WO2018223245A1 - Optimiser for transfer funnels - Google Patents

Optimiser for transfer funnels Download PDF

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Publication number
WO2018223245A1
WO2018223245A1 PCT/CL2018/050043 CL2018050043W WO2018223245A1 WO 2018223245 A1 WO2018223245 A1 WO 2018223245A1 CL 2018050043 W CL2018050043 W CL 2018050043W WO 2018223245 A1 WO2018223245 A1 WO 2018223245A1
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WO
WIPO (PCT)
Prior art keywords
vibration
chute
flow
sensors
scalar
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PCT/CL2018/050043
Other languages
Spanish (es)
French (fr)
Inventor
Marcos CASTRO
Cristian DOERR
Héctor LEIVA
Pierre DE LAMBERTERIE
Original Assignee
Emerson Electric (Us) Holding Corporation (Chile) Limitada
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.)
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Application filed by Emerson Electric (Us) Holding Corporation (Chile) Limitada filed Critical Emerson Electric (Us) Holding Corporation (Chile) Limitada
Priority to AU2018280425A priority Critical patent/AU2018280425A1/en
Publication of WO2018223245A1 publication Critical patent/WO2018223245A1/en

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
    • B65G43/00—Control devices, e.g. for safety, warning or fault-correcting
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01H—MEASUREMENT OF MECHANICAL VIBRATIONS OR ULTRASONIC, SONIC OR INFRASONIC WAVES
    • G01H17/00—Measuring mechanical vibrations or ultrasonic, sonic or infrasonic waves, not provided for in the preceding groups

Definitions

  • Transfer chutes are equipment used mainly to receive a material, input and / or product from a first place and direct it to a second or more places.
  • material will be used to define any element that circulates through the transfer chutes.
  • the chutes are used in different applications, being one of the main mineral transport in mining. Other applications correspond to the production lines in the assembly of products, dispatch lines and / or material disposal lines. In fact, the chutes of transfer are used in multiple applications where it is required to direct material from a point to one or several points, where said material circulates through the chute mainly by gravity. In this sense, the chutes that are part of different applications have practically the same essential structure, which is usually of the funnel type with one or more inputs and outputs.
  • one of the main problems that the transfer chutes present during their operation is the occurrence of interruptions in the circulation of the material that passes through the chute.
  • interruptions in circulation are commonly referred to as atolls, jams, "clogging” or even “plugging", in addition to other names specific technicians of each industry, being one of the main operational failures of transfer chutes.
  • the atolls are usually formed by the accumulation of material on the internal surfaces of the chute, accumulation that increases over time until a kind of plug is generated that reduces and / or blocks the free movement of the material towards the outlet (s) of the chute. This agglomeration may be due to the properties of the material entering the chute and / or due to problems in the arrangement of components or operating parameters outside normal ranges.
  • the operational dynamics of the chutes is associated with a continuous flow of material that enters it through one or more openings, leaving in the directions established by the one or more outputs that the equipment has, which usually acts as a screen in the "observation" inside the chute.
  • particles in suspension may appear that obstruct the opening thereof, blocking the "observation" of the instrumentation aimed at detecting the atolls.
  • Many of these solutions aimed at the detection of atollo require to be installed inside the chute, ending up damaged or losing its ability to sense. Then, common solutions to detect atolls face the difficulty of confusing the material flow itself or the presence of particles in suspension with the formation of atolls inside the chute, resulting in multiple false positives during the operation of this equipment.
  • a transfer chutes monitoring and control system is required that allows not only to reliably detect the formation of atolls inside a chute, but also to predict the formation of said atolls as long as they generate the operating conditions that favor them, allowing to establish control actions that increase the availability of chute, minimizing false positives.
  • a transfer chutes optimizer that has a transfer chutes monitoring and control system that uses vibration sensors arranged on the external surface of the chute to monitor the vibratory behavior of the chute, or at least of certain zones of the chute, in order to obtain data of the vibratory behavior and process them to identify operating states of the chute, which may be indicators of the formation of atolls inside.
  • the sensors can be wired or wireless.
  • the information captured by the sensors allows early detection of faults associated with the deterioration of the chute, such as detachment of internal coatings and / or any damage to the equipment that results in a change in the vibratory behavior of the sensed surface.
  • one of the objectives of the optimizer for transfer chutes is to propose a predictive, remote, non-invasive, easy-to-implement, low-maintenance and secure philosophy solution for people and assets (chutes, belts, ore). )
  • Another objective is to propose a solution aimed at minimizing or eliminating productivity losses, such as those caused by operational discontinuity and production losses, events of atolls or jamming ("Plugging") without early detection or false detection, for excessive times in unbalances and / or chutes cleaning, and negative impacts on HSEC (Health / Safety / Environment / Community). That is, avoiding unplanned stops based on false atolls and minimizing unplanned detention hours (towards zero unplanned downtime).
  • Another objective of the solution is to remotely monitor, online and in real time, the flow of ore through the transfer chute, thus enabling to dynamically know material flow patterns leading to significant atolls.
  • Another objective of the solution is to make it possible to model the evolution of the atolls over time, thus allowing the prevention or early warning of their occurrence - before or at the moment - that this occurs (with false or false minimums).
  • Another objective of the solution is to take immediate remediation actions when atolls occur, by generating online alerts to the operation's control systems.
  • Another objective of the solution is that it measure accurately and that it does not generate false alarms, that it is robust against variations in the flow of material and dust, that is not affected by corrosive environments of the ore in belts and chutes, that in its Control strategy aims at stopping the operation in a timely manner to prevent mineral spills or to not further aggravate the condition of atollo
  • Another objective of the solution is to detect early the occurrence of faults in the transfer chute, issuing early warnings that allow the early correction of the failure, minimizing downtime and productivity losses.
  • the system of monitoring and control of transfer chutes comprises multiple vibration sensors (wired or wireless) arranged on the external surface of the chute, to monitor the vibratory behavior of the same, or at least of certain areas of its surface, in order to obtain data on the vibratory behavior of the chute, complement them with operational data from historians (database that stores historical data), the same control system of the operation or another (tape speed, load, etc.). ) and process them to identify equipment operation states.
  • These states of operation can be indicators of the formation of atolls inside the chute, product of the vibratory changes of the monitored surfaces.
  • the information captured by the vibration sensors allows the early detection of faults associated with the deterioration of the chute, such as detachment of internal coatings and / or any damage to the equipment that results in a change in the vibratory behavior of the measured zone or zones.
  • the vibratory data that identify the operating state of the chute and comparing them with vibratory data during normal operation it is possible to identify changes in the operating states and discern if said changes are indicators of the formation of accumulations of material inside the chute. , which may result in an attack or blockage of same.
  • the vibratory data of the chute also allow detecting the occurrence of faults in the same, faults associated with vibratory changes in the chute or in part of it, as for example due to the wear or detachment of an internal coating.
  • a chute vibration measurement system that includes a set of vibration sensors arranged on the external surface of the chute, a vibration analysis system, operational information and an expert system.
  • the set of vibration sensors includes multiple vibration sensors located at different heights, levels or layers of the chute, wherein said sensors generate a plurality of analogous vibration signals of the material flow into the chute.
  • the vibration analysis system includes an analog-digital converter and one or more general vibration processing channels.
  • the analog-digital converter samples the analog vibration signals of the material flow into the chute at a fixed sampling frequency and converts the vibration signals of the flow into digital vibration signals.
  • One or more vibration processing channels process the digital signals to generate scalar vibration values representative of the passage of the internal flow in the different sensed zones or chute measurements. For this, the sum of the total vibrational energy in the frequency range of interest is calculated.
  • one or more bandpass filters are provided for filtering the digital signals to generate limited bandpass digital vibration signals.
  • the expert system operates communicated to a control system that acts on the operation of the process based, at least in part, on the scalar vibration values of the flow.
  • the vibration sensors are arranged so that the sensor axis of each vibration sensor is substantially perpendicular to the axis of the chute flow to which it is attached.
  • the vibration analysis system includes a comparison module or expert system that compares one or more of:
  • the comparison module compares the scalar vibration values of the flux within the chute in a preferred frequency range of 0 kHz to 10 kHz, measured during the first time period, with the scalar vibration values of the base flux in the same frequency range, measured during the period of time when the chute operated under normal conditions.
  • the comparison module generates control information to control the operation of the conveyor belt, when the energy levels of the scalar vibration values of the flow in the frequency range from 0 kHz to 10 Hz, measured during the first period of time, are different than the energy levels of the scalar vibration values of the base flow in the same frequency range, measured during the period of time when the chute operated under normal conditions.
  • the control information may comprise an alert message informing an operator in relation to the atollo condition that may be occurring in the flow of one or more chutes or the control information may comprise a control signal that initiates the arrest of feeding.
  • the comparison module generates control information to control the operation of one or more of the conveyor belts associated with the process, when:
  • Said change in the energy levels of the scalar vibration values of the output and / or input flow may indicate a condition of blockage of the chute.
  • the control information may comprise an alert message informing the operator in relation to the chute obstruction condition or the control information may comprise a control signal that initiates the belt stop or chute feed.
  • inflows and outflows should be understood to the effects of the flow of ore that circulates through the chute in the entry and exit areas thereof, where the chute in its entirety would be represented by those areas, which present a provision of levels of sensors arranged to characterize the vibrations of the same.
  • the invention provides a method for measuring and analyzing the vibration associated with a chute.
  • a preferred embodiment of the method includes the following steps:
  • the vibration sensors generate an analogous signal of vibration of the flow, indicative of the vibration of the first zone of the chute detected in stage (a);
  • the vibration sensors generate a second analogous signal of vibration of the flow, indicative of the vibration of the second zone of the chute detected in step (c);
  • the solution comprises splitting the chute into more than two zones, with a plurality of sensors associated with the different chute zones arranged to characterize the vibration levels of said zones.
  • the number of zones in which the chute is divided will depend on different factors, including the size of the chute, the type of feeding and unloading, the precision required in the characterization of its behavior, etc.
  • the method includes providing control information to a distributed control system, based, at least in part, on the scalar vibration values of the flow.
  • the chute is divided into multiple zones (three or more), said zones defined by the different levels of the chute from its entry portion to its exit portion, or vice versa.
  • set of vibration sensors located in the different levels of the chute are defined, characterizing the vibratory behavior of the same in said different levels.
  • the comparison of the behavior between the levels of the chute and the processing of the scalar vibration values of the flow in these levels allows to characterize the formation of accumulations that will result in atolls, information that allows to predict the formation of the wind before it occurs, managing itself integrated control actions, such as alarms and / or programmed stops, for example, to avoid the formation of said atollo.
  • Fig. 1 shows a scheme of the vibration detection and analysis system, according to a preferred embodiment of the invention.
  • Fig. 2 shows a diagram of a chute with the distribution of sensors thereon, according to a preferred embodiment of the invention.
  • Fig. 3 shows a diagram of the chute of Fig. 2 identifying the energy patterns of the chute during the formation of an atoll.
  • Fig. 4 shows a scheme with the architecture of the solution, according to a first preferred embodiment of the invention.
  • Fig. 5 shows a schematic with the architecture of the solution, according to a second preferred embodiment of the invention.
  • Fig. 6 shows a diagram of a vibration analysis for faults in the structure of the chute.
  • the accelerometers 12a-12h and 14a-14h grouped into a first and second group of sensors, respectively, are connected through sensor bypass boxes 16a-16b, to an analysis system of vibration 18, such as for example the CSI Model 6500, which is interconnected with an expert system and then a distributed control system (DCS) 20 and with an operator display device 22.
  • an analysis system of vibration 18 such as for example the CSI Model 6500, which is interconnected with an expert system and then a distributed control system (DCS) 20 and with an operator display device 22.
  • DCS distributed control system
  • the vibration analysis system 18 includes an analog-digital converter (ADC) 24, which oversamples the vibration signals of the two sets of accelerometers of the previous example, to generate digital vibration data.
  • ADC analog-digital converter
  • the vibration data Each accelerometer is digitally processed in a parallel processing channel separate from the vibration analysis system 18. To simplify Fig. 1, only two processing channels are represented, one for the processing data of the first level accelerometers ( First Group of Sensors) and one for the processing data of the accelerometers of a second level (Second Group of Sensors).
