Shaft guide measuring system, apparatus and method

Abstract

A shaft guide measuring system, apparatus, and method are provided. The shaft guide measuring system includes at least a first sensor array unit configured to measure distances with respect to a first shaft guide, a second sensor array unit configured to measure distances with respect to a second shaft guide, and a data logging unit in electronic communication with the first sensor array unit and the second sensor array unit. Each of the first sensor array unit and the second sensor array unit include a housing and a set of sensors affixed to the housing and configured to detect a set of distances between the respective set of sensors and the corresponding shaft guide. The data logging unit includes a processor configured to receive the sets of distances from the first sensor array unit and the second sensor array unit.

Description

SHAFT GUIDE MEASURING SYSTEM, APPARATUS AND METHODFIELD OF THE INVENTION

[0001] The present embodiments described in this specification relate generally to a system, apparatus, and method for measuring the alignment of a shaft guide, and specifically to measuring the alignment of a shaft guide with a single pass of a shaft conveyance and with minimal shaft downtime.BACKGROUND OF THE INVENTION

[0002] In the numerous activities involved in mining operations, mine shaft maintenance is one of the more crucial procedures to ensure the safety, efficiency, and longevity of mining infrastructure. Among the many components that demand meticulous attention, the maintenance of shaft guides in a mine shaft is a key focus area.

[0003] Mine shafts are the main arteries for underground mining operations, providing the conduit for transporting personnel, equipment, and extracted materials. Regular and proactive maintenance of these shafts is important for several reasons. For one, it ensures the safety of miners and equipment by preventing potential accidents and structural failures. In addition, well-maintained shafts contribute to operational efficiency, minimizing downtime and optimizing the flow of resources in and out of the mine. Moreover, preventive maintenance helps extend the lifespan of the shafts, reducing the need for costly repairs or replacements.

[0004] Shaft guides play a pivotal role in facilitating the smooth descent and ascent of cages, skips, and other shaft conveyances, making their structural integrity and alignment paramount. The alignment of these guides is very important as misalignment or deviations from the intended path can lead to friction, increased wear, and, in extreme cases, catastrophic failure. Straight shaft guides ensure a smooth and controlled movement of the shaft conveyance systems, preventing unnecessary strain on the equipment and enhancing the overall safety of the ascending or descending operation. Moreover, straight guides contribute to the efficient and timely transportation of materials, fostering a productive mining environment.

[0005] Maintaining the alignment of shaft guides comes with its own set of challenges. The harsh underground environment, characterized by dust, humidity, and varying temperatures,poses a constant threat to the structural integrity of the guides. Corrosion and material fatigue are common issues that can compromise the alignment of the guides over time. In addition, the sheer depth and complexity of mine shafts make routine inspections and maintenance a logistical challenge. Accessing remote or deep sections of the shafts requires specialized equipment and skilled personnel, adding to the overall complexity of the maintenance process. Furthermore, the dynamic nature of mining operations, with fluctuating loads and changing extraction patterns, puts additional stress on the shaft guides. Regular inspections, use of advanced monitoring technologies, and a proactive approach to addressing emerging issues are essential to overcome these challenges.

[0006] Notably, mining regulations require that shaft guides be measured annually to ensure the face-to-face and width dimensions are within specifications. Current practice is to have personnel ride the top of a conveyance, such as an elevator, and manually measure the face-to- face and width dimensions at 100-foot intervals with a measuring tape or handheld laser. This practice varies from site to site and company to company as the methodology to satisfy these mining regulations is not defined. However, this practice leaves significant sections of the shaft guides unmeasured between the measured points, thereby exposing mine shaft operations to risk of being outside specifications. This risk can cause, and has caused, the shaft conveyance to jam between the shaft guides or jump off the shaft guides. Accordingly, there is a need for a system able to collect accurate guide measurements along entire length of mineshaft without occupying the compartments for significant amounts of time.SUMMARY OF THE INVENTION

[0007] In broad form, the object of the present invention is a shaft guide measuring system and apparatus configured to be used in conjunction with a shaft conveyance and configured to improve the practice of measuring shaft guides for alignment in both speed and reliability. The system uses arrays of distance sensors able to be installed on a shaft conveyance to simultaneously measure various dimensions of a shaft guide as the shaft conveyance ascends or descends a mine shaft. The measured dimensions are collected and logged by a data logging unit to obtain the necessary measurements for satisfying regulations with respect to face-to-face and width dimensions of the shaft guides in the mine shaft.

