Wear sensor

Abstract

An optical wear sensor (1) for identifying the extent of wear of mining or similar equipment. The sensor (1) includes a probe (5) having one or more optical element (10), a deflector (4), and a transmitter / detector, and a base (6) which includes a processor (81) and wireless transmitter (33). The optical element (1) is provided within a body of a wear part (11) and has a first end and a second end defining a bi-directional optical signal transmission pathway (3). The optical deflector (1) is formed of deflective material and positioned at said second end of said optical element (10) to reflect the optical signal. The optical transmitter (18) / detector (19) is configured to transmit said optical signal from the first end of said optical element (1), and detect whether or not said optical signal is returned via said optical pathway to said first end of said optical element (10). The processor converts any optical signal received by said optical detector to an electrical response signal, and the wireless signal transmitter (33) transmits the electrical response signal indicative of the wear condition of said body (11) to an output device. A plurality of optical elements (10a - 10e), of differing lengths may be provided to identify the depth or extent of wear.

Description

Background

[0001] The present invention relates to a wear sensor which is configured to sense the wear condition of a body, such as a wear liner provided on equipment used in the mining and mineral processing industries. In particular, the present invention relates to a wear sensor which includes an optical fibre or other optical element.

[0002] The present invention also relates to a wear sensor arrangement, including a plurality of wear sensors, wherein each wear sensor is configured to extend to a predetermined depth within a wear body, so that the extent / depth of wear of the body may be sensed.

[0003] The present invention furthermore relates to a processing system and method to indicate a wear condition of a body, to a modelling system to display a model of the wear condition of the body, and, to a system for predicting the future wear of the body. Description of the Prior Art

[0004] Any reference in this specification to prior art, or matter which is said to be known, is not to be taken as an acknowledgement or admission that such prior art or matter forms part of the common general knowledge in the field of invention to which this specification relates.

[0005] Wear liners are commonly used in mining equipment and in mineral processing plants, including in mining dump truck trays, crusher concave liners, grinding mill liners, slurry pump liners, slurry pipelines, etc.

[0006] It is important to monitor the wear condition (length / thickness) of these liners to ensure the safe and efficient operation of these assets, and to determine when the liners should be replaced.

[0007] A number of technologies have been utilised to monitor the wear conditions of these liners, including manual ultrasonic measurements, laser scanning, online ultrasonic measurements, and online resistive / conductive measurements.

[0008] Manual ultrasonic measurement methods have inherent safety hazards and risks, and therefore typically require shutdown of the plant, inhibiting personnel from entering the inner space of the operating plant, consequently reducing the production efficiency whilst the wear monitoring process is being performed.

[0009] Laser scanning similarly also requires manual operation of the scanner as well as plant shutdown. Laser scanning additionally require calibrations using manual thickness measurements, such as ultrasonic measurement to ensure accurate calculations.

[0010] Online ultrasonic measurement methods, which use an ultrasonic sensor installed on the 2025232127  24 Apr 2026 back of the wear lining material to measure the current thickness, can be conducted without manual entry or plant shutdown. However, the ultrasonic wave requires calibration for each different alloy material, and it does not work with non-metallic or composite lining materials.

[0011] Online intrusive wear measurement methods typically employ a plurality of resistor, capacitor and / or inductor based circuits to represent respective wear increments. However, when such a resistor, capacitor and / or inductor based circuit is exposed under conductive conditions, such as a slurry environment, the resistance, capacitance and / or inductance result of the circuits may be adversely impacted, leading to an erroneous indication of the wear.

[0012] Online intrusive measurement based methods, such as resistive / conductive / inductive wear sensors, typically install a limited number of sensors in empirically selected locations on the lining body. Actual higher wear locations may not be captured by these selected locations, resulting in incorrect estimation of the wear level for lining bodies. Summary of the Invention

[0013] The present invention seeks to overcome at least some of the disadvantages and / or drawbacks of prior art apparatus and / or methods of monitoring the wear conditions of wear liners of equipment bodies.

[0014] The present invention also seeks to provide a wear sensor, a sensor arrangement, a sensing device, and / or a system for indicating and / or modelling the wear condition of a body.

[0015] The present invention also seeks to provide a wear sensor which operates functionally differently to prior art wear sensors by using an optical element to sense the wear of a body.

[0016] The present invention also seeks to provide a wear sensor in which the sensing is achieved using a substantially non-conductive sensor.

[0017] In a broad form, the present invention provides an optical wear sensor, including: an optical element, adapted to be provided within a body of a wear part, the optical element having a first end and a second end, defining a bi-directional optical signal transmission pathway therebetween; an optical deflector, formed of deflective material, positioned at said second end of said optical element, configured to reflect an optical signal; an optical transmitter and detector, configured to transmit said optical signal from the first end of said optical element, and, detect whether or not said optical signal is returned via said optical pathway to said first end of said optical element; a processor, configured to convert any optical signal received by said optical detector to an electrical response signal; and, 2025232127  24 Apr 2026 a wireless signal transmitter, configured to transmit said electrical response signal indicative of the wear condition of said body to an output device.

[0018] Preferably, said optical element includes an optical fibre.

[0019] Preferably, the optical deflector is adapted to be positioned within the body of the wear part substantially proximal to a wear surface of said wear part.

[0020] Preferably, the optical deflector includes a coating of optically deflective material.

[0021] Preferably, the coating is applied to a base.

[0022] Preferably, the base of the optical deflector is formed of a rigid material, such as polymers, glass or silicon.

[0023] Preferably, the deflective material provides a reflectivity of about 50% to 90%, and more preferably 70% to 90%, in relation to wavelength of the optical signal.

[0024] Preferably, the deflective material includes any one or combination of gold, silver, copper, aluminium, magnesium fluoride, silicon dioxide, calcium fluoride, zinc sulfide, tantalum pentoxide, titanium dioxide, and / or other suitable metals, oxides or sulfides.

[0025] Preferably, the optical signal has a wavelength in the range of 1260 nm to 1625 nm.

[0026] In a preferred form, the optical signal is a non-continuous, pulsatile signal.

[0027] In an alternative preferred form, the optical signal is a continuous signal.

[0028] Preferably, said optical element is at least partially formed of polymer or glass material.

[0029] Preferably, said optical element is formed of a material which is substantially non-conductive.

[0030] Preferably, said optical element is embedded within said body.

[0031] Preferably, said optical element is installed within said body.

[0032] Preferably, said sensor is passively powered by a transponder device including the wireless signal transmitter.

[0033] Preferably, said passively powered transponder device is configured as an RFID transponder.

[0034] Preferably, said transponder device is configured to: receive an input signal to power said sensor; and, transmit the electrical response signal indicative of the wear condition of said wear part.

[0035] Preferably, said transponder operates in a UHF range.

[0036] Preferably, said sensor is actively powered by a battery or other power source. 2025232127  24 Apr 2026

[0037] In a further broad form, the present invention provides an optical wear sensor device, adapted to be provided within a body of a wear part, configured to indicate a depth or extent of wear of the wear part, said device including: a plurality of optical elements, each optical element having a first end and a second end, defining a respective bi-directional optical signal transmission pathway of a different respective length therebetween; a plurality of optical deflectors, each formed of deflective material, each optical deflector positioned at the second end of the respective optical element, configured to reflect a respective optical signal; a plurality of optical transmission and detection devices, configured to transmit an optical signal from the first end of each respective optical element, and, detect whether or not said optical signal is returned via each optical pathway to said first end of the optical element; at least one processor and wireless signal transmitter, configured to: convert any optical signal(s) received by at least one of said plurality of optical deflectors; and, transmit the optical signal(s) received by said optical deflectors to an electrical response signal, wherein, in use, the electrical response signal is thereby indicative of the worn condition of the respective deflector and thereby indicative of the depth or extent of wear of the wear part.

