Monitoring of wear part

RELATED APPLICATIONS [0001] This application claims priority to U.S. Provisional Patent Application No. 61/908458, entitled "Wear Part Monitoring," filed November 25, 2013, which is incorporated herein by reference in its entirety.

[0002] The present invention relates to systems and tools for monitoring the condition, health and performance of wear parts used on various types of earth working equipment.

[0003] In mining and construction, wear parts (e.g., teeth, shrouds and lips) are commonly used to protect underlying equipment from excessive wear and, in some cases, to the mining edge. It is provided along the edge of the digging equipment for the purpose of further performing other functions such as breaking up the ground soil prior to the digging edge. For example, buckets, such as for dragline machines, cable shovels, face shovels and hydraulic excavators, are typically equipped with multiple wear components such as digging teeth and shrouds attached to the lip of the bucket. The teeth typically comprise an adapter that is fixed against the lip of the bucket and a wear member attached to the adapter for initial contact with the soil and breaking up the soil before the mining edge of the bucket. have.

[0004] In use, wear parts are typically subjected to high loads and become highly worn, which in some cases can lead to the wear parts becoming dislodged and lost from the excavating machine. For example, wear members, also known as points, may be lost from the adapter when the bucket is engaged with the ground. It is not always possible for an excavating machine operator to know when a wear part has been lost. It is well known that missing wear parts can damage downstream drilling equipment. For example, missing wear parts can be detrimental to extended downtime of conveyors, screens, pumps and crushers. For example, if wear parts get caught in a crusher, they can be pushed out and endanger the operator, and they can also become jammed, in which case the operator must remove the wear parts. must be removed, which in some cases can be a difficult, time consuming and/or dangerous process. Also, continued operation of the drilling equipment without wear parts can result in reduced production and can also cause excessive wear to other components on the drilling equipment.

[0005] In a worn condition, the wear parts will eventually wear out. If wear parts are not replaced in a timely manner, excessively worn wear parts can be lost, which can lead to lower production and unnecessarily wear other components of the drilling equipment. there is a possibility.

[0006] A number of systems have been used with varying degrees of success to monitor when wear members are worn or damaged and when replacement is required. For example, the Tooth-Wear Monitoring system sold by Motion Metrics and the Missing Tooth The Detection system uses an optical camera mounted on the excavator's shovel boom. Also, US Pat. No. 8,411,930 relates to a system and method for detecting damaged or missing wear parts. The system has a seismic video camera preferably mounted on the shovel boom. Since the above system is located above the shovel boom, the system will have a clear view of the wear parts during only part of the mining and dumping operation. As a result, the system may not immediately detect that a wear member has been lost or needs to be replaced. Also, if the system incorrectly detects that a wear member is missing, it may indicate that the wear member is indeed missing and that an object may be blocking the view of the system, thereby giving a false alarm. The system may have to wait until the next mining/dumping cycle to confirm that it is not.

[0007] Several other systems have been used with varying degrees of success to monitor whether a wear member is secured to a base on an excavating machine. For example, mechanical systems have been installed between the wear member and the base to detect the presence or absence of the wear member. In US Pat. No. 6,870,485 the system contains a spring-loaded switch between the wear parts. When the wear parts are separated, an electrical switch activates a radio transmitter that alerts the operator that the wear parts are missing. In US Pat. No. 5,743,031, a system comprises an indicator attached to the tooth and an actuator fixed relative to the nose. In one embodiment, an actuator actuates a flare for the purpose of providing a visual signal that a tooth is falling out or about to fall out. These systems do not determine when the wear member has reached the end of its life and when the wear member needs to be replaced, and these mechanical systems do not determine when the wear member has worn out. It can be costly to equip when it becomes necessary to replace it, and it can be cumbersome to do so.

<p>[0008] The present invention relates to systems and tools for monitoring wear parts for earthwork equipment. This monitoring tool is particularly well suited for monitoring the presence and health (ie, current wear profile) of wear parts utilized with buckets used for drilling in mining and built environments.</p>

