Strain measurement sensor device for earthmoving machinery

Abstract

A sensor arrangement (1-6) for an earthmoving machine comprising at least one body (10), a first plurality of strain measuring sensors (20) arranged on one or more of the at least one body to measure strain in at least two different axes (X, Y, Y'), the first plurality of sensors including at least four strain measuring sensors (20), and one or more electronic devices (210a-210n, 213) configured to provide, for the at least two different axes (X, Y, Y'), a difference between measurements of two different strain measuring sensors of the first plurality of sensors for each axis of the at least two different axes. Also provided are a method, a wear element, and a wear element assembly including the sensor arrangement.

Description

[Technical field]

[0001] The present disclosure relates to the field of earth moving machines. More particularly, the present disclosure relates to a sensor device, a wear element, and an assembly having the wear element, capable of measuring unit deformation in an accurate and reliable manner. [Background technology]

[0002] For example, earthmoving machines such as excavators, draglines, loaders, shovels, and the like, include excavating implements, e.g., buckets, shovels, dredge heads, and the like, by which material is pushed, penetrated, damaged, pulled, and / or collected. Each time the excavating implement engages the ground, it is subjected to high intensity loads, impacts, and stresses that can cause the excavating implement to deform, wear, or even break. Material engagement has adverse effects on the excavating implement.

[0003] For at least this reason, wear elements are coupled to the drilling implement. The wear elements protect the implement from wear and impacts that may deform and damage said drilling implement. Furthermore, the wear elements are designed to improve the engagement with the ground. As the wear elements are subject to the adverse effects of wear and impacts, they must be replaced frequently.

[0004] In order to replace the wearing elements in time and to operate the earthmoving machine properly, it is necessary to monitor the forces and stresses to which they are subjected. In this sense, information about the location, direction and intensity of the forces and stresses on the wearing elements can be used to know their condition in terms of wear and their potential remaining useful life. This kind of data can be used by the machine or the machine operator to adjust how the machine (and especially the wearing elements) engages and loads the geomaterial in terms of force, angle, speed etc. Likewise, the machine envelope and / or the commands issued by the operator can be modified to limit the movements of the machine or the excavation implement or even to modify the activities in the quarry, subjecting the condition or remaining useful life of the wearing elements. Summary of the Invention [Problem to be solved by the invention]

[0005] There is a need to measure the strain in wear elements in a reliable and cost-effective manner so that forces and / or stresses can be determined based on the measured strain. [Means for solving the problem]

[0006] A first aspect relates to a sensor device comprising at least one body, a first plurality of strain measuring sensors arranged on one or more of the at least one body such that the first plurality of sensors measures strain in at least two different axes, the first plurality of sensors including at least four strain measuring sensors, and one or more electronic devices configured to provide a difference between measurements of two different strain measuring sensors of the first plurality for each axis of the at least two different axes.

[0007] The sensor device is mountable in a cavity of a wear element for a drilling tool of an earthmoving machine, such that the strain of the wear element can be measured by the strain measuring sensor. At least in case the sensor device has multiple bodies, the sensor device may be mountable in multiple cavities of the wear element such that one or more bodies are mounted in a cavity and one or more other bodies are mounted in one or more other cavities.

[0008] When one or more sensor devices are attached to the wear elements, e.g., mounted or introduced into cavities of the wear elements to receive the sensor devices, the sensor devices measure the strain of the wear elements, said strain being transferred from other wear elements in direct contact with the soil or excavated material, e.g., teeth, shrouds, etc. That is, the sensor devices can be attached to wear elements that have limited or no engagement with the ground, but can measure the strain of wear elements that are actively engaged with the ground. Therefore, wear elements to which the sensor devices are attached are replaced less frequently than other wear elements for which a measurement of strain is desired. In the context of the present disclosure, strain refers to unit microdeformations of the material and / or fibers of the wear elements, as caused by forces / stresses exerted on the wear elements during the operation of the earthmoving machine.

[0009] The use of at least four strain measuring sensors allows the measurement of strains at four points distributed on one or more sensor bodies which deform proportionally to the excavating tool resisting the excavating force and transmitting the excavating force from the teeth to the bucket, making it possible to determine the forces in at least two perpendicular force axes, but also in up to three perpendicular axes in a Cartesian coordinate system, which is particularly useful for determining the efficiency at least in the operation of the machine.

[0010] The one or more electronic devices receive and process the measurements of the strain measuring sensors to provide at least a difference between them in each of two perpendicular axes, e.g., the difference between the measurements along the horizontal (or transverse) and vertical axes, where the difference value is relative to the axis corresponding to the arrangement of the strain measuring sensors, and potentially two other axes, including two non-perpendicular axes, which is typical when there are four or more of the first plurality of strain measuring sensors.

[0011] The strain measuring sensors on the sensor device are arranged such that at least one pair of sensors measures the strain with respect to a first axis and another pair of sensors measures the strain with respect to a second axis. The sensors of each pair are spaced apart from each other along the axis along which the strain is measured, resulting in two different strain measurements along the same axis. The difference between the two strain measurements represents the load on the wear element to which the sensor device is attached. When a load is applied, typically one sensor of the pair of sensors measures a traction resulting from a small deformation of at least one body that expands the surface on which the sensor is located, and the other sensor of the pair of sensors measures a compression resulting from a small deformation of at least one body that compresses the surface on which the sensor is located. However, in some cases, such a load may not cause opposite small deformations in the part on which the two sensors are located. This is because it may depend on the shape of the body or wear element on which the sensors are located and how it deforms, for example, the two parts may be compressed, but one part more compressed than the other part.

[0012] In some embodiments, the one or more electronic devices are configured to provide force values ​​in at least two different axes, with the force value in each axis being provided based on measurements of two different strain measuring sensors of the first plurality of strain measuring sensors, and more particularly, based on a difference between the measurements in each axis.

[0013] In some embodiments, the one or more electronic devices are configured to transmit, in a wired or wireless manner, the difference in measurements of the first plurality of strain measuring sensors to one or more other devices remote from the sensor device, thereby enabling the one or more other devices to provide force values ​​in at least two different axes.

[0014] One or more electronic devices process the strain measurements of each sensor to quantify, either analog or digital, the difference in strain experienced by the sensor device in each axis, thereby enabling subsequent determination of a force value. By processing the type of strain with the sign of the measurement, the direction in which the force is being applied to the assembly can be determined at the sensor device, or at one or more devices remote from the sensor device when the difference value is provided. The same processing is applied to at least two pairs of sensors, enabling acquisition of two-axis force values. The one or more remote devices may be within the earthmoving machine or at a location remote therefrom, such as a control center, an operator's wireless device, etc.

[0015] The sensitivity in determining the force along each axis depends on the strain difference resulting from the measurements of the corresponding strain measuring sensor, which in turn depends on the deformability (i.e. the level of deformation) of the parts of the device on which said sensors are located. The greater the deformability of these parts, the higher the sensitivity. Also, a factor that determines the accuracy with which the force along each axis is determined is the independence of the deformation along one axis with respect to the deformation along the axis perpendicular to it, i.e. the force is determined more accurately if the force along one axis causes little or no deformation along the perpendicular axis.

[0016] In some embodiments, the one or more electronic devices are configured to provide a combined measurement value of some or all of the strain measuring sensors of the first plurality of strain measuring sensors for a third axis of at least two different axes (i.e. the at least two different axes have three axes, preferably three perpendicular axes, e.g. horizontal (or lateral), vertical and longitudinal), the third axis being different from the first and second axes in which a difference between measurements of a pair of strain measuring sensors is provided.

[0017] In some embodiments, the one or more electronic devices are configured to provide force values ​​in three axes, preferably three orthogonal axes, for example horizontal (or lateral), vertical, and longitudinal.

[0018] In some embodiments, the one or more electronic devices are configured to transmit combined measurements of some or all of the strain measuring sensors of the first plurality of strain measuring sensors from the sensor device to one or more remote devices in a wired or wireless manner, thereby enabling the one or more remote devices to provide a value of the force in the third axis.

[0019] To provide the third axis force value, the electronic device combines measurements of some or all of the first plurality of strain measurement sensors to derive a traction or compression force value. The combination of values ​​measured by the sensors indicates whether the force applied to the sensor was a traction or compression force, because at least some of the sensors experienced traction or compression as some force was applied to the assembly when the drilling implement contacted the material. In this sense, the force is a traction or compression force, depending on the sign of the obtained value.

[0020] The combination of the measurements can be done, for example, by arithmetic sum of the measurements, the results of which can be averaged for an accurate magnitude value. The force value of the two first axes is obtained from the difference in strain between pairs of sensors, whereas the force value of the third axis is obtained from the positive combination of the strains of all sensors. This is because if there is compression or traction along the third axis, the infinitesimal deformation in the sensor arrangement in this axis is compression or traction, and the difference value between the measurements of pairs of sensors will yield a result of 0 or close to 0, since the same compression or traction is being measured by each sensor.

[0021] Notwithstanding the above, in some embodiments the first plurality of strain measuring sensors includes at least six strain measuring sensors arranged on at least one body such that the first plurality of sensors measures strain in three different axes, in such a case a third pair of sensors is arranged to measure strain in the third axis in the same manner as the strain in the other two axes is measured with pairs of sensors.

[0022] In some embodiments, the first plurality of strain measuring sensors is positioned to measure a strain corresponding to a shear force or stress. The first plurality of strain measuring sensors includes at least six strain measuring sensors.

[0023] At least one pair of strain measuring sensors may be arranged such that it forms an angle between 30° and 60°, preferably as close as possible to 45°, with respect to the first plurality of other strain measuring sensors, so that a shear force or stress can be calculated. In this way, the distance or position at which the wear element is loaded can be calculated from the measurements of the pair(s) of strain measuring sensors.

[0024] In the context of this disclosure, shear stress is the stress or component thereof that is tangential to the force or plane on which the force acts.

[0025] In some embodiments, the sensor apparatus further includes a second plurality of strain measuring sensors arranged on the at least one body, the number of the second plurality of strain measuring sensors being equal to or less than the number of the first plurality of strain measuring sensors, and each strain measuring sensor of the second plurality being arranged adjacent to and perpendicular to a different strain measuring sensor of the first plurality.

[0026] The use of additional strain measurement sensors allows compensation for temperature effects. Temperature can change the measurements of the first plurality of strain measurement sensors, so that the measurements for each axis are adjusted based on the values ​​of the second plurality of strain measurement sensors. Compensating for these effects improves the accuracy of both the measurements (and the deltas provided based on those measurements) and the force values.

[0027] Preferably, the number of sensors in the second plurality is equal to the number of sensors in the first plurality so that a correction can be made to the measurements of all strain measuring sensors in the first plurality.

[0028] In some embodiments, the sensor device further includes one or more (first) cables electrically connected to one or more of the first plurality of strain measuring sensors (and one or more of the second plurality of strain measuring sensors, if present) and either one or more electronic devices or at least one printed circuit board containing the one or more electronic devices.

[0029] In some embodiments, the sensor device further includes one or more (first or second) cables, the one or more cables being electrically connected at a first end thereof to one or more electronic devices or at least one printed circuit board including one or more electronic devices, and the one or more second ends of the one or more cables being connected or connectable to one or more other devices remote from the sensor device.

[0030] In some other embodiments, the one or more electronic devices, or at least one printed circuit board including the one or more electronic devices, comprises a wireless communication module for transmitting data in a wireless format to the one or more other remote devices.

[0031] In some embodiments, each of the first plurality of strain measuring sensors has an orientation of α=(n·360°) / N with respect to a first surface of the at least one body and is disposed on the at least one body with different values ​​for n, where n is a natural number ranging from 0 to N−1 and N is equal to the number of the first plurality of strain measuring sensors.

[0032] The strain measuring sensors are arranged evenly on the surface of the sensor device, preferably in one or more transverse planes having a normal vector parallel to one of the three axes of the sensor device, preferably the longitudinal axis. In this way, the strains experienced by different sides of the cavity in which the sensor devices are arranged and which are reproduced in the at least one body can be measured with greater precision in two or three different axes.

