Sensing apparatus for a crusher and methods thereof

Abstract

A sensing apparatus configured for detecting, measuring, or monitoring operational or physical changes within a crusher The sensing apparatus being attachable to a first portion of a fastening mechanism of a crusher. The sensing apparatus comprising a second portion of a fastening mechanism. The sensing apparatus further comprising a sensor unit configured to detecting, measuring, or monitoring operational or physical changes occurring within the crusher in a field of view. The sensing apparatus is configured to substantially occlude an inspection port of the crusher. The sensing apparatus has at least two configurations including a deployed and retracted position.

Description

SENSING APPARATUS FOR A CRUSHER AND METHODS THEREOFTECHNICAL FIELD

[0001] The present invention relates to a sensing apparatus and a system comprising a sensing apparatus and a crusher. The invention further relates to a method of fitting the sensing apparatus to a crusher. Additionally, the invention relates to use of the sensing apparatus, in particular a method of detecting a physical change in a crusher, for example, a gyratory crusher.BACKGROUND

[0002] Crushers are commonly utilized in the mining and minerals industry to downsize solid materials for further processing or transportation. The material added to a crusher is typically downsized by providing the material in between two parallel or tangent solid surfaces. Sufficient force is applied to bring the surfaces together such that enough energy is generated within the material. The material fractures and is thereby crushed into smaller size. Examples of crushers include jaw crushers, cone crushers, cylindrical roll crushers, and gyratory crushers.

[0003] Gyratory crushers comprise a moving mantle and a stationary concave both covered with liners. The mantle moves in an eccentric circular orbit within the concave, causing an annular gap at each radial location inside the crusher to narrow and widen as the mantle moves around its orbit. The narrowest gap between the mantle liner and the concave liner is known as the closed-side seting (CSS). The widest gap between the mantle liner and the concave liner is known as the openside seting (OSS).

[0004] It is desirable to maintain the CSS of a gyratory crusher at a constant value to ensure efficient and predictable operation. The concave liner and mantle liner experience frictional wear and tear during crushing operation which causes the CSS to get larger over time. Periodically adjustments are typically made to ensure that the CSS is maintained at a constant width. It is critical to know the crusher gap width as it relates to the CSS to ensure the crushed product size is optimum.

[0005] The mantle in a gyratory crusher typically has a conical shape. The conical shape helps to adjust the crusher gap width, by adjusting the height of the mantle relative to the concave.

[0006] As the liners gets worn, it is desirable monitor a variety of parameters besides the crusher gap width. As an example, the actual height of the mantle may differ from the height seting system. To predict life span of the liners and to ensure proper crusher gap width adjustments it is desirable to know the actual height of the mantle. Sometimes the liner may be worn unevenly, providing a different and uneven material flow and downsizing through different crusher section. The internal parts of the mantle may also be worn causing a difference in mantle and axle rational speeds.

[0007] An example of a prior art solution may be found in DE 19853900 Al

[0008] It is an object of the present invention to provide a sensing apparatus allowing for inspection of a crusher and the parameters of interest, such as the crusher gap width, sectional wear, mantle height, material flow and / or rotational speed of the mantle.SUMMARY

[0009] In a first aspect of the invention these and further objects are obtained by a sensing apparatus configured for detecting, measuring, or monitoring operational or physical changes occurring within a crusher. The sensing apparatus being atachable to a first portion of a fastening mechanism provided adjacent to, extending from, extending into, and / or forming a portion of an inspection port of the crusher. The sensing apparatus comprising:

[0010] - a second portion of said fastening mechanism engageable with, alignable with, and / or configured to co-operate with the first portion of the fastening mechanism;

[0011] - a sensor unit having a field of view, the sensor unit configured to detecting, measuring, or monitoring operational or physical changes occurring within the crusher in the field of view;

[0012] wherein the sensing apparatus is configured to substantially occlude the inspection port;

[0013] wherein the sensing apparatus has at least two configurations including a deployed and retracted position.

[0014] The fastening mechanism may be, but is not limited to, clamping fasteners and toggle fasteners, threaded fasteners, locking pins, bolts and welding.

[0015] In one or more embodiments the sensor unit it a camera, radar, stereoscopic camera, sound based-system or a range sensor which may utilize optical means. In particular, the sensor unit may be a laser scanner or a lidar sensor. The image-based data can be still images or a plurality of images, such as video.

[0016] In one or more embodiments, when the sensing apparatus is configured in the retracted position, less of a sensing region of the crusher is in the field of view of the sensor unit compared to the in the deployed position.

[0017] The sensing region of the crusher may as an example be a portion of the concave liner, a portion of the mantle liner, and / or a portion of the gap between the mantle liner and the concave liner.

[0018] One particular advantage of sensing the sensing region in an upwards direction from a position below the mantle is that the sensing apparatus can sense the outer surface of the mantle and liner which are not viewable from the top of the crusher. In particular surfaces which are facing a horizontal direction or even slightly downwards direction which typically is the case for the lower portion of the mantle and liner which determines the CCS.

[0019] The field of view may be adjusted / changed in several different ways.

[0020] In one or more embodiments the sensor unit is located in a position more proximate to a sensing region within the crusher in the deployed position compared to in the retracted position. The sensor unit is thus moveable between the deployed position and the retracted position.

[0021] In one or more embodiments the sensor unit remains proximate to a sensing region within the crusher in the deployed and retracted positions. A sensor unit cover shrouds the sensing unit in the retracted position. In the deployed position the sensor unit cover exposes the sensor unit.

[0022] In one or more embodiments the sensing apparatus further comprising an actuated member moveable between at least the deployed position and the retracted position. The sensor unit may be attached to a portion of the actuated member, or the actuated member is moveable in relation to the sensor unit.

[0023] In one or more embodiments the sensing apparatus further comprising a protective housing for accommodating the sensor unit when the sensing apparatus is configured in the retracted position.

[0024] In one or more embodiments the sensor unit is configured to index between at least two spatial orientations in relation to one or more other components of the sensing apparatus.

[0025] In one or more embodiments the sensing apparatus further comprising a moving system which is configured for either:

[0026] i) moving or articulating an actuated member for positioning the sensor unit more proximate to the sensing region in the deployed position or away from the sensing region in the retracted position, or for providing a better field of view to the sensor unit; or,

[0027] ii) moving or articulating a sensor unit cover.

[0028] The moving system comprises a component selected from the group consisting of: a pneumatic cylinder, a hydraulic cylinder, an electric solenoid, a linear drive, a motor, a rotational drive, an actuated linkage, a robotic or actuated arm, a telescopic actuator, and an electric linear actuator.

[0029] In one or more embodiments the sensing apparatus is configured such that the sensor unit may be cleaned. In some embodiments the sensing apparatus may comprise a cleaning device for cleaning the sensor unit. Preferably the cleaning device is configured to clean the sensing unit when it is in or near the retracted position. The cleaning device may be selected from the group consisting of: an air blade nozzle, a brush, a stationary or actuated wiper blade, and a fluid dispensing nozzle configured to emit a gas, liquid, or combination thereof.

[0030] The term "in or near the retracted position" should be understood to mean that the sensing unit is located in the retracted position or at a position towards the retracted position when moved from the deployed position towards the retracted position. The cleaning system may be moveable with respect to the sensing unit. For instance, the cleaning system may be configured to clean the sensing unit as it is positioned adjacent to the cleaning system. Alternatively, the cleaning system may be attached to the sensing apparatus such that it is in proximity to the sensing unit and at a fixed distance from the sensing unit. In this configuration the cleaning system may be clean at time intervals or for instance when the sensor unit cover is positioned to shroud over the sensor. In some embodiments the sensing apparatus may comprise a cleaning port which may be opened and allow for manual cleaning of the sensing unit.

[0031] In one or more embodiments the sensing apparatus further comprising a gasketing structure configured to communicate with two surface portions of the sensing apparatus in or nearthe retracted position. The gasketing structure may be configured to protect the sensor unit when the sensing apparatus is in or near the retracted position.

[0032] In one or more embodiments the sensor unit is configured to receive and transmit optical (image-based), acoustic (vibrational or sound-based), and / or thermal (temperature or heat-based) information.

[0033] In another aspect the invention relates to the use of the sensing apparatus for detecting a physical change in a crusher.