  • a general vibration processor 28a In the flow processing channel corresponding to the first level, a general vibration processor 28a generates general scalar vibration values, which indicate the general vibration energy detected by the accelerometers of the first level. For some data analysis and plotting or rendering operations, a bandpass filter 26a filters the general vibration data of the stream to generate limited bandpass data in the 0-10 kHz band, for example. In the flow processing channel corresponding to the second level, a general vibration processor 28b generates general scalar vibration values, which indicate the general vibration energy detected by the accelerometers of the first level. For some data analysis and plotting operations, a bandpass filter 26b filters the general vibration data of the stream to generate limited bandpass data in the 500-2500 Hz band, for example.
  • the general vibration values at the output of the general vibration processors 28a and 28b can be converted to frequency spectra based on Fast Fourier Transform (FFT) processing for plotting or plotting on the operator's monitor 22.
  • FFT Fast Fourier Transform
  • the general vibration values can be represented or plotted in time domain format on the monitor 22.
  • the vibration data at the output of the general vibration processors 28a and 28b are provided to a comparison module 30, which includes logic to compare scalar vibration energy levels of the accelerometer sets of both levels, to detect harmful conditions, such as agglomerations or atolls.
  • the control signals of the comparison module 30 are provided to the distributed control system 20, for use in controlling the operation of the chute feed, as described in detail below.
  • the comparison module 30 or expert system compares the baseline and historical vibration levels and compares the vibration signals of the accelerometer sets of both levels at the same time and at different times, to make decisions about the control of the operating conditions of the chute feed.
  • the analysis of the vibration data provides information that adds knowledge and value to a plurality of process measurements that come from other sources.
  • the vibration data are preferably combined with contributions from the interdependent process, to define a reliable process control, for the chutes used in the different operations, for example, mining.
  • the selective reduction of oversampling data provides significant information about the movements of material within the chute.
  • the vibration analysis system 18 executes software to analyze the oversampled data using methods described in the publication of the American Patent No. 2014/0324367, entitled “Selective Reduction and Analysis of the Oversampled Data”("the Publication '367 "), which is incorporated into this document entirely by reference.
  • Selective reduction methods are preferably applied to discern and characterize the conditions within the chutes, including agglomeration and atolls, and are precursors to those and other chutes processing conditions.
  • the selective reduction is implemented in the vibration analysis system 18 by collecting oversampled data for a block of time, such as for 10 seconds or 100 seconds or another regular oversampled interval.
  • the complete data block is analyzed at a sampling interval, using the methods disclosed in Publication '367.
  • the frequency analysis of information within each sampling interval preferably focuses on the resonance frequencies of the chute structure, to detect changes in amplitude and to detect modulation, since the vertices of the process add, subtract and align with those natural resonance frequencies.
  • the software executed by the vibration analysis system 18, analyzes the statistics of selective reduction for all or for a part of the sampling intervals.
  • the analysis of data attributes within the sampling intervals is particularly useful for distinguishing between operating states and process changes.
  • an impact test is used to determine one or multiple structural resonance characteristics in the vicinity of the accelerometers of the first group 12a-12h and of the accelerometers of the second group 14a-14h for a given chute, wherein both groups they may correspond to different levels in the chute.
  • Impact test is a preferred technique because it is typically conducted using negative linear averages, such as when performing a series of impacts (such as twelve), the large amount of vibration energy from most other sources, such as process materials moving through the running chute, it is subtracted leaving only the characteristic of the resonance response to the impacts of the impact test.
  • the vibration analysis system 18 Based on the resonance frequencies, damping and response information, the vibration analysis system 18 provides information to an operator about where the greatest multiplication of the vibration frequency information detected by the accelerometers, the smallest and the intermediate can be expected. This information can be provided as a scalar value through the Modbus interface.
  • Table 1 establishes characteristics of the process and related physical responses, together with the expected responses of the sensors and time lapses.
  • the behavior of the chute can be characterized by the monitoring of energy through its structure with a defined number of vibration sensors arranged on its outside in a certain distribution, as for example shown in Fig. 2. This allows to determine , the evolution of the development of the atolls in time, ending with the exact and precise moment (without false positives) in which the chute is stuck. Knowing the evolution of the development of the atolls enables preventive control strategies and avoids losses and unforeseen failures, with all the consequences that this implies in operational continuity and productivity.
  • the material flow changes until the chutes are blocked can be detected online, in real time, in a simple and non-invasive way, using specific sensors attached to the outer shell of the chutes.
  • its signals can be transmitted in wire or wireless form and processed remotely in control systems that emit alarms for the prompt action and resolution of problems.
  • Fig. 3 shows a diagram of the energy patterns measured by the sensors located in a chute 10, during normal operation and during the formation of an agglomeration or atoll in its interior until the collision or blocking of the chute occurs 10.
  • graph 101 shows the amplitude in the vibration in time, measured by the sensors arranged in the area receiving the impact of the mineral, identifying greater amplitudes of vibration in that area compared to those measured by the rest of the sensors , in fact, in graph 102 the amplitudes of vibration in time measured by the sensors arranged in the middle zone of the chute 10 are shown.
  • FIG. 103 of Fig. 3 a transition zone is shown in the vibrations given by the formation of the wind, where the amplitude of measured vibration decreases over time giving indications of the formation of the wind as shown in the graph, where the amplitude of vibration 113 corresponds to the normal vibratory behavior of the chute 10 and the amplitude of vibration 123 corresponds to the vibratory behavior that identifies the beginning of the atollo.
  • the graph 104 of Fig. 3 shows the amplitude of vibration in time when the chute 10 is blocked, that is, when the atollo gives rise to the complete blockage of the output of the chute.
  • the solution proposes to identify, by changing the vibratory behavior, the detachment of internal coating plates, premature wear of coatings, looseness of coatings, damage to the structure of the chute, looseness in the chute structure and other types of failures related to the structural integrity of the chute, allowing to carry out the respective control and correction actions to avoid that failures mean loss of productivity.
  • this approach also allows to characterize the wear of the chute over time, detecting high impact areas of material while it flows or circulates through the chute. In this sense, it is possible to determine the position and forces of the impact loads on the internal walls of the chute, in addition to the damages indicated above.
  • This information will allow preventive maintenance actions to be taken, reinforcing high-impact areas or generating replacement plans for materials with frequencies determined according to the type of chute zone (low, medium or high impact, for example). Then, the proposed solution allows to completely characterize the behavior of the chute by analyzing its vibrations, not only in terms of predicting the formation of atolls inside the chute, but also in terms of maximizing its operation during its useful life .
  • one of the main objectives of the solution is to reduce the number of false positives and reduce the detention time resulting from the atolls.
  • measurement indicators are proposed that are used in the prediction of atolls and / or faults, in such a way that the requirements for decreasing the number of stops due to false atolls and the reduction of detention time due to atolls are met. among other requirements that satisfies the solution
  • the signals coming from the accelerometers 12a-12h, 14a-14h, ... installed in strategic positions on the chute housing are sent in wired or wireless form to the vibration collector 42, which it delivers a first processing to the signals, for which a connection box 41 can be used that gathers the signals from the sensors.
  • this information is received by the expert system 43, which applies predefined rules including parameters of the process in which the chute operates (speed of the conveyor belt, load, type of material, etc.) coming from a historian 44 or from the same operation control system, such as a control system distributed (DCS).
  • DCS control system distributed
  • the alarms generated by the expert system are sent to the DCS or similar (PLC) to take action on the components that participate in the process and that require to be intervened to avoid the atolls or problems in the operation / condition of the chute.
  • PLC DCS or similar
  • these alarms can be historicized. It is important to note that communications between the components of the solution can be made based on different communication protocols such as Modbus TCP and / or OPC, selecting the most appropriate.
  • the architecture of the solution including modality with failure analysis is used in a similar way to that previously presented, using computational analysis to process the information, by means of a specific analysis software 51 , and associating the vibration values with the different operating factors of the chute, for example, distribution of load 52 on the internal surfaces of the chute, force of impact of the load 53, wear 54, looseness of the structure 55, looseness of plates of wear 56, etc.
  • This solution provides information on energy levels on the structure of the chute that can be associated with early detection of damage to the structure of the chute and looseness or dropping of internal cladding plates.
  • specialized processing units 57 are used that receive the signal from the sensors 12a-12h, 14a-14h, ... and deliver it to the analysis software 51.
  • Fig. 6 shows an example of the processing or analysis of vibrations on chute structure faults, which can be obtained from a specific analysis software 51.
  • a specific analysis software 51 it is possible to obtain graphic representations of impact zones, as exemplified in the graph of position 60 and in the evolution of vibrations of graphs 61 to 64, which exemplify the behavior of a portion of chute 10.

Abstract

The invention relates to an optimiser for transfer funnels, characterised in that it comprises a monitoring and control system implemented in the transfer funnels, monitoring the operation and state of said devices, thus allowing control actions to be executed by predicting events linked to an operation and by sending alerts to different control systems integrated into the operation line of the transfer funnel. According to the invention, the monitoring and control system comprises a set of vibration sensors disposed on the external surface of the funnel, a vibration analysis system, operating information and an expert system. The set of vibration sensors includes multiple vibration sensors placed at different heights, levels or layers of the funnel, the sensors generating a plurality of analogue vibration signals of the flow of material inside the funnel.

Description

OPTIMIZADOR PARA CHUTES DE TRANSFERENCIA  OPTIMIZER FOR TRANSFER CHUTES
MEMORIA DESCRIPTIVA DESCRIPTIVE MEMORY
En el presente texto descriptivo se presenta una solución denominada "Optimizador para In this descriptive text we present a solution called "Optimizer for
Chutes de Transferencia" o "Transfer Chutes Optimizer", dirigida a monitorear y controlar el estado y operación de chutes de transferencia, permitiendo predecir el comportamiento de los mismos en el tiempo y alertar tempranamente la ocurrencia de fallas. Además, la solución busca que su implementación sea sencilla y reduciendo la intervención de los equipos a monitorear. Antecedentes de la solución Transfer Chutes "or" Transfer Chutes Optimizer ", aimed at monitoring and controlling the status and operation of transfer chutes, allowing to predict the behavior of them over time and to alert early the occurrence of faults. implementation is simple and reducing the intervention of the equipment to be monitored.
Los chutes de transferencia son equipos empleados principalmente para recibir un material, insumo y/o producto desde un primer lugar y dirigirlo a un segundo o más lugares. Para efectos de la presente descripción se utilizará la expresión "material" para definir todo elemento que circula a través de los chutes de transferencia.  Transfer chutes are equipment used mainly to receive a material, input and / or product from a first place and direct it to a second or more places. For purposes of the present description, the expression "material" will be used to define any element that circulates through the transfer chutes.
Los chutes son empleados en distintas aplicaciones, siendo una de las principales el transporte de minerales en minería. Otras aplicaciones corresponden a las líneas de producción en el ensamblaje de productos, líneas de despacho y/o líneas de disposición de materiales. En efecto, los chutes de transferencia se usan en múltiples aplicaciones donde se requiere dirigir material desde un punto hacia uno o varios puntos, en donde dicho material circula a través del chute principalmente mediante gravedad. En este sentido, los chutes que forman parte de distintas aplicaciones poseen prácticamente la misma estructura esencial, que suele ser del tipo embudo con una o más entradas y salidas.  The chutes are used in different applications, being one of the main mineral transport in mining. Other applications correspond to the production lines in the assembly of products, dispatch lines and / or material disposal lines. In fact, the chutes of transfer are used in multiple applications where it is required to direct material from a point to one or several points, where said material circulates through the chute mainly by gravity. In this sense, the chutes that are part of different applications have practically the same essential structure, which is usually of the funnel type with one or more inputs and outputs.