[0008] In one embodiment, a shaft guide measuring apparatus is provided including a first sensor array unit configured to measure distances with respect to a first shaft guide. The first sensor array unit includes a housing, a first sensor positioned in a first end of the housing and configured to detect a distance between a first face of the first shaft guide and the first sensor, a second sensor positioned in a second end of the housing and configured to detect a second distance between a second face of the first shaft guide and the second sensor, and a third sensor positioned in a middle part of the housing and configured to detect a third distance between a front face of the first shaft guide and the third sensor.

[0009] An embodiment may further include a data logging unit in communication with the first, second and third sensors of the first sensor array unit. The data logging unit may have a processor configured to receive distance data from the first sensor array unit. Another embodiment may include a mounting assembly configured to affix the first sensor array unit to a shaft conveyance. The mounting assembly may have a first clamping means configured to clamp the mounting assembly to the shaft conveyance and a second clamping means configured to clamp the mounting assembly to the first sensor array unit. Where the first sensor array unit includes a first ball connector affixed to the first housing and the mounting assembly includes a support body, the first clamping means may be a clamp affixed to the support body, and the second clamping means may be a second ball connector affixed to the support body and a socket clamp configured to attach to the first ball connector and the second ball connector.

[0010] In a further embodiment, the shaft guide measuring apparatus further includes a Z-offset sensor array unit configured to measure distances with respect to the first shaft guide at a different height than the first sensor array unit. The Z-offset sensor array unit may include a similar array of sensors as the first sensor array unit configured to detect distances from the same faces of the shaft guide but at a different height of the shaft guide. A support arm maintains a fixed distance between the first sensor array unit and the Z-offset sensor array unit and the data logging unit has a processor configured to receive distance data from the first sensor array unit and the Z-offset sensor array unit.

[0011] In yet a further embodiment, the shaft guide measuring apparatus further includes a second sensor array unit including a similar array of sensors as the first sensor array unit butconfigured to detect distances from the faces of another shaft guide. The second sensor array unit is also in communication with the data logging unit.

[0012] In yet a further embodiment, a shaft guide measuring system is provided including a first sensor array unit configured to measure distances with respect to a first shaft guide, a second sensor array unit configured to measure distances with respect to a second shaft guide, and a data logging unit in electronic communication with the first sensor array unit and the second sensor array unit. Each of the first sensor array unit and the second sensor array unit include a housing and a set of sensors affixed to the housing and configured to detect a set of distances between the respective set of sensors and the corresponding shaft guide. The data logging unit includes a processor configured to receive the sets of distances from the first sensor array unit and the second sensor array unit.

[0013] The shaft guide measuring system may further include a third sensor array unit configured to measure distances with respect to a third shaft guide and a fourth sensor array unit configured to measure distances with respect to a fourth shaft guide. In this embodiment, the third sensor array unit and the fourth sensor array unit are in electronic communication with the data logging unit and the processor is further configured to receive the sets of distances from the third sensor array unit and the fourth sensor array unit.

[0014] In a further embodiment, the first sensor array unit, the second sensor array unit, the third sensor array unit, and the fourth sensor array unit are configured to be attached to a shaft conveyance via a first mounting assembly, a second mounting assembly, a third mounting assembly, and a fourth mounting assembly, respectively. The first mounting assembly, the second mounting assembly, the third mounting assembly, and the fourth mounting assembly may each include a first clamping means configured to clamp the respective mounting assembly to the shaft conveyance and a second clamping means configured to clamp the respective mounting assembly to the respective sensor array unit.

[0015] In yet a further embodiment, the shaft guide measuring system includes a Z-offset sensor array unit configured to measure distances with respect to the first shaft guide at a different height than the first sensor array unit. The Z-offset sensor array unit includes a housing and a set of sensors affixed to the housing and configured to detect a set of distances from the faces of the first shaft guide at a height offset from the first sensor array unit. The Z-offset sensor array unit is also in electronic communication with the data logging unit and the processor isfurther configured to receive the set of distances from the Z-offset sensor array unit. The Z- offset sensor array unit may be attached to the first sensor array unit via a support arm.BRIEF DESCRIPTION OF THE DRAWINGS

[0016] For a complete understanding of the nature and objects of the invention, reference should be made to the following detailed description taken in conjunction with the accompanying drawings in which:

[0017] FIG. 1 is an exploded view of a sensor array unit and a mounting assembly in accordance with an embodiment of the present invention;

[0018] FIG. 2 is a top view of a first sensor array unit, a second sensor array unit, and a data logging unit in accordance with an embodiment of the present invention;

[0019] FIG. 3 is a side view of a first sensor array unit, a second sensor array unit, and a data logging unit, in accordance with an embodiment of the present invention, installed on the top of a shaft conveyance;