[0033] In some embodiments, at least one body is polyamide, polypropylene, or polycarbonate.

[0034] The material that partially or completely fills the cavity should have sufficient stiffness to deform the at least one body, since the strain of the wear element transferred to the material that fills the cavity partially or completely will be transferred more effectively to the at least one body if the filling material is able to transfer the small deformation of the wear element to the at least one body. Furthermore, the at least one body is preferably less stiff (i.e. softer) than the means for attaching the sensor (i.e. the material that fills the cavity) and more effectively deformed by said means. For example, and without limitation, the at least one body is one of the materials mentioned above. In some of these embodiments, the material that fills the cavity has a reduced hardness.

[0035] In some embodiments, at least one body comprises or has a cylindrical or prismatic shape.

[0036] In some embodiments, the at least one body is a single body including a cavity or through-hole that hollows out the sensor device, or the at least one body includes multiple bodies coupled thereto such that a cavity or through-hole that hollows out the sensor device is formed. The at least one body includes multiple channels formed on the exterior of the at least one body, each channel being formed between two outer surfaces of the at least one body, and one or more electronic devices (and / or at least one printed circuit board, if any) are introduced into the cavity or through-hole of the at least one body. The first multiple strain measuring sensors (and the second multiple strain measuring sensors in embodiments in which the assembly includes it) are disposed on one or more outer surfaces of the at least one body, and each of the one or more cables of each strain measuring sensor extends between the one or more electronic devices or the at least one printed circuit board and the respective strain measuring sensor, with a portion of the cable extending through one of the multiple channels.

[0037] The sensor device is compact in size and, in some embodiments, contains all the electronics required for its operation, including a power supply means such as one or more batteries.

[0038] The cable does not protrude from the sensor device, since a channel for routing the cable is formed between the strain measuring sensor and the electronic device and / or the printed circuit board, and the electronic device and / or the printed circuit board are arranged in a cavity or through-hole of the body, so that they are protected by the at least one body and do not further increase the volume of the sensor device.

[0039] In some embodiments, one or more of the at least one body are molded to each have a cavity or through-hole formed therein, i.e., the body is hollow. In some of these embodiments, one or more electronic devices (and / or at least one printed circuit board, if any) are introduced into the cavity or through-hole of the one or more bodies, and a first plurality (or a second plurality in those embodiments in which the assembly includes one) of strain measuring sensors are disposed on one or more interior or exterior surfaces of the one or more bodies.

[0040] The hollow body can be characterized by shapes such as, but not limited to, cylindrical, oval, square, rectangular, etc.

[0041] In some embodiments, at least one end of the body is wider than the remainder of the body, i.e., the wider end has a greater width or diameter than the remainder of the body, In some of these embodiments, the body has one or more grooves and / or holes in the wider end.

[0042] The grooves or holes can direct strain deformation from the body to the strain measuring sensor with little or no reduction in the magnitude of the deformation, and can also reduce the temperature reaching the components of the sensor device during the welding operation.

[0043] To protect the sensor arrangement, in particular the electronics and the plurality of strain measuring sensors from external dust, dirt and collisions, a cover of the sensor arrangement can be arranged at the wide end of the body.

[0044] In some embodiments, at least one body has a roughened surface on its exterior. In some embodiments, the roughened surface is at least on each end of the at least one body. In some embodiments, the roughened surface includes ribs formed on the exterior portion.

[0045] The rough surface provides, on the exterior of the at least one body, greater friction between the sensor device and its surroundings, thereby reducing the mobility of the sensor device within the cavity and providing greater transferability of deformations of the wear elements to the sensor device. For example, if the sensor device is surrounded by material, for example, of a potting process, the greater friction between the body and the hardened flowable material limits the movement of the sensor device while allowing the sensor device to deform further.

[0046] In some embodiments, at least one body is a weldable material. In some embodiments, the weldable material is 30CrNiMo8 or 42CrMo4.

[0047] By manufacturing the at least one body from one of the aforementioned steels, the measurements of the sensor device are more reliable, especially if the sensor device is attached to the wear element by providing a welded seam therebetween, since the toughness of the at least one body is considerably higher and, moreover, the at least one body may be less porous than other materials, both of which allow the at least one body to undergo more deformation before breaking.

[0048] Preferably, at least one body has a hardness similar to that of the wear element or is less hard, i.e. softer, than the wear element. When such a hardness value relationship exists, strain is transferred to a greater level to the sensor device.

[0049] In some embodiments, the sensor device further comprises a cover comprising a steel material, the cover being coupled to the at least one body or being coupleable to a wear element (on which the sensor device is disposed) such that a cavity is formed therebetween (i.e., between the cover and the at least one body), the at least one body being a single body, the one or more electronic devices (and / or at least one printed circuit board, if present) being introduced into the cavity formed between the cover and the at least one body, and the first plurality (and second plurality, if present) of strain measuring sensors being disposed on one or more outer surfaces of the at least one body.

[0050] The cover protects the strain measuring sensor from particulates that would alter the electrical signal provided by the sensor, and also protects electronics embedded within the sensor device, such as wiring (if any) connecting one or more other devices remote from the sensor device or the wear element assembly containing the sensor device, for example wiring connecting to a power source that electrically powers the sensor device, from material pressure and wear. The electronics, in some embodiments, include a current carrying means, such as one or more batteries, in which case there may be no electrical wiring connecting the sensor device to other devices remote therefrom.

[0051] The electronic device and / or the printed circuit board are arranged in a cavity of the body and are therefore protected by the at least one body and do not increase the volume of the sensor device.

[0052] There may be some gap between the cover and the at least one body to avoid transmission of a blow from the cover to the body when the former is struck, and therefore preferably the cover does not contact the at least one body.

[0053] In some embodiments, the cover has a shape such that it covers and protects at least some or all of the first plurality (and second plurality, if present) of strain measuring sensors when the cover is coupled to at least one body or to a wear element on which the sensor device is disposed.

[0054] In some embodiments, the sensor apparatus further includes one or more shells, at least a portion of which is interposed between the at least one body and the cover, the shells being arranged to close a cavity formed between the at least one body and the cover, hi some embodiments, the shells are arranged to also cover some or all of the first plurality (and second plurality, if present) of strain measuring sensors.

[0055] The shell provides an additional layer of protection for the sensor device and its contents, with water tightness. In this sense, the shell covers at least the contents of the cavity formed between the at least one body and the cover. For example, in some embodiments, the shell covers one or more of the following: one or more electronic devices, at least one printed circuit board, one or more electrical cables or wires connecting the sensor device to one or more other devices remote from the assembly, electronics, etc. Also, since the wear element assembly is subject to shocks, if the sensor device is attached to the wear element, the shell can reduce the possibility of cables becoming detached from parts of the sensor device.

[0056] Additionally, by enclosing the cavity, the shell renders the cavity volume watertight, thereby preventing the ingress of water, particles, dust, etc. that may damage or destroy components within the cavity, and also protects the components within the cavity from forces applied to the sensor device that may, for example, alter the electrical signal provided.

[0057] In some embodiments, the first plurality (and in embodiments in which the assembly includes the second plurality) of strain measuring sensors are strain gauges or piezoelectric sensors.

[0058] In the context of this disclosure, a strain measurement sensor capable of measuring strain in more than one dimension, i.e., along more than one axis, is considered to be a multiple strain measurement sensor, specifically one sensor per dimension or axis, e.g., a T-rosette strain gauge capable of measuring strain along two axes is two strain gauges.

[0059] A second aspect relates to a wear element assembly for an excavating implement of an earth moving machine comprising: a wear element adapted at least for coupling with the excavating implement and / or another wear element for the excavating implement, the wear element comprising a cavity, a sensor device according to the first aspect, and means for mounting the sensor device inside the cavity.

[0060] The wear element has a cavity for receiving a sensor device for measuring the strain of the wear element, the cavity providing physical protection for the sensor device and, therefore, the cavity is sized to fit or is larger than the sensor device.

[0061] The mounting means mounts the sensor arrangement in the cavity such that strain in the wear element is coupled to the strain measuring sensor while maintaining the sensor arrangement within the cavity.

[0062] In some embodiments, the means for attaching includes a material that at least partially fills the cavity with the sensor device introduced into the cavity, hi some embodiments, the material is one of a thermosetting plastic, a silicone rubber gel, and an epoxy resin.

[0063] The material is preferably a flowable material that hardens after a period of time following its application. This material can be applied by a potting process, whereby the cavity is filled or partially filled with the material while the sensor device is introduced therein.

[0064] The material is watertight, which helps protect the sensor unit and its components from particles, water, etc. It also reduces the amount of slack in the cable that is placed inside the sensor unit, which reduces the risk of the cable accidentally becoming disconnected while the machine is in operation or during maintenance work.

[0065] In some embodiments, at least a portion of the cavity comprises a cylindrical shape and at least one body of the sensor device comprises a cylindrical shape.

[0066] In some embodiments, at least a portion of the cavity comprises a rectangular prism shape and at least one body of the sensor device comprises or has a rectangular prism shape.

[0067] In some embodiments, the assembly further comprises one or more lids respectively introduced into the openings of the cavities of the wear elements, hi some embodiments, each lid comprises an opening adapted for the introduction of one or more cables.

[0068] The lid reduces the probability of external fines or particles coming into physical contact with either the material filled in the cavity or the sensor device. Since force is required to remove the lid, the lid likewise reduces the possibility of the sensor device leaving the cavity during operation of the earthmoving machine. The lid does not exclude the possibility of connecting one or more cables to the sensor device from outside the cavity, e.g. for communication of data and / or for energizing the sensor device, since openings are preferably provided for this purpose.

[0069] In some embodiments, the means for attaching includes a plurality of weld seams between at least one of the body and the cavity.

[0070] In some embodiments, the plurality of weld seams includes four weld seams, each preferably located at a different corner of the at least one body and contacting a cavity of the wear element, hi some embodiments, a sum of the thicknesses of the four weld seams is greater than a thickness of a centralmost portion of the at least one body of the sensor device.

[0071] The four welded seams improve the transmission of strain and force along three orthogonal axes to the sensor body and allow their measurement.

[0072] A weld seam transmits and withstands said strains and forces more reliably when its combined thickness is greater than the thickness of at least one of the bodies. In this sense, all thicknesses are measured along a common orthogonal axis.

[0073] Moreover, said capacity to transmit and withstand strains and efforts is greater whenever said relationship between thicknesses is satisfied for two different orthogonal axes, said two axes being preferably axes defining at least one cross-section of the body, characterized in that in its most central portion and with its smallest surface.

[0074] In some embodiments, the wear element includes one of an adapter, a cast nose, a welded nose, a cast lip (or a portion thereof), or a shroud.

[0075] In some embodiments, the assembly further comprises one or more devices separate from the sensor device.

[0076] The one or more devices may receive data from the sensor apparatus, in either wired or wireless form, such as, for example, differences between measurements of the strain measuring sensors and / or combined measurements of some or all of the strain measuring sensors as described above in the first aspect. The one or more devices may include one or more processors and / or electronics configured to process the data received from the sensor apparatus and provide force values ​​in two or more axes.

[0077] In some embodiments, the cavity is formed in an outer surface of the wear element, such as an outer surface of the adapter, such as its top surface (opposite its bottom surface which is typically closer to the soil during ground-engaging operations), or a side surface thereof.

[0078] In some embodiments, the cavity is formed adjacent to a hole or through-hole adapted to receive a fastening means, such as a fastening pin, intended to securely attach the wear element to another wear element. In some embodiments, the cavity is parallel to the fastening means hole or through-hole. In some embodiments, the cavity is at a greater distance from the front end of the wear element than from the front end of the fastening means hole or through-hole.

[0079] In some other embodiments, the cavity is formed in an inner surface of the wear element, such as an inner surface of an adapter that is intended to receive the lip.

