EP4281948A1 - Système et procédé de surveillance de fonctionnement d'au moins un camion - Google Patents

Système et procédé de surveillance de fonctionnement d'au moins un camion

Info

Publication number
EP4281948A1
EP4281948A1 EP21920155.5A EP21920155A EP4281948A1 EP 4281948 A1 EP4281948 A1 EP 4281948A1 EP 21920155 A EP21920155 A EP 21920155A EP 4281948 A1 EP4281948 A1 EP 4281948A1
Authority
EP
European Patent Office
Prior art keywords
tray
data
stage
truck
real
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
EP21920155.5A
Other languages
German (de)
English (en)
Inventor
Marcelo MEDEL
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Nexus Mine Pty Ltd
Original Assignee
Nexus Mine Pty Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Nexus Mine Pty Ltd filed Critical Nexus Mine Pty Ltd
Publication of EP4281948A1 publication Critical patent/EP4281948A1/fr
Pending legal-status Critical Current

Links

Classifications

    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01G—WEIGHING
    • G01G19/00—Weighing apparatus or methods adapted for special purposes not provided for in the preceding groups
    • G01G19/08—Weighing apparatus or methods adapted for special purposes not provided for in the preceding groups for incorporation in vehicles
    • G01G19/12—Weighing apparatus or methods adapted for special purposes not provided for in the preceding groups for incorporation in vehicles having electrical weight-sensitive devices
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
    • G01B7/00—Measuring arrangements characterised by the use of electric or magnetic techniques
    • G01B7/02—Measuring arrangements characterised by the use of electric or magnetic techniques for measuring length, width or thickness
    • G01B7/06—Measuring arrangements characterised by the use of electric or magnetic techniques for measuring length, width or thickness for measuring thickness
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01G—WEIGHING
    • G01G23/00—Auxiliary devices for weighing apparatus
    • G01G23/18—Indicating devices, e.g. for remote indication; Recording devices; Scales, e.g. graduated
    • G01G23/36—Indicating the weight by electrical means, e.g. using photoelectric cells
    • G01G23/37—Indicating the weight by electrical means, e.g. using photoelectric cells involving digital counting
    • G01G23/3728—Indicating the weight by electrical means, e.g. using photoelectric cells involving digital counting with wireless means
    • G01G23/3735—Indicating the weight by electrical means, e.g. using photoelectric cells involving digital counting with wireless means using a digital network
    • G—PHYSICS
    • G06—COMPUTING; CALCULATING OR COUNTING
    • G06Q—INFORMATION AND COMMUNICATION TECHNOLOGY [ICT] SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES; SYSTEMS OR METHODS SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES, NOT OTHERWISE PROVIDED FOR
    • G06Q10/00—Administration; Management
    • G—PHYSICS
    • G06—COMPUTING; CALCULATING OR COUNTING
    • G06Q—INFORMATION AND COMMUNICATION TECHNOLOGY [ICT] SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES; SYSTEMS OR METHODS SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES, NOT OTHERWISE PROVIDED FOR
    • G06Q10/00—Administration; Management
    • G06Q10/06—Resources, workflows, human or project management; Enterprise or organisation planning; Enterprise or organisation modelling
    • G06Q10/063—Operations research, analysis or management
    • G—PHYSICS
    • G06—COMPUTING; CALCULATING OR COUNTING
    • G06Q—INFORMATION AND COMMUNICATION TECHNOLOGY [ICT] SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES; SYSTEMS OR METHODS SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES, NOT OTHERWISE PROVIDED FOR
    • G06Q10/00—Administration; Management
    • G06Q10/20—Administration of product repair or maintenance
    • G—PHYSICS
    • G06—COMPUTING; CALCULATING OR COUNTING
    • G06Q—INFORMATION AND COMMUNICATION TECHNOLOGY [ICT] SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES; SYSTEMS OR METHODS SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES, NOT OTHERWISE PROVIDED FOR
    • G06Q50/00—Information and communication technology [ICT] specially adapted for implementation of business processes of specific business sectors, e.g. utilities or tourism
    • G06Q50/02—Agriculture; Fishing; Forestry; Mining
    • G—PHYSICS
    • G06—COMPUTING; CALCULATING OR COUNTING
    • G06Q—INFORMATION AND COMMUNICATION TECHNOLOGY [ICT] SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES; SYSTEMS OR METHODS SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES, NOT OTHERWISE PROVIDED FOR
