Swinging without compromise

The next generation in swing pedal design for draglines, power rope shovels and hydraulic shovels

Traditional swing pedal technologies for controlling draglines in mining operations present several challenges for operators. One such challenge is repetitive strain injuries (RSI), which result in productivity loss and negatively impact a mine’s bottom line. However, one company has revolutionised how operators control draglines, power rope shovels, and hydraulic shovels, making the process safer and more efficient.

Swing Invent Holdings (SIH) understands first-hand the pressures of operating draglines and shovels on mine sites—and the launch of their innovative swing pedals reflects the company’s pursuit to transform dragline equipment design.

With decades of electrical expertise and hands-on industry experience, SIH founder Geoff Davis lives and breathes mining. The initial product design stage saw him using cardboard cutouts and working closely with dragline operators on the coalface to gain feedback and further refine the console design concept.

In collaboration with Leveltec Engineering and BHP, combined with a rigorous product development process, a new generation of swing pedals was born.

Today, as the only calibrated swing pedals globally, they are being used in world-class mining assets in both Australia and abroad, significantly reducing costs and operator fatigue. Showcased at MINExpo 2024 in Las Vegas, mining companies are looking to install the swing pedals in their OEM machines, some of which include Caterpillar 6040/6060, Hitachi EX5200, and Komatsu PC4000/PC8000 hydraulic shovels.

Slimline pedals, safer design

Unlike other companies, this patented Aussie-made swing pedal technology is more slimline, comfortable and safer for the operator. It enables operators to control the rotation of these mining machines while reducing the risk of RSI that’s common in traditional joystick controls.

For operators of draglines and shovels, no other pedal configuration presents such a complete solution to the challenges of traditional swing pedal technologies, with the costliest being RSI.

Geoff explained that RSI is a big issue for operators and it comes down to ergonomics.

“Our bodies are designed for forward movement (in and out), not for side-to-side wrist rotation. As operators are sitting in their chairs for 12-hour long shifts digging harder and shifting overburden, they’re unconsciously grabbing the joysticks harder. This unnatural rotation increases the strain on their wrist, which causes the RSI.”

In most cases, the technical issue of the joystick not returning to a neutral position when the operator releases the handle or the spring has been disabled, applies constant pressure on the wrist.

“Our swing pedal assembly incorporates an automatic return to neutral,” which mitigates any safety risks should operators suffer from an emergency medical issue,” added Geoff.

“The swing pedals’ ergonomic design includes a slide rotation bracket so that operators can easily adjust the height for optimised ergonomics and comfort. The pedal angle can also be adjusted to suit the operator’s posture, minimising pedal travel for reduced stress on the ankles and feet. The narrow pedal stance and pivoting pedal action contribute to a more comfortable and natural working position, reducing the likelihood of awkward manoeuvres that can cause RSI.”

Next level performance

The swing pedal technology was not just about solving technical problems; it was about reshaping the operator’s experience. Geoff’s attention to detail and commitment to addressing common issues in older pedal assemblies, such as unsafe designs, access to the controls, downtime and maintenance costs, drove him to refine the pedal’s functionality.

“Our advanced, fully self-contained pedal housing is suitable for console or floor-mounted applications, it’s simply a plug-and-play,” he said.

“It’s made from a durable cast aluminium that supports heat-treated pedals, guaranteeing long-life performance in tough conditions. The pedal assemblies can also be retrofitted seamlessly with existing OEM equipment. These feature a console-mounted application, which allows operators to make custom, personal adjustments to the pedal positioning in real-time while supporting the industry’s only genuine automatic return-to-neutral feature.”

Geoff added, “The new slimline pedals now give OEMs an adaptable, ergonomic option that reduces the unnecessary left or right-hand movements and rotations required by operators. And we’ve done it by introducing the complete slimline and fully adjustable control system into the operator’s cab. The self-contained console within the cab offers a streamlined and uncluttered profile, which minimises obstructions and maximises circulation space for a safe and efficient workspace.”

The SIH slimline pedals can be supplied compatible with new or existing control systems such as Potentiometer, Resolver, Absolute Encoder, 4 – 20mA + & -, 0 – 10Volts + & -, or Hall Effect control systems. All SIH pedals are the only calibrated pedals available in the market, and come with a certificate of calibration. OEM brand names can also be added to the pedals.

Collaborating for the future

With an estimated 600 draglines and 5,000 hydraulic shovels operating globally, SIH is committed to building long-term partnerships to transform how operators control their equipment.

SIH is working closely with its Australian agent Leveltec Engineering, in response to both domestic and international interest, including Latin America.

Leveltec designs and supplies a range of consoles, joysticks, seats, monitors and other equipment. Managing Director Ben Stokes, and Andrew McGarrigle from Leveltec, regularly visit mines across Australia to gain insights and operator feedback. Both SIH and Leveltec continue to secure local acceptance of this innovative technology and are excited about the positive impact it’s having on operators and mine sites in which they work.

SIH will be showcasing its Aussie-made swing pedal technology at GRX25 on 20–22 May 2025 in Brisbane. Visit Stand Z103B to learn how the swing pedal technology can support your operators.

For more information, visit www.swinginvent.com.au, email [email protected] or call +61 413 229 293.