System and method for collecting operational vibration data for a mining machine

Abstract

Mining machine (100) which features the following: a plurality of sensors (305), each of the plurality of sensors (305) being positioned at one of a plurality of measuring points on at least one component of the mining machine (100); a first electronic processor (235) coupled with and configured to be used with at least one component, to receive at least one movement order; and to control at least one component based on at least one movement command; and a second electronic processor coupled to the first electronic processor (235) and the plurality of sensors (305) and configured to determine at least one predicate parameter, wherein the at least one predicate parameter includes a rate of change of a motor parameter of the mining machine (100); to determine whether at least one predicate parameter is true; and while the first electronic processor (235) controls at least one component and at least one predicate parameter is true, to receive a large number of vibration data sets from the large number of sensors (305).

Description

AREA

[0001] Embodiments of the invention relate to systems and methods for performing vibration monitoring for industrial machines, including mining machines or extraction machines. BACKGROUND

[0002] Mining excavators, such as electric cable excavators or backhoe loaders, are used to remove material from, for example, a longwall face in a mine. An operator controls an excavator during a removal or conveying operation to load a bucket with material. The operator deposits the material contained in the bucket at a discharge point, such as into a utility vehicle, a mobile crushing plant, onto an area on the ground, onto a conveyor, etc. After the material is unloaded, the removal or conveying cycle is repeated when the operator turns the bucket back towards the longwall face to perform another removal or conveying operation. At a mining site, especially when the price of raw materials is high, every hour of downtime for a mining machine can result in a significant loss of revenue.Such revenue losses can be avoided by monitoring the mining excavator's activities to detect emerging errors before they develop into a more catastrophic disruption.

[0003] DE 11 2005 003 040 T5 describes a system and a method for detecting and analyzing anomalies in a machine during operation.

[0004] AU 2014233575 A1 describes a mining machine with a control system for operating the mining machine, wherein the mining machine has a sensor that detects the vibration of a component of the mining machine. OVERVIEW

[0005] Vibration data can be used to identify a variety of machine problems (for example, rolling element bearing defects, gear problems, imbalance, looseness or slack, resonance, pump cavitation, electrical problems, lubrication issues, belt problems, and the like). Accordingly, condition monitoring programs for mining operations often employ vibration monitoring of rotating components on board large mobile equipment, such as an electric mining excavator. Because offline vibration monitoring can lead to costly downtime, online vibration data acquisition systems have been developed.

[0006] Vibration monitoring data can be used to trigger rule-based alarms or warnings indicating when a component or components of an electric mining excavator require maintenance, repair, or replacement. The successful use of rule-based alarms or warnings can depend on consistent data quality, which can be derived from consistent machine conditions (e.g., a relatively constant state and load). However, the nature of a highly dynamic machine like an electric mining excavator (e.g., variable speed, variable load, and frequent shock events) makes it difficult to collect consistent data, and inconsistent data can lead to frequent false positives. Current vibration monitoring systems may also rely on repeatable machine conditions, which are not always achievable during active mining operations.

[0007] Accordingly, the embodiments described here provide systems and methods for collecting vibration data for a mining machine.

[0008] In accordance with the present invention, a mining machine having the features of claim 1 and a method for collecting operational vibration data for a mining machine having the features of claim 12 are provided.

[0009] Advantageous further training opportunities arise from the dependent sub-requirements.

[0010] Further aspects of the invention will become apparent from a consideration of the detailed description and the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS Fig. Figure 1 illustrates an electric mining excavator in accordance with some embodiments. Fig. Figure 2 is a block diagram of a control system for the electric mining excavator of Fig. 1 in accordance with some embodiments. Fig. Figure 3 is a block diagram of a vibration data collection system for the electric mining excavator in accordance with some embodiments. Fig. Figure 4 is a flowchart of a procedure for collecting operational vibration data for the electric mining excavator of Fig. 1 in accordance with some embodiments. Fig. Figure 5 is a line graph illustrating an exemplary valid vibration data set in accordance with some embodiments. Fig. Figure 6 is a line graph illustrating an exemplary invalid vibration data set representing a zero-line state in accordance with some embodiments. Fig. Figure 7 is a line graph illustrating an exemplary invalid vibration data set, showing mean-free deviation and absence of high-frequency energy in accordance with some embodiments. Fig. Figure 8 is a flowchart of a procedure for collecting vibration data during a stage test of the electric mining excavator of Fig. 1 in accordance with some embodiments. DETAILED DESCRIPTION