[0080] In some embodiments, the cavity has two openings, thereby forming a through hole.

[0081] A third aspect relates to an earthmoving machine comprising a drilling implement and one or more sensor devices according to the first aspect and / or one or more wear element assemblies according to the second aspect.

[0082] The earthmoving machine comprises one or more sensor devices and / or wear element assemblies capable of measuring the strains to which the wear elements are subjected in a reliable, simple and cost-effective manner. The sensor devices used therefor are furthermore protected and therefore capable of withstanding the large loads applied to the excavation implement.

[0083] A fourth aspect relates to a method comprising the steps of: introducing a sensor device into a cavity of a wear element for a drilling implement of an earth moving machine; arranging a first plurality of strain measuring sensors on at least one body of the sensor device, the first plurality of strain measuring sensors including at least four strain measuring sensors; mounting the sensor device into the cavity when the sensor device is introduced into the cavity; measuring strain of the at least one body with the first plurality of strain measuring sensors in at least two different axes; and providing with one or more (first) electronic devices, for the at least two different axes, a difference between measurements of two different strain measuring sensors of the first plurality for each axis of the at least two different axes.

[0084] To measure strain in two axes, at least two sets of the first plurality of strain measuring sensors are arranged on at least one body such that the sensors of each set are spaced apart along at least the axis along which strain is to be measured and are positioned at locations that cause strain differences between the strains present at said locations.

[0085] The one or more electronic devices providing the difference between the measured values ​​are preferably arranged within the wear element, in particular within or on the sensor device.

[0086] In some embodiments, the method further includes providing, using the one or more (first or second) electronic devices, force values ​​in at least two different axes, with the force values ​​in each axis being provided based on measurements of two different strain measuring sensors of the first plurality, more particularly based on the difference between the measurements.

[0087] The one or more electronic devices providing the force values ​​may be the same as the one or more electronic devices providing the difference between the measurements (i.e., one or more first electronic devices) or may be different (i.e., one or more first electronic devices and one or more second electronic devices).

[0088] The one or more electronic devices providing the force values ​​may be located within the wear element, in particular within or on the sensor device, or may be remote from the sensor device, optionally remote from the wear element.

[0089] In some embodiments the sensor device is a sensor device as described in the first aspect.

[0090] In some embodiments, the sensor device and the wear element form a wear element assembly according to the second aspect, i.e. the sensor device, the wear element or its cavity have features as described with reference to the second aspect, including features as described with reference to the embodiments of the second aspect.

[0091] In some embodiments, the method further comprises providing a combined measurement value of some or all of the strain measuring sensors of the first plurality of strain measuring sensors for a third axis of the at least two different axes (i.e., the at least two different axes comprises three axes, preferably three perpendicular axes), the third axis being different from the first and second axes for which a difference between measurements of a pair of strain measuring sensors was provided.

[0092] In some embodiments, the provision of force values ​​is performed in three different axes and a force value in a third axis is provided based on measurements of some or all of the first plurality of strain measuring sensors, in particular based on combined measurements of some or all of the first plurality of strain measuring sensors.

[0093] In some embodiments, the method further includes providing, with the one or more (first or second) electronic devices, a value of the shear force or a point of application of force to the wear element based on measurements of a first plurality of two different strain measuring sensors positioned at an angle between 30° and 60° relative to the first plurality of other strain measuring sensors. The first plurality of strain measuring sensors includes at least six strain measuring sensors.

[0094] In some embodiments, the method further includes disposing a second plurality of strain measuring sensors on one or more of the at least one body, where a number of the second plurality of strain measuring sensors is equal to or less than a number of the first plurality of strain measuring sensors, each strain measuring sensor of the second plurality being disposed adjacent to and perpendicular to a different strain measuring sensor of the first plurality, and providing the force value is further performed based on measurements of all strain measuring sensors of the second plurality.

[0095] In some embodiments, the method further includes electrically connecting one or more electronic devices, or at least one printed circuit board including one or more electronic devices, to each of the first plurality (or the second plurality in embodiments where a second plurality is disposed) of strain measuring sensors with one or more respective cables.

[0096] In some embodiments, the method further includes transmitting, in wired or wireless form, differences between the measurements of the first plurality of strain measuring sensors to one or more other devices remote from the sensor device, thereby enabling the one or more other devices to provide force values ​​in at least two different axes.

[0097] In some embodiments, the method further includes transmitting the combined measurements of some or all of the strain measuring sensors of the first plurality of strain measuring sensors from the sensor device to one or more remote devices in a wired or wireless format, thereby enabling the one or more remote devices to provide a force value in the third axis.

[0098] In some embodiments, the method further comprises the step of disposing a first plurality of strain measuring sensors on the at least one body such that each of the strain measuring sensors has an orientation of α=(n·360°) / N with respect to a first surface of the at least one body and has a different value for n, where n is a natural number ranging from 0 to N−1, and N is equal to the number of the first plurality of strain measuring sensors. In some embodiments, attaching the sensor device to the cavity includes at least partially filling the cavity with a flowable material when the sensor device is introduced therein, and hardening or waiting for the flowable material to harden when at least partially filling the cavity.

[0099] In some embodiments, the method further comprises filling the sensor device or portion thereof with a flowable material, hi some embodiments, filling the sensor device or portion thereof is performed with the sensor device or portion thereof in a mold.

[0100] In some embodiments, the method further comprises allowing the flowable material to harden or wait for it to harden before introducing the sensor into the cavity. In some embodiments, filling the sensor device or part thereof comprises providing an exterior of the sensor device or part thereof with a roughened surface and / or protruding members or ribs of the flowable material.

[0101] In some embodiments, the flowable material is one of a thermosetting plastic, a silicone rubber gel, and an epoxy resin.

[0102] In some embodiments, the at least one body is a single body including a cavity or through-hole through which the sensor device is hollow, or the at least one body includes multiple bodies coupled thereto such that a cavity or through-hole through which the sensor device is hollow is formed, the at least one body includes multiple channels formed on the exterior of the at least one body, each channel being formed between two exterior surfaces of the at least one body, the method further comprising the step of introducing one or more electronic devices (and / or at least one printed circuit board, if any) into the cavity or through-hole of the at least one body, In the step of arranging a plurality (or a second plurality in an embodiment where a second plurality is arranged) of strain measuring sensors, the strain measuring sensors are arranged on one or more outer surfaces of at least one body, and the step of electrically connecting each of the first plurality (or the second plurality in an embodiment where a second plurality is arranged) of strain measuring sensors to one or more electronic devices or at least one printed circuit board includes extending each of one or more cables of each strain measuring sensor between the electronic device or at least one printed circuit board and the respective strain measuring sensor, a portion of which extends through one of the multiple channels.

[0103] In some embodiments, one or more of the at least one body are shaped to each have a cavity or through hole formed therein. In some of these embodiments, the method further includes introducing one or more electronic devices (and / or at least one printed circuit board, if any) into the cavity or through hole of the one or more bodies, and in the step of disposing the first plurality (and, in those embodiments where a second plurality is disposed, the second plurality) of strain measuring sensors, the strain measuring sensors are disposed on one or more interior or exterior surfaces of the one or more bodies.

[0104] In some embodiments, the method further comprises introducing a lid into the opening of the cavity (or cavities) of the wear element. In some embodiments, the lid comprises an opening adapted for the introduction of one or more cables.

[0105] In some embodiments, attaching the sensor device to the cavity includes welding portions of the at least one body and the cavity.

[0106] In some embodiments, the method further includes coupling a cover comprising steel onto the at least one body or wear element such that a cavity is formed between the cover and the at least one body, the at least one body being a unitary body in contact with the cavity, and introducing one or more electronic devices (and / or at least one printed circuit board, if present) into the cavity formed between the cover and the at least one body. And in the step of disposing a first plurality (or a second plurality in embodiments where a second plurality is disposed) of strain measuring sensors, the strain measuring sensors are disposed on one or more outer surfaces of the at least one body.

[0107] In some embodiments, the method further comprises disposing a shell, at least a portion of which is interposed between the at least one body and the cover, such that the shell closes said cavity formed between the at least one body and the cover, hi some embodiments, the shell is disposed to also cover some or all of the first plurality (or the second plurality in embodiments where a second plurality is disposed) of strain measuring sensors.

[0108] In some embodiments, the method further includes manufacturing at least one body by one of forging, micro fusion casting, machining, or a combination thereof (e.g., at least one body cast by micro fusion and then machined).

[0109] For example, a forged body (or at least one body in the case of two or more bodies) is characterized by low porosity and high toughness, both of which are advantageous for the body to support deformation before it breaks. By accepting larger deformations, the sensor device can measure larger strains.

[0110] In some embodiments, the method further includes attaching the wear elements to the excavating implement, and operating the earthmoving machine after attaching the wear elements.

[0111] A fifth aspect relates to a wear element for a mining implement of an earthmoving machine comprising one or more cavities; a first plurality of strain measuring sensors, each sensor disposed within a cavity of the one or more cavities, the first plurality including at least four strain measuring sensors, the arrangement of the sensors of the first plurality being for measuring strain in at least two different axes; means for mounting each strain measuring sensor of the first plurality in a respective cavity; and one or more electronic devices configured to provide, for each axis of the at least two different axes, a difference between measurements of two different strain measuring sensors of the first plurality.

[0112] The wear element itself can function as a load cell, whereby the strains of different parts of the wear element are measured with a strain measuring sensor. The wear element is preferably adapted to couple with at least the excavation implement and / or another wear element for the excavation implement.

[0113] The one or more cavities protect the strain measuring sensor from impact and wear during operation of the earth moving machine, and likewise reduce the likelihood of the sensor falling off the wear element despite the means for mounting the sensor thereto.

[0114] The means for attaching the sensor may be any known in the art, such as an adhesive or resin, and may be as specifically described with reference to at least the second aspect.

[0115] The measurements provided by the sensor are processed by one or more electronic devices in the same way as described with reference to the first embodiment.

[0116] In some embodiments, one, some, or all of the strain measuring sensors of the first plurality of strain measuring sensors are embodied in a sensor device as described in the first aspect. In some embodiments, some or all of the strain measuring sensors are embodied in the same sensor device, while in some other embodiments, some or all of the strain measuring sensors are embodied in different sensor devices.

[0117] In some embodiments, the wear element includes one of an adapter, a cast nose, a welded nose, a cast lip (or a portion thereof), or a shroud.

[0118] In some embodiments, the one or more electronic devices are configured to provide force values ​​in at least two different axes, with each force value in the axis being provided based on measurements of two different strain measuring sensors in the first plurality.

[0119] In some embodiments, the one or more electronic devices are configured to provide a combined measurement of some or all of the strain measuring sensors of the first plurality of strain measuring sensors for a third axis of the at least two different axes.

[0120] In some embodiments, the one or more electronic devices are configured to provide force values ​​in three different axes, where a third axis force value is obtained by processing all measurements of the first plurality of sensors.

[0121] In some embodiments, the one or more electronic devices are configured to shear a force value or a point of force application on the wear element based on measurements of two different strain measuring sensors of the first plurality positioned at an angle between 30° and 60° relative to other strain measuring sensors of the first plurality.

[0122] In some embodiments, the wear element further includes a second plurality of strain measuring sensors, each sensor disposed within a cavity of one or more cavities, the number of the second plurality of strain measuring sensors being equal to or less than the number of the first plurality of strain measuring sensors, and each strain measuring sensor of the second plurality being disposed adjacent to and perpendicular to a different strain measuring sensor of the first plurality.

[0123] A sixth aspect is a method comprising the steps of: disposing one or more cavities in a wear element for an excavating tool of an earthmoving machine, or manufacturing a wear element having one or more cavities formed during the manufacturing process; attaching a first plurality of strain measuring sensors to one of the one or more cavities, the first plurality of strain measuring sensors including at least four strain measuring sensors; measuring strain of at least one body in at least two different axes with the first plurality of strain measuring sensors; and providing with one or more (first) electronic devices, for the at least two different axes, a difference between measurements of two different strain measuring sensors of the first plurality for each axis of the at least two different axes.