[0020] FIG. 4 is a top view of a shaft guide measuring system in accordance with an embodiment of the present invention;

[0021] FIG. 5 is an elevated side view of a shaft guide measuring system in accordance with an embodiment of the present invention, installed on the top of a shaft conveyance;

[0022] FIG. 6 is perspective view of a shaft guide measuring system including a Z-offset sensor array in accordance with an embodiment of the present invention, installed on the top of a shaft conveyance; and

[0023] FIG. 7 is a flowchart of a method for shaft guide measuring suing the shaft guide measuring system, in accordance with an embodiment of the present invention.DETAILED DESCRIPTION OF EMBODIMENTS

[0024] Preferred embodiments of the present invention will be described with reference to the accompanying drawings. It will be readily understood that the components of the present embodiments, as generally described and illustrated in the Figures herein, may be arranged and designed in a wide variety of different configurations. Thus, the following detailed description of the embodiments of the brassiere of the present embodiments, as presented inthe Figures, is not intended to limit the scope of the embodiments, as claimed, but is merely representative of selected embodiments.

[0025] Reference throughout this specification to “a select embodiment,” “one embodiment,” or “an embodiment” means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment described herein. Thus, appearances of the phrases “a select embodiment,” “in one embodiment,” or “in an embodiment” in various places throughout this specification are not necessarily referring to the same embodiment.

[0026] As depicted in FIG. 1, a shaft guide measuring apparatus is depicted including a sensor array unit 100 with a housing 120. Three sensors are embedded within the housing 120 and configured to detect distances from a face of a shaft guide to be positioned between the three sensors when the shaft guide measuring apparatus is installed for measuring shaft guide alignment. A first sensor 131 is positioned within a first end 122 of the housing 120 and oriented to emit a distance-measuring laser 132 towards a shaft guide to be positioned at the center of the housing 120. The distance-measuring laser 132 is configured to measure a first distance between the first sensor 131 and a first face of the shaft guide. A second sensor 133 is positioned within a second end 124 of the housing 120 and oriented to emit a distancemeasuring laser 134 towards the shaft guide to be positioned at the center of the housing 120. The distance-measuring laser 134 is configured to measure a second distance between the second sensor 133 and a second face of the shaft guide. A third sensor 135 is positioned in a middle part 126 of the housing 120 and oriented to emit a distance-measuring laser 136 towards the shaft guide to be positioned at the center of the housing 120. The distancemeasuring laser 132 is configured to measure a third distance between the third sensor 135 and a front face of the shaft guide.

[0027] The housing 120 may include internal spacing to accommodate electronic wiring from sensors 131, 133, and 135. In addition, the housing 120 may include a top cover 120a fastened or otherwise affixed to a top side of the housing 120 and a bottom cover 120b fastened or otherwise affixed to a bottom side of the housing 120. A power and signal connector 127 may be included in the housing 120. The power and signal connector 127 is electrically connected to the sensors 131, 133, and 135 and provides a collection point for any power and communication wiring to and from the sensors 131, 133, and 135 of the sensor array unit 100.

[0028] A mounting assembly 150 is configured to affix the sensor array unit 100 to a shaft conveyance. The mounting assembly 150 includes a support body 140, a first clamping means 170 configured to clamp the mounting assembly 150 to the shaft conveyance, and a second clamping means configured to clamp the mounting assembly 150 to the sensor array unit 100. The first clamping means may be in the form of any variety of clamp, fastener, magnet, or adhesive which allows for the affixing of the sensor array unit 100 to a surface of a shaft conveyance. However, the first clamping means 170 must be able to be affixed to the support body 140 of the mounting assembly 150. As shown in FIG. 1, the second clamping means may be in the form of a first ball connector 162 affixed to the housing 120 of the sensor array unit 100, a second ball connector 164 affixed to the support body 140, and a socket clamp 160 configured to clamp onto the first ball connector 162 and second ball connector 164 to join the sensor array unit 100 to the mounting assembly 150. The second clamping means may also be in other forms that allow for attaching the sensor array unit 100 to the mounting assembly 150, such as by the use of fasteners, clamps, adhesives, magnets, etc.

