AU2016101787A4 - Wireless wear detector and testing device to test a plurality of wired or wireless wear detector with tempreture and pressure sensor embeded in any surface and method - Google Patents

Abstract

An wireless wear detector with temperature and pressure sensors, reader interface apparatus and tester is disclosed for testing of plurality of wireless wear detector locations or embedded in at any surface, wherein each wear point is connected to a respective reader or common reader interface. The testing device is adapted to test the wear condition, pressure and temperature at the location. The interface apparatus comprises a plurality of reading devices or common reader device, each reading device being associated with wear detector location respective and each reading device is connected to the tester; and a controller for selecting a wear location or receiving status information of the plurality of wear position for testing and for activating the associated alarm location on the monitor graphically of any fixed or mobile device or on the machine or remotely at the control station. A method of testing a plurality of wire and wireless wear position on any surface or location is also disclosed. 13,-- 12- ZIZ I L \ 19 Figure- -I

Description

2016101787 12 Oct 2016

WIRELESS WEAR DETECTOR AND TESTING DEVICE TO TEST A PLURALITY OF WIRED OR WIRELESS WEAR DETECTOR WITH TEMPRETURE AND PRESSURE SENSOR EMBEDED IN ANY SURFACE AND METHOD

FIELD OF THE INVENTION

[0001] The present invention relates broadly to detect wear condition at any given location on a wearing surface or fasteners or both wirelessly and in particular relates to wireless wear detector and an reader interface apparatus for interfacing wired or wireless wear detector a testing and monitoring device to a plurality of wear position.

BACKGROUND OF THE INVENTION

[0002] Surface wear is common when two or more surface make frictional contact. When the surfaces are enclosed or remote it is hard to know the surface condition. Detecting surface condition prior to breakdown helps in reducing downtime of machines, equipment and safety of road, bridges, amusement equipment like roller coaster etc. Also detecting wear in artificial bone replacement such as hip, shoulder and knee etc. Detecting surface wear wireless at any given position on the surface helps in monitoring the surface condition remotely and dynamically. Determining the road surface wear remotely helps in planning road work, determining numbers of lanes, material used for building the road etc.

[0003] the present invention may at least alleviate the aforementioned disadvantages by providing a quicker, more convenient and safer alternative to traditional testing of wear condition. The Interface to tester and monitor provides real-time surface monitoring, activation of alarm, helps in acquiring data (Temperature & Pressure) for material analysis or contact surface analysis and provide early warning to remote location via cloud to any fix or mobile device.

[0004] A reference herein to a patent document or other matter which is given as prior art is not to be taken as an admission that that document or matter was known or that the information it contains was part of the common general knowledge in Australia or elsewhere as at the priority date of any of the disclosure or claims herein. Such discussion of prior art in this specification is included to explain the context of the present invention in terms of the inventor's knowledge and experience.

[0005] Throughout the description and claims of this specification the words "comprise" or "include" and variations of those words, such as "comprises", "includes" and "comprising" or "including, are not intended to exclude other additives, components, integers or steps.

SUMMARY OF THE INVENTION

[0006] According to one aspect of the present invention there is provided an interface apparatus suitable for interfacing to a plurality of wear position detector with temperature and pressure sensor at any given location/locations on a wearing surface, fasteners or both, wherein each wear detector is connected to a respective reading interface or common reading interface and the testing device is adapted to test the said wear condition at any location; said interface apparatus comprising: a 2016101787 12 Oct 2016 plurality of reading interface devices or common reading interface device, each reading device or common reading device being associated with a respective wear detector position and to said testing device; and a controller for receiving or selecting a wear condition status of said plurality of wear detectors and for activating the associated actuating device so as to raise audio and visual alarms on static and mobile devices.

[0007] Every wear detector position may include wear detector that is embedded in the surface holding fastener (example nuts, Bolts, pins and rivets) or in the wearing surface or both. Each reader device may connect wirelessly or wired to the testing device. The controller may include a microprocessor or microcontroller.

[0008] The reader interface may include a temperature, pressure monitoring device to provide data and status at the wearing position or positions.

[0009] The testing device may be adapted to measure and/or record a wear condition, temperature and pressure associated at the given wearing position. The testing device may include a manual or an automatic operation. The wear position may be moving surface, vibrating surface or static surface in air or liquid or in flesh [00010] The testing device may be adapted to communicate with a digital computer such as a portable PC or Mobile or tablet computer. The digital computer may include computer software including a control application for controlling the interface apparatus.

[00011] The digital computer and control application may communicate with the interface apparatus to select a particular wearing position to allow it to be tested or receive wear condition, temperature, pressure status from different location automatically. The apparatus may include a facility to record the results of a test.

[00012] method of testing a plurality of wear positions at any location on the wearing surface or fastener or both, wherein each wear detector is connected to a respective reader interface or common reader and tester, said method comprising the steps of: providing an interface apparatus suitable for interfacing a testing device to said plurality of wired or wireless wear detectors, wherein said testing device is adapted to test said wear position at said surface location; providing a plurality of reading interface or common interface device, each reading interface or common reading interface device being associated with a respective wired or wireless wear detector and said testing device; and using a controller to select a wear position of said plurality of wear positions for testing and to actuate the associated reading interface device so as to communicate with the selected wear position to said testing device for said testing or the wear detector communicated to the tester, controller automatically at set intervals or on reaching threshold level of wear.

