WO2006072123A1

WO2006072123A1 - Wear monitoring system

Info

Publication number: WO2006072123A1
Application number: PCT/AU2005/001317
Authority: WO
Inventors: Tony Parezanovic; Jeremy Michael Hoslin
Original assignee: Wear Applications & Management Services Pty Ltd
Priority date: 2005-01-10
Filing date: 2005-09-01
Publication date: 2006-07-13
Also published as: AU2005324285B2; AU2010241517B2; AU2010241517A1; AU2005324285A1

Abstract

A method of monitoring wear of liner plates provided in a material transport system. The method includes having a processing system receive measurement data representing the thickness of a plurality of selected liner plates distributed in defined wear zones. The processing system uses the measurement data to determine a thickness change for a liner plate in each wear zone and then uses this, together with a material amount indicative of the amount of material transported by the transport system to determine a wear rate. The wear rate can then be used to determine a wear zone replacement date indicative of when the liner plates in each wear zone should be replaced.

Description

WEAR MONITORING SYSTEM

Background of the Invention

The present invention relates to a method and apparatus for monitoring wear, and in particular to a method and apparatus for monitoring wear in liner plates provided in material transport systems.

Description of the Prior Art

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

Wear protection systems are used in heavy industries, such as the mining, quarrying and minerals processing industries, in order to protect expensive equipment from wear. In particular, when material such as ore is being transported, it is typical to direct the material using a sequence of chutes, conveyor belts, skips and the like, in order to allow the material to be provided to a desired location. During this transport process significant wear occurs between the material and the sides, walls, or floors of the transport systems.

Replacement of such transport systems is extremely expensive and time consuming, and therefore undesirable. In order to overcome this, it is therefore known to use wear protection systems such as liner plates, which are installed on surfaces of the transport system to form a sacrificial layer which protects the surfaces from wear. The liner plates can be formed from highly wear resistant materials to therefore provide an extended life, whilst additionally allowing liner plates to be replaced on a liner plate by liner plate basis, as required.

However, liner plates are subject to different amounts of wear, depending for example on their location on a surface. In addition to this, liner plate replacement typically requires that the associated transport system is closed to allow the liner plates to be replaced. This in turn can lead to a requirement that the plant operate either on a reduced capacity, or even shut down completely for a time period. This in turn represents a large cost burden for the relevant industry.

In order for avoid this scenario, it is therefore preferable to time liner plate replacement so that this occurs at a time of normal plant shutdown, for example by predicting when liner plate replacement will be required. Currently this is achieved by having individuals examine the liner plates and make an assessment, based on their own experience, as to when liner plates may fail and need replacing. This is an inherently inaccurate system, and costs the industry significant amounts of money when inaccurate assessments are made. Additionally, when individuals leave and a new individual is required to make the assessment, it will take period of up to several months in order for the operator to gain sufficient experience to know when liner plate replacement is required.

Summary of the Present Invention In a first broad form the present invention provides a method of monitoring wear of liner plates provided in a material transport system, the method including, in a processing system: a) receiving measurement data representing the thickness of a plurality of selected liner plates, the liner plates being distributed in defined wear zones, and the selected liner plates including a plurality of liner plates in each defined wear zone; b) determining, from the measurement data, a thickness change for at least one liner plate in each wear zone, the thickness change being indicative of a change in thickness of the respective liner plate over a time period; c) determining a material amount indicative of the amount of material transported during the time period; d) determining, using the thickness change and the material amount, a wear rate for at least one liner plate in each wear zone; e) determining a current material transport rate; and, f) calculating, using the current material transport rate and the wear rate, a wear zone replacement date indicative of when the liner plates in each wear zone should be replaced.

Typically the method includes, in the computer system: a) generating an indication of the calculated replacement date for each wear zone; and, b) providing the indication to an operator.

Typically the method includes, in the computer system: a) determining scheduled maintenance periods; and, b) generating the indication using the scheduled maintenance periods.

Typically the indication is in the form of at least one of: a) a GANT chart; and, b) an e-mail including a list of dates.

Typically the replacement date is in the form of a date range.

Typically the method includes, in the computer system, receiving the measurement data from: a) input commands supplied via a user interface; b) one or more sensors provided on the liner plates; and, c) a second processing system.

Typically the computer system is coupled to a number of sensors, each sensor being adapted to detect the thickness of one of the selected liner plates, and wherein the method includes, in the computer system, periodically obtaining the measurement data from the sensors.

Typically the method includes, in the processing system, determining a thickness change for at least three liner plates in each wear zone.

Typically the method includes, in the processing system determining at least one of the thickness change and the wear rate of at least one liner plate at least partially on a time period prior to the most recent wear zone replacement.

Typically the time period extends between successive wear zone replacements

Typically the method includes, in the processing system, determining at least one of the thickness change and the wear rate using a regression analysis.

Typically the method includes, in the processing system: a) determining, from the measurement data, a current thickness value representing the current thickness of a respective liner plate; b) obtaining one or more previously determined thickness values for the respective liner plate; and, c) determining the thickness change using the current thickness value and the one or more previously determined thickness values.

Typically the method includes, in the processing system, determining the thickness change using at least three thickness values.

Typically the method includes, in the processing system: a) determining the number of thickness values determined since the last wear zone replacement; b) comparing the number to a threshold; and, c) using previously measured thickness values from prior to the last wear zone replacement in response to an unsuccessful comparison.

Typically the method includes, in the processing system: a) determining a liner plate minimum thickness; and, b) calculating, for at least one selected liner plate, a time when the liner plate thickness will fall below the a predetermined threshold; and, c) determining the wear zone replacement date using the calculated time. - A -

Typically the method includes, in the processing system: a) calculating, for each of the selected liner plates, a predicted replacement time; and, b) determining the wear zone replacement in accordance with the earliest predicted replacement time.

Typically the method includes: a) having an operator define one or more wear zones; and, b) receive, in the computer system: i) wear zone data representing the one or more wear zones; and, ii) liner plate data representing the selected liner plates.

Typically the method includes, in the processing system, determining at least one of the thickness change, the wear rate and the replacement date using a predetermined algorithm.

