EA046535B1 - LINING UNIT FOR GRINDING MILL, GRINDING MILL, METHOD FOR TRANSPORTING LINING UNIT FOR GRINDING MILL AND METHOD FOR CONTROLLING LINING UNIT FOR GRINDING MILL - Google Patents

Description

Field of technology

Embodiments relate to a sensor and other components for a grinding mill, in particular for measuring changes in the configuration of the mill, as well as a method for monitoring the mill, in particular a method for monitoring operating conditions and changes in the configuration of the mill.

State of the art

Grinding mills are used to grind materials into smaller pieces. An economically significant application of mills is in the mining industry, where they are used to grind ore into smaller pieces for more efficient further processing of the ore.

Examples of grinding mills used include autogenous mills, in which a turning drum creates a cascade of pieces of ore of different sizes, which, when said pieces collide with each other, causes grinding, producing smaller stones. In semi-autogenous mills, balls of steel or other hard materials are added to the ore to facilitate the grinding process.

As the mill drum rotates, the material to be crushed (called the charge) forms a flowing cascade in the drum. The leading edge of the charge before it falls is called the shoulder, and the trailing edge of the charge, or the material that recently fell, is called the toe.

Establishing the optimal grind size for a particular mill can be a complex process that depends on a number of factors. One of the main factors is the rotation speed of the drum. If the speed is too high, the centripetal forces will cause the charge arm to be carried too far up the drum wall, so that when dropped the cascade will fall directly onto the drum. Too low a speed results in a reduction in the height of the cascade, which reduces the efficiency of the mill.

Since the inner surface of the drum is subject to significant impact from the falling charge cascade, the drum is equipped with replaceable linings that protect the cylindrical drum casing and form replaceable wear parts that extend the life of the mill. However, these replacement liners impose significant operating costs on the mill and replacement interrupts mill operation, reducing productivity.

The high wear resistance of the materials required to make the casing and lining means that the operator cannot see the inside of the drum while the mill is running, making it difficult to improve the mill's operating conditions.

It should be understood that if reference is made in this document to any prior art publication, such reference does not constitute an admission that such publication forms part of the general knowledge of the art in Australia or any other country.

The essence of the invention

The embodiment relates to a mill lining for a grinding mill, wherein the lining has a wear surface and an opposing inner surface, which during operation is located opposite the inner surface of the mill casing, and a vibration sensor located in the lining and detecting vibration of the lining during operation of the mill.

Vibration measurements can be used to obtain information about mill operating characteristics, such as charge head positions, which can be used to improve mill operating efficiency. The advantage of this configuration is that by locating the vibration sensor in the lining, more accurate vibration readings can be obtained compared to vibration measurements at locations remote from the lining, such as in a casing. In one embodiment, the data collected from the vibration sensors may include the angle of rotation of the mill, the amplitude and frequency of the built-in sensor.

The mill lining may further comprise a wear sensor to detect wear of the lining wear surface during operation.

A wear sensor and a vibration sensor can be connected to form a sensor unit.

The wear sensor may wear out along with the lining.

The wear sensor may contain a circuit resistor.

The mill lining may further include means for transmitting information related to detected vibration and/or wear of the mill lining to a location remote from the mill.

The means for transmitting information may comprise an antenna, which is configured to be attached to the sensor unit through the opposite inner surface of the lining. Installing an antenna may help activate the sensor.

The vibration sensor may include at least one accelerometer. In one embodiment, the vibration sensor may be a two- or three-axis accelerometer. In one embodiment, the vibration sensor may be a 6-axis accelerometer (consisting of a 3-axis accelerometer and a 3-axis gyroscope). This configuration also provides rotational measurement capabilities on the mill lining. In another embodiment, the accelerometer may be a 9-axis accelerometer (consisting of a 3-axis accelerometer, a 3-axis gyroscope, and a 3-axis compass).

- 1 046535

The sensor unit is located in the empty space formed in the mill lining. The specified space can be obtained in the lining previously by casting. The sensor unit can be enclosed in an empty space and seal. The seal can be made of epoxy resin. If the mill lining contains an antenna, said antenna may be inserted from the opposite inner surface. The antenna can be inserted after installing the sensor unit. The antenna may be installed through access holes in a void space, with the access hole being accessible through a frangible portion of the interior surface.

In a particular embodiment, access to the sensors can be obtained through the internal surface through the mill casing and, in particular, through pre-formed holes formed in the casing. In service, many mill casings have knockout holes formed in the casing designed to accommodate a suitable shaped tool for pushing worn liners (that have been detached from the casing) into the mill for collection and replacement. The use of these holes (by aligning the position of the sensor assembly on the liner with the knockout holes during installation) provides a convenient point of access to the sensor and adjustment of the antenna after installation. An additional benefit is that placing the antenna through the knockout holes ensures clear transmission of RF signals from the sensor.

Another embodiment provides a liner sensor for use with a liner located on an internal surface of a grinding mill drum, the liner sensor comprising a vibration sensor for detecting vibration of the liner during operation of the mill and a wear sensor for detecting wear on a surface of the liner during operation.

The vibration sensor and the wear sensor can be made as parts of a structural element. The structural element can be used to secure the lining to the drum. The structural element may be a bolt.

The wear sensor may wear out along with the lining.

The wear sensor may include a chain resistor and/or the vibration sensor may include an accelerometer.

The lining sensor may also include a thermometer and/or a battery capacity meter.

The lining sensor may also include a wireless communication module. The wireless communication module may be configured to provide LTE (4G communication standard) and/or LoRa (long-range radio) communications.