<p>[0009] In one aspect of the present invention, electronic sensors are used in conjunction with programmable logic to determine if wear parts are present on earthwork equipment. Programmable logic triggers an alert if no wear parts are present. Alerts notify operators when wear parts are missing from drilling equipment. This allows the operator to take necessary action to ensure that the missing wear parts are replaced and to prevent the missing wear parts from damaging downstream drilling equipment. Become. By way of example, the electronic sensor may be a camera, laser rangefinder, ultrasonic sensor, or another distance measuring sensor. In one preferred arrangement the camera is selected from the group consisting of a 2D camera, a 3D camera and an infrared camera.</p><p>[0010] In another aspect of the invention, electronic sensors are used in conjunction with programmable logic to determine how worn parts on earthmoving equipment are. Programmable logic activates an alert when the wear part has worn a predetermined amount. Alerts notify the operator that worn wear parts should be replaced. This allows the operator to take the actions necessary to replace worn wear parts in order to prevent unnecessary wear to other components of the earthmoving equipment. By way of example, the electronic sensor may be a camera, laser rangefinder, ultrasonic sensor, or other distance measuring sensor. In one preferred arrangement the camera is selected from the group consisting of a 2D camera, a 3D camera and an infrared camera.</p><p>[0011] In another aspect of the invention, electronic sensors are used in conjunction with programmable logic to determine how heavily loaded a bucket is during mining operations. In one preferred configuration, the programmable logic can be programmed to communicate the current load and historical load to the operator or wireless device for each mining cycle. This allows the operator to tailor the mining operation with the goal of optimally filling the bucket to the desired capacity. This system may be a stand-alone system or it may be integrated with another system, such as a monitoring system for monitoring the presence and/or health of wear parts mounted on the bucket. By way of example, the electronic sensor may be a camera, laser rangefinder, ultrasonic sensor, or another distance measuring sensor. In one preferred arrangement the camera is selected from the group consisting of a 2D camera, a 3D camera and an infrared camera.</p><p>[0012] In another aspect of the invention, electronic sensors and programmable logic are used to determine the percentage that the bucket is full. The percentage can be determined by measuring the most recent fill of the bucket and comparing the most recent fill to the rated capacity of the bucket. Electronic sensors can be, for example, cameras, laser rangefinders, ultrasonic sensors or other distance measuring sensors. In one preferred arrangement the camera is selected from the group consisting of a 2D camera, a 3D camera and an infrared camera. This system may be a stand alone system or it may be integrated with another system such as a bucket fill monitoring system.</p><p>[0013] In another aspect of the invention, an electronic sensor is used to determine the mining cycle time. In one preferred configuration, the programmable logic may be programmed to communicate the latest and past cycle times to the operator or wireless device for each mining cycle of the bucket. This allows the operator to tune mining operations for optimum performance. By way of example, accelerometers and/or inclinometers may be used to determine when a mining cycle has begun. This system may be a stand-alone system or it may be integrated with another system, such as a monitoring system for monitoring the presence and/or health of wear parts mounted on the bucket.</p><p>[0014] According to another aspect of the invention, an electronic sensor is used to determine when the mining edge of the bucket has undergone a strong impact (ie, an impact exceeding that of a normal mining operation). . In one preferred configuration, programmable logic can record the time of the high impact event. Programmable logic may be programmed to communicate a high impact event to an operator or wireless device. As an example, accelerometers are used to determine when a high impact event occurs. This system may be a stand-alone system, but may be integrated with another system, such as a monitoring system for monitoring the presence and/or health of wear parts mounted on the bucket. This will tell you what the current state of the wear parts is (e.g. wear part present, wear part missing, wear part worn out, etc.). Allows the operator or service personnel to better determine what may have happened.</p><p>[0015] In another aspect of the invention, the tool is mounted on a wear component that engages and displaces the soil to be excavated. In one preferred arrangement, the tool is mounted on the bucket used for excavation so that the monitoring system has a clear line of sight to the mining edge of the bucket during mining and dumping operations. The tool can be fixed against the inner surface of the bucket, or the tool can be fixed against the outer surface of the bucket. By way of example, the monitoring system may be integrated into the shell of the bucket, integrated between the two inner plates of a bucket with a double-walled shell, or mounted on the bridge or top of the bucket.</p><p>[0016] According to another aspect of the invention, features are incorporated into the wear parts to assist in presence/absence detection. In one preferred configuration, this feature is incorporated into the adapter so that if the monitoring system can detect this feature, the monitoring system will alert the user that a wear member is missing. is programmed to transmit In another preferred arrangement, this feature is incorporated into the wear member so that if the monitoring system can detect this feature, the monitoring system will detect the loss of the wear member from the drilling equipment. is programmed to indicate that</p><p>[0017] In another aspect of the invention, features are incorporated into the wear parts to assist in determining the degree of wear of the wear parts on the drilling equipment. In one preferred configuration, the wear part contains a plurality of features along the length of the expected wear profile such that as the wear part wears, the monitoring system detects features left on the wear part. The number of parts can be detected.</p><p>[0018] In accordance with another aspect of the invention, a monitoring system provides alerts to equipment operators, databases and remote devices when wear parts on the drilling equipment require servicing. In one preferred configuration, the monitoring system communicates wirelessly.</p><p>[0019] In another aspect of the invention, a monitoring system is equipped with devices for displaying or indicating the condition, health and performance of wear parts. In one preferred configuration, the monitoring system is equipped with a monitor. In another preferred arrangement, the monitoring system is integrated into a display system that is part of the drilling equipment being monitored or a display that is remote from the monitoring system.</p><p>[0020] In another aspect of the invention, a monitoring system stores a history of the condition, health and performance of wear parts.</p><p>[0021] In another aspect of the invention, the monitoring system utilizes light to illuminate the wear parts to be monitored, so that the electronic sensors provide an indication of the condition, health and performance of the wear parts. Accurate readings can be made for</p>