[0011] Before any embodiments of the invention are explained in detail, it should be understood that the invention is not limited in its application to the details of the design and arrangement of components or parts set forth in the following description or illustrated in the accompanying drawings. The invention is capable of other embodiments and is also capable of being practiced or carried out in various ways. It should also be clear that the language and terminology used herein serve descriptive purposes and are not to be considered limiting. The use of "comprise," "include," "feature," or "have," and variations thereof, is intended here to include the points listed thereafter and their equivalents, as well as additional points. The terms "attached" or "attached" are used here to refer to the following:The terms "mounted" or "attached," "connected," and "coupled" are used here in a comprehensive manner and include both direct and indirect attachment, mounting, or fastening, connecting, and coupling. Furthermore, "connected" and "coupled" are not limited to physical or mechanical connections or couplings and can also include electrical connections or couplings, whether direct or indirect. Electronic communications and notifications can also be carried out using any known means, including direct connections, wireless connections, etc.

[0012] It should also be noted that a variety of hardware- and software-based devices, as well as a variety of different structural components, can be used to implement the invention. Furthermore, it should be clear that embodiments of the invention may include hardware, software, and electronic components or modules, which, for the purposes of discussion, may be illustrated and described as if the majority of the components or modules were implemented solely in hardware. However, a person skilled in the art would recognize, even after reading this detailed description, that in at least one embodiment, the electronically based aspects of the invention may be implemented in software (that is, stored on a non-volatile, computer-readable medium) executable by one or more electronic processors.It should therefore be noted that a variety of hardware- and software-based devices, as well as a variety of different structural components, can be used to implement the invention. Furthermore, and as described in the following paragraphs, the specific mechanical configurations illustrated in the drawings are intended to represent exemplary embodiments of the invention, and other alternative mechanical configurations are also possible. The "controllers" described in the patent specification can also include processing components such as one or more electronic processors (e.g.,This includes microprocessors, digital signal processors (DSPs), field-programmable gate arrays (FPGAs), application-specific integrated circuits (ASICs), and the like, non-volatile computer-readable memory modules, input / output interfaces, and various connections (e.g., a system bus) that link the components together.

[0013] Fig. Figure 1 illustrates an electric mining excavator 100. The embodiment shown in Fig. Figure 1 illustrates the electric mining excavator 100 as a cable excavator. However, in other embodiments, the electric mining excavator 100 can be a different type of mining machine, for example, a hybrid mining excavator, a dragline excavator, and the like. It should also be clear that the embodiments described here can be used with other types of industrial machinery besides mining machines. The electric mining excavator 100 has crawler tracks 105 for propelling the electric mining excavator forwards and backwards and for rotating or turning the electric mining excavator 100 (for example, by varying the speed or rotational speed, the direction, or both of the left and right crawler tracks relative to each other). The crawler tracks 105 support a base 110 that includes a cabin or operator's cab 115.The base 110 can be pivoted or rotated about a pivot axis 125, allowing the excavator 100 to move from an extraction or conveying point to a discharge point. In some embodiments, the movement of the crawler tracks 105 is not required for the rotation. The electric mining excavator 100 also has a bucket boom 130, which carries a pivoting dipper arm 135 and a bucket 140. The bucket 140 has a flap 145 for emptying contents from inside the bucket 140 into a discharge point, such as a hopper or dump truck.

[0014] The electric mining excavator 100 also features taut wire or suspension cables 150 coupled between the base 110 and the bucket boom 130 for supporting the bucket boom 130; a hoist cable 155 attached to a winch (not shown) inside the base 110 for winding the hoist cable 155 to raise and lower the bucket 140; and a bucket flap cable 160 attached to another winch (not shown) for opening the flap 145 of the bucket 140. In some cases, the electric mining excavator 100 is an excavator from the P&H series. ® 4100, manufactured by P&H Mining Equipment Inc., although the electric mining excavator 100 may also be a different type or model of electric mining equipment.

[0015] When the crawler tracks 105 of the electric mining excavator 100 are stationary, the bucket 140 can be actuated to move based on three control actions: lift, extend, and rotate. The lift control raises and lowers the bucket 140 by winding and unwinding the lift cable 155. The extend control extends and retracts the stick 135 and the bucket 140. In one embodiment, the stick 135 and bucket 140 are extended using a rack and pinion system. In another embodiment, the stick 135 and bucket 140 are extended using a hydraulic drive system. The rotate control rotates the stick 135 relative to the axis of rotation 125. The electric mining excavator 100 has a control system 200 (see Fig. 2) The control system 200 comprises an electronic controller 205, one or more operator controls 210, one or more bucket controls 215, one or more sensors 220, and one or more user interfaces 225. The electronic controller 205, the operator controls 210, the bucket controls 215, the sensors 220, and the user interfaces 225 are directly coupled by one or more control or data buses, or by a combination thereof. The components of the control system 200 can communicate via wired connections, wireless connections, or a combination thereof. The control system 200 may have additional, fewer, or different components, and the components described in Fig. The illustrated embodiment 2 is provided only as an example.