The lining sensor may also include a housing, wherein the vibration sensor is located in said housing.

Another embodiment provides a fastening element for attaching a liner to the inner surface of a mill drum casing, the fastening element including a liner sensor according to any embodiment described above.

In one embodiment, the fastener includes a lining sensor including a vibration sensor and a wear sensor. In one embodiment, the fastening element includes a shank and a housing configured to connect to the shank, wherein the shank contains a wear sensor, and a vibration sensor is located in the housing.

The connection between the body and the shank can be flexible. The connection may be vulcanized and may be made of rubber.

Another embodiment relates to a grinding mill comprising a casing and a lining that has a wear surface and an opposing inner surface located on the inner surface of the casing, the mill also including a lining sensor built into the lining and including a vibration sensor for detecting vibration of the lining during the process. operation of the mill.

The grinding mill may also include a wear sensor to detect wear on the lining wear surface during operation of the mill. A wear sensor can be built into the lining. The wear sensor can be connected to the vibration sensor or can be made separately from it.

The grinding mill may also include a set of liners, each of which contains a corresponding vibration sensor and a wear sensor.

The grinding mill may also include means for transmitting information related to detected vibration and/or wear of the mill lining to a location remote from the mill.

The communication means may be coupled to the vibration sensor and may be provided through the outer surface of the housing.

Another embodiment relates to a method for monitoring a grinding mill comprising a casing and a lining that has a wear surface and an opposing inner surface located on the inner surface of the casing, the mill also comprising a lining sensor built into the lining and including a vibration sensor for detecting vibration of the lining at during the operation of the mill, the method includes:

- 2 046535 comparison of measurements from a vibration sensor for a given period of time; and setting a profile for the mill based on the compared measurements.

Another embodiment relates to a method for monitoring a grinding mill comprising a casing and a lining that has a wear surface and an opposing inner surface located on the inner surface of the casing, the mill also comprising a lining sensor comprising a vibration sensor for detecting vibration of the lining during operation of the mill and a wear sensor for determining the wear of a wearing surface, wherein the method includes: comparing measurements from a vibration sensor over a given period of time, comparing measurements from a wear sensor over a given period of time with setting a profile for the mill based on the compared measurements.

The mill may include a set of liner sensors and/or wear sensors located at different locations in the mill, wherein the method may also include correlating measurements from the set of vibration sensors and/or wear sensors together with location information related to the location of each vibration sensor and/or wear sensors. or wear sensor.

The method may also include the step of changing at least one operating parameter of the mill and determining changes in correlated measurements associated with the changed parameter.

The modified parameter may be one or more of the following: batch size, aggregate particle size, drum rotation speed, mill slurry feed rate.

The mill may also include an angle sensor for determining the angular orientation of the drum, measured as an angle, wherein the method may also include the step of matching angle measurements, and the profile of the mill depends on the angle measurements. These angular measurements can be obtained by using a 6-axis accelerometer as a vibration sensor.

The method may also include correlating measurements from the vibration sensor with angle measurements.

The method may also include setting vibration characteristics on the lining, such as amplitude and frequency.

Another embodiment relates to a mill lining assembly for a grinding mill, comprising: a mill lining having a wear surface and an opposing inner surface, which in operation is located opposite the inner surface of the grinding mill casing, a lining sensor built into the lining, and a control or power device, configured to control or power the lining sensor and also built into the mill lining.

During operation, the control or power device can be activated through an opening made in the grinding mill casing.

Said hole may be made separately from the mounting hole designed to accommodate a fastening element for attaching the lining assembly to the grinding mill.

The liner sensor may comprise a wear sensing device configured to measure wear of a wear surface, a vibration sensor configured to measure vibration of the mill lining as it is used in a grinding mill, or both.

The lining sensor may include at least one active sensing component.

The at least one active sensor component may be a polling component (or a portion thereof) configured to provide a polling signal.

The mill lining or a response component incorporated into the mill lining may be configured to interact with the interrogating signal to generate a response signal.

The at least one active sensor component may be a responsive component (or part thereof) configured to interact with the interrogating signal and provide a response signal.

The power or control device may be located in a cavity formed in the mill lining, or in a plug designed to substantially seal the cavity.

Another embodiment relates to a mill lining assembly for a grinding mill, comprising a mill lining having a wear surface and an opposing inner surface, which in use is located opposite the inner surface of the grinding mill casing, and a vibration sensor built into the lining and detecting vibration of the lining during use. in a grinding mill.

Another embodiment relates to a mill lining assembly for a grinding mill. Said assembly comprises: a mill lining having a wear surface and an opposite inner surface, which during operation is located opposite the inner surface of the grinding mill casing, and a wear recording device designed to determine the wear of the wear surface during operation, wherein said recording device contains a first component made with the ability to supply a polling signal and built into the lining. The wear recorder also contains a reacting component, you

- 3 046535 complete with the ability to interact with the interrogating signal to provide a response signal, the reacting component also being built into the lining.

Another embodiment relates to a mill lining assembly for a grinding mill, comprising a mill lining having a wear surface and an opposing inner surface, which in use is located opposite the inner surface of the grinding mill casing, and a wear recording device for detecting wear of the wear surface in use, wherein said recording device comprises a first component configured to supply an interrogating signal and integrated into the lining. The wear detection device comprises a power or control device configured to control the operation of said first component.

The response signal received in response to the interrogation signal may provide two-dimensional data related to the wear surface.

The power supply or control device may be incorporated into the mill lining or into a plug configured to at least partially close a cavity in the lining into which said first component is embedded.