[0038] Preferably, each optical element includes an optical fibre.

[0039] In a preferred form, a processor and wireless signal transmitter is provided for each optical element.

[0040] In an alternative preferred form, a processor and wireless signal transmitter is provided for one or more of said plurality of optical elements.

[0041] Preferably, each optical deflector is configured to be worn away as said wear part wears away.

[0042] Preferably, said plurality of optical elements and deflectors are housed in the form of a probe.

[0043] Preferably, each optical deflector includes a coating of optically deflective material.

[0044] Preferably, the coating is applied to a base.

[0045] Preferably, the base of each optical deflector is formed of a rigid material, such as polymers, glass or silicon.

[0046] Preferably, the deflective material provides a reflectivity of about 50% to 90%, and more 2025232127  24 Apr 2026 preferably 70% to 90%, in relation to wavelength of the optical signal.

[0047] Preferably, the deflective material includes any one or combination of gold, silver, copper, aluminium, magnesium fluoride, silicon dioxide, calcium fluoride, zinc sulfide, tantalum pentoxide, titanium dioxide, and / or other suitable metals, oxides or sulfides.

[0048] Preferably, the optical signal has a wavelength in the range of 1260 nm to 1625 nm.

[0049] In a preferred form, the optical signal is a non-continuous, pulsatile signal.

[0050] In an alternative preferred form, the optical signal is a continuous signal.

[0051] Preferably, said sensor device further includes a passive transponder including the wireless signal transmitter(s).

[0052] Preferably, said passive transponder is housed in a base at an end of said probe.

[0053] Preferably, said transponder is configured to: receive an input signal to power said sensor device; and, transmit the electronic response signal indicative of the depth / extent of wear of the wear part.

[0054] Preferably, said device further includes an optical-electrical converter including the processor(s), configured to: convert an electrical power signal received by said transponder to an optical transmission signal for transmission by said optical transmission device; and, convert any optical signal received by said optical-electrical detector device to the electrical response signal.

[0055] Preferably, said passive transponder includes an antenna which is substantially circular, semi-circular, rectangular or square in shape.

[0056] Preferably, said antenna of said wear sensor is configured to be in communication with a wear sensor writer which is of complementary or compatible shape.

[0057] Preferably, said wireless signal transmitter(s) uses a communications channel including using Wi-Fi, a cellular network, or similar.

[0058] In a further broad form, the present invention provides a wear sensing arrangement including a plurality of optical wear sensors arranged at different positions within a body of a wear part, wherein each optical wear sensor is as described above, and configured to indicate the wear condition at a respective location within the wear part.

[0059] Preferably, each optical wear sensor is configured to extend to a predetermined depth within said body so that the extent / depth of wear of the body is thereby sensed. 2025232127  24 Apr 2026

[0060] In a further broad form, the present invention relates to an optical wear sensor as described above, or, a wear sensing arrangement as described above, adapted to indicate the wear condition of any one or combination of: a truck tray lining; a gyratory crusher concave lining; a grinding mill lining; a slurry pump lining; and, a slurry pipeline lining.

[0061] In a further broad form, the present invention provides a system for modelling a wear condition of a body including: at least one optical wear sensor, each optical wear sensor is as described above, and adapted to be provided within a body of a wear part, and configured to provide sensor data indicative of a wear condition of the wear part; and, a modelling processor, configured to construct a model of the wear condition of the body based on said sensed data.

[0062] Preferably, said modelling processor is further configured to predict future wear of the body based on a comparison of original body data representative of the original condition of said body and said sensed data.

[0063] Preferably, said modelling processor uses any one or combination of: a numerical modelling programme; a machine learning algorithm; an artificial intelligence neural network; and, a deep learning or predictive modelling criteria.

[0064] Preferably, said modelling processor is further configured to predict a replacement time to replace a wear part.

[0065] Preferably, said modelling processor is further configured to initiate the ordering of a replacement wear part at a predetermined period prior to the predicted replacement time.

[0066] According to one aspect, the present invention provides an optical wear sensor, including: an optical fibre, adapted to be provided within a body of a wear part, the optical fibre having a first end and a second end, defining a bi-directional optical signal transmission pathway therebetween; an optical reflector, formed of reflective material that is substantially metallic, adapted to be positioned at the second end of the optical fibre within the body of the wear part proximal to a 2025232127  24 Apr 2026 wear surface of said wear part, and configured to be worn away as the body of the wear part is worn away; an optical transmitter and detector, configured to transmit said optical signal from the first end of an optical fibre, and, detect whether or not said optical signal is returned via said optical pathway to said first end of said optical fibre; a processor, configured to convert any optical signal received by said optical detector to an electrical response signal; and, a wireless signal transmitter, configured to transmit said electrical response signal indicative of the wear condition of said body to an output device, wherein, in use: when the optical reflector is connected to the second end of the optical fibre, the optical reflector is configured to reflect said optical signal, and prevent said optical signal from exiting the second end of the optical fibre, and, when the optical reflector is worn away as the body of the wear part is worn away, the optical signal exits from the second end of the optical fibre.

[0067] According to a further aspect, the present invention provides an optical wear sensor device, adapted to be provided within a body of a wear part, configured to indicate a depth or extent of wear of the wear part, said device including: a plurality of optical fibres, each optical fibre having a first end and a second end, defining a respective bi-directional optical signal transmission pathway of a different respective length therebetween; a plurality of optical reflectors, each formed of reflective material that is substantially metallic, each optical reflector adapted to be positioned at the second end of a respective optical fibre within the body of the wear part proximal to a wear surface of said wear part, each optical reflector configured to be worn away as the body of the wear part is worn away; a plurality of optical transmission and detection devices, configured to transmit an optical signal from the first end of each respective optical fibre, and, detect whether or not said optical signal is returned via each optical pathway to said first end of the optical fibre; at least one processor and wireless signal transmitter, configured to: convert any optical signal(s) received by at least one of said plurality of optical reflectors; and, transmit the optical signal(s) received by said optical reflectors to an electrical response signal, wherein, in use: when the respective optical reflector is connected to the second end of the respective optical 2025232127  24 Apr 2026 fibre, the respective optical reflector is configured to reflect said respective optical signal, and prevent said respective optical signal from exiting the second end of the respective optical fibre, and, when the respective optical reflector is worn away as the body of the wear part is worn away, the respective optical signal exits from the second end of the respective optical fibre, wherein, in use, the electrical response signal is thereby indicative of the worn condition of the respective optical reflector and thereby indicative of the depth or extent of wear of the wear part.