<figref num="1">[0022] Fig. 1 is a side view of a prior art mining excavator;</figref><figref num="2">[0023] FIG. 1 is a perspective view of a prior art excavator hoe bucket;</figref><figref num="3">[0024] Fig. 4 is a perspective view of the lip of a prior art excavator hoe bucket;</figref><figref num="4">[0025] Fig. 2 is a perspective view of a prior art tooth assembly;</figref><figref num="5">[0026] Fig. 5 is an exploded perspective view of the tooth assembly shown in Fig. 4;</figref><figref num="6">[0027] Fig. 2 is a partially exploded perspective view showing a prior art tooth assembly having only a point and an adapter;</figref><figref num="7A">[0028] FIG. 4 is a schematic diagram showing the overall process steps for monitoring the condition and health of wear parts in accordance with the present invention;</figref><figref num="7B">1 is a schematic diagram showing the overall process steps for monitoring the condition and health of wear parts according to the present invention; FIG.</figref><figref num="8">[0029] Fig. 2 is a cross-sectional view of the monitoring system of the present invention;</figref><figref num="9">[0030] Fig. 3 is a perspective view of a bucket with a monitoring system mounted on the bridge of the bucket in accordance with the present invention;</figref><figref num="10">[0031] FIG. 4 is a perspective view of the upper portion of a hydraulic face shovel bucket with a monitoring system integrated with the shell of the bucket according to the present invention; Bucket lips, bottom walls, side walls and other details have been eliminated to simplify the drawing.</figref><figref num="11">[0032] Fig. 3 is a perspective view of an enclosure for a surveillance system according to the present invention;</figref><figref num="12">[0033] Fig. 4 is a perspective view of a nozzle and/or wiping tool for keeping transparent walls clean in accordance with the present invention;</figref><figref num="13">[0034] Fig. 2 is a front perspective view of a device for keeping transparent materials clean according to the present invention;</figref><figref num="14">[0035] FIG. 4 is a perspective view of a wear member with unique features and/or patterns along the length of the expected wear profile of the wear member, in accordance with the present invention;</figref><figref num="15">[0036] Fig. 15 is a partial side view taken along line 15-15 showing the wear member shown in Fig. 14;</figref><figref num="16">[0037] According to the present invention, a unique feature and/or pattern is provided in the top surface of the base in such a manner that the unique feature and/or pattern can only be seen in the absence of a wear member. Fig. 2 is a perspective view showing a base provided;</figref><figref num="17">[0038] Fig. 2 is a front view of a Human Machine Interface (HMI) for use with a surveillance system in accordance with the present invention;</figref><figref num="18">[0039] Fig. 2 is a front view of a mobile HMI for use with a surveillance system according to the present invention;</figref><figref num="19">[0040] Fig. 4 is a side view of an electronic sensor for determining the fill of a bucket according to the present invention;</figref><figref num="20">[0041] Fig. 4 is a side view of an electronic sensor for determining the fill level of a truck body in accordance with the present invention;</figref>

[0042] The present invention provides drilling equipment and ground transportation. It relates to systems for monitoring the condition, health and performance of wear parts used on various types of earthmoving equipment, including, for example, conveying equipment. Excavating equipment is intended to be a general term meaning any of a variety of excavating machinery used in mining, construction and other operations, including, for example, bulldozers, loaders, dragline machines, cable Excavators, face shovels and hydraulic excavators are included. Excavating equipment also means the earth-engaging components of these machines, such as buckets, blades or cutterheads. Earth soil handling equipment is also intended to be a general term meaning a variety of equipment used to transport earthen materials, including, for example, chutes and mining truck beds or bodies. included. The present invention is suitable for monitoring the condition, health and performance of wear parts used on excavating equipment, for example in the form of excavating buckets, blades, lips, teeth and shrouds. In addition, certain aspects of the present invention are also suitable for monitoring the condition and health of wear surfaces, for example in the form of runners and truck beds or bodies. For the sake of discussion, the wear parts monitoring process will be discussed in the context of a monitoring system that monitors points on a mining excavator, but this monitoring process is also applicable to other wear parts used with many types of earthmoving equipment. can be used.

[0043] For convenience of discussion, relative terms such as anterior, posterior, top and bottom are used. The terms front or front are generally used to indicate the normal direction of movement of earthen material relative to wear parts in use (e.g. mining), the terms top or top are used e.g. Generally used as a reference is the surface through which the material passes when it is applied. However, it should be recognized that the wear assembly can be oriented in various directions and can move in all directions in use when operating various earthmoving machines.

