Stress or accumulated damage monitoring system

A monitoring system implemented on a hydraulic shovel having a boom, stick and bucket, the monitoring system comprising:

• a plurality of strain gauges each gauging strain at one of a plurality of corresponding strain gauge locations on at least the boom or stick of the hydraulic shovel, the strain gauge locations including critical locations predicted to fail in one or more of a range of operating states or adapted to predict failure in another location on the boom or stick in one or more of the range of operating states;
• pressure gauges configured to measure how much force is applied through hydraulic actuators to at least the boom and stick;
• position or orientation gauges on at least the boom and stick;
• a data acquisition unit adapted to acquire real-time strain data from the strain gauges, the pressure gauges and the position or orientation gauges;
• a processor and memory adapted to process the acquired real-time strain data from the strain gauges to calculate one or more measures of actual instantaneous stress or accumulated damage, adapted to process the acquired real-time data from the pressure gauges to calculate real-time forces applied to the boom and stick through the hydraulic actuators, adapted to process the acquired real-time data from the position or orientation gauges to calculate a real-time position of the boom and stick, and adapted to determine a real-time operating state of the hydraulic shovel from the range of operating states using the real-time forces and the real-time position of the boom and stick, and adapted to determine real-time information derived from the real-time operating state;
• and
• at least one output device, at least one of which is configured to provide information comparing the one or more measures of actual instantaneous stress or accumulated damage with corresponding reference values of maximum allowable stress or accumulated damage, and to provide the real-time information derived from the real-time operating state;
• and
• wherein the real-time information derived from the real-time operating state comprises a warning when one of the measures of actual instantaneous stress or accumulated damage exceeds or approaches a corresponding reference value;
• and further comprises programmed advice to a driver of appropriate corrective action having regard to the real-time operating state to reduce the one or more measures of actual instantaneous stress or accumulated damage and allow continued excavation.