[0068] According to a further aspect, the present invention provides a system for modelling a wear condition of a body including: at least one optical wear sensor, each optical wear sensor is as described hereinabove, and adapted to be provided within a body of a wear part, and configured to provide sensor data indicative of a wear condition of the wear part; and, a modelling processor, configured to construct a model of the wear condition of the body based on said sensed data. Brief Description of the Drawings

[0069] The present invention will become more fully understood from the following detailed description of preferred but non-limiting embodiments thereof, described with reference to the accompanying drawings in which: Figure 1 shows an optical wear sensor probe according to a first example embodiment of the present invention; Figure 2 shows an optical wear sensor probe according to a second example embodiment of the present invention; Figure 3 shows an optical wear sensor probe arrangement incorporating a plurality of optical elements; Figure 4 shows the sensor arrangement of Figure 3 installed in a wear part; Figure 5 shows the sensor arrangement installed in a wear part, wherein the wear part and probe of the optical sensor device are partially worn; Figure 6 details a schematic diagram of the wear sensor probe arrangement, constructed in the form of a multi-layer PCB, incorporating optical fibres and micro fibre deflectors; Figure 7 shows an example embodiment of an optical element / optical fibre and an optical deflector / micro fibre deflector, that can be incorporated in an optical wear sensor probe or an optical wear sensor probe arrangement. Figure 8 illustrates a schematic diagram of an example operation of an optical wear sensor 2025232127  24 Apr 2026 probe arrangement, constructed in the form of a multi-layer PCB, incorporating the optical element and the optical deflector shown in Figure 7, and installed in a wear part. Figure 9 shows a schematic diagram of another example operation of the optical wear sensor probe arrangement shown in Figure 8, with the optical deflector worn off. Figure 10 shows a wear sensor probe arrangement, incorporating a plurality of optical loops; Figure 11 shows a passively powered optical wear sensor system utilising radio frequency identification (RFID) to power the probe and for signal transmission; Figure 12 shows alternative example RFID antenna arrangements with passively powered optical wear sensors; Figure 13 shows an example embodiment of a passively powered optical wear sensor antenna housing; Figures 14 shows an example embodiment of an actively powered optical wear sensor; Figure 15 shows an example embodiment of a pair of optical sensors which are actively powered, one sensor having equidistantly spaced deflectors and the other having variably spaced deflectors; Figure 16 shows an example embodiment of a plurality of optical wear sensor installations in a truck tray lining body; Figure 17 shows an example embodiment of an optical wear sensor installation in a gyratory crusher concave lining body; Figure 18 shows a cross-sectional view of an example embodiment of wear sensors installed in a liner body; Figure 19 shows an example embodiment of actively powered optical wear sensors installed in a slurry pump liner body; Figure 20 shows an example embodiment of an actively powered optical wear sensor installed in a slurry pipeline liner body; Figure 21 shows an example data transmission system / process associated with passively powered optical wear sensors of the present invention; Figure 22 shows an example data transmission system / process associated with actively powered optical wear sensors of the present invention; Figure 23 illustrates a flowchart of an example global wear prediction and reconstruction process with optical wear sensor installations; Figure 24 illustrates a flowchart of another example of a wear prediction algorithm; Figure 25 illustrates another flowchart of a wear prediction algorithm; Figure 26 illustrates an example system showing an implementation of a replacement 2025232127  24 Apr 2026 schedule system for replacing a worn wear sensor, according to the present invention; and, Figure 27 shows an example installation arrangement to install the optical wear sensor into a wear plate body. Detailed Description of Preferred Embodiments

[0070] Throughout the drawings, like numerals will be used to identify like features, except where expressly otherwise indicated.

[0071] Figure 1 shows an example embodiment of an optical wear sensor, generally designated by the numeral 1, in accordance with the present invention. The optical wear sensor 1 includes an optical element 2, formed in a loop arrangement. The optical element 2 is shown to be encapsulated within a probe-like configuration 5 extending from a base portion 6. As illustrated, the optical element 2 has two ends 7 and 8, providing an optical pathway 10 therebetween, the optical element 2 extending within the probe 5 in an elongate manner as shown, with a loop arrangement 9 at the far end of the probe 5, that is, at the end of the probe 5 distal from the base portion 6.

[0072] In use, as will be described hereinafter, an optical signal may be provided at an input end 7 of the optical element 2, for transmission along the optical pathway 10, in this case being formed by the elongate portions of the optical element 2 via the loop 9, to an output end 8 of the optical element 2.

[0073] Figure 2 shows an alternative example embodiment of an optical wear sensor 1. In this case, the optical wear sensor 1 includes a two-way optical pathway 10 which is formed by optical element 3 and an optical deflector 4 provided at the far end of the probe 5.

[0074] In use, an optical signal may be inputted at the base end 7 of the optical element 3, and also be outputted at this base end 8 of the optical elements 3. That is the optical element permits a two way transmission of the optical signal.

[0075] In both the aforementioned example embodiments, the optical elements 2 and 3 define an optical signal transmission pathway 10 between the input end 7 and the output end 8 of the optical element 2 or 3.

[0076] Figure 3 shows another alternative example embodiment of an optical wear sensor 1 in accordance with the present invention. In this example embodiment, the probe 5 of the optical wear sensor 1 is provided with a plurality of optical pathways therein. In the example embodiment illustrated, five optical pathways 10a, 10b, 10c, 10d and 10e are provided, with each pathway including an optical element 3 operating in association with a respective optical deflector 4. Specifically, five optical deflectors 4a, 4b, 4c, 4d and 4e are positioned at different spacings along the length of the probe 5. Optical element 3a and its associated deflector 4a forms a first short 2025232127  24 Apr 2026 optical pathway, whilst increasingly longer optical pathways are formed by optical element and deflector combinations 3b and 4b, 3c and 4c, 3d and 4d, and, 3e and 4e, respectively.

[0077] Figure 4 illustrates the optical wear sensor 1 installed in the body of a wear part 11.

[0078] Figure 5 illustrates the wear part 11 and the optical wear sensor 1 installed therein, similar to that of Figure 4, but with the wear part and optical wear sensor 1 both being partly worn away.

[0079] The probe 5 of the wear sensor 1 are configured such that, the probe 5 and the optical element 2 or 3 installed therein, is adapted to wear away as the wear part 11 wears away.

[0080] Specifically, as the optical elements 2 or 3 wear away, the optical element 2 or 3 become discontinuous such that any optical signal provided at an input end 7 is not received at an output end 8.

[0081] This absence of the optical signal been received at an output end of the optical pathway 10 is indicative that the wear part has worn away to at least the worn depth of the probe 5 and the optical element 2 or 3 housed therein.

[0082] In use, each of the optical pathways 10a, 10b, 10c, 10d and 10e, formed by each respective optical element and deflector combination, may be sequentially worn away as the probe 5 is worn away, indicating the progressive wearing of the probe 5 and the wear part 11.

[0083] An optical transmitter 18 (schematically shown in Figure 6) is configured to be supplied at an input end 7 of each optical pathway 10, to transmit an optical signal through the optical pathway 10.

[0084] An optical detector 19 (also schematically shown in Figure 6) is configured to be supplied at an output end 8 of each optical pathway 10, to detect whether or not an optical signal is received at the output end of the optical pathway.

[0085] In use, the absence of receiving an optical signal at an output end 8 of the optical pathway 10 is indicative of a worn condition of the wear part.

[0086] The optical element may be an optical fibre, or any other element which permits the transmission of an optical signal therethrough. The optical element may be at least partially formed of polymer or glass material. The optical element is preferably non-conductive, which may have certain advantages in use when monitoring readings in conductive ore bodies in equipment, and / or, when installed within a wear plate formed of metal or other conductive material, and / or, when installed within a working environment with conductive wear medium, such as mineral slurry.

[0087] The optical element may, in various alternative example embodiments, be embedded within and / or be integrally formed with the wear part, or may be formed separately in the form of the probe 5 or similar, and then attached to the wear part 11 or inserted within an orifice or cut out 11 2025232127  24 Apr 2026 formed within the wear part 11.