[0029] One or more sensor array units may be in electronic communication with a data logging unit 10. As shown in FIG. 2, a data logging unit 10 is in electronic communication with a first sensor array unit 100 and a second sensor array unit 200. The data logging unit 10 may include a variety of inputs and outputs, such as inputs to collect data from sensor array units and outputs to upload compiled data onto a connected computer or electronic memory device. In the embodiment shown in FIG. 2, the data logging unit 10 includes a power input port 20, a back / left guide port 30, a front / left guide port 40, a back / right guide port 50, and a front / right guide port 60. The power input port 20 receives power to run the data logging unit 10 and may also provide power to the sensor array units 100, 200. The communication between the data logging unit 10 and the sensors of the sensor array units may be via a physical cable, such as the use of a 4-20 mA signal via an electronic cable and using an A / D converter or serial communication. However, in an alternative embodiment, the communication between the data logging unit 10 and the sensors of the sensor array units 100, 200 may be wireless, such as via Bluetooth ® or similar wireless signal.

[0030] The data logging unit 10 includes a processor configured to receive distance data from the sensors of the first sensor array unit. Specifically, when the first sensor array unit 100 is positioned to measure distances with respect to shaft guide 110, the sensors 131, 133, and 135of the first sensor array unit 100 are oriented around the shaft guide 110 and are configured to emit distance-measuring lasers 132, 134, and 136, respectively, onto faces of the shaft guide 110. Preferably, when the first sensor array unit 100 is correctly positioned, the distancemeasuring lasers 132, 134, and 136 are normal to the faces of the shaft guide 110.Accordingly, distance-measuring laser 132 measures the distance between the first face 111 of the shaft guide 110 and the sensor 131 (not shown), distance-measuring laser 134 measures the distance between the second face 112 of the shaft guide 110 and the sensor 133 (not shown), and distance-measuring laser 136 measures the distance between the front face 113 of the shaft guide 110 and the sensor 135 (not shown). The sensors 131 and 133 of the first sensor array unit 100 are fixed in the housing 120 and point towards each other. These two sensors are positioned on opposite sides of shaft guide 110 and at a span that will allow for the placement of the shaft guide 110 at the midspan of the sensing range of lasers emitted from the sensors 131 and 133. Because shaft guide widths in the mining industry vary, the spacing between the sensors 131 and 133 is such that the median shaft guide width across the industry is midspan to the sensing range of the sensors 131 and 133 when the shaft guide 110 is placed in center between the sensors 131 and 133.

[0031] Like the first sensor array unit 100, the second sensor array unit 200 also sends distance data to the processor of the data logging unit 10. When the second sensor array unit 200 is positioned to measure distances with respect to shaft guide 210, the sensors of the second sensor array unit 200 are oriented around the shaft guide 210 and are configured to emit distance-measuring lasers 232, 234, and 236, respectively, onto faces of the shaft guide 210. Similar arrangements of the distance-measuring lasers 232, 234, and 236 with respect to the faces of the shaft guide 210 apply to the second sensor array 200 as in the first sensor array 100. Accordingly, distance-measuring laser 232 measures the distance between the first face 211 of the shaft guide 210 and the first sensor (not shown) positioned in a first end 222 of the second sensor array unit 200, distance-measuring laser 234 measures the distance between the second face 212 of the shaft guide 210 and the second sensor (not shown) positioned in a second end 224 of the second sensor array unit 200, and distance-measuring laser 236 measures the distance between the front face 213 of the shaft guide 210 and the third sensor (not shown) positioned in a middle part 226 of the second sensor array unit 200.

[0032] Underneath sensor array units 100, 200, the respective mounting assemblies 150, 250 are depicted, which are configured to attach the sensor array units 100, 200 to a shaft conveyance. As mentioned above, the mounting assembly 150 for sensor array unit 100 includes a clamp means 170 attached to a support body 140. Equally, the mounting assembly 250 for sensor array unit 200 includes a clamp means 270 attached to a support body 240, as depicted in FIG. 2.

[0033] As depicted in the side view of FIG. 3, the sensor array units 100, 200 are connected to a shaft conveyance 180 via the mounting assemblies 150, 250 respectively. Mounting assembly 150 includes the first clamp means 170 attached to the shaft conveyance 180 on one end and attached to the support body 140 on the other end. The second clamp means 160 is attached to the first sensor array unit 100 on one end and attached to the support body 140 on the other end. Similarly, mounting assembly 250 includes the first clamp means 270 attached to the shaft conveyance 180 on one end and attached to the support body 240 on the other end. The second clamp means 260 is attached to the second sensor array unit 200 on one end and attached to the support body 240 on the other end.

