AU2018220056A1 - Pump data system - Google Patents

Abstract

A module which collects and stores, in a memory, data relating to the operation of an emulsion pump, and which transmits that data to a receiver, and wherein the module is powered by energy generated by movement of a part of the pump.

Description

PUMP DATA SYSTEM

BACKGROUND OF THE INVENTION [0001] This invention relates to a system for capturing data relating to the operation of a pump, in a mobile or portable charging unit, which is used for the loading of an emulsion explosive into a blast hole.

[0002] An emulsion explosive includes a base emulsion which is mixed with a sensitizer to render the resulting mixture explosive. Typically a mobile charging unit draws emulsion from a cassette or silo underground. A portable charging unit, which has a small pump on board, is replenished, as required, from a portable bag of base emulsion which is supplied to the pump. The portable charging unit, which has a small pump on board, is used at a work site to place the aforementioned explosive mixture into boreholes for blasting purposes.

[0003] The pump on the portable charging unit is designed to mix the base emulsion with the sensitizer in a predetermined and controlled ratio and then to place the resulting mixture in a blasting location, typically into a borehole.

[0004] Each mobile charging unit is regarded, from a legal point of view, as a mobile explosive factory and therefore is subject to tight control. The use of each mobile charging unit is permitted in terms of a licence from the appropriate authorities. It is therefore necessary from a regulatory point of view to be able to ascertain with certainty the physical location of each mobile charging unit. It should also be possible, with ease,

2018220056 22 Aug 2018 to ascertain the physical location of each mobile charging unit and to formulate a schedule which facilitates the carrying out of preventative maintenance on each unit.

[0005] If information is available on the usage of each mobile charging unit then the task of exercising stock control on the base emulsion and on the sensitizer is more readily effected.

[0006] Information and data of the aforementioned kind can be gathered using manual techniques. Inevitably this type of approach, which is laborious, difficult to implement and control, is subject to human error.

[0007] An object of the present invention is to address, at least to some extent, the aforementioned factors.

SUMMARY OF THE INVENTION [0008] The invention provides, in the first instance, a data collection module for use with an emulsion pump, the module including at least one sensor, responsive to actuation of the pump, to generate data relating to the operation of the pump, a memory unit in which said data is stored, a power source and a transmitter, powered by the power source, for transmitting at least said data to a receiver.

[0009] The power source, in one embodiment of the invention, may be an on-board battery provided for the purpose. Alternatively the power source may include a generator which is driven by movement of a part of the pump to generate electrical energy which is preferably then stored in a battery.

2018220056 22 Aug 2018 [0010] The part of the pump which drives the generator may vary from pump type to pump type. For example if the pump is a reciprocating pump then upon reciprocating action of a component of the pump, one or more magnets could be caused to move relatively to a coil arrangement in order to generate electrical energy. If the pump is based on rotatable movement then a coil could be rotated through a magnetic field, or vice versa. A pneumatically driven electrical generator could alternatively be used to produce the electrical energy which is required for charging the battery. The invention is not limited in respect of the battery charging technique which can be used.

[0011] The module may include any appropriate circuit for monitoring the strength, e.g. the voltage, of the battery. The battery voltage data comprises an important parameter relating to the functioning of the module for it can be analysed to explain why the associated module is not generating information. This can be due to diverse reasons e.g. the pump may be faulty, the battery may require replacement or the generator may be defective.

[0012] The energy generator may include a rectifier and a smoothing circuit which processes the electrical output of the energy generator and makes it suitable for recharging a battery.

[0013] The module may include a RFID tag or a similar device which, in response to an interrogating signal, transmits pump identity data to a receiver or which otherwise makes pump identity data available to a transmitter which thereafter transmits such pump identity data together with data relating to the operation of the pump to the receiver.

2018220056 22 Aug 2018 [0014] The module may include a timing mechanism which generates time and date information relating to operation of the pump. Such information may be logged, e.g. stored in a memory unit, and may be included in data which is transmitted to said receiver.

[0015] The module may include a controller, for example a processor, to control operation of elements or components of the module.

[0016] The module, if included in or added to a mobile or portable charging unit, enables data pertaining to the operation of the pump to be ascertained.

[0017] In order to make use of the data which is collected by a module, data may be transferred from the module to an appropriate receiver. The way in which this is done may vary according to requirement. A miner, for example, is required by law to carry a cap lamp and thus each miner, in an underground position, has an energy source. It is possible to add to the cap lamp a transmitter-receiver unit which can interrogate a module of the aforementioned kind and which can then receive data which is transmitted by the module. The miner, with the respective cap lamp, may return to surface or to a different control location at an appropriate time and, upon the miner entering into a defined region, data may be transferred from the cap lamp arrangement to a secondary receiver.