[0016] The electronic controller 205 comprises an electronic processor 235 (for example, a microprocessor or another electronic controller) and a memory 240. The memory 240 may include read-only memory (ROM), random access memory (RAM), other non-volatile, computer-readable media, or a combination thereof. The electronic processor 235 is configured to retrieve instructions and data from the memory 240 and, among other things, execute instructions for carrying out the procedures described herein, which include procedures 400 and 500, or parts thereof.

[0017] The electronic controller 205 receives input from the operating controls 210. In some embodiments, the operating controls 210 comprise a feed control 245, a rotary control 250, a lift control 255, and a flap control 260. The feed control 245, the rotary control 250, the lift control 255, and the flap control 260 can, for example, include input devices controlled by an operator, such as joysticks, levers, foot pedals, and other actuators. The operating controls 210 receive input from an operator via the operator-controlled input devices and output digital motion commands to the electronic controller 205.The movement commands can include, for example, raising, lowering, extending the feed, retracting the feed, rotating clockwise, rotating counterclockwise, releasing the bucket flaps, moving the left track forward, moving the left track backward, moving the right track forward, and moving the right track backward.

[0018] Upon receiving a movement command, the electronic controller 205 generally controls one or more of the bucket controls 215 based on the movement command. The bucket controls 215 can include one or more feed motors 265, one or more rotary motors 270, and one or more lift motors 275. For example, if the operator specifies via the rotary control 250 that the stick 135 should be rotated counterclockwise, the electronic controller 205 controls the rotary motor 270 so that it rotates the stick 135 counterclockwise. In some embodiments, the electronic controller 205 also restricts movement commands from the operator and generates movement commands independently of operator input.

[0019] The electronic controller 205 also communicates with the sensors 220 to monitor the position and status of the bucket 140. For example, the electronic controller 205 can communicate with one or more feed sensors 280, one or more rotation sensors 285, and one or more lift sensors 290. The feed sensors 280 detect the degree of extension or retraction of the bucket 140. The rotation sensors 285 detect the angle of rotation of the stick 135. The lift sensors 290 detect the height of the bucket 140 (e.g., based on the position of the lift cable 155). In some embodiments, the sensor 220 also includes one or more flap lock sensors that detect whether the bucket flap 145 is open or closed and measure the weight of a load contained in the bucket 140.

[0020] The user interface 225 provides the operator with information about the status of the electric mining excavator 100 and other systems that communicate with the electric mining excavator 100. The user interface 225 may include one or more of the following: a display screen (for example, a liquid crystal display (LCD)); one or more light-emitting diodes (LEDs) or other lighting devices; a head-up display (e.g., projected onto a window of the cab or operator's cabin 115); speakers for acoustic feedback (e.g., tones, spoken messages, and the like); haptic or tactile feedback devices, such as vibration devices that cause vibration of the operator's seat or the control panels 210; or other feedback devices.In some embodiments, the user interface 225 also includes one or more input devices. For example, in some embodiments, the user interface 22 includes a touchscreen that serves as both an output device and an input device. Embodiments of the user interface 225 can provide graphical user interfaces (GUIs) for providing output to an operator, for receiving input from an operator, or a combination thereof.

[0021] Fig. Figure 3 is a block diagram of a vibration data acquisition system 300 for the electric mining excavator 100. The vibration data acquisition system 300 comprises one or more accelerometer sensors 305, one or more tachometers 307, and a vibration spectral analysis processor 310, which are directly coupled via one or more control or data buses, or a combination thereof, through wired or wireless connections. The vibration data acquisition system 300 is also communicatively coupled to the electronic controller 205. The vibration data acquisition system 300 may include additional, fewer, or different components, and the components shown in Figure 3 are not shown in the diagram. Fig. The illustrated embodiment shown in Figure 3 is provided only as an example. In some embodiments, the functionality performed by the control system 200 and the vibration data acquisition system 300, as described herein, may also be combined and distributed in various ways. For example, in some embodiments, the control system 200 (i.e., the electronic controller 205) may be configured to perform the functionality of the vibration data acquisition system 300, or vice versa. The vibration data acquisition system 300, or parts thereof, may be contained within the electric mining excavator 100, or it may be located remotely from the electric mining excavator 100.In some embodiments, for example, one or more components of the vibration data acquisition system 300 can communicate with one or more components of the control system 200 via a wireless connection, which allows the components of the vibration data acquisition system 300 to be located remotely from the components of the control system 200.