[0034] In another aspect the invention relates to a method of fiting a crusher with a sensing apparatus. The sensing apparatus may be built into to a crusher during manufacturing or assembling, i.e. before commissioning. The sensing apparatus may alternatively be retrofited into an existing crusher, i.e. after commissioning. The term "fiting" is used to accommodate both options, i.e. a method of fiting a sensing apparatus into a crusher either before or after commissioning. The sensing apparatus having at least two configurations including a deployed and retracted position. The crusher comprising an inspection port and having a first portion of a fastening mechanism provided adjacent to, extending from, extending into, and / or forming a portion of the inspection port. The method comprising the steps of:

[0035] providing a sensing apparatus comprising a third fastening mechanism engageable with, alignable with, and / or configured to co-operate with the first portion of said fastening mechanism,

[0036] at least partially occluding the inspection port with the sensing apparatus;

[0037] mounting and / or securing the sensing apparatus to the crusher by at least partially engaging, aligning, and / or co-operating the first portion of the fastening mechanism and the third portion of the fastening mechanism.

[0038] In one or more embodiments of the method, the crusherfurther comprising a removable safety cover. The removable safety cover having a second portion of said fastening mechanism engageable with, alignable with, and / or configured to co-operate with said first portion of said fastening mechanism. The method further comprising the step of:

[0039] - removing the safety cover from the crusher by disengaging the first portion of the fastening mechanism from the second portion of the fastening mechanism.

[0040] In some embodiments the removable safety cover is externally removable, i.e. it can be removed from the outside of the crusher.

[0041] In one or more embodiments the crusher is fitted with a sensing apparatus according to a first aspect of the invention.

[0042] In one or more embodiments the step of removing the safety cover from the crusher is achieved by disengaging the first portion of the fastening mechanism from the second portion of the fastening mechanism and further comprises at least one of the following steps:

[0043] - actuating a clamp or toggle member on the first and / or second portion;

[0044] - unthreading one or more threaded fasteners from the first and / or second portions;

[0045] - removing a locking pin;

[0046] - unthreading the safety cover from the crusher.

[0047] The method of fiting a crusher with a sensing apparatus, said crusher having an inspection port and having a first portion of a fastening mechanism for securing a safety cover to the crusher, may in some aspect comprise the steps of:

[0048] at least partially disengaging, un-aligning, or un-cooperating a portion of the first portion of a fastening mechanism;

[0049] exposing the inspection port by moving and / or removing the safety cover in relation to the crusher;

[0050] providing a sensing apparatus comprising a third fastening mechanism engageable with, alignable with, and / or configured to co-operate with one or more portions of the inspection port and / or one or more portions of the first portion of said fastening mechanism,

[0051] introducing a portion of the sensing apparatus into or at least partially through the inspection port;

[0052] substantially occluding the inspection port with the sensing apparatus; and

[0053] mounting and / or securing the sensing apparatus to the crusher by at least partially engaging, aligning, and / or co-operating the third portion of the fastening mechanism with one or more portions of the inspection port and / or and one or more portions of the first portion of the fastening mechanism.

[0054] It is preferred that mounting and / or securing the sensing apparatus is such that at least a portion of the sensing apparatus remains immovable with respect to the crusher.

[0055] It is preferred that the mounting and / or securing of the third portion of the fastening mechanism with one or more portions of the inspection port and / or and one or more portions of the first portion of the fastening mechanism is detachably mounted. Alternatively the sensing apparatus may in some embodiments be fixedly mounted to the crusher by securing the third portion of the fastening mechanism to by first portion of the fastening mechanism using a weld, deformed bolts, cotter pinned fasteners, hot rivet, adhesive or other more permanent fixation means.

[0056] In another aspect the invention relates to a system comprising a crushing apparatus, a safety cover, and a sensing apparatus according to a first aspect of the invention.

[0057] The crushing apparatus having an inspection port and a first portion of a fastening mechanism provided adjacent to, extending from, extending into, and / or forming a portion of the inspection port. The safety cover is suitable for covering at least a portion of the inspection port, the safety cover having a second portion of said fastening mechanism being engageable with, alignable with, and / or configured to co-operate with the first portion of the fastening mechanism.

[0058] In yet another aspect the invention relates to a method of detecting, measuring, or monitoring operational or physical changes occurring within a crusher with the sensing apparatus according to the first aspect. The method may be carried out with a sensing apparatus manually operated or automated to achieve the measurement.

[0059] In some embodiments where the crusher is already provided with a sensing apparatus according to the first aspect of the invention, the method may comprise the steps of:

[0060] - configuring the sensing apparatus such that it is in the deployed position;

[0061] - with the sensor unit proximate the sensing region within the crusher in the deployed position, sensing an operational or physical change within the crusher using the sensor unit.

[0062] To return the crusher to operating condition the method may additionally comprise the steps of:

[0063] - subsequently configuring the sensing apparatus such that it is in the retracted position;

[0064] - protecting the sensor unit from material processed within the crusher while the sensing apparatus is in the retracted position.

[0065] In particular for crusher not already configured with a sensing apparatus, but having an inspection port having a first portion of a fastening mechanism provided adjacent to, extending from, extending into, and / or forming a portion of the inspection port , the method may additionally comprise the steps of:

[0066] - providing a sensing apparatus comprising a third fastening mechanism engageable with, alignable with, and / or configured to co-operate with the first portion of said fastening mechanism, the sensing apparatus being configured to substantially occlude the inspection port;

[0067] mounting and / or securing the sensing apparatus to the crusher by engaging the first and third fastening mechanisms;

[0068] - wherein the sensing apparatus has at least two configurations including a deployed and retracted position.

[0069] The positioning of the sensor unit proximate to the sensing region may achieved by manually moving a one or more portions of the sensing apparatus. The sensing apparatus may alternatively position itself automatically upon receiving a control input. Such a control input may be activation switch or a command sent digitally to the sensing apparatus.

[0070] In one or more embodiments the method comprising the steps of:

[0071] - with the third portion of the fastening mechanism engaged, aligned, and / or cooperating with the first portion of the fastening mechanism, delivering a control input to the sensing apparatus;

[0072] - upon delivery of the control input configuring the sensing apparatus into the deployed position from the retracted position (e.g., , moving or articulating an actuated member of the sensing apparatus, turning the sensor unit on from an "off" or "standby" status, or improving a field of view of the sensor unit);- detecting, measuring, or monitoring operational or physical changes occurring within the crusher by virtue of receiving input data via the sensor unit, the input data comprising optical (image-based), acoustic (vibrational or sound-based), and / or thermal (temperature or heat-based) information;

[0073] - delivering the input data to a controller unit.

[0074] The controller unit may comprise displaying means to display the detected / measured / monitored data or transmiting means to transmit the data to a receiver.

[0075] In one or more embodiments the controller unit is configured to process the delivered input data. The control input may be either a signal or a manual input.

[0076] In one or more embodiments the sensing apparatus is configured to allowing a period of time (e.g., a predetermined period of time) to lapse with the sensing apparatus in the deployed position and reconfiguring the sensing apparatus into the retracted position from the deployed position.

[0077] In yet another aspect the invention relates to the manufacturing of a sensing apparatus according to the first aspect of the invention. The method comprising modifying a safety cover that is configured for covering an inspection port of a crusher, providing an assembly comprising a sensor unit and an actuated member, and attaching the assembly to the modified safety cover using fastening means. The fastening means preferably comprising a weld, an adhesive, a thread, a hook, a latch connector, and / or one or more fasteners such as screws or bolts.

[0078] Methods according to the invention may comprise removing a safety cover from a crusher, the safety cover having a third portion of the fastening mechanism which is substantially equivalent to a second portion of the fastening mechanism and / or equally engageable with the first portion of the fastening mechanism.

[0079] In one or more embodiments the method of modifying a safety cover is performed while the safety cover is located in one of the following positions:

[0080] - fully-mounted to the crusher;

[0081] - partially-mounted to the crusher;

[0082] - removed from the crusher.BRIEF DESCRIPTION OF DRAWINGS

[0083] The invention will now be described in more details below by means of non-limiting examples of presently preferred embodiments and with reference to the schematic drawings, in which:

[0084] Fig. 1 shows a cross-sectional view of a gyratory crusher comprising an inspection device according to one embodiment of the invention in a retracted position;

[0085] Fig. 2 shows a perspective view of a sensing apparatus according to one embodiment of the invention;

[0086] Fig. 3 shows a perspective view of a sensing apparatus according to one embodiment of the invention;

[0087] Fig. 4 shows a cross-sectional view of a sensing apparatus according to one embodiment of the invention.

[0088] Fig. 5 depicts a system comprising a sensing apparatus according to one embodiment of the invention (shown installed on a crusher), a control unit and a safety cover. Fig. 5 more particularly shows the sensing apparatus installed at an inspection port of a mainframe of the crusher.

