FIELD OF THE INVENTION
The present invention relates in general to systems and methods for determining the
wear of screen panels in mining industry and in particular to a wear indicator apparatus,
a system and method for remote detection of wear.
BACKGROUND OF THE INVENTION AND PRIOR ART
Industrial screening arrangements are used in mining and other industries and are
required for size separation applications. Some screening arrangements include modular
screening systems which comprises of a plurality of modular and replaceable screening
media mounted on the support frame.
Screening media can include a plurality of apertures for separating desired sizes of
particle from undesired and the media can be of made different resilient materials like
polyurethane, rubber and other polymeric materials with metallic or non-metallic
reinforcement embedded inside the resilient material to provide additional strength to
the screen.
Conventionally, punched steel plates or wire-mesh were used as screening media, as
these were easy to manufacture. However, these suffered from one major drawback -
low life. The screening media is subjected to intense vibrations from the supporting
frame which is under constant vibration during the screening process and thus are the
materials above the screen deck.
Mineral particles are highly abrasive and they cause heavy wear and tear of wire-mesh
and punched-hole screens, due to which the screens were reported to either fall
regularly or their aperture sizes increased above the desired cut-point. Due to this
problem, the users suffer a loss not only due to frequent down-times of the plant for
maintenance, but also due to inefficient separation of mineral particles, causing overall
reduction in quality of products of the plants.
The excessive vibration and the flow of abrasive material over the screen panels lead to
wear of the screen panels and which in turn lead to enlargement in the aperture size of
the screen panel and allow material of larger size to pass through the screen panel,
which is undesirable.
Due to this problem, the user suffers a loss not only due to frequent down-times of the
plant for maintenance, but also due to inefficient separation of mineral particles, causing

reduction in quality of products of the plants. Such maintenance operations as stated in
the preceding paragraph also cause hindrance to the screening operation.
The main problem associated with the replacement of the damaged screen panel is that
it is quite difficult to ascertain how much wear has actually taken place in the screen
panel. A visual inspection to determine the wear of a screen panel is not sufficient as not
all part of the screen panel is equally damaged or worn out. Further, replacement of
screen panels based on past experience is also not reliable. As a result, it is not possible
to replace the screen panels in opportune time, which leads to inappropriate segregation
of ore particles.
An additional problem relates to the periodical visual inspection of the panel which
causes shut down of the whole system.
These sorts of maintenance operations lead to loss of the machine's production capacity
and such losses need to be kept at a minimum.
Thus there is a need for a system, method for identifying and notifying the user when
the panel has worn out to a certain threshold level so that timely replacement of the
panels can be done saving precious time and production of the plant.
This invention discloses a system for remote monitoring of wear of screen panels in
industrial screening applications in industrial vibrating screen machines and trommel
screens. The present invention comprises of a plurality of screen panels with embedded
components and signaling system to transmit wear rate information to a
receiving/processing unit which in turn processes it to give the wear rate data on an
interface.
United States Patent Application no. 13/275,566 discloses a wear indicator apparatus,
system and method for allowing wear information from an internal flow surface of a
chute to be obtained from outside the chute so as not to require access to the interior for
wear inspection purposes. In one form, the wear indicator apparatus has a wear
indicator portion that is configured to be fit into a through opening in the chute wall
assembly. The wear indicator portion has a layer of wear material that is of the same
material as an inner liner of the chute wall assembly, and a mounting portion that is
configured to be removably fixed to an exterior surface of the wall assembly. Preferably,
the wear indicator apparatus includes a removal mechanism connected to the mounting
portion that is operated outside of the chute for retracting the wear indicator portion out
from the wall assembly through opening.