[0124] In some embodiments, the method further includes providing, using the one or more (first or second) electronic devices, force values ​​in at least two different axes, each force value in an axis being provided based on measurements of two different strain measuring sensors of the first plurality.

[0125] In some embodiments, one, some or all of the strain measuring sensors of the first plurality of strain measuring sensors are embodied in a sensor apparatus according to the first aspect.

[0126] In some embodiments the wear element is a wear element as described in the fifth aspect.

[0127] A seventh aspect relates to an earthmoving machine comprising a digging implement and one or more wear elements according to the fifth aspect.

[0128] Similar advantages as discussed with reference to the first and second aspects are applicable to the remaining aspects of the disclosure.

[0129] In order to complete this specification and to provide a better understanding of the invention, the drawings are provided. The drawings form an integral part of this specification, illustrate embodiments of the invention, and should not be construed as limiting the scope of the invention, but merely as examples of how the invention may be implemented. The drawings include the following figures: [Brief description of the drawings]

[0130] [Figure 1A] 1A-1B and 2 show a sensor device according to an embodiment. [Figure 1B] 1A-1B and 2 show a sensor device according to an embodiment. [Diagram 2] 1A-1B and 2 show a sensor device according to an embodiment. [Diagram 3] FIG. 3 shows a sensor arrangement in a cavity of a wear element of an assembly according to an embodiment. [Figure 4] FIG. 4 shows a cross section of a wear element of an assembly according to an embodiment. [Figure 5A] 5A-5B show a sensor apparatus for a wear element assembly according to an embodiment. [Figure 5B] 5A-5B show a sensor apparatus for a wear element assembly according to an embodiment. [Figure 6] FIG. 6 shows the sensor device of FIGS. 5A-5B within a cavity of a wear element of an assembly according to an embodiment. [Figure 7] 7-8 partially illustrate a sensor arrangement of a wear element assembly according to an embodiment. [Figure 8] 7-8 partially illustrate a sensor arrangement of a wear element assembly according to an embodiment. [Figure 9] FIG. 9 illustrates an exploded view of a sensor arrangement of a wear element assembly according to an embodiment. [Figure 10]10-11 show wear elements and assemblies according to embodiments. [Figure 11] 10-11 show wear elements and assemblies according to embodiments. [Figure 12] 12-14 show several possible locations for the cavities in the wear elements of an assembly according to embodiments. [Figure 13] 12-14 show several possible locations for the cavities in the wear elements of an assembly according to embodiments. [Figure 14] 12-14 show several possible locations for the cavities in the wear elements of an assembly according to embodiments. [Figure 15] Figures 15-16 show diagrammatically the electronics for processing the measurements and providing force values. [Figure 16] Figures 15-16 show diagrammatically the electronics for processing the measurements and providing force values. [Figure 17A] 17A-17B and 18A-18B show two examples of strain measurements of a strain measuring sensor according to an embodiment. [Figure 17B] 17A-17B and 18A-18B show two examples of strain measurements of a strain measuring sensor according to an embodiment. [Figure 18A] 17A-17B and 18A-18B show two examples of strain measurements of a strain measuring sensor according to an embodiment. [Figure 18B] 17A-17B and 18A-18B show two examples of strain measurements of a strain measuring sensor according to an embodiment. [Figure 19A] 19A-19B and 20-24 show sensor devices and / or parts thereof according to embodiments. [Figure 19B] 19A-19B and 20-24 show sensor devices and / or parts thereof according to embodiments. [Figure 20] 19A-19B and 20-24 show sensor devices and / or parts thereof according to embodiments. [Figure 21] 19A-19B and 20-24 show sensor devices and / or parts thereof according to embodiments. [Figure 22] 19A-19B and 20-24 show sensor devices and / or parts thereof according to embodiments. [Diagram 23] 19A-19B and 20-24 show sensor devices and / or parts thereof according to embodiments. [Figure 24] 19A-19B and 20-24 show sensor devices and / or parts thereof according to embodiments. [Diagram 25] FIG. 25 partially illustrates a sensor device arranged on a wear element according to an embodiment. [Figure 26] FIG. 26 illustrates a cavity in a wear element for a sensor device according to an embodiment. [Figure 27] FIG. 27 shows a wear element with a sensor device according to an embodiment. [Figure 28] FIG. 28 shows a cross section of a wear element showing a cavity according to an embodiment. [Figure 29] FIG. 29 illustrates a sensor arrangement within a cavity according to an embodiment. [Diagram 30] FIG. 30 shows a sensor device according to an embodiment. [Diagram 31] 31 to 33 show components of a sensor device such as that of FIG. [Diagram 32] 31 to 33 show components of a sensor device such as that of FIG. [Diagram 33] 31 to 33 show components of a sensor device such as that of FIG. [Diagram 34] FIG. 34 shows a wear element equipped with a sensor arrangement similar to that of FIGS. [Diagram 35] FIG. 35 illustrates a sensor device according to an embodiment. [Diagram 36] FIG. 36 partially illustrates a sensor arrangement similar to that of FIG. [Figure 37] FIG. 37 shows a cross section of a sensor arrangement similar to that of FIGS. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0131] Detailed explanation FIG. 1A shows a perspective view of a sensor device 1 according to an embodiment, and FIG. 1B shows the sensor device 1 in a side view.

[0132] The sensor device 1 comprises a body 10, which in this embodiment has a cylindrical shape, N strain measuring sensors 20 and one or more electronic devices mounted, for example, on a printed circuit board 25. In this example, the strain measuring sensors 20 are provided in the form of strain gauges, while in other examples, the strain measuring sensors 20 are provided in the form of piezoelectric sensors. In this example, N is a natural number equal to 4, while in other examples it is greater than 4 and is preferably an even number, although this does not necessarily have to be the case.

[0133] The body 10 includes a portion with a number of planes 11, in this case as many planes 11 as there are strain measuring sensors, i.e. N planes 11, but in other embodiments there are fewer, more or no planes at all because the surface is completely cylindrical. On each of the planes 11 is mounted one of the N strain measuring sensors 20, which are arranged with respect to at least one first face of the body in an orientation of α=(n·360°) / N with different values ​​for n, where n is a natural number with values ​​ranging from 0 to N-1. In this embodiment with four strain measuring sensors 20, the orientations α are for example 0°, 90°, 180°, 270°. It should be noted that a tolerance in the orientation, for example ±5°, is possible, since a perfect arrangement may be complicated with respect to such orientations.

[0134] The strain measuring sensors on the side according to the diagram of Fig. 1B allow for the measurement of strain along a first axis, in particular the illustrated X-axis, and the sensors on the top and bottom according to the diagram of Fig. 1B allow for the measurement of strain along a second axis, in particular the illustrated Y-axis. Additional strain measuring sensors may be added for additional strain measurements and / or compensation for temperature effects, as known in the art.

[0135] The body 10 is shaped to have a through hole 12 formed therein. The printed circuit board 25 resides within the through hole 12 so as to remain protected, and the printed circuit board 25 may remain attached within the through hole 12 by friction, form fitting joints, screws, clamps, nuts, etc. The body 10 is also shaped to have ribs 14 formed on an exterior portion thereof, for example, on each end of the body 10. The ribs 14 increase the friction that the body 10 creates against the surrounding material to securely secure the sensor device 1 within the cavity.

[0136] One or more cables 15, shown by dashed lines only for the sake of clarity, connect each strain measuring sensor 20 to a printed circuit board 25. In this sense, each cable 15 preferably passes through a channel 13 formed on the outside of the body 10. In this sense, each cable 15 preferably passes through a channel 13 formed on the outside of the body 10. There may be as many channels 13 as there are strain measuring sensors 20, in order to avoid tangling of the cables.

[0137] The printed circuit board 25 and one or more electronic devices mounted thereon may include, for example, in this embodiment and / or some other embodiments of the present disclosure, one or more of the following devices:

[0138] - electronic equipment for reading the measurements of the strain measuring sensor 20 (including digitization of analog measurements), and / or - electronic data communication devices for transmission to and / or reception from the sensor device, whether the transmission or reception is in wired or wireless form; and / or - electronics for controlling the power supply of the electronics and / or the printed circuit board 25. To this end, these electronics can take in, stabilize and / or reduce the input power. Furthermore, the electronics can include electronics configured to protect the printed circuit board 25 and the electronics from overcurrents and / or surges; and / or - electronic devices, such as microcontrollers, configured to process digital data, e.g. data provided by electronic devices for reading the measurements, and to provide said data and / or additional data to the electronic devices for communication. In some cases, as part of the processing of the digital data, these electronic devices calculate the difference between the measurements of pairs of strain measuring sensors, and / or calculate a combination of measurements from several or all of the strain measuring sensors, and / or - at least one accelerometer to measure acceleration and tilt, and / or - at least one thermometer for measuring the temperature of the sensor device, and / or -At least one Hall effect sensor for detecting the presence of a wear element.

[0139] In these embodiments, body 10 comprises a single body, while in other embodiments, body 10 comprises multiple bodies adapted to be joined together to form a cylinder.

[0140] FIG. 2 shows a sensor device 2 according to an embodiment.

[0141] 1A-1B, but in these embodiments the body 10 has a rectangular prism shape. As will be apparent, the shape of the body 10 influences the shape of the cavity of the wear element to receive the sensor device.

[0142] FIG. 3 shows the sensor device 1 in a cavity 52 of a wear element of an assembly according to an embodiment.

[0143] The sensor device 1 is similar to that described with reference to Figures 1A-1B, although it will be apparent that other sensor devices are possible as well, including but not limited to the sensor device 2 of Figure 2.

[0144] The sensor device 1 is in a cavity 52 formed through an opening, such as the opening 50 shown in FIG. 4. Once inserted into the cavity 52, a flowable material 55 is added to fill at least a portion or all of the sensor device 1, as in these embodiments. The material 55, for example an epoxy resin, can be poured into the cavity 52 by a potting process. Once the material 55 hardens, the sensor device 1 is securely attached to the cavity 52 and further facilitates the transfer of strain of the wear element 100 to the sensor device 1. The ribs 14 of the sensor device 1 also increase the reliability of the attachment of the sensor device 1 to the cavity 52 due to contact with the material 55.

[0145] A lid 60 is added to close the opening defining the cavity 52. ​​The escape of the sensor device 1 from the cavity 52 is also limited by the lid 60. The lid 60 includes an opening in the form of a through hole through which one or more cables 70 can reach the sensor device 1 from outside the cavity 52. ​​The cables 70 may be ruggedized to increase their service life and protected from deformation, wear, breakage, etc. of the parts outside the cavity 52 by means of a protective tube 62. In other embodiments, the lid 60 is not provided and the cables 70 pass directly through the opening forming the cavity 52.

[0146] The cable 70 can transmit the measurements of the strain measuring sensor 20 towards one or more electronic or other devices in the wear element, the excavation implement or other parts of the earthmoving machine or remote from the earthmoving machine, such as a cabin, a control centre remote from the machine, etc. The cable 70 can additionally or alternatively be used for transporting electrical energy, making it possible to power the sensor device 1 when it has no means of energising it or when it has run out of stored energy.

[0147] FIG. 4 shows a cross section of a wear element 100, in particular an adapter 100, of an assembly according to an embodiment.

[0148] The adapter 100 has, relative to its longitudinal axis, a first end 101 adapted for coupling with another wear element, e.g., a tooth, an intermediate adapter, etc., and a second end 102 opposite the first end 101 adapted for coupling with a drilling implement, e.g., a bucket, a shovel, a dredge head, etc., e.g., a plate lip or its blade. The adapter 100 can be coupled to the drilling implement more securely by welding, or it can be cast on, as is known in the art. In this embodiment, the first end 101 includes a male portion (but in other embodiments the first end 101 includes a female portion) and the second end 102 is the mounting end.