[0088] In other example embodiments, the wear sensor 1 may be installed after manufacture of the wear component and may for example be installed thereto by either using adhesives or a locking mechanism. By way of example, an embodiment of a locking mechanism, which includes a quick lock mechanism 91 installed on the wear sensor 1, and a compatible mating face 92 provided on the body of the wear material 11, is shown in figure 27.

[0089] In Figure 6 is shown a schematic diagram of an example optical wear sensor probe which includes a plurality of optical fibres 3a, 3b, 3c, 3d and 3e. Also shown is an optical deflector 4a, 4b, 4c, 4d and 4e fitted at the end of each optical fibre 3a, 3b, 3c, 3d, 3e. The plurality of optical fibre and micro fibre deflector combination may be fitted within a multilayered printed circuit board (PCB) 12. An optical-electrical converter unit 13 is fitted at the end of the optical fibres to transmit signals via the optical fibre via an optical transmitter 18 and receive any deflective signal via an optical detector 19. When a micro fibre deflector 4a, 4b, 4c, 4d and 4e is removed due to wear, no deflection signal is received at the detector 19 of the optical-electrical converter unit 13, indicating the worn status of the respective optical fibre 3a, 3b, 3c, 3d, 3e to a predetermined length.

[0090] As illustrated in Figure 7, the optical deflector 4 may include a base 402 and an optical coating 401 located on the base 402. The optical coating 401 may be a coating of optically deflective material, and may be applied to the base 402. The base 402 of the optical deflector 4 may be formed of a rigid material, such as polymers, glass or silicon, and the optical coating 401 of the optical deflector 4 may be a metal coating, dielectric coating or high-reflection coating (also known as dielectric mirrors).

[0091] The optical coating 401 of the optical deflector 4 may be formed of a deflective material which provides a sufficient or adequate reflectivity in relation to wavelength / frequency of the optical signal. In some forms, the material of the optical coating may provide sufficient or adequate reflectivity when it provides a reflectance / reflectivity of about 50% to 90%, or perhaps more preferably, about 70% to 90% in relation to wavelength of the optical signal. In some forms, depending on the surface roughness, the material of the optical coating may provide sufficient or adequate reflectivity when it provides a reflectance / reflectivity in the range of 0.5 to 0.9, or perhaps more preferably, 0.7 to 0.9.

[0092] Typically, the deflective material may include any one or combination of gold, silver, copper, aluminium, magnesium fluoride, silicon dioxide, calcium fluoride, zinc sulfide, tantalum pentoxide, titanium dioxide, and / or other suitable metals, oxides or sulfides. However, it can be appreciated that other suitable materials may be used so long as the deflective material used for 2025232127  24 Apr 2026 the optical coating 401 provides sufficient or adequate reflectivity of the optical signal.

[0093] The optical signal may have a wavelength of 1260 nm to 1625 nm, or other suitable wavelengths, including those that are part of the visible light wavelength range, the infra-red wavelength range, and the ultra-violet wavelength range. For example, when the optical signal transmitted from the optical transmitter 18 has a wavelength ranging from 1260 nm to 1625 nm, the optical coating 401 may suitably use a silver metal coating to provide a reflectivity close to 100%.

[0094] In some forms, the base 402 of the optical deflector 4 may be adapted to support the optical coating 401 to prevent disconnection of the optical coating 401 from the end of the optical element / optical fibre 3, when the wear part 11 is exposed to strong vibrations during use. However, it is readily known that an alternative optical deflector, consisting only of the optical coating, may be used to provide deflection of the optical signal transmitted from the optical transmitter 18.

[0095] Additionally or alternatively, It will be appreciated that the thickness of the optical coating 401 may be kept to a minimum, in order to keep manufacturing costs low. In some forms, during manufacture, the optical deflector 4 may be connected to the optical fibre 3 via brushing technique.

[0096] Furthermore, in order for the optical element and deflector combination to work properly, it will be appreciated that the optical element / optical fibre 3 would include a bi-directional optical signal transmission pathway 10, so that the optical signal can travel back through the optical element / optical fibre 3, when it is deflected by the optical deflector 4.

[0097] Figure 8 shows a schematic diagram of an example operation of the optical wear sensor 1. As shown, the optical wear sensor 1 includes an optical element / optical fibre 3, an optical deflector 4, an optical transmitter 18, and an optical detector 19. The optical element / optical fibre 3 is adapted to be provided within a body of a wear part 11, the optical element / optical fibre 3 having a first end and a second end, defining a bi-directional optical signal transmission pathway 10 therebetween, and, the optical deflector 4 is positioned at the second end of the optical element / optical fibre 3. In addition, the optical transmitter 18 is configured to transmit an optical signal from the first end of said optical element, and the optical detector 19 is configured to detect whether or not said optical signal is returned via said optical pathway 10 to said first end of said optical element. In use, the absence of said optical signal being received by the optical detector 19 is indicative of a worn condition of said optical deflector 4 and the wear part 11.

[0098] As shown in figure 8, the input and output ends of the optical pathway 10 are associated with the first end of the optical element / optical fibre 3, and the optical deflector 4 includes the base 402 and the optical coating 401 located on the base 402. 2025232127  24 Apr 2026

[0099] Initially, the optical transmitter 18 transmits a non-continuous pulsatile optical signal into a first end of the optical element / optical fibre 3. The pulsatile optical signal then travels from the first end of the optical fibre 3 (part (I) of optical pathway 10) to a second end of the optical element / optical fibre 3 (part (II) of optical pathway 10). The pulsatile optical signal is then deflected / reflected by the optical coating 401 of the optical deflector 4, and travels back from the second end of the optical element / optical fibre 3 (part (III) of optical pathway 10) to the first end of the optical element / optical fibre 3 (part (IV) of optical pathway 10). The deflected pulsatile optical signal is then detected by the optical detector 19, which then determines that the wear part 11 or probe 5 is not worn.

[0100] Figure 9 shows a schematic diagram of another example operation of the optical wear sensor 1, similar to that shown in figure 8 but with the optical deflector 4 being worn off. Initially, the optical transmitter 18 transmits a non-continuous pulsatile optical signal into a first end of the optical element / optical fibre 3. The pulsatile optical signal then travels from the first end of the optical element / optical fibre 3 (part (I) of optical pathway 10) to a second end of the optical element / optical fibre 3 (part (II) of optical pathway 10). However, unlike the example operation of figure 8, the pulsatile optical signal shown in Figure 9 does not travel back from the second end of the optical element / optical fibre 3 to the first end of the optical element / optical fibre 3, due to the absence of the optical deflector 4. Consequently, the optical detector 19, having not received the deflected pulsatile optical signal over a period of time, determines that the wear part 11 or probe 5 has been worn.

[0101] Whilst figures 8 and 9 both show that the wear sensor 1 uses a non-continuous pulsatile signal to detect wearing of the wear part 11 / probe 5, it will appreciated that a continuous signal may also be alternatively used by the wear sensor 1 to detect same wearing of the wear part 11 / probe 5. However, it is readily known that the continuous signal would use significantly more energy than the non-continuous pulsatile signal. Additionally or alternatively, it will be appreciated that the optical detector 19 may determine that the wear part 11 or probe 5 is worn, if the power of the received optical signal is zero, or, below a predetermined threshold.