[0022] The accelerometer sensors 305 collect vibration data from the electric mining excavator 100 while the excavator is operating. The accelerometer sensors 305 measure vibrations of a structure and communicate these measurements to the vibration spectral analysis processor 310. In some embodiments, the accelerometer sensors 305 include, for example, piezoelectric material that generates an electrical charge proportional to the force exerted by the vibrations. The accelerometer sensors 305 can be radial or axial. The radial accelerometer sensors, for example, measure the acceleration at the bearings of the electric mining excavator 100. The axial accelerometer sensors, for example, measure the acceleration at the shafts of the electric mining excavator 100.In alternative embodiments, other types of sensors (for example, speed sensors, proximity sensors and laser distance or displacement sensors) can also be used to detect vibrations.

[0023] In some embodiments, an accelerometer 305 is positioned at one of a plurality of measuring points on the excavator 100. Accelerometers 305 can also be arranged in groups of measuring points. Each group of measuring points is positioned to detect vibrations for a specific component or group of related components of the excavator 100, such as, for example, the one or more lifting motors 274 and pinion shafts; the lifting intermediate shafts; the lifting drum; the one or more rotary motors 270 and pinion shafts; the rotary intermediate shafts; the rotary output shafts; the one or more feed motors 265; the feed input shaft; the feed intermediate shaft; a lifting gearbox; a feed gearbox; and a rotary gearbox.

[0024] The one or more tachometers 307 detect the rotational speed and direction of the various motors of the electric mining excavator 100 and communicate the measurements to the vibration spectral analysis processor 310. In some embodiments, the one or more tachometers 307 are implemented in software.

[0025] The vibration spectral analysis processor 310 comprises an electronic processor (for example, a microprocessor or other electronic controller) that executes instructions for analyzing and processing vibration data received from the accelerometer sensors 305. In some embodiments, the vibration spectral analysis processor 310 collects and processes the vibration data from the accelerometer sensors 305 in parallel. For example, the vibration spectral analysis processor 310 can coordinate the measurement start time and sampling duration for the accelerometer sensors 305 to collect vibration data sets of approximately the same duration at approximately the same time. In some embodiments, the vibration data processed by the vibration spectral analysis processor 310 includes a vibration data set that incorporates a time-series waveform representing the acceleration (e.g.,(in acceleration forces) that were detected over time by an accelerometer 305. In some embodiments, a vibration data set must be of a desired duration to be used for certain vibration analysis. Accordingly, the vibration spectral analysis processor 310 can generate a vibration data set of the desired duration by concatenating several shorter time-series segments.

[0026] The vibration spectral analysis processor 310 can communicate the vibration data (for example, raw data or processed vibration data sets) to the electrical controller 205 (for example, for display to an operator via the user interface 225) or to an external system (for example, via a local network, a wide area network, a wireless network, the Internet, or a combination of the above (not shown)).

[0027] In some embodiments, the vibration data acquisition system 300 receives vibration data during the operation of the electric mining excavator 100 in a normal production environment (that is, while mining operations are taking place in a mine). Alternatively, or in addition, the vibration data acquisition system 300 receives vibration data during a "step test" of the electric mining excavator 100. During the step test, the electric mining excavator 100 moves in one or more predetermined patterns (for example, lifting the bucket 140 up and down; moving the bucket 140 inward and outward; and rotating the stick 135 left and right). By moving the electric mining excavator 100 in predetermined patterns, vibration data can be acquired at known points while the electric mining excavator 100 is operating at a constant speed.The predetermined patterns can also be repeated until sufficient vibration data has been collected. An example of a step test is described in US patent application no. 13 / 743,894.

[0028] Fig. Figure 4 illustrates a method 400 for collecting vibration data for the electric mining excavator 100 in accordance with one embodiment. As an example, the method 400 is described with respect to a first electronic processor (for example, the electronic processor 235) that controls the operation of at least one component (for example, a feed motor) of a mining machine (for example, the electric mining excavator 100), and to a second electronic processor (for example, the vibration spectral analysis processor 310) that collects and processes vibration data from vibration sensors (for example, the accelerometer sensors 305) positioned in a group to detect vibrations of the at least one component. This example is not to be considered limiting.Alternative embodiments of Method 400 can be implemented, for example, using additional electronic processors or using a single electronic processor that performs all of the functions described herein.

[0029] In block 402, the second electronic processor initiates the automated operational vibration data collection process. In some embodiments, the data collection process begins when the electric mining excavator 100 is switched on. In other embodiments, the data collection process begins only after a predetermined time has elapsed since the electric mining excavator 100 was switched on, or when the first electronic processor instructs the second electronic processor to begin the data collection process.