The lining assembly may also include a vibration sensor located in the mill lining and detecting vibration of the lining during operation of the mill.

The interrogating component and the vibration sensor may be coupled to form a sensor unit.

The reacting component may wear out along with the mill lining.

The response component may comprise one of the following: a chain resistor, an ultrasonic probe, a sacrificial dielectric, or optical components.

The lining assembly may also include means for transmitting information related to detected vibration and/or wear of the mill lining to a location remote from the mill.

The means for transmitting information may comprise an antenna which is attached to the wear detection device through an opposite inner surface of the lining.

The means for transmitting information may be a transceiver device.

The means for transmitting information may be located in an opening made in the casing of the grinding mill.

The transceiver device may be configured to provide an activation signal to the wear detection device when in use.

The vibration sensor, if present, may include at least one accelerometer.

The wear detection device may be located in a void space formed in the mill lining.

The sensor or recording device may be incorporated such that it is located within the lining shell and/or is completely enclosed within the lining.

Components connected to the sensor or recording device may be embedded such that they are located within the lining shell and/or are completely enclosed within the lining.

In other configurations, the sensor or recording device may comprise all or at least a majority of the components mounted on or integrated with the mill lining. In this way, the lining and sensor can be constructed as a single unit, which can be assembled off-site and transported as a single component to the site. In some embodiments, the mill lining itself provides primary protection for the sensor components. This approach simplifies the fabrication, transportation and on-site installation of the lining and sensor.

In one aspect, embodiments provide a liner sensor for use with a liner located on an internal surface of a grinding mill drum, the liner sensor comprising a vibration sensor for detecting vibration of the liner during operation of the mill and a wear recording device for detecting wear of a wear surface of the liner during operation. operation, wherein said wear recording device comprises at least one array of transducers.

The vibration sensor and the wear recording device can be made as parts of a structural element.

The wear detection device may have a wear part that wears together with the lining.

The vibration sensor may include an accelerometer.

The lining sensor may also include a thermometer and/or a battery capacity meter.

The lining sensor may also include a wireless communication module.

The lining sensor may also include a housing housing said vibration sensor.

In one aspect, embodiments relate to a grinding mill comprising a casing and

- 4 046535 one of the above-mentioned lining units or a set of these units.

In another aspect, embodiments relate to a method for monitoring a grinding mill that includes a casing and one or more of the aforementioned lining assemblies, wherein the lining sensor further comprises a vibration sensor for detecting vibration of the lining during operation of the mill. This method includes: comparing measurements from a vibration sensor over a given period of time and setting a mill profile based on the compared measurements.

In another aspect, an embodiment relates to a method for monitoring a grinding mill that includes a casing and one or more of the aforementioned lining assemblies, each of which includes a vibration sensor for detecting vibration of the lining assembly during operation of the mill, the method comprising: correlating measurements from the vibration sensor over a given period of time, comparing measurements from a wear sensor for a given period of time with setting the mill profile based on the compared measurements.

In one embodiment, the mill includes a set of vibration sensors and/or wear sensors located at different locations in the mill, wherein the method further includes correlating measurements from said set of vibration sensors and/or wear sensors together with location information related to the location of each vibration sensor and/or wear recording devices.

In one embodiment, the method also includes the step of changing at least one operating parameter of the mill and determining changes in correlated measurements associated with the changed parameter.

The modified parameter may be one or more of the following: batch size, aggregate particle size, drum rotation speed.

The mill may also include an angle sensor for determining the angular orientation of the drum, measured as an angle, wherein the method includes the step of matching the angle measurements and the profile of the mill depending on the angle measurements.

The method may also include correlating measurements from the vibration sensor with angle measurements.

In another aspect, embodiments relate to a method of transporting a mill liner for a grinding mill, comprising: using a liner sensor configured for use with the grinding mill, incorporating the liner sensor into the mill liner, the mill liner having a wear surface and an opposing inner surface that, in use, is located against the inner surface of the grinding mill casing, and transporting the mill lining with a lining sensor built into it.

In yet another aspect, embodiments relate to a method of transporting a grinding mill liner assembly, comprising: using a liner sensor configured for use with the grinding mill, combining the liner sensor with the mill liner, wherein the mill liner has a wear surface and an opposing inner surface that, in use, is located against the inner surface of the grinding mill casing, and transporting the mill lining with the lining sensor as an integrated unit.

Description of drawings

This document describes embodiments with reference to the accompanying drawings, in which:

fig. 1 is a perspective view of a mill lining according to an embodiment and a removal machine;

fig. 2 is a perspective view of a grinding mill with a set of linings according to embodiments;

fig. 3 a is a plan view of an embodiment of a mill lining connecting component;

fig. 3b is a cross-sectional view of the mill lining shown in FIG. 2a, along line B-B;

fig. 4a is a plan view of an embodiment of a mill lining connecting component;

fig. 4b is a cross-sectional view of the mill lining shown in FIG. 2a, along line B-B;

fig. 5 is a schematic view of a lining sensor according to an embodiment;

fig. 6 is a sectional view of a portion of the lining showing the lining sensor according to FIG. 5 on site;

fig. 7 is a schematic sectional view of a fastening element according to an embodiment;

fig. 8 depicts an exemplary wear sensor circuit diagram for use in embodiments;

fig. 9 shows a system for implementing a method for monitoring a grinding mill according to an embodiment;

fig. 10 illustrates a method for monitoring a grinding mill according to an embodiment;

fig. 11 depicts a liner sensor according to another embodiment comprising a wear part embedded in the liner and an interrogation component embedded in the plug;

- 5 046535 fig. 12 depicts a lining assembly according to another embodiment, in which the lining sensor includes a wear part and an interrogating component embedded in the lining;

fig. 13 shows a lining assembly according to another embodiment comprising an ultrasonic device integrated into the lining;

fig. 14 depicts an embodiment of the liner sensor assembly shown in FIG. 12, which is designed without an antenna to activate the built-in sensor;

fig. 15 depicts another embodiment of the liner sensor assembly shown in FIG. 12, which is configured with an antenna for activating the built-in sensor;

fig. 16 depicts another embodiment of a liner sensor assembly in which an integral power or control device seals or closes the liner cavity in which the liner sensor is embedded; and fig. 17 depicts a configuration in which the control device supplies power to a set of active sensor elements.

