Claims:1. A wear measurement sensor arrangement comprising :

a component consists of an electrical circuit including elements each having measurable electrical characteristics, coupled with each other and defines initial characteristics of the circuit;
a casing configured to house the said electrical circuit with an external anchor type cylindro - conical array structure helps it to grip within the liner body and needs to be punched in the liners with nail and hammer concept;
a Logical Unit to convert the obtain data i.e. electrical characteristics of the component into logical data;
a transmission unit to transmit and obtain informative data from the component i.e. response of the wearing of the structure;
wherein the component is electrically connected with the data transmission and logical unit and configured to determine the wear of the component by the means of its electrical properties which is further calibrated into the length by the logical unit; and wherein the connection between the sensor and the transmission units is such that it can be coupled or decoupled any time by the use of connectors (male & female connectors).
.
2. The wear measurement sensor arrangement as claimed in claim 1, wherein the said electrical circuit comprises a plurality electronic components including resistors, capacitors or inductors whose electrical properties are the electrical characteristics of the circuit.

3. The wear measurement sensor arrangement as claimed in claim 1, wherein the material for the said casing can either be same as of the lining material or Polyurethane.

4. The wear measurement sensor arrangement as claimed in claim 1, wherein after embedding sensor into the liners it need to be coupled with data servers.

5. The wear measurement sensor arrangement as claimed in claim 1, wherein the said electrical circuit consists of the electrical strip made from several electrical components including resistors, capacitors or inductors connected in parallel circuit connection each part contributing its own electrical properties and the circuit value is total of all the electrical properties of components been connected in the circuit.

6. The wear measurement sensor arrangement as claimed in claim 1, wherein said elements of the electrical circuit possess electrical properties that are directly related to its wear length and is capable of decoupling i.e. during the process of wearing of the component thus changing the measurable electrical properties of the circuit

7. The wear measurement sensor arrangement as claimed in claim 1, wherein the said circuit is further connected with the data transmission device located behind the liner body and is responsible for measuring the electrical properties of the circuit and transmitting it to data servers.

8. The wear measurement sensor arrangement as claimed in claim 7, wherein the connection between the transmission unit and the circuit is such that it can be connected or disconnected whenever needed as required during the replacements of liners consisting of sensors embedded in them.

9. The wear measurement sensor arrangement as claimed in claim 1, wherein said logical unit converts the circuit’s electrical characteristics into the sensor/casing/liner height and the data is further transmitted through data transmission module to the servers.

10. The wear measurement sensor arrangement as claimed in claim 1, wherein the data transmission module is responsible for measuring circuit values and is located outside the liner body and is connected by each other through the means of electrical wires and connectors.

11. The wear measurement sensor arrangement as claimed in claim 1, wherein the data transmission unit is located behind the liner and is protected by a casing which aligned and held through welding on the liner body or the mother plate of the equipment.

12. The wear measurement sensor arrangement as claimed in claim 1, wherein said sensor is installed at any position within the liners or the mother body and needs to be punched at the position within the liners.

13. The wear measurement sensor arrangement as claimed in claim 1, wherein the said arrangement further includes a monitoring unit configured to monitor the wear rate and to graphically display all the measurable data and user interface for better optimization.

14. The wear measurement sensor arrangement as claimed in claim 1, wherein the maximum diameter of the sensor body along with casing is 12mm to 15mm and minimum diameter of 10mm respectively.

15. The wear measurement sensor arrangement as claimed in claim 1, wherein the length/ height of the sensor is adjustable according to the part in which the sensor needs to be installed and the dimensions varies along with the use.
, Description:THE PATENTS ACT,1970 (39 OF 1970)

&

THE PATENTS RULES, 2003
COMPLETE SPECIFICATION
(SECTION 10, RULE 13)

TITLE
“WEAR MEASUREMENT SENSOR ARRANGEMENT”

APPLICANT(S)

TEGA INDUSTRIES LIMITED,
An INDIAN Company,
having registered office at 147, Block – G, New Alipore, Kolkata – 700053,

The following specification particularly describes invention and the manner in which it is to be performed.

WEAR MEASUREMENT SENSOR ARRANGEMENT

FIELD OF THE INVENTION

The present invention in general relates to monitoring the wear of lining material used in mineral beneficiation industries. More particularly, the present invention relates to modular progressive arrangement including a sensor circuit configured for real time comprehensive monitoring the wear of lining material.