[0044] A mining excavator 1 is equipped with a bucket 3 for collecting earthen material during mining (Figure 1). A bucket 3 has a frame or shell 4 defining a cavity 16 for collecting material during mining operations (Fig. 2). The shell 4 has a top wall 6 with an attachment support 8 for attaching the bucket 3 to the earthmoving implement 1, a bottom wall 10 opposite the top wall 6, a rear end with a rear wall 12, and a pair of Opposite side walls 14 , each positioned between top wall 6 , bottom wall 10 and rear wall 12 . The shell 4 may consist of a wall with a single plate, or it may consist of parts of a bucket with double plates as is well known. Several configurations of buckets are known, and a variety of bucket geometries exist, for example, the bucket may not have a top wall such as found in dragline buckets, or the rear wall may be It may be hinged as found in a dipper bucket, or a portion of the sidewall may be hinged as found in a hydraulic face excavator bucket. The particular geometry of the bucket is not intended to be limiting, as the present invention may be used with various types of buckets and with various types of wear parts used on earthmoving equipment. . The bucket 3 has a lip 5 extending forward of the bottom wall 10, which is the mining edge of the bucket 3 (Figs. 2 and 3). The mining rim is the part of the equipment that first contacts the ground. A tooth assembly and shroud are often fixed against the mining rim for the purpose of protecting the rim and crushing the ground soil ahead of the lip 5 . A plurality of tooth assemblies 7 and shrouds 9 as disclosed in US Patent Application Publication No. US-2013/0174453, incorporated herein by reference, may be attached to the lip 5 of the bucket 3 (Figs. 2-5). The teeth 7 shown are mounted on the adapter 11 welded to the lip 5, the intermediate adapter 13 mounted on the adapter 11 and the base 13 point (also called tip) 15. A point 15 has a rearwardly open cavity for receiving the nose 17 of the base 13 and a forward end 19 for penetrating the ground (Fig. 5). A locking mechanism or lock 21 is used to secure the wear member 15 to the base 13 and to secure the base 13 to the nose 23 (Fig. 5). Other tooth configurations are also possible, for example as disclosed in U.S. Pat. No. 7,882,649, incorporated herein by reference, an adapter 11a in which the tooth assembly 7a is fixed against the lip and the point It may be defined only by 15a (Fig. 6). One aspect of the invention relates to monitoring the presence and/or health of wear members on the base. For ease of discussion, this application generally discusses monitoring the presence and/or health of wear members on a fixed base relative to an excavating bucket. However, the present invention can also be used to monitor the presence and/or health of wear members on bases on various types of earthwork equipment, as well as points on adapters, points on mid-adapters. , intermediate adapters on adapters, adapters, cast lip noses, shrouds, lips, blades, wear runners, track liners, or other wear parts on other types of earthmoving equipment can do. Over the life of the bucket or other piece of equipment, the wear members wear out requiring frequent replacement. As disclosed in '649, tooth assembly 7a may be defined only by adapter 11a fixed against the lip and point 15a (FIG. 6). One aspect of the invention relates to monitoring the presence and/or health of wear members on the base. For ease of discussion, this application generally discusses monitoring the presence and/or health of wear members on a fixed base relative to an excavating bucket. However, the present invention can also be used to monitor the presence and/or health of wear members on bases on various types of earthwork equipment, as well as points on adapters, points on mid-adapters. , intermediate adapters on adapters, adapters, cast lip noses, shrouds, lips, blades, wear runners, track liners, or other wear parts on other types of earthmoving equipment can do. Over the life of the bucket or other piece of equipment, the wear members wear out requiring frequent replacement. As disclosed in '649, tooth assembly 7a may be defined only by adapter 11a fixed against the lip and point 15a (FIG. 6). One aspect of the invention relates to monitoring the presence and/or health of wear members on the base. For ease of discussion, this application generally discusses monitoring the presence and/or health of wear members on a fixed base relative to an excavating bucket. However, the present invention can also be used to monitor the presence and/or health of wear members on bases on various types of earthwork equipment, as well as points on adapters, points on mid-adapters. , intermediate adapters on adapters, adapters, cast lip noses, shrouds, lips, blades, wear runners, track liners, or other wear parts on other types of earthmoving equipment can do. Over the life of the bucket or other piece of equipment, the wear members wear out requiring frequent replacement.

[0045] When the wear member reaches the minimum recommended wear profile (i.e., the wear member is considered fully worn), the wear member is replaced, resulting in no loss of production and no wear. Unnecessary wear of the base on which the component rests is eliminated. Figures 7A and 7B illustrate the steps of a monitoring system that monitors the condition and health of wear members on an excavator bucket. This process shows three different wear part tests performed in parallel, and the results of these three tests determine the outcome of the process (e.g., that the wear part is okay to continue to operate, The wear member is worn, the wear member is missing, etc.) is obtained. Processes vary, for example, it may be desirable to monitor only if a wear member is present or only when a wear member has worn to the point where it should be replaced. In other examples, it may be desired to perform more than three different wear part tests or less than three wear part tests, or to utilize only a portion of the process. In another example, the process may be performed serially (ie, perform a first wear member test and advance to the next wear member test if necessary). It is also possible for the system to estimate the remaining useful life of the wear parts based on the amount of wear parts remaining and the wear rate, in order to assist the operator in determining when to replace the wear parts. be.