Detailed description

In fig. 1 shows a mill lining 10 according to an embodiment. The mill liner 10 is installed on and removed from the mill by the replacement machine 12. The lining 10 includes a connecting component 14 (not shown in FIG. 1) that forms a portion between the lining 10 and a connecting tool 16 removably mounted on the working arm of the machine 12.

The lining 10 has a wear surface 20 and an opposing inner surface 22. When installed in the grinding mill 1 (FIG. 2), the inner surface 22 is located opposite and adjacent to the inner mill surface 24 when the lining 10 is installed on the inner mill surface 24. In the illustrated embodiment, the liner 10 also includes a fastening device 26 for releasably securing the liner 10 to the inner surface 24 of the mill. The connection component 14 may be accessed through the inner surface 22 and/or the wear surface 20. In alternative embodiments, the mill lining may not be mounted directly on the inner surface of the grinding mill, but may be mounted indirectly on said surface by another lining.

Typically, the liner 10 is removably mounted on the inner surface 24 of the grinding mill 1 by means of a fastening device 26. Once installed, the inner surface 22 of the lining 10 is opposite the inner surface 24 of the grinding mill 1 (Fig. 2) and adjacent to the specified surface 24. The fastening device 26 is made in the form of holes that pass through the mill lining and the wall of the grinding mill (which has an internal surface). Mechanical fasteners 26 extend through the aligned holes and can be attached and detached from the outside of the grinding mill. It should be understood that the fastening device may have another suitable shape and does not necessarily need to extend through the entire mill lining.

In general, mill liner replacement requires removal of worn mill liners and installation of new mill liners.

In fig. 2 illustrates one of the operators 5 removing the mill lining 10 from the inner surface 24 of the grinding mill 1. Operator 5 disconnects the fastening device 26 using the liner removal tool 52. In the illustrated embodiment, the fastening device 26 is made in the form of mechanical fastening elements 26, providing installation of the lining 10 on the wall of the mill 1. The mechanical fastening elements 26 pass through aligned holes in the lining 10 and the wall of the mill 1. The fastening elements 26 generally comprise at least two components that are in a threaded connection for securing the liner 10 to the wall of the mill 1. Each fastener 26 has a drive end 52 configured to engage the end of the liner removal tool 52. Rotation of end 52 either secures or disengages the mechanical fastener depending on the direction of rotation.

Tool 52 includes an elongated shaft 56 having an end 58 and rotatable. The end 58 of the said machine engages the drive end 52 and rotates to release the fastening element 26. After removing the element 26 from the hole, the shaft 56 of the tool 52 can be driven to pass through the hole of the mill wall 1 and knock out the lining 10.

In some embodiments, the wall 1 of the mill may have additional holes that are not intended to accommodate fastening elements, but are used for driving in linings 10.

In fig. 2 shows the lining 10 immediately after it has been removed from the inner surface 24 of the mill 1 and as it falls under the influence of gravity to the ground in the mill 1.

Typically, the mill lining falls with the inner surface 22 facing upward, thereby allowing access to said surface 22.

In embodiments, a lining sensor 30 is located in the cavity defining the connecting component 14. In fig. 3a-4b show such a configuration.

- 6 046535

In the illustrated embodiment, the lining sensor 30 is located within the lining connecting component. The sensor 30 is mounted on the inner surface of the cavity 14 and contains a wear sensor 32, which extends into the cavity 14. The cavity 14 is accessible for connection to the connecting tool by a wear indicator located in the cavity 14. The cavity 14 can extend across the entire width of the lining 10, i.e. . extend from the inner surface 22 to the wear surface 20. The lining sensor wear sensor 32 may extend along the entire length of the cavity 14 to terminate at the wear surface 20 of the lining 10.

The wear sensor 32 is configured to decrease in length as the wear surface 20 wears. As best shown in FIG. 4a and 4b, the more surface 20 wears, the less sensor 32 material remains.

Other mill lining configurations that may be suitable for use in embodiments are disclosed in PCT/AU2019/050864, the contents of which are incorporated herein by reference.

In fig. 5 is a schematic view of a lining sensor 30 according to an embodiment. The lining sensor 30 includes a wear sensor 32 attached by a wire 28 to the housing 34. The housing 34 houses a vibration sensor, which in this embodiment is a set of accelerometers that measure vibration of the lining 10 in the direction of at least two spatial axes. Thus, the vibration sensor is configured to detect the frequency and amplitude of vibration on the housing. The vibration sensor preferably measures not only vibration in these two dimensions, but may also provide 6- or 9-axis measurements, such as a 3-axis accelerometer, a 3-axis gyroscope (to provide vibration measurements), and in one embodiment, a 3-axis compass. Although the vibration sensor of this embodiment uses accelerometers, it should be understood that other types of vibration sensors may be used instead. In an alternative embodiment, transducers may be used to convert the movement into electrical signals.