En este contexto, uno de los principales problemas que presentan los chutes de transferencia durante su operación es la ocurrencia de interrupciones en la circulación del material que pasa a través del chute. Dichas interrupciones en la circulación se denominan comúnmente atollos, atascos, "clogging" o incluso "plugging", además de otros nombres técnicos específicos de cada industria, siendo una de las principales fallas operativas de los chutes de transferencia. Los atollos suelen formarse por la acumulación de material sobre las superficies internas del chute, acumulación que aumenta en el tiempo hasta que se genera una especie de tapón que reduce y/o bloquea la libre circulación del material hacia la o las salidas del chute. Esta aglomeración puede deberse por las propiedades del material que ingresa al chute y/o por problemas en la disposición de componentes o por parámetros de operación fuera de rangos normales. Además, otro tipo de problemas en los chutes de transferencia se asocian a fallas en la estructura de los mismos, dada por el desprendimiento de piezas, por ejemplo, revestimientos internos, producto del impacto del material con las superficies internas del chute y/o producto de la continua operación, fallas que pueden resultar en el deterioro del equipo, equipos aguas abajo y/o en la formación de atollos al interior del chute. In this context, one of the main problems that the transfer chutes present during their operation is the occurrence of interruptions in the circulation of the material that passes through the chute. Such interruptions in circulation are commonly referred to as atolls, jams, "clogging" or even "plugging", in addition to other names specific technicians of each industry, being one of the main operational failures of transfer chutes. The atolls are usually formed by the accumulation of material on the internal surfaces of the chute, accumulation that increases over time until a kind of plug is generated that reduces and / or blocks the free movement of the material towards the outlet (s) of the chute. This agglomeration may be due to the properties of the material entering the chute and / or due to problems in the arrangement of components or operating parameters outside normal ranges. In addition, other problems in transfer chutes are associated with faults in the structure of the same, given by the detachment of pieces, for example, internal coatings, product of the impact of the material with the internal surfaces of the chute and / or product of the continuous operation, faults that can result in the deterioration of equipment, equipment downstream and / or in the formation of atolls inside the chute.
En este contexto, existen variadas soluciones que buscan detectar la ocurrencia de atollos al interior de los chutes de transferencia, encontrándose dichas soluciones principalmente dirigidas a "observar" el interior del chute, mediante instrumentación específica. Dicha "observación" resulta en la detección de los atollos cuando estos son detectados por la instrumentación utilizada, que puede ser sensores de microondas dirigidos al interior del chute, cámaras para la obtención de imágenes, tilt switches, etc. Si bien estas soluciones suelen permitir la detección de la ocurrencia de un atollo, tienen grandes desventajas en lo que respecta a falsos positivos, lo que perjudica severamente la productividad por detenciones innecesarias. Además, este tipo de soluciones son incapaces de predecir la formación de atollos al interior del chute, así como también no se encuentran dirigidas a proporcionar alertas tempranas cuando ello ocurre.  In this context, there are several solutions that seek to detect the occurrence of atolls inside the transfer chutes, these solutions being mainly aimed at "observing" the interior of the chute, through specific instrumentation. This "observation" results in the detection of the atolls when they are detected by the instrumentation used, which may be microwave sensors directed inside the chute, cameras for obtaining images, tilt switches, etc. Although these solutions usually allow the detection of the occurrence of an event, they have great disadvantages when it comes to false positives, which severely damages productivity due to unnecessary detentions. In addition, these types of solutions are unable to predict the formation of atolls inside the chute, as well as they are not aimed at providing early warnings when this occurs.
En efecto, la dinámica operativa de los chutes se asocia a un flujo continuo de material que ingresa al mismo por una o más aberturas, saliendo en las direcciones establecidas por las una o más salidas que posea dicho equipo, lo que actúa usualmente como una pantalla en la "observación" interior del chute. Además, dependiendo del tipo de material que es recibido por el chute, pueden presentarse partículas en suspensión que obstruyen la abertura del mismo, bloqueando la "observación" de la instrumentación dirigida a detectar los atollos. Gran parte de estas soluciones destinadas a la detección de atollo, requieren ser instaladas al interior del chute, terminando dañadas o perdiendo su capacidad de sensar. Luego, las soluciones comunes para detectar atollos enfrentan la dificultad de confundir el propio flujo de material o la presencia de partículas en suspensión con la formación de atollos al interior del chute, resultando en múltiples falsos positivos durante la operación de este equipo. In effect, the operational dynamics of the chutes is associated with a continuous flow of material that enters it through one or more openings, leaving in the directions established by the one or more outputs that the equipment has, which usually acts as a screen in the "observation" inside the chute. In addition, depending on the type of material that is received by the chute, particles in suspension may appear that obstruct the opening thereof, blocking the "observation" of the instrumentation aimed at detecting the atolls. Many of these solutions aimed at the detection of atollo, require to be installed inside the chute, ending up damaged or losing its ability to sense. Then, common solutions to detect atolls face the difficulty of confusing the material flow itself or the presence of particles in suspension with the formation of atolls inside the chute, resulting in multiple false positives during the operation of this equipment.
Por lo tanto, se requiere de un sistema de monitoreo y control de chutes de transferencia que permita no solo detectar en forma confiable la formación de atollos al interior de un chute, sino que también permita predecir la formación de dichos atollos en la medida que se generan las condiciones de funcionamiento que propician los mismos, permitiendo establecer acciones de control que aumenten la disponibilidad del chute, minimizando los falsos positivos.  Therefore, a transfer chutes monitoring and control system is required that allows not only to reliably detect the formation of atolls inside a chute, but also to predict the formation of said atolls as long as they generate the operating conditions that favor them, allowing to establish control actions that increase the availability of chute, minimizing false positives.
Además, de acuerdo con una solución alternativa se hace necesario contar con una solución integrada que no solo prediga la formación de atollos, sino que también permita detectar fallas en el chute.  In addition, according to an alternative solution it is necessary to have an integrated solution that not only predicts the formation of atolls, but also allows detecting failures in the chute.
Descripción de la solución Description of the solution
La solución planteada para resolver los problemas existentes actualmente se dirige a un optimizador para chutes de transferencia que posee un sistema de monitoreo y control de chutes de transferencia que emplea sensores de vibración dispuestos en la superficie externa del chute para monitorizar el comportamiento vibratorio del mismo, o al menos de ciertas zonas del chute, con el objeto de obtener datos del comportamiento vibratorio y procesarlos para identificar estados de operación del chute, los que pueden ser indicadores de la formación de atollos en su interior. Los sensores pueden ser alambrados o inalámbricos. Además, la información captada por los sensores permite detectar en forma temprana fallas asociadas al deterioro del chute, como desprendimiento de revestimientos internos y/o cualquier daño en el equipo que resulte en un cambio en el comportamiento vibratorio de la superficie sensada. En este contexto, uno de los objetivos del optimizador para chutes de transferencia es proponer una solución de automatización de filosofía predictiva, remota, no invasiva, fácil de implementar, de bajo mantenimiento y segura para las personas y los activos (chutes, correas, mineral) The solution proposed to solve the current problems is addressed to a transfer chutes optimizer that has a transfer chutes monitoring and control system that uses vibration sensors arranged on the external surface of the chute to monitor the vibratory behavior of the chute, or at least of certain zones of the chute, in order to obtain data of the vibratory behavior and process them to identify operating states of the chute, which may be indicators of the formation of atolls inside. The sensors can be wired or wireless. In addition, the information captured by the sensors allows early detection of faults associated with the deterioration of the chute, such as detachment of internal coatings and / or any damage to the equipment that results in a change in the vibratory behavior of the sensed surface. In this context, one of the objectives of the optimizer for transfer chutes is to propose a predictive, remote, non-invasive, easy-to-implement, low-maintenance and secure philosophy solution for people and assets (chutes, belts, ore). )
Otro objetivo es proponer una solución orientada a minimizar o eliminar pérdidas de productividad, tales como las causadas por discontinuidad operacional y pérdidas de producción, eventos de atollos o atascos ("Plugging") sin detección temprana o falsa detección, por tiempos excesivos en desatollos y/o limpieza de los chutes, y por impactos negativos en HSEC (Health/Safety/Environment/Community). Es decir, evitando paradas no planeadas en base a falsos atollos y minimizar horas de detención no planeadas (hacia zero unplanned downtime).  Another objective is to propose a solution aimed at minimizing or eliminating productivity losses, such as those caused by operational discontinuity and production losses, events of atolls or jamming ("Plugging") without early detection or false detection, for excessive times in unbalances and / or chutes cleaning, and negative impacts on HSEC (Health / Safety / Environment / Community). That is, avoiding unplanned stops based on false atolls and minimizing unplanned detention hours (towards zero unplanned downtime).
Otro objetivo de la solución es monitorear remotamente, en línea y en tiempo real, el flujo de mineral por el chute de traspaso, posibilitando con ello conocer dinámicamente patrones de flujo de material conducentes a atollos significativos.  Another objective of the solution is to remotely monitor, online and in real time, the flow of ore through the transfer chute, thus enabling to dynamically know material flow patterns leading to significant atolls.
Otro objetivo de la solución es posibilitar modelar la evolución de los atollos en el tiempo, permitiendo así la prevención o la alerta temprana de su ocurrencia - antes o al momento - que ello ocurra (con mínimos o nulos falsos positivos).  Another objective of the solution is to make it possible to model the evolution of the atolls over time, thus allowing the prevention or early warning of their occurrence - before or at the moment - that this occurs (with false or false minimums).
Otro objetivo de la solución es tomar acciones de remediación inmediatas cuando se producen atollos, mediante la generación de alertas en línea hacia los sistemas de control de la operación.  Another objective of the solution is to take immediate remediation actions when atolls occur, by generating online alerts to the operation's control systems.
Otro objetivo de la solución es que ella mida con precisión y que no genere falsas alarmas, que sea robusta frente a variaciones de flujo de material y polvo, que no se vea afectada por ambientes corrosivos del mineral en las correas y chutes, que en su estrategia de control apunte a la detención de la operación en forma oportuna para evitar derrames de mineral o para no agravar más la condición de atollo Otro objetivo de la solución es detectar en forma temprana la ocurrencia de fallas en el chute de transferencia, emitiéndose alertas tempranas que permitan la pronta corrección de la falla, minimizando los tiempos de parada y las pérdidas de productividad. Another objective of the solution is that it measure accurately and that it does not generate false alarms, that it is robust against variations in the flow of material and dust, that is not affected by corrosive environments of the ore in belts and chutes, that in its Control strategy aims at stopping the operation in a timely manner to prevent mineral spills or to not further aggravate the condition of atollo Another objective of the solution is to detect early the occurrence of faults in the transfer chute, issuing early warnings that allow the early correction of the failure, minimizing downtime and productivity losses.
Los objetivos anteriores se logran mediante el optimizador para chutes de transferencia que se describe en el presente documento, en donde dicho optimizador está formado por un sistema de monitoreo y control que se implementa en los chutes de transferencia, monitorizando tanto la operación como el estado de dichos equipos, permitiendo ejercer acciones de control mediante la predicción de eventos ligados a la operación y mediante el envío de alarmas a los distintos sistemas de control que se integran en la línea de operación.  The above objectives are achieved by the transfer chutes optimizer described herein, wherein said optimizer is formed by a monitoring and control system that is implemented in the transfer chutes, monitoring both the operation and the status of the transfer. These equipment, allowing to exercise control actions by predicting events linked to the operation and by sending alarms to the different control systems that are integrated into the operation line.
En este sentido, el sistema de monitoreo y control de chutes de transferencia comprende múltiples sensores de vibración (alámbricos o inalámbricos) dispuestos en la superficie externa del chute, para monitorizar el comportamiento vibratorio del mismo, o al menos de ciertas zonas de su superficie, con el objeto de obtener datos del comportamiento vibratorio del chute, complementarlos con datos operacionales provenientes de historizadores (base de datos que almacena historización de los datos) , el mismo sistema de control de la operación u otro (velocidad de cinta, carga, etc.) y procesarlos para identificar estados de operación del equipo. Dichos estados de operación pueden ser indicadores de la formación de atollos en el interior del chute, producto de los cambios vibratorios de las superficies monitoreadas. Además, la información captada por los sensores de vibración permite detectar en forma temprana fallas asociadas al deterioro del chute, como desprendimiento de revestimientos internos y/o cualquier daño en el equipo que resulte en un cambio del comportamiento vibratorio de la o las zonas medidas.  In this sense, the system of monitoring and control of transfer chutes comprises multiple vibration sensors (wired or wireless) arranged on the external surface of the chute, to monitor the vibratory behavior of the same, or at least of certain areas of its surface, in order to obtain data on the vibratory behavior of the chute, complement them with operational data from historians (database that stores historical data), the same control system of the operation or another (tape speed, load, etc.). ) and process them to identify equipment operation states. These states of operation can be indicators of the formation of atolls inside the chute, product of the vibratory changes of the monitored surfaces. In addition, the information captured by the vibration sensors allows the early detection of faults associated with the deterioration of the chute, such as detachment of internal coatings and / or any damage to the equipment that results in a change in the vibratory behavior of the measured zone or zones.