This disclosure is an attempt for determining the wear of components of a chute system
at various locations along the material flow path. Such a method of wear detection is
labour-intensive, requires frequent down-times of the plant for checking of screen panels
and visual inspection of wear is not dependable.
United States Patent no. 7,270,890 discloses a system for monitoring the wear of a
component. A conductor can be embedded in the component at a depth from a surface
of the component. The conductor can be operatively connected to a power source to
form an electrical circuit. The resistance across the conductor can be measured. As the
component contacts a second component, the component can begin to wear. Once the
wear progresses to the conductor, changes in the measured resistance will result. Thus,
an operator can be alerted that the component has worn to a certain point and that
service may be needed. Alternatively, impedance can be measured across the conductor.
Because the dielectric permeability of the material surrounding the conductor can affect
impedance, changes in impedance can occur as the surface material of the component is
worn away.
This disclosure is an attempt for determining the wear of components of a chute system
by way of measuring the resistance, current, voltage and/or impedance at least a portion
of the first conductor and the conductive surface of the second component. Thus
changes in the measured resistance, current, voltage and/or impedance can indicate that
a predetermined amount of wear is occurred. Such a method of wear detection requires
regular measurement of resistance across the conductor, hence it is labour-intensive,
time consuming and lacking remote monitoring of wear.
United States Patent application no. 12/782,198 discloses a system, method, and
apparatus for detecting wear in a screening arrangement. Here, a conductor is
embedded in resilient material. The conductor is configured to be coupled to a sensor
that emits a notification signal when the screening surface of the screen panel has worn
to a threshold level. The threshold level can be based at least in part on the amount of
wear that requires replacement of a screen panel to prevent breakthrough or
contamination. The notification signal can be used to identify which screen panel or
region of screen panels have been worn to the threshold level so that the screen panels
can be replaced in a timely manner.
The sensor further comprises a RFID device for the purpose of communication. The
sensor provides the notification when the conductor becomes decoupled from said

sensor. A receiver unit is present to catch the signal emitted by the sensor. When a
notification signal is received by the receiver it gives warning in the form of alert.
This disclosure is an attempt for determining the wear of screen panel by measuring the
threshold level when the conductor decoupled from the sensor. Such a method of wear
detection is expensive due to use of RFID and sensor element and it is complex in
structure.
There has thus been a persistent need for a wear inspection mechanism for screen
panels in industrial screening applications, in industrial vibrating screen machines and
trommel screens. More particularly, there is need for a simple system and method that
provides remote monitoring of wear of screen panels when the panel has worn out to a
certain threshold level so that timely replacement of the panels can be done saving
precious time, money and production of the plant. The present invention meets the
aforesaid long felt need.
All throughout the specification including the claims, the words "screen panel", "electrical
conductor", "controller unit (CU) and/or microcontroller unit (MCU)", "transmitter",
"radio wave receiver unit", "radio wave amplifiers", "Wi-Fi routers", "Wi-Fi access
points", "networked signal boosters and other kinds of signal boosters", "relay units",
"wave amplifiers", "decoder", "electrical receiver unit", "wired or wireless communication
system", "network interface", "server and display unit", "remote users", "stands and
frames" and "power source" and so on are to be interpreted in the broadest sense of the
respective terms and includes all similar items in the field known by other terms, as may
be clear to persons skilled in the art. Restriction/limitation, if any, referred to in the
specification, is solely by way of example and understanding the present invention.
OBJECTS OF THE INVENTION
It is the principal object of the present invention to provide a wear indicator apparatus
for screen panels which has a very simple construction and method of working.
It is a further object of the present invention to provide a wear indicator for determining
the wear of screen panels which is reliable and economic.
Another object of the present invention is to improve the quality of screening of mineral
particles by applying wear indicator apparatus, thereby improving the quality and
productivity of screening machine.