Typically the method includes: a) determining the thickness of replaced liner plates; and, b) using the thickness of replaced liner plates to modify at least one of: i) a predetermined algorithm; ii) a method of determining at least one of:

(1) the wear rate; and,

(2) the replacement date; and, iii) one or more of the defined wear zones.

Typically the method includes, in the processing system, determining at least one report relating to the replacement of liner plates.

Typically the report includes at least one of: a) a material frequency comparison; b) a material cost comparison; c) an area utilisation report; d) an area cost report; and, e) an area deviation report.

In a second broad form the present invention provides Apparatus for monitoring wear of liner plates provided in a material transport system, the apparatus including, a processing system for: a) receiving measurement data representing the thickness of a plurality of selected liner plates, the liner plates being distributed in defined wear zones, and the selected liner plates including a plurality of liner plates in each defined wear zone; b) determining, from the measurement data, a thickness change for at least one liner plate in each wear zone, the thickness change being indicative of a change in thickness of the respective liner plate over a time period; c) determining a material amount indicative of the amount of material transported during the time period; d) determining, using the thickness change and the material amount, a wear rate for at least one liner plate in each wear zone; e) determining a current material transport rate; and, f) calculating, using the current material transport rate and the wear rate, a wear zone replacement date indicative of when the liner plates in each wear zone should be replaced.

Typically the apparatus includes at least one sensor system for: a) measuring the thickness of at least one liner plate; and, b) generating the measurement data.

Typically the sensor system includes a transceiver for: a) generating an ultrasonic pulse which is directed through the liner plate from a first side towards a second opposing side; b) detecting reflection of the ultrasonic pulse from the second side; and, c) generating the measurement data using the detected reflected pulse.

Typically the sensor system includes a number of conductive elements, each conductive element extending a respective distance from a first side of the liner plate towards a second opposing side, the measurement data being determined using the conductivity of each element.

Typically the conductive elements are wires embedded within the liner plate.

Typically the processing system is coupled to the sensor system via one or more communications networks.

Typically a respective sensor system is coupled to each liner plate to be monitored.

Typically the apparatus includes a second processing system for determining the measurement data from the sensor system and transferring the measurement data to the processing system.

Typically the first processing system is coupled to the sensor system via a socket.

Typically the apparatus performing the method of claim 1. In a third broad form the present invention provides A method of improving wear protection in a material transport system, the method including: a) analysing the material transport system to selected one or more areas requiring improved wear protection; b) determining aims for the improved wear protection for the selected areas; c) designing a wear protection solution; d) manufacturing liner plates required to implement the wear protection solution; e) supplying the liner plates, the supplied liner plates being installed in the installing the selected areas; and, f) monitoring the performance of the wear protection solution.

Typically the method includes, monitoring the performance of the wear protection solution by monitoring wear of the liner plates using the method of claim 1.

Typically the method includes: a) determining operational data relating to a number of areas, the operational data including at least one of: i) type of material being transported; ii) material S.G.; iii) bulk density or composition; iv) abrasive or index or moisture content or graduations; v) tonnes per hour; vi) target tonnes per annum; vii) OHS equipment areas; viii) OHS mobile plant; ix) current wear materials; x) level of concern; xi) method of current inspection; xii) existing costs; xiii) typical wear duration required; and, b) using the operational data to select the one or more areas.

Typically the method includes: a) using the aims to determine operational benchmarks; and, b) using the benchmarks to design a proposed wear liner solution.

Typically the method includes having the proposed wear liner solution reviewed and revised if required. Typically the method includes: a) monitor the operation of the liner plates to predict liner plate replacement; and, b) using the prediction to order and install liner plates.

Brief Description of the Drawings An example of the present invention will now be described with reference to the accompanying drawings, in which: -

Figures IA to 1C are schematic views of an example of liner plate distribution on inner surfaces of a skip;

Figure 2 is a flow chart outlining the process of predicting a time for replacement of the liner plates; Figure 3 is a schematic diagram of an example of a processing system;

Figures 4A to 4D are a flow chart detailing the process of predicting a time for replacement of the liner plates;

Figure 5 A is a schematic view of a GUI for entering data;

Figure 5B is a schematic view of a GUI for providing an output; Figure 5C is a graph showing liner wear over time for liner plates in the skip of Figures IA to 1C;

Figure 5D is a graph showing liner wear over time for three individual liner plates in the skip of

Figures IA to 1C;

Figure 5E is a graph showing liner wear against material flow for liner plates in the skip of Figures IA to 1C; Figures 6A to 6E are examples of report graphs providing information regarding the operation of the monitoring process;

Figure 7 is a schematic diagram of an example of a sensor for sensing liner plate thickness;

Figure 8 is a schematic diagram of an example of a distributed architecture for determining the replacement for a number of different transport systems; Figure 9 is a flow chart outlining the process for improving liner plate utilisation; and,

Figures 1OA and 1OB are a flow chart detailing the process for improving liner plate utilisation.

Detailed Description of the Preferred Embodiments

An example of a method and apparatus for assessing liner plates and predicting their replacement will now be described with reference to Figures 1 and 2. In particular, this example will be described with reference to a skip, but it will be appreciated that the techniques may be applied to any surface of a transport system which suffers wear in use. In this example, Figures IA, IB and 1C, show the relative placement of liner plates 1 on inner surfaces of the skip's wall, floor and roof, respectively. As shown, the skip incorporates forty two liner plates generally designated A1-A20 and B1-B22, as will be described in more detail below.

In general, wear throughout the skip will be uneven due to varying impacts of material as it enters and leaves the skip, as well as the varying point of contact between the material and the inner surfaces of the skip caused by motion of the material placed therein. In this example, two regions of high wear are shown at 2, corresponding to the entry and discharge points of material.

In any event, a methodology for predicting liner plate replacement requirements is set out in Figure 2.

In particular, as shown at step 100, an operator defines one or more wear zones for the skip. The wear zones are defined so that each liner plate in the wear zone has a roughly equivalent wear rate. In the example shown in Figure 1, the liner plates A1-A20 are designated to be in a first wear zone A, whilst the wear zone B is defined to include the liner plates B1-B22.