Luego, empleando los datos vibratorios que identifican el estado de operación del chute y comparándolos con datos vibratorios durante operación normal, es posible identificar cambios en los estados de operación y discernir si dichos cambios son indicadores de la formación de acumulaciones de material al interior del chute, que pueden resultar en un atollo o bloqueo del mismo. Con ello se logra predecir la formación de los atollos durante los inicios de su formación, detectándose los patrones de cambio del comportamiento vibratorio del chute asociados a la formación temprana de acumulaciones de material en su interior, que finalmente resultan en atollos si no se realizan acciones de control correctivas. Adicionalmente, los datos vibratorios del chute también permiten detectar la ocurrencia de fallas en el mismo, fallas asociadas a cambios vibratorios en el chute o en parte del mismo, como por ejemplo debido al desgaste o desprendimiento de un revestimiento interno. Then, using the vibratory data that identify the operating state of the chute and comparing them with vibratory data during normal operation, it is possible to identify changes in the operating states and discern if said changes are indicators of the formation of accumulations of material inside the chute. , which may result in an attack or blockage of same. With this it is possible to predict the formation of the atolls during the beginning of its formation, detecting the patterns of change of the vibratory behavior of the chute associated with the early formation of accumulations of material inside, which eventually result in atolls if no actions are performed of corrective control. Additionally, the vibratory data of the chute also allow detecting the occurrence of faults in the same, faults associated with vibratory changes in the chute or in part of it, as for example due to the wear or detachment of an internal coating.
Uno de los aportes más relevantes de la solución es que caracteriza en línea la evolución del flujo de mineral a través del chute, y en base a ello posibilita con alta precisión y oportunidad la detección temprana de cambios de estado y particularmente cuando los chutes comienzan a obstruirse a causa de la formación de aglomeraciones que llevan a atollos. Por esa condición, también conocida como "plugging", el chute se bloquea impidiéndose la circulación de mineral, debiéndose detener la línea de producción para desbloquear el chute.  One of the most relevant contributions of the solution is that it characterizes in line the evolution of the mineral flow through the chute, and based on this it allows with high precision and opportunity the early detection of changes of state and particularly when the chutes begin to obstructed because of the formation of agglomerations leading to atolls. Due to this condition, also known as "plugging", the chute is blocked, preventing the circulation of ore, and the production line must be stopped to unblock the chute.
Como se ha indicado, los objetivos de la solución y otras necesidades se cubren con un sistema de medición de vibración del chute que incluye un set de sensores de vibración dispuestos sobre la superficie externa del chute, un sistema de análisis de vibración, información operacional y un sistema experto. En una modalidad preferida, el set de sensores de vibración incluye múltiples sensores de vibración emplazados a distintas alturas, niveles o capas del chute, en donde dichos sensores generan una pluralidad de señales de vibración análogas del flujo de material al interior del chute.  As indicated, the objectives of the solution and other needs are covered by a chute vibration measurement system that includes a set of vibration sensors arranged on the external surface of the chute, a vibration analysis system, operational information and an expert system. In a preferred embodiment, the set of vibration sensors includes multiple vibration sensors located at different heights, levels or layers of the chute, wherein said sensors generate a plurality of analogous vibration signals of the material flow into the chute.
El sistema de análisis de vibración incluye un convertidor análogo-digital y uno o más canales de procesamiento de vibración general. El convertidor análogo-digital muestrea las señales análogas de vibración del flujo de material al interior del chute a una frecuencia de muestreo fija y convierte las señales de vibración del flujo en señales de vibración digitales. Uno o más canales de procesamiento de vibración procesan las señales digitales para generar valores de vibración escalares representativos del paso del flujo interior en las distintas zonas sensadas o medidas del chute. Para esto, se calcula la sumatoria de la energía vibratoria total en el rango de frecuencias de interés. The vibration analysis system includes an analog-digital converter and one or more general vibration processing channels. The analog-digital converter samples the analog vibration signals of the material flow into the chute at a fixed sampling frequency and converts the vibration signals of the flow into digital vibration signals. One or more vibration processing channels process the digital signals to generate scalar vibration values representative of the passage of the internal flow in the different sensed zones or chute measurements. For this, the sum of the total vibrational energy in the frequency range of interest is calculated.
En algunas modalidades, se proporcionan uno o más filtros paso banda para el filtrado de las señales digitales, para generar señales de vibración digitales limitadas de paso banda.  In some embodiments, one or more bandpass filters are provided for filtering the digital signals to generate limited bandpass digital vibration signals.
En algunas modalidades, el sistema experto opera comunicado a un sistema de control que actúa sobre la operación del proceso en base, al menos en parte, a los valores de vibración escalares del flujo.  In some embodiments, the expert system operates communicated to a control system that acts on the operation of the process based, at least in part, on the scalar vibration values of the flow.
En algunas modalidades, los sensores de vibración están dispuestos de manera que el eje sensor de cada sensor de vibración está sustancialmente perpendicular al eje del flujo del chute al cual está unido.  In some embodiments, the vibration sensors are arranged so that the sensor axis of each vibration sensor is substantially perpendicular to the axis of the chute flow to which it is attached.
En algunas modalidades, el sistema de análisis de vibración incluye un módulo de comparación o sistema experto que compara uno o más de:  In some embodiments, the vibration analysis system includes a comparison module or expert system that compares one or more of:
Los valores de vibración escalar del flujo provenientes de un primer set de sensores, medidos durante un primer período de tiempo, con los valores de vibración escalar del flujo provenientes de un segundo set de sensores, medidos durante el primer período de tiempo;  The values of scalar vibration of the flow coming from a first set of sensors, measured during a first period of time, with the values of scalar vibration of the flow coming from a second set of sensors, measured during the first period of time;
Los valores de vibración escalar del flujo provenientes de un set de sensores, medidos durante el primer período de tiempo, con los valores de vibración escalar del flujo provenientes del mismo set de sensores, medidos durante un segundo período de tiempo, que es diferente al primer período de tiempo; y  The scalar vibration values of the flow coming from a set of sensors, measured during the first period of time, with the values of scalar vibration of the flow coming from the same set of sensors, measured during a second period of time, which is different from the first time frame; Y
Los valores de vibración escalar del flujo provenientes de un set de sensores, medidos durante el primer período de tiempo, con los valores de vibración escalar base del flujo provenientes del mismo set de sensores, medidos durante el período de tiempo cuando uno o más chutes operaban en condiciones normales. En base a una o más de estas comparaciones, más la información proveniente de la operación, el módulo de comparación genera información de control que puede ser utilizada en el control de inicio o en la toma de decisiones acerca del control del chute. The scalar vibration values of the flow coming from a set of sensors, measured during the first period of time, with the scalar base vibration values of the flow coming from the same set of sensors, measured during the period of time when one or more chutes operated under normal conditions. Based on one or more of these comparisons, plus the information coming from the operation, the comparison module generates control information that can be used in the start control or in making decisions about the control of the chute.
En algunas modalidades, el módulo de comparación compara los valores de vibración escalar del flujo al interior del chute en un rango de frecuencia preferente de 0 kHz a 10 kHz, medidos durante el primer período de tiempo, con los valores de vibración escalar del flujo base en el mismo rango de frecuencia, medidos durante el período de tiempo cuando el chute operaba en condiciones normales.  In some embodiments, the comparison module compares the scalar vibration values of the flux within the chute in a preferred frequency range of 0 kHz to 10 kHz, measured during the first time period, with the scalar vibration values of the base flux in the same frequency range, measured during the period of time when the chute operated under normal conditions.
En algunas modalidades, el módulo de comparación genera información de control para controlar la operación de la correa transportadora, cuando los niveles de energía de los valores de vibración escalar del flujo en el rango de frecuencia de 0 kHz a 10 Hz, medidos durante el primer período de tiempo, son diferentes que los niveles de energía de los valores de vibración escalar del flujo base en el mismo rango de frecuencia, medidos durante el período de tiempo cuando el chute operaba en condiciones normales. La información de control puede comprender un mensaje de alerta que informa a un operador en relación a la condición de atollo que puede estar ocurriendo en el flujo de uno o más chutes o la información de control puede comprender una señal de control que inicia la detención de la alimentación.  In some embodiments, the comparison module generates control information to control the operation of the conveyor belt, when the energy levels of the scalar vibration values of the flow in the frequency range from 0 kHz to 10 Hz, measured during the first period of time, are different than the energy levels of the scalar vibration values of the base flow in the same frequency range, measured during the period of time when the chute operated under normal conditions. The control information may comprise an alert message informing an operator in relation to the atollo condition that may be occurring in the flow of one or more chutes or the control information may comprise a control signal that initiates the arrest of feeding.
En algunas modalidades, el módulo de comparación genera información de control para controlar la operación de una o más de las correas transportadoras asociadas al proceso, cuando:  In some embodiments, the comparison module generates control information to control the operation of one or more of the conveyor belts associated with the process, when:
- Los niveles de energía de los valores de vibración escalar del flujo de salida, medidos durante el primer período de tiempo, cambian con respecto a los niveles de energía de los valores de vibración escalar del flujo de salida, medidos durante el segundo período de tiempo, el cual ocurre después del primer período de tiempo, y/o  - The energy levels of the scalar vibration values of the output flow, measured during the first period of time, change with respect to the energy levels of the scalar vibration values of the output flow, measured during the second period of time , which occurs after the first period of time, and / or
Los niveles de energía de los valores de vibración escalar del flujo de entrada, medidos durante el primer período de tiempo, cambian con respecto a los niveles de energía de los valores de vibración escalar del flujo de entrada, medidos durante el segundo período de tiempo. The energy levels of the scalar vibration values of the inflow, measured during the first period of time, change with respect to the energy levels of the Scalar vibration values of the inflow, measured during the second period of time.
Dicho cambio de los niveles de energía de los valores de vibración escalar del flujo de salida y/o de entrada, pueden indicar una condición de obstrucción del chute. La información de control puede comprender un mensaje de alerta que informa al operador en relación a la condición de obstrucción del chute o la información de control puede comprender una señal de control que inicia la detención de la correa o de la alimentación al chute. Por flujos de entrada y salida se debe entender a los efectos del flujo de mineral que circula a través del chute en las zonas de entrada y salida del mismo, en donde el chute en su totalidad estaría representado por dichas zonas, las que presentan una disposición de niveles de sensores dispuestos para caracterizar las vibraciones de las mismas.  Said change in the energy levels of the scalar vibration values of the output and / or input flow may indicate a condition of blockage of the chute. The control information may comprise an alert message informing the operator in relation to the chute obstruction condition or the control information may comprise a control signal that initiates the belt stop or chute feed. For inflows and outflows should be understood to the effects of the flow of ore that circulates through the chute in the entry and exit areas thereof, where the chute in its entirety would be represented by those areas, which present a provision of levels of sensors arranged to characterize the vibrations of the same.