[0030] In Block 404, the second electronic processor determines at least one predicate parameter. In some embodiments, the second electronic processor determines the predicate parameters by reading one or more predicate parameters from one or more configuration files stored in memory. As will be explained in more detail below, a predicate parameter is a condition that must be true for the second electronic processor to collect vibration data from the vibration sensors. In particular, to collect vibration data of consistent quality, the second electronic processor preferably collects data during consistent mining machine states (e.g., when the mining machine is operating in a relatively constant state and with a relatively constant load).Accordingly, the predicate parameters can specify conditions which, if true, indicate that the mining machine is operating in a constant state and with a constant load. Such predicate parameters, which are explained in more detail below, and the values ​​for which they are true, can be determined experimentally.

[0031] In Block 406, the mining machine operates in a normal production environment (that is, during active mining operations). For example, an operator can control the mining machine to extract material from a longwall face and deposit it into a tipper truck. When the operator operates the mining machine, the first electronic processor receives at least one motion command and controls at least one component of the mining machine based on that command. For example, the operator can control the mining machine to perform a feed extension, and the first electronic processor receives at least one motion command to control the feed motor to extend the stick 13 5 and the bucket 140.In other examples, the first electronic processor can control components of the mining machine to perform lifting, lowering, feed-in, clockwise rotation, counterclockwise rotation, and the like.

[0032] In block 408, the second electronic processor determines whether the predicate parameters (determined above in block 404) are true. As noted above, the predicate parameters are conditions which, if true, are more likely to result in consistent quality for the vibration data being collected. In some embodiments, the predicate parameter, or a combination of predicate parameters, may depend on the group of sensors that provide vibration data sets to the second electronic processor.

[0033] An example of a predicate parameter is the time elapsed since the second electronic processor last completed the vibration data collection. The second electronic processor might, for instance, be configured to collect vibration data every three hours during the operation of the mining machine. In this situation, the predicate parameter is true if more than three hours have passed since the second electronic processor last collected vibration data, and it remains true until the second processor has completed processing the currently collected vibration data.

[0034] Another exemplary predicate parameter can be an operating state of at least one component or at least one motor driving that component. For example, a predicate parameter can include a motor rotation direction, a permissible motor speed range, a permissible instantaneous rate of change in motor speed, and a permissible moving average rate of change in motor speed. In this situation, the predicate parameter is true if a measured value (for example, a speed, a direction, or a rate of change) corresponds to the parameter to be considered or lies within a predetermined range of a predetermined value for the parameter to be considered. In one example, the second electronic processor receives a signal from at least one tachometer (from the one or more tachometers 307) that monitors the feed motor.The second electronic processor determines the rotational speed and direction of rotation of the feed motor based on the received signal. Similarly, and depending on one or more predicate parameters determined at block 404, the second electronic processor can determine an instantaneous rate of change for the feed motor speed and a moving average rate of change for the feed motor speed.

[0035] A predicate parameter need not be based on motor speed and direction. For example, the motor speed and direction might not provide enough information for the second electronic processor to accurately determine whether the bucket 140 is currently carrying a payload. In such a case, the predicate parameter can include a digital machine state (for example, derived by a cycle decomposition state machine algorithm and provided by the first electronic processor to the second). In this situation, the predicate parameter is true as long as the first electronic processor indicates that the mining machine is in a desired state (for example, at a specific stage of the extraction or conveying cycle).

[0036] Other exemplary predicate parameters can be based on a torque for at least one component or a motor driving that at least one component. For example, a predicate parameter can include a permissible motor torque range, a permissible instantaneous rate of change in the motor torque, and a permissible moving average rate of change in the motor torque. In these situations, a predicate parameter is true if the measured value (for example, the torque or the rate of change) is equal to the parameter being considered or lies within a predetermined range of a predetermined value for the parameter being considered. For example, the second electronic processor can receive torque values ​​for the feed motor from the first electronic processor.Depending on the one or more predicate parameters determined at block 404, the second electronic processor can also determine an instantaneous rate of change for the feed motor torque and a moving average rate of change for the feed motor torque.

[0037] If the second electronic processor determines that one or more of the predicate parameters (determined at block 404) are incorrect, the second electronic processor continues to monitor the predicate parameters as long as the mining machine continues to operate (at block 406).

[0038] If the second electronic processor determines that the predicate parameters (determined at block 404) are true, it performs extended data collection (at block 410). During extended data collection, the second electronic processor receives a multitude of vibration data sets, one from each of the multiple sensors. The second electronic processor can receive these multiple vibration data sets in parallel.

[0039] In block 412, the second electronic processor determines whether each vibration data record exceeds a desired duration. If the vibration data records do not exceed the desired duration, the second electronic processor continues collecting vibration data from the sensors while the predicate parameters are true (in blocks 408 to 410). In some situations, the predicate parameters may not remain true long enough to collect vibration data records that exceed the desired duration. For example, the feed motor may operate within a desired speed range and also outside of it. In such situations, the second electronic processor can collect shorter data segments and generate a vibration data record of the desired duration by concatenating a sufficient number of these shorter data segments.