[0018] Variations on the aforementioned procedure may be implemented. For example a miner may be issued with a wrist watch or another user-wearable item which carries

2018220056 22 Aug 2018 out a function similar to that which has been envisaged to be carried out by equipment added to a cap lamp. The invention is not limited in this respect.

[0019] Preferably data collected in the described manner is transferred from a collection location, e.g. on surface, to a data bank, or to a supervisor, or is processed into graphical form to be made available to a supervisor, other control personnel or to a supplier of the explosive material.

[0020] It is also possible to collect other information relating to a mobile or portable charging unit, or particularly to an environment in which the unit is positioned. Such information may include a licence number or identity number for the charging unit, timing information relating to its use, positional information relating to a location in which the charging unit is in operation and the like. The invention is not limited in this respect. Additionally, data pertaining to the identity of the operator of the charging unit may be collected.

BRIEF DESCRIPTION OF THE DRAWINGS [0021] The invention is further described by way of example with reference to the accompanying drawings in which :

Figure 1 is a schematic illustration of an underground mine in which a pump data collection system, according to the invention, is implemented,

Figure 2 illustrates in block diagram form components of a module according to the invention which is attached to, or included in, a miner’s cap lamp,

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Figure 3 is a block diagram of some components of an emulsion charging unit which includes a module according to the invention,

Figure 4 depicts a possible sequence of movements during which data generated underground is conveyed to a surface or control location, and

Figure 5 depicts the possible construction of a record which contains data collected in the data system of the invention.

DESCRIPTION OF PREFERRED EMBODIMENT [0022] Figure 1 of the accompanying drawings illustrates, schematically, an arrangement of an underground mine 10 which includes a shaft 12 which extends from surface 18 to a number of underground levels 20, 22, 24 etc.

[0023] A store 26 is located at the surface 18. A number of sensors S1 to SN are positioned at strategic locations at the mine. Thus, by way of example only, a sensor S1 is at an entry to the shaft 12 from the surface 18. A sensor S2 is positioned in the level 20 extending from the shaft 12 to a first working area 30. A sensor S3 is installed in the level 22. A sensor S4 is installed in the level 24 which extends to a second working area 34.

[0024] A portable emulsion charging unit 40, which includes a pump 42, is located in the working area 30. Another portable charging unit 44, which has a pump 46, is in the working area 34. Each unit 40, 44 is operated by means of a respective operator (not shown).

2018220056 22 Aug 2018 [0025] Figure 2 schematically depicts a miner’s cap lamp system 48 which includes a data handling module 50, according to the invention.

[0026] The lamp system 48 includes a lamp 52 which, in normal usage, is mounted to a protective helmet of a miner (not shown). The lamp 52 is powered by means of a battery 54 which, typically, is tied to a belt of the miner. The battery has connections 56 which enable the battery to be recharged, automatically, after each shift when the cap lamp is returned to a cap lamp battery system.

[0027] The module 50 includes at least one sensor 58, a processor 60, a memory unit 62 and a transmitter-receiver unit 64.

[0028] Figure 3 depicts, in block diagram form, elements of a data collection system 66 associated with a portable charging unit (40 or 44 as the case may be) and an associated pump (42 or 46 as the case may be).

[0029] In Figure 3 the pump is labelled 70. Typically the pump 70 is powered by means of a motive source 72 such as a source of compressed air or a source of pressurised hydraulic fluid. The pump 70 is designed to pump metered quantities of a base emulsion and a sensitizer from a supply source 76 and to discharge a resulting mixture 78 into a usage point (not shown). As may be necessary the supply source 76 is replenished from a silo or bagged emulsion unit 80.

[0030] If the motive source 72 comprises a source of compressed air or a pressurised source of hydraulic fluid then, inevitably, the pump 70 or the associated portable charging unit (40, 42) does not have an independent electrical power supply. In

2018220056 22 Aug 2018 accordance with one embodiment of the present invention an appropriate battery is included in the system 66 for this purpose. In a different form of the invention, the pump 70 has an energy generator 82 which includes a component 84 (see the inset drawing to Figure 3) which is movable when the pump 70 is operated by the motive source 72. The component 84 may be rotated or reciprocated. The invention provides that, for example, when the component 84 moves, a coil 86 is caused to pass through a magnetic field created by magnets 88. Electrical energy produced by the energy generator 82 is fed via a rectifier 90 and a smoothing capacitor 92 to a battery 94 to ensure that the battery 94 is kept fully charged. The battery 94 is used to power a processor 96, a sensor or sensors 98, a memory unit 100 and a transmitter-receiver 102.

[0031] The processor 96 has an on-board time and date keeping system 104. Coupled to or included in the system 66 is a RFID tag 106. The memory unit 100 is loaded with reference data 108.