En otro aspecto, la invención proporciona un método para medir y analizar la vibración asociada a un chute. Una modalidad preferida del método incluye las siguientes etapas:  In another aspect, the invention provides a method for measuring and analyzing the vibration associated with a chute. A preferred embodiment of the method includes the following steps:
a) detectar la vibración asociada a una primera porción del flujo al interior del chute, utilizando uno o más sensores de vibración unidos a una primera zona del chute, por ejemplo, una zona cercana a la entrada del chute;  a) detecting the vibration associated with a first portion of the flow inside the chute, using one or more vibration sensors attached to a first zone of the chute, for example, an area near the entrance of the chute;
b) los sensores de vibración generan una señal análoga de vibración del flujo, indicativa de la vibración de la primea zona del chute detectada en la etapa (a);  b) the vibration sensors generate an analogous signal of vibration of the flow, indicative of the vibration of the first zone of the chute detected in stage (a);
c) detectar la vibración asociada a una porción del flujo al interior del chute, utilizando uno o más sensores de vibración unidos a una segunda zona del chute, por ejemplo, una zona cercana a la salida del chute;  c) detecting the vibration associated with a portion of the flow inside the chute, using one or more vibration sensors attached to a second zone of the chute, for example, an area near the outlet of the chute;
d) los sensores de vibración generan una segunda señal análoga de vibración del flujo, indicativa de la vibración de la segunda zona del chute detectada en la etapa (c);  d) the vibration sensors generate a second analogous signal of vibration of the flow, indicative of the vibration of the second zone of the chute detected in step (c);
e) muestrear las señales análogas de vibración del flujo en las distintas zonas del chute a una frecuencia de muestreo fija y convertir las señales análogas de vibración del flujo, a señales digitales de vibración del flujo; y f) procesar las señales digitales de vibración del flujo para generar valores de vibración escalar del flujo, que representan la vibración general, medida en la primera y segunda zonas del chute. e) sampling the analog vibration signals of the flow in the different zones of the chute at a fixed sampling frequency and converting the analogous vibration signals of the flow to digital vibration signals of the flow; Y f) processing the digital vibration signals of the flow to generate scalar vibration values of the flow, which represent the general vibration, measured in the first and second chute zones.
En algunas modalidades la solución comprende dividir el chute en más de dos zonas, disponiéndose una pluralidad de sensores asociados a las distintas zonas del chute, dispuestos para caracterizar los niveles de vibración de dichas zonas. En efecto, la cantidad de zonas en las que se divide el chute dependerá de distintos factores, encontrándose entre ellos el tamaño del chute, el tipo de alimentación y descarga, la precisión requerida en la caracterización de su comportamiento, etc.  In some embodiments, the solution comprises splitting the chute into more than two zones, with a plurality of sensors associated with the different chute zones arranged to characterize the vibration levels of said zones. In fact, the number of zones in which the chute is divided will depend on different factors, including the size of the chute, the type of feeding and unloading, the precision required in the characterization of its behavior, etc.
En algunas modalidades, el método incluye proporcionar información de control a un sistema de control distribuido, en base, al menos en parte, a los valores de vibración escalar del flujo.  In some embodiments, the method includes providing control information to a distributed control system, based, at least in part, on the scalar vibration values of the flow.
De acuerdo con otra modalidad, el chute se divide en múltiples zonas (tres o más), dichas zonas definidas por los distintos niveles del chute desde su porción de entrada a su porción de salida, o viceversa. En este sentido, se definen set de sensores de vibración localizados en los distintos niveles del chute, caracterizando el comportamiento vibratorio del mismo en dichos distintos niveles. Luego, la comparación del comportamiento entre los niveles del chute y el procesamiento de los valores de vibración escalares del flujo en dichos niveles permite caracterizar la formación de acumulaciones que derivarán en atollos, información que permite predecir la formación del atollo antes de que ocurra, gestionándose acciones de control integradas, como alarmas y/o detenciones programadas, por ejemplo, para evitar la formación de dicho atollo.  According to another modality, the chute is divided into multiple zones (three or more), said zones defined by the different levels of the chute from its entry portion to its exit portion, or vice versa. In this sense, set of vibration sensors located in the different levels of the chute are defined, characterizing the vibratory behavior of the same in said different levels. Then, the comparison of the behavior between the levels of the chute and the processing of the scalar vibration values of the flow in these levels allows to characterize the formation of accumulations that will result in atolls, information that allows to predict the formation of the wind before it occurs, managing itself integrated control actions, such as alarms and / or programmed stops, for example, to avoid the formation of said atollo.
Cómo se ha esbozado anteriormente, el sistema y método propuestos por esta solución permiten extrapolar la misma al monitoreo y control de varios chutes en una misma línea de proceso, estableciendo un control integral que maximiza la productividad de la línea al mismo tiempo que se minimizan las detenciones por falsos positivos. Breve descripción de las figuras As outlined above, the system and method proposed by this solution allow it to be extrapolated to the monitoring and control of several chutes in the same process line, establishing an integral control that maximizes the line's productivity while minimizing False positive detentions. Brief description of the figures
Como parte de la presente solicitud se presentan las siguientes figuras representativas de la invención, las cuales enseñan modalidades preferentes de la misma y, por lo tanto, no deben considerarse como limitante a la definición de la solicitud.  As part of the present application, the following representative figures of the invention are presented, which teach preferred modalities thereof and, therefore, should not be considered as limiting the definition of the application.
La Fig. 1 muestra un esquema del sistema de detección de vibración y análisis, de acuerdo a una modalidad preferente de la invención.  Fig. 1 shows a scheme of the vibration detection and analysis system, according to a preferred embodiment of the invention.
La Fig. 2 muestra un esquema de un chute con la distribución de sensores sobre el mismo, de acuerdo con una modalidad preferente de la invención.  Fig. 2 shows a diagram of a chute with the distribution of sensors thereon, according to a preferred embodiment of the invention.
La Fig. 3 muestra un esquema del chute de la Fig. 2 identificando los patrones de energía del chute durante la formación de un atollo.  Fig. 3 shows a diagram of the chute of Fig. 2 identifying the energy patterns of the chute during the formation of an atoll.
La Fig. 4 muestra un esquema con la arquitectura de la solución, de acuerdo con una primera modalidad preferente de la invención.  Fig. 4 shows a scheme with the architecture of the solution, according to a first preferred embodiment of the invention.
La Fig. 5 muestra un esquema con la arquitectura de la solución, de acuerdo con una segunda modalidad preferente de la invención.  Fig. 5 shows a schematic with the architecture of the solution, according to a second preferred embodiment of the invention.
La Fig. 6 muestra un esquema de un análisis de vibraciones para fallas en la estructura del chute.  Fig. 6 shows a diagram of a vibration analysis for faults in the structure of the chute.
Descripción de las modalidades preferentes Description of preferred modalities
Según se muestra en la Fig. 1, los acelerómetros 12a-12h y 14a-14h, agrupados en un primer y segundo grupo de sensores, respectivamente, están conectados a través de cajas de derivación de sensores 16a- 16b, a un sistema de análisis de vibración 18, como por ejemplo el CSI Modelo 6500, el cual está interconectado con un sistema experto y luego a un sistema de control distribuido (DCS) 20 y con un dispositivo de visualización del operador 22.  As shown in Fig. 1, the accelerometers 12a-12h and 14a-14h, grouped into a first and second group of sensors, respectively, are connected through sensor bypass boxes 16a-16b, to an analysis system of vibration 18, such as for example the CSI Model 6500, which is interconnected with an expert system and then a distributed control system (DCS) 20 and with an operator display device 22.
El sistema de análisis de vibración 18 incluye un convertidor análogo-digital (ADC) 24, que sobremuestrea las señales de vibración de los dos sets de acelerómetros del ejemplo anterior, para generar datos digitales de vibración. En una modalidad preferida, los datos de vibración digitales de cada acelerómetro son procesados en un canal de procesamiento paralelo separado del sistema de análisis de vibración 18. Para simplificar la Fig. 1, sólo dos canales de procesamiento están representados, uno para los datos de procesamiento de los acelerómetros de un primer nivel (Primer Grupo de Sensores) y uno para los datos de procesamiento de los acelerómetros de un segundo nivel (Segundo Grupo de Sensores). The vibration analysis system 18 includes an analog-digital converter (ADC) 24, which oversamples the vibration signals of the two sets of accelerometers of the previous example, to generate digital vibration data. In a preferred embodiment, the vibration data Each accelerometer is digitally processed in a parallel processing channel separate from the vibration analysis system 18. To simplify Fig. 1, only two processing channels are represented, one for the processing data of the first level accelerometers ( First Group of Sensors) and one for the processing data of the accelerometers of a second level (Second Group of Sensors).
En el canal de procesamiento del flujo correspondiente al primer nivel, un procesador de vibración general 28a genera valores de vibración escalar generales, que indican la energía de vibración general detectada por los acelerómetros del primer nivel. Para algunas operaciones de análisis de datos y ploteado o representación, un filtro paso banda 26a filtra los datos de vibración generales del flujo para generar datos limitados de paso banda en la banda de 0-10 kHz, por ejemplo. En el canal de procesamiento del flujo correspondiente al segundo nivel, un procesador de vibración general 28b genera valores de vibración escalar general, que indican la energía general de vibración detectada por los acelerómetros del primer nivel. Para algunas operaciones de análisis de datos y ploteado, un filtro paso banda 26b, filtra los datos de vibración generales del flujo, para generar datos limitados de paso banda en la banda de 500-2500 Hz, por ejemplo.  In the flow processing channel corresponding to the first level, a general vibration processor 28a generates general scalar vibration values, which indicate the general vibration energy detected by the accelerometers of the first level. For some data analysis and plotting or rendering operations, a bandpass filter 26a filters the general vibration data of the stream to generate limited bandpass data in the 0-10 kHz band, for example. In the flow processing channel corresponding to the second level, a general vibration processor 28b generates general scalar vibration values, which indicate the general vibration energy detected by the accelerometers of the first level. For some data analysis and plotting operations, a bandpass filter 26b filters the general vibration data of the stream to generate limited bandpass data in the 500-2500 Hz band, for example.
Mientras que las bandas de frecuencia de 0-10 kHz y 500-2500 Hz han sido determinadas para que sean apropiadas para los ejemplos del chute descritos en el presente documento, otros chutes pueden presentar energía de vibración en rangos de frecuencia diferentes, debido a la composición estructural, configuraciones y a los materiales que están siendo procesados. De ese modo, el experto en el arte apreciará que las invenciones en el presente documento no se limitan a cualquier modalidad en particular, que involucra cualquier rango de frecuencia de interés en particular. En efecto, los rangos anteriores, así como también cualquier especificación de los parámetros de operación del sistema deben ser considerados como modalidades ejemplificadoras de la solución, ya que la misma puede adaptarse a distintos parámetros sin modificar sus aspectos técnicos esenciales. Los valores de vibración general a la salida de los procesadores de vibración general 28a y 28b, se pueden convertir a espectros de frecuencia en base al procesamiento de Fast Fourier Transform (FFT) para la representación o ploteado en el monitor del operador 22. Alternativamente, los valores de vibración general pueden ser representados o ploteados en formato de dominio de tiempo en el monitor 22. While the frequency bands 0-10 kHz and 500-2500 Hz have been determined to be appropriate for the chute examples described herein, other chutes may exhibit vibration energy in different frequency ranges, due to the structural composition, configurations and the materials that are being processed. Thus, the skilled artisan will appreciate that the inventions herein are not limited to any particular embodiment, which involves any particular frequency range of interest. Indeed, the above ranges, as well as any specification of the operating parameters of the system should be considered as exemplary modalities of the solution, since it can be adapted to different parameters without modifying its essential technical aspects. The general vibration values at the output of the general vibration processors 28a and 28b can be converted to frequency spectra based on Fast Fourier Transform (FFT) processing for plotting or plotting on the operator's monitor 22. Alternatively, the general vibration values can be represented or plotted in time domain format on the monitor 22.
En una modalidad preferida, los datos de vibración a la salida de los procesadores de vibración general 28a y 28b se proporcionan a un módulo de comparación 30, que incluye lógica para comparar niveles de energía de vibración escalar de los sets de acelerómetros de ambos niveles, para detectar condiciones perjudiciales, tales como aglomeraciones o atollos. En una modalidad preferida, las señales de control del módulo de comparación 30 se proporcionan al sistema de control distribuido 20, para su uso en el control de la operación de la alimentación del chute, según se describe en detalle más adelante.  In a preferred embodiment, the vibration data at the output of the general vibration processors 28a and 28b are provided to a comparison module 30, which includes logic to compare scalar vibration energy levels of the accelerometer sets of both levels, to detect harmful conditions, such as agglomerations or atolls. In a preferred embodiment, the control signals of the comparison module 30 are provided to the distributed control system 20, for use in controlling the operation of the chute feed, as described in detail below.