In this example, the wear zone A incorporates all the liner plates on the floor of the skip, as well as a single line of liner plates around the lower edge of the walls of the skip. This therefore incorporates all the liner plates that are in maximal contact with the material being transported, as well as the regions of high wear 2, and are therefore incorporates all the liner plates subject to the greatest wear.

At step 110, the thickness of some of the liner plates in each wear zone is periodically monitored. Each wear zone typically has a significant number of liner plates, and it is not necessary to monitor the thickness of each liner plate. In this example, the liner plates used for monitoring are liner plates Al, AlO, A14, Bl, BI l, and B13, as highlighted in Figures IA to 1C. It will be appreciated by persons skilled in the art that the liner plates whose thickness is measured, may be selected arbitrarily, or may be selected on the basis that they are in a particularly high wear area. Additionally, it is important that the same liner plates are measured each time thickness measurements are taken to ensure that an accurate reflection of the rate of wear is obtained.

In any event, at step 120, skip usage is periodically monitored to determine the volume of material that is travelling through the skip.

At step 130, a rate of wear is calculated for each wear zone. The rate of wear is calculated on the basis of the changing thickness of the liner plate over time, and the skip usage over that corresponding time period. This wear rate can then be used to calculate a replacement window at step 140, which is based on the current rate of usage of the skip. At step 150, the liner plates in each wear zone are replaced based on the determined replacement window. In this instance, every single liner plate within a wear zone is replaced at the same time to ensure that all liner plates within the wear zone have a roughly equivalent amount of wear.

Optionally, at step 160, collected data, such as a thickness of the liner plates on removal from the skip, variation in thickness between plates, or the like, can be used to revise calculations and wear zones, as required.

It will be appreciated by persons skilled in the art that this methodology may be performed in a number of manners. However, in a preferred example, it is achieved utilising a processing system which is able to receive data regarding liner plate thickness and automatically perform the calculations in step 130 and 140 to determine a replacement window.

An example of suitable processing system is shown in Figure 3. In particular, in this example, the processing system 10 includes a processor 20, a memory 21, an input/output device 22, such as a keyboard and display, and an external interface 23 coupled together via a bus 24. The external interface 23 may be used to couple the processing system 10, directly to a number of sensors 30 for measuring liner plate thickness. Alternatively, the liner plate thickness can be determined manually from the sensors 30, and input via an operator using the input/output device 22. Additionally, the processing system 10 may be coupled to a database 11, as shown.

In use, the processing system 10 operates to receive data defining the thickness of selected liner plates within the wear zones, and executes applications software to allow calculation to be performed to predict a replacement time for the wear zone. An indication of this prediction is then provided to an operator, thereby allowing the operator to make an assessment of when liner plates are to be replaced.

In any event, it will be appreciated from this that the processing system 10 may be any suitable processing system 10, such as a laptop, desktop, PDA, suitably programmed mobile phone, server, specialised hardware or the like.

An example of the process when performed using the processing system 10 will now be described in more detail with respect to the flow chart shown in Figures 4A to 4D and the representations shown in Figures 5A to 5E.

In particular, at step 200, an operator inspects liner plates in a skip and then determines one or more wear zones containing a number of liner plates at step 210. Thus, in the example outlined above, two wear zones are defined, namely wear zones A and B. Whilst only two wear zones A, B are defined in this example, it will be appreciated that a large number of wear zones may be required for different transport systems depending on the geometry or manner of use. In order to determine the wear zones, an understanding of the flow of material through the transport system is required, and this therefore requires a skilled assessment to be performed. Thus, in general, steps 200 and 210 may be performed when the system is first installed by a skilled operator, or by receiving feedback from a current operator on their knowledge of wear within the skip. Whilst it is preferred that a skilled person perform this analysis, the methodology can in any event identify wear zones that are defined incorrectly, and hence will allow correction of any liner plates that are placed within the wrong wear zone.

At step 220, the operator selects a number of liner plates in each wear zone that are to be used for measurement. Again, the liner plates may be selected based on an individual's experience, by trial and error, or by simple arbitrary selection, as will be appreciated by persons skilled in the art.

At step 230, the operator provides details of the wear zones and liner plates to the processing system 10. This will typically be achieved by using the input/output device 22, and an appropriate graphical user interface (GUI), which allows the user to define the wear zones and liner plates.

In particular, the GUI will typically include a number of fields into which required data is provided, and this will generally include information such as:

• an indication of the transport system and location;

• an identifier for each wear zone;

• an identifier for each liner plate from which measurements are to be taken;

• an indication of the wear zone in which each liner plate is provided; and, • an indication of the initial thickness of the liner plates.

• an indication of the minimum operational thickness of the liner plates.

Additional information may also be provided depending on the implementation.

At step 240, the processing system 10 stores details of the liner plates and wear zones in the database 11 to allow it to be subsequently retrieved as will be appreciated by persons skilled in the art.

Once the system has be configured in steps 200 to step 240, this process will not need to be repeated during use for monitoring a given transport system, although it will be appreciated that similar steps will be repeated each time a new transport system portion is to be added to the system.

In any event, at step 250, when the monitoring procedure is first initiated it is necessary for all the liner plates within a wear zone to be replaced, to thereby ensure that the liner plates are all at the same state of wear. When this is performed, details of the replacement are provided to the processing system 10, which stores details of the wear zone replacement at step 260. This will typically be achieved using a GUI as shown for example in Figure 5A. In particular, the GUI includes a selection field 40 indicating the currently selected skip, a wear zone field 41, showing the defined wear zones A, B, and a measure points field 42, showing for a selected wear zone A, the liner plates Al, AlO, A14, which are to be used as the measure points.

When all the liner plates in a wear zone are replaced, an operator selects a replaced check box 43, and enters the replacement date in a replacement date field 44, which in turn triggers an update of the wear zone installation date 45.

Details of the initial plate thickness are shown in the previous value field 46. This information may be entered via the new value field 47, which is used to indicate the most recent thickness measurement for a respective liner plate, or may be obtained from the data entered at step 230 above. When the current plate thickness is updated, an indication of the date on which this occurs is displayed in the date entered field 48.

It is also possible to enter details of the tonnes of material flowing through the transport system as shown in the dates and tonnes field 49, as will be explained in more detail below.

In any event, the processing system 10 stores details of the wear zone replacement in the database 11 at step 260.