[0032] The sensor or sensors 98 are intended to monitor chosen aspects of operation of the pump 70. A basic requirement in this respect is to monitor or record the amount of mixed emulsion delivered by the pump, in use. As the pump 70 is designed to work within a predetermined degree of accuracy then, by way of example only, it is known that for each cycle of pump operation a fixed quantity of mixed emulsion is delivered for example if the pump is a reciprocating pump then for each forward and return stroke, the pump 70 delivers a known quantity of the mixed emulsion. If the number of reciprocating strokes is counted, for example by means of appropriate limit switches, then the product of the number of strokes and the volume of emulsion pumped per

2018220056 22 Aug 2018 stroke is easily ascertainable. The time and date keeping system 104 gives an indication of the time periods during which the pump is in operation.

[0033] The various sensors S1 to SN, shown in Figure 1, are used to detect the passage of a pump 70 or, more particularly, of the RFID tag 106, which is associated with the emulsion charging unit which contains the pump. Information gathered in this respect can be generated in two ways. Firstly, when the pump 70 is moved past a sensor (S1 to SN) the sensor can detect the passage of the pump, e.g. by means of an interrogating signal, and then transmit data pertaining to the sensor to the transmitterreceiver unit 102 in the system 66. In a variation, the sensor (S1 to SN) detects the passage of the pump 70 and, in response to an interrogating signal, sent by the particular sensor, the RFID tag 106 outputs information which identifies the pump, and that information is collected by the same sensor.

[0034] The various sensors S1 to SN can be coupled by means of any suitable communication link to a surface location so that on an ongoing basis the position of each charging unit in the underground mine 10 is known. That information can be validated by collecting information, stored in the various pumps, and then, at chosen intervals, transferring that information from each pump to a data collection point.

[0035] The reference data 108, shown in the block diagram in Figure 3, can be included in each record 110 of information (see Figure 5) assembled in the memory unit 100. The charging unit or pump can have an identity number 112 and, also, is normally licensed for use in a particular location. Data 114 pertaining to such licence is included in the reference data 108. Data 116 identifying the mine in which the charging unit is

2018220056 22 Aug 2018 used, is recorded. The time and date information, produced by the unit 104, is inserted, when required, into a field 118 in the record 110. Data 120 relating to the use of the pump, e.g. the measured volume of emulsion delivered by the pump, or the number of pump cycles is assembled and updated, as the count of volume delivered increases.

[0036] Data relating to the time and date at which operation of a pump is commenced and the time and date at which operation of a pump ceases, during each pump cycle say, from day to day, or date relating to the time and date of information transfer into the record 110 (as described hereinbefore), is stored in a field 122.

[0037] As the pump is moved through the mine 10 data transmitted from each of the sensors (S1 to SN) which the pump passes, can be collected in a field 124 when can thus contain a full history of pump movement as recorded by passage of the pump past the various sensors. The actual location, or working position, of a charging unit, to the extent that it is not ascertainable from sensor information, can be pre-recorded in a field 128, and data 130 which identifies the operator who is handling the pump can be prerecorded. This data can be obtained by means of an input signal which the miner in question is required to give to the module 50 via an appropriate keyboard or other input device (not shown). Alternatively the cap lamp 48 which carries the module 50 is encoded with a unique identity number and that identity number is held in the memory 62 and transferred, as appropriate, to the memory unit 100.

[0038] The structure of the record 110 shown in Figure 5 is exemplary and additional information can be added as may be required, or certain fields can be omitted. By way

2018220056 22 Aug 2018 of example, environmental factors such as readings of prevailing humidity and temperature levels at an installation site may be logged.

[0039] Figure 4 illustrates a sequence of operations which relates to the data collection system of the invention.

[0040] Each miner is required after each shift to have the battery 54 of his cap lamp system recharged at a surface store or location 26 (see Figure 1). When the cap lamp system is drawn from the store information on the time and date of withdrawal is generated by the processor 60 and transferred to the memory unit 62.

[0041] The miner, as indicated, may have an identity number which is also stored in the memory unit 62. As the miner moves through the underground workings the miner passes some of the sensors S1 to SN. At each sensor data 140 is generated which thus indicates the position of the miner. That data may be accumulated in the memory unit 62. Thus the position of the miner is logged at all times.

[0042] Once the miner is in possession of a mobile charging unit or pump at a working area the miner is in a position to commence operation, generally in the manner which has been described, for the pumping of the emulsion. Information 142 relating to the working of the pump 70 is then generated and accumulated in the memory unit 100. Depending on the nature of the system 66, further information pertaining to the working of the pump, its position and, optionally, environmental data is generated and recorded. If the emulsion charging unit is moved past a sensor (S1 to SN) then that event is detected by the respective sensor and transmitted to surface. Additionally, positional data which identifies the sensor in question, is transferred to the memory unit 100.