En algunas modalidades, el módulo de comparación 30 o sistema experto compara la línea base y los niveles de vibración histórica y compara las señales de vibración de los sets de acelerómetros de ambos niveles al mismo tiempo y a tiempos diferentes, para tomar decisiones acerca del control de las condiciones de operación de la alimentación del chute. El análisis de los datos de vibración proporciona información que agrega conocimiento y valor a una pluralidad de mediciones del proceso que vienen de otras fuentes. Los datos de vibración son preferentemente combinados con aportes del proceso interdependiente, para definir un control del proceso confiable, para los chutes utilizados en las distintas operaciones, por ejemplo, mineras.  In some embodiments, the comparison module 30 or expert system compares the baseline and historical vibration levels and compares the vibration signals of the accelerometer sets of both levels at the same time and at different times, to make decisions about the control of the operating conditions of the chute feed. The analysis of the vibration data provides information that adds knowledge and value to a plurality of process measurements that come from other sources. The vibration data are preferably combined with contributions from the interdependent process, to define a reliable process control, for the chutes used in the different operations, for example, mining.
En algunas modalidades, la reducción selectiva de los datos de sobremuestreo proporciona información significativa acerca de los movimientos de material dentro del chute. En una modalidad preferida, el sistema de análisis de vibración 18 ejecuta un software para analizar los datos sobremuestreados utilizando métodos descritos en la publicación de la Patente Americana No. 2014/0324367, titulada "Reducción Selectiva y Análisis de los Datos Sobremuestreados" ("la Publicación '367"), la cual es incorporada al presente documento íntegramente por referencia. Los métodos de reducción selectiva son aplicados preferentemente para discernir y caracterizar las condiciones dentro de los chutes, incluyendo aglomeración y atollos y son precursores de aquellas y otras condiciones de procesamiento de chutes. In some modalities, the selective reduction of oversampling data provides significant information about the movements of material within the chute. In a preferred embodiment, the vibration analysis system 18 executes software to analyze the oversampled data using methods described in the publication of the American Patent No. 2014/0324367, entitled "Selective Reduction and Analysis of the Oversampled Data"("the Publication '367 "), which is incorporated into this document entirely by reference. Selective reduction methods are preferably applied to discern and characterize the conditions within the chutes, including agglomeration and atolls, and are precursors to those and other chutes processing conditions.
En algunas modalidades, la reducción selectiva es implementada en el sistema de análisis de vibración 18 mediante la recolección de datos sobremuestreados para un bloque de tiempo, como durante 10 segundos o 100 segundos u otro intervalo regular sobremuestreado. El bloque de datos completo es analizado a un intervalo de muestreo, utilizando los métodos divulgados en la Publicación '367. El análisis de frecuencia de información dentro de cada intervalo de muestreo preferentemente se enfoca en las frecuencias de resonancia de la estructura del chute, para detectar cambios de amplitud y para detectar modulación, ya que los vértices del proceso suman, restan y se alinean con aquellas frecuencias de resonancia naturales.  In some embodiments, the selective reduction is implemented in the vibration analysis system 18 by collecting oversampled data for a block of time, such as for 10 seconds or 100 seconds or another regular oversampled interval. The complete data block is analyzed at a sampling interval, using the methods disclosed in Publication '367. The frequency analysis of information within each sampling interval preferably focuses on the resonance frequencies of the chute structure, to detect changes in amplitude and to detect modulation, since the vertices of the process add, subtract and align with those natural resonance frequencies.
En algunas modalidades, el software ejecutado mediante el sistema de análisis de vibración 18, analiza las estadísticas de reducción selectiva para todos o para una parte de los intervalos de muestreo. El análisis de atributos de los datos dentro de los intervalos de muestreo es particularmente útil para distinguir entre los estados operativos y los cambios del proceso. Dichos métodos de análisis de atributo y los métodos para diagnosticar el movimiento de material en un proceso mediante reducción selectiva, son divulgados en la Publicación '367.  In some embodiments, the software executed by the vibration analysis system 18, analyzes the statistics of selective reduction for all or for a part of the sampling intervals. The analysis of data attributes within the sampling intervals is particularly useful for distinguishing between operating states and process changes. These methods of attribute analysis and the methods to diagnose the movement of material in a process through selective reduction are disclosed in Publication '367.
En algunas modalidades, se utiliza un test de impacto para determinar una o múltiples características estructurales de resonancia en la vecindad de los acelerómetros del primer grupo 12a-12h y de los acelerómetros del segundo grupo 14a-14h para un chute determinado, en donde ambos grupos pueden corresponder a distintos niveles en el chute. El test de impacto es una técnica preferida porque es conducido típicamente utilizando promedios lineales negativos, tales como cuando se realiza una serie de impactos (como doce), la gran cantidad de energía de vibración de la mayoría de las otras fuentes, como materiales del proceso moviéndose a través del chute en funcionamiento, se resta dejando sólo la característica de la respuesta de resonancia a los impactos de la prueba de impacto. En base a las frecuencias de resonancia, amortiguación e información de respuesta, el sistema de análisis de vibración 18 proporciona información a un operador acerca de dónde se puede esperar la mayor multiplicación de la información de frecuencia de vibración detectada por los acelerómetros, la menor y la intermedia. Dicha información se puede proporcionar como un valor escalar a través de la interfaz Modbus. In some embodiments, an impact test is used to determine one or multiple structural resonance characteristics in the vicinity of the accelerometers of the first group 12a-12h and of the accelerometers of the second group 14a-14h for a given chute, wherein both groups they may correspond to different levels in the chute. Impact test is a preferred technique because it is typically conducted using negative linear averages, such as when performing a series of impacts (such as twelve), the large amount of vibration energy from most other sources, such as process materials moving through the running chute, it is subtracted leaving only the characteristic of the resonance response to the impacts of the impact test. Based on the resonance frequencies, damping and response information, the vibration analysis system 18 provides information to an operator about where the greatest multiplication of the vibration frequency information detected by the accelerometers, the smallest and the intermediate can be expected. This information can be provided as a scalar value through the Modbus interface.
La Tabla 1 establece características del proceso y respuestas físicas relacionadas, junto con las respuestas esperadas de los sensores y lapsos de tiempo.  Table 1 establishes characteristics of the process and related physical responses, together with the expected responses of the sensors and time lapses.
Figure imgf000017_0001
Figure imgf000017_0001
La descripción anterior de las modalidades preferidas de esta invención, han sido presentadas con el propósito de ilustración y descripción. No intentan ser exhaustivas o limitar la invención a la forma divulgada de manera precisa. Son posibles las modificaciones o variaciones obvias, a la luz de las enseñanzas anteriores. Las modalidades son escogidas y descritas en un esfuerzo por proporcionar las mejores ilustraciones de los principios de la invención y su aplicación práctica, y de ese modo habilitar al experto en el arte para utilizar la invención en distintas modalidades y con distintas modificaciones, según sean adecuadas al uso contemplado en particular. Todas estas modificaciones y variaciones están dentro del alcance de la invención, según lo determinado por las reivindicaciones adjuntas, al interpretarlas de acuerdo al alcance al que están facultadas de manera justa, legal y equitativa. The above description of the preferred embodiments of this invention have been presented for the purpose of illustration and description. They do not try to be exhaustive or limit the invention to the form disclosed in a precise manner. Modifications or obvious variations are possible, in light of the previous teachings. The modalities are chosen and described in an effort to provide the best illustrations of the principles of the invention and their practical application, and thereby enable the person skilled in the art to use the invention in different modalities and with different modifications, as appropriate. to the contemplated use in particular. All these modifications and variations are within the scope of the invention, as determined by the appended claims, when interpreting them according to the scope to which they are entitled in a fair, legal and equitable manner.
Luego, el comportamiento del chute puede ser caracterizado por el monitoreo de energía a través de su estructura con un número definido de sensores de vibración dispuestos en su exterior en una distribución determinada, como por ejemplo se muestra en la Fig. 2. Esto permite determinar, la evolución del desarrollo de los atollos en el tiempo, terminando con el momento exacto y preciso (sin falsos positivos) en el cual el chute se encuentre atollado. Conocer la evolución del desarrollo de los atollos posibilita estrategias de control preventivo y evita pérdidas y fallas imprevistas, con todas las consecuencias que ello implica en continuidad operacional y productividad.  Then, the behavior of the chute can be characterized by the monitoring of energy through its structure with a defined number of vibration sensors arranged on its outside in a certain distribution, as for example shown in Fig. 2. This allows to determine , the evolution of the development of the atolls in time, ending with the exact and precise moment (without false positives) in which the chute is stuck. Knowing the evolution of the development of the atolls enables preventive control strategies and avoids losses and unforeseen failures, with all the consequences that this implies in operational continuity and productivity.
Los cambios de flujo de material hasta llegar a la obstrucción de los chutes (atollos) pueden ser detectados en línea, en tiempo real, de una forma simple y no invasiva, utilizando sensores específicos adheridos a la carcasa externa de los chutes. Así, sus señales pueden ser transmitidas en forma alámbrica o inalámbrica y procesadas remotamente en sistemas de control que emiten alarmas para la pronta acción y resolución de los problemas.  The material flow changes until the chutes are blocked (atolls) can be detected online, in real time, in a simple and non-invasive way, using specific sensors attached to the outer shell of the chutes. Thus, its signals can be transmitted in wire or wireless form and processed remotely in control systems that emit alarms for the prompt action and resolution of problems.
Los sensores empleados en la presente solución son posicionados externamente y en forma no invasiva en los chutes, facilitando la implementación del sistema de monitoreo y control en equipos convencionales. Dichos sensores colectan las señales de energía en distintas zonas del chute, detectando en forma inmediata cuando el mismo pierde su capacidad de dirigir el mineral debido a un atollo. En la Fig. 3 se muestra un esquema de los patrones de energía medidos por los sensores emplazados en un chute 10, durante la operación normal y durante la formación de una aglomeración o atollo en su interior hasta producirse el atollo o bloqueo del chute 10. Por ejemplo, el gráfico 101 muestra la amplitud en la vibración en el tiempo, medida por los sensores dispuestos en la zona que recibe el impacto del mineral, identificándose mayores amplitudes de vibración en dicha zona en comparación con las medidas por el resto de los sensores, en efecto, en el gráfico 102 se muestran las amplitudes de vibración en el tiempo medidas por los sensores dispuestos en la zona media del chute 10. The sensors used in the present solution are positioned externally and non-invasively in the chutes, facilitating the implementation of the monitoring and control system in conventional equipment. These sensors collect energy signals in different areas of the chute, detecting immediately when it loses its ability to direct the mineral due to an atollo. Fig. 3 shows a diagram of the energy patterns measured by the sensors located in a chute 10, during normal operation and during the formation of an agglomeration or atoll in its interior until the collision or blocking of the chute occurs 10. For example, graph 101 shows the amplitude in the vibration in time, measured by the sensors arranged in the area receiving the impact of the mineral, identifying greater amplitudes of vibration in that area compared to those measured by the rest of the sensors , in fact, in graph 102 the amplitudes of vibration in time measured by the sensors arranged in the middle zone of the chute 10 are shown.
Por otra parte, en el gráfico 103 de la Fig. 3 se muestra una zona de transición en las vibraciones dadas por la formación del atollo, en donde la amplitud de vibración medida disminuye en el tiempo dando indicios de la formación del atollo como se muestra en el gráfico, en donde la amplitud de vibración 113 corresponde al comportamiento vibratorio normal del chute 10 y la amplitud de vibración 123 corresponde al comportamiento vibratorio que identifica el comienzo del atollo. Finalmente, el gráfico 104 de la Fig. 3 muestra la amplitud de vibración en el tiempo cuando el chute 10 se encuentra bloqueado, es decir, cuando el atollo da lugar al bloqueo completo de la salida del chute.  On the other hand, in Figure 103 of Fig. 3 a transition zone is shown in the vibrations given by the formation of the wind, where the amplitude of measured vibration decreases over time giving indications of the formation of the wind as shown in the graph, where the amplitude of vibration 113 corresponds to the normal vibratory behavior of the chute 10 and the amplitude of vibration 123 corresponds to the vibratory behavior that identifies the beginning of the atollo. Finally, the graph 104 of Fig. 3 shows the amplitude of vibration in time when the chute 10 is blocked, that is, when the atollo gives rise to the complete blockage of the output of the chute.