    • G06Q50/00—Information and communication technology [ICT] specially adapted for implementation of business processes of specific business sectors, e.g. utilities or tourism
    • G06Q50/40—Business processes related to the transportation industry
    • G—PHYSICS
    • G07—CHECKING-DEVICES
    • G07C—TIME OR ATTENDANCE REGISTERS; REGISTERING OR INDICATING THE WORKING OF MACHINES; GENERATING RANDOM NUMBERS; VOTING OR LOTTERY APPARATUS; ARRANGEMENTS, SYSTEMS OR APPARATUS FOR CHECKING NOT PROVIDED FOR ELSEWHERE
    • G07C5/00—Registering or indicating the working of vehicles
    • G07C5/006—Indicating maintenance
    • G—PHYSICS
    • G07—CHECKING-DEVICES
    • G07C—TIME OR ATTENDANCE REGISTERS; REGISTERING OR INDICATING THE WORKING OF MACHINES; GENERATING RANDOM NUMBERS; VOTING OR LOTTERY APPARATUS; ARRANGEMENTS, SYSTEMS OR APPARATUS FOR CHECKING NOT PROVIDED FOR ELSEWHERE
    • G07C5/00—Registering or indicating the working of vehicles
    • G07C5/008—Registering or indicating the working of vehicles communicating information to a remotely located station
    • G—PHYSICS
    • G07—CHECKING-DEVICES
    • G07C—TIME OR ATTENDANCE REGISTERS; REGISTERING OR INDICATING THE WORKING OF MACHINES; GENERATING RANDOM NUMBERS; VOTING OR LOTTERY APPARATUS; ARRANGEMENTS, SYSTEMS OR APPARATUS FOR CHECKING NOT PROVIDED FOR ELSEWHERE
    • G07C5/00—Registering or indicating the working of vehicles
    • G07C5/08—Registering or indicating performance data other than driving, working, idle, or waiting time, with or without registering driving, working, idle or waiting time
    • G07C5/0816—Indicating performance data, e.g. occurrence of a malfunction
    • G—PHYSICS
    • G07—CHECKING-DEVICES
    • G07C—TIME OR ATTENDANCE REGISTERS; REGISTERING OR INDICATING THE WORKING OF MACHINES; GENERATING RANDOM NUMBERS; VOTING OR LOTTERY APPARATUS; ARRANGEMENTS, SYSTEMS OR APPARATUS FOR CHECKING NOT PROVIDED FOR ELSEWHERE
    • G07C5/00—Registering or indicating the working of vehicles
    • G07C5/08—Registering or indicating performance data other than driving, working, idle, or waiting time, with or without registering driving, working, idle or waiting time
    • G07C5/0841—Registering performance data
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
    • G01B2210/00—Aspects not specifically covered by any group under G01B, e.g. of wheel alignment, caliper-like sensors
    • G01B2210/58—Wireless transmission of information between a sensor or probe and a control or evaluation unit
    • G—PHYSICS
    • G08—SIGNALLING
    • G08G—TRAFFIC CONTROL SYSTEMS
    • G08G1/00—Traffic control systems for road vehicles
    • G08G1/20—Monitoring the location of vehicles belonging to a group, e.g. fleet of vehicles, countable or determined number of vehicles
    • G—PHYSICS
    • G16—INFORMATION AND COMMUNICATION TECHNOLOGY [ICT] SPECIALLY ADAPTED FOR SPECIFIC APPLICATION FIELDS
    • G16Y—INFORMATION AND COMMUNICATION TECHNOLOGY SPECIALLY ADAPTED FOR THE INTERNET OF THINGS [IoT]
    • G16Y10/00—Economic sectors
    • G16Y10/20—Mining
    • G—PHYSICS
    • G16—INFORMATION AND COMMUNICATION TECHNOLOGY [ICT] SPECIALLY ADAPTED FOR SPECIFIC APPLICATION FIELDS
    • G16Y—INFORMATION AND COMMUNICATION TECHNOLOGY SPECIALLY ADAPTED FOR THE INTERNET OF THINGS [IoT]
    • G16Y20/00—Information sensed or collected by the things
    • G16Y20/30—Information sensed or collected by the things relating to resources, e.g. consumed power

Definitions

  • the invention relates to a system and method for monitoring the operation of one or more trucks at worksites, preferably one or more mining trucks at mine sites.
  • the main object of the invention is to provide an online platform that addresses underproduction and inefficiencies at mine sites, implementing Industry 4.0 concepts to include mine analytics and performance monitoring on mining trucks, particularly on its hoppers or trays.
  • the main approach of this invention is to be able to monitor the truck’s performance in terms of payload, cycle efficiency, availability, fuel consumption, wear analysis, fatigue analysis, asset tracking and speed control.
  • the highest technology in terms of sensors, data transmission and analytics is implemented.
  • the enclosure being installed in the dump body of trucks is independent of the type of truck, meaning that it is possible to adapt the same to any truck in the industry.
  • the enclosure can be presented as part of a kit, with minimum intervention to existing trucks or its dump bodies.
  • a sensor for metal/uncrushable early detection At the moment, the mining industry is highly impacted by metal fragments that breach the operation when the ore is being processed.