2018220056 22 Aug 2018 [0043] The charging unit is used in the normal manner for the placing of a mixed emulsion product. Energy which is required for the reading or transmission of data is produced by the energy generator 82 which ensures, as well, that the processor 96 is kept updated.

[0044] During a working shift the data referred to in connection with Figure 5 is transferred on an on-going basis to the memory 62 which is associated with the cap lamp worn by the miner. At the end of a shift the miner returns to surface 144 and engages the cap lamp with the charging system in the surface store 26. The return data and time are logged (146).

[0045] The data which is carried in the memory unit 62 is transferred (150) to a data bank or directly to a user together with the relevant time and date information (146) which relates to this event.

[0046] With each transfer of data which takes place to the memory 62, whether from a memory unit 100 or from one or more of the sensors S1 to SN, the accuracy of the data transfer is confirmed. Thus when data is sent in one direction, a return signal transfers data in the return direction for validation and correction procedures. Coding and error rectification techniques known in the art for the transmission of data can be employed, as appropriate, to minimise errors.

[0047] A benefit of the invention lies in the fact that the emulsion charging unit which carries the pump monitoring system is used in the normal manner. No deviation from standard operating procedures is required. Data collected during operation of a pump, stored in the associated memory unit 100, is automatically transferred to the memory 62

2018220056 22 Aug 2018 in a module 50 when the operator who carries the module 50 with his cap lamp 48 is in the vicinity of the pump. The miner, upon returning to surface, carries that data with him and once the cap lamp has been placed into a cap lamp battery bank, the transferred data is available for use or further transmission etc. at a surface location.

[0048] The data which is collected allows for the reliability of each pump to be ascertained and for its work cycle to be closely monitored. Maintenance and updating procedures can be facilitated. If the energy generator system 82 is responsive to pump movement then no on-board battery is required. It is possible though to place a battery on the charging unit and thereby dispense with the energy generator.

[0049] The invention has been described in the context of the module 50 being associated with a cap lamp. This is not necessarily the case. Any usable wearable item such as a watch or body belt may incorporate a device which is an equivalent to the module 50. Data generated and captured during the use of the module can be transferred to any chosen destination e.g. an emulsion supplier, a mine official or a regulatory authority.

[0050] It will be understood that the term “comprise” and any of its derivatives (eg comprises, comprising) as used in this specification is to be taken to be inclusive of features to which it refers, and is not meant to exclude the presence of any additional features unless otherwise stated or implied.

[0051] The reference to any prior art in this specification is not, and should not be taken as, an acknowledgement of any form of suggestion that such prior art forms part of the common general knowledge.

2018220056 22 Aug 2018 [0052] It will be appreciated by those skilled in the art that the invention is not restricted in its use to the particular application described. Neither is the present invention restricted in its preferred embodiment with regard to the particular elements and/or features described or depicted herein. It will be appreciated that various modifications can be made without departing from the principles of the invention. Therefore, the invention should be understood to include all such modifications in its scope.

Claims (12)

1. A data collection module for use with an emulsion pump, the module including at least one sensor, responsive to actuation of the pump, to generate data relating to the operation of the pump, a memory unit in which said data is stored, a power source and a transmitter, powered by the power source, for transmitting at least said data to a receiver.

2. A data collection module according to claim 1 wherein the power source is an onboard battery.

3. A data collection module according to claim 1 wherein the power source includes a generator which is driven by movement of a part of the pump to generate electrical energy which is stored in a battery.

4. A data collection module according to claim 3 wherein the pump is a reciprocating pump and upon reciprocating action of a component of the pump, one or more magnets move relatively to a coil arrangement in order to generate electrical energy.

5. A data collection module according to claim 2 wherein the pump includes a pneumatically driven electrical generator which produces electrical energy which is required for charging the battery.

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6. A data collection module according to claim 3 wherein the power source includes a rectifier and a smoothing circuit which processes the electrical output of the generator and makes it suitable for recharging the battery.

7. A data collection module according to claim 1 which includes a RFID tag which, in response to an interrogating signal, transmits identity data on the pump to a receiver or which makes the identity data available to a transmitter which thereafter transmits such pump identity data together with data relating to the operation of the pump to the receiver.

8. A data collection module according to claim 1 which includes a timing mechanism which generates time and date information relating to operation of the pump.

9. A data collection module according to claim 8 wherein such time and date information is stored in a memory unit, and is included in data which is transmitted to the receiver.

10. A data collection module according to claim 1 which includes a processor to control operation of at least the memory unit, the transmitter, or at least one sensor.

11. In combination, a user wearable item and a data collection module according to claim 1 transfers data to a receiver.

12. A combination according to claim 11 which includes a transmitter-receiver unit which interrogates and receives data transmitted by the user wearable item.