Liner sensor 30 also includes an antenna 36 attached to housing 34. Housing 34 houses a wireless transmitter that is attached to antenna 36 and uses it to wirelessly transmit information. The wear sensor 32 is attached to the vibration sensor to form a sensor unit.

In fig. 6 shows a lining sensor 30 mounted in the lining 10. As shown, the sensor 30 is located in the cavity 14 such that the wear sensor 32 extends to the outermost portion of the lining forming the wear surface 20. In the embodiment shown in FIG. 6, a cavity 14 is preformed in the lining 20 and is sealed into the cavity during the manufacturing process of the lining 20. Essentially, the lining 10 is delivered to the site with a sensor 30 embedded therein. In the particular embodiment described, the sensor 30 is positioned such that it extends to the inner surface 47 and is aligned with the knockout hole 42 in the mill lining casing 44.

The portion of the cavity 14 closest to the inner surface 47 of the lining 10 is closed by a plug 40. The knockout hole 42 passes through the mill casing 44, and the antenna 36 is located in the cavity 42 and passes through the plug 40. During operation, the antenna 36 can be inserted after the lining is installed on the wall mill by accessing the knockout hole 42. The antenna may extend rearward through said hole to provide better transmission of the RF signal from the sensor. Installation of the antenna may cause the sensors located in the housing 34 to turn on.

Thus, the housing 34, in which the vibration sensor is located, is enclosed in, placed in or built into the lining 10. In some embodiments, it may be preferable to provide the lining so that it completely surrounds the housing (except for the extent of the cavity 14 containing the wear sensor and the cavity into which the antenna 36 is inserted), and to locate the vibration sensor in the housing so that more direct transmission is provided vibrations in the lining to the vibration sensor.

In fig. 6, a wear sensor 32 integrated into the lining 20 is a wear part or wear probe. In this case, the wear sensor 32 can be considered as a responsive component since it provides a feedback signal carrying information that can be passed on for further processing or monitoring. The information transferred relates to the degree of wear of the lining. In this embodiment, sensor 32 is configured to interact with a polling signal from the polling component to provide a feedback signal. A polling component may include a component that emits or generates a polling signal, or a component that provides energy that acts as a polling signal.

A vibration sensor that provides feedback in response to vibration detection can also be considered a responsive sensing component. However, instead of interacting with the interrogating signal, it provides a feedback signal in response to vibration detection.

As shown in FIG. 6 and 12, the interrogating component(s) may be built into, inserted into, or enclosed within the lining 20. It may be located in a housing 51 that also houses other sensors, such as vibration sensors or acoustic sensors

- 7 046535 ki, if provided. Alternatively, component(s) 31 may be at least partially contained within a plug to provide a seal to the cavity in which wear portion 32 is located (see FIG. 11).

In the illustrated embodiments, an antenna is inserted through the knockout hole 42 to activate the sensors. However, this antenna is optional. For example, in FIG. 14 and 15 depict alternative embodiments in which activation of the sensor components can be accomplished through the knockout hole 42, but without the presence of an antenna. Thus, this activation may be a direct activation through the knockout hole 42, for example to activate sensor components. Power or control components coupled to the sensors may further be configured to be wirelessly charged, which may also be accomplished through opening 42. The sensor components and corresponding associated components, such as those comprising components for one or more of the power, control, or communications can be built in so that during operation they will not be located in the housing and/or require installation on it.

In fig. 15 also shows an example in which the housing 51 is configured to act as a seal to close a cavity in which the wear sensor 32 is embedded. In an alternative embodiment, the sealing or closing function to close the cavity in the lining 20 in which the lining sensor 30 is embedded may instead be provided by an integrated power or control device 53 together with its housing or casing (see FIG. 16).

The lining sensor 30, containing the interrogating means 31 and the wear part 32, is built into the lining 20 and is part of the lining assembly and is transported with it. The interrogating means 31 may be externally powered or preferably independently powered (eg, contains a battery). If provided, a control device for controlling the sensor 30, or a power device for powering the sensor 30, or both, may also be built into the lining 20.

It should be understood that various types of wear portions 32 may be provided. For example, wear portion 32 may include a tread material (eg, a wear probe) the length of which is measured using a polling signal. Therein, tread circuit components, optical mirrors, semiconductor components, etc. may be located or attached to it. Interrogating signals or waves from the interrogating component are applied to the responsive component, which is expected to be able to provide signals with different characteristics such as different phase, strength, time, frequency, etc., depending on the degree of wear of the lining, resulting in to corresponding wear in the wear sensor.

In some cases, the interrogation signal interrogates the liner itself and does not require wear portion 32 or tread material. The return signal is generated as a result of the interaction between the lining and the interrogating signal, for example, but not limited to, due to echo, reflection, or attenuation of signal power levels. In these embodiments, again, if present, control devices or power devices, or both, may be built into the lining 20.

In the disclosed embodiments, polling signals may be generated by a set of polling means, such as converters. The interrogating means may be arranged in an array or matrix and located around the lining 20 with the ability to obtain information related to different parts of the same lining 20. For example, see FIG. 17, which conceptually illustrates a configuration in which the control device 53 enables a set of interrogating components (e.g., converters) 55.

To generate multidirectional polling signals, selective or sequential inclusion of polling components can be used. In particular, when an array of interrogating components is activated together - either simultaneously or within the same activation sequence - they can be used to obtain two-dimensional response signals. The response signal, which has at least two dimensions, provides two-dimensional data regarding the wear surface.