BACKGROUND OF THE INVENTION

In mining and mineral beneficiation industries wear resistant liners/ lining materials are generally used to protect the mother plate of an equipment from damage and wearing out from the material been transported or passed. These liners are subject to wear by the continuous flow of abrasive minerals. The application of these liners are basically in Conveyor/Screen Chutes, trucks, chutes, hoppers, mills, crushers, wagon tippler, etc. These liners need continuous monitoring of its wear/ wear rate for replacements and proper inventory management. Sometimes it is not possible to monitor or check the wear length/depth of liners without taking shutdown like in mills, complicated chutes where access is not possible in the running state. As taking a shutdown incorporates a huge cost. Thus for such type of conditions, wear sensing system can be incorporated in the liners to monitor the wear of the parts from a remote location without visiting the hazardous sites & without taking shutdowns.

In the prior art a PCT specification WO 2012/122587 discloses a system for monitoring wear of a part comprising of an electronic structure is in electrical communication with the monitoring unit which is arranged to measure an electrical property of the electronic structure, the electronic structure being arranged such that in use the measured electrical property is dependent on the degree of wear of the electronic structure is arranged in use to wear as the part wears; a monitoring unit operative to obtain information indicative of the wear of the part in response to the wear state of the electronic structure and a communications unit in communication with the monitoring unit and arranged to transmit transmission data indicative of the information.
Drawbacks
• Installation in lining
• Sensor & Casing Make
• Preferential Wear

OBJECTS OF THE INVENTION

It is the principal object of the present invention to eliminate the aforesaid drawback and provide the wear depth/pattern of the component such as wear resistant liners.

SUMMARY OF THE INVENTION

The present invention is directed to a modular progressive arrangement including a sensor circuit configured for monitoring the wear of lining material. The sensor has a plurality of parallel-arranged spaced apart resistors / capacitors / inductors in connection with a sensing circuit. Each resistor mounted onto a PC board which is encapsulated within a specific designed casing wear sensor casing i.e. Zig-Zag shape to grip within the liners. The sensor is disposed into the casing and placed within the lining. As the lining progressively wears, the resistors / capacitors / inductors are progressively worn away thus changing the overall resistance / capacitance / inductance of the sensor. The change in resistance / capacitance / inductance indicates state of wear.

The installation example shown in FIG. 2 shows a specially designed casing with the sensor element inside it. The sensor arrangement is installed in liner body of the chute/equipment. The liner is fixed on chute/equipment mother plate. Transmission module is fixed on the back of the chute/equipment body. Transmission module and the sensor are being brought in connection through wires with the help of connectors. The linings are usually fastened by means of a plurality of rivets, and to which a cylindrical countersink is assigned in the lining. The sensor element is located in a two-stage, sleeve-shaped housing The casing is in turn designed in a zig zag shape such that a section of larger diameter corresponds to the dimensions of the cylindrical countersink and a casing section of smaller diameter, is equal to the diameter of the rivet shaft.
Thus, the housing 16 can be inserted into the through holes in the lining and clamped. As a variant, it is conceivable, for example, to provide the casing section is then assembled by pressing into the rivet opening provided, i.e. that the means for screwing the housing can be omitted.

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 fig-1 shows the general layout of the sensor been placed inside a liner body.

Fig-1 illustrates the general view of Wear Sensor installed in a part/lining body of the equipment in accordance with the present invention;
Fig-2 illustrates the general make of Wear Sensor body i.e. anchor type in accordance with the present invention;
Fig-3 illustrates General assembly of Wear Sensor Circuit with data transmission and logical unit in accordance with the present invention;
Fig-4 illustrates the general Resistance/Capacitor circuit assembly in accordance with the present invention;
Fig-5 illustrates the general assembly of Wear Sensor Circuit & Casing in accordance with the present invention;
Fig-6 illustrates the make of wear sensor casing i.e. Zig-Zag shape to grip within the liners in accordance with the present invention;
Fig-7 illustrates the general dimension of the Wear Sensor in accordance with the present invention;
Fig-8 illustrates the Wear Sensor installed in the part/ lining body in accordance with the present invention.

DETAILED DESCRIPTION OF THE INVENTION

The following describes a preferred embodiment of the present invention, which is purely for the sake of understanding the present invention and not by way of any sort of limitation.

The Figure-1 illustrates the general view of the sensor 1 installed in a part 2 for example in this figure the sensor is installed in a liner body 2 of the chute. The liner is fixed on chute mother plate 5. Transmission module 3 is fixed on the back of the chute body. Transmission module 3 and the sensor 1 are being brought in connection through wires 9 with the help of connectors 4. Accordingly, the present invention provides a wear sensing sensor arrangement.

