WO2022251980A1 - Kit, système et méthode de surveillance à distance, autonome, en temps réel, de l'usure d'un moyeu d'engin de déplacement de terre - Google Patents

Kit, système et méthode de surveillance à distance, autonome, en temps réel, de l'usure d'un moyeu d'engin de déplacement de terre Download PDF

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Publication number
WO2022251980A1
WO2022251980A1 PCT/CL2022/050025 CL2022050025W WO2022251980A1 WO 2022251980 A1 WO2022251980 A1 WO 2022251980A1 CL 2022050025 W CL2022050025 W CL 2022050025W WO 2022251980 A1 WO2022251980 A1 WO 2022251980A1
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WO
WIPO (PCT)
Prior art keywords
wear
bushing
chip
measurement module
layer
Prior art date
Application number
PCT/CL2022/050025
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English (en)
Spanish (es)
Inventor
Álvaro Patricio ESPEJO PIÑA
Omar Andrés DAUD ALBASINI
Dora Rosa ALTBIR DRULLINSKY
Sebastián Andrés SEPÚLVEDA VÁSQUEZ
Carlos Javier EUGENIO HERRERA
Matías Bernardo TARGARONA HERRERA
Gabriel Esteban FUENTES AMPUERO
Original Assignee
Universidad De Santiago De Chile
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Universidad De Santiago De Chile filed Critical Universidad De Santiago De Chile
Priority to CA3221356A priority Critical patent/CA3221356A1/fr
Publication of WO2022251980A1 publication Critical patent/WO2022251980A1/fr

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62D—MOTOR VEHICLES; TRAILERS
    • B62D55/00—Endless track vehicles
    • B62D55/08—Endless track units; Parts thereof
    • B62D55/14—Arrangement, location, or adaptation of rollers
    • B62D55/15—Mounting devices, e.g. bushings, axles, bearings, sealings
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16C—SHAFTS; FLEXIBLE SHAFTS; ELEMENTS OR CRANKSHAFT MECHANISMS; ROTARY BODIES OTHER THAN GEARING ELEMENTS; BEARINGS
    • F16C17/00—Sliding-contact bearings for exclusively rotary movement
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
    • G01B7/00—Measuring arrangements characterised by the use of electric or magnetic techniques
    • G01B7/02—Measuring arrangements characterised by the use of electric or magnetic techniques for measuring length, width or thickness
    • G01B7/06—Measuring arrangements characterised by the use of electric or magnetic techniques for measuring length, width or thickness for measuring thickness
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N3/00—Investigating strength properties of solid materials by application of mechanical stress
    • G01N3/56—Investigating resistance to wear or abrasion

Definitions

  • the present invention refers to a kit, system and method for remote, autonomous, real-time monitoring of bushing wear or thickness installed in an earthmoving machine, preferably in the ear of a bucket of a mining machine, where the kit includes: a measurement module, an acquisition module, and an adapter with one flexible and one rigid end.
  • the system comprises the aforementioned kit in communication with a wireless receiving means and a wireless communication network comprising at least one central unit that can be located inside or outside the mine, which are in communication to receive and manage remotely, the collected bushing wear data and schedule stops to replace the bushing either temporarily or permanently.
  • the monitoring method is based on the complementarity, but not limited to, of two ways to determine bushing wear; while the first method is based on capacitance measurements with thermal compensation, in at least one test piece of the measurement module, which is located in the bushing mantle, and which wears jointly with it, the other performs quantification measurements of the level of the electrical conduction lines spaced in the witness specimen, which are eliminated as the level of wear progresses.
  • the purpose of the bushings is to protect other critical components from wear caused by friction between moving mechanisms, in this case, between the bucket ear and the pin. They are made of a special steel alloy that allows them to operate for a certain period of time or for a certain number of tons of displaced material. However, these elements can suffer a reduction in their useful life due to accelerated, excessive and unforeseen wear, causing damage to other components that the bushing is intended to protect, resulting in unscheduled stoppages with significant economic losses for the mine.
  • US10696337B2 or US10046815B2 relate to a wear train control device comprising a roller assembly including a stationary roller component and a bushing. An opening is formed within the stationary roller component.
  • a first sensor is disposed within the opening of the fixed roller component on the bushing. The first sensor is configured to detect a first physical characteristic of the hub.
  • the stationary roller component is either a shaft or a housing.
  • the first sensor is a temperature sensor or a Hall effect sensor.
  • a magnet is arranged in the roller assembly.
  • a second sensor is disposed within the opening of the fixed roller component on the bushing. The second sensor is configured to detect a second physical characteristic of the hub.
  • a data transmission device is coupled to the first sensor. Data is collected from the sensor and transmitted to a receiving device
  • US6868711 B2 discloses a method for controlling mechanical wear caused by a first component on a second component, in which the first and second components are movable relative to each other and in which the first and second components are adjacent to each other. At least sometimes, in mechanical contact with each other, at least one sensor head is arranged in a wear area to monitor the second component. The at least one sensor head is mechanically worn by the first component upon reaching a predetermined wear limit. When the at least one sensor head is mechanically worn, a measurement signal is generated by the at least one sensor head or a change in a measurement signal is detected, produced by the at least one sensor head before it was mechanically worn. The measurement is the intensity of light reflected from the metal cover.
  • US20150066291 A1 discloses a Wear Monitoring System for an undercarriage component includes an ultrasonic sensor disposed on the undercarriage component.