[0102] Additionally or alternatively, whilst figures 8 and 9 only illustrate the wear sensor 1 having an optical element / optical fibre 3 and an optical deflector 4, it will be appreciated that a plurality of optical fibres 3 and optical deflectors 4 may be used, such as that shown in figure 6, with each optical element / fibre (3a, 3b, 3c, 3d, 3e) and optical deflector (4a, 4b, 4c, 4d, 4e) pair operating similarly to that shown in figures 8 and 9. Alternatively, it will be appreciated that each optical element / fibre (3a, 3b, 3c, 3d, 3e) and optical deflector (4a, 4b, 4c, 4d, 4e) pair may operate with the use of one or more continuous signals. 2025232127  24 Apr 2026

[0103] Figure 10 shows an example embodiment of an optical wear sensor 1 wherein the probe 5 of the optical wear sensor 1 is provided with a plurality of optical pathways 10, each of which is formed using an optical element 2 with a loop configuration. As each loop 2e, 2d, 2c, 2b and 2a are progressively worn away, the optical pathway 10e, 10d, 10c, 10b, 10b and 10a are progressively worn away resulting in the absence of an optical signal, or a zero magnitude optical signal, being received at the output end of the respective optical pathway, indicative of the worn condition of the wear part to the length / depth to which the loop extends from the base 13.

[0104] In Figure 11 is shown a schematic diagram of an example passively powered non conductive wear sensor 1 which includes a plurality of optical fibres 3a, 3b, 3c, 3d and 3e, each of which extends from a base 6. Each of the optical fibres 3a, 3b, 3c, 3d and 3e provides an optical signal transmission path.

[0105] Each optical deflector 4a, 4b, 4c, 4d and 4e may be substantially equidistantly spaced from each adjacent deflector, or, may be provided at any other desired variable spacing, as will be explained hereinafter. Additionally or alternatively, each optical deflector 4a, 4b, 4c, 4d and 4e may include a base or an optical coating, similar to that shown in figures 7 to 9.

[0106] As shown in figure 11, the base portion of the wear sensor 1 may include a passively powered transponder arrangement, including one or multiple RFID devices, the or each transponder incorporating an antenna 20, to send and / or receive data information between the sensor 1 and the other componentry 21. An electrical capacitor 22 may be used to store the energy from the radio frequency signal, and to discharge power to supply current to a low power micro controller unit (MCU) 24. The MCU 24 examines each optical element 3a, 3b, 3c, 3d and 3e via an electrical-optical converter 23.

[0107] The antenna 20 may be embodied in a variety of configurations and shapes, such as shown in figure 12. For example, in figure 12a, the base portion 6a may be of overall circular shape, divided into a predefined number of segments. Each segment may be embodied as a single RFID transponder, or may include multiple RFID transponders, each of which incorporates a send-receive antenna 20, low power MCU 24, and a capacitor 22.

[0108] Some example alternative configurations and shapes of the base portion and / or antennas 20 are illustrated in figures 12b, 12c, and 12d, showing overall rectangular 6b, square 6c, and semicircular 6d configurations, each of which may be segmented in a variety of ways, as illustrated. It will be apparent to a person skilled in the art that many other alternative configurations and shapes could be implemented.

[0109] In a first exemplary form, each of the antennas 20 of the segments of the base portion 6 may be associated respectively with each of the optical elements / fibres 3 and optical deflectors 4. 2025232127  24 Apr 2026 Thus, in some forms, the data may be transmitted by each of the antennas 20 to the optical wear sensor reader / other componentry 21 to respectively indicate the presence and / or absence of each of the optical deflectors 4, which thereby is indicative of the extent / depth of the wear of the wear part.

[0110] Alternatively, in other forms, the data may be transmitted by the antenna 20 to the optical wear sensor reader / other componentry 21 to indicate the presence of the respective optical deflector 4, and the absence of data from the antenna 20 to the optical wear sensor reader / other componentry 21 would be indicative of the absence of the respective optical deflector 4. The optical wear sensor reader / other componentry 21 may then determine the presence and / or absence of each of the optical deflectors 4 from the received one or more data, and indicate the extent / depth of the wear of the wear part.

[0111] As an example, the antennas 20 of the eight segments of the base portion 6b of the wear sensor 1, shown in figure 12b, may, in some cases, be respectively associated with eight optical elements / fibres 3 and optical deflectors 4. When the wear sensor 1 is in use, the antennas 20 may send data signals to the optical wear sensor reader / other componentry 21 to indicate the presence and / or absence of their respective optical deflectors 4, which thereby indicates the extent / depth of the wear of the wear part.

[0112] In a second exemplary form, each of the antennas 20 of the segments of the base portion 6 may be associated with one or more of the optical elements 3 and optical deflectors 4. Thus, the data transmitted by each of the antennas 20 to the optical wear sensor reader / other componentry 21 would indicate the presence and / or absence of the associated optical deflectors 4, which thereby indicates the extent / depth of the wear of the wear part.

[0113] As an example, the antennas 20 of the four segments of the base portion 6c of the wear sensor 1, shown in figure 12c, may, in some cases, each be respectively associated with four optical elements / fibres 3 and optical deflectors 4, with the wear sensor 1 having a total of sixteen optical elements / fibres 3 and optical deflectors 4. When the wear sensor 1 is in use, the antennas 20 may send data signals to the optical wear sensor reader / other componentry 21 to indicate the presence and / or absence of their associated one or more optical deflectors 4, which thereby indicates the extent / depth of the wear of the wear part.

[0114] Additionally or alternatively, in a third exemplary form, each of the antennas 20 of the segments of the base portion 6 may be associated with one or more of the same optical elements 3 and optical deflectors 4, and the antennas 20 are configured and / or arranged to cooperatively provide an increased transmission / receiving range and / or angle for the optical wear sensor reader / other componentry 21. Thus, the data transmitted by any one of the antennas 20 to the optical 2025232127  24 Apr 2026 wear sensor reader / other componentry 21 would indicate the presence and / or absence of all the optical deflectors 4, which thereby indicates the extent / depth of the wear of the wear part.

[0115] As an example, each of the antennas 20 of the eight segments of the base portion 6a of the wear sensor 1, shown in figure 12a, may, in some cases, be respectively associated with the optical elements / fibres 3 and optical deflectors 4. When the wear sensor 1 is in use, any one or more of the antennas 20 may send data signals to the optical wear sensor reader / other componentry 21 to indicate the presence and / or absence of all the optical deflectors 4, which thereby indicates the extent / depth of the wear of the wear part.

[0116] Additionally, due to each of the antennas 20 sending data to indicate the presence and / or absence of all the optical deflectors 4, the third exemplary form can also allow for the optical wear sensor reader / other componentry 21 to correct the received data if it becomes corrupted, and / or, to determine whether the wear sensor 1 is faulty or functioning correctly.

[0117] It can be appreciated that the antennas 20 shown in figures 12a to 12d can implement any one of the first to third exemplary forms described above.

[0118] The antenna 20 and its associated electronics may be housed in a casing such as shown in figure 13, and extends from the base 6 of the wear sensor 1 at the end of the probe 5.

[0119] The optical wear sensor 1 preferably further operates in conjunction with a wear sensor writer, which may be complimentary or otherwise compatible in shape to the antenna 20 configuration.

[0120] It can be appreciated that the first to third exemplary forms, as described above, may also be implemented into an actively powered wear sensor or semi-actively powered wear sensor, in which the antenna 20 is included in a wireless signal transmitter and transmits data to a wireless signal receiver.