[0040] In block 414, when the vibration data sets exceed the desired sampling duration, the second electronic processor selects a subset of vibration data from each of the many collected vibration data sets. In some embodiments, the second electronic processor selects a subset of vibration data such that it corresponds to a desired final waveform duration. For example, a waveform with a duration of one second (i.e., one vibration data subset) can be selected from an initially extended waveform with a duration of approximately five to six seconds (i.e., one vibration data set).The second electronic processor can select the vibration data subsets based on a time window or time windows with minimal parameter fluctuation, such as the lowest peak motor acceleration, the lowest overall fluctuation in motor speed, the lowest rate of change in motor torque, and the lowest overall fluctuation in motor torque.

[0041] In block 416, the second electronic processor determines whether the vibration data sets are valid. This second electronic processor can determine data validity by testing the vibration data sets or selected subsets of vibration data. A vibration data set or subset can be considered valid if it provides useful information regarding the vibration of the monitored component. Fig. Figure 5 illustrates, for example, a diagram 500 that shows a valid vibration data set 502. The valid vibration data set 502 shows a constant mean value at zero acceleration forces and illustrates a high-frequency energy.

[0042] In contrast, a vibration data set or subset of vibration data is not valid if it is unusable (that is, if it will not provide any useful information regarding the vibration of the monitored component). Fig. Figure 6 illustrates, for example, a diagram 600 showing an invalid data set 602. The invalid data set 602 shows a wide variance in the oscillation (acceleration forces) followed by a zero line. In another example, Fig. 7 a diagram 700, which shows a second invalid data set 702. The second invalid data set 702 shows a large degree of mean-free deviation and an absence of high-frequency energy.

[0043] Referring back to Fig. 4. The second electronic processor in block 418 records the vibration data records (or subsets thereof) when all vibration data records (or subsets thereof) are valid (e.g., by writing the vibration data records to a memory). In some embodiments, the second electronic processor records the vibration data records in a memory of the vibration spectral analysis processor 310. In other embodiments, the second electronic processor records the vibration data records in a database located external to the mining machine.

[0044] At block 420, the second electronic processor determines whether at least one of the vibration data sets is valid. Consistently invalid vibration data sets received from sensors in a group may indicate, for example, that one or more predicate parameters determined at block 404 are incorrect, that one or more validity test thresholds are set incorrectly, or that the sensors in that group need to be repaired or replaced. Accordingly, if none of the vibration data sets are valid, the second electronic processor at block 421 determines whether all vibration data sets failed data validation (at block 416) for a threshold across consecutive trials. If the threshold is not exceeded, the second electronic processor restarts vibration data collection at block 406.If the threshold has been exceeded, the second electronic processor marks the affected data records as invalid with a flag at block 424 (for example, by writing an invalidity flag into the metadata associated with the group of sensors).

[0045] Consistently invalid vibration data sets received from one or more (but not all) sensors may indicate that one or more of the sensors need to be repaired or replaced. For example, the zero-line response in invalid data set 602 may indicate a transient shock event that could temporarily saturate a sensor. In another example, the lack of a high-frequency response in the second invalid data set 702 may indicate excessive shock or a loose sensor, which could impair the transmission of high-frequency energy. Such sensors will not provide valid data until the underlying problems are identified and resolved.Accordingly, the second electronic processor at block 422 determines, if at least one vibration data record is valid, whether invalid vibration data records from specific sensors have failed data validation (at block 416) for a threshold value across successive trials. If the threshold has not been exceeded, the second electronic processor restarts vibration data collection at block 406. If the threshold has been exceeded, the second electronic processor flags the affected data records as invalid at block 424. For example, in some embodiments, the second electronic processor writes an invalidity flag to metadata associated with each affected sensor and writes the metadata to the memory containing the vibration data records (at block 418).In other embodiments, the second electronic processor places an invalidation flag for each affected sensor in a memory and discards the invalid data records.

[0046] Regardless of where or why the invalidation flags are written, the first or second electronic processors can read the invalidation flags and alert an operator of the mining machine (for example, by triggering an alarm on the user interface 225). In some embodiments, the flags can also trigger an alarm on a system located external to the mining machine.

[0047] At block 426, the second electronic processor can reset a predicate clock to indicate that a set of vibration data sets has been successfully collected. As described above, at block 404, the second electronic processor can use the predicate clock to determine when to restart the vibration data collection process (i.e., how much time has elapsed since the last vibration data collection).