  • the invention can implement metal detector sensors and/or cameras in order to identify these metal fragments before it damages the crusher or the conveyor belt, affecting the entire operation.
  • the applicant is developing first-class technology for cycle monitoring and timing improvement.
  • one of the key characteristics of the invention is its online technology and real time data processing, using 3G, 4G or 5G.
  • Non-invasive sensors monitor the performance of the truck in real time, giving relevant information for improving the productivity of the operations.
  • the invention is related to a system and method for monitoring the operation of one or more trucks at worksites, preferably one or more mining trucks at mine sites.
  • the system and method are implemented in a hardware-software environment, directed to monitor, process and display data, including calculation of specific operational parameters.
  • the hardware related features of the invention are directed to monitor operational data of the trucks or trays, storing said operational data and communicating said data to an online platform.
  • the hardware related features can also preprocess the operational data, e.g. calculating operational parameters from raw operational data, debugging the operational data or preparing tables or graphs with the captured data, providing pre-processed operational data to one or more users.
  • the monitored, stored and/or preprocessed operational data is communicated to an online platform for processing, obtaining operation information and statistics of all the trucks at one or more worksites.
  • the online platform is software-implemented, providing different tools for analyzing the operational data according to preferences of end users. Besides, this platform provides a clear visualization of the data through a user interface, which can be displayed in different user equipment.
  • a system for monitoring the operation of one or more trucks comprises: at least one truck with a tray; an inertial measurement unit (IMU) arranged on a first surface of the tray, configured to characterize the movement of the tray, obtaining real-time movement data of the tray; a location sensor configured to track the location of the tray, obtaining real-time location data of the tray; at least one processing unit configured to process the movement and location data, obtaining processed data; at least one server configured to receive the real-time movement and location data and/or the processed data; at least one communication unit configured to communicate the real-time movement and location data and/or the processed data from the at least one truck to the at least one server; and a display interface configured to display the real-time movement and location data and/or the processed data to a user.
  • IMU inertial measurement unit
  • the at least one server is further configured to obtain truck operation information from the real-time movement and location data and/or the processed data, said operation information including at least one or a combination of truck status information, truck payload information, truck travel information, truck efficiency information, truck cycle information and truck availability information.
  • the display interface is further configured to display said truck operation information.
  • a method for monitoring the operation of one or more trucks comprises: providing at least one truck with a tray; characterizing the movement of the tray by means of an inertial measurement unit (IMU) arranged on a first surface of the tray, obtaining real-time movement data of the tray; tracking the location of the tray by means of a location sensor, obtaining real-time location data of the tray; processing the movement and location data by means of at least one processing unit, obtaining processed data; receiving the real-time movement and location data and/or the processed data by at least one server, wherein said real-time movement and location data and/or the processed data is communicated from the at least one truck to the at least one server by at least one communication unit; obtaining, by the at least one server, truck operation information from the realtime movement and location data and/or the processed data, said operation information including at least one or a combination of truck status information, truck payload information, truck travel information, truck efficiency information, truck cycle information and truck availability information; and displaying the real-time
  • IMU inertial measurement unit
  • a monitoring kit for monitoring the operation of a truck comprises: at least one processing unit; an inertial measurement unit (IMU) in communication with the at least one processing unit; a location sensor in communication with the at least one processing unit; at least one communication unit in communication with the at least one processing unit; at least one data storage unit in communication with the at least one processing unit; and at least one power source.
  • IMU inertial measurement unit
  • the at least one processing unit, the IMU, a first part of the location sensor, a first part of the at least one communication unit, the at least one data storage and the at least one power source are housed within a Sensor Signal Processing Cabinet or enclosure, said enclosure being arranged on the first surface of the tray.
  • An embodiment of the invention further comprises at least one power source that can be configured to energize the IMU, the location sensor, the at least one processing unit and/or the at least one communication unit.
  • the at least one power source can be comprised in said kit, within the enclosure.
  • At least part of the location sensor and/or at least part of the at least one communication unit can be arranged on a second surface of the tray, facing sky.
  • first parts of the location sensor and communication unit are comprised by the kit, within the enclosure.
  • a second part of the location sensor and a second part of the at least one communication unit are arranged on a second surface of the tray, facing sky, wherein said second parts are in data communication with said first parts wirelessly or by means of a data cable.
  • said second parts are one or more antennas of the location sensor and communication unit.
  • all the components of the location sensor and communication unit, including the antennas are housed inside the enclosure, which is possible when said arrangement does not jeopardize the location and communication data acquisition by the system.
  • the IMU, the at least one processing unit and the at least one power source can be housed within the enclosure, said enclosure being arranged on the first surface of the tray.
  • the enclosure can comprise at least one data storage unit in communication with the at least one processing unit.
  • the system and kit can further comprise wear sensors arranged on wear surfaces of the tray.