[0046] Since each type of wear member has a recommended minimum wear profile or a set minimum wear profile, one of the wear member inspections is to determine the most recent length of each wear member on the bucket. may be to determine A monitoring system 25 can use electronic sensors 27 to determine the current length of each wear member on the bucket (FIG. 8). The length of the wear member can be determined, for example, by a camera, an ultrasonic sensor, a laser interferometer, or another distance measuring sensor. In some embodiments, the camera may be an optical camera or the camera may be a thermal imaging camera. In some embodiments, the monitoring system can be equipped with a light to illuminate the monitored wear parts so that the electronic sensors can take accurate readings. The light that illuminates the wear parts may alternatively be part of the earthmoving equipment, or it may not be necessary to illuminate the wear parts. If the monitoring system uses a camera to determine the length of the wear member on the bucket, the camera can first acquire an image of the lip 5 and the attached tooth assembly 7 (Fig. 3). . Central Processing Unit (CPU), Controller, PC, or Programmable Logic Controller (PLC) The following programmable logic on the Controller (all of which are generally referred to as controllers) can apply a baseline to the image of the bucket lip (not shown). The datum line may, for example, define the allowable wear limit for each wear member or may indicate the lip of a bucket, or the datum line may be a "trailing edge" or end point for programmable logic. may be any line for establishing The reference line may be straight or non-linear depending on the type of lip and/or wear member. A reference line (not shown) is preferably located behind the leading edge of the lip 5 (Fig. 5). Programmable logic may have integrated visual recognition software for determining the leading edge of each wear member on the lip of the bucket. The visual recognition software may be, for example, In-Sight sold by Cognex. Programmable logic is programmed to count the number of pixels between the reference line and the leading edge of each wear member. Based on the number of pixels, programmable logic is programmed to determine the current length of each wear member. Once the current length of each wear member is determined, programmable logic compares the current length to a minimum wear profile set for the type of wear member installed on the bucket. The programmable logic can look up a database for the most recent type of wear member installed on the bucket, or use visual recognition software to determine the type of wear member installed on the bucket. . The programmable logic can also reference a database of bucket and wear member geometries to assist the visual recognition software in determining the type and number of wear members to be installed on the bucket. The length of each wear member on the bucket is greater than the set minimum wear profile (i.e., within the set range), and the results of other wear member tests in parallel are acceptable (e.g., wear section When the material is on the base and the number of edges extending from the base matches the expected number of edges extending from the base, the programmable logic loops back to the start of the process to It can be programmed to again determine the length of the wear member (FIGS. 7A and 7B). Programmable logic may loop this process continuously, or a delay may be built into the process to ensure that the process occurs once within a set time limit. The current length of at least one wear member is close to the minimum wear profile (i.e., within a set range) and the results of the parallel other wear member tests are acceptable (e.g., wear member is on the base and the number of edges extending from the base matches the expected number of edges extending from the base), the programmable logic determines the condition that the particular wear member requires replacement. can be programmed to provide proactive alerts of approaching Alerts may be, for example, visual alerts, haptic feedback, and/or audio alerts. The monitoring system provides alerts wirelessly to the operator of the equipment and/or to a wireless device for access by the operator or other person, such as a maintenance worker or mining manager. be able to. However, the length of each wear member is not greater than the minimum wear profile (i.e. less than the set range) and the results of other wear member tests in parallel are acceptable (e.g. and the number of edges extending from the base matches the expected number of edges extending from the base), the programmable logic is programmed to alert that the wear member is worn. can be Programmable logic may be programmed to issue an immediate alert or programmed to reduce false alarms; to repeat the process the specified number of times or repeat the process within a preset time frame. can be programmed to return This reduces the likelihood that the programmable logic will fail to detect a wear member or an object interfering with the electronic sensor as a worn or missing wear member.

[0047] Since each wear member and each base has a specific geometry, another wear member test may be performed on each wear member for the purpose of helping to know if the wear member is still attached to the base. Determining the features of the wear member and the features of the base on the bucket may be determined. As will be disclosed in detail later, unique features and/or patterns may also be included on the wear member or on the base for the purpose of assisting in determining whether the wear member is still attached to the base. can be For example, features for cues, unique features and/or patterns may be incorporated into the wear member so that the monitoring system can detect the features and the results of other wear member inspections in parallel. If acceptable (e.g., the wear profile is acceptable and the number of edges extending from the base matches the expected number of edges extending from the base), the monitoring system detects wear members from the drilling equipment. is not lost. In alternative embodiments, unique features and/or patterns are incorporated into the base such that only the unique features and/or patterns are visible in the absence of wear members. The monitoring system detects features and/or patterns and the results of other wear part inspections in parallel are unacceptable (e.g., the wear profile is unacceptable, the number of edges extending from the base is (not matching the expected number of edges to wear), the monitoring system is programmed to generate an alert that a wear member is missing.

[0048] Since each base has a certain number of edges extending from the base (that is, in each base, one wear part extends from the base), wear members are still attached to the base. Another wear member test may be to determine the number of edges extending from the base that are attached to the lip of the bucket to help determine if it is. This is done by counting the number of edges extending from the base or lip (i.e. the number of edges extending forward from the base or lip in a direction parallel to the movement of the bucket during normal mining operations) and dividing it , the expected number of edges extending from the base or lip. For example, the number of edges extending from the base or lip does not match the expected number of edges extending from the base or lip, and the results of other wear member tests in parallel are acceptable (e.g., If the wear profile is acceptable and the wear part is on the base, the programmable logic can be programmed to give a proactive alert (not shown) and/or can be programmed to repeat the monitoring process from the beginning. . If there is a possible error in the process (eg, if a rock or other item is misinterpreted as a wear member), the monitoring process can be repeated. In a similar fashion, the wear member is on the base, but the number of edges extending from the base does not match the expected number of edges extending from the base, and the wear profile of the wear part is unacceptable. If so, the programmable logic is programmed to repeat the monitoring process from the beginning (not shown in Figures 7A or 7B). In an alternative embodiment, the programmable logic can be programmed to send a proactive alert (e.g. the wear member may be worn but something may be between the wear member). or if a wear member may be missing and an object is misinterpreted as a wear member). The wear profile is allowed and the number of edges extending from the base matches the expected number of edges extending from the base. If there is a match, but the wear member is not above the base (e.g., a unique feature on the base is not normally visible when the wear member is visible at that point), the programmable logic determines if something The monitoring process can be programmed to repeat from the beginning (not shown in Figures 7A or 7B) because it may be causing the process to error. If the wear profile is unacceptable and the wear member is not on the base, but the number of edges extending from the base matches the expected number of edges extending from the base, then what is the programmable logic? (not shown in FIG. 7A or 7B) to repeat the monitoring process from the beginning, as it may have caused the process to error. If the wear profile is acceptable, but the number of edges extending from the base does not match the expected number of edges extending from the base, and no wear members are on the base, the programmable logic The monitoring process can be programmed to repeat from the beginning (not shown in Figures 7A or 7B) because something may have caused the process to error.