[0048] As mentioned above, vibration data can be collected during normal operation of the mining machine or during a stage test. Accordingly, this is illustrated Fig. 8. A method 800 for collecting vibration data during the step test of the mining machine in accordance with one embodiment. In some embodiments, method 800 is an adaptation of method 400. Accordingly, blocks are in Fig.8 similarly marked blocks, as described above in relation to Method 400, are performed. As noted above, during the step test, an operator moves the mining machine in one or more predetermined patterns (i.e., movements). Accordingly, at block 802, the operator initiates a test for a selected step test movement (for example, inward and outward movement of the bucket 140). The mining machine operator can, for example, select the movement using the user interface 225. In some embodiments, the operator selects a movement to be performed. Alternatively or additionally, the second electronic processor can select a movement and display the selected movement to the operator via the user interface 225.

[0049] At block 804, the operator operates the mining machine according to the selected step test motion, and the first electronic processor receives at least one motion command to control the mining machine so that the step test motion is performed. At blocks 408 to 426, the second electronic processor collects and validates vibration data sets as described above in relation to procedure 400. The operator continues to operate the mining machine according to the selected step test motion at block 802, repeating the selected step test motion if necessary, until the vibration data sets exceed the desired sampling duration (at block 412). At block 806, the second electronic processor indicates that the step test and vibration data collection for that step test are complete.In some embodiments, the second electronic processor can communicate a complete specification to the first electronic processor, which can display the specification for the operator on the user interface 225.

[0050] At block 808, the second electronic processor determines whether selected movements have been completed. If the selected movements have been completed, the second electronic processor performs a step test reset. In some embodiments, a step test reset includes resetting a timer (for example, to track, similar to the predicate clock described above, how much time has elapsed since the last vibration data collection step test). If the selected movements have not been completed, the second electronic processor collects vibration data for the next selected step test movement at block 802.

[0051] The invention thus provides, among other things, a system and a method for collecting operational vibration data for a mining machine. Various features and advantages of the invention are set forth in the following claims.