[0034] As depicted in FIG. 4, a shaft guide measuring system may include four sensor array units 100, 200, 300, and 400 to measure distances with respect to the four shaft guides, 110, 210, 310, and 410, respectively. Each of the four sensor array units 100, 200, 300, and 400 are in electronic communication with the data logging unit 10. In this configuration, the shaft guide measuring system is able to calculate variances in key measurements that pertain to the alignment of the shaft guides 110, 210, 310, and 410. For example, by positioning the first sensor array unit 100 around shaft guide 110 and at a fixed position on the shaft conveyance and positioning the second sensor array unit 200 around shaft guide 210 and at a fixed position on the shaft conveyance, a fixed dimension is achieved between the first sensor array unit 100 and the second sensor array unit 200. Adding this fixed dimension to the distances measured by lasers 136 and 236 yields the rear face-to-face distance, which is the distance between the front face of shaft guide 110 and the front face of shaft guide 210. As the shaft conveyance ascends or descends, variances in the measured rear face-to-face distance between shaft guide 110 and shaft guide 210 may be calculated with detection of those variances by the lasers 136 and 236.

[0035] A similar calculation of the front face-to-face distance between shaft guides 310 and 410 may be achieved using the third sensor array unit 300 and fourth sensor array unit 400. Specifically, by positioning the third sensor array unit 300 around shaft guide 310 and at a fixed position on the shaft conveyance and positioning the fourth sensor array unit 400 around shaft guide 410 and at a fixed position on the shaft conveyance, a fixed dimension is achieved between the third sensor array unit 300 and the fourth sensor array unit 400. Adding this fixed dimension to the distances measured by lasers 336 and 436 yields the front face-to-face distance, which is the distance between the front face of shaft guide 310 and the front face of shaft guide 310. As the shaft conveyance ascends or descends, variances in the measured rear face-to-face distance between shaft guide 310 and shaft guide 410 may be calculated with detection of those variances by the lasers 336 and 436.

[0036] Variances in the width of each shaft guide may be detected by comparing the distances detected by the first and second sensors of each sensor array unit. For example, comparing the detected distance from lasers 132 and 134 will yield a detection of a variance in the width measurement of shaft guide 110 as the shaft conveyance ascends or descends.

[0037] Moreover, with the first sensor array unit 100 positioned around shaft guide 110 and at a fixed position on the shaft conveyance and the third sensor array unit 300 positioned around shaft guide 310 and at a fixed position on the shaft conveyance, a fixed dimension is achieved between the first sensor array unit 100 and the third sensor array unit 300. Adding this fixed dimension to the distances measured by lasers 132 and 334 yields the left front-to-back distance, which is the distance between the inner side face of shaft guide 110 and the inner side face of shaft guide 310. As the shaft conveyance ascends or descends, variances in the measured left front-to-back distance between shaft guide 110 and shaft guide 310 may be calculated with detection of those variances by the lasers 132 and 334.

[0038] A similar calculation of the right front-to-back distance between shaft guides 210 and 410 may be achieved using the second sensor array unit 200 and fourth sensor array unit 400. Specifically, with the sensor array unit 200 positioned around shaft guide 210 and at a fixed position on the shaft conveyance and with the fourth sensor array unit 400 positioned around shaft guide 410 and at a fixed position on the shaft conveyance, a fixed dimension is achieved between the second sensor array unit 200 and the fourth sensor array unit 400. Adding this fixed dimension to the distances measured by lasers 232 and 434 yields the right front-to-backdistance, which is the distance between the inner side face of shaft guide 210 and the inner side face of shaft guide 410. As the shaft conveyance ascends or descends, variances in the measured right front-to-back distance between shaft guide 210 and shaft guide 410 may be calculated with detection of those variances by the lasers 232 and 434.

[0039] As depicted in FIG. 5, the shaft guide measuring system may be affixed to the shaft conveyance 180 in such a manner as to position the sensor array units 100, 200, 300, and 400 on the same plane or approximately on the same plane. The first sensor array unit 100, which is positioned around shaft guide 110, is attached to the shaft conveyance 180 via the mounting assembly 150. Similarly, the second sensor array unit 200, the third sensor array unit 300, and the fourth sensor array unit 400 are attached to the shaft conveyance 180 via mounting assemblies 250, 350, and 450, respectively. In the embodiment depicted in FIG. 5, the data logging unit 10 rests on or is affixed to the top of the shaft conveyance 180. In one embodiment, a camera may be installed onto the shaft conveyance to record the shaft guide measurement system as it is used. Video feed obtained from the camera may be used to show footage of the shaft guides at the points where significant data points have been collected. The footage may also be used to overlay telemetry from collected data points onto mine shaft footage for viewing. Such video footage may be used to index the shaft guide measurements along the depth of the mine shaft by marking key points such as ‘sets’ ( / .< ., the spacing of concrete liners along the depth of the mine shaft). An additional camera may be mounted to a hoist operators console to record the depth values of the shaft conveyance. This video may then be fed through an Optical Character Recognition program (OCR) on each frame to convert the video of the depth values to text. The start points of the shaft conveyance are marked in the datasets and the software run by a user’s computer may merge the depth values obtained from the camera aimed at the hoist console with the measured values from the shaft conveyance. This data can then be graphed and overlaid on the shaft conveyance video footage.