  • the ultrasonic sensor is configured to emit ultrasonic waves to detect wear on the landing gear component.
  • the wear control system further includes a wear control device disposed in communication with the ultrasonic sensor.
  • the wear control device is located away from the ultrasonic sensor.
  • the wear monitoring device is configured to generate an output indicative of landing gear component wear.
  • US20160121945A1 discloses a roller of an undercarriage track system for a machine, comprising a body and a sensed function.
  • the body is a solid of revolution formed around a roller axis.
  • the body includes a perforation surface and a roller contact surface.
  • the hole surface defines a hole that extends through the body.
  • the surface of the hole is a radially inner surface of the body.
  • the contact surface of the roller is located away from the surface of the hole.
  • the detected feature is located on the body.
  • the detected function is configured to rotate with the body and be detected by a sensor.
  • the sensor is a magnetic speed sensor, and measures the length of a tooth/protrusion or recess extending from and integral to the body.
  • US20160221618A1 discloses a wear sensor device that can be used in conjunction with a carrier roller assembly of a track assembly and may have a wear sensor roller mounted on a shaft of the carrier roller assembly, which may be configured to contact a set of track pins connected to one or more track links of the track set.
  • the wear detection device may further have a wear sensor mounted on the wear sensor roller and configured to generate a signal indicative of a wear parameter of one or more chain links.
  • the sensor is a Hall effect sensor, an ultrasonic sensor, a magnetic sensor, an induction sensor, or a laser sensor.
  • US20090223083A1 (Pacific Bearing Co) discloses a bearing that includes a portable section that includes a wear sensor.
  • the hub includes a wear sensor that provides feedback to the user regarding the life of the bearing that has been used.
  • the sensor may be in the form of a wire embedded in the wearable section of the bearing, so that as the wearable section wears over time, the wire can wear out by breaking a circuit that includes the wire.
  • An indicator module can detect a cable break and determine the amount of bearing life that has been used.
  • the bearing is used in a drying drum; and method for monitoring bearing wear including monitoring changes in the electrical properties of a bearing-mounted sensor.
  • DE102007063519A1 discloses a wear and overload control system having two elements moving against each other, where the elements are supported or coupled by means of a spring or absorption coupling.
  • the medium comprises an elastomeric component.
  • a unit is built into or attached to the elastic component for electrical wear monitoring or absorption measurement and overload indication.
  • the elastic component consists of two mutually movable elements which by means of a spring and/or release coupling are mutually supported or coupled to one another, which comprises at least one elastomeric component.
  • the electrically conductive, conductive or semiconductive structures in the elastomeric component are inserted or vulcanized, and produce the electrical contact between the two mutually movable elements which in turn are electrically conductive or have electrically conductive contacts and have a sensor and/or open circuit or closed with different parameters, and have conductive structures with fracture or fatigue behavior or life time based on defined physical, thermal or chemical parameters.
  • US20150081166A1 discloses a wear monitoring system for monitoring wear of a surface of a track roller associated with an undercarriage of a machine, comprising a sensor device positioned under an upper surface of the track roller, which in turn comprises a probe configured to undergo wear along with the upper surface of the track roller, a controller circuit configured to monitor the degree of wear on the upper surface of the track roller based on the wear of the probe, an antenna, and a power source.
  • the wear control system further comprises a transceiver configured to transmit a signal indicative of the degree of wear of the follow roller.
  • the wear monitoring system further includes a monitoring device configured to generate an output indicative of the degree of wear on the track roll.
  • KRRI KR101863909B1 discloses a controller and a control method of an abrasion tester in an axle floor brush of a railway vehicle, a controller for receiving a detected detection signal from the plurality of sensors of the abrasion tester. performance simulating the driving characteristics of the railway vehicle and issuing a command to control the motor device of the performance tester; an input/output board for receiving an input signal, converting the signal into a digital signal and transmitting the signal to the controller, and sending an analog signal to the performance tester according to a command from the controller, and a controller for motor to control the motor device according to a command from the controller.
  • the apparatus enables an automatic abrasion resistance test of a railway vehicle axle ground brush and a performance tester control method.
  • An abrasion resistance test environment that simulates a real vehicle environment is built during the wear test of an axle floor brush for a railway vehicle and a skid disc to reproduce a dynamic numerical change measured on a vehicle. real railway, and perform the test at low cost
  • US20150266527A1 discloses a link for a rail assembly for a machine, comprising: a link body defining an opening configured to receive a tracking pin therein.
  • the link body further includes a first surface configured to contact a rotatable member of the rail assembly and a second surface configured to contact a rail shoe coupled to the link body.
  • the link further includes a plurality of indicia defined on the body of the link proximate the first surface. Each of the plurality of marks is indicative of progressive wear of the link body with respect to the first surface.
  • the present invention refers to a kit, system and method for monitoring, remote, autonomous, in real time, the wear of a bushing installed in an earthmoving machine, preferably in the ear (1) of a mining machine bucket, where the kit is installed directly on the bushing (2), and provides information on its wear status, reliably and with low energy consumption.
  • This kit includes at least one small-sized measurement module that can be installed in small spaces, thus adapting to spaces of various geometries, and includes at least one test tube, at least one capacitive chip, at least one digital counter chip and at least one temperature measurement chip, and at one end, a female connector for flexible planar circuit connections.
  • This kit also includes at least one multilayer printed circuit acquisition module with an antenna that does not have electromagnetic shielding due to the high presence of metals in its environment, which is a frequent problem in telecommunications, and instead emits microwave/radio frequency signals from a metallic environment where small gaps and gaps exist.