[0089] Fig. 6 depicts one non-limiting embodiment of a sensing region of a crusher according to embodiments of the invention.

[0090] Fig. 7 depicts one non-limiting embodiment of a sensing region of a crusher according to embodiments of the invention, as shown on a GUI display of a controller unit or activation means.

[0091] Fig. 8 depicts a side cutaway section of a crusher showing an installed sensing apparatus and one or more sensing regions according to embodiments of the invention.

[0092] Fig. 9 depicts an external isometric view of a crusher showing an installed sensing apparatus on a crusher adjacent an inspection port according to embodiments of the invention.

[0093] Fig. 10 depicts a cutaway section of a crusher showing an installed sensing apparatus according to embodiments of the invention. The sensing apparatus is depicted in a deployed position for receiving information pertaining to operational or physical changes occurring within the crusher.

[0094] Figs, lla-c suggest a non-limiting embodiment of a sensing apparatus showing expandable means (second portion of a fastening mechanism) for securing it to an inner surface (first portion of a fastening mechanism) of an inspection port. Fig. 11a shows an installation phase of a sensing apparatus, Fig. lib shows an installed configuration of the sensing apparatus in its deployed position, and Fig. 11c shows the installed sensing apparatus in its retracted position. The deployed and retracted positions are made possible by provision of a movable sensor unit acting as an actuated member, with the sensor unit position being indexable or changeable in relation to the sensing apparatus. In the particular embodiment depicted, a geared drive is provided to rotate the sensor unit between deployed and retracted positions to protect the sensor unit when not receiving information pertaining to operational or physical changes occurring within the crusher. The sensorunit is more proximate to or within a better field of view of a sensing region in the deployed position for receiving information pertaining to operational or physical changes occurring within the crusher.

[0095] Figs. 12a-b suggests a non-limiting embodiment of a sensing apparatus showing first and second portions of a fastening mechanism (provided as latching means) for securing it to a crusher adjacent to an inspection port. Fig. 12a shows an installation phase of a sensing apparatus in a deployed position, and Fig. 12b shows an installed configuration of the sensing apparatus in its retracted position. The deployed and retracted positions are made possible by provision of a controllable flap or sensor unit cover acting as an actuated member, with the sensor unit position being fixed in relation to the sensing apparatus. The sensor unit is protected in the retracted position when not receiving information pertaining to operational or physical changes occurring within the crusher. The sensor unit is more proximate to or within a better field of view of a sensing region in its deployed position for receiving information pertaining to operational or physical changes occurring within the crusher.

[0096] Figs. 13a-b suggests a non-limiting embodiment of a sensing apparatus showing first (e.g., threaded hole(s)) and second (e.g., threaded fastener) portions of a fastening mechanism for securing it to a crusher adjacent to an inspection port. Fig. 13a shows an installed sensing apparatus in a deployed position, and Fig. 13b shows an installed configuration of the sensing apparatus in its retracted position. The deployed and retracted positions are made possible by provision of a controllable flap or sensor unit cover acting as an actuated member, with the sensor unit being mounted thereto. The sensor unit is protected in the retracted position when not receiving information pertaining to operational or physical changes occurring within the crusher. The sensor unit is more proximate to or within a better field of view of a sensing region in its deployed position for receiving information pertaining to operational or physical changes occurring within the crusher.

[0097] Figs. 14a-b suggests a non-limiting embodiment of a sensing apparatus showing first (e.g., threaded hole(s)) and second (e.g., threaded fastener) portions of a fastening mechanism for securing it to a crusher adjacent to an inspection port. Fig. 14a shows an installed sensing apparatus in a deployed position, and Fig. 14b shows an installed configuration of the sensing apparatus in its retracted position. The deployed and retracted positions are made possible by provision of a controllable (e.g., robotic) linkage or extendable arm acting as an actuated member. The sensor unit is protected in the retracted position when not receiving information pertaining to operationalor physical changes occurring within the crusher. The sensor unit is more proximate to or within a better field of view of a sensing region in its deployed position for receiving information pertaining to operational or physical changes occurring within the crusher.

[0098] Fig. 15a suggests a non-limiting embodiment of a sensing apparatus (top plan view) showing an embodiment of a sensing apparatus in a retracted position, wherein a sensor unit cover protects the sensor unit and restricts its field of view of a sensing region and / or places the sensor unit less proximate to a sensing region. Fig. 15b shows the sensing apparatus of Fig. 15a in its deployed position, wherein the sensor unit cover exposes the sensor unit to a better field of view of a sensing region and / or places the sensor unit in greater proximity to a sensing region, without limitation. The deployed and retracted positions are made possible by provision of a sliding sensor unit cover acting as an actuated member. The sensor unit is protected in the retracted position when not receiving information pertaining to operational or physical changes occurring within the crusher. The sensor unit is more proximate to or within a better field of view of a sensing region in its deployed position for receiving information pertaining to operational or physical changes occurring within the crusher.

[0099] Fig. 16b suggests a non-limiting embodiment of a sensing apparatus (side plan cross- sectional view) showing an embodiment of a sensing apparatus in a retracted position, wherein a sensor unit cover protects the sensor unit and restricts its field of view of a sensing region and / or places the sensor unit less proximate to a sensing region. Fig. 16a shows the sensing apparatus of Fig. 16b in its deployed position, wherein the sensor unit cover exposes the sensor unit to a better field of view of a sensing region and / or places the sensor unit in greater proximity to a sensing region, without limitation. The deployed and retracted positions are made possible by provision of a pivoting sensor unit cover acting as an actuated member, wherein the sensor unit is not mounted to the actuated member. The sensor unit is protected in the retracted position when not receiving information pertaining to operational or physical changes occurring within the crusher. The sensor unit is more proximate to or within a better field of view of a sensing region in its deployed position for receiving information pertaining to operational or physical changes occurring within the crusher.

[0100] Fig. 17a suggests a non-limiting embodiment of a sensing apparatus (side plan view) showing an embodiment of a sensing apparatus in a retracted position, wherein a sensor unit cover protects the sensor unit and restricts its field of view of a sensing region and / or places the sensorunit less proximate to a sensing region. Fig. 17b shows the sensing apparatus of Fig. 17a in its deployed position, wherein the sensor unit cover exposes the sensor unit to a better field of view of a sensing region and / or places the sensor unit in greater proximity to a sensing region, without limitation. The deployed and retracted positions are made possible by provision of a pivoting sensor unit cover acting as an actuated member, wherein the sensor unit is mounted to the actuated member. The sensor unit is protected in the retracted position when not receiving information pertaining to operational or physical changes occurring within the crusher. The sensor unit is more proximate to or within a better field of view of a sensing region in its deployed position for receiving information pertaining to operational or physical changes occurring within the crusher.

[0101] Figs. 18 and 19 are alternative isometric prospective views of a sensing unit according to some embodiments of the invention. Similar to the embodiments depicted in Figs. 1-5 and 8-10, and unlike the embodiments depicted in Figs. ll-17b, a majority of the sensing apparatus shown is provided externally to the crusher, and wherein the actuated member moves a sensor unit into better field of view or in greater proximity to a sensing region in its deployed position.

[0102] Fig. 20 suggests a non-limiting embodiment of a sensing apparatus 1300 in a retracted position and configured similarly to that depicted in Fig. 14, showing first (e.g., threaded hole(s)) and second (e.g., threaded fastener) portions of a fastening mechanism for securing it to a crusher adjacent to an inspection port, with the exception that a controllable (e.g., robotic) linkage or extendable arm acting as an actuated member 1303 is positioned on a safety cover portion 1302 rather than a body 801. The sensor unit 1304 is protected in the retracted position when not receiving information pertaining to operational or physical changes occurring within the crusher. The sensor unit 1304 is more proximate to or within a better field of view of a sensing region 406 in its deployed position for receiving information pertaining to operational or physical changes occurring within the crusher. One or more adjustment means 1306 may be provided to a mount of the actuating member 1303, without limitation.