[0049] Results and alerts from the process may be sent to a Human Machine Interface (HMI). The details of the HMI will be considered in more detail later. The bucket health monitoring system also indicates that a particular wear member needs maintenance either because the wear member is missing or because the wear member has worn past the minimum wear profile. Needs can be communicated wirelessly or via cable to other computer systems. Additionally, the monitoring system can store all of the results from the process.

[0050] In addition to monitoring the condition and health of wear members on buckets, the monitoring system can monitor the performance of buckets or other wear members. For example, the monitoring system can determine how overfilled a bucket is during a mining cycle. When the bucket is loaded, the material being excavated tends to fill the bucket with a defined profile. When the bucket 3a is filled by the operator, the electronic sensor 27 measures the distance D1 to the load 91 in the bucket 3a (FIG. 19) and programmable logic determines the amount of load in the bucket by: Using this distance and a database of established fill profiles. Also, electronic sensors 27 and programmable logic can determine the percentage that the buckets are full. This percentage can be determined by comparing the most recent fill of the bucket to the rated capacity of the bucket. In an alternative embodiment, the electronic sensor 27 can measure the distance D1 to the load 91 in the truck body 3b (Fig. 20) and the programmable logic determines the amount of load in the truck body. , using this distance and a database of established fill profiles. As with the bucket, electronic sensors can be used to determine the percentage that the truck body is full. The electronic sensor may be a camera, laser rangefinder, ultrasonic sensor, or another distance measuring sensor. Programmable logic can determine the percentage full of the bucket based on the distance to the load within the bucket. Results from current and past mining cycles may be communicated to equipment operators or to other databases or computer systems. This allows the operator of the equipment to vary the mining technique in order to optimally fill the buckets and truck bodies. Monitoring systems, for example, monitor the condition and health of wear parts. or a separate electronic sensor for monitoring the filling of the bucket can be used. Electronic sensors can be, for example, cameras, laser rangefinders, or ultrasonic sensors. The camera may be, for example, a 3D camera capable of determining depth, or it may be a camera coupled to visual recognition software as outlined above. It is also possible that the electronic sensor for determining the fill level of the bucket is a separate component of the monitoring system that is not incorporated into the monitoring system. Using a monitoring system to monitor filling of buckets may be utilized as a stand-alone system, ie, without a system for monitoring the presence and/or health of wear parts. This type of monitoring system can also be used in non-bucket applications (eg, truck trays, etc.) to monitor operator efficiency or optimization.

[0051] The monitoring system can be equipped with electronic sensors that can determine the cycle time of the mining cycle. For example, the monitoring system can be equipped with accelerometers and inclinometers (not shown). The inclinometer provides the orientation of the bucket and the accelerometer detects a spike in force when the bucket is in the proper mining orientation, thereby indicating that a mining cycle has begun. Programmable logic determines the time from the start of one mining cycle to the start of a second mining cycle (that is, the time between peaks when the inclinometer indicates the bucket is in the proper mining direction). be able to. Results from the most recent cycle time and past cycle times can be communicated to the equipment operator or wireless device. This allows the operator to tune mining operations for optimum performance. It is also possible not to incorporate electronic sensors into the monitoring system for determining cycle time. Monitoring the fill and/or cycle time of buckets or truck trays helps miners in better optimizing their operation. operator) (etc.). In alternative embodiments, pressure sensors may be used instead of accelerometers to determine when a mining cycle has started. The pressure sensor may be a hydraulic pressure sensor integrated into the boom of the earthmoving equipment. In another preferred embodiment, strain gauges or load cells are used to determine when a mining cycle has started. A strain gauge or load cell may be located in the bucket or in a wear member on the bucket. In an alternative embodiment, GPS may be used to determine the orientation of the bucket.

[0052] The monitoring system may be equipped with electronic sensors that can determine when a strong impact (ie, an impact exceeding that of a mining operation) has occurred on the mining edge of the bucket. For example, the monitoring system can utilize accelerometers, strain gauges, load cells, or pressure sensors (not shown) to determine peak impact. Programmable logic can record when a high impact event occurs. The consequences of a high impact event can be communicated to the equipment operator or wireless device. It is also possible that the electronic sensor for determining high impact events is a separate component or not incorporated into the monitoring system from the electronic sensor for determining mining cycle time. .

[0053] According to one embodiment of the invention, a monitoring system 25 having at least one electronic sensor is incorporated into the bucket 3 so as to monitor how the operator is orienting the bucket 3 during mining and dumping operations. Regardless, the sensor will have a clear line of sight to the mining edge or lip 5 of the bucket 3 (FIGS. 9 and 10). The electronic sensors can, for example, be integrated into the shell 4 of the bucket (Fig. 10), integrated between two inner plates of a bucket with a double-walled shell (not shown), or It can be mounted on the bridge 29 or the top (Fig. 9). Electronic sensors can be, for example, cameras, ultrasonic sensors, or laser interferometers. The camera may be, for example, a Cognex7100 camera. However, the monitoring system may also be installed or integrated into the boom or other support of the drilling equipment, for example, or into the body of the drilling equipment. For non-bucket applications, the monitoring system may preferably be installed or integrated into the base member that supports the wear parts. The base member may be, for example, a truck tray or blade. If a monitoring system is installed for the truck tray, the monitoring system can monitor the presence and/or health of runners on the truck tray. Similarly, if the monitoring system is installed against a bulldozer or earthmoving machine blade, the monitoring system can monitor the presence and/or health of the end bit on the blade or the leading edge of the blade. Similar to mounting the monitoring system on a bucket, mounting it on a truck tray or blade can also provide a clear line of sight to the part being monitored.