The arrangement includes a component embedded in the part such as wear resistant liners, having electrical characteristics that varies as the length of the component changes i.e. during the wear of the component takes place.

The component consists of an electrical circuit comprising of elements each having measurable electrical characteristics, these elements are coupled with each other and defines initial characteristics of the circuit. These elements are capable of decoupling i.e. during the process of wearing of the component thus changing the measurable electrical properties of the circuit.

A Logical Unit to convert the obtain data i.e. electrical characteristics of the component into logical data.

A transmission unit to transmit and obtain informative data from the component i.e. response of the wearing of the structure.

During the process the component is electrically connected with the data transmission and logical unit. These are connected to determine the wear of the component by the means of its electrical properties which is further calibrated into the length by the logical unit.

The connection between the sensor and the transmission units is such that it can be coupled or decoupled any time by the use of connectors (male & female connectors).

The setup of the components electrical structure is such that its electrical properties are directly related to its wear length i.e. its properties changes with the height of the component.

The electrical circuit has plurality electronic components such as resistors, capacitors or inductors whose electrical properties are the electrical characteristics of the circuit.

The electrical circuit has a casing. Casing material can either be same as of the lining material or Polyurethane. The build of the structure is anchor type cylindro - conical array structure as shown in figure-2. Sensor make is such that it needs to be punched in the liners wherever needed, simply nail and hammer concept. Its anchor type cylindro - conical array structure make helps it to grip within the liner body. After embedding Sensor into the liners it just need to be coupled with data servers.

The electrical circuit is embedded inside the casing providing the structure with electrical properties that varies as the structure/casing wears with the liner.

The circuit is further connected with the data transmission device located behind the liner body and is responsible for measuring the electrical properties of the circuit and transmitting it to data servers. The assembly of casing, electrical circuit and data transmission module is shown in figure-1. The connection between the transmission unit and the circuit is such that it can be connected or disconnected whenever needed as required during the replacements of liners consisting of sensors embedded in them.

The electrical circuit consists of the electrical strip made from several electrical components connected in parallel circuit connection as shown in figure-4, each part contributing its own electrical properties. Thus, the circuit value is total of all the electrical properties of components been connected in the circuit. In an embodiment, the general circuit includes components like resistance/capacitance/inductors wherein the components are being connected in parallel connection electrically. In the figure 4 the resistance R are mounted on the printed circuit board made of FR-4 glass epoxy material which is flexible in nature thus it can sustain high impact loads.

The resistance R connected sequentially wear out during the working conditions. As the resistance R disconnects one by one it tends to change the electrical characteristics of the circuit 8 i.e. total resistance Req which is measured to calibrate the wear depth. The resistance R are arranged at a particular distance or fixed distance from each other along the sensor length. The no. of resistance R for a fixed length defines the sensitivity of the circuit 8 as more the resistance R within a confined length the more will be the sensitivity of the circuit 8. Therefore, at each level the resistance Req value of the circuit is known thus as the total resistance Req value changes during wear of the circuit the wear depth is known.
For the above mentioned circuit 8 the resistance of the circuit (Req) for n no. of resistance is calculated by: -

1/Req = 1/R1 + 1/R2 + 1/R3…. + 1/Rn

The components are arranged along the length of the liners, and are capable of decoupled from the circuit. As each element disconnects from the circuit, the circuit value tends to change thus calibrating the circuit value results in change of length of the total sensor height. The circuit is incorporated in the casing made of polyurethane as shown in figure-3. The sensor body build is of anchor type cylindro - conical array structure as shown in figure-5 so as to provide better gripping in the liners.

The electrical strip is made by using various electrical components such as resistors, capacitors or inductors. The circuit can be built accordingly by using either one type of component or multiple depending on the application. The circuit assembly of the resistance circuit is as shown in figure-3. The resistors are connected in parallel arrangement with the help of conducting wires and are aligned along the length of the liner in the casing. The sensor 1 may be installed at the site or for example on the chute up to transmission module 3. The Circuit 8 characteristics are converted or calibrated into the length with the help of logical unit 3 and is further transmitted by the transmission unit 3.

Figure-5 illustrates the general arrangement of the sensor 1. The resistance circuit 8 after preparation is placed/dipped/cured within the casing material and cured at the required temperature. Casing material is same as of lining body i.e. it may be in the form of rubber/polymer/polyurethane etc. During curing the sensor 1 acquires its anchor type cylindro - conical array shape. The female part of the connectors 4 is connected to the circuit 8. After curing the sensor 1 is ready to be punched within the liner 2 as shown in figure-1. The female part of the connector 4 is inside the sensor 1 as shown in figure-1&6.