Al respecto, es relevante indicar que la misma distribución y disposición de sensores empleada para detectar la evolución de un atollo al interior del chute es empleada para monitorizar el estado de su estructura, siendo posible detectar en forma temprana daños y/o fallas en el chute que afecten su operación. En efecto, la solución propone identificar, mediante el cambio del comportamiento vibratorio, el desprendimiento de placas de revestimiento interno, desgaste prematuro de revestimientos, soltura de los revestimientos, daños en la estructura del chute, soltura en la estructura del chute y otro tipo de fallas relacionadas con la integridad estructural del chute, permitiendo realizar las acciones de control y corrección respectivas para evitar que las fallas signifiquen pérdidas de productividad. Además, esta aproximación también permite caracterizar el desgaste del chute en el tiempo, detectando zonas de alto impacto de material mientras el mismo fluye o circula a través del chute. En este sentido, es posible determinar la posición y las fuerzas de las cargas de impacto en las paredes internas del chute, además de los daños indicados anteriormente. In this regard, it is relevant to indicate that the same distribution and arrangement of sensors used to detect the evolution of an atollo inside the chute is used to monitor the state of its structure, being possible to detect early damage and / or failure in the chute that affect your operation. In effect, the solution proposes to identify, by changing the vibratory behavior, the detachment of internal coating plates, premature wear of coatings, looseness of coatings, damage to the structure of the chute, looseness in the chute structure and other types of failures related to the structural integrity of the chute, allowing to carry out the respective control and correction actions to avoid that failures mean loss of productivity. In addition, this approach also allows to characterize the wear of the chute over time, detecting high impact areas of material while it flows or circulates through the chute. In this sense, it is possible to determine the position and forces of the impact loads on the internal walls of the chute, in addition to the damages indicated above.
Esta información permitirá tomar acciones de mantenimiento preventivo, reforzando las zonas de alto impacto o generando planes de reemplazo de materiales con frecuencias determinadas según el tipo de zona del chute (impacto bajo, medio o alto, por ejemplo). Luego, la solución que se propone permite caracterizar completamente el comportamiento del chute mediante el análisis de sus vibraciones, no solo en función de predecir la formación de atollos en el interior del chute, sino que además en función de maximizar su operatividad durante su vida útil.  This information will allow preventive maintenance actions to be taken, reinforcing high-impact areas or generating replacement plans for materials with frequencies determined according to the type of chute zone (low, medium or high impact, for example). Then, the proposed solution allows to completely characterize the behavior of the chute by analyzing its vibrations, not only in terms of predicting the formation of atolls inside the chute, but also in terms of maximizing its operation during its useful life .
Como se ha descrito anteriormente, unos de los principales objetivos de la solución son disminuir el número de falsos positivos y reducir el tiempo de detención producto de los atollos. Para dichos objetivos en particular, se proponen indicadores de medición que son utilizados en la predicción de atollos y/o fallas, de manera que se cumple con los requerimientos de disminución de número de paradas por falsos atollos y disminución del tiempo de detención por atollos, entre otros requerimientos que satisface la solución  As described above, one of the main objectives of the solution is to reduce the number of false positives and reduce the detention time resulting from the atolls. For these purposes in particular, measurement indicators are proposed that are used in the prediction of atolls and / or faults, in such a way that the requirements for decreasing the number of stops due to false atolls and the reduction of detention time due to atolls are met. among other requirements that satisfies the solution
Mediante dichos parámetros es posible gestionar la precisión de la detección de la evolución de atollo, precisión que en este caso viene dada por la naturaleza de la medición de las señales vibratorias, y planificar las acciones correctivas necesarias para evitar o reducir al mínimo las detenciones por atollos.  By means of these parameters it is possible to manage the accuracy of the detection of the evolution of atollo, precision that in this case is given by the nature of the measurement of the vibratory signals, and to plan the necessary corrective actions to avoid or minimize the arrests by atolls
Arquitectura de la Solución Solution Architecture
Como se muestra en la Fig. 4, las señales provenientes de los acelerómetros 12a-12h, 14a-14h,... instalados en posiciones estratégicas sobre la carcasa del chute son enviadas en forma alámbrica o inalámbrica al recolector de vibraciones 42, el cual entrega un primer procesamiento a las señales, para lo cual se puede emplear una caja de conexiones 41 que reúne las señales de los sensores. Luego, esta información es recibida por el sistema experto 43, el cual aplica reglas predefinidas incluyendo parámetros del proceso en el que opera el chute (velocidad de la cinta transportadora, carga, tipo de material, etc) provenientes de un historizador 44 o del mismo sistema de control de las operaciones, como puede ser un sistema de control distribuido (DCS). Las alarmas generadas por el sistema experto son enviadas al DCS o similar (PLC) para tomar acción sobre los componentes que participan en el proceso y que requieran ser intervenidos para evitar los atollos o problemas en la operación/condición del chute. A la vez, estas alarmas pueden ser historizadas. Es relevante destacar que las comunicaciones entre los componentes de la solución pueden realizarse en base a diferentes protocolos de comunicación como Modbus TCP y/o OPC, seleccionándose el más adecuado. As shown in Fig. 4, the signals coming from the accelerometers 12a-12h, 14a-14h, ... installed in strategic positions on the chute housing are sent in wired or wireless form to the vibration collector 42, which it delivers a first processing to the signals, for which a connection box 41 can be used that gathers the signals from the sensors. Then, this information is received by the expert system 43, which applies predefined rules including parameters of the process in which the chute operates (speed of the conveyor belt, load, type of material, etc.) coming from a historian 44 or from the same operation control system, such as a control system distributed (DCS). The alarms generated by the expert system are sent to the DCS or similar (PLC) to take action on the components that participate in the process and that require to be intervened to avoid the atolls or problems in the operation / condition of the chute. At the same time, these alarms can be historicized. It is important to note that communications between the components of the solution can be made based on different communication protocols such as Modbus TCP and / or OPC, selecting the most appropriate.
De la misma forma, como se muestra en la Fig. 5, la arquitectura de la solución incluyendo modalidad con análisis de falla se emplea de forma similar a la anteriormente presentada, utilizándose análisis computacional para procesar la información, mediante un software de análisis específico 51, y asociar los valores de vibración a los distintos factores de operación del chute, por ejemplo, distribución de carga 52 sobre las superficies internas del chute, fuerza de impacto de la carga 53, desgaste 54, soltura de la estructura 55, soltura de placas de desgaste 56, etc. Esta solución entrega información de niveles de energía sobre la estructura del chute que puede asociarse a detección temprana de daños sobre la estructura del chute y soltura o caída de placas de revestimientos internos. Para esto se emplean unidades de procesamiento especializadas 57 que reciben la señal de los sensores 12a-12h, 14a-14h,... y la entregan al software de análisis 51.  In the same way, as shown in Fig. 5, the architecture of the solution including modality with failure analysis is used in a similar way to that previously presented, using computational analysis to process the information, by means of a specific analysis software 51 , and associating the vibration values with the different operating factors of the chute, for example, distribution of load 52 on the internal surfaces of the chute, force of impact of the load 53, wear 54, looseness of the structure 55, looseness of plates of wear 56, etc. This solution provides information on energy levels on the structure of the chute that can be associated with early detection of damage to the structure of the chute and looseness or dropping of internal cladding plates. For this, specialized processing units 57 are used that receive the signal from the sensors 12a-12h, 14a-14h, ... and deliver it to the analysis software 51.
La Fig. 6 muestra un ejemplo del procesamiento o análisis de vibraciones sobre fallas en la estructura del chute, que es posible obtener desde un software de análisis específico 51. En este caso es posible obtener representaciones gráficas de zonas de impacto, como se ejemplifica en el gráfico de posición 60 y en la evolución de vibraciones de los gráficos 61 a 64, que ejemplifican el comportamiento de una porción del chute 10.  Fig. 6 shows an example of the processing or analysis of vibrations on chute structure faults, which can be obtained from a specific analysis software 51. In this case it is possible to obtain graphic representations of impact zones, as exemplified in the graph of position 60 and in the evolution of vibrations of graphs 61 to 64, which exemplify the behavior of a portion of chute 10.

Claims

REIVINDICACIONES
1. Un optimizador para chutes de transferencia caracterizado porque comprende un sistema de monitoreo y control que se implementa en los chutes de transferencia, monitorizando tanto la operación como el estado de dichos equipos, permitiendo ejercer acciones de control mediante la predicción de eventos ligados a la operación y mediante el envío de alarmas a los distintos sistemas de control que se integran en la línea de operación del chute de transferencia, en donde el sistema de monitoreo y control comprende: 1. An optimizer for transfer chutes characterized in that it comprises a monitoring and control system that is implemented in the transfer chutes, monitoring both the operation and the status of said equipment, allowing to exercise control actions by predicting events linked to the operation and by sending alarms to the different control systems that are integrated in the line of operation of the transfer chute, where the monitoring and control system includes:
- un set de sensores de vibración dispuestos sobre la superficie externa del chute,  - a set of vibration sensors arranged on the external surface of the chute,
- un sistema de análisis de vibración,  - a vibration analysis system,
- información operacional, y  - operational information, and
- un sistema experto.  - an expert system.
en donde el set de sensores de vibración incluye múltiples sensores de vibración emplazados a distintas alturas, niveles o capas del chute, en donde dichos sensores generan una pluralidad de señales de vibración análogas del flujo de material al interior del chute. wherein the set of vibration sensors includes multiple vibration sensors located at different heights, levels or layers of the chute, wherein said sensors generate a plurality of analogous vibration signals of the material flow into the chute.
2. El optimizador para chutes de transferencia de acuerdo con la reivindicación 1, caracterizado porque además comprende un convertidor análogo-digital y uno o más canales de procesamiento de vibración general, en donde el convertidor análogo-digital muestrea las señales análogas de vibración del flujo de material al interior del chute a una frecuencia de muestreo fija y convierte las señales de vibración del flujo en señales de vibración digitales y, en donde el uno o más canales de procesamiento de vibración procesan las señales digitales para generar valores de vibración escalares representativos del paso del flujo interior en distintas zonas sensadas del chute. 2. The transfer chutes optimizer according to claim 1, characterized in that it further comprises an analog-digital converter and one or more general vibration processing channels, wherein the analog-digital converter samples the analogous signals of flow vibration. of material inside the chute at a fixed sampling frequency and converts the vibration signals of the flow into digital vibration signals and, where the one or more vibration processing channels process the digital signals to generate scalar vibration values representative of the passage of the internal flow in different sensed areas of the chute.
3. El optimizador para chutes de transferencia de acuerdo con una cualquiera de las reivindicaciones anteriores, caracterizado porque además comprende uno o más filtros paso banda para el filtrado de las señales digitales, para generar señales de vibración digitales limitadas de paso banda. 3. The transfer chutes optimizer according to any one of the preceding claims, characterized in that it further comprises one or more bandpass filters for filtering the digital signals, to generate limited digital bandpass vibration signals.
4. El optimizador para chutes de transferencia de acuerdo con una cualquiera de las reivindicaciones anteriores, caracterizado porque el sistema experto opera comunicado a un sistema de control que actúa sobre la operación del proceso en base, al menos en parte, a los valores de vibración escalares del flujo. 4. The transfer chutes optimizer according to any one of the preceding claims, characterized in that the expert system operates communicated to a control system that acts on the operation of the process based, at least in part, on the vibration values scalars of the flow.