  • the acquisition module also includes high-capacity batteries, micro SD memory for error recording and information storage, a rigid connector that allows joining the adapter, a microcontroller, RF chips, a power management chip, led lights, among others.
  • the acquisition module comprises an outer protective casing (13) that protects - both the aforementioned electronic components and other passive electronic components, including resistors, capacitors and inductances, among others, from an environment with high thermal fluctuations and corrosive , and blows/impacts and vibrations that occur as a result of the acceleration/deceleration of the mining machine, and the loading and unloading of ore, among others.
  • This kit also includes an adapter (7) with a rigid vertical connector (8) at one end, and a flexible connector (9) at the other end, which allows you to dispense with other mechanical connection elements (such as bolts, screws, nuts, among others), and with this, be able to resist low temperatures without deteriorating, where said flexible connector comprises a flexible flat circuit that is housed in the female connector of the measurement module, and said rigid vertical connector comprises a circuit which is attached to the acquisition module.
  • the present system comprises the kit described above, a wireless receiving means and a wireless communication network with at least one central communication unit, in communication with said kit, specifically, in communication with said acquisition module of said kit.
  • the method is based on the complementarity, but not limited to, of two ways of determining bushing wear.
  • the first form comprises the measurement of capacitance with thermal compensation, considering that the wear of the bushing varies proportionally with the length of the wear of said at least one test piece of said measurement module that wears jointly with the bushing, and that is located to the except in a rectangular channel in the bushing mantle.
  • the second way performs length measurements on said at least one control specimen by detecting and quantifying the level of its spaced conduction power lines (21, 22), which reflects the progress/degree of wear, this means that at lower levels of electrical conduction lines or lower level quantization density, the wear in said at least one control specimen is greater, while at higher levels of electrical conduction lines or higher level quantization density, the wear in control specimens is less.
  • the bushing comprises in its mantle, at least one shallow rectangular channel, and also at least one through-hole in said channel where said at least one witness specimen of said measurement module is located, and a flared end.
  • the bushing may have multiple channels evenly distributed in the mantle, and each channel may have multiple through-bore holes to receive multiple core specimens.
  • FIGURE 1 Shows a section of the ear (1) of a mining bucket, with a cylindrical opening to house the bushing.
  • FIGURES 2A-2F Show hub (2) with at least one rectangular, low profile/shallow groove (Figs. 2A and 2B), which ends at its end with an enlargement of the groove. It can have 1 or more cylindrical through holes distributed along the channel to accommodate test tubes or cores (4). Bushing with 3 shallow rectangular grooves and one or more cylindrical through-holes distributed along the groove are illustrated (Figs. 2C and 2D). Bushing with 5 shallow rectangular grooves and one or more cylindrical through-holes distributed along the groove are illustrated (Figs. 2E and 2F).
  • FIGURES 3A and 3B Sample Bushing (2), with at least one channel installed in the ear (1) of the mining bucket.
  • FIGURE 4 Shows a measurement module (3) for at least one channel that contains at least 1 or more witness specimens (4) of wear, at least 1 or more measurement chips, which can be capacitive, digital counters or both, at minus 1 or more temperature measurement chips. It also contains a female connector (5) at one of its ends for connections of flat flexible circuits.
  • FIGURES 5A-5C Shows at least one measurement module (3) installed in at least one channel of the hub (2), with one channel (Fig. 5A), three channels (Fig. 5B) and five channels (Fig. 5C ).
  • FIGURES 6A and 6B Hub with measurement module (2) installed in ear (1) of the mining machine bucket.
  • a section of the canal (6) can be seen that protrudes from the side of the ear, a section that allows the adapter to be installed later (Fig. 6A).
  • a cut view of the ear is shown (1) (Fig. 6B).
  • FIGURES 7A-7C Sample Perspective View (Fig. 7A) of adapter (7). Lower plan view (Fig. 7B). Top elevation view (Fig. 7C). A flat flexible connector (9) and a rigid connector (8) can be seen.
  • FIGURES 8A-8C Shows a cutaway view of the ear (1) of the measurement module (3) and adapter (7) connected and installed in the channel (6) of the bushing (2).
  • the adapter (7) has two ends, the first consists of a flexible flat circuit that is housed in the connector of the measurement module, the second end consists of a rigid vertical connector.
  • FIGURES 9A-9C Shows different perspectives of the system after the installation of the swivel (10). It can be seen that the vertical end of the adapter (7) is completely sealed except for the upper opening of the screw hole cavity (11), a cavity that later allows the acquisition module to be installed from above.
  • FIGURES 10A-10I Shows different perspectives of the acquisition module (12) and assembly with casing (13).
  • FIGURES 11 A-11 D Shows different perspectives of the system after the acquisition module (12) with casing (13) has been installed.
  • FIGURES 12A and 12B Shows a cross section of the complete system.
  • FIGURE 13 Shows the acquisition module (12) with connector (14), the antenna (15) and batteries
  • FIGURE 14 Shows an operation scheme of the present system and method.
  • FIGURE 15 Sample Specimen Capacitance vs. Bushing Wear Graph.
  • FIGURE 16 Sample Graph Digital level of probe versus Bushing wear.
  • FIGURE 17 Shows wireless connectivity between acquisition modules and receiver on the cabin roof.
  • FIGURE 18 Shows wireless connectivity between acquisition modules, receivers on the cabin roof, cloud or server, with end user devices, such as computers, tablets, mobile phones, among others.