[0121] In Figure 14 is shown a schematic diagram of an optical wear sensor 1 being actively powered. In the embodiment illustrated, each optical element 3 is shown to extend from a base circuitry, and an optical deflector 4 is fitted at the end of each optical element 3. Each optical element 3 may be embodied as an optical fibre signal transmission path. An MCU 31, to control the operation of an optical-electrical converter unit 34 may be fitted at the base at the end of the probe 5 of the wear sensor 1.

[0122] The MCU 31 is configured to connect with a battery unit 30 via a power and data cable 32. The battery unit 30 supplies current to the low power micro controller unit (MCU) 31. The MCU 31 examines each optical fibre / optical element 3 via an electrical-optical converter 34. The wireless transmitter 33 sends the response signal via Wi-Fi / Cellular network or other 2025232127  24 Apr 2026 communications channel.

[0123] In some forms, the response signal or absence thereof (which may be understood to be a zero response signal) may include the presence and / or absence of the optical deflectors 4, which is later processed to indicate the extent / depth of the wear of the wear part. Alternatively, in some forms, the response signal may include the extent / depth of the wear of the wear part.

[0124] Figure 15 shows a diagram of a pair of actively powered optical wear sensors 1 being actively powered with a battery unit 30 via a cable 32. It should be noted that in this example embodiment, the deflectors 4 in one of the sensors are equidistantly spaced, whilst the other has variable spacing. The use of variable spacing in some applications ensures that only relevant and targeted data is captured, enhancing its usefulness. For example, as the wear part nears the end of its life, deflectors can be placed closer together to provide a more precise indication of wear extent and depth. It will be appreciated that multiple wear sensors 1 may be connected to a central unit 30.

[0125] The wear sensors 1 may be used in a variety of applications to indicate the extent of wear of a wear part. Some example applications will be described, noting that numerous other applications will be possible, as will be understood by persons skilled in the art.

[0126] Figure 16 shows an example embodiment of multiple passively powered wear sensors 1 installed into a dump truck tray lining body 40. Wear sensors 1 may be inserted into the truck tray lining body from the back face via drill holes, noting that installation locations may be selected to avoid structural beams of the lining body. As will be appreciated by persons skilled in the art, the wear sensors 1 may be located at different positions in the truck, depending on the specific truck and the particular application in which the truck is being used for, etc.

[0127] Figure 16 also shows an example optical wear sensor reader 21 positioned near the dump truck tray lining body 40. In use, the sensor reader 21 sends out an electromagnetic signal to the wear sensors 1, so that a capacitor embedded within the RFID chip may be charged, then reflected back a reply electromagnetic signal, using electromagnetic wave reflective coupling. The RFID chip may be directly connected to the microelectronic circuitry. During the electromagnetic wave replying stage, the current signal transmission status from the optical pathways of the wear sensor 1 may also be sent back to the sensor reader 21. Consequently, the wear condition of the truck tray lining body can thereby be monitored.

[0128] In Figure 17 is shown an example embodiment of multiple actively powered wear sensors 1 incorporated into a gyratory crusher 41, which typically includes concave lining bodies 42. Optical wear sensors 1 are inserted into concave lining bodies 42 from the backing plate via drill holes, positioned to avoid structural beams of the lining body. 2025232127  24 Apr 2026

[0129] In Figure 18 is shown an example embodiment of multiple actively powered non conductive optical wear sensors 1 incorporated into a grinding mill liner body both at lifter section 51 and the mill shell 52. Multiple power and data cables for each actively powered non conductive wear sensor 1 are fused into one power and data connector 53, which is configured to be connected to a battery unit 30 and a wireless transmitter 33 installed on the exterior of the mill shell. Figure 18 also shows a planar washer plate 54, which is secured in place by two bolts 55 and nuts 56 from the grinding mill lining body. The battery unit 30 and the wireless transmitter 33 may be fastened to the planar washer plate 54 via magnets, via thread locking mechanism, via epoxy, or via another fastening technique.

[0130] Figure 18 also shows an example embodiment of actively powered non conductive optical wear sensors 1 within a tapered orifice 57 for easy incorporation of the wear sensor 1. Tapered holes may be specially designed in the shell lining body during the manufacturing process. The tapered orifice 57 is secured within the grinding mill lining body by an O-ring seal.

[0131] Figure 18 also shows an example of multiple power and data cables for each actively powered non conductive optical wear sensor are fused into one power and data connector 53. The fused power and data connector is configured to connect to a battery unit 30 and a wireless transmitter 33 on the exterior of the mill shell via a specially designed rubber plug 58 installed in a bolt hole. The rubber plug 58 has a middle drill hole for routing the power and data cable 32, and two side bolts for the rubber plug, and the rubber plug will expand in lateral direction once two side bolts are tightened, after which the rubber plug is fastened in the bolt hole.

[0132] In Figure 18 is also shown an example of an actively powered optical wear sensor battery unit 30 and wireless transmitter 33 connected to wear sensors 1 via a power and data cable 32. The low power MCU may be powered by the battery unit 30 and sends out the current signal transmission status of the optical pathways from the wear sensor 1 via the wireless transmitter 33. Consequently, the wear of the lifter 48 and the plate 49 on the wear liner can then be measured. The wear of the lifter 48 is critical to determine the charge trajectory under current operating conditions, thereby impacting on the grinding performance of the mill. The wear of the plate 49 or lifter 48 will trigger the replacement of the respective lining bodies when excessive wear occurs.

[0133] In Figure 19 is shown an example embodiment of multiple actively powered optical wear sensors 1 incorporated into a slurry pump 60 wear lining body 61. Optical wear sensors 1 may be inserted into the slurry pump wear lining body 61 from the backing plate via drill holes, that is, from the outside in, rather than the inside out, the installation locations being selected to avoid structural beams of the lining body.

[0134] In Figure 20 is shown an example embodiment of multiple actively powered wear sensors 2025232127  24 Apr 2026 1 incorporated into a slurry pipeline 70 and its wear lining body 71. Wear sensors 1 are inserted into the slurry pipeline lining body 71 via exterior via drill holes, the installation locations being selected to cover all four orientations of the slurry pipeline due to manual rotation of the pipeline orientation may be applied during operation.

[0135] Figure 20 also shows an example of an actively powered optical wear sensor battery unit 30 and wireless transmitter 33 connected to non conductive optical wear sensors 1 via a power and data cable 32. The low power MCU is powered by the battery unit 30 to send out the current signal transmission status of the optical fibres 3 from the wear sensor 1 via the wireless transmitter 33. Consequently, the wear of the slurry pipeline lining body 71 at selected locations can then be measured.

[0136] The present invention additionally provides an overall system for measuring and / or modelling the global wear condition of the body, such as shown in figure 21. The system preferably incorporates at least one passively powered non conductive wear sensor 1, configured to provide sensed data indicative of the wear condition on selected locations of a wear lining body, passively powered by a RFID reader 21. The response signal of the non conductive optical wear sensor 1 may be transmitted to a cloud platform 80 via a wired or wireless network. A processor 81 is configured to provide output data representative of the global wear condition of the body based upon original wear lining body geometry and sensed data, and to display results to a user output device 82.

[0137] This output data may be displayed or provided to a user, in a variety of formats. The output data may, in a simplistic version, simply provide feedback to a user to indicate that the wear material has worn to a sufficient degree for replacement. Additionally, or alternatively, the output data may provide a quantitative indication as to the extent of wear based upon information provided from the plurality of optical pathways provided within a particular wear sensor, and / or, a combination of a plurality of wear sensors distributed throughout the wear lining body of wear material.