Claims

[1] Mining machine (100) comprising the following: a plurality of sensors (305), each of the plurality of sensors (305) being positioned at one of a plurality of measuring points on at least one component of the mining machine (100); a first electronic processor (235) coupled with and configured to be used with at least one component, to receive at least one movement order; and to control at least one component based on at least one movement command; and a second electronic processor coupled to the first electronic processor (235) and the plurality of sensors (305) and configured to determine at least one predicate parameter, wherein the at least one predicate parameter includes a rate of change of a motor parameter of the mining machine (100); to determine whether at least one predicate parameter is true; and while the first electronic processor (235) controls at least one component and at least one predicate parameter is true, to receive a large number of vibration data sets from the large number of sensors (305). [2] Mining machine (100) according to claim 1, wherein the plurality of sensors (305) comprises a plurality of accelerometers (305). [3] Mining machine (100) according to claim 1, wherein the at least one component is a component selected from a group consisting of a lifting motor (275) and a pinion shaft; a lifting intermediate shaft; a lifting drum; a rotary motor (270) and a pinion shaft; a rotary intermediate shaft; a rotary output shaft; a feed motor (265); a feed input shaft; and a feed intermediate shaft. [4] Mining machine (100) according to claim 1, wherein the rate of change of the motor parameter of the mining machine (100) comprises at least one selected from a group consisting of a permissible instantaneous rate of change in the motor speed; a permissible moving average rate of change in the motor speed; a permissible instantaneous rate of change in the motor torque; and a permissible moving average rate of change in the motor torque. [5] Mining machine (100) according to claim 4, which further comprises: at least one tachometer (307) positioned to monitor a motor of the mining machine (100); wherein the second electronic processor is coupled with the speedometer (307) and Furthermore, it is configured to to receive at least one speedometer signal from at least one speedometer (307); and to determine, on the basis of at least one tachometer signal, whether at least one predicate parameter is true. [6] Mining machine (100) according to claim 1, wherein, in addition to the rate of change of the motor parameter of the mining machine (100), the at least one predicate parameter comprises at least one selected from a group consisting of a digital machine state; a permissible motor torque range; a motor rotation direction; and a permissible motor speed range. [7] Mining machine (100) according to claim 1, wherein the second electronic processor is further configured to determine whether a duration of at least one of the plurality of vibration data sets exceeds a desired sampling duration. [8] Mining machine (100) according to claim 1, wherein the second electronic processor is further configured to select a vibration data subset from one of the plurality of vibration data sets, wherein the subset is selected to be written to a memory, and the subset is selected based on a set of parameter fluctuations within the subset, compared to other subsets of the plurality of vibration data sets. [9] Mining machine (100) according to claim 1, wherein the second electronic processor is further configured to to determine whether each of the multitude of vibration data sets is valid or invalid; and if each of the multitude of vibration data sets is valid, to write the multitude of vibration data records into a memory; and if at least one of the multitude of vibration data records is not valid, to determine whether a failing threshold has been reached; and if the failing threshold has been reached, to write an invalidation flag to the metadata; and to write the multitude of vibration data sets and the metadata into memory. [10] Mining machine (100) according to claim 1, wherein the at least one movement command comprises a selected step test movement. [11] Mining machine (100) according to claim 1, wherein the second electronic processor is configured to receive the plurality of vibration data sets in parallel. [12] Method for collecting operational vibration data for a mining machine (100) wherein the method comprises the following steps: Receiving at least one movement order; and Control of at least one component based on at least one movement command; Determination by an electronic processor of at least one predicate parameter, wherein at least one predicate parameter includes a rate of change of a motor parameter of the mining machine (100); Determine, using the electronic processor, whether at least one predicate parameter is true; and while at least one component is controlled on the basis of at least one movement command and at least one predicate parameter is true, the reception by the electronic processor of a plurality of vibration data sets from a plurality of sensors (305), wherein each of the plurality of sensors (305) is positioned at one of a plurality of measuring points on the at least one component of the mining machine (100). [13] Method according to claim 12, wherein receiving the plurality of vibration data sets comprises receiving the plurality of vibration data sets from a plurality of accelerometers. [14] Method according to claim 12, wherein controlling the at least one component comprises controlling at least one selected from a group consisting of a lifting motor (275) and a pinion shaft; a lifting intermediate shaft; a lifting drum; a rotary motor (270) and a pinion shaft; a rotary intermediate shaft; a rotary output shaft; a feed motor (265); a feed input shaft; and a feed intermediate shaft. [15] Method according to claim 12, wherein determining the rate of change of the engine parameter of the mining machine (100) comprises determining at least one selected from a group consisting of a permissible instantaneous rate of change in the engine speed; and a permissible moving average rate of change in the engine speed; a permissible instantaneous rate of change in the engine torque; and a permissible moving average rate of change in the engine torque. [16] The method of claim 15, further comprising the following steps: Receiving at least one tachometer signal from at least one tachometer (307) positioned to monitor a motor of the mining machine (100); and Determine, based on at least one speedometer signal, whether at least one predicate parameter is true. [17] Method according to claim 12, wherein, in addition to determining the rate of change of the motor parameter of the mining machine (100), determining the at least one predicate parameter comprises determining at least one selected from a group consisting of a digital machine state; a permissible motor torque range; a motor rotation direction; and a permissible motor speed range. [18] Method according to claim 12, wherein receiving the plurality of vibration data sets comprises receiving the plurality of data sets until a duration of each of the plurality of vibration data sets exceeds a desired sampling duration. [19] The method of claim 12, further comprising the following step: Determining a multitude of optimal vibration data subsets, each selected from a multitude of vibration data sets, each of the subsets being selected to be written to memory, and selecting a subset based on a set of parameter fluctuations within the subset, compared to other subsets of the multitude of vibration data sets, is selected. [20] The method of claim 12, further comprising the following steps: Determine whether each of the numerous vibration data sets is valid or invalid; and If each of the multitude of vibration data sets is valid, write the multitude of vibration data sets to a memory; and If at least one of the numerous vibration data sets is invalid, determine whether a failing threshold has been reached; and when the threshold for failing has been reached, Writing an invalidation flag to metadata; and Writing the multitude of vibration data sets and metadata to memory. [21] Method according to claim 12, wherein controlling the at least one component on the basis of the at least one motion command comprises controlling the at least one component on the basis of a selected step test movement. [22] Method according to claim 12, wherein receiving the plurality of vibration data sets comprises receiving the plurality of data sets in parallel. [23] Mining machine (100) according to claim 9, wherein it is determined that the threshold for failure is reached when the vibration data sets from individual sensors have failed a certain number of consecutive trials. [24] Mining machine (100) according to claim 9, wherein determining whether each of the plurality of vibration data sets is valid or invalid is based on determining at least one selected from a group consisting of a constancy of a mean value of each of the plurality of vibration data sets at zero acceleration forces and a frequency energy level of each of the plurality of vibration data sets. [25] Method according to claim 20, wherein it is determined that the threshold for failure is reached when the vibration data sets from individual sensors have failed a certain number of consecutive trials. [26] Method according to claim 20, wherein determining whether each of the plurality of vibration data sets is valid or invalid is based on determining at least one selected from a group consisting of a constancy of a mean value of each of the plurality of vibration data sets at zero acceleration forces and a frequency energy level of each of the plurality of vibration data sets.

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