At step 270, the monitoring process commences. Thus, the processing system 10 selects a wear zone, such as wear zone A, and determines liner plate thicknesses for the selected liner plates Al, AlO, A14 in the wear zone A.

The manner in which the thicknesses are determined will depend on the particular implementation, and may, for example, include having the processing system 10 download measurement data from appropriate sensors 30, or, may involve having an operator manually input the information into the new value field 44. In either case, the new thickness is imported into the new value field 47, and the date entered field 48 updated accordingly.

At step 280, the processing system determines if any liner plates have been replaced. In particular, if one of the measured liner plates Al, AlO, A14 is replaced then this will have an impact on subsequent calculations for predicting wear zone replacement. Alternatively, if a non-measured liner plate is replaced, this may not have an impact on the calculations, but needs to be taken into account as it may indicate that the wear zones are incorrectly defined. The operator indicates if a liner plate is replaced by selecting the override check box 50. The processing system 10 can then confirm if the replaced liner plate is a measured liner plate Al, AlO, A14 by confirming if the thickness in the new value field 47 is greater than the thickness in the previous value field 46. If positive determination is performed, and the replaced liner plate is a measured liner plate Al, AlO, A14, the processing system 10 discounts the replaced liner plates from subsequent calculations at step 290.

In order to predict the failure of liner plates, it is necessary to have a minimum number of measurements to allow a rate of wear to be determined. Accordingly, at step 300, the processing system 10 determines the number of thickness measurements since the previous wear zone replacement.

At step 310, the processing system determines if there are sufficient ones of these measurements available to allow a prediction to be made regarding when wear zone replacement will be required.

In particular, the processing system 10 operates to determine changes in thickness of the liner plates over a time period, and then using an indication of the amount of material passing through the skip in this time period, calculates a wear rate per tonne.

The number of measurements required depends on the respective implementation and the exact formula used in the calculation. Generally, the wear rate is modelled using a regression analysis, and accordingly, typically at least three thickness measurements are required.

In one example, if three measurements have been made since the wear zones were last replaced, then the processing system 10 can calculate the wear based solely on these measurements, in which case the processing system moves onto step 330 to determine a change in thickness for each liner plate Al, AlO, A14, for a number of different time periods. Thus, in this instance the time periods will typically correspond to the time period between successive thickness measurements.

However, if the processing system 10 determines that insufficient data is available, the process moves onto step 320 to utilise data collected prior to the most recent wear zone replacement. As data from prior to zone replacement are collected for different liner plates Al, AlO, A14, there may be variations in the wear rates etc, for example due to minor variations in liner plate properties. Accordingly, it is typical to determine the change in thickness over a time period corresponding to the entire installation period of the liner plates (i.e. corresponding to a time period between successive zone replacements - hereinafter referred to as a zone life). In one example, the processing system 10 operates to determine the change in thickness over three previous zone lives, although any suitable number may be used.

In any event, at step 340, the processing system 10 determines the amount of material flowing through the skip over the corresponding time period. This information will generally be available from the plant itself, and is typically contained within internal databases or the like. Accordingly, the processing system 10 is generally able to extract this information directly from the plants internal systems, although alternatively the information may be entered directly using the date and tonnes field 49 provided on the GUI shown in Figure 5A.

In any event, by using the change in thickness and the amount of material for a given time period, the processing system 10 determines a wear rate per tonne for each liner plate Al, AlO, A14, at step 350. This then allows predictions to be made regarding when the liner plates will next need to be replaced for a given wear zone.

In the example above, the wear rate may be determined solely from time periods since the last wear zone replacement occurred if sufficient measurements are available. If insufficient measurements are available, the wear rate may be derived at least partially from time periods prior to the most recent zone replacement.

However, it will also be appreciated that a number of variations on this process may be performed. For example, information from previous zone life periods may always be used, with the wear rate being determined from a weighted average of the wear rate during the current zone life and the wear rate during previous zone lives.

In any event, once this process has been completed for a wear zone, the processing system will determine if all the zones have been completed at step 360. If not, the processing system will return to step 270 to repeat the process for other zones. Thus, in this example, once the wear rate has been calculated for zone A, the process will be repeated for zone B. it will be appreciated that it is not essential that the steps are completed in sequence for each wear zone, and therefore this is for the purpose of example only. Thus, for example, the processing system 10 may operate to determine the thickness measurements for all of the liner plates Al, AlO, A14, Bl, BIl, B13 of interest, before calculations are performed for each wear zone A, B.

In any event, once a wear rate has been determined for each liner plate Al, AlO, A 14, this can be used to predict when the liner plates will fail.

This is contingent on the amount of material flowing through the skip, and accordingly, at step 370 the processing system 10 determines the current amount of material passing through the skip, using this to determine predict the wear for each liner plate at step 380.

The processing system 10 then determines the worst case wear for the wear zone based on the project wear for each liner plate Al, AlO, A14 at step 390. Thus, it will be appreciated that the liner plate Al may be higher than that for the liner plates AlO or A14, or vice versa. In this example, it is necessary to ensure that all the liner plates within a wear zone are replaced before the liner plate Al fails. Accordingly, the processing system 10 determines a replacement window at step 400. This is calculated based on the worst case predicted wear, and to take into account safety factors. Thus, this will be calculated to ensure that the liner plates are replaced before they reach the minimum thickness specified at step 230 above. Additionally, the earliest point of the replacement time frame is typically calculated to ensure that the liner plates are not replaced unduly early, which would typically compromise the efficiency of liner plate usage.

Have determined a replacement window, the processing system can determine scheduled transport system shut-off times at step 410, and provide an indication of these and the replacement windows to the operator at step 420.

Whilst this may be achieved in a number of ways, such as providing an e-mail to an operator in charge of liner plate replacement, in one. example, this is achieved using a suitable GUI, an example of which is shown in Figure 5B. In this example, the GUI includes a selection field 51 indicating the currently selected skip, a report selection section 52, to allow different reports to be selected, and a report display section 53.

The report selection section 52 includes a reports field 54, which allows different types of report for indicated date periods to be selected. Additionally, this includes an input field 55 to allow a skip throughput amount to be specified, which is used by the processing system 10 at step 370 above.