  • Said wear sensors, forming a wear sensor arrangement can be configured to obtain real-time thickness data of the tray, which can be used by the at least one server to calculate and display tray lifetime information.
  • the wear sensors can be in data communication with the at least one processor of the system and kit by means of data cables or wirelessly.
  • the data cables can be embedded in the structure of the tray, inside columns/beams, or wired over said structure.
  • the wear sensors are implemented in fixing elements used for fixing one or more plates forming the tray or for fixing one or more wear plates to working surfaces of the tray.
  • Said wear sensors can form a mesh of wear sensors communicating the thickness data of the tray wirelessly through the mesh, from multiple sensing points to the at least one processing unit.
  • each wear sensor is capable of sensing thickness data and communicating the same to neighboring wear sensors, propagating the thickness data of each sensor through the mesh and towards the at least one processing unit, for further processing.
  • the system and kit further comprise weight sensors arranged on predetermined locations of the tray and/or of a chassis of the at least one truck. Said weight sensors are configured to obtain real-time weight data of the payload in the tray.
  • the weight sensors, the IMU and the location sensor comprise a cycle timing sensor arrangement.
  • the weight sensors can be in data communication with the at least one processor of the system and kit by means of data cables or wirelessly.
  • the data cables can be embedded in the structure of the tray and/or truck chassis, inside columns/beams, or wired over said structures.
  • the cycle timing sensor arrangement obtains real-time movement, location and weight data of the tray. Said data is communicated to the at least one processor and/or to the at least one server to identify and count timing of the truck on each of the following operation cycle stages: queuing to load stage, defined as a stage in which a truck is waiting for being loaded; loading stage, defined as a stage in which a truck is being loaded at a load site; to dump or returning stage, defined as a stage in which a truck is loaded and in movement from the load site to a dump site; queuing to dump stage, defined as a stage in which a truck is waiting for dumping the load; dumping stage, defined as a stage in which a truck is dumping the load at the dump site; to load stage, defined as a stage in which a truck is returning to the load site from the dump site; fueling stage, defined as a stage in which a truck is being fueled; other stages, defined as a stage that is not part of an operation cycle, like a service stage.
  • the cycle timing sensor arrangement can obtain a time it takes a truck to complete the above operation cycle stages, allowing complete characterization of the operation cycle.
  • the queuing to load stage is identified when: the real-time movement data from the IMU indicates that a speed of the tray is approximately zero, that a tilt angle of the tray is approximately zero and that an acceleration/impact indicator of the tray is approximately zero; the real-time location data from the location sensor indicates that the tray is within an area near the load site; the real-time weight data from the weight sensors indicates that the weight of the pay load is approximately zero; and a previous operation cycle stage was the to load stage.
  • the loading stage is identified when: the real-time movement data from the IMU indicates that a speed of the tray is approximately zero, that a tilt angle of the tray is approximately zero and that an acceleration/impact indicator of the tray is positive; the real-time location data from the location sensor indicates that the tray is within an area near the load site; the real-time weight data from the weight sensors indicates that the weight of the pay load is increasing; and a previous operation cycle stage was the to load stage or queuing to load stage.
  • the to dump or returning stage is identified when: the real-time movement data from the IMU indicates that a speed of the tray is above zero, that a tilt angle of the tray is approximately zero and that an acceleration/impact indicator of the tray is zero or positive; the real-time location data from the location sensor indicates that the tray is within a road area; the real-time weight data from the weight sensors indicates that the weight of the pay load is above zero; and a previous operation cycle stage was the loading stage.
  • the queuing to dump stage is identified when: the real-time movement data from the IMU indicates that a speed of the tray is approximately zero, that a tilt angle of the tray is approximately zero and that an acceleration/impact indicator of the tray is approximately zero or negative; the real-time location data from the location sensor indicates that the tray is within an area near the dump site; the real-time weight data from the weight sensors indicates that the weight of the pay load is above zero; and a previous operation cycle stage was the to dump or returning stage.
  • the dumping stage is identified when: the real-time movement data from the IMU indicates that a speed of the tray is approximately zero, that a tilt angle of the tray is above zero and that an acceleration/impact indicator of the tray is positive; the real-time location data from the location sensor indicates that the tray is within an area near the dump site; the real-time weight data from the weight sensors indicates that the weight of the pay load is decreasing; and a previous operation cycle stage was the queuing to dump or to dump stage.
  • the to load stage is identified when: the real-time movement data from the IMU indicates that a speed of the tray is above zero, that a tilt angle of the tray is approximately zero and that an acceleration/impact indicator of the tray is zero or positive; the real-time location data from the location sensor indicates that the tray is within the road area; the real-time weight data from the weight sensors indicates that the weight of the pay load is approximately zero; and a previous operation cycle stage was the dumping stage.