After preparation of sensor 1 a through hole is drilled at the required position in the part 2 and mother body 5. The diameter of the drilled hole is same as that of the sensor 1 minimum diameter. Then the sensor 1 is punched or push fitted inside the part 2 i.e. liner body. After the installation of sensor 1 transmission module 3 is fixed at the outer body of the mother plate 5. The transmission module 3 compromises of two parts i.e. logical unit & transmission unit. The transmission module 3) and the sensor 1 is then connected through the connectors 4 as shown in figure-1. The power to the circuit is supplied by the transmission module 3.

As the wear of liner takes place, the circuit embedded in casing also wears out with the liner which is embedded in liner. During the wear of circuit, the resistance one by one gets decoupled from the circuit which tends to change the resistance value of the circuit which can be calibrated to measure the wear depth/rate of the liner.

The logical unit converts the circuit’s electrical characteristics into the sensor/casing/liner height. Then this data is further transmitted through data transmission module to the servers.

The data transmission module is responsible for measuring circuit values and is located outside the liner body. The circuit and the device is connected by each other through the means of electrical wires and connectors. Figure-2 shows the general assembly of the sensor body 7 i.e. Anchor type or zigzag or any other similar pattern to help the sensor 1 grip within the body 2 in which the sensor 1 is to be installed. The casing/sensor material is same as that of the part in which it needs to be installed or else polyurethane. The flexibility of the sensor body 7 helps to easily punch within the liners 2 and provides a better gripping.

The casing provides an advantage of anchor make design of its griping capability within a liner hence providing more stability and accuracy for wear measurement within a liner. The casing is made up of polyurethane or the lining material thus providing more accurate results in terms of wearing of parts thus no differential wear from the lining material.

The make of the sensor provides the main advantage of being installed at any position within the liners or the mother body. Sensor just needs to be punched at the desired position within the liners.

The data transmission unit is located behind the liner and is protected by a casing. The casing is aligned and held through welding on the liner body or the mother plate of the equipment. The data transmission unit then further transmit data to the servers.

A monitoring unit to monitor the wear rate and to graphically display all the measurable data and user interface for better optimization.

The maximum diameter of the sensor body along with casing (PenSen) is 12mm to 15mm and minimum diameter of 10mm respectively. The length/ height of the sensor can be adjusted accordingly with the part in which the sensor needs to be installed. The dimensions may vary along with the application keeping the basic anchor type cylindro - conical array design.

Figure-8 illustrates the general view after installation of sensor 1 and transmission module 3 in the part 2.

The data from the transmission module 3 is transmitted to the servers. The data form the servers are then accessed through monitoring units. The monitoring unit compromises of user interface where user can interpret data and can be used in many forms.

INVENTIVE STEP:
1. Sensor Make: -
o FR-4 glass epoxy material a flexible substrate as compared to PCB used by prior art, as in rubber liners at great forces i.e during impact due to compression solid PCB may break.
2. Installation in liner: -
o As compared to prior art, new installation method is very simple and easy when it comes to installation of sensors on site within liner or chute. As sensor just need to be punched within liner and to be connected with the transmission module by means of connectors. Transmission unit is placed at the back of the chute or mother body. The connecting wires between the connectors are protected by the solid body may be a hollow pipe or hollow cuboidal structure on which the transmission unit is mounted.

3. Casing: -
o Prior Art follows concept of forcing adhesive or settable material b/w the liner and the circuit whereas our concept is using more robust design as compared by using anchor make design with more stability and gripping within the liners. Also casing is same as of the mother body in which the sensor is installed.
4. Preferential Wear: -
o As prior art uses settable resin or epoxy resin or adhesive for its casing of circuit, it may cause a differential wear of sensor compared to liner body i.e. wearing out of sensor faster as compared to liner as the wear resistance of the sensor casing is less as compared to liner, whereas new concept uses same material of casing as of liner.
5. Sensor Design & handling: -
o Our design does not require any additional substrates to be added at installation on site like in prior art epoxy resin is forced within the liners. our design follows nail and hammer concept where the sensor cells are being developed and just need to be punch at desired location and connected by using connectors.
6. Impact force handling in rubber or flexible liners: -
o Our new design consists of a flexible strip of FR-4 glass epoxy material thus the sensor is flexible at high compression forces and does not break.
7. Benefits in new design
o Ease of installation on site.
o Easy handing
o Low installation time required
o Untrained person can install
o Punch and connect concept
o No differential wear

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.