The processing system 10 then operates to indicate the mine shut-off times and calculated replacement windows in the report display section 53. In one example this can be provided in the form of a GANT chart, as shown for example at 56.

The operator can use this indication to determine a suitable wear zone replacement time. Thus, in the example shown, shut-off periods are indicated at 57, with the next predicted replacement for wear zones A, B being shown at 58, 59 respectively. Accordingly, in the case of wear zone B, the operator can simply decide to replace the liner plates during the corresponding shut-off. In the case of wear zone A, the replacement window does not coincide with a shut-off period and an assessment must therefore be made as to whether replacement should occur at an alternative time, or during previous shut-off times, which in general will depend on external economic factors such as the cost of a shutdown.

Thus, on a day-by-day basis, the operator or processing system can determine if the wear zone replacement is due at step 440, and if so, return to step 250 to cause the liner plates to be replaced. Additional Reports

Additional information can also be presented to further assist the operator in assessing the predicted replacement window, as well as the accuracy of the definitions of the wear zones A, B, at step 450.

Examples of these are shown in Figures 5C to 5E, which are graphs of the mean liner plate wear against time for the liner plates Al, AlO, A14, the liner wear versus time for each of the liner plates Al, AlO, A14, and the liner wear versus tonnes throughput.

These representations therefore represent an indication of the values determined at 330 and 350, and can be used by operators to assess whether liner plates are correctly designated within certain wear zones or the like.

Thus, for example, Figure 5D highlights that the liner plate AlO generally wears faster than the liner plates Al and A14, which may be an indication that the liner plate needs to be included in a alternative zone. In this case, an assessment is made of the cost benefit of creating a new zone, and consequently increasing the measurements required and the additional potential expense of introducing additional shut-down requirements, versus the costs saved by optimum usage of the liner plates.

Figure 5E highlights differences in the current predicted wear of the liner plates, versus the wear measured during the previous zone life. This indicates that the predicted wear appears to be lower than the previously measured wear, which the operator will consider in assessing when a zone replacement is to occur. For example, if liner plates have a tendency to wear a greater amount towards the end of their life, then in the case of the zone A, it may not be feasible to await the next transport system shut- off before replacement is performed. It will be appreciated that if there is constantly a variation between the predicted and measured wear, then this can be used to revise the calculations used to determine the predicted replacement window.

A number of additional reports can also be generated if suitable data is available. Examples of these will now be described with reference to Figures 6A to 6E.

Ih particular, Figures 6A and 6B show material frequency and material cost comparisons. These reports utilise information regarding the replacement of the liner plates prior to implementation of the above described monitoring system, and by comparing this to the replacement of liner plates after implementation of the monitoring system, allow improvements in efficiency to be evaluated.

Thus, for example, Figure 6A shows the "Material Frequency Comparison" for each of a number of areas within the material transport system. This is indicative of the frequency of liner plate replacement, both before and after installation of the monitoring system. This example shows a dramatic improvement in the length of the time for which liner plates are retained in place, primarily due to the definitive determination of replacement windows made by the monitoring process described above versus the previous subjective evaluation by an operator. It is evidence that this leads to a significant improvement in liner plate life span, such as in the OREPASS area in which the duration has been extended from about eight weeks through to about thirty two weeks.

The "Material Cost Comparison" shown in Figure 6B indicates the cost of replacing the liner plates both before and after the monitoring process has been installed, again highlighting that a large saving is made, particularly in high wear areas such as impact areas.

Thus, it will be appreciates by persons skilled in the art that reports of this form may be utilised by site owners to determine the levels of economic improvement that can be obtained using the monitoring process described above.

Figures 6C, 6D and 6E are reports that relate to the relative utilisation of the liner plates in different areas.

In particular, Figure 6C shows, for each area, the degree to which the liner plates have been used. This is achieved by measuring the thickness of the liner plates when they are removed to thereby determine the amount of material that remains. This allows the processing system 10 to determine the amount of material remaining with respect to the defined threshold set by the site operators. Thus, 100% utilisation would indicate that the liner plates have worn down exactly to their threshold.

In this example, the liner plates in most areas demonstrate wear by more than 85%, highlighting that the liner plates are being used substantially to their greatest potential. However, the liner plates in the TRUNK area are only utilised to approximately 55%, indicating that the liner plates are being replaced more frequently than is required, which in turn suggests that there may be inaccuracies in the prediction of the replacement window for the TRUNK area. This may be due to any number of reasons, such as incorrect definitions of wear zones or the like. In any event, having identified this, an operator can then consider the situation, and make adjustments to the monitoring process to ensure that the wear liner plates are more fully utilised.

Similarly, when liner plates show wear of greater than 100%, this indicates that the liner plates have worn down to below the threshold. Whilst this may have occurred simply due to the relative timing of the replacement window and mine shut down time, if values of above 100% are consistently obtained, this may indicate inaccuracies in the prediction of liner plate wear, which may need to be addressed to prevent liner plate failure.

As shown in Figure 6D, an area cost report can also be generated to show the relative costs involved in liner replacement. This highlights that although the TRUNK liner plates are to a large extent inefficiently utilised, there is not necessarily a huge degree of cost associated with this when compared to other areas. This allows operators to make assessments regarding the relative importance of ensuring that liner plate wear is as close to 100% in some areas.

In Figure 6E, an area deviation report is shown. This allows the current performance of the liner plate configuration to be compared to benchmarks to thereby determine the success of the current liner plate solution. The benchmarks can be defined for any one of a number of values including for example, the wear rate, the residual thickness or utilisation of liner plates upon replacement, the cost per quarter of maintaining the liner plates for a given area or wear zone, or the like.

In order to achieve this, in use, benchmark values are defined for the operation of selected aspects of the liner plates, and this is typically performed as part of audit and analysis procedure used in establishing a wear liner solution, as will be described in more detail below. Once relevant data is collected, these are compared to the benchmarks allowing an indication of benchmark attainment to be displayed.

Thus, the processing system 10 can for example determine the cost of replacing the liner plates over a given time period, and then compare this to a projected cost. This allows the operator to easily compare the actual performance of selected areas compared to the desired performance.