  • FIGURE 19 Shows different manufacturing layers of the same specimen (4), which includes wear capacitor (19), reference capacitor (20) and circuits that form the different levels of conduction lines (21, 22). DESCRIPTION OF THE INVENTION
  • This kit, system and method for remote, autonomous, real-time monitoring of bushing wear installed in an earthmoving machine, preferably in the ear of a bucket of a mining machine, allows periodic monitoring and reporting wirelessly or telematics, the level of accumulated wear in one or more bushings, in one or more machines, and in response, schedule their maintenance and permanent or temporary replacement in order to prolong its useful life, and thus prevent unwanted damage or unexpected stoppages in the mining machine.
  • the present kit then makes it possible to measure the wear of the bushing, positioning in at least one rectangular channel, of little depth, in the outer layer of the bushing, at least one measurement module, which is connected to at least one acquisition module ( data) by means of an adapter, where the acquisition module is located in a cavity of the swivel, and where said bushing wear information collected and processed by said at least one measurement module and received by said at least one acquisition module, that transmits to a wireless receiving medium and from said wireless receiving medium to a central unit of a communication network, which can be the cloud (Internet) or a server (connected to the Internet or to a local network), thus enabling the management of maintenance, replacement or removal of the bushing(s) monitored.
  • a communication network which can be the cloud (Internet) or a server (connected to the Internet or to a local network
  • the channel where the measurement module is housed, does not negatively affect the performance of the bushing during operation, nor does it reduce its useful life, and instead, it allows reliable measurement of wear from its own body, without the need to estimate it from the outside of the bucket ear of a mining machine or from a similar position on the mining machine, as is done hitherto.
  • the measurement module in addition to the acquisition module, once connected, are autonomous and do not require external on/off, guaranteeing low energy consumption with a 2-year autonomy.
  • the bushing comprises in its mantle, at least one shallow rectangular channel, and also at least one through-hole in said channel where said at least one witness specimen of said measurement module is located, and where said at least one channel has a flared end to receive said adapter connecting the measurement module and said acquisition module.
  • the hub can thus comprise multiple rectangular grooves distributed in a regular manner in the shell of the hub, as well as multiple through-holes equally distributed in each groove.
  • Multiple measurement modules with multiple witness probes allow a complete wear profile to be achieved for the entire bushing body, while with a single measurement module and more than one witness probe, a localized wear profile is achieved on a mantle line. of the bushing, and particularly, for only one test piece, a single point of wear is reached.
  • the measurement module has a reduced size that allows it to be installed in small spaces, thus adapting to spaces with different geometries, and it has a low-profile female connector at its end for flat and flexible circuit connections. This type of connector supports high vibrations and temperatures.
  • the measurement module comprises at least one witness probe, at least one capacitive measurement chip, at least one digital counter chip, at least one temperature measurement chip, and a female connector for flexible planar circuit connections, at one end, and also includes passive electronic components selected from capacitors, resistors, inductances, among others.
  • the control specimen (4) comprising at least two functional layers (bilayer), comprising at least a first external layer comprising at least one wear capacitor (19), and a second internal layer comprising at least one reference capacitor (20). ), where the first outer layer can optionally alternate its location with the second inner layer, and also optionally, the control sample can comprise a third inner layer and a fourth complementary inner layer that comprise at least one circuit each layer, and together they form the different levels of conduction lines (21, 22).
  • These third inner layer and fourth inner layer can be located either immediately after or before the first outer layer and second inner layer bilayer or between said first outer layer and said second inner layer, and where the wear capacitor (19) It allows measuring the capacitance of the witness specimen as it wears out, while from the reference capacitor (20) measurements are obtained that allow the measurement of wear on the witness specimen to be corrected depending on the effect of temperature. Meanwhile, said third internal layer and fourth internal layer that form the different levels of conduction lines (21, 22) additionally allow the wear of the witness specimen to be measured.
  • the control sample can comprise at least one additional layer to the aforementioned configuration and that increases the bilayer by at least one layer, comprising a first external layer and a second internal layer, either in an additional layer comprising a wear capacitor, an additional layer comprising a reference capacitor or both or different combinations thereof.
  • the control sample can also comprise at least one additional complementary layer comprising circuits that complement the conduction lines, which can be located immediately before or after or between the aforementioned layers of wear capacitors and reference capacitors.
  • the wear capacitor comprises two conducting wires or two conducting tracks facing each other in a comb-like fashion.
  • the reference capacitor differs from the wear capacitor only in that it is shorter in length.
  • the acquisition module comprises at least one antenna that does not have electromagnetic shielding due to the high presence of metals in its environment, emitting signals of Microwave/RF from a metallic environment where small gaps and gaps exist; it also comprises a set of light indicators with patterns and colors that allows visualizing a successful connection with said measurement module, where said light indicators can be of permanent or intermittent light emission, preferably a set of RGB LED lights, and are visible from the end gullion open; a microcontroller (MCU) that manages/controls the performance of said daily periodic measurements of said measurement module and processes them, including errors from said measurement module and other peripherals, and in general, the execution of tasks of the others components of this module; a memory card that stores the information/data of said daily periodic measurements of the measurement module and its errors or those of other peripherals, including RF chips, power managers, among others, preferably selected from a microSD card memory; an integrated circuit/chip that maintains intermittent or continuous communication with said receiving means to wirelessly send/transmit said information/data accumulated from said daily periodic measurements and said errors coming from
  • the acquisition module also includes an outer protective casing (13) that protects the electronic components that make up the module, from an environment with high thermal fluctuations and corrosive, and from blows/impacts and vibrations that occur as a result of acceleration/deceleration. of the mining machine, and the loading and unloading of ore, among others.