[0149] The adapter 100 includes means 110 for securing the connection with another wear element. In this case, the means 110 is a through hole for receiving a pin that passes through the tooth when connected to the adapter 100. Other means 110 are possible as known in the art.

[0150] The adapter 100 has a cavity 52 formed via an opening 50 in the inner surface 105 of the adapter 100, the cavity 52 being adapted to receive the sensor device 1, 2. Depending on how the sensor device 1, 2 is positioned in the cavity 52 and how the strain measuring sensors of the sensor device 1, 2 themselves are oriented, the sensor device 1, 2 allows for the measurement of, for example, lateral strain corresponding to the illustrated X-axis and longitudinal strain corresponding to the illustrated Y-axis. However, it should be noted that depending on how the sensor device 1, 2 measures the strain, different axes may be provided in alignment. In such a case, when lateral and longitudinal strain or force values ​​are provided, as in Figures 10 and 11, the strain measurements of the sensor device 1, 2 may be resolved, for example, using trigonometry, into the illustrated X-axis and Y-axis.

[0151] One or more cables 70 can extend from the sensor devices 1, 2 to other parts of the same wear element 100 and even reach other wear elements or devices of the machine. The sensor devices 1, 2 can transmit and / or receive data via said cables 70, for example from the cabin of the machine, and / or can be powered via the cables 70, for example from the power supply of the machine.

[0152] The sensor arrangements 1, 2 are capable of making measurements, both due to the way in which they are arranged and due to the arrangement and the number of the strain measuring sensors of the sensor arrangements.

[0153] 5A-5B show a sensor device 3 for a wear element assembly according to an embodiment in side and perspective views.

[0154] The sensor arrangement 3 includes a body 10, a cover 19, a number of strain measurement sensors (not visible because of the cover 19), and one or more electronic devices and / or printed circuit boards (both not visible because of the cover 19). The sensor arrangement 3 may also include a cable protector 28, which may be rigid or flexible, through which the cables may be routed towards a wear element or other part of the earthmoving machine.

[0155] The body 10 comprises an edge adapted for mounting the sensor device 3 in a cavity of a wear element by welding, which can be seen better in figure 6. One or more weld chamfers 18 can be provided, in this way the sides of the cover 19 can extend along the weld chamfers 18 to better protect the body 10.

[0156] The body 10 may include one or more flat surfaces adapted for mounting a strain measuring sensor. Between the body 10 and the cover 19, a space or cavity may be formed for housing electronics, such as a printed circuit board and current carrying means.

[0157] FIG. 6 shows the sensor device 3 of FIGS. 5A-5B, but without the cover 19, within a cavity 52 of a wear element of an assembly according to an embodiment, the wear element being an adapter 100.

[0158] The sensor device 3 can be kept fixedly attached in the cavity 52 formed by the opening 50 by a number of weld seams 16. The weld seams 16 are formed between the end of the body 10 and the end of the cavity 52. ​​The cover 19 is also preferably welded to the cavity 52 by weld seams, preferably such that the cover 19 or its weld seams do not come into contact with the body 10 or its weld seams 16, to avoid hits on the cover that are measured by the strain measuring sensors (which are intended to measure strains present in the cavity 52 or the body 10). Furthermore, the opening 50 can also be formed with a recess or indentation 53 to allow the connection of a cable with the sensor device 3, this recess or indentation 53 being aligned with a recess or indentation 17 also formed in the body 10 for that purpose.

[0159] The location of cavity 52 allows for the measurement of, for example, lateral strain, corresponding to the illustrated X-axis, and longitudinal strain, corresponding to the illustrated Y-axis. Furthermore, this location is advantageous because it is at or is one of the largest cross-sectional areas and volumes of the adapter, and thus the formation of cavity 52 has little effect on the resistance of the adapter.

[0160] FIG. 7 partially illustrates a sensor device 3 as shown in FIGS. 5A, 5B and 6 of a wear element assembly according to an embodiment, with weld seams 16a to 16d provided between the sensor device and a cavity of a wear element (not shown).

[0161] In particular, FIG. 7 shows the body 10 in a top view, on which a strain measuring sensor 20 is attached. The illustrated extensometer 20 is a strain gauge, but it may equally be a piezoelectric sensor. An additional strain measuring sensor 20 is attached to the other face of the body 10, preferably the plane 11. In this sense, two other strain measuring sensors 20 are shown in a side view. On the lowermost face, which is not illustrated in FIG. 7, there is preferably at least one strain measuring sensor, all strain measuring sensors being preferably arranged according to α=(n·360°) / N, with their orientations being different, but with n values ​​increasing from 0 to N-1. The strain measuring sensors are strain gauges.

[0162] The thickness S of the welded seams 16a to 16d at the four corners of the sensor device 3 W (For clarity, the thickness S of the weld seam 16b) Wb The thickness S of the central part of the sensor device 3, where the strain gauge is attached, is shown. D When the weld seams 16a to 16d are larger than 0.05 mm, the weld seams 16a to 16d can better withstand the traction and compression forces (transmitted from the wear elements and before being transmitted to the sensor device 3). That is, the following relationship is preferably satisfied: S D Wa +S Wb +S Wc +S Wd , where S Wa , S Wc , S Wd is the thickness of the other three corner weld seams 16a, 16c-16d.

[0163] ​The resistance of the at least one body 10 to a force transmitted to it is greater than the resistance of the weld seams 16a-16d to a force transmitted to it. This phenomenon is even worse when considering the material of the at least one body 10 and the weld seams 16a-16d, since the steel of the at least one body 10 has superior resistance. Thus, the resistance of the weld seams 16a-16d is greater and more suitable to withstand forces when the sum of their thicknesses exceeds the thickness of the most central part of the at least one body 10.

[0164] Although this relationship is described with reference to the thicknesses shown in FIG. 7, i.e., thicknesses measured in the same plane as the illustrated YZ plane, the same relationship can alternatively or additionally be satisfied with thicknesses measured in the same plane as the illustrated XZ plane. Thus, the two thicknesses of the body 10 define the minimum cross section of the body 10. Preferably, the two relationships (i.e., thicknesses measured with respect to the XZ and YZ planes) are satisfied in order to largely withstand the forces due to the weld seams 16a-16d. It should be noted that the thickness along one axis may be equal to or different from the thickness along another (perpendicular) axis.

[0165] FIG. 8 partially illustrates a sensor device 3 as shown in FIGS. 5A, 5B, 6 and 7 of a wear element assembly according to an embodiment.

[0166] 8 is an exploded perspective view showing the body 10, the printed circuit board 25, and the cable protector 28, all of which are to reside within a cavity formed between the body 10 and a cover (not shown). The printed circuit board 25 and / or the protector 28 may be attached to the body 10 by friction, a form-fitting fit, or a series of attachment devices 29a-29d, such as screws 29a (in this case the printed circuit board 25 includes holes adapted to receive the screws 29a), clamps 29b, nuts 29c, etc.

[0167] FIG. 9 illustrates an exploded view of a sensor device 3 as shown in FIGS. 5A, 5B, 6, 7 and 8 of a wear element assembly according to an embodiment.

[0168] The sensor device 3 includes a cover 19 for the at least one body 10 of the sensor device 3 and a shell 26 for protecting a cavity between the cover 19 and the at least one body 10 .

[0169] The cover 19 includes a first portion 19a, a second portion 19b, and a third portion 19c. The first portion 19a is shaped and dimensioned to cover and protect the top of the sensor device. The second portion 19b can be welded to the cavity in which the sensor device 3 is located in order to attach the cover 19, and through the weld seam or seams, the cover 19 transfers the loads and tensions it is subjected to to the cavity and thereby does not transfer them to the electronic components of the sensor device 3. Furthermore, the second portion 19b may have two portions (one on each side) and is preferably shaped and dimensioned to cover and physically protect one or both sides of the sensor device 3. The third portion 19c is shaped and dimensioned to form a passage for the cables and / or a protector for the cables.

[0170] Both the first and second portions 19a, 19b typically cover the strain measuring sensor, thereby protecting the sensor from impacts, abrasion, etc., which are phenomena normally encountered during ground engaging operations.

[0171] The shell 26 is attached to at least one body 10 and closes the cavity that exists between it and the cover 19 when it is placed thereon. The shell 26 further protects the interior of the cavity from impacts and the ingress of water and fine powder. In addition to closing the cavity, the shape of the shell 26 can be such that it also extends to the sides of the body 10 so as to cover and thus protect one or more strain measuring sensors of the sensor device 3.

[0172] The shell 26 preferably includes teeth 27 adapted to securely attach the cover 19 to the shell 26. The teeth 27 increase friction between the shell 26 and the cover 19, which increases friction reduces accidental dislodging of the cover 19, particularly during operation of the earthmoving machine. In embodiments where a shell 26 is not provided, the teeth 27 may be disposed on at least one body 10 to achieve increased friction.

[0173] In some embodiments, the shell 26 is preferably made of a flexible material, such as an elastomer, rubber, epoxy, or the like.

[0174] FIG. 10 shows a wear element 100, in particular an adapter 100, and a wear element assembly according to an embodiment.

[0175] The adapter 100 includes a cavity 53 formed through an opening in the outer surface of the adapter 100. The cavity 53 is adapted to receive the sensor device 3. In some embodiments, such as in Figures 10 and 11, the cavity 53 is adjacent to a means for fixing the coupling 110 in the form of a through hole.

[0176] Once the sensor device 3 has been introduced into the cavity 53 , it is fixedly attached there by means of a welded seam provided between the wall of the cavity 53 and the body of the sensor device 3 .

[0177] The cable or cables 70 can extend from the sensor device 3 to other parts of the same wear element 100 and even reach other wear elements or devices of the machine. In this case, the cable or cables 70 can be routed towards a through-hole in the means 110 and, after being introduced there, can exit the means 110 through a through-hole formed between the means 110 and the inner surface 105. In this way, the cable 70 is hardly exposed and can be protected by the wear element 100 itself after the cable 70 has extended through the inner surface 105, for example in the manner shown in FIG.

[0178] 10 only one side of the adapter 100 is shown, in some embodiments a similar cavity 53 is arranged on the other side of the adapter 100, in which one or more additional sensor devices 3 are introduced. In this way, the axes along which the strain measurements are taken can be distributed among different sensor devices 3, in which case the strain measuring sensors of the different sensor devices 3 are arranged in different orientations, or multiple sensor devices 3 are provided for redundancy, in which case the strain measuring sensors of the different sensor devices 3 are arranged in the same orientation.

[0179] Only one sensor device 3 has at least four strain measuring sensors provided therein. Two sensors, e.g. on the top and bottom faces (relative to the illustrated Y' axis) of a part of the sensor device 3, provide strain measurements, the difference of which indicates the strain and / or force for the axis along which the two sensors are separated (e.g. the illustrated Y' axis). Two other sensors, e.g. on the front and bottom faces (relative to the illustrated X axis) of a part of the sensor device 3, provide strain measurements, the difference of which indicates the strain and / or force for the axis along which the two sensors are separated (e.g. the illustrated X axis). The sum of the strain measurements of the four sensors indicates the strain and / or force for the remaining axis (e.g. the illustrated Z' axis).

[0180] In the case of more than one sensor device 3, each device 3 has fewer strain measuring sensors and the determination of the force value along one or more axes can be based on the difference between the strain measuring values ​​of the different sensor devices 3. For example, if another sensor device 3 is arranged on the opposite side of the wear element 100 as represented in Fig. 10, the two strain measuring sensors are spaced apart along the X-axis, so that the force value along the X-axis can be the result of the difference between the strain measuring value of one strain measuring sensor of the illustrated sensor device 3 and the strain measuring value of one strain measuring sensor of a sensor device not shown.

[0181] The Y' and Z' axes are the own vertical and longitudinal axes of the sensor device 3, which do not correspond to the illustrated vertical axis Y and longitudinal axis Z, but to e.g. orthogonal axes defined for the blade or drilling implement receiving the wear element 100. In this case, the X axis is common to both the sensor device 3 and the wear element 100. The sensor device 3 is preferably arranged such that the measurements of the X, Y and Z axes correspond to the lateral, longitudinal and longitudinal forces withstood by the wear element 100, taking into account the angle of attack of the wear element 100.