[0138] In an alternative example embodiment, the system may incorporate a processor configured to reconstruct a topological model of the wear lining body, which for example may incorporate data representative of the original geometry of the body, and, data indicative of the current state of the wear lining body. Such a model may be visually displayed to a user.

[0139] In a preferred but nonlimiting example embodiment, it will be appreciated that the present invention may be implemented as a composite passive (no-battery required) wear material tracking and wear monitoring sensor and system. In this example embodiment, the sensor / system is able to track and measure the live length / thickness of wear lining materials without the need of active 2025232127  24 Apr 2026 supply of power. It is able to predict and reconstruct the global wear in an asset with a large quantity of wear liner materials. As such, the invention provides an intelligent, yet reliable solution for wear monitoring solutions.

[0140] In this example but nonlimiting embodiment of a composite wear monitoring system, the system may typically incorporate the following components: - at least one UH-RFID non conductive passive wear sensor 1 - the UH-RFID non conductive passive wear sensor integrates multiple radio frequency identification modules with wear detection microelectronics, including: antenna 20, low power MCU, on-board capacitor 22, and optical pathways 10. When the UH-RFID based passive wear sensor 1 receives a communication signal, suitable levels of excitation current may be generated, powering the low power MCU. The low power MCU examines the status of wear sensors 1, from which a wear condition signal is generated. Subsequently, the low power MCU combines the sensor identifier from the on-board memory with the wear status, and sends a reply signal; - at least one UH-RFID based passive wear sensor writer 21 - using the UH-RFID based non conductive passive wear sensor writer 21 and its software. The system is able to customise the identifier data and write into the UH-RFID based non conductive passive wear sensor 1. It may also be used to initialise the wear length and resolution for the wear sensor 1; - at least one long range reader 21 - after the UH-RFID based non conductive passive wear sensor 1 receives a communication signal from the long-range reader 21, excitation current is generated, and the wear sensor 1 is powered. Sensor identifier and current status of the optical pathways 10 are sent back to the long-range reader 21; - at least one wear reconstruction system 81 - the long-range reader 21 sends the sensor identifier and the wear status to the wear reconstruction system 81 for wear interpretation. The sensor identifier may also contain data for tracking and cross-referencing the wear sensor installation locations on the wear material. The wear reconstruction system further integrates the wear interpretation results, installation locations, installation geometries, a numerical modelling suite of code which may include discrete element modelling, smoothed particle hydrodynamics and computational fluid dynamics optionally with a machine learning algorithm to predict and reconstruct the global wear distribution on a selected wear lining body.

[0141] The present invention additionally provides an overall system for measuring and / or modelling the global wear condition of the body as shown in figure 22. The system preferably incorporates at least one actively powered wear sensor 1, configured to provide sensed data 2025232127  24 Apr 2026 indicative of the wear condition on selected locations of a wear lining body, actively powered by a battery unit 30. The response signal of each wear sensor 1 may be transmitted to the cloud platform 80 via a power and data cable 32 and a wireless transmitter 33. A processor 81 is configured to provide output data representative of the global wear condition of the body based upon original wear lining body geometry and sensed data, and display results to a user via an output device 82.

[0142] This output data may be displayed or provided to a user, in a variety of formats. The output data may, in a simplistic version, simply provide feedback to a user to indicate that the wear material has worn to a sufficient degree for replacement. Additionally, or alternatively, the output data may provide a quantitative indication as to the extent of wear based upon information provided from the plurality of optical pathways 10 provided within a particular wear sensor 1, and / or, a combination of a plurality of wear sensors 1 distributed throughout the wear lining body 11 of wear material.

[0143] In an alternative example embodiment, the system may incorporate a processor configured to reconstruct a topological model of the wear lining body, which for example may incorporate data representative of the original geometry of the body, and, data indicative of the current state of the wear lining body. Such a model may be visually displayed to a user.

[0144] In a preferred but nonlimiting example embodiment, it will be appreciated that the present invention may be implemented as an active wear material tracking and wear monitoring sensor and system. In this example embodiment, the sensor / system is able to track and measure the live length / thickness of wear lining materials. It is able to predict and reconstruct the global wear in an asset with a large quantity of wear liner materials. As such, the invention provides an intelligent, yet reliable solution for wear monitoring solutions.

[0145] In this example but nonlimiting embodiment of a composite wear monitoring system, the system may typically incorporate the following components: - at least one wear sensor 1 - the wear sensor integrates wear detection microelectronics, including: power and data cable 32, battery unit 30, wireless transmitter 33, low power MCU 31, and the wear sensors 1. When the wear sensor 1 receives current supplied to the low power MCU 31, it examines the status of the optical pathway 10, from which a wear condition signal is generated. Subsequently, the low power MCU 31 combines the sensor identifier from the on-board memory with the wear condition status, and sends a response signal via a wireless transmitter 33; - at least one wear reconstruction system - the gateway sends the sensor identifier and the wear status to the wear reconstruction system for wear interpretation. The sensor identifier 2025232127  24 Apr 2026 may also contain data for tracking and cross-referencing the wear sensor installation locations on the wear material. The wear reconstruction system further integrates the wear interpretation results, installation locations, installation geometries, a numerical modelling suite of code which may include discrete element modelling, smoothed particle hydrodynamics and computational fluid dynamics optionally with a machine learning algorithm to predict and reconstruct the global wear distribution on a selected wear lining body.

[0146] The numerical modelling suite of programs may compute the shear and impact force induced from the bulk materials / slurry onto the wear lining body and convert the force results into a non-dimensional wear intensity value. A qualitative wear intensity based overall / global distribution result on the wear material may therefore be obtained.

[0147] A machine learning algorithm may be used to couple the wear sensor installation location, wear length / thickness, and overall / global wear intensity distribution data to thereby predict the actual wear on areas where sensors are not installed.

[0148] The invention therefore provides, in one example embodiment, a passive ultra-high radio frequency identification (UH-RFID) based passive wear sensor and / or an actively powered optical wear sensor, and, a wear reconstruction system. The system includes at least one UH-RFID based passive wear sensor, which may also work as a product identifier as well as wear monitoring device, at least one wear sensor writer which is designed to write sensor identifier and initialise wear sensor metrics, and at least one long range sensor reader, sending communication signals to an area with wear sensors. After the wear sensors receive the communication signals, excitation current is generated and the logic control module within the sensor sends the current wear sensor status back to the long-range sensor reader. The long-range sensor reader then sends wear sensor status to a wear reconstruction system via, for example, an Ethernet connection or wireless communication method. The wear reconstruction system integrates the wear materials’ mechanical design, sensor wear results, a numerical modelling and a machine learning algorithm to predict the wear distribution on the wear material. Visualisation of the reconstructed wear results may also be achieved with the wear reconstruction system.

[0149] Numerical modelling programme such as the discrete element modelling method, may be employed to produce non-dimensional wear intensity results. This also takes in account for the wear material's mechanical geometry, operating conditions and wear medium (ore) properties. Plant operating conditions includes the throughput, mass loading, and mechanical motions detail (if any). Wear medium (ore) properties includes the particles density, size distribution and moisture content of the processed bulk materials. 2025232127  24 Apr 2026

[0150] The non-dimensional wear intensity, wear material geometry, sensor location identifier and wear results may also input into machine learning algorithm, such as a LightGBM algorithm, in which the algorithm establishes a data-based correlation between the wear intensity results obtained from numerical modelling and wear measurements, for the locations where sensors were installed. This data-based correlation is the trained LightGBM predictive model, using which the global wear prediction results are produced by integrating the global non-dimensional wear intensity.