In this example, a deviation of 0% indicates that the defined benchmarks are being met, with a higher percentage indicating a degree of deviation from the benchmark. Thus, in this instance, it is evident that the majority of the areas are operating within a 15% deviation from the projected benchmark. However, the TRUNK area deviates from the set benchmark by over 30%, thereby indicating either that the set benchmark is unrealistic or that the TRUNK area is functioning incorrectly.

In this instance, it will be appreciated that when considered in conjunction with the Area Asset Utilisation Report discussed above, this indicates that the liner plates in the TRUNK area are underutilised, and hence the defined benchmarks are not being met. This would indicate that the TRUNK area needs to be reconfigured if the benchmarks are to be met.

Thickness Measurements

As described above, a number of different sensor mechanisms may be utilised. A first example is shown in Figure 6, which shows two sensors 30A, 30B, positioned in respective liner plates IA, IB. In this example, the sensor 30 is formed from a number of trip wires 31 placed inside a recess 32 in the corresponding liner plate 1. In general the recess 32 is preformed during liner plate construction by drilling a hole in the liner plate 33 and filling it with a softer material, which allows the trip wires 31 to be subsequently inserted therein as shown, although any of construction may be used. The trip wires 31 may be coupled to a socket 33, to allow a processing system 10 to be coupled thereto, either via a network or via direct connection. Alternatively, the socket 33 may be replaced by a wired or wireless communication system, allowing the sensor 30 to be coupled to the processing system 10 either directly, or via an appropriate network, as will be described in more detail below.

In either case, as the liner plate 1 becomes worn, as shown by the liner plate IB, the trip wires 31 will progressively break, allowing the liner plate thickness to be determined. It will be appreciated by persons skilled in the art that the number of trip wires 31 and their relative lengths and positioning can be used to determine the current liner plate thickness to varying degrees of accuracy. In general, liner plates are up to 60mm thick, and may include, for example, twenty trip wires 31 to allow the liner plate thickness to be determined within 3mm, although any number may be used depending on the level of accuracy desired.

In any event, in this particular instance, the processing system 10 can determine the thickness of the liner plates by monitoring the resistance of each trip wire 31, with a broken trip wire being indicated by a higher resistance than the unbroken trip wires.

Alternatively, other sensing techniques may be used. For example, ultrasound techniques can be used by placing a transducer on a surface of the liner plate 33, allowing an ultrasonic pulse to be directed across the liner plate, and reflected from the opposing side. The time taken for the ultrasonic pulse to traverse the width of the liner plate can then be used to determine then thickness of the liner plate, based on the speed of travel of the pulse through the liner plate material.

Additional techniques such as inductive effects can also be used. Thus, for example, a transmission line can be provided in the liner plate extending across the liner plate width. In this instance, the inductance of the transmission line will depend on its length. Accordingly, as the liner plate is worn down, the length and hence inductance of the transmission line will alter, allowing the liner plate thickness to be determined.

As mentioned briefly above, the sensors 30 may be coupled to the processing system 10 via directly or via a number of intermediate connections, as shown for example, in Figure 7.

In this example, the processing system 10 is coupled to the database 11, and provided in a base station 1, as shown. The base station 1 is coupled to a number of end stations 3 and sensors 30, via a communications network 2, such as the Internet, and/or via communications networks 4, such as local area networks (LANs) 4. Thus it will be appreciated that the LANs 4 may form an internal network at a plant, mine, or the like. This allows liner plates at a number of different locations to be monitored centrally, for example by the liner plate supplier. Thus, it will be appreciated that depending on the sensor 30 used, the sensor may be capable of being coupled directly to the networks 2, 4, allowing them to communicate directly with the base station 1. This may be achieved using either wired or wireless connections, and allows the process to be controlled substantially remotely.

Alternatively, for example if the sensors are passive devices, the sensors may need to be coupled to the end stations 3 to allow the liner plate thickness to be determined by the end station 3, before being forwarded onto the base station 1 as required. This may be performed, for example, by using a portable end station 3, which can be selectively connected to the sensors 30, for example via a socket 33, allowing a measurement to be made and then transferred to the processing system 10 at a suitable time. Alternatively, the end station 3 may be permanently coupled to the sensors 30.

In any event, in use the end stations 3 are adapted to communicate with the processing system 10. Accordingly, the end stations 3 may be formed from any suitable processing system, such as a suitably programmed PC, Internet terminal, lap-top, hand-held PC, or the like, which is typically operating applications software to enable data transfer and in some cases web-browsing.

In any event, this allows the calculations to be performed centrally, with the results of the calculations being made available to the operators of the respective transport systems, for example, via an appropriate web-page.

In this case, it will be appreciated that access to the process may be controlled using a subscription system or the like, which requires the payment of a fee to access a web site hosting the process. This may be achieved using a password system or the like, as will be appreciated by persons skilled in the art.

It will be appreciated that by analysing data collected centrally for a number of different transport systems, this will allow more accurate models to be developed in an iterative process.

Improvement Process In addition to providing the monitoring system described above, it is also possible to utilise the monitoring system as part of an overall wear protection solution, and in particular, in a process of improving existing wear protection solutions.

An example of this may be achieved will now described with reference to Figure 9.

At step 500, it is typical for an audit and analysis of a site to be performed to determine the wear requirements. As will be described in more detail below, this is typically achieved by having skilled personnel review the operation of a site and determine areas within the site that would provide the most benefit from implementation of an improved wear protection system.

At step 510, performance benchmarking is performed to determine benchmarks for the wear protection requirements. This is used in selecting the wear protection to be used, and will include considering factors involved in making the improved wear protection system economically viable.

At step 520, a product and design selection is performed. This will involve assessing the different forms of wear protection systems available, and whether these are able to meet the defined benchmarks, as well as designing the necessary elements of the system, such as designing suitable liner plates for installation.

At step 530, the defined selection is manufactured. In many cases that can be achieved relatively easily by use of standard plates having fixed dimensions. However, it will be appreciated that some areas will require custom designed liner plates, and it will be necessary to configure the manufacturing process to create these plates as required.

At step 540, supply management protocols are determined and implemented to allow liner plates and any other required equipment to be supplied to the site as required. This needs to be arranged so that replacement liner plates can be made available on demand, thereby avoiding the need to store large quantities of liner plates on site.