[0040] The shaft guide measuring system may further include a Z-offset sensor array unit 500. The Z-offset sensor array unit 500 is a sensor array unit that is positioned above an existing sensor array unit to provide data regarding shaft guide variances at an offset height from the plane in which the other sensor arrays are positioned. For example, as shown in FIG. 6, the Z- offset sensor array unit 500 is attached to the first sensor array unit 100 via a support arm 505.The support arm 505 maintains a fixed height ( / .< ., in the z-axis) between the first sensor array unit 100 and the Z-offset sensor array unit 500. Because the Z-offset sensor array unit 500 detects variances along the same shaft guide 110 as the first sensor array unit 100 but simultaneously measures at an offset height from the first sensor array unit 100, anomalies in the shaft guide 110 may be detected which cannot be detected by measuring only distances along a single plane.

[0041] Note that although elements of the shaft guide measuring system such as the sensor array units 100, 200, 300, and 400 may be attached to the shaft conveyance 180 via mounting assemblies 150, 250, 350, and 450, respectively, the sensor array units 100, 200, 300, and 400 may be attached to the shaft conveyance 180 via alternative means. For example, the sensor array units 100, 200, 300, and 400 may be attached to the shaft conveyance 180 by a quick detach connection or similar means that facilitates the installation and uninstallation of the shaft guide measuring system to a shaft conveyance 180. Such quick detach connection or similar means may also be in the form of a permanent fixture affixed to the shaft conveyance 180.

[0042] A shaft guide measurement method 600 utilizes an embodiment of the shaft guide measurement system to perform alignment measurements of shaft guides. As shown in FIG. 7, the shaft guide measurement method 600 begins with attaching a set of sensor array units to a shaft conveyance installed within a shaft (605). Each sensor array unit may include three distance measurement sensors configured to detect distances from three faces of a shaft guide of the shaft. Each sensor array unit must be leveled to ensure the lasers are normal to the face of the guide and may be positioned such that the sensor at the middle part of each sensor array unit is aligned with the center of an idler wheel on the shaft conveyance. If the shaft guide measurement system includes a Z-offset sensor array unit, the Z-offset sensor array unit should then be attached to one of the sensor array units such that the Z-offset sensor array unit is fixed at an offset height relative to the sensor array unit to which the Z-offset sensor array unit is attached (610). In the next step (615), each sensor array unit of the set of sensor array units is connected to a data logging unit. If the shaft guide measurement system includes a Z- offset sensor array unit, the Z-offset sensor array unit is also connected to the data logging unit (620). A user must then measure the distance between the two front faces of opposing shaft guides at the starting point and input this initial value into the data logging unit or acomputer. A user may also measure the front-to-back spacing between shaft guide sets and input this into the computer as an initial value. Optionally, a camera may be installed onto the shaft conveyance to record the shaft guide measurement system as it is used.

[0043] Once the set of sensor array units are connected, the data logging program may be initiated (625) whereby the data logging unit begins logging data points related to the distances detected from the distance measurement sensors on the set of sensor array units. The shaft conveyance is then operated to either ascend or descend from a start point as the data logging program runs (630). As such, data points are collected by the data logging unit along the height of the shaft guides. These data points are collected as the shaft conveyance moves and are saved to memory in the data logging unit (635). These logged values will likely fluctuate from the initial value measured at the starting point. In addition, if a camera was installed on the shaft conveyance, video feed of the shaft guide measurement system may be obtained as data points are being logged by the data logging unit. The collected data can then be used to calculate dimensions such as face-to-face dimensions along height of shaft guide (640), front-to-back dimensions along height of shaft guide (645), and (if a Z-offset sensor array unit has been used) offset variances along height of shaft guide (650).