For example, phased array scanning may be used to scan a plane or slice of the lining 20. In one embodiment, shown conceptually in FIG. 13, the interrogating components include an oscillator 120 and at least one array of ultrasonic transducers 122, wherein the oscillator 120 provides wave signals to the transducers 122. The phased array 122 is in connection or communication with a controller 124 that controls the operation of the transducers, for example, to provide delay between activation of successive converters or for simultaneous activation of at least a subset of converters. Oscillator 120 is activated wirelessly by an antenna 126 located in knockout hole 42, however, it may instead be activated directly, in which case an antenna is not required for activation. The delay can be programmable to change the phase angle. In other embodiments, dynamic phased arrays may be used instead,

- 8 046535 which can provide more information about mill linings. Corresponding components for interacting with dynamic phased arrays are also covered by these embodiments.

In fig. 13, controller 124, which controls the activation of the transducers, is built into the plug 40. However, it may instead be built into the mill lining.

The use of image sensors may provide the technical advantage of obtaining an image of the lining 20 rather than just an estimate of the thickness of the lining. By obtaining an image of the lining, it is possible to obtain information about the quality of the lining as a whole: for example, the presence of cracks or other defects in the lining, as well as information about the location and size of these cracks or defects. Depending on the image sensors used, adjustments to the scanning orientation can also be made so that a more complete image of the lining can be obtained. In embodiments using phased array ultrasound, the controllable delay for the phased array ultrasound can be changed to adjust the scanning angle. Additionally, the oscillator can be activated to different degrees to generate polling beams of varying strengths.

Where applicable, this generalized embodiment or embodiments may contain various elements described with reference to FIGS. 6. For example, as in the case shown in FIG. 6, a responsive component and an interrogating component are incorporated into the liner 20 and are further enclosed or substantially sealed by a lid or plug 40. As another example, as in the embodiment shown in FIG. 6, a transceiver means such as an antenna may be inserted through the knockout hole to activate the interrogating component. The antenna may be a radio frequency (RF) antenna.

The sensor components, which may be interrogation components, response components, or combined interrogation and response devices, are preferably aligned with a knockout hole in the housing 44 through which the interrogation component is activated when the liner assembly is placed on the housing 44. The knockout holes are provided separately from the installed sensing holes. fastening the lining to the casing. Thus, activation of the sensor and transmission of interrogation waves is structurally and functionally separated from the fastening means for attaching the liner 20 to the mill casing 44.

The above embodiments are of the type in which the lining 20 and the sensor(s) embedded therein form a lining assembly. The components of the lining assembly are preferably pre-assembled and the lining assembly can be transported to the site together. In one embodiment, installing a lining assembly with a grinding device involves installing the lining assembly onto the housing 44 such that the interrogating component 31 of the lining sensor 30 is aligned with the knockout hole 42. Fasteners are then installed through the mounting holes in the housing 44 to attach the lining assembly and secure it. on the casing 44. An antenna, which may be formed in a male threaded insert, may be inserted through the knockout hole 42 to provide an activation signal to activate one or more sensors in the lining, such as a wear sensing device or a vibration sensor, or both, built into the lining 20. The antenna can also be used to transmit data from the sensor(s). Or another information transmitter (which can also be an antenna) can be designed to transmit data from the sensors.

Preferably, the lining assembly also includes an integrated power source and/or controller for the sensors contained in the lining 20. Thus, the lining assembly already contains the device required to enable the operation of the sensors and supply power to the active sensor elements embedded in the lining 20, in if they exist.

It should be understood that the above benefit can be achieved regardless of the presence of active sensor elements and whether the active sensor elements are embedded in the interrogating sensor component, the responsive sensor component, or both. Sensors built into the lining assembly do not have to be a specific type of sensor. For example, the sensor or sensors may include wear recording devices, vibration sensors, or other types of recording devices. The above embodiments containing both wear detection devices and vibration sensors are possible examples for lining assemblies.

In the embodiment shown in FIG. 6, the liner sensor 30 is integrated to such an extent that the sensor components, including the wear sensor 32 and the electronics (located in the housing), are completely contained within the liner 20. The plug 40 closes the cavity 14 in which the sensor components are located, and in this regard these components are isolated. However, in other embodiments and modifications of the embodiment shown in FIG. 6, the sensor components may be incorporated into the lining 20 such that they are contained within the shell of the lining (20), ie, there may be no plug or other sealing element to close the cavity.

In all embodiments, where applicable, the components that must be connected

- 9 046535 with actual recording components or elements, can also be built into the lining using the methods described above. For example, a power device, a control device, or both, or a combined power and control device may also be integrated to activate or control the touch components. Other components that may be integrated may include data communication components or wireless power transmission components to provide the power required by the sensor components. Embedding ensures that the lining assembly with the components necessary for wear recording or other recording operations is implemented as an integrated unit that can be transported together. Control and power components can also be integrated and transported together in this way.

In particularly preferred embodiments, by completely encapsulating the components or placing them within the lining shell, the assembled lining can be transported using existing transport structures. There is no need to provide additional space that might be required for sensor components or components coupled thereto, or to consider separately protecting or stabilizing the components.

In fig. 7 shows a fastening element 60 according to an embodiment. Fastener 60 contains a lining sensor and is used in place of fasteners 26 described above and shown in FIG. 1 and 2. The fastener 60 includes a shank 46 having a threaded portion 48. A wear sensor 32' is located in a cavity formed in the central portion of the shank 46. A body 50 is attached to the shank 46.

In alternative embodiments, the body may be attached to the shank using a connecting element. The connecting element can be made of rubber. In alternative embodiments, it is possible to use a different, flexible, preferably waterproof material.