Yet another object of the present invention is to remotely monitor the wear of screen
panels by viewing the wear profile on a display unit.
A further object of the present invention is to provide a system for remote detection of
wear comprising of transmitter, controller unit and power source.
A still further object of the present invention is to provide a wear indicator apparatus
that functions on the principle of break of circuit.
A further object of the present invention is to provide a circuit system of the wear
indicating apparatus which can be re-used in another wear indicating apparatus when
the screen panel is completely worn out.
Yet another object of the present invention is to determine the approximate life of a
screen panel.
How the foregoing objects are achieved and the other aspects of the present invention
will be clear from the following description which is purely exemplary and does not
impose any limitation on the scope of the invention.
SUMMARY OF THE INVENTION
A vibrating screen panel health monitoring system comprises of an embedded part and a
distal part operatively connected to it. The embedded part comprises of a controller
system, a power supply and one or a plurality of threshold conductors which are
embedded in the screen panel. The distal part comprises of a circuit break data
acquisition system, a network server connected to internet, a user interface and a screen
panel layout display. The circuit break data acquisition system is adapted to
receiving/processing the wear rate data of the screen panel.
The controller system has a transmitter module with or without antenna which is either
an infra-red transmitter or a RF module or an ultrasonic transmitter or a wired
communicator. The distal part is located within the range of the transmitter module. The
transmitter module transmits a certain packet of data wirelessly which are received by
the circuit break data acquisition system as long as the panel is healthy.
The circuit break data acquisition system comprises of a radio wave receiver unit along
with other integrated circuitry for suitably decoding the signals into desired information
and/or electrical signals.

One or a plurality of the embedded conductors is laid out in the form of one or multiple
thresholds, which are put in a manner to cover the most strategic portions of the screen
panels.
The plurality of thresholds works as multiple levels of wear detection. The transmitter
module stops transmitting the packet of data when any threshold conductor breaks.
The circuit break data acquisition system is adapted to generate warning through an
interface system when it does not receive the signals as in healthy condition of the
panel.
Provision is made for removal/replacement of the controller system from the embedded
conductors of a screen panel either for repair/replacement or for re-use of a healthy
controller system when the panel has worn out.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
The nature and scope of the present invention will be better understood from the
accompanying drawings, which are by way of illustration of a preferred embodiment and
not by way of any sort of limitation. In the accompanying drawings:-
Figure 1 is a perspective view of a screen panel showing the system through a section
view.
Figure 2 is a block diagram of the screen panel health monitoring system according to
the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Having described the main features of the invention above, a more detailed and non-
limiting description of a preferred embodiment is given in the following paragraphs, with
reference to the accompanying drawings which is purely for the sake of understanding
the performance of the invention, and does not impose any limitation on its scope.
With reference to the embodiments of the present invention there exists a vibrating
screen panel health monitoring system which is a system of wear detection and which
comprises of a simple circuitry and method of working. There exists predetermined
threshold or a plurality of thresholds which can be in the form of an electrical conductor.
The threshold is directly or indirectly coupled with the controller system (1). The

controller system (1) comprises of a transmitter (which may or may not include an
antenna) in circuit with a microcontroller unit (MCU) or controller unit which generates a
pulse-train of electrical signals which pass through the conductor (2) put at a threshold
distance inside the panel. Thus there exists an electrical conductivity in the threshold
conductors (2) which in turn drives the MCU unit to transmit through its transmitter
module a certain packet of data wirelessly, or through wire. The transmitter module of
the MCU or controller unit (1) can be of any type, i.e. infra-red transmitter, RF module,
ultrasonic transmitters, wired communicator or other types of transmitter units. It is
embedded inside the panel (3) at a suitable location. The transmitter unit may or may
not include antenna or a plurality of antennas depending on the area of coverage. The
transmitter module, when it is wireless, transmits radio signals on one or more carrier
frequencies. Several carrier frequencies are commonly used in commercially-available
transmitter units, including 433.92MHz, 315MHz, 868MHz, 915 MHz and other carrier
frequencies. These frequencies are used because of national and international
regulations governing the use of radio for communication.
In one embodiment, the transmitter unit can be a unified transmitter and receiver unit
which can perform bi-directional communication with other similar units capable of doing
so and can also relay signals to other repeater units for more coverage.
The present invention works on the principle of circuit break. The embedded conductor
(2) is laid out in the form of a threshold. There can be a plurality of thresholds put in a
strategic manner so as to cover the most strategic portions of the screen panels where
most wear is likely to occur. The plurality of thresholds can work as multiple levels of
wear detection. The conductor (2) in turn is resistant to certain amount of heat and
comes out of the enclosure through suitable connectors. As described earlier, it is put
around the aperture at a particular threshold. There may be a single threshold or
multiple thresholds made up of one or more conductors (2) looped around the apertures.
As the resilient material of the screen panels wears out due to abrasion, impact and
other types of actions exposing the threshold conductor (2), the conductor (2) also
begins to wear out and finally breaks, and then the electrical conductivity which existed
in it is lost. As the conductivity is lost, the circuit breaks, becomes an open one and thus
the signals that were being transmitted get interrupted. The receiver (4) on the other
side, best shown in figure 2, which consists of suitable components to receive the
incoming signals from the transmitter and process them further, does not receive the
signals as was getting in healthy condition of the panel and switches modes to generate
warning in the form of visual, audio visual or any other desired type of warning through
an interface system (7) which is installed on the site indicating the wear on the panels.
The receiver (4) can be connected to the interface (7) through wired or wireless