Provide maximum wear condition alarm to the tester through the reading interface.

[00013] The present invention may also provide a method of testing a surface wear using wired or wireless wear detector on any wearing surface, fasteners or both including a method of interfacing a testing device to one or more wear detectors at one or more positions as described herein. 2016101787 12 Oct 2016

BRIEF DESCRIPTION OF THE DRAWINGS

[00014] Preferred embodiments of the present invention will now be described with reference to the accompanying drawings wherein: [00015] Figure 1 shows wireless wear detector 11 associated with wearing surface being tested by technician accordance with an embodiment of the present invention [00016] Figure 2 shows wireless wear detector device in plug form [00017] Figure 3 shows wireless wear detector device in plug form with temperature and pressure sensor [00018] Figure 4 shows a Block Diagram in accordance with an embodiment of the present invention [00019] Figure 5 shows a flow chart of associated software [00020] Figure 6 shows wireless wear detector embedded in mining screen at various location.

DETAILED DESCRIPTION OF THE INVENTION

[00021] The following detailed description of a preferred embodiment of the invention refers to the accompanying drawings. Although the description includes exemplary embodiments, other embodiments are possible and changes may be made to describe embodiments without departing from the spirit and scope of the invention.

[00022] Figure 1 shows wireless wear detector 11 associated with wearing surface being tested by a technician 18. Wearing surface 10 includes pre-installed wireless or wired wear detector 11 or may be pre-installed in fasteners 19 or both. In the vicinity of the wearing surface, reader module 12 is installed. It is associated with a wear detector or a plurality of wear detectors.

In accordance with the present invention one or more pre-installed reader module 12 in association with wear detectors 11 from various frequencies. Testing module 13 and reader modules 12 interact with wear detector installed in wearing surface 10 or fasteners 19 or both to allow each wear position to be tested via testing module 13. A testing sequence may be initiated via handheld tablet computer 14 or 17 or mobile 16 with control software which communicates with testing module 13 via a radio link. In some embodiments the wireless communications link may be replaced with a communications cable which may include a serial, LAN or other standard interface. Wear detector can communicate automatically to the controller proactively when pre-determined wear threshold is reached.

[00023] Figure 2 is a diagram showing a wireless wear detector. Wireless wear detector housing 10 encloses detector electronics. Depending on type of wearing surface and detector frequency the housing material may change. Depth of threshold point 11 from the top surface is adjusted according to the application and users requirements. Point 11 is a resistive conductor that connects detector electronics and the identification chip 13 one or more points can be added during construction or by setting set pints in the tester software though controller server. The detector can be embedded in the wearing surface or in the wearing surface fastener or both. 2016101787 12 Oct 2016 [00024] Figure 3 is a diagram showing a wireless wear detector with temperature detector. Wireless wear detector housing 10 encloses detector electronics. Depending on type of wearing surface detector frequency the housing material may change. Depth of threshold point and number of threshold points 11 from the top surface is adjusted according to the application and users requirements, number. Point 11 is a resistive conductor that connects detector electronics and the identification chip 13 one or more points can be added during construction or by setting set pints in the tester software though controller server. Temperature sensor 14 and pressure sensor in association with thermal conductor rod 15 is wired to Identification chip 13. Temperature and pressure threshold can be set in the tester through the controller server.

[00025] Figure 4 Block diagram of one form of reader interface apparatus according to the present invention connected at wearing surface 10 to a plurality of wear detectors 11A - 11D and wear detector embedded in fastener 19 or installed on the wearing surface 10 or both and connected to reader interface module 12

The interface module 12 communicates with testing module 13 via radio link or wired link. Testing module 13 is connected to digital (tablet) computer 14 via wireless communications, LAN, serial cable or any standard communication methods, with control software for controlling and listening interface module 12. In some embodiments testing module 13 may include a stand-alone testing device with inbuilt intelligence.

[00026] Interface module 12 includes wireless wear reader 21 that reads the wear detector conditions and their respective ID at pre-set intervals or on request initialled by controller or on reaching threshold level, it may have its own microcontroller or may share with the active reader 20 controller. Wear reader 21 connects to Active reader interface 20 via communication link and power cable 22 and 23. Active reader 20 is powered by battery and vibration power generator 25 connected by cable 24. Active reader 20 is wirelessly connected to Tester module 13 via Active receiver 26 via radio link or other customised or free to air frequency or wired using standard communication links.

[00027] Tester Module 13 connects to multiple reader module 12,12A, 12B etc and can read status at variable reads per second.

[00028] Active reader 26 in tester module connects to digital computer or server by LAN, Wireless LAN or standard serial communication. Digital computer 14 may include software having a control application which may initiate a test sequence and automatically record the results, as distinct to a manual test sequence. The results may be transmitted via a communications network such as the internet, intranet to a remote database facility 29 allowing for detailed reports to be compiled about surface wear condition. Digital computer 14 connects to SCADA (Supervisory Control And Data 2016101787 12 Oct 2016

Access) or DCS (Distributed Control System) 27 and Alarm system 28 to report wear status locally to mobile device 16 and tablets 17. In some embodiments digital computer 14 or at least some of its functions may be integrated with interface module 12 and/or testing module 13.