  • the fueling stage is identified when: the real-time movement data from the IMU indicates that a speed of the tray is approximately zero, and that an acceleration/impact indicator of the tray is approximately zero; and the real-time location data shows that the truck is within a fueling area.
  • the at least one communication unit is configured to communicate all data to a communication system of the at least one truck and/or to wirelessly communicate said data to the at least one server, for instance, by means of a wireless network.
  • Fig. 1 is a graph of the Truck Operation Cycle from sensor data, according to an embodiment of the invention.
  • Fig. 2a and Fig. 2b are a representation of the payload sensor arrangement with pressure sensors in the tire struts, according to an embodiment of the invention.
  • Fig. 3a is a representation of wire loops inside wear bolts or cylinders installed on critical locations of the tray, according to an embodiment of the invention.
  • Fig. 3b is a representation of an internal perspective of a wear bolt or cylinder implementing the tray wear sensor, according to a first embodiment of the invention.
  • Fig. 3c is a representation of an external perspective of wear bolts or cylinder implementing the tray wear sensor, according to the first embodiment of the invention.
  • Fig. 3d is an exploded view of a wear cylinder implementing the tray wear sensor, according to a second embodiment of the invention.
  • Fig. 3e is a cross-section view of the wear cylinder of Fig. 3d.
  • Fig. 3f is a perspective view of a wear cylinder implementing the tray wear sensor, according to a third embodiment of the invention.
  • Fig. 3g is a cross-section view of the wear cylinder of Fig. 3f.
  • Fig. 3h is a perspective view of a wear cylinder implementing the tray wear sensor, according to a fourth embodiment of the invention.
  • Fig. 3i is a cross-section view of the wear cylinder of Fig. 3h.
  • Fig. 3j is a perspective view of a wear cylinder implementing the tray wear sensor, according to a fifth embodiment of the invention.
  • Fig. 3k is a first cross-section view of the wear cylinder of Fig. 3j.
  • Fig. 31 is a second cross-section view of the wear cylinder of Fig. 3j.
  • Fig. 3m is a view of the installation system of the wear cylinder of Fig. 3j on the tray.
  • Fig. 4 is a representation of the location of the location sensor (GPS) and communication antenna on a surface of the tray, according to an embodiment of the invention.
  • GPS location sensor
  • Fig. 5 is a representation of the Sensor Signal Processing Cabinet or enclosure, according to an embodiment of the invention.
  • Fig. 6a is a representation of the location of the enclosure at the front of the tray, according to an embodiment of the invention.
  • Fig. 6b is a representation of the location of the enclosure at the front of the tray according to Fig. 6a.
  • Fig. 7 is a scheme of the system arrangement on the tray (enclosure and external sensor/devices), according to an embodiment of the invention.
  • Fig. 8 is a representation of the system arrangement on the cabin of the truck, according to an embodiment of the invention.
  • Fig. 9 is a representation of the system arrangement with the integration of the wear cylinder and the mesh network system.
  • the invention implements different types of sensors, with specific aims.
  • the main sensors being installed are described below, as implemented in connection to a single truck or tray.
  • the named Cycle Timing Sensors are a set of sensors directed to identify the truck operation cycle stages. These sensors count timing of the truck on each of the following stages: returning or to dump, dumping, queuing to dump, to load, loading, queuing to load, fueling, and other unknown activity.
  • the cycle timing sensors provide the time it takes a truck to complete the loading, travelling and dumping processes, allowing complete characterization of the operation cycle.
  • the cycle timing sensors are formed by a set of sensors allowing timing calculation, such as:
  • This sensor is for tracking the tray location, for instance tracking its latitude and longitude, and its speed with standard GPS accuracy. Jointly with the online platform, the data from the location sensor is able to provide 3D visualization of tray data overlaid on aerial view of the worksite or mine site. According to a preferred embodiment, the sensor for this purpose is a GNSS (Global Navigation Satellite System).
  • GNSS Global Navigation Satellite System
  • IMU Inertial Measurement Unit
  • This sensor is for tracking impacts in the tray, inclination angle, acceleration and speed.
  • the IMU uses a combination of accelerometers, gyroscopes, and sometimes magnetometers, directed to obtain data with the aim of characterize the movement of the tray.
  • Pressure/weight sensor This sensor is for tracking the weight of the payload or changes in the weight of the tray.
  • Fig. 1 The logic behind the procedure or algorithm for determining the stage of the operation cycle can be visualized in connection to Fig. 1, showing the output of the sensors, or sensor data, in connection to the main stages of the truck operation cycle.
  • the output of the sensors is a clear indication operational changes, which in combination allow for clear determination of the cycle stages identified above.
  • Table 1 shows how the data from the sensors can be used for determining the stage of the operation cycle.
  • Table 1 Truck Operation Cycle from sensor data.
