Fatigue life optimized modular bucket assembly

Abstract

A fatigue life optimized modular bucket assembly for a work machine and a method of manufacturing thereof are disclosed. The bucket assembly includes a bucket core having a pair of side sections, a continuous wrapper, a supporting element, and a receptacle; and an extension module having a pair of side bars, a guard module, an edge module, and, optionally, a set of extension plates. The method includes prebuilding the bucket core, receiving an order, providing parts for the extension module, and assembling the bucket core and the extension module parts. The bucket assembly may include universal and customizable components without exhibiting reduction to fatigue life commonly associated with weld seams.

1 . A bucket assembly for a work machine comprising:
 a bucket core including:
 a pair of side sections, the side sections being spaced apart to define a width of the bucket, 
 a wrapper extending between the pair of side sections, the wrapper including:
 a substantially planar, upward sloping, upper section, 
 an arcuate middle section, 
 a substantially planar, downward sloping, first lower section, 
 an obtuse bend, and 
 a substantially planar, second lower section, 
 wherein the wrapper forms a concave, even, continuous surface defined thereover between the upper section and the middle section, and between the middle section and the first lower section, with the obtuse bend demarking the first lower section and the second lower section and continuous therewith, and 
 
 a support extending between the pair of side sections and fully contained within a boundary defined by an outward edge of the pair of side sections, the support being attached to a rear of the upper section; and an extension attached to the bucket core, including: 
 a pair of side bars operatively and respectively attached to the pair of side sections, the pair of side bars being spaced apart by the width of the bucket, 
 a guard extending between the pair of side sections and attached to the upper section of the wrapper, and 
 an edge portion extending between the pair of side sections and rigidly attached to the bucket core solely at the second lower section of the wrapper. 
   
     
     
         2 . The bucket assembly according to  claim 1 ,
 wherein inner surfaces of the wrapper and the side sections define a receptacle, and   wherein a contact face of the wrapper is exclusive of fasteners extending therethrough.   
     
     
         3 . The bucket assembly according to  claim 1 , wherein the extension is welded to the bucket core. 
     
     
         4 . The bucket assembly according to  claim 1 ,
 wherein the bucket core further includes a brace extending across the concave surface of the wrapper and including:
 a frame attached to the upper section and at least one of the first lower section, the obtuse bend, and the second lower section, and 
 a pair of side frames connecting the frame to the pair of side sections of the bucket core, and 
   wherein the brace is removably welded to the wrapper.   
     
     
         5 . The bucket assembly according to  claim 1 , wherein the guard of the extension is attached to the support and a distal end of the upper section of the wrapper. 
     
     
         6 . The bucket assembly according to  claim 1 , wherein the extension includes a pair of side extension plates respectively attached to and between the pair of side sections and the pair of side bars. 
     
     
         7 . The bucket assembly according to  claim 1 , wherein the bucket core further includes a paddle plate extending from a bottom of the first lower section of the wrapper, the paddle plate being substantially parallel to the second lower section of the wrapper. 
     
     
         8 . The bucket assembly according to  claim 7 , wherein the edge portion is operatively attached to a distal end of the second lower section of the wrapper and a distal end of the paddle plate. 
     
     
         9 . The bucket assembly according to  claim 7 , wherein the extension further includes:
 a first edge extension plate attached to and between a distal end of the second lower section and the edge portion, and   a second edge extension plate attached to and between a distal end of the paddle plate and the edge portion.   
     
     
         10 . The bucket assembly according to  claim 1 , wherein the bucket assembly is constructed to distribute stress on the bucket core and away from a plurality of weld seams attaching the bucket core to the extension solely at the second lower section. 
     
     
         11 . The bucket assembly according to  claim 10 , wherein the stress occur(s) on the obtuse bend of the bucket core. 
     
     
         12 . The bucket assembly of  claim 1 , wherein the support is attached to a rear of the upper section of the wrapper at distal and proximal edges thereof. 
     
     
         13 . A method comprising:
 providing a bucket assembly comprising:
 a bucket core including:
 a pair of side sections, the side sections being spaced apart to define a width of the bucket, 
 a wrapper extending between the pair of side sections, the wrapper including:
 a substantially planar, upward sloping, upper section, 
 an arcuate middle section, 
 a substantially planar, downward sloping, first lower section, 
 an obtuse bend, and 
 a substantially planar, second lower section, 
 wherein the wrapper forms a concave, even, continuous surface defined thereover between the upper section and the middle section, and between the middle section and the first lower section, with the obtuse bend demarking the first lower section and the second lower section and continuous therewith, and 
 a support extending between the pair of side sections and fully contained within a boundary defined by an outward edge of the pair of side sections, the support being attached to a rear of the upper section; and 
 
 
 an extension attached to the bucket core, including:
 a pair of side bars operatively and respectively attached to the pair of side sections, the pair of side bars being spaced apart by the width of the bucket, 
 a guard extending between the pair of side sections and attached to the upper section of the wrapper, and 
 an edge portion extending between the pair of side sections and rigidly attached to the bucket core solely at the second lower section of the wrapper. 
 
   
     
     
         14 . The method according to  claim 13 , further comprising:
 prior to said providing the bucket assembly, performing the following:
 prebuilding the bucket core; 
 rigidly attaching a brace to the bucket core, a brace extending across the concave surface of the wrapper and including:
 a frame attached to the upper section and at least one of the first lower section, the obtuse bend, and the second lower section, and 
 a pair of side frames connecting the frame to the pair of side sections of the bucket core; and 
 
 attaching at least some of a plurality of parts of the extension to the bucket core, the attaching of the extension to the bucket core being solely at the second lower section of the wrapper. 
   
     
     
         15 . The method according to  claim 14 , wherein the bucket core is fully welded before said attaching the bucket core to said at least some of the plurality of parts of the extension. 
     
     
         16 . The method according to  claim 14 , further comprising, before said attaching at least some of the plurality of parts of the extension to the bucket core, receiving an order for said bucket assembly, the order reflecting at least one custom requirement, and the at least one custom requirement including the plurality of parts of the extension.