  • Fig. 1 shows, by way of illustration, the ear of the mining shovel bucket. While figs. 2A-2F show, illustratively, at least one mining shovel hub modified to comprise, in its mantle, one shallow rectangular channel, three shallow rectangular channels, or five shallow rectangular channels. In Figs. 3A and 3B, the installation of the bushing in the ear of the mining shovel bucket is illustrated by way of example.
  • the configuration of the measurement module and the control specimens are illustrated by way of example in Fig. 4 and Fig. 19, where in the latter figure a three-layer embodiment is shown on the surface of the specimen with an external layer for the wear capacitor (19), an intermediate layer for the reference capacitor (20) and an internal layer for the circuits that form the different levels of conduction lines (21, 2.
  • the installation of the measurement module in at least one hub with one shallow rectangular channel, three shallow rectangular channels, or five shallow rectangular channels, are illustrated as a example, in Figs. 5A-5C. While bushing with the measurement module installed in the ear of the mining shovel bucket, illustrated in Figs. 6A and 6B, showing in a section in section, the side of the ear that later allows the installation of the adapter.
  • Figs 7A-7C illustrate, by way of example, the adapter observed from different views, and highlighting the end that receives the flexible connector of the measurement module and the rigid vertical connector that receives the rigid connector of the acquisition module, where each connector is located on opposite ends of the adapter. While Figs. 8A-8C show a cutaway view of the bushing ear with the measurement module installed and the adapter connected to the measurement module via the flat flexible connector, where the connectors correspond to circuits. Figs.9A-9C illustrate, by way of example, different views of the rear swivel installation system, showing that the vertical end of the adapter is completely sealed except for the upper opening of the swivel cavity, where the acquisition module is installed. from above, connecting the rigid connector of the acquisition module with the rigid vertical module of the adapter.
  • Figs. 10A-1 OH illustrate by way of example, different views of the acquisition module without casing and with casing assembled. While Figs. 11A-11 D illustrate, by way of example, different views of the rear installation system of the acquisition module with casing.
  • the Figs. 12A and 12B illustrate, by way of example, a cross section of the complete system installed in the hub and Fig. 13 illustrates, by way of example, the acquisition module with rigid connector, the antenna and the power supply that can comprise at least one cell, battery, among other sources of energy.
  • Fig. 14 shows the scheme of operation of the present system and method. While Fig. 17 shows wireless connectivity between acquisition modules and receiver module on the roof of the cab of an earthmoving machine, and Fig. 18 shows wireless connectivity between acquisition modules, receiver module on the roof of cabin, cloud or server, with end user devices, such as computers, tablets, mobile phones, among others.
  • Fig. 15 and Fig. 16 show a plot of blank capacitance versus bushing wear and a plot of blank digital level versus bushing wear.
  • an electronic circuit ico comprises said capacitive chip that receives and processes the capacitance measurements coming from said at least one control probe and is located immediately before the beginning of the flexible area of said single electronic board; said counter chip that receives and processes the count of the interrupted/cut electrical conductive lines that connect said counter chip with said witness probe, and is located immediately before the beginning of the flexible zone of said at least one witness probe, where each conductive line electrical is a level that corresponds to a cable/conductor that goes from a witness sample to the counting chip, where the number of levels can vary as required, and preferably, the number of levels is 32, and said levels are located in said witness specimen, and also comprises a temperature measurement chip that is located in the center of said single electronic board, and measures the temperature in
  • This remote, autonomous, real-time monitoring system of bushing wear or thickness installed in an earthmoving machine, preferably in the bucket ear of a mining machine includes: a) at least one kit as described above, comprising: a.1) at least one measurement module to be located in said at least one rectangular channel of the outer shell of said hub, comprising: a.1.1) at least three chips located on a single electronic board, which can have diverse geometry and perform daily periodic measurements of at least 2 parameters selected from: bushing wear/thickness, a capacitive chip and a digital counter chip; and hub temperature, a temperature measurement chip, which allows thermal compensation to be carried out to adjust the measurements coming from said capacitive chip, eliminating the dependence on temperature that generates distortion in them, and thus, increasing the degree of confidence in the measurements, a.1.2) at least one control specimen that is projected from said single electronic board, through a flexible conductor forming a variable angle between 0 and 180 e , preferably at an angle of 90 e , which allow obtaining measurements of variations in the wear of
  • a.2 at least one acquisition module that is located in a cavity in the swivel, having a unique individual identifier code (ID) that allows the bushing to be identified and registered in a local, wireless network, connected to a server, which may or may not be connected to the Internet, and comprises: a.2.1) a set of light indicators with patterns and colors that allow visualizing a successful connection with said measurement module, where said light indicators can be of permanent or intermittent light emission, preferably a set of RGB LED lights, and are visible from the open end of the swivel; a.2.2) a microcontroller (MCU) that manages/controls the performance of said daily periodic measurements of said measurement module, including errors from said measurement module or other peripherals, and in general, the execution of component tasks remaining of this module, a.2.3) a memory card that stores the information/data of said daily periodic measurements of said measurement module, as well as any error coming from it or other peripherals, including chips, such as RF chips , power management chips, RGB LED light control
  • the bushing made of polyamide and FR4, to be located at the end of said rectangular channel of the bushing, and to be connected at the flexible end, with said measurement module, while at the other rigid end, it is connected to said acquisition module by means of a vertical connector ; b) at least one receiver module or Gateway located, preferably, on the roof of the cabin of the mining machine, in communication with said acquisition module and said network server; c) at least one network server that processes said information/data from said daily periodic measurements that are sent/transmitted by said receiving module to estimate the state of wear and the useful life of the bushing by means of a projection according to the rate of wear calculated at from daily periodic wear measurements, accumulated over time, and optionally, includes means of alarms, be they visual, audible or both, which report a risk either because a risky wear of the bushing has been reached, that is to say , the bushing has a thickness/thickness less than 6mm; a dangerous temperature in the bushing, that is, the bushing has reached a temperature greater than 85
  • each control specimen Prior to its use, each control specimen is electrically characterized by the relationship between capacitance and length, at different temperatures, since its electrical characteristics depend both on length and temperature, and with this, a relationship between capacitance and length is determined. length, depending on the temperature, which allows estimating the level of wear on the bushing. See Figures 14 and 15.