connections, also the connection between transmitter and the receiver units can be
either wired or wireless. The MCU unit/controller unit also processes the signal for
desired packets of data and decodes the encrypted packets of data for desired results
which is matched to show the wear profile on the user interface.
A separate part of the system that is the receiver unit (4), (in case of wired transmitter
system the receiver is also a device for sensing electrical signal through wired
communication) or circuit break data acquisition system (4) comprises of a radio wave
receiver unit along with other integrated circuitry for suitably decoding the signals into
desired information and/or electrical signals. This receiver unit (4) operates at a suitable
frequency and is located within the range of the transmitter unit so as to receive the
signals sent by the panel-transmitter unit. The signals can be further amplified using
amplifiers which can be radio wave amplifiers, Wi-Fi routers, Wi-Fi access points,
networked signal boosters and other kinds of signal boosters, relay units etc, which can
be connected to a network (5) as well as the internet (6) so as to provide an accessibility
for the client as well as other users to get the wear information remotely on the first
hand. The receiver unit (4) can be mounted on the vibrating screen machine frames
and/or trommel structures or can also be mounted on stands and frames away from the
screening unit but within the range of the transmitter on the panels at a suitable location
and can be powered by suitable methods like battery, solar power, internally or
externally generated power from different suitable power sources. The receiver unit can
also be housed inside a protective casing to protect it from adverse conditions at the
plant site.
The screen deck consists of a plurality of screen panel (3) which can be made of resilient
materials like polyurethane, rubber etc. The screen panel (3) is modular in nature and is
fitted in numbers to form the screen deck bed of the screen. The screen panel/panels (3)
along with the circuit break signaling system (transmitter along with controller unit) are
powered internally or externally using external and internal power sources. The powering
source can be of any form like solar panels, batteries, externally generated power etc.
The panels (3) which are placed side by side of each other can be interconnected using
specially developed connection interfaces or connectors which are resistant to vibrations
from the screen machines. A screen panel layout display (8) shown in figure 2 remotely
displays the arrangement of the screen panels.
The embedded conductors (2) lead out to the connectors. The connectors have male and
female type parts which, when connected, provide a steady electrical connectivity. The
connectors may also have provision for replacement when they have worn out or are
damaged. The connectors can be made of any electricity conducting material like brass,