[0182] FIG. 11 shows a wear element 100, in particular an adapter, and a wear element assembly according to an embodiment.

[0183] The adapter includes a cavity 53 on the side as in Figure 10, but in these embodiments includes two sensor devices 3 per cavity 53 that are spaced apart relative to the vertical axis (the illustrated Y-axis of the wear element 100 and the illustrated Y'-axis of the sensor device 3). Due to the different vertical positions of the sensor devices 3, the force value relative to the vertical axis can be calculated as the difference between the measurements of the strain measuring sensors 20 of both sensor devices 3, in this case such that the distance along the Y'-axis between the respective sensors is maximized.

[0184] A similar cavity 53 can be placed on the opposite side to more accurately calculate the force values ​​along the Y' axis and to calculate the force values ​​along the X axis.

[0185] It should be noted that in Fig. 10 and Fig. 11 a sensor device 3 for measuring the strain in the adapter is illustrated, but instead it is also possible to arrange the strain measuring sensor 20 directly in the cavity and mount it there in order to measure the strain. In this case, however, the need to mount each sensor on the wear element tends to make the mounting of the sensors on the wear element more cumbersome and more costly than the mounting of a sensor device in which the strain measuring sensor is provided. The mounting of the sensor device is easier than the mounting of a strain measuring sensor thanks to at least one body adapted for mounting on the wear element and also because by the time the sensor device is mounted, one or more electronic devices may already be integrated therein. Moreover, each sensor device may contain more than one sensor, for example four, or even eight if an additional sensor is provided for temperature compensation, but only one sensor device needs to be mounted each time, as opposed to mounting each specific sensor. The same applies in the case of maintenance and repairs, where the sensor device is easier to repair or replace than the sensor itself.

[0186] Figure 12 shows some locations of the adapter cavities 52. Figure 13 shows some of the cavities 52 in a perspective view.

[0187] The multiple openings 50 providing respective cavities 52 are shown for illustrative purposes only, and typically only one cavity 52 is sufficient for strain sensing by the sensor devices 1, 2, although multiple cavities 52 and sensor devices 1, 2 may be provided for more accurate measurements.

[0188] All but one of the cavities 52 shown are within the inner surface 105 of the adapter. When a sensor device is disposed within each cavity 52, one or more cables 70 are provided and routed towards the rear end 102 of the adapter for communication of measurements or force values ​​provided by the sensor device's electronics or devices. When the adapter is attached to the lip, the openings 50 are blocked by the lip, thereby protecting the cavities 52, and the cables 70 pass between the inner surface of the adapter and the outer surface of the lip.

[0189] The front end 101 of the adapter is provided with another cavity 52 on its outer surface. In such a position, the cable 70 can be routed up the side of the nose of the adapter and then optionally through the means 110 or through a channel formed in the nose (as shown) to reach said means 110. Also, another channel can be provided from the means 110 towards the rear end of the adapter 100 for cable routing.

[0190] The cabling can go all the way to the drilling implement or cabin, for example to an electronic control unit or wireless communication module that transmits data wirelessly to other parts of the earthmoving machine or to devices remote from the machine, including the control centre.

[0191] 14 shows a wear element 150, specifically a cast lip, with several locations where one or more openings 50 can be placed to provide cavities for strain measurement sensors or sensor devices. The same locations are also possible in the weld nose.

[0192] The opening 50 may be formed in the nose portion of the casting lip, typically on the exterior surface above where the teeth 160 cover, but covered by a wear cap that protects the nose portion, and thus the casting lip itself, specifically under a shroud element (not shown). The protection provided by the wear cap and the amount of distortion present in the nose portion make such a location sufficient for placement of an apparatus to measure the distortion.

[0193] Additionally or alternatively, one or more openings 50 can be formed in a portion 151 between the nose sections where the shroud is intended to be attached. The portion 151 where the shroud is received is recessed relative to the remainder of the surface of the cast nose, and the openings 50 can be located in either the top surface, the front surface, or the surface in between. When the shroud is attached, any sensors or sensor devices in any of these cavities remain protected from particulates, impacts, abrasion, etc.

[0194] 15-16 show diagrammatically the electronics for processing the measurements and providing force values.

[0195] In particular, Fig. 15 shows electronic devices 200a to 200n for supplying a voltage 202 corresponding to the measured value of the strain measuring sensors 203a, 203b expressed as impedance. The circuit provided at the terminal 201 comprises a strain measuring sensor 203a for measuring the strain, for which a force value is calculated, for example with a voltage divider, and another strain measuring sensor 203b, preferably arranged vertically (so as not to measure the deformation that the other sensor 203a measures) on the device or wear element for temperature compensation, for example a T-rosette strain gauge. In this way, the measurement voltage 202 is subject to temperature compensation. Each electronic device 200a to 200n is dedicated to the measurement of a different strain measuring sensor and is configured according to the characteristics of the sensor used. In embodiments in which temperature effects are not compensated, the second strain measuring sensor 203b is generally not present.

[0196] With reference to FIG. 16, a number of electronic devices 210a through 210n, 213 are shown.

[0197] Considering that strain measurement sensors provide low voltages, typically below 5V, the electronic devices 210a to 210n are preferably differential amplifiers in which the electrical signal at the input terminal 211a is amplified relative to the electrical signal at the other input terminal. The differentially amplified electrical signal is provided at the output terminal 212, so that a subtraction of the electrical signals at the input terminals 211a, 211b is provided together with an amplification of the resulting subtraction.

[0198] The electrical signals at the input terminals 211a, 211b can be measurements of two different strain measuring sensors (e.g. voltage 202 in FIG. 15) that measure strain relative to the same axis and output electrical signals of similar voltage. Alternatively, they can be measurements of a strain measuring sensor and a predefined reference voltage, for example, about 1.0 V. In the latter case, this is to amplify the measurement and increase its dynamic range, taking into account that the deformation of the wear element is a minute deformation, so that the measurement may not use the full dynamic range of the strain measuring sensor. As an example, the measurements when the sensor is placed in the adapter are, for example, about 1.1 V and 0.9 V. The strain represents traction for voltages above 1.0 V and compression for voltages below 1.0 V.

[0199] The electronic device 213 is a module for combining the electrical signals of the inputs 214a to 214n and produces an electrical signal at the output 215 corresponding, for example, to the sum of the inputs 214a to 214n, the average of the inputs 214a to 214n, etc. By means of the electronic device 213, it is possible to calculate the value of the difference between the measurements of the strain measuring sensors and / or the force applied to the wear element, when a plurality of strain measuring sensors are arranged to measure the strain according to axes corresponding, for example, to lateral and longitudinal strains, and the force is in an axis different from the lateral and longitudinal strain axes and thus corresponds, for example, to a longitudinal strain. For a correct combination of the electrical signals, preferably the amplified measurements are input to the electronic device 213 and an amplification is performed using a predefined reference voltage as a reference for the differential amplification, and the difference with respect to another strain measurement is not used, since it would mask the force applied to a third axis, since the difference in strain between pairs of sensors is zero or close to zero.

[0200] Although not shown, the electrical signals at output terminals 212, 215 are preferably provided to another electronic device which converts the force values ​​in the electrical signals into meaningful values, i.e., the electrical signals undergo a calibration step to provide numerical values ​​quantifying the force in each axis.

[0201] In these examples, the electronics of Figures 15 and 16 are part of an electrical circuit that handles analog signals. In other examples, the electronics are one or more digital processors (e.g., microcontrollers, digital signal processors, processing units, etc.) that receive the strain measurement sensor measurements after passing through an analog-to-digital converter and digitally process the measurements to provide force values ​​as digital data.

[0202] 17A-17B show an example of strain measurements of a strain measuring sensor according to an embodiment.

[0203] In this example, the strain measurement sensor is placed within a wear element, such as an adapter, and a normal force is applied to a tooth attached to the adapter at a location near the ground engaging end of the tooth, the force being applied from above.

[0204] Figure 17A shows strain measurements from upper and lower sensors spaced apart vertically, and Figure 17B shows measurements from side sensors spaced apart horizontally. Figure 17B shows measurements from lateral sensors, which are spaced apart horizontally. The lower sensor is preferably closer to the terrain as the earthmoving machine operates.

[0205] The first curve shows the force applied to the teeth by a dynamometer (DYN) that gradually increases over time (X-axis), while the Y-axis on the right side of the graph shows the applied force in kilograms.

[0206] As can be seen, the strain measured by the upper and lower sensors indicates compression. The difference between the two measurements makes it possible to determine the presence of a vertical force applied from the bottom (e.g., a force along the Y or Y' axis in Figures 10 and 11) since the compression measured by the lower sensor is greater than the upper sensor. A force value can be derived from the magnitude of the difference. The force value can be provided using a calibration value.

[0207] The adapter microdeforms not only in the vertical direction, but also the strain is measured by both lateral sensors, since the force applied to the tooth microdeforms the adapter along the longitudinal direction. This phenomenon is more common when the force generates a larger torque. The strain measuring sensor measures this microdeformation. The type of microdeformation is the same, in this case compression. The difference in the measurements of both sensors is close to zero, which means that no horizontal force is applied to the wear element.

[0208] Additionally, the force corresponding to the longitudinal axis (e.g., the force along the Z or Z' axis in Figures 10 and 11) can also be measured. In this case, all four sensors are measuring the small deformation in the form of compression, meaning that there is compression along the longitudinal axis. Summing the measurements of the four sensors gives a value for this axial force. Again, with a calibration value, the summed result will indicate how much force was applied; alternatively, an average can be calculated and calibrated.

[0209] Conversely, Figures 18A-18B show another example where the same configuration is provided, but the forces applied to the teeth are lateral forces (e.g., forces along the X-axis in Figures 10 and 11). In this case, small deformations of traction and compression forces are picked up and measured by the lateral sensors. The top and bottom sensors similarly measure small deformations even though the forces are lateral, but from their magnitude and type it can be determined that the predominant forces acting on the teeth are lateral.

[0210] In this example, the left sensor measures the traction micro-deformation and the right sensor measures the compression micro-deformation. Left and right can be set depending on whether you are looking at the wear element from the front (the end closest to the terrain when the earthmoving machine contacts the ground) or from the rear. The side with the stronger traction force, i.e. the side with the weaker compression force, is the side from which the force comes. So in this example the force is applied from left to right.

[0211] 17A, 17B, 18A and 18B describe an example having strain measurement sensors located above, below, left and right, which may be considered as angular arrangements of, for example, 0°, 90°, 180° and 270° or similar values, but it will be understood that other arrangements are possible as well. For example, but not limited to, angular arrangements of, for example, 25°, 115°, 205° and 295° or similar values, or, for example, 45°, 135°, 225° and 315° or similar values ​​are also possible. Furthermore, additional strain measurement sensors are possible as well.

[0212] 19A-19B show a sensor device, or a portion thereof, according to an embodiment from two different perspective views.

[0213] The sensor arrangement may be formed by two identical or similar parts 4a of the sensor arrangement as shown. Sensor arrangements formed by two parts are shown for example in Figures 25, 28 and 29. Alternatively, the sensor arrangement may be formed by a single part as shown. The choice of one or more parts depends on the arrangement of said sensors on the sensor arrangement, in particular on the positioning and spacing so as to allow the measurement of strain along two different axes.

[0214] The sensor device has at least one hollow body 10, which may be one body or several bodies joined together. In embodiments where the sensor device is divided into two or more parts, there are at least as many bodies as there are parts.

[0215] 19A-19B is wider at a first end 8 than the remainder of the body 10, in particular a second end 9 opposite the first end 8, as indicated by the arrows W1, W2, i.e., in this case the diameter of the body at the first end 8 is greater than the diameter of the body at the second end 9. The body 10 includes a base 30 at the wider end.