At step 550, the process involves monitoring performance of the wear protection system, to ensure that the proposed solution is working correctly. It will be appreciated that in one example this can be achieved using the monitoring system described above, and in particular can be achieved by comparison of the performance to the benchmarks, for example by using a deviation report discussed above.

Accordingly, this provides a solution to allow custom liner plate solutions to be developed for specific sites, as required.

This process will now be described in more detail with respect to Figures 6A and 6B.

In particular, at step 600, it is necessary for an expert to inspect and record details of each area at a respective site. This is typically performed in association with mine personnel by inspecting and recording (photographically) each area under consideration. Data collected is consolidated and analysed to assist application analysis.

Following this, at step 610, the initial review is used to select areas for more detailed analysis. In particular, the monitoring process and provision of liner plates can be relatively expensive. Accordingly, in some circumstances, such monitoring is simply uneconomic. Thus, inspecting and recording details of each asset allows selected assets to be chosen for specific monitoring.

These will typically be key areas, such as those that represent bottlenecks in the transport system. Such areas will typically have a large impact on site operation should liner plate failure occur. Thus, for example, in situations where only a single chute is available to transport material, failure of this chute could lead to shutdown of the site. In contrast, however, if a number of alternative chutes are available, such monitoring become less important as an alternative chute used without impacting on the site operation.

At step 620, an analysis of the selected areas is completed to collect operational data including information such as:

• type of material being transported;

• material S.G.;

• bulk density or composition;

• abrasive or index or moisture content or graduations; • tonnes per hour;

• target tonnes per annum;

• OHS equipment areas;

• OHS mobile plant;

• current wear materials; • level of concern;

• method of current inspection;

• existing costs;

• typical wear duration required.

At step 630, the operational data is to determine definitively the areas that require liner plates to be provided with an associated monitoring system.

At step 640, the operational data is examined to determine aims for the wear liners in each area. This includes, for example, determining whether the existing wear liners can be improved, and therefore generally involves analysing existing wear solutions and how these can be improved.

At step 650, the aims for each area are analysed to determine operational benchmarks for each area. The operational benchmarks include, for example, an indication of the acceptable cost for liner monitoring and replacement, the desired life span for the liner plates, and the like. At step 660, these benchmarks are used to design a proposed wear liner solution for each area. Thus, the operator performing the analysis will assess, based on the operational data and the required benchmarks, potential solutions that would achieve the desired aims. This will include details not only of the nature of the wear solution, but details of supply management to ensure

This will typically involve identifying each wear liner plate that is used with an individual part number, stock code and material prefix, allowing the exact nature and intended location of each liner plate to be uniquely identified. This ensures that the liner plates are correctly allocated to each area, and allows a just in time supply to be implemented, thereby avoiding costs associated with storage or unavailability of liner plates.

At step 670, the proposed solution is provided to site management for review. If it is determined that the proposal is not acceptable at step 680, then the proposed solution is reviewed and revised as required at step 690, before being again presented to site management for review at step 670.

Once an acceptable proposal has been determined at step 700, the operator will use the proposed solution to coordinate manufacture of appropriate liner plates. This will involve a number of stages depending on the nature of the wear liner, the specifications involved and the like. In particular, the operator will typically coordinate the producing the liner general arrangements, a bill of materials, tolerances and specifications, stock codes and individual manufacturing drawings.

At step 710, the liner plates are supplied and installed on-site. This involves supplying and installing the liner plates in accordance with the supply arrangement.

At step 720, the operation of the wear liners is monitored to predict liner replacement, which may be performed for example, as described above with respect to Figures 1 to 8. At step 730, the prediction is used to order and install replacement liner plates as required, with the monitoring process being used to collect operational data at step 740.

The operational data, such as the reports shown in Figures 6A to 6E allow the wear solution to be revised if it is incorrect, for example, by redefining wear zones, the types of liner plates used, or the like. Thus, the performance of the liner plate solution can be compared to determined benchmarks using for example the deviation report shown in Figure 6E.

However, additionally, the data can be used to allow the entity supplying the liner plates to create more accurate models of liner wear, which can in turn be used to increase the accuracy of the replacement prediction, thereby allowing a further improvement in the cost effectiveness of the overall process. Persons skilled in the art will appreciate that numerous variations and modifications will become apparent. All such variations and modifications which become apparent to persons skilled in the art, should be considered to fall within the spirit and scope that the invention broadly appearing before described.

Claims

THE CLAIMS DEFINING THE INVENTION ARE AS FOLLOWS:

1) A method of monitoring wear of liner plates provided in a material transport system, the method including, in a processing system: a) receiving measurement data representing the thickness of a plurality of selected liner plates, the liner plates being distributed in defined wear zones, and the selected liner plates including a plurality of liner plates in each defined wear zone; b) determining, from the measurement data, a thickness change for at least one liner plate in each wear zone, the thickness change being indicative of a change in thickness of the respective liner plate over a time period; c) determining a material amount indicative of the amount of material transported during the time period; d) determining, using the thickness change and the material amount, a wear rate for at least one liner plate in each wear zone; e) determining a current material transport rate; and, f) calculating, using the current material transport rate and the wear rate, a wear zone replacement date indicative of when the liner plates in each wear zone should be replaced.

2) A method according to claim 1, wherein the method includes, in the computer system: a) generating an indication of the calculated replacement date for each wear zone; and, b) providing the indication to an operator. 3) A method according to claim 2, wherein the method includes, in the computer system: a) determining scheduled maintenance periods; and, b) generating the indication using the scheduled maintenance periods.

4) A method according to claim 2, wherein the indication is in the form of at least one of: a) a GANT chart; and, b) an e-mail including a list of dates.

5) A method according to claim 1 , wherein the replacement date is in the form of a date range.

6) A method according to claim 1, wherein the method includes, in the computer system, receiving the measurement data from: a) input commands supplied via a user interface; b) one or more sensors provided on the liner plates; and, c) a second processing system.

7) A method according to claim 1, wherein the computer system is coupled to a number of sensors, each sensor being adapted to detect the thickness of one of the selected liner plates, and wherein the method includes, in the computer system, periodically obtaining the measurement data from the sensors.