5. El optimizador para chutes de transferencia de acuerdo con una cualquiera de las reivindicaciones anteriores, caracterizado porque los sensores de vibración están dispuestos de manera que el eje sensor de cada sensor de vibración está sustancialmente perpendicular al eje del flujo del chute al cual está unido. 5. The transfer chutes optimizer according to any one of the preceding claims, characterized in that the vibration sensors are arranged so that the sensor axis of each vibration sensor is substantially perpendicular to the axis of the chute flow to which it is attached .
6. El optimizador para chutes de transferencia de acuerdo con una cualquiera de las reivindicaciones anteriores, caracterizado porque el sistema de análisis de vibración incluye un módulo de comparación o sistema experto que compara uno o más de: 6. The transfer chutes optimizer according to any one of the preceding claims, characterized in that the vibration analysis system includes a comparison module or expert system that compares one or more of:
Los valores de vibración escalar del flujo provenientes de un primer set de sensores, medidos durante un primer período de tiempo, con los valores de vibración escalar del flujo provenientes de un segundo set de sensores, medidos durante el primer período de tiempo;  The values of scalar vibration of the flow coming from a first set of sensors, measured during a first period of time, with the values of scalar vibration of the flow coming from a second set of sensors, measured during the first period of time;
Los valores de vibración escalar del flujo provenientes de un set de sensores, medidos durante el primer período de tiempo, con los valores de vibración escalar del flujo provenientes del mismo set de sensores, medidos durante un segundo período de tiempo, que es diferente al primer período de tiempo; y Los valores de vibración escalar del flujo provenientes de un set de sensores, medidos durante el primer período de tiempo, con los valores de vibración escalar base del flujo provenientes del mismo set de sensores, medidos durante el período de tiempo cuando uno o más chutes operaban en condiciones normales. The scalar vibration values of the flow coming from a set of sensors, measured during the first period of time, with the values of scalar vibration of the flow coming from the same set of sensors, measured during a second period of time, which is different from the first time frame; Y The scalar vibration values of the flow coming from a set of sensors, measured during the first period of time, with the scalar base vibration values of the flow coming from the same set of sensors, measured during the period of time when one or more chutes operated under normal conditions.
7. El optimizador para chutes de transferencia de acuerdo con la reivindicación 6, caracterizado porque en base a una o más de las comparaciones, más la información operativa, el módulo de comparación genera información de control que puede ser utilizada en el control de inicio o en la toma de decisiones acerca del control del chute. 7. The transfer chutes optimizer according to claim 6, characterized in that on the basis of one or more of the comparisons, plus the operational information, the comparison module generates control information that can be used in the start control or in making decisions about the control of chute.
8. El optimizador para chutes de transferencia de acuerdo con una cualquiera de las reivindicaciones 6 y 7, caracterizado porque el módulo de comparación compara los valores de vibración escalar del flujo al interior del chute en un rango de frecuencia preferente de 0 kHz a 10 kHz, medidos durante el primer período de tiempo, con los valores de vibración escalar del flujo base en el mismo rango de frecuencia, medidos durante el período de tiempo cuando el chute operaba en condiciones normales. The transfer chutes optimizer according to any one of claims 6 and 7, characterized in that the comparison module compares the scalar vibration values of the flux to the interior of the chute in a preferred frequency range of 0 kHz to 10 kHz , measured during the first period of time, with the scalar vibration values of the base flow in the same frequency range, measured during the period of time when the chute operated under normal conditions.
9. El optimizador para chutes de transferencia de acuerdo con una cualquiera de las reivindicaciones 6 a 8, caracterizado porque el módulo de comparación genera información de control para controlar la operación de la correa transportadora, cuando los niveles de energía de los valores de vibración escalar del flujo en el rango de frecuencia de 0 kHz a 10 Hz, medidos durante el primer período de tiempo, son diferentes que los niveles de energía de los valores de vibración escalar del flujo base en el mismo rango de frecuencia, medidos durante el período de tiempo cuando el chute operaba en condiciones normales. The transfer chutes optimizer according to any one of claims 6 to 8, characterized in that the comparison module generates control information to control the operation of the conveyor belt, when the energy levels of the scalar vibration values of the flux in the frequency range of 0 kHz to 10 Hz, measured during the first period of time, are different than the energy levels of the scalar vibration values of the base flux in the same frequency range, measured during the period of time when the chute operated under normal conditions.
10. El optimizador para chutes de transferencia de acuerdo con la reivindicación 9, caracterizado porque la información de control puede comprender un mensaje de alerta que informa a un operador en relación a la condición de atollo que puede estar ocurriendo en el flujo de uno o más chutes o la información de control puede comprender una señal de control que inicia la detención de la alimentación. The transfer chutes optimizer according to claim 9, characterized in that the control information may comprise an alert message informing an operator in relation to the condition of atollo that may be occurring in the flow of one or more chutes or the control information may comprise a control signal that initiates the stopping of the power supply.
11. El optimizador para chutes de transferencia de acuerdo con una cualquiera de las reivindicaciones 6 a 10, caracterizado porque el módulo de comparación genera información de control para controlar la operación de una o más de las correas transportadoras asociadas al proceso, cuando: The transfer chutes optimizer according to any one of claims 6 to 10, characterized in that the comparison module generates control information to control the operation of one or more of the conveyor belts associated with the process, when:
Los niveles de energía de los valores de vibración escalar del flujo de salida, medidos durante el primer período de tiempo, cambian con respecto a los niveles de energía de los valores de vibración escalar del flujo de salida, medidos durante el segundo período de tiempo, el cual ocurre después del primer período de tiempo, y/o  The energy levels of the scalar vibration values of the output flow, measured during the first period of time, change with respect to the energy levels of the scalar vibration values of the output flow, measured during the second period of time, which occurs after the first period of time, and / or
Los niveles de energía de los valores de vibración escalar del flujo de entrada, medidos durante el primer período de tiempo, cambian con respecto a los niveles de energía de los valores de vibración escalar del flujo de entrada, medidos durante el segundo período de tiempo.  The energy levels of the scalar vibration values of the inflow, measured during the first period of time, change with respect to the energy levels of the scalar vibration values of the inflow, measured during the second period of time.
en donde dicho cambio de los niveles de energía de los valores de vibración escalar del flujo de salida y/o de entrada, pueden indicar una condición de obstrucción del chute, y en donde por flujos de entrada y salida se debe entender a los efectos del flujo de mineral que circula a través del chute en las zonas de entrada y salida del mismo, en donde el chute en su totalidad estaría representado por dichas zonas, las que presentan una disposición de niveles de sensores dispuestos para caracterizar las vibraciones de dichas zonas. wherein said change of the energy levels of the scalar vibration values of the output and / or input flow, can indicate a condition of blockage of the chute, and where by input and output flows it must be understood for the purposes of flow of mineral that circulates through the chute in the entry and exit areas of the same, where the chute in its entirety would be represented by said zones, which present a disposition of levels of sensors arranged to characterize the vibrations of said zones.
12. El optimizador para chutes de transferencia de acuerdo con la reivindicación 11, caracterizado porque la información de control puede comprender un mensaje de alerta que informa al operador en relación a la condición de obstrucción del chute o la información de control puede comprender una señal de control que inicia la detención de la correa o de la alimentación al chute.. The transfer chutes optimizer according to claim 11, characterized in that the control information may comprise an alert message informing the operator in relation to the chute obstruction condition or the control information may comprise a signal from control that starts the stop of the belt or the feeding to the chute ..
13. El optimizador para chutes de transferencia de acuerdo con una cualquiera de las reivindicaciones anteriores, caracterizado porque el chute se divide en múltiples zonas, por ejemplo tres o más, estando dichas zonas definidas por los distintos niveles del chute desde su porción de entrada a su porción de salida, o viceversa, en donde el set de sensores de vibración define sensores localizados en los distintos niveles del chute, caracterizando el comportamiento vibratorio del mismo en dichos distintos niveles. The transfer chutes optimizer according to any one of the preceding claims, characterized in that the chute is divided into multiple zones, for example three or more, said zones being defined by the different levels of the chute from its entry portion to its output portion, or vice versa, where the set of vibration sensors defines sensors located at different levels of the chute, characterizing the vibratory behavior of the same at said different levels.
14. Un método para medir y analizar la vibración asociada a un chute de transferencia, caracterizado porque comprende las siguientes etapas: 14. A method for measuring and analyzing the vibration associated with a transfer chute, characterized in that it comprises the following stages:
a) detectar la vibración asociada a una primera porción del flujo al interior del chute, utilizando uno o más sensores de vibración unidos a una primera zona del chute, por ejemplo, una zona cercana a la entrada del chute;  a) detecting the vibration associated with a first portion of the flow inside the chute, using one or more vibration sensors attached to a first zone of the chute, for example, an area near the entrance of the chute;
b) generar una señal análoga de vibración del flujo por parte de los sensores de vibración, dicha señal indicativa de la vibración de la primea zona del chute detectada en la etapa b) generate an analogous signal of vibration of the flow by the vibration sensors, said signal indicative of the vibration of the first zone of the chute detected in the stage
(a); (to);
c) detectar la vibración asociada a una segunda porción del flujo al interior del chute, utilizando uno o más sensores de vibración unidos a una segunda zona del chute, por ejemplo, una zona cercana a la salida del chute; d) generan una señal análoga de vibración del flujo por parte de los sensores de vibración, dicha señal indicativa de la vibración de la segunda zona del chute detectada en la etapac) detecting the vibration associated with a second portion of the flow inside the chute, using one or more vibration sensors attached to a second zone of the chute, for example, an area near the outlet of the chute; d) generate an analogous signal of vibration of the flow by the vibration sensors, said signal indicative of the vibration of the second zone of the chute detected in the stage
(c); (c);
e) muestrear las señales análogas de vibración del flujo en las distintas zonas del chute a una frecuencia de muestreo fija y convertir las señales análogas de vibración del flujo, a señales digitales de vibración del flujo; y  e) sampling the analog vibration signals of the flow in the different zones of the chute at a fixed sampling frequency and converting the analogous vibration signals of the flow to digital vibration signals of the flow; Y
f) procesar las señales digitales de vibración del flujo para generar valores de vibración escalar del flujo, que representan la vibración general, medida en la primera y segunda zonas del chute.  f) processing the digital vibration signals of the flow to generate scalar vibration values of the flow, which represent the general vibration, measured in the first and second chute zones.
15. El método de acuerdo con la reivindicación 14, caracterizado porque además comprende dividir el chute en más de dos zonas, disponiéndose una pluralidad de sensores asociados a las distintas zonas del chute, dispuestos para caracterizar los niveles de vibración de dichas zonas. 15. The method according to claim 14, characterized in that it further comprises dividing the chute into more than two zones, a plurality of sensors being associated with the different chute zones, arranged to characterize the vibration levels of said zones.
16. El método de acuerdo con una cualquiera de las reivindicaciones 14 y 15, caracterizado porque además comprende proporcionar información de control a un sistema de control distribuido, en base, al menos en parte, a los valores de vibración escalar del flujo. 16. The method according to any one of claims 14 and 15, characterized in that it further comprises providing control information to a distributed control system, based, at least in part, on the scalar vibration values of the flow.
PCT/CL2018/050043 2017-06-09 2018-06-08 Optimiser for transfer funnels WO2018223245A1 (en)

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JPH11262692A (en) * 1998-03-17 1999-09-28 Taiheiyo Cement Corp Cyclone
JP3428476B2 (en) * 1998-12-21 2003-07-22 Ｊｆｅエンジニアリング株式会社 Device and method for detecting clogging in hopper
CA2110613C (en) * 1992-12-04 2003-11-11 Yasuhiro Miura Pipe clogging detecting device
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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CA2110613C (en) * 1992-12-04 2003-11-11 Yasuhiro Miura Pipe clogging detecting device
JPH11262692A (en) * 1998-03-17 1999-09-28 Taiheiyo Cement Corp Cyclone
JP3428476B2 (en) * 1998-12-21 2003-07-22 Ｊｆｅエンジニアリング株式会社 Device and method for detecting clogging in hopper
CN103866068B (en) * 2012-12-18 2016-04-27 秦皇岛秦冶重工有限公司 Vibration detection device on blast-furnace channel distributor and blast-furnace channel distributor

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