[0054] Electronic sensors 27 are housed within one or more enclosures 31 at one or more locations on the wear parts that engage and move the soil to be excavated. This ensures that the electronic sensor 27 is protected from harsh mining environments and also that the aperture 33 in the housing of the electronic sensor 27 protects the electronic sensor 27 from powdery substances, mud, etc. that could adversely affect the electronic sensor 27. , or become maintained free of other substances (FIGS. 8 and 11). Enclosure 31 may have one or more mounting brackets 35 for mounting enclosure 31 on the first wear part. Enclosure 31 may also house additional electronics (not shown) for controlling and processing data from electronic sensors 27 . In alternate embodiments, some or all of the additional electronic equipment may be housed on the drilling equipment or may be at a remote location (not shown). For example, one or more electronic sensors 27 may be located at one or more locations in/on the bucket, electronic sensors 27 via wires or wirelessly with other electronic sensors, and/or may communicate with additional electronics in the cab of the drilling equipment. In an alternative embodiment, one or more electronic sensors 27 (shown in thin lines in FIG. 9) are attached to a first wear component that engages and displaces the soil to be excavated. It may be located on or in the second wear part to be attached. The first wear part may be, for example, a bucket, blade or truck body, and the second wear part may be, for example, a point, intermediate adapter, adapter, shroud, nose, lip, wear runner or track liner. It's okay. The electronic sensor in the second wear part may be located on the first wear part, the electronic sensor on the second wear part, and/or on the first wear part or on the first wear part. Additional electrons that may be located remotely from the component It can communicate with equipment. Similar to the electronic sensors in the first wear part, the electronic sensors in the second wear part can communicate via wires or wirelessly. Additional electronics may be, for example, controllers, power supplies, cameras, and/or wireless devices. The controller may be, for example, an S7-1200PLC sold by Siemens. The power supply can power only the electronic sensors, or it can power additional electronics as well. In an alternative embodiment, two power supplies are provided. A first power supply is for powering the electronic equipment and a second power supply is for powering the additional electronic equipment. The power supply may be, for example, the power supply sold by TDK-Lambda and/or the SDC-5 Power Supply. The camera may be, for example, a Closed-Circuit Television (CCTV) camera. A CCTV camera can provide the HMI with live footage of the bucket lip. The details of the HMI will be considered in more detail later. The wireless device may be, for example, a wireless serial device server sold by B&amp;B Electronics (formerly Quatech). Closed-Circuit Television) camera. A CCTV camera can provide the HMI with live footage of the bucket lip. The details of the HMI will be considered in more detail later. The wireless device may be, for example, a wireless serial device server sold by B&amp;B Electronics (formerly Quatech). Closed-Circuit Television) camera. A CCTV camera can provide the HMI with live footage of the bucket lip. The details of the HMI will be considered in more detail later. The wireless device may be, for example, a wireless serial device server sold by B&amp;B Electronics (formerly Quatech). Closed-Circuit Television) camera. A CCTV camera can provide the HMI with live footage of the bucket lip. The details of the HMI will be considered in more detail later. The wireless device may be, for example, a wireless serial device server sold by B&amp;B Electronics (formerly Quatech). Closed-Circuit Television) camera. A CCTV camera can provide the HMI with live footage of the bucket lip. The details of the HMI will be considered in more detail later. The wireless device may be, for example, a wireless serial device server sold by B&amp;B Electronics (formerly Quatech).

[0055] The enclosure may have at least one notch 37 on one side so that the aperture 33 of the at least one electronic sensor 27 has a clear line of sight to the lip 5 of the bucket 3. (Figures 8, 9 and 11). In an alternative embodiment, the bucket may have cutouts 39 so that the aperture of the electronic sensor has a clear line of sight to the lip (not shown) of the bucket (FIG. 10). The cutout 37 or 39 may be covered by a transparent wall 41, a translucent wall or a transparent wall so that the electronic sensor is completely sealed within the enclosure (Figs. 8, 10). and 11). In addition, the nozzles 43 may be directed to spray air, water or another type of cleaning agent onto the transparent wall 41 so that if dirt and powdery material builds up, the air can be removed. , the water or detergent washes the transparent wall 41 to keep the transparent wall 41 transparent (FIG. 12). In an alternative embodiment, the electronic sensor can have a built-in transparent cover to protect the aperture of the electronic sensor, and the nozzle sprays air, water or cleaning agent directly onto the transparent cover of the electronic sensor. (not shown). In an alternative embodiment, a wiping tool 45 may be provided for wiping the aperture transparent cover or transparent wall 41 (FIG. 12). A wiping tool may be integrated into the nozzle for spraying air, water or cleaning agent. In alternative embodiments, the wiping tool may be a separate tool from the nozzle. The wiping tool can be, for example, a comb, brush or squeegee. In an alternative embodiment, a cutout 37 in the enclosure or a cutout in the bucket can be equipped with a first spool 47 of transparent material 49 that extends across the cutout to the second spool 51 (Fig. 13). When the transparent material 49 becomes opaque, a motor (not shown) can rotate the second spool 51 so that the transparent material 49 is forced onto the first spool 47. to the second spool 51 so that a new section of transparent material 49 covers the notch. In an alternative embodiment, the cutout may be equipped with multiple layers of transparent material so that when the top layer needs to be replaced, the old top layer is peeled away to expose a new layer of transparent material. (not shown). In another alternative embodiment, the aperture of the electronic sensor can have a movable cover. A removable cover can cover the electronic sensor when not in use, or it can be removed so that the electronic sensor can take measurements (not shown).