[0103] Fig. 21 suggests a non-limiting embodiment of a sensing apparatus 1400 which may, in certain circumstances, always be in a deployed position (or moved into a deployed position by turning the sensor unit 1404 "on" from an "off” or "standby" position), without limitation. A sensor unit 1404 may be provided to a portion of the sensing apparatus 1400, for example, to a body 1401 portion or a safety cover portion 1402 thereof as shown. Adjustment means 1406 (e.g., such as agimbal or track that may be infinitely adjustable or positionable into one or more predetermined indexable positions, in one or more directions, and / or axes of rotation) may be provided at or adjacent the point of connection of the sensor unit 1404 without limitation. A mirror 1450 may be optionally provided to a portion of the sensing apparatus (e.g., to an inner body 1401 portion thereof), without limitation. The mirror 1450 may be adjustable (e.g., provided with adjustment means 1406 at a mount thereof, which is configured for manually and / or automatically controlling or seting a relative spatial orientation of the mirror 1450). Accordingly, mirror 1450 may be fixed in a spatial orientation with respect to other portions of the sensing apparatus 1400 to allow the sensor unit 1404 to have an improved field of view of a sensing region 406 without exposing it to debris. An actuated member or moving system (not shown) may be employed to move the sensor unit 1404 and / or the mirror 1450 at any point in time after installation, without limitation. For example, the mirror 1450 and / or sensor unit 1404 may be adjusted periodically for recalibration or improvement of the field of view of one or more sensing regions 406 over time.

[0104] Fig. 22 suggests a non-limiting embodiment of a sensing apparatus 1500 which may, in certain circumstances, always be in a deployed position (or moved into a deployed position by turning the sensor unit 1504 "on" from an "off” or "standby" position), without limitation. A sensor unit 1504 may be provided to a portion of the sensing apparatus 1500, for example, to a safety cover portion 1502 thereof. The body of the sensing apparatus 1500 may be entirely or substantially comprised of the safety cover portion 1502 as shown. The sensor unit 1504 may be connected to the safety cover portion 1502 in a fixed spatial orientation or in one of a plurality of adjustable spatial orientations. Adjustment means 1506 (e.g., such as a gimbal or track that may be infinitely adjustable or positionable into one or more predetermined indexable positions, in one or more directions, and / or axes of rotation) may be provided at or adjacent the point of connection between the safety cover 1502 and sensor unit 1504 without limitation. A mirror 1450 may not be necessary in such a non-limiting embodiment. While not shown, an actuated member may be used to move or re-orientate the sensor unit 1504 between a deployed and retracted position or between one or more deployed positions to observe one or more sensing regions 406 within a crusher, wherein the sensor unit 1504 may detect, measure, monitor, and / or analyze one or more operational or physical changes occurring within a crusher.DETAILED DESCRIPTION

[0105] Fig. 1 shows a portion of a gyratory crusher 100. A stationary outer shell 101 or portion thereof is provided having an interior surface 102. A crushing means in the form of a crushing mantle110 is located within the outer shell 101 and is configured to move in an eccentric manner, relative to the outer shell 101. The crushing mantle 110 comprises a protective lining 111. The interior surface 102 comprises a protective lining 105. A gap 120 is defined between the protective lining111 and 105. As the mantle 110 orbits in an eccentric manner, it is the minimum size of the gap 120, i.e. the smallest distance between the lining 111 and 105 that defines the size of the downsized material. This is referred to as the closed-side seting (CSS). The gyratory crusher 100 has an opening (not shown) in an upper portion of the outer shell 101 allowing material into the gyratory crusher 100. A sensing apparatus 1 is atached to the gyratory crusher 100, such that it substantially occludes an inspection port 103 therein. The inspection port 103 may be located at a height below the crushing mantle 110, such that when the sensor unit (not shown) is in its deployed position the gap 120 may be in a beter field of view and / or in closer proximity to a sensing region 406 than in its retracted position. As can be seen in Fig. 1 it may be advantageous to position the sensing apparatus 1 such that the sensing regions 406 can be sensed from below. In particular, the lower portions of the mantle lining 111 and lining 105 are inclined slightly downwards, so they can only be inspected from a position below the below the mantle 110.

[0106] As depicted in Fig. 1, embodiments of a sensing apparatus 1 may comprise a shaft 2. The shaft may have a proximal end 3 and a distal end (not shown). The sensing apparatus 1 may further comprise a safety cover 5 configured to occlude portions of the inspection port 103 not occluded by the shaft 2. In the particular embodiment shown, the safety cover 5 is sized to match the inspection port 103, but it may also be configured with a different size or shape than what is depicted, so long as it substantially occludes the inspection port 103 and has a corresponding third portion of a fastening mechanism which is operable to engage a first portion of the fastening mechanism provided to the crusher 100. The crusher 100 may comprise a first portion of a fastening mechanism, for example, in the form of a collar, boss, or inset 6 (e.g., which may be polygonal, annular, tubular, or simply circular as shown) protruding from, machined into, or cast into the outer shell 101 of the crusher 100.

[0107] The collar, boss, or inset 6 may comprise a first portion of a fastening mechanism, for example, threaded holes for connection with one or more bolts or receiving portions operably configured to engage with fasteners provided to the sensing apparatus 1. The safety cover 5 may comprise a third portion of a fastening mechanism, for example, in the form of clearance holes through the safety cover 5 and threaded bolts for passage through the holes and for threadedly engaging the first portion of the fastening mechanism for fastening the safety cover 5 to the collar, boss, or inset 6. A sensor unit (not shown) is located at or near the distal end of the shaft 2 which is interior of interior surface 102 and / or within the inspection port 103.

[0108] In the particular embodiment shown in Fig. 1, the shaft 2 may be movable (e.g., in translation and / or rotation) with respect to the safety cover 5. By moving the proximate end 3 towards the safety cover 5 and / or outer surface 101, the distal end of the shaft 2 is deployed further into the crusher 1, and the field of view of the sensor unit is oriented towards the desired sensing region or regions 406. In the embodiment shown in Fig. 1 the sensing apparatus 1 is shown to be configured in its retracted position. The configuration into the deployed position may be carried out by manually moving the shaft 2, without limitation. Alternatively, the configuration into the respective deployed and retracted positions may be achieved with an actuator or moving system, such as one comprising an actuated member as will be described hereinafter.

[0109] Turning now to Fig. 2 and Fig. 3 showing a sensing apparatus 200 according to some embodiments of the invention. The sensing apparatus 200 may comprise a body 201 which is hollow and functions as an outer sleeve for an actuated member 203 which is movable (e.g., telescopingly) in relation to the body 201. In one end (i.e., near a distal end) of the body 201 closest to the crusher, a safety cover 202 may be provided as shown. The safety cover 202 has a distal side for being in communication with a crusher (e.g., in surface contact with or facing outer shell 101), and a proximal side (e.g., not contacting or facing away from the outer shell 101. The safety cover 202 may be mounted internally (e.g., against interior surface 102) or externally (e.g., against collar boss or inset 6 or inspection port 103) with respect to the outer shell 101. The sensing apparatus 1 is attachable to a first portion of a fastening mechanism extending from and / or forming a portion of an inspection port 103 of a crusher 100. The sensing apparatus 1 comprising a second portion of the fastening mechanism engageable with the first portion of the fastening mechanism (not shown in Fig. 2 and Fig. 3). For example, as shown, the second portion of the fastening means may comprise a hole(s)205 in the safety cover 202 for receiving and / or holding a fastener(s) which may be engaged with a corresponding receiving portion in the outer shell. For example, the fastener(s) may comprise a threaded fastener such as a bolt, and the receiving portion may comprise a threaded bore configured to receive the same. Preferably, one or more of the receiving portion(s), hole(s), and fastener(s) align to facilitate mounting the sensing apparatus 1 to the crusher 100.

[0110] In some embodiments, the safety cover 202 may be configured as a modular unit within a system of differently-configured safety covers 202, each of the safety covers 202 within the system of differently-configured safety covers 202 matching differently-configured first portions of a fastening mechanism (e.g., which are provided to different outer shell 101 configurations, different inspection port 103 configurations, and / or different collar boss or inset 6 configurations), without limitation. As such, a safety cover 202 of a sensing apparatus 200 swapped for another in the system of differently-configured safety covers 202 to improve retrofitabilty and attachment of a sensing apparatus 200 to different crushers 100. For example, each modular safety cover 202 within the system may comprise a different number of holes 205 and / or a different pattern of holes 205, or a different shape or size, without limitation. The provision of such a system would allow a sensing apparatus 200 to be attached to different crushers 100 by simply removing a safety cover 202 from the sensing apparatus 200, and replacing it with another safety cover 202 from within the system which has a second portion of a fastening mechanism which mates with a first portion of a fastening mechanism of a particular crusher 100.

[0111] One or more support members 209, such as the pairs of gussets depicted, may extend between the safety cover 202 and the body 201 to support the cantilevered body 201 of the sensing apparatus 200 in relation to the safety cover 202 while the sensing apparatus 200 is connected to a crusher 100.