[00029] When the wearing surface reaches the wear threshold depth the wear detector 11,11A,11B or may be 11D or the wireless wear detector embedded fastener 19 will change its state and transmitting its new status to the reader 21. In some cases wear detector embedded fastener 19 or wearing surface 10 may get loose and drops off triggering a no read condition at the reader 21 that is reported to tester module 13.

[00030] Figure 5 shows a flow chart for an associated software application. The software application scans all the wear reader status parameters or reads selected wear detector or when a wear detector changes state step 80, the reader interface provides an interrupt to active interface reader at step 81. Active reader interface relays the status with parameter to Active reader 26, at step 83 it compares the ID, status and transfers status package to the tester if there is a bad read or mismatch it repeated step 81. Step 84 Tester decrypts the package and server updates local and remote database. Step 85 local server updates wear sensor status on the graphical user displays accordingly. It also updates assigned DCS tag for SCADA interface. Mobile alert via SMS or email may be activated to assigned mobile equipment. Server updates the Smart Screen Web Portal data. At step 82, if the maximum wear threshold is not detected then temperature, pressure and wear parameter are sent to the active reader.

[00031] Smart Screen Portal is web based portal or mobile App and can be accessed on any mobile device such as smart phone, tablet, laptop etc.

[00032] Figure 6 shows a practical implementation on mining screens, mining screen surface 10 in embedded with wireless wear detractors at defined positions 13,14,15 the screen fixed to the frame using fasteners 11, 19 which have embedded wireless wear detector. Reader interface 12 reads the status data and transmits to receiver and tester 16 for further processing and to Server 17. Server 17 that has local and cloud DB updates the status and alarm 18 accordingly. The Smart Screen Portal updates wear detector statuses and displays accordingly. It also updates assigned DCS tag for SCADA interface. Smart Screen Portal is web based portal and can be accessed on any mobile device such as smart phone, tablet, laptop etc.

[00033] Embodiment of inversion includes: A system for detecting wear out of surfaces comprising an interface for a testing device and controller. a plurality of wear detectors attached to the wearing surface or fasteners having pressure and temperature sensors a communication means for sending signals from the wear detectors to a controller and a database wherein the controller analysis the signal and compares the signal with the reference data, previous signal data acquired through the communication means about the wear detectors to identify the specific location of the wear out position on the surface testing or when wear detector reaches the 2016101787 12 Oct 2016 maximum level of wear, it communicated through the reading interface to the tester to update the status and activate alarms. A system as defined in claim 1, wherein the signal is generated from the wear detectors by a change in the resistance created within the wear detector. A system as defined in any of the previous claim, wherein the signal is communicated either wired or wirelessly to the said reader interface and the said tester and controller. A system as defined in any of the previous claims, wherein the signal is activated when a wear threshold level is reached and the wear threshold level is defined in the database and in the construction of the wear detector. A method of testing wear out of a surface comprising a plurality of detectors are embedded into the surface, the embedded detectors have a pressure and a temperature sensor the plurality of detectors are connected to an interface for continuous reading of signal generated by the plurality of detectors the interface is connected to the controller which has a predefined data for comparing wear level of the surface and surface holding fasteners to detect wear out of the specific area of the surface or surface holding fasteners using a pictorial presentation of the wear surface on the controller, mobile devices local and remote using smart wear portal and mobile App.

Claims (5)

1. The claims defining the invention are as follows: 1A system for detecting wear out of surfaces comprising an interface for a testing device and controller. a plurality of wear detectors attached to the wearing surface or fasteners having pressure and temperature sensors a communication means for sending signals from the wear detectors to a controller and a database wherein the controller analysis the signal and compares the signal with the reference data, previous signal data acquired through the communication means about the wear detectors to identify the specific location of the wear out position on the surface testing or when wear detector reaches the maximum level of wear, it communicated through the reading interface to the tester to update the status and activate alarms.
2. 2 A system as defined in claim 1, wherein the signal is generated from the wear detectors by a change in the resistance created within the wear detector.
3. 3 A system as defined in any of the previous claim, wherein the signal is communicated either wired or wirelessly to the said reader interface and the said tester and controller.
4. 4 A system as defined in any of the previous claims, wherein the signal is activated when a wear threshold level is reached and the wear threshold level is defined in the database and in the construction of the wear detector.
5. 5 A method of testing wear out of a surface comprising a plurality of detectors are embedded into the surface and surface holding fasteners, the embedded detectors have a pressure and a temperature sensor in it. the plurality of detectors are connected to an interface for continuous reading of signal generated by the plurality of detectors the interface is connected to the controller which has a predefined data for comparing wear level of the surface and surface holding fasteners to detect wear out of the specific area of the surface or surface holding fasteners using a pictorial presentation of the wear surface on the controller, mobile devices local and remote using smart wear portal and mobile App.