  • said at least one rectangular groove of the bushing is obtained by machining the bushing, preserving its mechanical properties, that is, without generating significant stress or stress deformation in said rectangular groove of the bushing, which can eventually give origin of micro-fractures, which during work may eventually propagate, shortening the useful life of the bushing.
  • the bushing may be eccentric, ie the circular bore of the bushing is not concentric with the outside diameter of the bushing.
  • said bushing with said measurement module, or simply the bushing sensorized it is submerged in liquid nitrogen, until it reaches a radius less than the radius it would have at room temperature, with the aim of being able to enter with the necessary clearance inside the ear of the bucket.
  • the measurement module has been designed to withstand immersion in liquid nitrogen without damage.
  • the measurement module has a design that allows none of its electronic components and parts to protrude from the contour of the bushing volume to the outside, which ensures that it is not damaged, both during the transport of the bushing, and during its installation process in bucket ear.
  • the measurement module is resistant to vibrations and shocks transmitted to the bushing that are typical in work, since said single electronic board and said at least one control specimen are a continuous or single body. This resistance would not be achieved if the witness specimens are joined to the plate by welding or other joining means.
  • the single electronic board of the measurement module has holes/drills that assist in fixing to the bushing, either by a means of fixing such as a threaded stud, rivet, through means or by means of adhesion. These perforations also allow the alignment of said single electronic board over the length and width of said rectangular channel of the bushing, which facilitates the later installation of the adapter.
  • the installation of the measurement module is done prior to the installation of the bushing in the bucket lug.
  • the witness specimens are introduced into the corresponding perforations of the bushing, and then, said single electronic plate is inserted into said rectangular channel, and said single electronic plate is fixed to the bushing.
  • both the perforations that receive the witness specimens, as well as the rest of the volume of the channel are filled with a liquid polymeric resin and the curing of said polymeric resin is awaited.
  • Electrical lead lines or wear levels are wires/conductors that run from a witness probe to the digital counter chip.
  • the levels are located in the probes and these are close to the counter chip, otherwise, if they were not close, it would require a large volume of cables / conductors that would require extra space across the width of the board, and with it, it should also widen the bushing groove, which would make it brittle and reduce its useful life to enable monitoring, which is an undesirable effect.
  • An adapter connects the measurement module and the acquisition module. It is quick and easy to install. It is installed once the bushing has been installed in the ear of the bucket and prior to the installation of the swivel. It is located at the end of the hub channel where the measurement module goes. It is a plate made of flexible rigid material, which allows greater comfort at the time of its installation and better dampens vibrations. At one end it has a set of flat conduit paths that mates with the connector on the measurement module. At the other end it has a vertical connector, which fits with the connector of the acquisition module. All the connectors, both of the measurement module, as well as of the adapter and of the acquisition module, are connectors for high vibration environments that withstand temperatures of up to 125 ° C.
  • the acquisition module comprises an outer protective casing that allows easy movement through the cavity or emptying of the swivel. In the final installation position, said casing is embedded inside the swivel cavity and is only visible from the upper end of its hollowing. In this way, none of its electronic components or parts are exposed to the external environment, where it could become damaged, for example, by the impact of rocks on the bucket ear.
  • the acquisition module communicates wirelessly with the outside by means of an antenna that can be tuned despite the essentially metallic environment that surrounds it, at an emission frequency between 2.4 GHz and 2.5 GHz, thus allowing the transmission of measurement information from the measurement module in the hub to the Gateway or receiving medium, and from there to a network server.
  • the Receiver or Gateway module is located so that it has line of sight or direct line of sight with the direction of propagation of the antenna.
  • it could be installed on the mining machine and even more preferably on the roof of the mining machine cabin, the mast that holds the bucket, as well as some other place that has a line of sight.
  • This system begins to monitor from the moment the installation of the kit is completed, that is, when the acquisition module is connected to the adapter through the cavity, closing the electrical supply circuit.
  • the acquisition module wirelessly links/communicates with said receiver module and said web server, and the kit then registers itself by a unique identification (ID) code and provides information of the time it was installed. Then, it begins to report daily and at pre-established/pre-scheduled times, the level of wear on the bushing.
  • ID unique identification
  • a capacitor which is a device formed by two electrical conductors close to each other and surrounded by a dielectric medium, an electric field is generated and, consequently, a distribution of charges inside that allows energy to be stored.
  • Conductors can be foils, thin films, metal tracks, or electrolytes.