[0112] At, near, or proximate to a distal end region of the actuated member 203 a sensor unit 204 may be provided. The sensor unit 204 may comprise a field of view and is configured for detecting, measuring, monitoring, and / or analyzing operational or physical changes occurring within a crusher within its field of view. The field of view of the sensing apparatus may be improved with respect to a sensing region 406 in a deployed position of the sensing apparatus 202. The field of view of the sensing apparatus may be reduced with respect to a sensing region 406 in a retracted position of the sensing apparatus 202.

[0113] The sensing apparatus 200 has at least two configurations including a deployed and retracted position. In the embodiment shown, the deployed position is achieved when the actuated member 203 is moved in relation to the body 201 of the sensing apparatus 200 to expose the sensor unit 204 to the sensing region. For example, in the particular non-limiting embodiment shown, the sensor unit 204 is exposed from protection within the body 201 during this movement. By moving the actuated member 203 to one or more desired deployed positions, the sensor unit 204 may align its field of view towards one or more desired sensing regions 406 in the crusher 100.

[0114] The inventors anticipate that for certain sensing units 204 (e.g., X-ray, sonar / ultrasonic / RF, thermal imaging, or inductive-type sensing units) and / or for certain material configurations of actuated member 203 or body 201 (e.g., radiolucent polymers or the like), the deployed position of the sensing apparatus 200 may simply include an "on" configuration of the sensor unit 204, and a retracted position of the sensing apparatus 200 may include an "off" or "standby" configuration of the sensor unit 204, without limitation. In such embodiments (not shown), no actuated member 203 may be required. The particular embodiment shown suggests an optical-based (e.g. lidar-, camera-, and / or infrared- based) sensor unit 204.

[0115] The sensor unit 204 may be attached to the actuated member 203 in a way such that it is configured that it may pivot or adjust its field of view in some manner (e.g., to change or adjust focal length, modify a relative distance in relation to a sensing region 406, adjust optical magnification, provide mechanical shuttering, apply electronic cropping, or the like, without limitation). In the particular embodiment shown, the sensor unit 204 may be manually adjusted by adjusting means 206. The adjusting means 206 may comprise a mechanical mechanism for discretely indexing and / or infinitely-adjusting a spatial orientation or relative position of the sensor unit 204 in relation to a sensing region 406. For example as shown, a sensor unit 204 may be pivitolly-supported by the actuated member 103 and a pin or ball detent mechanism may be inserted into one of a series of holes in the actuated member 103 to lock the orientation of the sensor unit 206 into a desired angle to adjust the field of view of the sensor unit 204. Alternatively, or in addition to the same, a set screw or other fastening means may be used to fix an adjusted position of the sensor unit 204 relative to other portions of the sensing apparatus 200, such as in relation to the actuated member 103 as shown. In alternative embodiments, the angle or distance from a sensing region 406 may be adjusted by a motor or actuator based on an input signal. It isimportant to understand that adjusting means 206 may be configured in many different ways and may be applied to other components of a sensing apparatus 200, such as to the body 201, as will be appreciated hereinafter from the description and accompanying figures.

[0116] A sensor unit cleaning device 230 may be optionally-provided to a portion of the sensing apparatus 200 (such as on the body 201 as shown), in order to periodically or continuously clean a portion of the sensor unit 204. In some embodiments, the sensor unit cleaning device 230 may also include one or more stationary brushes or wipers (Fig. 3) for cleaning surfaces between body 201 and the actuating member 203 to prevent binding or material buildup between surfaces during operation. For example, these one or more stationary brushes or wipers may entirely surround actuated member 230 covering all sides of opening 208, without limitation.

[0117] The actuated member 203 shown in the embodiment of Figs. 2 and 3 is configured to move relative to the body 201 and be maintained at least partially inside the body 201. In the retracted position, the sensor unit 204 is moved into the body 201 such that less of the sensing region 406 of the crusher 100 is in the field of view of the sensor unit 406, compared to in the deployed position.

[0118] The actuated member 203 may comprise an end plate 207 as shown. The end plate 207 may, for example, be provided at a distal end of the actuated member 203. A gasketing structure may be provided between end plate 207 and safety cover 202 for protecting the sensor unit 204 in the retracted position. For example, the gasketing structure could be an annular foam ring or polymeric O-ring which is adhered to or recessed within a groove of either component 202, 207.

[0119] It should be understood that the sensor unit 204 may be positioned in many other positions than just a retracted and a deployed position. For example, there may be a plurality of deployed positions. There may also be a number of positions (e.g., deployed positions) between a retracted and deployed position, without limitation.

[0120] Turning to Fig. 4, a top plan cross-sectional view of a sensing apparatus 300 according to an embodiment of the invention is shown. The sensing apparatus 300 may comprise a body 301 movably connected to an actuating member 303. A safety cover 302 may be coupled to the body 301 and may be suitable for being attached to a crusher. One or more support members 309 may be connected to and / or extend between the body 301 and the safety cover 302 to support the body 301 as discussed above. An end plate 307 may be provided towards a distal end of the actuatingmember 303. The actuating member 303 may further comprise a sensor unit 304. The sensing apparatus 300 may further comprise a moving system 310. The moving system 310 may, for example, as shown, comprise an actuator. The actuator may be coupled to the body 301 and to the actuating member 303 by a connecting member 311, such as a pin as shown. The moving system 310 may be in communication with a controller unit 403 or an activation means which, upon providing a control input, activates the actuator and thereby moves the actuated member 303 of the sensing apparatus 300 with respect to the body 301.

[0121] Turning to Fig. 5, a system 400 is shown. The system 400 may be present during a retrofit and / or installation of the sensing apparatus 401 shown and described. The system 400 may include a crusher 404 or at least a portion of a crusher 404, such as a mainframe section or stationary outer shell 101. The system 400 may include an inspection port 405 on the crusher 404 or portion thereof. The system 400 may include a safety cover 402 which is configured to secure to a portion of the crusher 404 to prevent egress / ingress of material through the inspection port 405. The safety cover 402 (if present) may be removed from the crusher 404 (or the portion thereof) to expose the inspection port 405 for mounting of the sensing apparatus. In some embodiments (not shown), the safety cover 402 may remain hingedly-attached to a crusher 404 or portion thereof, wherein the safety cover 402 may be swung or pivoted with respect to the crusher 404 (or portion thereof) to expose the inspection port 405 enough that the sensing apparatus 401 may be adequately installed without completely removing the safety cover 402 from the crusher 404 or portion thereof.

[0122] The sensing apparatus 401 may be mounted to the crusher 404 adjacent the inspection port such that a portion of the device 401 may pass through the inspection port 405 and / or at least partially or substantially occlude the inspection port 405. The sensing apparatus 401 may be in operable communication with a controller 403 which may have a display, receive information from the sensor unit of the sensing apparatus 401, and / or provide control inputs to the sensing apparatus 401 (e.g., instructions to move an actuated member of the sensing apparatus 401 between deployed and retracted positions of the sensing apparatus 401).

[0123] Turning to Fig. 6, within a crusher 100, such as within a mainframe portion 404 or an outer stationary shell 101 thereof, a concave protective liner 408 and a mantle protective liner 409 may be provided. An adjustable / dynamic gap 410 may be provided therebetween, wherein the largest dimension therebetween is an open side seting (OSS) and the smallest dimensiontherebetween is a closed side seting (CSS). A sensing region 406 may be located at a portion of the crusher 100 adjacent the gap 410 and in the field of view of a sensor unit for measuring the OSS and / or CSS. A sensing apparatus 401 mounted to the crusher 100 may comprise an actuating member 407 that extends through an inspection port 405 to place the sensor unit in greater proximity to the sensing region 406 in a deployed position. The sensing apparatus 401 may be configured to move the sensor unit into closer proximity or expose the sensor unit to a beter field of view of the sensing region 406 in the deployed position. The sensing apparatus 401 may be configured to move the sensor unit away from or cover or reduce or limit a field of view of the sensing region 406 in the retracted position.

[0124] Turning to Fig. 7, a controller 403 may comprise a graphical user interface or display. As shown, the display may depict a sensing region 406 (e.g., gap 410 and / or surfaces of one or more protective liner(s) 408, 409), without limitation. In the particular preferred embodiment shown, the controller 403 may be configured to measure, detect, monitor, and / or analyze the OSS and / or CSS operating parameter(s) of a crusher 100 so that control inputs or recommended control seting adjustments can be relayed to the distributed control system 403 and / or user of the crusher 100. For example, the display may depict messaging prompting a user to make an operational adjustment of a control seting of the crusher 100. Such control inputs or recommended control seting adjustments may include a recommended or automatic adjustment of mantle 412 shaft vertical position (i.e., "mantle height adjustment"), without limitation. Such control inputs or recommended control seting adjustments may include a recommendation to replace one or more protective linings 408, 409, without limitation. Such control inputs or recommended control seting adjustments may include an average measured wear rate of one or both protective liners 408, 409, or depict a change in gap 410 width over time or a current OSS and / or CCS gap 410 value in realtime, without limitation.