8) A method according to claim 1, wherein the method includes, in the processing system, determining a thickness change for at least three liner plates in each wear zone. 9) A method according to claim 1, wherein the method includes, in the processing system determining at least one of the thickness change and the wear rate of at least one liner plate at least partially on a time period prior to the most recent wear zone replacement.

10) A method according to claim 9, wherein the time period extends between successive wear zone replacements

H) A method according to claim 1, wherein the method includes, in the processing system, determining at least one of the thickness change and the wear rate using a regression analysis. 12) A method according to claim 1, wherein the method includes, in the processing system: a) determining, from the measurement data, a current thickness value representing the current thickness of a respective liner plate; b) obtaining one or more previously determined thickness values for the respective liner plate; and, c) determining the thickness change using the current thickness value and the one or more previously determined thickness values. 13.) A method according to claim 12, wherein the method includes, in the processing system, determining the thickness change using at least three thickness values.

14) A method according to claim 12, wherein the method includes, in the processing system: a) determining the number of thickness values determined since the last wear zone replacement; b) comparing the number to a threshold; and, c) using previously measured thickness values from prior to the last wear zone replacement in response to an unsuccessful comparison.

15) A method according to claim 1, wherein the method includes, in the processing system: a) determining a liner plate minimum thickness; and, b) calculating, for at least one selected liner plate, a time when the liner plate thickness will fall below the a predetermined threshold; and, c) determining the wear zone replacement date using the calculated time.

16) A method according to claim 1, wherein the method includes, in the processing system: a) calculating, for each of the selected liner plates, a predicted replacement time; and, b) determining the wear zone replacement in accordance with the earliest predicted replacement time.

17) A method according to claim 1, wherein the method includes: a) having an operator define one or more wear zones; and, b) receive, in the computer system: i) wear zone data representing the one or more wear zones; and, ii) liner plate data representing the selected liner plates. 5 001317

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18) A method according to claim 1, wherein the method includes, in the processing system, determining at least one of the thickness change, the wear rate and the replacement date using a predetermined algorithm.

19) A method according to claim 1, wherein the method includes: a) determining the thickness of replaced liner plates; and, b) using the thickness of replaced liner plates to modify at least one of: i) a predetermined algorithm; ii) a method of determining at least one of:

(1) the wear rate; and, (2) the replacement date; and, iii) one or more of the defined wear zones.

20) A method according to claim 1, wherein the method includes, in the processing system, determining at least one report relating to the replacement of liner plates.

21) A method according to claim 20, wherein the report includes at least one of: a) a material frequency comparison; b) a material cost comparison; c) an area utilisation report; d) an area cost report; and, e) an area deviation report. 22) Apparatus for monitoring wear of liner plates provided in a material transport system, the apparatus including, a processing system for: a) receiving measurement data representing the thickness of a plurality of selected liner plates, the liner plates being distributed in defined wear zones, and the selected liner plates including a plurality of liner plates in each defined wear zone; b) determining, from the measurement data, a thickness change for at least one liner plate in each wear zone, the thickness change being indicative of a change in thickness of the respective liner plate over a time period; c) determining a material amount indicative of the amount of material transported during the time period; d) determining, using the thickness change and the material amount, a wear rate for at least one liner plate in each wear zone; e) determining a current material transport rate; and, f) calculating, using the current material transport rate and the wear rate, a wear zone replacement date indicative of when the liner plates in each wear zone should be replaced. 23) Apparatus according to claim 22, wherein the apparatus includes at least one sensor system for: a) measuring the thickness of at least one liner plate; and, b) generating the measurement data. 24) Apparatus according to claim 23, wherein the sensor system includes a transceiver for: a) generating an ultrasonic pulse which is directed through the liner plate from a first side towards a second opposing side; b) detecting reflection of the ultrasonic pulse from the second side; and, 5 c) generating the measurement data using the detected reflected pulse.

25) Apparatus according to claim 23, wherein the sensor system includes a number of conductive elements, each conductive element extending a respective distance from a first side of the liner plate towards a second opposing side, the measurement data being determined using the conductivity of each element. 0 26) Apparatus according to claim 25, wherein the conductive elements are wires embedded within the liner plate.

27) Apparatus according to claim 23, wherein the processing system is coupled to the sensor system via one or more communications networks.

28) Apparatus according to claim 23, wherein a respective sensor system is coupled to each liner plate 5 to be monitored.

29) Apparatus according to claim 23, wherein the apparatus includes a second processing system for determining the measurement data from the sensor system and transferring the measurement data to the processing system.

30) Apparatus according to claim 29, wherein the first processing system is coupled to the sensor 0 system via a socket.

31) Apparatus according to claim 22, the apparatus performing the method of claim 1.

32) A method of improving wear protection in a material transport system, the method including: a) analysing the material transport system to selected one or more areas requiring improved wear protection; 5 b) determining aims for the improved wear protection for the selected areas; c) designing a wear protection solution; d) manufacturing liner plates required to implement the wear protection solution; e) supplying the liner plates, the supplied liner plates being installed in the installing the selected areas; and,

50 f) monitoring the performance of the wear protection solution.

33) A method according to claim 32, wherein the method includes, monitoring the performance of the wear protection solution by monitoring wear of the liner plates using the method of claim 1.

34) A method according to claim 32, wherein the method includes: a) determining operational data relating to a number of areas, the operational data including at \5 least one of: i) type of material being transported; ii) material S.G.; iii) bulk density or composition; iv) abrasive or index or moisture content or graduations; v) tonnes per hour; vi) target tonnes per annum; vii) OHS equipment areas; viii) OHS mobile plant; ix) current wear materials; x) level of concern; xi) method of current inspection; xii) existing costs; xiii) typical wear duration required; and, b) using the operational data to select the one or more areas.

35) A method according to claim 32, wherein the method includes: a) using the aims to determine operational benchmarks; and, b) using the benchmarks to design a proposed wear liner solution.

36) A method according to claim 35, wherein the method includes having the proposed wear liner solution reviewed and revised if required.

37) A method according to claim 32, wherein the method includes: a) monitor the operation of the liner plates to predict liner plate replacement; and, b) using the prediction to order and install liner plates.