  • the sensors will have to show: speed is zero (“0”) or approximately 0, weight is increasing and is greater than 0, angle of the tray is 0 and the tray is receiving impacts, though is increasing or positive.
  • speed is zero (“0”) or approximately
  • weight is increasing and is greater than
  • angle of the tray is 0 and the tray is receiving impacts, though is increasing or positive.
  • the accelerations/impact can output zero (or negative) or positive during the to load task, to dump or returning tasks, being expected to receive a continuous oscillation between zero and positive reads during said tasks, due to the smoothness or roughness of the truck path. Said oscillations are not affecting the determination of the task due to the other data received from the sensors (location, speed, pay load weight, title angle and previous task).
  • Pressure Sensors installed in the tire struts of the truck.
  • Pressure sensors can measure the pressure inside the struts, which are connected to specific locations of the chassis of the truck and have a response to the weight of the payload.
  • Different approaches can be implemented to calculate payload weight from various algorithms. For instance, pressure measurements from sensors in the tire struts can be converted to payload weight from a correlation between pressure inside each strut and weight of the pay load being loaded into the tray.
  • Fig. 2a and 2b show a scheme of the payload sensor arrangement, with pressure sensors in the struts that are connected to the chassis, according to an embodiment of the invention.
  • the Pressure Sensors can be located in connection to each tire strut of the truck and, by means of testing the response of the struts during loading operations, a correlation between payload weight and pressure measurement in each strut can be defined. Said correlation is useful for obtaining payload weight data in trucks with similar strut configuration, meaning that different correlations may be required depending on the model of the truck.
  • the information can be obtained from the truck through a wired connected device or wirelessly, if applicable.
  • the tray wear sensor measures the thickness of the wear floor plate, using said information to determine the end of the tray life.
  • the proposed approach measures the reduction on the tray thickness over time to schedule tray replacement on time, implementing wear bolts or cylinders with wire loops to be electronically monitored.
  • Fig. 3a, Fig. 3b and Fig. 3c show how the proposed approach works, implementing special wear cylinders including an electrical circuit inside, wherein the wear of the plates will break the electrical circuit indicating wear depth and though predict beforehand when plates should be replaced.
  • the wear sensor considers the design and fabrication of a device directly installed in the tray, with an independent power system through batteries and independent communication that goes directly to the enclosure. The evaluation of the thickness of the tray will be carried out every 1mm of wear, with a range of up to 50mm.
  • the communication of the thickness data to the enclosure can be over a mesh network system through wireless communication, like Bluetooth, between the sensors itself and a mesh gateway included in the system of the invention.
  • the wear sensors can implement a special configuration as shown in Figs. 3b-l.
  • Figs. 3b and 3c are representing an embodiment using wired sensors, which are connected to the processing unit by means of data cable. Said cables are also energizing the sensors from a power source in the enclosure.
  • the wear sensors can communicate thickness data wirelessly, and can be presented as independent units with its own power source, as shown in Figs. 3d-l. According to said wireless embodiment of the wear sensors, the same can be distributed in multiple measurement points of the tray forming the mesh network system or sensor mesh, communicating the thickness data to the processing unit through said mesh.
  • each wear sensor is a mesh node and includes a mesh gateway that can be implemented in the enclosure as another component of the system of the invention, for retrieving the wear data from each node.
  • Figs. 3d and 3e represent a first embodiment of the wireless wear sensor, in which power, communication and sensing units are attached to an existing wired sensing wear cylinder, converting the same to wireless sensing wear cylinder.
  • the power unit and the communication unit, jointly with related circuitry, are housed in a wear sensor enclosure that can be fixed to the head of the existing sensing wear cylinder, having a lid for accessing to the components without requiring removal of the wear cylinder.
  • Fig. 3e shows a cross-sectional view of this embodiment, wherein the wear cylinder is fixing a wear plate to a surface of the tray.
  • Figs. 3f and 3g represent a second embodiment of the wireless wear sensor, similar to the first embodiment but in which the wear sensor enclosure housing the power unit, communication unit and related circuitry is integrated to the head of the wear bolt or cylinder.
  • Figs. 3h and 3i represent a third embodiment of the wireless wear sensor, similar to the second embodiment but in which the wear sensor enclosure housing the power unit, communication unit and related circuitry is the head of the wear bolt or cylinder.
  • Figs. 3j, 3k, 31 and 3m represent a fourth embodiment of the wireless wear sensor, in which the wear sensor is not implemented in an existing bolt, being a completely different sensing unit that includes a first portion and a second portion.
  • the first portion is an elongated probe that projects towards the wear plates, having the sensing means within.
  • the second portion is a probe head that houses the power unit, communication unit and related circuitry. Said second portion is fixed to the tray from outside, by common fixing bolts, and the first portion is inserted into a perforation of said tray and related wear plate.
  • Fig. 3m shows how the wear sensor can be installed on the tray.