[0125] Turning to Fig. 8, a cross-sectional side plan view of a crusher 404 is shown. As depicted, one or more sensing regions 406 may exist within the crusher 100, without limitation. Embodiments of a sensing apparatus 401 may be configured such that its sensor unit (or units) can detect, measure, monitor, or analyze multiple sensing regions 406 simultaneously or independently (e.g., in succession), without limitation.

[0126] Turning to Fig. 9, a crusher portion 404 may comprise a sensing apparatus 401 configured to secure to the crusher 100 at or adjacent an inspection port 405 thereof.

[0127] Turning to Fig. 10, which is an alternative cross-sectional view of the crusher 100 shown in Fig. 9, an actuated member 407 comprising a sensing unit 411 may extend through an inspection port 405 of a crusher portion 404. The actuated member 407 may linearly move (e.g., telescopingly) between a deployed (shown) and a retracted position within the body 413 of the sensing apparatus 401.

[0128] Turning to Figs, lla-llc, a crusher 100 may comprise a sensing apparatus 500, or a sensing apparatus 500 for a crusher 100 may be provided. A moving system 510 and / or sensor unit 504 of the sensing apparatus 500 may be configured to operably communicate with a controller403 as depicted in Fig. 11a. A first portion 121 of a fastening mechanism may comprise a surface of the inspection port 103. A second portion 522 of a fastening mechanism may be provided to the sensing apparatus 500, for example on an outer portion of body 501. The second portion may comprise a circ clip in a groove of the inspection port 103 or body 501, an expandable ring on an outer surface profile of body 501, a ball detent mechanism, a pawl or latch mechanism, a snap fit fastening mechanism, a semi-permanent adhesive, or expandable member (e.g., inflatable, compressible polymer, slightly-oversized or interference fit external sleeve or body 501 portion, an expanding wedge and sleeve mechanism, or the like) to secure itself to the first portion of the fastening mechanism 121. A sensor unit 504 may be rotated between deployed (Fig. lib) and retracted (Fig. 11c) positions via an actuated member 503 and associated moving system 510, without limitation.

[0129] Turning to Figs. 12a-b, a crusher 100 may comprise a sensing apparatus 600, or a sensing apparatus 600 for a crusher 100 may be provided. A moving system 610 and / or sensor unit 604 of the sensing apparatus 600 may be configured to operably communicate with a controller 403 as depicted in Fig. 12a. A first portion 121 of a fastening mechanism may comprise a first portion of a latch mechanism extending from a portion 101 of the crusher 100 such as from the inspection port 103 or region of the crusher proximate to the inspection port 103. A second portion 622 of a fastening mechanism may be provided to the sensing apparatus 500, for example in the form of a second portion of a latch mechanism on an outer portion of body 601 (e.g., extending from safety cover portion 622 as shown). The second portion 622 is configured to secure itself to the first portion of the fastening mechanism 121. A sensor unit 604 may be fixed or adjustable (i.e., maycomprise adjustable means 606). The sensor unit 604 may be stationary between deployed and retracted positions, wherein an actuated member 603 (e.g., in the form of an articulating sensor unit cover) is moved between deployed (Fig. 12a) and retracted (Fig. 12b) positions via a moving system 610. As shown, the actuated member 603 rotates, however it could alternatively fold, pivot, or slide (as will be appreciated from the embodiment shown in Figs. 15a-b).

[0130] Turning to Figs. 13a-b, a crusher 100 and a sensing apparatus 700 combination, or a sensing apparatus 700 for a crusher 100 may be provided. The sensing apparatus 700 may use a threaded fastener and / or holes as a second portion 722 of a fastening mechanism. The crusher 100 or portion 101 thereof may comprise threaded holes to receive the threaded fastener as the first portion 121 of the fastening mechanism. Alternatively, integral fasteners such as plugs or expandable fasteners or clips can be provided to the sensing apparatus as the second portion 722 of a fastening mechanism, and a complimentary receiving portion such as an opening may be provided to the crusher 100 or portion 101 thereof, without limitation. These plugs or expandable fasteners or clips may be integrally-provided to safety cover 702 or body 701, without limitation. In the particular embodiment shown, the actuated member 703 serves as a sensor unit cover, and the sensing unit 704 is connected / mounted to it.

[0131] Turning to Figs. 14a-b, a crusher 100 and sensing apparatus 800 combination, or a sensing apparatus 800 for a crusher 100 may be provided. The sensing apparatus 800 may use a threaded fastener(s) and / or hole(s) as a second portion 822 of a fastening mechanism. The crusher 100 or portion 101 thereof may comprise a threaded hole(s) (i.e. as a first portion 121 of a fastening mechanism) to receive the threaded fastener(s). Alternatively, integral fasteners such as plugs or expandable fasteners or clips can be provided to the sensing apparatus as the second portion 822 of a fastening mechanism, and a complimentary receiving portion such as an opening may be provided to the crusher 100 or portion 101 thereof, without limitation. In the particular embodiment shown, the actuated member 803 comprises an actuated arm, such as a controllable linkage or robotic arm, without limitation, wherein the sensing unit 804 is connected to a portion of it, for example, adjacent a distal end thereof. A moving system 810, for example, a motor with internal chain or belt drive or servo motor may be employed to articulate the actuated member 803 between deployed and retracted positions. A portion of the moving system 810, for example, a base portion of a main pivot or fulcrum of the actuated member 803 may comprise adjustmentmeans for fine tuning the location of the moving system 810 with respect to other portions of the sensing apparatus 800, such as the body 801. Fig. 14a shows the sensing apparatus 800 configured in a deployed position, and Fig. 14b shows the sensing apparatus 800 configured in a retracted position. As depicted, an optional sensor unit cleaning device 830 may be provided to embodiments of a sensing apparatus 800 for cleaning (e.g., de-dusting) the sensor unit 804, without limitation. The sensor unit cleaning device 830 may comprise, for instance, an air blade, a stationary or mechanically actuated wiper, a stationary or mechanically actuated brush, and / or equivalent dedusting means for cleaning a sensor unit between deployed and retracted positions, without limitation. As suggested in Figs. 14a-b, the sensor unit cleaning device 830 may be mounted internally to body 801, recieved or located within the inspection port 103, unlike the embodiment shown and described in Figs. 2 & 3.

[0132] Turning to Figs. 15a-b, embodiments of a sensing apparatus 900 may comprise a body 901 configured to extend within an inspection port 103, a means for mounting to a crusher 100 including a second portion of a fastening mechanism (e.g., provided to a safety cover portion 902 configured to substantially occlude portions of the inspection port 103 not occluded by the body 901), and a sensor unit 904. The sensing apparatus 900 may be configured with a deployed and retracted position, wherein an actuated member 903 may comprise a movable sensor unit cover. The actuated member 903 may be articulated (e.g., slid linearly) over an opening 905 of the body 901. The opening 905 in the body 901 may allow a sensor unit 904 within the body 901 to be exposed in a deployed position of the sensing apparatus. In the deployed position, the sensor unit 904 may have a better field of view of a sensing region 406 within the crusher 100, and thus, be positioned more proximate to a sensing region 406 than in the retracted position. Figs. 15a-b depict a top plan view of the sensing apparatus 900, wherein the moving system for moving the acutated member 903 is not shown for clarity.

[0133] Turning to Figs. 16a-b, embodiments of a sensing apparatus 1000 may comprise a body 1001 configured to extend within an inspection port 103, a means for mounting to a crusher 100 including a second portion of a fastening mechanism (e.g., provided to a cover portion 1002 configured to substantially occlude portions of the inspection port 103 not occluded by the body 1001), and a sensor unit 1004. The sensing apparatus 1000 may be configured with a deployed and retracted position, wherein an actuated member 1003 may comprise a movable sensor unit cover.The actuated member 1003 may be articulated (e.g., rotated or pivoted angularly) over an opening 1005 of the body 1001. The opening 1005 in the body 1001 may allow a sensor unit 1004 within the body 1001 to be exposed in a deployed position of the sensing apparatus. In the deployed position, the sensor unit 1004 may have a better field of view of a sensing region 406 within the crusher 100, and thus, be positioned more proximate to a sensing region 406 than in the retracted position. Figs. 16a-b depict a side plan view of the sensing apparatus 1000, wherein the moving system for moving the acutated member 1003 is not shown for clarity.