[0044] While embodiments disclosed herein include four sensor array units, any number of sensor array units may be used to form a complete shaft guide measuring system. For example, in mine shafts with more than four shaft guides, more than four sensor array units may be used at a time to measure distances related to each of the multiple shaft guides. In addition, while embodiments disclosed herein include at least one Z-offset sensor array unit, embodiments of the shaft guide measuring system, apparatus, and method may include multiple Z-offset sensor array units. Specifically, each sensor array unit may have a corresponding Z-offset sensor array unit attached to it and configured to measure distances with respect to the corresponding shaft guide at a different height. For example, in an embodiment of the shaft guide measuring system with four sensor array units configured to measure distances related to four shaft guides, one, two, three or four Z-offset sensor array units may be added to the shaft guide measuring system at a different height of the four sensor array units. It follows that in a mine shaft having six shaft guides, six sensor array units may be used with six Z-offset sensor array units.

[0045] The disclosed shaft guide measuring system, apparatus, and method provide for a faster and higher accuracy process of sampling the alignment of shaft guides of a mine shaft. In addition, because personnel are not needed on the shaft conveyance as measurements are taken, the process is also safer for users. The higher rate of sampling of the shaft guides along their height allows for higher accuracy in detecting abnormalities in the alignment of the shaft guides. Moreover, the ability to quickly perform measurements regarding shaft guide alignment as a shaft conveyance ascends or descends a mine shaft results in lower downtime of a mine shaft for regular maintenance checks, thereby maximizing mine shaft availability for other mining operations.

Claims

What I claim is:

1. A shaft guide measuring apparatus comprising: a first sensor array unit configured to measure distances with respect to a first shaft guide, the first sensor array unit including: a first housing, a first sensor positioned in a first end of the first housing and configured to detect a first distance between a first face of the first shaft guide and the first sensor, a second sensor positioned in a second end of the first housing and configured to detect a second distance between a second face of the first shaft guide and the second sensor, and a third sensor positioned in a middle part of the first housing and configured to detect a third distance between a front face of the first shaft guide and the third sensor.

2. The shaft guide measuring apparatus of claim 1, further comprising a data logging unit in electronic communication with the first, second and third sensors of the first sensor array unit, the data logging unit including a processor configured to receive distance data from the first sensor array unit.

3. The shaft guide measuring apparatus of claim 1, further comprising a mounting assembly configured to affix the first sensor array unit to a shaft conveyance.

4. The shaft guide measuring apparatus of claim 3, wherein the mounting assembly includes a first clamping means configured to clamp the mounting assembly to the shaft conveyance and a second clamping means configured to clamp the mounting assembly to the first sensor array unit.

5. The shaft guide measuring apparatus of claim 4, wherein: the first sensor array unit includes a first ball connector affixed to the first housing,the mounting assembly includes a support body, the first clamping means includes a clamp affixed to the support body, and the second clamping means includes a second ball connector affixed to the support body and a socket clamp configured to attach to the first ball connector and the second ball connector.

6. The shaft guide measuring apparatus of claim 3, further comprising: a Z-offset sensor array unit configured to measure distances with respect to the first shaft guide at a different height than the first sensor array unit, the Z-offset sensor array unit including: a housing, a first offset sensor positioned in a first end of the housing and configured to detect a first offset distance between the first face of the first shaft guide and the first offset sensor, a second offset sensor positioned in a second end of the housing and configured to detect a second offset distance between the second face of the first shaft guide and the second offset sensor, and a third offset sensor positioned in a middle part of the housing and configured to detect a third offset distance between the front face of the first shaft guide and the third offset sensor; and a support arm configured to maintain a fixed distance between the first sensor array unit and the Z-offset sensor array unit, wherein the first sensor array unit and the Z-offset sensor array unit are connected to a data logging unit, the data logging unit including a processor configured to receive distance data from the first sensor array unit and the Z-offset sensor array unit.

7. The shaft guide measuring apparatus of claim 1, further comprising: a second sensor array unit configured to measure the alignment of a second shaft guide, the second sensor array unit including: a second housing,a fourth sensor positioned in a first end of the second housing and configured to detect a fourth distance between a first face of the second shaft guide and the fourth sensor, a fifth sensor positioned in a second end of the second housing and configured to detect a fifth distance between a second face of the second shaft guide and the fifth sensor, and a sixth sensor positioned in a middle part of the second housing and configured to detect a sixth distance between a front face of the second shaft guide and the sixth sensor; and a data logging unit in electronic communication with the sensors of the first sensor array unit and the second sensor array unit, the data logging unit including a processor configured to receive distance data from the first sensor array unit and the second sensor array unit.

8. A shaft guide measuring system comprising: a first sensor array unit configured to measure distances with respect to a first shaft guide, the first sensor array unit including: a first housing, and a first set of sensors affixed to the first housing and configured to detect a first set of distances between the respective first set of sensors and the first shaft guide; a second sensor array unit configured to measure distances with respect to a second shaft guide, the second sensor array unit including: a second housing, and a second set of sensors affixed to the second housing and configured to detect a second set of distances between the respective second set of sensors and the second shaft guide; and a data logging unit in electronic communication with the first sensor array unit and the second sensor array unit, the data logging unit including a processor configured to receive the first set of distances and the second set of distances.