  • the invention also contemplates other sensors per truck or tray, for instance:
  • Time sensor the aim of this sensor is to precisely record all operational data that is collected against time, and to collect raw data that will enable the classification of time, location, speed, vibration, acceleration, angle and height. Allows for accurate time stamping of all collected data from each of the trucks.
  • the system is able to time stamp all incoming data and system actions which allows for accurate data comparisons to be made across all devices. Allows for global pinpointing when events occur on the data.
  • Uncrushable/metal detector at least one metal detector sensor and/or one or more cameras can be implemented in order to detect uncrushable or metal fragments inside the tray (payload). If those fragments get to the crusher and/or conveyor belt, may affect and stop the entire operation. Uncrushable/metal detectors (sensors and/or cameras) are installed facing the load area of the tray, at one or more heights, detecting metal uncrushable within the load. Fuel sensor: the invention is also able to obtain fuel level data from the truck’ s fuel sensor or from a specific sensor arranged in connection to fuel tanks.
  • Sensor Signal Processing Cabinet or enclosure Said enclosure is strategically fixed to the tray of each truck, housing most of the sensors and connected to all the sensors at the tray.
  • some sensors/devices may be required to be external to the enclosure.
  • the location sensor e.g., GPS
  • the communication antenna may need to be installed at the top of the tray, facing the sky, preferably at the top of the tray canopy for improving location accuracy and communication fidelity (see Fig. 4).
  • Said sensor/devices are named external sensor/devices.
  • Other main sensors, like the IMU, can be implemented inside the enclosure, which is presented as a hardcase housing enclosing electronics and circuitry (see Fig. 5).
  • current technologies in location and communication antennas allow implementing the location sensor and/or the communication antenna inside the enclosure, without substantially jeopardizing the operation of the system.
  • the enclosure can be located at the front wall of the tray, where possible, for ease of access.
  • Fig. 6a and Fig. 6b show a preferred location of the enclosure at the front side of the tray, facing the driver access of the truck.
  • the information processed in the enclosure can be sent directly to the online platform or through an internal system on the cabin of the truck via Bluetooth, were further data collection, storage and/or processing can be made, as well as data displaying for the driver’s consideration.
  • the information is transmitted from the sensors to the cloud or online platform via the system arrangement on the tray, which main components are the enclosure and sensors, as shown in Fig. 7.
  • main components are the enclosure and sensors, as shown in Fig. 7.
  • internal components like a processor, an IMU, a data storage and a power supply (battery pack), as represented in Fig. 7, are housed inside the enclosure, jointly with circuitry related to data communication (3G/4G, Bluetooth), positioning (GPS), and power management, among others.
  • external components are represented by dots in the perimeter of Fig. 7, arranged outside the enclosure to send/receive data from/to the enclosure.
  • the external components in the represented embodiment are: an antenna arranged to send/receive data to/from the online platform, establishing data communication within the enclosure and the online platform; an antenna arranged to receive location related data (GPS); and/or one or more external sensors, located in the truck but remote the enclosure, for instance, the fuel and/or pay load related sensors.
  • GPS location related data
  • the external sensors in the truck but remote the enclosure for instance, the fuel and/or pay load related sensors.
  • all the information gathered in the enclosure can be sent via Bluetooth to the internal system arrangement installed in the cabin of the truck. From the cabin, the information can be uploaded to the cloud for analysis through the online platform, as show in Fig. 8. As in Fig. 7, Fig. 8 also shows dots at the perimeter of the figure, representing external existing components that would be related to the internal system arrangement installed in the cabin of the truck.
  • said external existing components might be a truck computer, providing truck information to the payload system; and/or a truck alternator/generator/batteries, as power source to the components of the invention.
  • Fig. 9 shows an embodiment of the system arrangement according to Fig. 7 and integrating the wear cylinder and the mesh network system.
  • a Mesh Gateway can be implemented as an internal component within the enclosure, said gateway in wireless communication with remote sensors that need to be arranged at different points of the tray, like the wear sensors that are also nodes of the mesh network system.
  • other remote sensors with similar communication capabilities can be implemented, like the pressure sensors for obtaining weight data and/or uncrushable/metal detectors.
  • the aim of the software related features is to create a platform to gather all the information mentioned above, for instance, using a WEB service Front-end with HMI (human machine interface) approach.
  • HMI human machine interface
  • Data storage all data is remotely communicated using a cloud server from the pit, in real time.
  • the purpose of the data storage is to store data to upload to the cloud while disconnected, as well as ensure record keeping in case upload is not possible.
  • Cloud storage this feature has the ability to automatically count the number of loads/cycles and report results.
  • the cloud server will be used to transmit all the data obtained from the sensors and transmit it to the display interface. Different algorithms process the data to generate relevant information.