[0134] Turning to Figs. 17a-b, embodiments of a sensing apparatus 1100 may comprise a body 1101 configured to extend within an inspection port 103, a means for mounting to a crusher 100 including a second portion of a fastening mechanism (e.g., provided to a cover portion 1102 configured to substantially occlude portions of the inspection port 103 not occluded by the body 1101), and a sensor unit 1104. The sensing apparatus 1100 may be configured with a deployed and retracted position, wherein an actuated member 1103 may comprise a movable sensor unit cover. The actuated member 1103 may be articulated (e.g., rotated or pivoted angularly) over an opening 1105 of the body 1101. The opening 1105 in the body 1101 may allow a sensor unit 1104 within the body 1101 to be exposed in a deployed position of the sensing apparatus. In the deployed position, the sensor unit 1104 may have a better field of view of a sensing region 406 within the crusher 100, and thus, be positioned more proximate to a sensing region 406 than in the retracted position. Figs. 17a-b depict a side plan view of the sensing apparatus 1100, wherein the moving system for moving the acutated member 1103 is not shown for clarity. As depicted, a sensor unit 1104 may be attached to the actuated member 1103.

[0135] Turning to Figs. 18 and 19, a sensing apparatus 1200 (similar to the ones depicted in Figs 2-4) may comprise a body 1201 having a safety cover portion 1202 for mounting to a crusher, an internal actuated member 1203 configured to telescopingly extend through an inspection port 103 and into a crusher to expose a sensor unit (not shown) on the actuated member 1203 to a sensing region 406 in a deployed position. As shown, the sensing apparatus 1200 is in a retracted position with an endplate 1207 of the actuated member 1203 sealed against the safety cover portion 1202. A sealing means such as a gasketing structure (e.g., O-ring, gasket, or equivalent) may be present between the end plate 1207 and safety cover portion 1202 or body 1201. A second portion of a fastening mechanism 1205 may be provided to a portion of the body 1201, such as to one or moreportions of the safety cover portion 1202 as shown. A moving system 1210 is further provided for articulating (e.g., extending) the actuated member 1203 in relation to the body 1201 and other portions of the sensing apparatus 1200. Upon movement of the actuated member 1203 from the retracted to deployed position, and / or upon movement of the actuated member 1203 from the deployed to the retracted position, a sensor unit cleaning device 1230 may be activated to clean (i.e., "de-dust") the sensor unit provided to the actuated member 1203. In the particular embodiment shown, the sensor unit cleaning device 1230 comprises a pneumatic air blade for spraying high pressure gas across a surface of the sensor unit. In the particular embodiment depicted, the sensor unit cleaning device 1230 may also include one or more stationary brushes or wipers (not shown) for cleaning surfaces between body 1201 and the actuating member 1203 to prevent binding or material buildup between surfaces during operation. The same stationary brushes or wipers may be provided between elements 202 and 203 as depicted in Figs. 2 and 3.

[0136] Turning to Figs. 20-22, alternative embodiments are suggested. In some embodiments, (Figs. 20 & 22) a body of a sensing apparatus may simply comprise a safety cover 1302, 1502 or portion thereof. Moreover, as suggested in Fig. 21, a sensing apparatus 1400 may comprise one or more mirrors 1450 (which may be adjustable), for improving a field of view in a deployed position of the sensing apparatus 1400, and / or for allowing more compact or protective locations / orientations of a sensor unit 1404 within an inspection port 103. Additionally, as suggested in Figs. 21 and 22, a deployed position of a sensing apparatus may simply comprise an "on" status of the sensor unit 1404, 1504, and a retracted position of a sensing apparatus may simply comprise an "off” or "standby" status, without limitation.

[0137] It should be understood that for any of the depicted and described embodiments, multiple sensor units and / or multiple moving systems or actuated members may be incorporated into a sensing apparatus in order to detect, measure, monitor, and / or analyze operational or physical changes occurring within multiple sensing regions 406 of the crusher in different fields of view, without limitation. Where a plurality of sensor units are employed, the sensor units may simultaneously gather information pertaining to the various sensing regions 406 simultaneously, or independently, in succession. Moreover, it should be understood that a sensing apparatus according to embodiments may be configured with multiple deployed positions, wherein an actuated member may be configured with multiple configurations to deploy a single sensor unit ina number of spatial orientations or deployed positions to assess multiple sensing regions 406 within the crusher.

[0138] It should also be understood that a sensing apparatus may comprise a customizable clamp (e.g., as a second portion of a fastening mechanism), configured to attach to a flange portion, surface, or other portion (e.g., a first portion of a fastening mechanism) of an outer stationary shell 101 to support it, mount it, or secure it to a crusher, without limitation. Moreover, a customizable mount may extend from the sensing apparatus and the mount may be secured (e.g., bolted or welded) to a portion of a crusher, such as to an external surface or flange portion of an outer stationary shell 101, without limitation.

[0139] Where used herein, the term "control unit", "controller", "controller unit" and the like may comprise a task-specific module, but also may be, comprise, or include a distributed control system (DCS), local crusher controller, remote cloud-based computing device or the like, without limitation.

[0140] Where used herein, the term "sensing region" may incorporate one or more regions of interest within a crusher. The one or more regions of interest may include a field of view of a wear liner or protective lining 108, 109, 408, 409 surface, a spacing 110, 410 between crusher parts, or the like. For example, a sensor unit may be used to detect, measure, and / or monitor one or more operational or physical changes occurring at one or more specific locations within the crusher within its field of view including, but not limited to an open- or closed- side seting (OSS / CSS).

[0141] REFERENCE NUMERAL IDENTIFIERS1 Sensing apparatus2 Shaft3 Proximal end of shaft5, 202, 302, 402, 502, 602, 702, 802, 902, 1002, 1102, 1202, 1302, 1402, 1502 Safety cover (or portion thereof)6 Collar, boss, or inset100 Crusher (e.g., gyratory crusher)101 404 Crusher portion (e.g., stationary outer shell, portion of crusher, or mainframe section of crusher)102 Interior surface103, 405 Inspection port105, 408 Protective lining (concave)110 Crushing means (e.g., crushing mantle, mantle shaft)111, 409 Protective lining (mantle)120, 410 Gap121 First portion of fastening system (of crusher or portion thereof)122, 205, 522, 622, 722, 822, 1205, 1322, 1422, 1522Second portion of fastening system (sensing apparatus)123 Inner wear surface200, 300, 401, 500, 600, 700, 800, 900, 1000, 1100, 1200, 1300, 1400, 1500Sensing apparatus201, 301, 413, 501, 601, 701, 801, 901, 1001, 1101, 1201, 1401 Body203, 303, 407, 503, 603, 703, 803, 903, 1003, 1103, 1203, 1303 Actuated / actuating member204, 304, 411, 504, 604, 704, 804, 904, 1004, 1104, 1304, 1404, 1504 Sensor unit206, 506, 606, 806, 1306, 1406, 1506 Adjusting means(e.g., for positioning / orienting sensor unit relative to body)207, 307, 1207 End plate208, 905, 1005, 1105 Opening (e.g., space between body and articulated member)209 Support member(s)309 Support member(s)310, 510, 610, 710, 810, 1210 Moving system (e.g., actuating mechanism, actuator, device for moving actuated member, etc.)311 Connecting member400 System403 Control unit, controller,406 Sensing region (e.g., region of interest)230, 830, 1230 Sensor unit cleaning device(e.g., air blade, wiper, brush, and / or equivalent de-dusting means)1450 Mirror (e.g., translatable and / or angularly adjustable)

Claims

CLAIMS1. A sensing apparatus configured for detecting, measuring, monitoring, and / or analysing operational or physical changes occurring within a crusher, the sensing apparatus being attachable to a first portion of a fastening mechanism provided adjacent to, extending from, extending into, and / or forming a portion of an inspection port of said crusher, the sensing apparatus comprising:- a second portion of said fastening mechanism engageable with, alignable with, and / or configured to co-operate with the first portion of the fastening mechanism;- a sensor unit having a field of view, the sensor unit configured to detecting, measuring, monitoring, and / or analyzing operational or physical changes occurring within the crusher in the field of view; wherein the sensing apparatus is configured to substantially occlude the inspection port; wherein the sensing apparatus has at least two configurations including a deployed and retracted position.2 The sensing apparatus according to claim 1, wherein in the retracted position, less of a sensing region of the crusher is in the field of view of the sensor unit compared to the in the deployed position.3 The sensing apparatus according to any previous claim, wherein at least one of the following statements is true: i) in the deployed position, the sensor unit is located in a position more proximate to a sensing region within the crusher than in the retracted position; ii) in the deployed and retracted positions, the sensor unit remains proximate to a sensing region within the crusher; a sensor unit cover shrouds the sensing unit in the retracted position; and said sensor unit exposes the sensor unit in the deployed position.4 The sensing apparatus according to any previous claim, further comprising an actuated member moveable between at least the deployed position and the retracted position, whereinRECTIFIED SHEET (RULE 91 ) ISA / EP- the sensor unit is attached to a portion of the actuated member, or- the actuated member is moveable in relation to the sensor unit.