[0151] The invention therefore provides, in the other example embodiment, an actively powered optical wear sensor and a wear reconstruction system. The system includes at least one actively powered optical wear sensor, which works as a product identifier as well as a wear monitoring device, at least one battery unit which is designed to supply power requirement for the sensor, and at least one wireless transmitter, sending response signals from the wear sensors. The wear reconstruction system integrates the wear materials’ mechanical design, sensor wear results, a numerical modelling and a machine learning algorithm to predict the wear distribution on the wear material. Visualisation of the reconstructed wear results may also be achieved with the wear reconstruction system.

[0152] The present invention can track the wear material during manufacturing and transport, as well as track the live wear status of the material, with and / or without actively supplying power. Additionally, coupling of the localised, point based wear data, numerical modelling results, and a machine learning algorithm enables reconstruction of a wear condition distribution within the wear material. Such a solution offers a wear monitoring system without the need to cover the entire wear lining body with wear sensors. It is more affordable as well as more reliable for industrial wear monitoring applications.

[0153] Embodiments of the present disclosure may take on various modifications and alterations without departing from the spirit and scope of the disclosure. Accordingly, it is to be understood that the embodiments of the present disclosure are not to be limited to the following described exemplary embodiments but is to be controlled by the limitations set forth in the claims and any equivalents thereof.

[0154] The term “optical wear sensor” described herein is to be understood to refer to a wear sensor that uses any form of optical communications for its operation, that is, utilising optical telecommunications transmission pathways, such as optical fibres, for the transmission of its signals therethrough. As will be understood by persons skilled in the art, such signals may include electromagnetic signals of any wavelength, whether visible or not.

[0155] Throughout this specification, unless the context requires otherwise, the word 2025232127  24 Apr 2026 “comprise”, and any variations thereof such as “comprises” or “comprising”, are to be interpreted in a non-exhaustive sense.

Claims

1. An optical wear sensor, including:an optical fibre, adapted to be provided within a body of a wear part, the optical fibre having a first end and a second end, defining a bi-directional optical signal transmission pathway therebetween;an optical reflector, formed of reflective material that is substantially metallic, adapted to be positioned at the second end of the optical fibre within the body of the wear part proximal to a wear surface of said wear part, and configured to be worn away as the body of the wear part is worn away;an optical transmitter and detector, configured to transmit said optical signal from the first end of an optical fibre, and, detect whether or not said optical signal is returned via said optical pathway to said first end of said optical fibre;a processor, configured to convert any optical signal received by said optical detector to an electrical response signal; and,a wireless signal transmitter, configured to transmit said electrical response signal indicative of the wear condition of said body to an output device, wherein, in use:when the optical reflector is connected to the second end of the optical fibre, the optical reflector is configured to reflect said optical signal, and prevent said optical signal from exiting the second end of the optical fibre, and,when the optical reflector is worn away as the body of the wear part is worn away, the optical signal exits from the second end of the optical fibre.

2. The optical wear sensor as claimed in claim 1, wherein the optical reflector includes acoating of the reflective material, wherein the coating is optionally applied to a base.

3. The optical wear sensor as claimed in claim 2, wherein the base of the optical reflector isformed of a rigid material, such as polymers, glass or silicon.

4. The optical wear sensor as claimed in any one of claims 1 to 3, wherein the reflectivematerial provides a reflectivity of about 50% to 90%, and more preferably 70% to 90%, in relation to wavelength of the optical signal.

5. The optical wear sensor as claimed in any one of claims 1 to 4, wherein the reflectivematerial includes any one or combination of gold, silver, copper, aluminium and / or other suitable metals.

6. The optical wear sensor as claimed in any one of claims 1 to 5, wherein the optical signal2025232127  24 Apr 2026has a wavelength in the range of 1260 nm to 1625 nm.

7. The optical wear sensor as claimed in any one of claims 1 to 6, wherein the optical signalis a non-continuous, pulsatile signal.

8. The optical wear sensor as claimed in any one of claims 1 to 6, wherein the optical signalis a continuous signal.

9. The optical wear sensor as claimed in any one of claims 1 to 8, wherein said optical fibreis at least partially formed of polymer or glass material.

10. The optical wear sensor as claimed in any one of claims 1 to 9, wherein said optical fibre is formed of a material which is substantially non-conductive.

11. The optical wear sensor as claimed in any one of claims 1 to 10, wherein said optical fibre is embedded within said body.

12. The optical wear sensor as claimed in any one of claims 1 to 10, wherein said optical fibre is installed within said body.

13. The optical wear sensor as claimed in any one of claims 1 to 12, wherein said sensor is passively powered by a transponder device including the wireless signal transmitter, and, wherein said passively powered transponder device is optionally configured as an RFID transponder.

14. The optical wear sensor as claimed in claim 13, wherein said transponder device is configured to:receive an input signal to power said sensor; and,transmit the electrical response signal indicative of the wear condition of said wear part.

15. The optical wear sensor as claimed in claim 13 or 14, wherein said transponder operates in a UHF range.

16. The optical wear sensor as claimed in any one of claims 1 to 12, wherein said sensor is actively powered by a battery or other power source.

17. An optical wear sensor device, adapted to be provided within a body of a wear part, configured to indicate a depth or extent of wear of the wear part, said device including:a plurality of optical fibres, each optical fibre having a first end and a second end, defining a respective bi-directional optical signal transmission pathway of a different respective length therebetween;a plurality of optical reflectors, each formed of reflective material that is2025232127  24 Apr 2026substantially metallic, each optical reflector adapted to be positioned at the second end of a respective optical fibre within the body of the wear part proximal to a wear surface of said wear part, each optical reflector configured to be worn away as the body of the wear part is worn away;a plurality of optical transmission and detection devices, configured to transmit an optical signal from the first end of each respective optical fibre, and, detect whether or not said optical signal is returned via each optical pathway to said first end of the optical fibre;at least one processor and wireless signal transmitter, configured to:convert any optical signal(s) received by at least one of said plurality of optical reflectors; and,transmit the optical signal(s) received by said optical reflectors to an electrical response signal,wherein, in use:when the respective optical reflector is connected to the second end of the respective optical fibre, the respective optical reflector is configured to reflect said respective optical signal, and prevent said respective optical signal from exiting the second end of the respective optical fibre, and,when the respective optical reflector is worn away as the body of the wear part is worn away, the respective optical signal exits from the second end of the respective optical fibre,wherein, in use, the electrical response signal is thereby indicative of the worn condition of the respective optical reflector and thereby indicative of the depth or extent of wear of the wear part.

18. The optical wear sensor device as claimed in claim 17, wherein a processor and wireless signal transmitter is provided for each optical fibre.

19. The optical wear sensor device as claimed in claim 17, wherein a processor and wireless signal transmitter is provided for one or more of said plurality of optical fibres.

20. A system for modelling a wear condition of a body including:at least one optical wear sensor, each optical wear sensor is as claimed in any one of claims 1 to 16, and adapted to be provided within a body of a wear part, and configured to provide sensor data indicative of a wear condition of the wear part; and,a modelling processor, configured to construct a model of the wear condition of the body based on said sensed data.

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