9. The shaft guide measuring system of claim 8, further comprising: a third sensor array unit configured to measure distances with respect to a third shaft guide, the third sensor array unit including: a third housing, and a third set of sensors affixed to the third housing and configured to detect a third set of distances between the respective third set of sensors and the third shaft guide; and a fourth sensor array unit configured to measure distances with respect to a fourth shaft guide, the fourth sensor array unit including: a fourth housing, and a fourth set of sensors affixed to the fourth housing and configured to detect a fourth set of distances between the respective fourth set of sensors and the fourth shaft guide, wherein the third sensor array unit and the fourth sensor array unit are in electronic communication with the data logging unit and the processor is further configured to receive the third set of distances and the fourth set of distances.

10. The shaft guide measuring system of claim 9, wherein: the first sensor array unit, the second sensor array unit, the third sensor array unit, and the fourth sensor array unit are configured to be attached to a shaft conveyance via a first mounting assembly, a second mounting assembly, a third mounting assembly, and a fourth mounting assembly, respectively.

11. The shaft guide measuring system of claim 10, wherein: the first mounting assembly, the second mounting assembly, the third mounting assembly, and the fourth mounting assembly each include a first clamping means configured to clamp the respective mounting assembly to the shaft conveyance and a second clamping means configured to clamp the respective mounting assembly to the respective sensor array unit.

12. The shaft guide measuring system of claim 9, further comprising:a Z-offset sensor array unit configured to measure distances with respect to the first shaft guide at a different height than the first sensor array unit, the Z-offset sensor array unit including: a fifth housing, and a fifth set of sensors affixed to the fifth housing and configured to detect a fifth set of distances between the respective fifth set of sensors and the first shaft guide, wherein the Z-offset sensor array unit is in electronic communication with the data logging unit and the processor is further configured to receive the fifth set of distances.

13. The shaft guide measuring system of claim 12, wherein: the first sensor array unit, the second sensor array unit, the third sensor array unit, and the fourth sensor array unit are configured to be attached to a shaft conveyance via a first mounting assembly, a second mounting assembly, a third mounting assembly, and a fourth mounting assembly, respectively, and the Z-offset sensor array unit is attached to the first sensor array unit via a support arm.

14. A shaft guide alignment measuring method comprising: attaching a set of sensor array units to a shaft conveyance installed within a shaft, each sensor array unit including three distance measurement sensors configured to detect distances from three faces of a shaft guide of the shaft; connecting each sensor array unit of the set of sensor array units to a data logging unit; starting a data logging program; operating the shaft conveyance to ascend or descend from a start point as the data logging program runs; and having the data logging unit collect a series of data points from the set of sensor array units.

15. The shaft guide measuring method of claim 14, further comprising: calculating a face-to-face dimension of the shaft guides based on the collected series of data points from the set of sensor array units; calculating a front-to-back dimension of the shaft guides based on the collected series of data points from the set of sensor array units.

16. The shaft guide measuring method of claim 14, wherein the collected series of data points corresponds to distances detected from the distance measurement sensors of each sensor array unit along a height of the corresponding shaft guide as the data logging program runs during the operation of the shaft conveyance.

17. The shaft guide measuring method of claim 14, further comprising, before starting the data logging program: attaching a Z-offset sensor array unit to one sensor array unit of the set of sensor array units such that the Z-offset sensor array unit is fixed at an offset height relative to the sensor array unit to which the Z-offset sensor array unit is attached; and connecting the Z-offset sensor array unit to the data logging unit, wherein the Z-offset sensor array unit includes three distance measurement sensors configured to detect distances from three faces of the shaft guide at the offset height.

18. The shaft guide measuring method of claim 17, further comprising: calculating a face-to-face dimension of the shaft guides based on the collected series of data points from the set of sensor array units; calculating a front-to-back dimension of the shaft guides based on the collected series of data points from the set of sensor array units; and calculating offset variances between the Z-offset sensor array unit and the sensor array unit to which the Z-offset sensor array unit is attached.

19. The shaft guide measuring method of claim 14, further comprising, after attaching a set of sensor array units to a shaft conveyance installed within a shaft: measuring an initial face-to-face value for opposing shaft guides; measuring an initial front-to-back value for adjacent shaft guides; and recording the initial face-to-face value and initial front-to-back value in the data logging program.