5. The sensing apparatus according to any previous claim, further comprising a protective housing for accommodating the sensor unit when the sensing apparatus is configured in the retracted position.6 The sensing apparatus according to any previous claim, wherein the sensor unit is configured to index between at least two spatial orientations in relation to one or more other components of the sensing apparatus.7 The sensing apparatus according to any previous claim, further comprising a moving system which is configured for either: i) moving or articulating an actuated member for positioning the sensor unit more proximate to the sensing region in the deployed position or away from the sensing region in the retracted position, or for providing a better field of view to the sensor unit or, ii) moving or articulating a sensor unit cover; wherein the moving system comprises a component selected from the group consisting of: a pneumatic cylinder, a hydraulic cylinder, an electric solenoid, a linear drive, a motor, a rotational drive, an actuated linkage, a robotic or actuated arm, a telescopic actuator, a cam and follower mechanism, and an electric linear actuator.8 The sensing apparatus according to any previous claim, further comprising a cleaning device for cleaning the sensor unit, preferably when the sensing apparatus is in or near the retracted position, preferably the cleaning device being selected from the group consisting of: an air blade nozzle, a brush, a stationary or actuated wiper blade, and a fluid dispensing nozzle configured to emit a gas, liquid, or combination thereof.9 The sensing apparatus according to any previous claim, further comprising a gasketing structure configured to communicate with two surface portions of the sensing apparatus in or nearRECTIFIED SHEET (RULE 91 ) ISA / EPthe retracted position and further configured to protect the sensor unit when the sensing apparatus is in or near the retracted position.

10. The sensing apparatus according to any previous claim, wherein the sensor unit is configured to receive and transmit optical (image-based), acoustic (vibrational or sound-based), and / or thermal (temperature or heat-based) information.

11. A method of fiting a crusher with a sensing apparatus having at least two configurations including a deployed and retracted position, the crusher comprising an inspection port and having a first portion of a fastening mechanism provided adjacent to, extending from, extending into, and / or forming a portion of the inspection port, the method comprising the steps of: providing a sensing apparatus comprising a third fastening mechanism engageable with, alignable with, and / or configured to co-operate with the first portion of said fastening mechanism, at least partially occluding the inspection port with the sensing apparatus; mounting and / or securing the sensing apparatus to the crusher by at least pa rtia I ly engaging, aligning, and / or co-operating the first portion of the fastening mechanism and the third portion of the fastening mechanism.

12. The method of fitting a crusher with a sensing apparatus according to claim 11 wherein the crusher further comprising a removable safety cover having a second portion of said fastening mechanism engageable with, alignable with, and / or configured to co-operate with said first portion of said fastening mechanism, the method further comprising the step of:- removing the safety cover from the crusher by disengaging the first portion of the fastening mechanism from the second portion of the fastening mechanism.

13. A method of fiting a crusher with a sensing apparatus according to claim 11 or 12 with a sensing apparatus according to any of claim 1 to 10.RECTIFIED SHEET (RULE 91 ) ISA / EP14. The method according to claim 11 to claim 13, wherein the step of removing the safety cover from the crusher by disengaging the first portion of the fastening mechanism from the second portion of the fastening mechanism further comprises at least one of the following steps:- actuating a clamp or toggle member on the first and / or second portion;- unthreading one or more threaded fasteners from the first and / or second portions;- removing a locking pin;- unthreading the safety cover from the crusher.

15. A method of fitting a crusher with a sensing apparatus, the crusher comprising an inspection port and having a first portion of a fastening mechanism for securing a safety cover to the crusher, the method comprising the steps of: at least partally disengaging, un-aligning, or un-cooperating a portion of the first portion of a fastening mechanism; exposing the inspection port by moving and / or removing the safety cover in relation to the crusher; providing a sensing apparatus comprising a third fastening mechanism engageable with, alignable with, and / or configured to co-operate with one or more portions of the inspection port and / or one or more portions of the first portion of said fastening mechanism, introducing a portion of the sensing apparatus into or at least partially through the inspection port; substantially occluding the inspection port with the sensing apparatus; and mounting and / or securing the sensingapparatus to the crusher by at least partially engaging, aligning, and / or co-operating the third portion of the fastening mechanism with one or more portions of the inspection port and / or and one or more portions of the first portion of the fastening mechanism.

16. A system comprising:- a crushing apparatus having an inspection port and a first portion of a fastening mechanism provided adjacent to, extending from, extending into, and / or forming a portion of the inspection port;RECTIFIED SHEET (RULE 91 ) ISA / EP- a safety cover for covering at least a portion of the inspection port, the safety cover having a second portion of said fastening mechanism being engageable with, alignable with, and / or configured to co-operate with the first portion of the fastening mechanism; and- the sensing apparatus according to any one of preceding claims 1 to 10.

17. A method of using a sensing apparatus according to any one of claims 1-10 as shown and described for any of Figs. 1-22.

18. A method of detecting, measuring, monitoring, and / or analysing operational or physical changes occurring within a crusher using the sensing apparatus according to any one of preceding claims 1-10, comprising the following steps:- with the second portion of the fastening mechanism engaged, aligned, and / or cooperating with the first portion of the fastening mechanism, delivering a control input to the sensing apparatus;- upon delivery of the control input, configuring the sensing apparatus into the deployed position from the retracted position;- detecting, measuring, monitoring, and / or analysing one or more operational or physical changes occurring within the crusher by virtue of receiving input data via the sensor unit, the input data comprising optical (image-based), acoustic (vibrational or sound-based), and / or thermal (temperature or heat-based) information;- delivering the input data to a controller unit;- processing the delivered input data using the controller unit;- allowing a period of time to lapse with the sensing apparatus in the deployed position;- reconfiguring the sensing apparatus into the retracted position from the deployed position.

19. A method of detecting, measuring, or monitoring operational or physical changes occurring within a crusher comprising the steps of:- providing the sensing apparatus according to claims 1-10;- configuring the sensing apparatus such that it is in the deployed position;RECTIFIED SHEET (RULE 91 ) ISA / EP- with the sensor unit proximate the sensing region within the crusher in the deployed position, sensing an operational or physical change within the crusher using the sensor unit;- subsequently configuring the sensing apparatus such that it is in the retracted position;- protecting the sensor unit from material processed within the crusher while the sensing apparatus is in the retracted position.

20. A method of attaching a sensing apparatus to a crusher comprising an inspection port having a first portion of a fastening mechanism provided adjacent to, extending from, extending into, and / or forming a portion of the inspection port, the method comprising the steps of: providing a sensing apparatus comprising a second portion of the fastening mechanism engageable with, alignable with, and / or configured to co-operate with the first portion of said fastening mechanism, the sensing apparatus being configured to substantially occlude the inspection port; mounting and / or securing the sensing apparatus to the crusher by engaging the first and second fastening mechanisms; wherein the sensing apparatus has at least two configurations including a deployed and retracted position.

21. The method according to claim 20, further comprising removing a safety cover from the crusher, the safety cover having a third portion of the fastening mechanism which is substantially equivalent to the second portion of the fastening mechanism and / or equally engageable with the first portion of the fastening mechanism.

22. A method of making a sensing apparatus according to any one of claims 1-10 comprising: modifying a safety cover that is configured for covering an inspection port of a crusher; providing an assembly comprising a sensor unit and an actuated member; attaching the assembly to the modified safety cover using fastening means, the fastening means preferably comprising a weld, an adhesive, a thread, a hook, a latch connector, and / or one or more fasteners such as screws or bolts.RECTIFIED SHEET (RULE 91 ) ISA / EP23. The method according to claim 22, wherein the step of modifying a safety cover is performed while the safety cover is located in one of the following positions: fully-mounted to the crusher; partially-mounted to the crusher; removed from the crusher.RECTIFIED SHEET (RULE 91 ) ISA / EP

Images