  • control specimens were designed as capacitors or sensitive elements that comprise a first external layer that comprises a wear capacitor that in turn comprises two conductors facing each other interspersed in the form of combs, which when worn lose sections and decreasing the capacitance of the capacitor.
  • the measurement of the capacitance change corresponds to an analog-to-digital conversion of the measured physical signal, for which a capacitive microchip is used, specially dedicated to measuring the capacitance of the witness specimens.
  • the microchip delivers a digital value proportional to the division of the resonance frequency of the circuit that includes the witness probe and an internal reference frequency of the chip.
  • This chip is managed from the acquisition module by the microprocessor (MCU), which through a power management chip turns the capacitive microchip on or off, efficiently managing power and indicating when to measure.
  • MCU microprocessor
  • the MCU can iterate one or several consecutive measurements, to obtain a set of statistically significant measurements, and in this way eliminate the noise and artifacts of the analog-to-digital conversion, including "aliasing", quantization noise, among others. Additionally, you can calculate the standard deviation of the set of measurements and set a degree of confidence.
  • the MCU transforms the digital frequency reading from the capacitive microchip into length values, using a relationship obtained experimentally from sensor calibration (f c ), which relates the digital reading to the analog-to-digital conversion ( ⁇ 3 ⁇ 4 with length of the control specimen (L), see Eq. 1.
  • the acquisition module can compensate the digital frequency measurement and establish an effective value of the measurement, D t .
  • the compensation consists of adjusting the current reading of the capacitive microchip with its temperature response f T , obtained experimentally by relating the capacitance measurement at different temperatures. See Eq. 2 and Eq. 3.
  • the method additionally comprises the incorporation of an intermediate layer that comprises a reference capacitor located as a layer following the wear capacitor, which will be used to obtain a differential measurement or referential correction measurement.
  • This condenser does not wear out during the operation of the measurement module so that its length L 2 remains constant, however, the measurement is affected by the temperature difference.
  • the capacitance of the reference capacitor C R can be modeled as follows (Eq. 4):
  • B corresponds to a geometric factor and m corresponds to the value of the dielectric constant as a function of temperature. Since the geometry of the capacitor is constant, B is constant, which implies that the variations of the capacitance measurements are attributable only to temperature changes in the medium.
  • the wear capacitor can be modeled as (Eq. 5):
  • the capacitance measurement stage is complemented by an additional stage of discrete measurement, that is, the measurement of a variable that can take only certain values in a given interval, which may or may not be equidistant, and where the resolution of the measurement is determined by the difference between two consecutive values.
  • the discrete measurement corresponds to a digital state counter, for which a witness probe is used that has at least 32 circuits, and each circuit can have two states, 1 or 0, which means energized or not energized.
  • the digital counter chip evaluates the state of each circuit and counts the positive states (1), with a first counting sensor, each circuit is spaced equidistantly along the length of the specimen in the direction of wear, preferably at a difference of 1mm. Alternatively, they can be located so that there are more circuits (dense area) in the most critical areas of wear, for example, in the area closest to the measurement module.
  • the counter detects 22 circuits on, which translates to a length of 22mm.
  • the digital counter chip is managed from the MCU through the power management chip. This turns the counter chips on and off each time an update of the measurements is required.
  • the counter chips deliver a number of active circuits and send that information to the MCU, which transforms it into the current thickness of the bushing and reports it to the Gateway or receiver, and this to its once to a network server.
  • the main advantage of this type of measurement is that it is invariant or independent of temperature changes.
  • both measurement methods it is possible to establish a redundant routine for checking the measured wear and error.
  • the digital measurement is of low resolution, of the order of 1 mm, it allows to measure efficiently and independently of the thermal variations.
  • the capacitive method has a much higher resolution, but it depends on the temperature and the analog-digital conversion. By combining both methods, it is possible to check if the capacitive measurement is correct by comparing it with the current and previous digital measurement. If the current measurement is not in the range, it is discarded and must be measured again until both results are consistent.
  • the present method of remote, autonomous monitoring, in real time, of bushing wear installed in an earthmoving machine, preferably, in a bucket ear of a mining machine, which uses the system described above, comprises the following stages: a ) adapt a bushing so that in its outer layer it has at least one shallow rectangular channel, and adapt a bushing swivel so that it includes a cavity, where in said rectangular channel at least one measurement module is located and where in Said screw cavity is located at least one acquisition module, where said at least one measurement module comprises at least three chips located on a single electronic board, which can have different geometry and perform daily periodic measurements of at least 2 selected parameters of : bushing wear/thickness, a capacitive chip and a digital counter chip; and hub temperature, a temperature measurement chip, which allows thermal compensation to be carried out to adjust the measurements coming from said capacitive chip, eliminating the dependence on temperature that generates distortion in them, and thus, increasing the degree of confidence in the measurements, at least one control specimen that is projected from said single electronic board, through a flexible
  • said at least one acquisition module has a unique individual identifier code (ID) that allows the hub to be identified and registered in a local, wireless network, connected to a server, which may or may not be connected to the Internet, and comprises a set of light indicators with patterns and colors that allows visualizing a successful connection with said measurement module, where said light indicators can be of permanent or intermittent light emission, preferably a set of RGB LED lights, and are visible from the open end of the golillion; a microcontroller (MCU) that manages/controls the performance of said daily periodic measurements of said measurement module, including errors coming from said measurement module or other peripherals, and in general, the execution of tasks of the remaining components of this module , a memory card that stores the information/data of said daily periodic measurements of said measurement module, as well as any errors coming from it or other peripherals, including chips, such as RF chips, power management chips, chips for controlling RGB LED lights, among others, preferably selected from a microSD card memory, an integrated circuit/chip that maintains intermittent or continuous communication with said receiving means
  • an adapter for high vibration environments that withstand temperatures of up to 125 ° C, which is selected from a flexo-rigid plate selected from polyamide and FR4, which joins said measurement module and said acquisition module, connecting at the flexible end, with said measurement module, while at the other rigid end, it is connected to said acquisition module by means of a vertical connector, b) preparing a curve of capacitance compensation values of the control specimens based on the measurements of the measurement chip of measurement module temperature; c) determine the value of the bushing wear from the capacitance measurements of the test piece of the measurement module, thermally compensating according to the compensation values of the curve obtained in stage b), d) determining the temperature of the bushing a from the measurements of the temperature measurement chip, e) establish the level of the accumulated wear value of the bushing in time according to the values of the determined wear in c) accumulated in time, and optionally f) activate means of alarms either visual
  • the bushing has a thickness/thickness of less than 6mm; or a dangerous temperature in the bushing, that is, the bushing has reached a temperature higher than 85 ° C, among others, and optionally, where said alarm means are selected from alarm means that send/transmit to the user, a warning message.