  • Report Generator Generate reports for evaluating different operational parameters. For instance, issue operational reports on each one of the trays with the following information: GPS location, cycle status, speed and inclination, payload, efficiency, availability, real time monitor, impact loads, time between loads, fuel usage, wear analysis, and impacts on stress zones
  • Display Interface Display all available tray sensor information in online tools that can be accessed anywhere.
  • the display interface can be useful for visualizing the location of tray using a map visualization platform like Google Maps.
  • the display interface can:
  • the online platform has the following capabilities: support integration with a third-party data, support all trays sending data to the cloud, can use the processor on the phone/desktop/laptop, generate reports from any device for qualified operators, provide manual data analysis via a data processor like Excel, automatically classify data collected from the tray into cycle times, and remotely communicate with cloud server from the pit in real time.
  • the display interface is the key component for user interaction, providing access to the online platform and to the gathered information for the end users, mine site operators an any other relevant user duly registered for access.
  • the online platform uses the online platform to select a truck, display current location and previous path on an open map. Also, users are able to see graphs and information displaying wear, payload, cycle timing, fuel consumption, efficiency, availability, speed, fueling, wear and fatigue, impacts on stress zones, and all data provided by the sensors. In addition, the online platform is also capable of comparing data in connection to the truck’ s performance, driver’s performance or full mine site, as well as by specific data requirements such as payload comparison by truck, timing comparison by truck, fuel consumption and any combinations from the above. [0069] Upon mine site requests, the online platform can be connected to the mine site previous hardware system, meaning that the software is independent from the hardware and it can be used with any sensors or data recollection system.

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Abstract

La divulgation concerne un système permettant de surveiller le fonctionnement d'au moins un camion, le système étant caractérisé en ce qu'il comprend : au moins un camion doté d'un plateau ; une unité de mesure inertielle (IMU) disposée sur une première surface du plateau, configurée pour caractériser le mouvement du plateau, afin d'obtenir des données de mouvement en temps réel du plateau ; un capteur de localisation configuré pour suivre la localisation du plateau, afin d'obtenir des données de localisation en temps réel du plateau ; au moins une unité de traitement configurée pour traiter les données de mouvement et de localisation, afin d'obtenir des données traitées ; au moins un serveur configuré pour recevoir les données de mouvement et de localisation en temps réel et/ou les données traitées ; au moins une unité de communication configurée pour communiquer les données de mouvement et de localisation en temps réel et/ou les données traitées du ou des camions au ou aux serveurs ; et une interface d'affichage configurée pour montrer les données de mouvement et de localisation en temps réel et/ou les données traitées à un utilisateur. Le ou les serveurs sont en outre configurés pour obtenir des informations de fonctionnement du camion à partir des données de mouvement et de localisation en temps réel et/ou des données traitées, lesdites informations de fonctionnement comprenant des informations de l'état du camion, et/ou des informations de charge utile du camion, et/ou des informations de déplacement du camion, et/ou des informations d'efficience du camion, et/ou des informations de cycle du camion et/ou des informations de disponibilité du camion ; et l'interface d'affichage est configurée pour afficher lesdites informations de fonctionnement du camion.
EP21920155.5A 2021-01-22 2021-12-17 Système et procédé de surveillance de fonctionnement d'au moins un camion Pending EP4281948A1 (fr)

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US202163140504P 2021-01-22 2021-01-22
PCT/AU2021/051509 WO2022155701A1 (fr) 2021-01-22 2021-12-17 Système et procédé de surveillance de fonctionnement d'au moins un camion

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US8477027B2 (en) * 2007-10-24 2013-07-02 Gerald E. Givens Wireless sensor system
CL2009001924A1 (es) * 2009-09-30 2010-06-25 Tecnologia Integral S A Un sistema y metodo para detectar piezas metalicas ocultas dentro de una carga de mineral, directamente en un medio de transporte hacia un chancador primario.
US9302859B2 (en) * 2010-10-04 2016-04-05 Leica Geosystems Mining, Inc. Vehicle loading and unloading detection
US9792739B2 (en) * 2015-12-10 2017-10-17 Caterpillar Inc. Operation monitoring system for machine and method thereof
US10037634B2 (en) * 2016-03-22 2018-07-31 Deere & Company System and method for idle state determination
US10308157B2 (en) * 2016-08-31 2019-06-04 Caterpillar Inc. Truck cycle segmentation monitoring system and method
AU2018263818B2 (en) * 2017-05-01 2024-03-07 Rei, Inc. Method and system for component wear monitoring
BR112021004248A2 (pt) * 2018-09-07 2021-05-18 Stone Three Digital (Pty) Ltd monitoramento de minério
PE20211621A1 (es) * 2018-09-26 2021-08-23 Brian Investments Pty Ltd Sistema para pronosticar el desgaste y sensor de desgaste

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CA3206076A1 (fr) 2022-07-28

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