[0216] The base 30 may be cap-shaped or the like, thereby forming a stop that prevents the sensor device 4 from being fully inserted into a cavity sized according to a narrow portion of the sensor device 4. The base 30 may have no spaces between its portions, as in the embodiment of Figures 19A-19B, or may have different portions with one or more spaces (i.e., slots, holes) therebetween, as in the embodiment of Figures 22 and 23.

[0217] The body 10 can house electronic devices, such as, for example, electronics for measurement processing, at least one printed circuit board 25, current carrying means, etc. To that end, the body 10 has a length and width suitable for the insertion of the electronic devices. The hollow space can be filled with an elastomeric material, for example by a potting process, to further protect the device therein from dust, moisture and other particles, and also to buffer distortions.

[0218] In this example, body 10 has a circular cross-section, although other shapes of cross-section are possible within the scope of the present disclosure, including rectangular, oval, hexagonal, etc. Additionally, the sensor device and / or body 10 may include at least one poka-yoke to enforce a particular orientation of portion 4a of the sensor device when inserted into a cavity.

[0219] The body 10 and sensor device of these and other embodiments can have one, two, or no axes of symmetry, as shown, for example, in FIGS. 20 and 21.

[0220] The arrangement of the strain measuring sensors on the sensor device or parts thereof is described in relation to Figures 20 to 23.

[0221] Figure 20 shows a portion of a sensor device according to an embodiment such as the sensor device of Figures 19A and 19B. A side view showing the base 30 is shown.

[0222] The strain measuring sensor 20 is disposed on the base 30, in this example disposed on the outermost surface of the sensor arrangement. In other embodiments, the strain measuring sensor 20 is disposed on the opposite surface of the base 30, facing towards the inside of the sensor arrangement.

[0223] It is preferable to place the strain measuring sensor 20 as far away as possible, although not close to the edge of the base 30, in order to reduce the level of damage that may be incurred when attaching the sensor device to the wear element.

[0224] At least two identical or similar parts to those illustrated in FIG. 20 form a sensor device, in which two strain measuring sensors 20 are arranged on FIG. 20 allowing the measurement of strain with respect to an axis perpendicular to the illustrated vertical axis.

[0225] For ease of illustration, a peripheral weld seam 16 is shown. The peripheral weld seam 16 attaches a portion of the sensor device to the wear element. The weld seam does not have to be peripheral, and may have multiple weld seams rather than a single weld seam.

[0226] Figure 21 shows a sensor device or part thereof according to an embodiment such as the sensor device of Figures 19A and 19B, the sensor device being shown from its side.

[0227] The strain measuring sensors 20 are positioned on the sides of the illustrated body 10 along their length such that the distance to one end of each sensor 20 is less for one sensor 20 than for the other sensor 20 .

[0228] In some cases, one or more further pairs of strain measuring sensors 20 may be positioned around the periphery of the body 10, for example at the other end of the body diameter. If one or more additional pairs of strain measuring sensors 20 are positioned to measure strain along additional axes, a single component may form a sensor arrangement.

[0229] 22 and 23 show components of a sensor device according to an embodiment such as the sensor device of FIGS. 19A and 19B.

[0230] In these embodiments, the base is integrally formed (or in some embodiments mechanically joined) with a number of portions 30a, 30b having therebetween a number of grooves 33 that provide space. The grooves 33 improve the induction of strain to the strain measuring sensor and reduce welding temperatures that could otherwise damage the strain measuring sensor if the sensor device 4 is attached to the wear element by welding.

[0231] 22 shows several weld seams 16 for attaching the base to the wear element, but in this example the weld seams 16 are only provided on a portion of the circumference of the ring portion 30a adjacent to the groove 33, specifically the portion of the circumference that is radially aligned with the groove 33. The groove 33 reduces the temperature that reaches the strain measuring sensor 20 during the welding process.

[0232] The strain measuring sensor 20 is located on either the outermost or innermost surface of the portion 30b that is connected to the ring portion 30a.

[0233] FIG. 24 shows a sensor arrangement, or a part thereof 4a, depending on the arrangement and number of the strain measuring sensors.

[0234] The sensor device or part 4 a is similar to that of FIGS. 19A and 19B, but includes a cover 19 arranged at one end 8 thereof, in particular at the wide end of at least one body 10 .

[0235] The cover 19 protects the body 10 and adds another level of protection to the electronics within the sensor device. The cover 19 may be attached to a surface of the wear element, such as the cavity itself, or may be formed near the end of the cavity of the wear element with a welded seam, such as at one or more of the opening where the cavity is formed, the surface adjacent to the cavity, etc.

[0236] In some embodiments, a flexible and / or soft protective member is placed between the cover 19 and the body 10 to prevent any impact on the cover 19 from being directly transmitted to the body 10 and to ensure that any load (e.g., compression) on the body 10 is lost due to deformations that the flexible and / or soft protective member undergoes. The material of the protective member may be any known in the art, including materials that can be used in a potting process, such that in some embodiments the sensor device or parts thereof are filled with material by the potting process. In this regard, in some embodiments, parts of the sensor device or the body of the sensor device are introduced into a mold (with the electronics already placed therein) and filled with material by a potting process to fill all free space therein, as shown in FIG. 29 .

[0237] FIG. 25 shows a sensor device disposed on a wear element according to an embodiment.

[0238] The sensor device has two parts 4a, 4b, which in these embodiments are arranged in the same cavity 52 of the wear element 100, even though in other embodiments they may be arranged in different cavities. The cavity 52 may in this example be a through hole.

[0239] Cavity 52 may be, for example, but is not limited to, any of those shown in FIG. 26 or those shown in FIGS. 10-14 and may be either a blind hole or a through hole.

[0240] Within the cavity 52 in which the sensor devices 4a, 4b are arranged, further cavities or through-holes 59 may be arranged which allow the routing of one or more cables to other locations on the earth moving machine if the sensor device 4 has or is coupled to one or more cables for transmitting and / or receiving data such as strain measurements and / or force values ​​(if force values ​​are calculated).

[0241] The two parts 4a, 4b are identical in this example, but arranged one inverted with respect to the other. Each of the parts 4a, 4b includes a respective cover 19, which may also be in the cavity 52, each such cover 19 being preferably welded to the opening 50. In other embodiments, the sensor device is formed of a single part (single body or multiple bodies joined together) which preferably extends at least from one end of the cavity to the other, with a cover 19 arranged at each of the two ends.

[0242] The strain measuring sensors 20 are preferably as far apart as possible along the vertical axis of the figure, and as far apart as possible along the horizontal axis of the figure, to improve the accuracy of the calculated forces. In these embodiments, the strain measuring sensors 20 are disposed on the outer surface of each base 30.

[0243] FIG. 26 shows a cavity 52 in a wear element for a sensor device according to an embodiment.

[0244] A wear element, in this case an adapter 100, is shown with a tooth 200 attached to it. The tooth 200 is fixedly attached to the adapter 100 by fastening means such as a pin that is introduced into at least a pin receiving hole 111 in both the adapter 100 and the tooth 200.

[0245] The cavity 52 is located next to the hole 111 of the adapter 100 on the side facing the drilling tool, rather than on the side facing the tooth 200. Thus, the cavity 52 is located somewhere between the hole 111 and the inner surface 105.

[0246] This cavity arrangement is advantageous because it generally orients the strain more along the front axis (the Z-axis as illustrated) than other cavity arrangements, improving the measured magnitude of the strain and thus the calculation of forces along this axis.

[0247] Cavity 52 is connected to a cavity or through hole 59 that leads to the inside of adapter 100 and through which one or more cables 70 can pass if wired data communication is used.

[0248] The shape of cavity 52 is preferably the same as or similar to at least one body of sensor device 4, or slightly larger in size so that at least one body is disposed therein. The wide end of the body may be larger than the cross section of cavity 52, so that the wide end does not allow the sensor device to be introduced into cavity 52, thus effectively acting as a stopper. Thus, as seen in Fig. 25, sensor device 4 may be disposed flush (or nearly flush) with the outer surface of adapter 100 in which cavity 52 is formed.

[0249] FIG. 27 shows a wear element 100 with a sensor device according to an embodiment.

[0250] The wear element 100 with the sensor device 4 of FIG. 26 is shown in a different representation for clarity, in particular without the teeth 200 but with a lip 250 engaging the inner surface 105 .

[0251] FIG. 28 shows a cross section of a wear element 100 showing a cavity 52 according to an embodiment.

[0252] The wear element 100 contains a sensor device 4 in a cavity 52, the cross section of which corresponds, for clarity, to another representation of the embodiment of figures 26 and 27. The cross section is taken through a plane corresponding to the dashed line in figure 26. The illustrated axes correspond to the axes of figure 26.

[0253] The sensor device is made up of two parts 4a, 4b between which one or more cables 70 are shown, with a second cavity or through-hole 59 for routing them towards other parts of the machine, for example the cabin or elsewhere where electronics are located for processing the data, for example to calculate force values.

[0254] As can be seen, the cover 19 reaches or is close to the outer surface of the adapter 100. When the adapter is impacted by the excavated material, the material striking the adapter 100 strikes the cover 19, reducing the intensity of the load reaching the sensor arrangement and its components, thus extending its useful life. Interposing a flexible and / or soft material between the cover 19 and the body 10, as shown in Figure 29, further reduces the intensity of the load reaching the sensor arrangement.

[0255] FIG. 29 shows a sensor arrangement having two parts 4a, 4b within a cavity according to an embodiment.

[0256] The sensor device can be any of Figures 19A to 29. Each portion 4a, 4b has a flowable material 55 introduced therein by a potting process, thereby reducing or eliminating free space that may be present within each body 10. There may also be a flowable material 55 between the base 30 and the cover 19.

[0257] The potting is preferably performed outside the cavity, in particular with the entire parts 4a, 4b or bodies in a mould that is filled with a flowable material 55. The mould can be constructed to feature recesses that provide the sensor device with protruding members or ribs 56 that can surround the entire periphery of the respective body. Such protruding members or ribs 56 improve the mounting of the sensor device in the cavity by providing additional friction between them. As the protruding members or ribs 56 are flexible, the parts 4a, 4b of the sensor device can be inserted and slid into the cavity under pressure.

[0258] This figure also shows that the base 30 of each part 4a, 4b is welded to the wear element. Between the base 30 and the surface of the opening in which, in this case, the cavity is formed, one or more weld seams 16e are provided.

[0259] Furthermore, the cover 19 is welded to the wear element by means of a weld seam 19f.

[0260] In the illustrated embodiment, the strain measuring sensors 20 are disposed on the inner surface of each base 30 .

[0261] FIG. 30 shows a sensor device 5 according to an embodiment.

[0262] The sensor device 5 includes at least one body 10, preferably a cover formed by first and second portions 19a, 19b, and a number of strain measuring sensors not visible in this view. The sensor device 5 may also include at least one printed circuit board, a sensor such as a Hall effect sensor, and / or other parts or components as described with reference to Figures 31-33.

[0263] The first part 19a of the cover is intended to cover at least a part of the at least one body, and the second part 19b is an extension intended to protrude sufficiently from the first part 19a so that the cover does not contact the at least one body. When the cover is attached to the preferably wear element, a small gap is created between the cover and the at least one body, so that shocks are not transmitted from the cover to the body. By being a weldable material, the second part 19b can be welded to the wear element.

[0264] The cover may include a cutout or window in which a separate protective member 32 is placed and attached thereto, for example by screws 29a or any other means known in the art. The protective member 32 is preferably permeable to electric and / or magnetic fields so as to pass the electric and / or magnetic fields, the material of the protective member 32 being, for example, polycarbonate.

[0265] FIG. 31 shows a part of a sensor device like that of FIG.

[0266] The parts shown are at least one body 10, at least one printed circuit board 25, and a Hall effect sensor 31, which is useful for detection of a fallen wear element, if a magnet is placed on the wear element whose presence is to be monitored. The field measurable by the Hall effect sensor 31 can be received via the protective member 32. If the sensor device additionally or alternatively includes a wireless communication module, the transmission and reception of data can also take place through the protective member 32.