  • notification email a visual or audio message displayed on the screen of a selected wireless device of a computer laptop, mobile phone, a Tablet, among others, where said audio message is selected from a horn/siren, an audio message, among others, and where said visual message is selected from a fixed or flashing light signal, among others, and where said alarm messages are updated automatically and periodically.
  • step g optionally after step b), preparing a curve of bushing wear values as a function of the measurements of the digital counter chip; h) determining the bushing wear value from the measurements of the digital counter chip of the measurement module according to the curve obtained in step g); yi) establishing the level of the wear value of the bushing accumulated over time according to the wear values determined in g) accumulated over time, to complement stage e).
  • the following examples refer to obtaining the calibration curves of the capacitance and the digital level of the probe and the wear of the bushing.
  • Example 1 Capacitance of control specimen versus bushing wear
  • a 32 mm specimen connected to the capacitive chip was worn in a controlled manner.
  • the wear was generated with a mechanical lathe at a rate of 1 mm feed per pass, completely grinding the face of the specimen in each pass.
  • the capacitance value was acquired, thus obtaining a relationship between the length of the specimen and the capacitance value at constant temperature.
  • Figure 15 shows the length measured by the measurement module vs. the length of the specimen as the wear increased.
  • Example 2 Digital level of witness probe vs. bushing wear

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Abstract

La présente invention concerne un kit, un système et une méthode de surveillance à distance, autonome, en temps réel, de l'usure sur le corps d'un moyeu, installé sur un engin de déplacement de terre, y compris le pourtour d'une benne à terre, qui comprend: un module de mesure, un module d'acquisition et un adaptateur qui relie les deux. Le système comprend ledit kit, en communication avec un moyen de réception et un réseau de communication sans fil, avec une unité centrale située à l'intérieur du lieu de fonctionnement de l'engin minier, ou en dehors de ce lieu, et une fois que les données de l'usure du moyeu sont reçues, son retrait temporel ou permanent est programmé. La méthode de surveillance comprend des mesures de capacitance à compensation thermique, dans un échantillon témoin dans le module de mesure de l'enveloppe du moyeu, qui s'use de manière solidaire avec celui-ci; et comprend, de manière complémentaire, la quantification du niveau des lignes électriques de conduite espacées dans l'échantillon témoin qui diminuent avec l'usure.
PCT/CL2022/050025 2021-06-04 2022-03-22 Kit, système et méthode de surveillance à distance, autonome, en temps réel, de l'usure d'un moyeu d'engin de déplacement de terre WO2022251980A1 (fr)

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CA3221356A CA3221356A1 (fr) 2021-06-04 2022-03-22 Kit, systeme et methode de surveillance a distance, autonome, en temps reel, de l'usure d'un moyeu d'engin de deplacement de terre

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CL1477-2021 2021-06-04
CL2021001477A CL2021001477A1 (es) 2021-06-04 2021-06-04 Kit, sistema y método de monitoreo remoto, autónomo, en tiempo real, del desgaste en bujes de máquina de movimiento de tierra, preferentemente en oreja de balde de pala minera

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Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2013152807A1 (fr) * 2012-04-13 2013-10-17 Aktiebolaget Skf Dispositif de détection d'usure de bague
WO2013152802A1 (fr) * 2012-04-13 2013-10-17 Aktiebolaget Skf Dispositif de détection d'usure de bague
US20150081166A1 (en) * 2014-11-21 2015-03-19 Caterpillar Inc. Wear monitoring system for a track roller
US20160221618A1 (en) * 2015-02-02 2016-08-04 Caterpillar Inc. Wear sensing device for a carrier roller

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2013152807A1 (fr) * 2012-04-13 2013-10-17 Aktiebolaget Skf Dispositif de détection d'usure de bague
WO2013152802A1 (fr) * 2012-04-13 2013-10-17 Aktiebolaget Skf Dispositif de détection d'usure de bague
US20150081166A1 (en) * 2014-11-21 2015-03-19 Caterpillar Inc. Wear monitoring system for a track roller
US20160221618A1 (en) * 2015-02-02 2016-08-04 Caterpillar Inc. Wear sensing device for a carrier roller

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