ s control system raises and lowers the body, with no human intervention required.
• HiVol ® specialty bodies: Whether hauling mining payload, overburden, scrap metal, refuse or other material, Philippi- Hagenbuch’ s ultra-high strength, abrasionresistant HiVol bodies are designed to haul the greatest volumetric capacity. The company engineers each body to match the unique characteristics of the material being hauled, the truck’ s rated weight and operational goals. When on an autonomous haul truck, a customengineered Philippi-Hagenbuch body will dump in exactly the same way as an OEM body, the company says.
• HiVol Water Tanks: Each Philippi- Hagenbuch Water Tank is custom engineered to haul the greatest possible volume for the specific make and model of traditional or autonomous articulated- and rigid-frame haul trucks. The company’ s patented Water Tanks feature a stable, square design and internal baffling system to improve stability and safety. Since Philippi-Hagenbuch custom engineers every water tank, the company will design the tank to fit the water distribution system and plumbing guidelines of any make of truck. This, the company says, ensures a seamless fit and that Philippi- Hagenbuch’ s water tank components will work harmoniously with autonomous truck distribution systems.
• Rear Eject Bodies: Featuring safety, stability and increased productivity as hallmarks of their design, Philippi- Hagenbuch’ s patented Rear Eject Bodies are the ideal solution for challenging hauling applications in general construction, road construction, sand and gravel, mine reclamation and underground
International Mining | JUNE 2026