copper, etc or can be readily available socket and plug system along with other
connection mechanisms and wirings. The whole system can be kept in a vibration and
temperature resistant enclosure and embedded inside the panels (3) so as to protect the
system from damage.
Provision is made for removal/replacement of the controller system (1) from the
conductors in case any of the components of the system fails or is damaged. The
provision of removal/replacement is also provided so that a healthy controller system (1)
can be reused after the panel has worn out but the system circuitry comprising of the
transmitter, controller unit and/or power source are intact and operational.
The whole system (1) can be embedded at the middle of the panel or at any suitable
strategic point within the panel (3). The conductors are looped around the apertures.
The placements of the system depends on aperture size, shape, and open area of the
panel, thickness of the panel and the edges of the panel, the threshold limits and the
number of thresholds needed.
In the present embodiment of the invention, the receiver is connected to a computer
system (not shown) through suitable connection which may be wired or wireless and can
comprise of different connection systems Ethernet, Serial Communication using RS-232,
RS-422, RS-423, RS-428 ports etc, Parallel Communication using LPT1,LPT2,LPT3 ports,
USB, Bluetooth, Wi-Fi and other connection methods. On this computer, the user
interface (7) comprising a software is installed. The user's computer/server in turn is
connected to the internet (6). The user's computer/server is configured with IP (Internet
Protocol) address and is used as an access point and the information can be accessed
from it through internet using a similar front end software interface.
In another embodiment of the present invention, the receiver unit can be connected to a
standalone interface which may or may not be connected to networks or internet, and
can consist of switches, embedded circuits, power sources, connectors, wires, LCD/LED
or other kinds of display unit that displays the wear profile or the status of panel through
different color codes or glowing of LED's and/or display of numbers on the display unit
directly or indirectly depicting the panel layout arrangement on the screening system.
The present invention has been described with reference to some drawings and a
preferred embodiment purely for the sake of understanding and not by way of any
limitation and the present invention includes all legitimate developments within the
scope of what has been described herein before and claimed in the appended claims.

We claim:
1. A vibrating screen panel health monitoring system comprises of an embedded
part and a distal part operatively connected to it, said embedded part comprising
of controller system (1), a power supply and threshold conductors (2) which are
embedded in screen panel (3), said distal part comprising of circuit break data
acquisition system (4), network server (5) connected to internet (6), user
interface (7) and a screen panel layout display (8), wherein said circuit break
data acquisition system (4) is adapted to receiving/processing the wear rate data
of said screen panel (3).
2. The system as claimed in claim 1, wherein said controller system (1) has a
transmitter module with or without antenna which is either an infra-red
transmitter or a RF module or an ultrasonic transmitter or a wired communicator.
3. The system as claimed in claims 1, wherein said distal part is located within the
range of said transmitter module.
4. The system as claimed in claim 1, wherein said transmitter module transmits a
certain packet of data wirelessly which are received by said circuit break data
acquisition system (4).
5. The system as claimed in claim 1, wherein said circuit break data acquisition
system (4) comprises of a radio wave receiver unit along with other integrated
circuitry for suitably decoding the signals into desired information and/or
electrical signals.
6. The system as claimed in claim 1, wherein one or a plurality of said embedded
conductors (2) are laid out in the form of one or multiple thresholds, which are
put in a manner to cover the most strategic portions of said screen panels (3).
7. The system as claimed in claim 1, wherein said plurality of thresholds works as
multiple levels of wear detection.
8. The system as claimed in claims 1 and 4, wherein said transmitter module stops
transmitting said packet of data when said threshold conductor (2) breaks.
9. The system as claimed in claims 1 and 8, wherein said circuit break data
acquisition system (4) is adapted to generate warning through an interface
system (7) when it does not receive the signals as in healthy condition of said
panel (3).

10. The system as claimed in claim 1, wherein provision is made for
removal/replacement of said controller system (1) from said embedded
conductors for repair/replacement or for re-use of healthy controller system (1).

ABSTRACT

A vibrating screen panel health monitoring system comprises an embedded part
and a distal part. The embedded part has controller system (1), power supply,
and threshold conductors (2) embedded in screen panel (3). Distal part has
circuit break data acquisition system (4), network server (5), user interface (7)
and screen panel layout display (8). The circuit break data acquisition system (4)
is adapted to receiving/processing the wear rate data of said screen panel (3).
Controller (1) has transmitter module. The distal part is located within range of
the transmitter which transmits packet of data wirelessly received by circuit break
data acquisition system (4) which has a radio wave receiver unit and circuitry for
decoding the signals into desired information and/or electrical signals.
The embedded conductors (2) are laid out as thresholds, which are placed to
cover most strategic portions of screen panels (3) and work as multiple levels of
wear detection.