During installation, a shank 46 may first be installed and act as a connecting member to connect the liner to the casing. Once the shank 46 is installed, the housing 50 is connected to a shank containing an electrical connector such that the wear sensor 32' is connected to the electronics located in the housing 50.

Housing 50 houses an electronics unit 52 (not shown in FIG. 7), which contains a vibration sensor and a wireless transmitter, as well as an antenna. Unlike the configuration shown in FIG. 5 and 6, the housing 50 containing the vibration sensor is not enclosed in, housed in, or built into the lining, but once installed is located in close proximity to the lining and connected to it by a bolt shank 48. Although in the embodiment shown in FIG. 7, the coupling member is not shown, but may be included in an alternative configuration to provide some damping means that can potentially isolate some of the vibration of the sensor and may also receive vibration transmitted through the mill wall 44. However, the bolt design provides an integrated sensor assembly that can measure both wear and vibration.

In addition to the vibration sensor, the electronics unit 52 may include a battery, a sensor for determining the charge level of the battery, a temperature sensor, and electronics necessary to read the wear sensor to which it is connected.

In fig. 8 shows an electrical circuit 80 suitable for use as a wear sensor in embodiments. Circuit 80 includes electrical resistors 82, 84, 86, ..., 100 with varying resistances, as indicated in FIG. 8.

The resistors are electrically connected in parallel through two conductors, designated respectively by position numbers 110 and 112 and running along the elongated body. Conductors 110, 112 terminate at contacts 114 and 116, which are connected to electronics 52, for example, according to the embodiment shown in FIG. 7.

The length of the electronic structure depends on the thickness of the controlled wear part. Typically, lengths range from 5 to 200 mm, although other lengths are suitable in some circumstances. In the illustrated embodiments, the wear sensor contains a printed circuit board with a width of 3 mm and a thickness of 1 mm, however, in other embodiments these values may be smaller or larger.

In another embodiment, resistors are installed on both sides of the printed circuit board. Resistors on one side of the board can be offset relative to resistors on the other side of the board (the array on one side is staggered with respect to the array on the other side). Therefore, for a given PCB length, the depth resolution of the sensor can be greater than if the components are mounted on only one side of the PCB.

Each resistor has a corresponding component parameter value (i.e., resistance), such that the measured value of a given electrical characteristic increases in essentially the same increments as the components wear successively. Any quantity can be used

- 10 046535 VA resistors - more or less than the ten shown - and in this case the resistor values shown in FIG. 8, subject to change. The greater the number of resistors used, the higher the accuracy of the wear sensor's wear depth. The following algorithm can be used to calculate the values of an arbitrary number of resistors in a wear sensor so that the measured resistance value increases in essentially the same increments.

Luck = V _DD Equation (1)

Kv = Udatch V---V--- Equation (2) ^m Uro-UDATCH ^R B = i _{/r +} i _/r +- ₊ 1/ _r Equation (3)

The number and individual resistance values of resistors can be calculated as follows.

1. Select the RA value (which determines the energy consumption).

2. Select the desired resolution (ie the number of resistors in the wear recorder).

3. Calculate the VDD values at each resistor location (step) using VDD and the number of resistors.

4. For all values of _ATP , RB is calculated using equation (2).

5. For each resistor/step and RB value, calculate R ₁ >R _X using equation (3).

It should be understood that capacitors or inductors can be used instead of resistors.

Other examples of suitable wear sensors for use in embodiments of the invention are described in WO 2012122587, the contents of which are incorporated herein by reference.

With reference to the above, the wear sensor, or more specifically, the wear sensor wear part, is not limited to the above arrangement. For example, the wear part may simply be a wear probe that is coupled to at least one ultrasonic transducer, which may be a piezoelectric or electromagnetic acoustic transducer. In other examples, the wear part may comprise non-resistive electrical devices. Alternatively, other types of devices, such as dielectric, optical, semiconductor devices designed to respond to other types of interrogation signals other than electrical current, can be used to form the sensor with a tread wear part.

In fig. 9 shows a system 130 for implementing a grinding mill monitoring method according to an embodiment. The system 130 includes a grinding mill 1 in which a set of lining sensors 30 is installed. Lining sensors 30 may be provided from one or more of the mill linings or mill lining assemblies discussed herein. Each of the liner sensors is in wireless communication with the base station 120. In this embodiment, the wireless communication is accomplished using LTE. In an alternative embodiment, LoRa may be used instead. The advantage of LTE and LoRa is the ability to transmit signals despite significant interference that may be caused by the metal components of the grinding mill 1.

The base station 120 communicates with the processor 124, which in this embodiment resides in the computing cloud 122. In other embodiments, the processor 124 may be configured as a dedicated server that may be connected via a wired or wireless network. Processor 124 communicates with data storage 126 and with user