[0056] The electronic sensor 27 and additional electronics (not shown) may be installed on the vibration damping device 53 so that the vibrations of the mining and dumping operation are transmitted to the electronic sensor 27 and the additional electronics (FIG. 8). no longer have a negative impact. Various vibration dampening devices 53 known in the art may be used to dampen the vibrations that occur. Vibration damping devices 53 may be mounted, for example, on the top and bottom of a mounting unit 55 holding electronic sensors 27 . Vibration damping device 53 may be, for example, an elastomer or a spring.

[0057] To assist the monitoring system in determining the current wear profile of the wear member 15, unique features and/or patterns 57 are provided along the length of the expected wear profile of the wear member 15. may be added (Figs. 14 and 15). Unique features and/or patterns 57 may be added to wear member 15 during or after manufacture. The unique features and/or patterns 57 may be, for example, grooves 59 and/or ridges cut, cast, or forged into the upper exterior surface 61 of the wear member 15. good. In an alternative embodiment, the unique feature and/or pattern may be a hard facing material applied to the upper exterior surface of the wear member (not shown). As wear member 15 wears into the ground, unique features and/or patterns 57 are also worn away. Electronic sensors can detect how many unique features and/or patterns 57 remain (eg, how many grooves 59 and/or ridges remain). Based on the latest wear profile and the set minimum wear profile, the health monitoring unit alerts (visual, audio and/or (which may be a haptic alert). Another alert may be sent when the wear member 15 wears past the minimum wear profile.

[0058] Unique features and/or patterns may be incorporated into the wear member or base to aid in presence/absence detection. Unique features and/or patterns may be added to the wear member or base during or after manufacture. The unique features and/or patterns 57 may be, for example, grooves 59 and/or ridges cut, cast, or forged into the upper exterior surface 61 of the wear member. (Figures 14 and 15). In an alternative embodiment, the unique feature and/or pattern may be a hard facing material applied to the upper exterior surface of the wear member (not shown). In alternative embodiments, the unique features and/or patterns 63 may be shapes that are cut, cast, or forged into the top surface 65 of the base 13, for example; In this case, the unique features and/or patterns 63 are only visible when no wear member is attached to the base 13 (FIGS. 9 and 16). In an alternative embodiment, hardfacing may be utilized to shape the top surface of the base (not shown). In an alternative embodiment, shape 67 may be cut into top surface 65 of base 13 and medallion 69 may be pressed into the cut, glued or otherwise secured ( Figure 16).

[0059] At least one HMI 71 may be provided to display the current status and health of the wear members on the bucket (Figs. 17 and 18). The HMI 71 may be hardwired into the monitoring system or may be a wireless device 81 (FIG. 18). The HMI 71 may be located within the cab 2 (FIG. 1) of the drilling equipment 1 or may be located at a remote location. Also, the HMI may be integrated into a display system that is still in the drilling rig today (e.g., with an OEM display), integrated into a new display system in the drilling rig, or a remote It may be integrated into the display system at the location. The HMI 71 may be configured to provide an up-to-date graphical representation 73 of the wear members on the lip of the bucket (FIGS. 17 and 18). HMI 71, for example, can provide visual alerts (eg, text 75 and/or graphical images), tactile feedback (eg, vibration), and audio alerts regarding the status of each wear member (FIG. 17). The visual alert may be, for example, a graphic diagram 77 that displays each wear member and the status of each wear member (ie, presence, acceptable wear, maintenance required). The HMI 71 may be designed to display a live image 79 of the bucket lip so that the operator can visually inspect the validity of the alert. The HMI may be designed to display historical charts (not shown) so that the operator can determine when an alert has occurred, thereby determining if a wear member is missing. Allows the operator to take necessary actions.

[0060] These various monitoring systems and features may be used together or as a single stand-alone system with no other capabilities. While the discussion above has discussed the invention in relation to teeth on the bucket, the system senses the presence and/or health of other wear parts on the bucket, such as shrouds, wings and/or runners. can also be used to The system of the present invention is also useful for monitoring the presence and/or health of wear parts on other types of earthmoving equipment, such as runners on chutes or track trays, or end bits on blades. can be used.

[0061] The above disclosure describes specific embodiments for a bucket wear monitoring system. This system includes various aspects and features of the invention. Features of one embodiment may be used with features of another embodiment. The examples given and combinations of features disclosed are not intended to be restricted in the sense that they must be used together.