[0267] At least one body 10 includes one or more weld chamfers 18 for attachment to a wear element by one or more weld seams, such as weld seams 16a-16d shown in Figures 32 and 33. The weld chamfers 18 are preferably spaced apart to allow the second portion 19b of the cover to reach the surface of the wear element.

[0268] FIG. 32 shows part of a sensor arrangement similar to FIGS. 30 to 31.

[0269] The illustrated portion is a body 10 having disposed thereon a number of strain measuring sensors 20. In this embodiment there are three strain measuring sensors 20, for example and without limitation, the two sensors 20 closest to either end of the body 10 may be positioned to allow for calculation of force values ​​in at least two different axes, and the sensor 20 closest to the center of the body 10 may be positioned to allow for calculation of shear forces or stresses.

[0270] The face of the body 10 shown is either the face closest to the wear element (bottom in FIG. 31) or the opposite face (higher up in FIG. 31, between the bottom and the printed circuit board 25).

[0271] To attach the printed circuit board to the body 10, one or more screws 29a, for example, may be used.

[0272] Adjacent each weld chamfer 18 is a weld seam 16a-16d which attaches the body 10 to the surface of a wear element.

[0273] FIG. 33 shows part of a sensor arrangement similar to that of FIGS.

[0274] The portion shown is the portion nearest the cover and includes the printed circuit board 25 with the Hall effect sensor 31, the body 10 below the printed circuit board 25, the weld chamfer 18, and the weld seams 16a-16d.

[0275] FIG. 34 shows a mounting element, in particular an adapter 100, with a sensor device 5 similar to those of FIGS.

[0276] The arrangement of the sensor device 5 is similar to that of FIG. 11, with the sensor device 5 mounted on its side in the cavity 53 of the adapter 100. The sensor device 5 is preferably made up of two parts, one on each side of the adapter 100, and therefore only one part of the sensor device 5 is shown in FIG. 11. Each part includes a respective body (or bodies), a strain measuring sensor, a cover, a Hall effect sensor (if any), and electronics for processing the sensor measurements. The processed measurements of the different parts of the sensor device 5 can be processed together in one of the parts of the sensor device 5 or in a separate device remote from the sensor device 5.

[0277] FIG. 35 shows a sensor device 6 according to an embodiment.

[0278] Sensor apparatus 6 includes at least one body, a number of strain measuring sensors not visible in this view, and a cover 19. Sensor apparatus 6 may also include at least one printed circuit board, a sensor such as a Hall effect sensor, and / or other parts or components, as described with reference to Figures 36 and 37.

[0279] The cover 19 includes a protective member 32 cut out of the cover 19 to pass electric and / or magnetic fields to and from the sensor device 6 .

[0280] FIG. 36 partially illustrates a sensor device 6 similar to that of FIG.

[0281] The illustrated portions of the sensor device 6 are the body 10 together with a printed circuit board 25 mounted thereto, for example by one or more screws 29a. The device 6 includes a Hall effect sensor 31.

[0282] The strain measuring sensor can be located on the side closest to the wear element (bottom in FIG. 37) or on the opposite side (top in FIG. 37, between the bottom and the printed circuit board 25).

[0283] A weld chamfer 18 may also be provided on the body 10.

[0284] FIG. 37 shows a cross section of a sensor device 6 similar to that of FIGS. 35-36.

[0285] In this embodiment, the strain measuring sensor 20 is arranged on the surface of the body 10 closest to the surface of the wear element, e.g. the adapter 100. As shown, a recess can be provided in that part of the body 10 to avoid direct contact between the sensor 20 and the surface of the wear element. A weld seam 16e is provided between the body 10 and the cover 19 for secure attachment of one to the other. Furthermore, a weld seam 16f is provided between the cover 19 and the adapter 100 for secure attachment of one to the other.

[0286] In this text, the terms "comprises", "comprises" and their derivatives (such as "including", "comprises") should not be understood in an exclusive sense, i.e., these terms should not be interpreted as excluding the possibility that what is described and defined may include additional elements, steps, etc.

[0287] However, it is clear that the present invention is not limited to the particular embodiments described herein, but encompasses all modifications conceivable to those skilled in the art (e.g., with regard to the selection of materials, dimensions, components, configurations, etc.) within the general scope of the invention as defined in the claims.

Claims

1. Sensor device (1-6) for earthmoving machinery, comprising: at least one body (10); first plurality of strain measuring sensors (20), wherein the first plurality of strain measuring sensors are arranged on one or more bodies of the at least one body to measure strain, enabling the provision of force values ​​in at least two different axes (X, Y, Y'), and the first plurality of strain measuring sensors includes at least four strain measuring sensors (20); and one or more electronic devices (210a-210n, 213) configured to provide the difference between measured values ​​of two different strain measuring sensors of the first plurality of strain measuring sensors for each of the at least two different axes (X, Y, Y').

2. The sensor device according to claim 1, wherein the at least two different axes comprise first, second, and third axes (X, Y, Y', Z, Z'), and one or more electronic devices (210a to 210n, 213) are configured to provide combined measurements of some or all of the first plurality of strain measuring sensors (20) with respect to the third axis (Z, Z').

3. The sensor device according to claim 1 or 2, wherein one or more electronic devices (210a to 210n, 213) are configured to provide force values ​​in at least two different axes (X, Y, Y'), and the force value in each axis is provided based on the difference of the measured values ​​for each axis.

4. The sensor device according to claim 1 or 2, further comprising a lid (60) or cover (19) coupled to the body of at least one body (10) or capable of being coupled to a wear element on which the sensor device is located, wherein a cavity is formed between the body and the lid (60) or cover (19), and one or more electronic devices (210a-210n, 213) are introduced into the cavity.

5. The sensor device according to claim 1 or 2, wherein the at least one body (10) includes an edge adapted for mounting the sensor device to a cavity of a wear element by welding.

6. The sensor device according to claim 1 or 2, wherein each of the first plurality of strain measuring sensors (20) is positioned on the body of the at least one body (10) with respect to a first surface of the at least one body (10) in an orientation of α = (n・360°) / N and with different values ​​for n, where n is a natural number in the range of 0 to N-1, and N is equal to the number of the first plurality of strain measuring sensors.

7. The at least one body (10) is a single body having a cavity or through-hole (12) that makes the sensor device hollow, or the at least one body comprises a plurality of bodies coupled thereto to form a cavity or through-hole (12) that makes the sensor device hollow. The at least one body (10) comprises a plurality of channels (13) formed on the exterior of the at least one body, each channel being formed between two outer surfaces (11) of the at least one body. The one or more electronic devices (25, 210a-210n, 213) are introduced into the cavity or through-hole of the at least one body. Each of the plurality of strain measuring sensors (20) is positioned on one or more outer surfaces (11) of the at least one body, and The sensor device according to claim 1 or 2, wherein each of the strain measuring sensors comprises one or more cables (15), each of the one or more cables of each of the strain measuring sensors extends between the one or more electronic devices and each of the strain measuring sensors, and a portion of the cable extends through one of the plurality of channels.

8. A wear element assembly for an excavation tool of an earthmoving machine, A wear element (100) having cavities (52, 53), wherein the wear element is adapted to be coupled with at least the drilling tool and / or another wear element for the drilling tool, and The sensor device (1-6) according to claim 1 or 2, and A wear element assembly comprising means (16, 55) for mounting the sensor device inside the cavity.

9. The wear element assembly according to claim 8, wherein the at least one body (10) is 30CrNiMo8 or 42CrMo4.

10. The means for mounting (16, 55) comprises a plurality of welded joints (15) between the at least one body (10) of the sensor device and the cavities (12, 13) of the wear element (100), as described in claim 8.

11. The wear element assembly according to claim 10, wherein the plurality of welded joints (16) comprises four welded joints, each welded joint located at a different corner of the at least one body (10), and the sum of the thicknesses (SW) of the four welded joints is greater than the thickness (SD) of the central part of the at least one body of the sensor device.

12. The sensor device further comprises a cover (19) made of steel, the cover being coupled to the at least one body (10) or the wear element such that a cavity is formed between the cover and the at least one body (10), The at least one body of the sensor device is a single body that contacts the cavities (52, 53) of the wear element (100), The one or more electronic devices (25, 210a to 210n, 213) are introduced into the cavity formed between the bar and the at least one body, and Each of the plurality of strain measuring sensors (20) is positioned on one or more outer surfaces (11) of the at least one body. The wear element assembly according to claim 10.

13. The wear element assembly according to claim 12, wherein the cover (19) is shaped to cover part or all of each of the plurality of strain measuring sensors (20) for protection when the cover is coupled to the at least one body (10) or the wear element (100).

14. The wear element assembly according to claim 8, wherein the means for mounting (16, 55) comprises a material (16) that at least partially fills the cavity (52, 53) when the sensor device is introduced into the cavity (52, 53).

15. The wear element assembly according to claim 8, wherein the cavity (52) is formed adjacent to a hole or through-hole adapted to receive fastening means for attaching the wear element to another wear element, and the cavity (52) is parallel to the hole or through-hole for the fastening means.

16. A process of introducing a sensor device (1-6) into the cavity (52, 53) of the wear element (100) for the excavation tool of earthwork machinery, A step of arranging a first plurality of strain measuring sensors (20) in one or more bodies of at least one body (10) of the sensor device, wherein the first plurality of strain measuring sensors (20) includes at least four strain measuring sensors (20), When the sensor device is introduced into the cavity, the process involves attaching the sensor device to the cavity, A step of measuring the strain in at least one body (10) using the first plurality of strain measuring sensors, A method comprising the steps of: providing force values ​​in at least two different axes (X, Y, Y') using one or more first electronic devices, wherein the force values ​​in each axis are provided based on measurements from two different strain measuring sensors of the first plurality of strain measuring sensors.

17. The method according to claim 16, further comprising the step of providing force values ​​in at least two different axes (X, Y, Y') using one or more second electronic devices (210a-210n, 213), wherein the force values ​​in each axis are provided based on the difference between measurements of the two different strain measuring sensors (20).

18. The method according to claim 16 or 17, wherein the first electronic device is located away from the sensor device (1-6).

19. The method according to claim 16, wherein the sensor device (1-6) is the sensor device according to claim 1 or 2.

20. A step of bonding a cover (19) containing steel material to the at least one body (10) or the wear element (100) such that a cavity is formed between the cover and the at least one body, wherein the at least one body is a single body that contacts the cavity (52, 53), The process further comprises the step of introducing one or more electronic devices (25, 210a-210n, 213) into the cavity formed between the cover and the at least one body, The method according to claim 16 or 17, wherein, in the step of arranging the first plurality of strain measuring sensors (20), the strain measuring sensors are arranged on one or more outer surfaces (11) of the at least one body.

21. A wear element (100) for an excavation tool of earthmoving machinery, One or more cavities (52, 53) and A first plurality of strain measuring sensors (20), each sensor being located within the cavity of one or more cavities, the first plurality of strain measuring sensors comprising at least four strain measuring sensors, the arrangement of the first plurality of strain measuring sensors being for measuring strain that enables the provision of force values ​​in at least two different axes (X, Y, Y'), Means (16, 55) for attaching each of the first plurality of strain measuring sensors to their respective cavities, A wear element comprising one or more electronic devices (210a-210n, 213) configured to provide the difference between the measured values ​​of two different strain measuring sensors (20) of the first plurality of strain measuring sensors (20) for each of the at least two different axes (X, Y, Y').

22. The wear element according to claim 21, wherein one or more electronic devices (210a-210n, 213) are configured to provide force values ​​in at least two different axes (X, Y, Y'), and the force values ​​in each axis are provided based on the difference between the measured values ​​of the two different strain measuring sensors (20).

23. Earthmoving machine, Excavation equipment, and One or more sensor devices according to claim 1 and / or one or more wear element assemblies according to claim 8, Earthmoving machine comprising one or more wear elements according to claim 21.

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