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Claims (23)

workstation 128. User workstation 128, processor 124, and data store 126 interact using known client/server mechanisms to provide the functionality described herein. Data related to vibration and liner wear of mill 1 is generated by liner sensors 30, collected by base station 120, and recorded in storage 126 by processor 124. The sensor may be configured to operate continuously to transmit data or at specified or user-selectable time intervals as needed. . Each of the lining sensors 30 has a unique identifier associated with it. During the initial setup phase, a record is made in storage 126 that associates the identification number with the position of the corresponding lining sensor. Thus, embodiments of the invention provide correlation of vibration and wear to a specific location. In the illustrated embodiment, the mill 1 also includes an angle sensor that detects the angular position of the mill. This information is also transmitted to base station 120 and stored in storage 126 by processor 124. By comparing the change in angle over time, processor 124 can calculate the rotation speed of the mill drum. In fig. 10 illustrates a method 140 for monitoring a grinding mill according to an embodiment. At the initial stage 142, data is collected from the sensors, as described above with reference to FIG. 9. At step 144, a profile of the grinding mill 1 is created. It should be understood that the profile may depend on the characteristics of the particular grinding mill. In an embodiment, the profile contains vibration correlated with wear for a number of locations. The next step, step 146, changes the operating conditions of mill 1. Again, this may depend on the specific operating conditions of the respective mill. In one embodiment, this involves changing one or more of the following: batch size, aggregate particle size, drum rotation speed, etc. In the next step, step 148, sensor data is collected for the changed operating conditions, and in step 150 the mill profile is updated. By comparing the original profile with the updated profile, the user can determine whether changes made to operating conditions have had a positive impact on mill performance. For example, if changes in operating conditions have reduced lining wear, this will be reflected in the wear data collected from the sensors and recorded in the updated profile. At an additional step 152, the user can inspect the liners to correlate sensor information with the visual inspection. Then, at steps 154 and 156, the operating conditions are changed and sensor data is again collected for the changed operating conditions. If necessary, the process can return to step 150, such that steps 153 through 156 form a loop during which the user can update operating conditions and determine whether those updated conditions have a positive or negative impact on mill operation by updating the mill profile. In the following claims and in the above description, unless the context otherwise requires by express indication or necessary implication, the word contain or its derivatives such as contains or containing are used in an inclusive sense, i.e. to indicate the presence of the listed elements, but not to exclude the presence or addition of other elements in various embodiments. Likewise, the word device is used in a broad sense to include components configured as a single unit, as well as an embodiment in which one or more component parts are configured separately from each other. CLAIM 1. Lining assembly for a grinding mill, designed to be installed on the mill casing and containing: a mill lining having a wear surface and an opposite inner surface, which during operation is located opposite the inner surface of the mill casing; lining sensor built into the mill lining; and a control and/or power device configured to control the lining sensor and/or power it and also built into the mill lining; wherein the lining sensor and the control and/or power device are built in so that they are located inside the lining shell; wherein the lining sensor comprises a wear recording device configured to measure wear of the wear surface, a vibration sensor configured to measure vibration of the mill lining when used in a grinding mill, or both. 2. Lining unit according to claim 1, in which the control and/or power device is completely enclosed in the lining. - 12 046535 3. The lining unit according to claim 1 or 2, in which the control and/or power device is configured to be activated during operation from the inner surface of the lining, accessible through an opening in the grinding mill casing. 4. The lining assembly according to claim 3, in which said hole is made separately from the mounting hole designed to accommodate a fastening element for attaching the lining assembly to the grinding mill. 5. The lining assembly according to any one of claims 1 to 4, wherein the lining sensor comprises at least one active sensor component. 6. The lining assembly of claim 5, wherein said at least one active sensor component is an interrogating component configured to provide an interrogating signal, or a part of said interrogating component. 7. The lining assembly of claim 6, wherein the mill lining or a response component incorporated in the mill lining is/are configured to interact with the interrogating signal to generate a response signal. 8. The lining assembly according to claim 5 or 6, wherein said at least one active sensor component is a responsive component configured to interact with the interrogating signal and provide a response signal, or a part of said responsive component. 9. The lining assembly according to any one of claims 1 to 8, wherein the power or control device is located in a cavity formed in the mill lining, or in a plug designed to substantially seal said cavity. 10. The lining assembly of claim 6 or 7, wherein the response signal received in response to the interrogation signal provides two-dimensional data related to the wear surface. 11. The lining assembly according to claim 7 or 8, in which the reacting component is designed to wear together with the mill lining. 12. The lining assembly of claims 7, 8, or 11, wherein the reacting component comprises one of the following: a circuit resistor, an ultrasonic probe, a sacrificial dielectric, or optical components. 13. A lining assembly as claimed in any one of the preceding claims, wherein information relating to detected vibration and/or wear of the mill lining can be transmitted to a location remote from the mill using communication means. 14. The lining assembly according to claim 13, wherein the means for transmitting information comprises an antenna configured to be attached to the wear recording device through said opposite inner surface of the lining. 15. The lining assembly according to claim 13 or 14, in which the means for transmitting information are a transceiver device. 16. The lining assembly according to any one of claims 13-15, in which the means for transmitting information are located in an opening made in the casing of the grinding mill. 17. The lining assembly according to claim 14 or 16, wherein said transceiver device is configured to provide an activation signal to the lining sensor when in use. 18. The lining assembly according to any one of claims 1 to 17, wherein the lining sensor is located in a void space formed in the mill lining. 19. The lining assembly according to any one of claims 1 to 18, in which the lining sensor contains a thermometer and/or a battery capacity meter. 20. Lining assembly according to any one of claims 1-19, containing a wireless communication module. 21. A grinding mill comprising a casing and one or more lining units according to any one of claims 1 to 20. 22. A method for transporting a lining assembly for a grinding mill, including: using a lining assembly according to any one of claims 1-20; and transporting the lining assembly with the lining sensor integrated therein as an integrated assembly, the mill lining protecting the integrated sensor during transportation. 23. A method for controlling a lining unit for a grinding mill, made according to any of claims 1-20, and/or powering it, including: when attaching the lining assembly to the grinding mill so that the inner surface of the lining is located opposite the inner surface of the mill casing; supplying an activation signal through an opening in the grinding mill casing to activate a control and/or power device built into the lining. -