System for obtaining data in a mining comminution system

Abstract

The invention relates to a system and method for obtaining real-time data concerning physical variables inside a mining comminution system, wherein the system comprises: data capture means (100) with a body comprising at least one electronic wear-measuring circuit (106), signal channelling means (104), a processor (105) configured to determine wear, and wireless communication means (500) for emitting an indicative wear signal; and information capture means (200) for receiving the emitted signal and sending same to a computer (201).

Description

[0001] DATA COLLECTION SYSTEM IN A COMMINUTION MINING SYSTEM

[0002] DESCRIPTIVE MEMORY

[0003] FIELD OF INVENTION

[0004] The present invention relates to the mining, cement, aggregates, comminution / grinding and data analysis industries. In particular, the present invention relates to a system and method for obtaining real-time data on physical / chemical variables inside grinding equipment that, through the analysis of load behavior, allows for more precise operational control, anticipating failures in said equipment, improving mineral processing, and determining the wear of grinding media and / or consumption of steel and polymeric materials such as rubber and / or plastics, through electronics with wear sensors, an accelerometer, a gyroscope, and a thermocouple, which are integrated in preferred configurations and in accordance with the different equipment and inputs of the mining comminution / grinding process.in order to obtain data that is processed by advanced computer systems in order to optimize and automate the chain of processes involved in the comminution stages, that is, the system and method of the present invention allows moving from a traditional comminution / grinding to one that allows performing, controlling, anticipating failures, improving mineral processing, and determining the wear of the equipment involved, in a non-invasive and easy-to-implement manner.

[0005] The present system and method for obtaining real-time data on physical / chemical variables was designed to be integrated into various systems and inputs of the comminution or grinding process, whether in mining equipment with high operational complexity or in complex environments such as the interior of mills, where the invention can be integrated into various components such as liners, balls and / or grinding bars, in order to monitor, in real time, the interior of the mill to determine the level and behavior of the load and its physical / chemical variables and level of wear determined by the consumption of steel and other materials that make up the comminution and / or grinding system, as well as the expected wear of the grinding components under certain physical conditions of the material together with the configuration, feed or energy used by the mill.

[0006] The present data acquisition system also comprises a microcontroller, capacitors, crystals where the crystals are made of quartz that are conductive and for signal processing (with a frequency between 500KHz and 60MHz and more preferably between 758KHz and 32.000 KHz), accelerometer, gyroscope, thermocouple, battery and transmitter of electromagnetic signals, where said electromagnetic signals pass to a polymer transparent to these electromagnetic signals, which can be immersed in a ball constructed of polymeric material agglomerated with solid components, to give it resistance to the operating conditions of the mill, capable of simulating the conditions of density, weight and size compared to conventional forged or cast grinding media, constituting as a whole and deployed inside grinding equipment, which, through data processing, obtains the wear, trajectory of the grinding elements, load, fill level in grinding, spraying or other equipment, which is complemented by sensors incorporated on various types of nuts in the different external bolts of the mill that perform both lifter holding tasks. 1), internal linings, mill crown, as well as structural at the flange level of the mill cylinders. With the data from at least one of these sensors in real time of the physical / chemical variables arranged in at least one of the comminution / grinding equipment that, through the analysis of the integral behavior of the load, can anticipate the failures of said equipment, determine a processing rate and steel consumption of the comminution / grinding or pulverization system, in order to optimize the internal design of linings, energy consumption, quantity of mineral, water, lime or other inputs, quality and quantity of grinding media through the contrast with the solid sensorized polymeric balls, where the complete comminution / grinding systems comprise various configurations, which can be open or closed, depending on this it can be found from the loading of the mineral to the mining truck from the extraction point,passing through different crushers, ball mills, SAG mills, rod mills, ISA-MILL mills, on surfaces or elements subject to wear, conveyor belts, sieves with or without a vibration system, mineral recirculation subsystems, truck hoppers, a means of transport and / or mining equipment such as a backhoe crawler, bucket or shovel bucket, to hydrocyclones or a mixture of them. The data obtained can be transmitted from at least one of these sensors of the physical / chemical variables in real time through wireless communication means to information capture means, to analyze the data, either from each of the sensors or through communication between these sensors. This communication between them is through small transceivers that are used to create a local positioning system, called pseudolites (known in English as pseudolites), which form a network of pseudolites,and with this, it is possible to obtain a channeling of the data to one of these sensors and they are sent to the wireless communication media.

[0007] This technology is applied to both wet and dry grinding, with one or more internal chambers, in the cement and / or aggregate industries. In mining, rocks extracted from mines undergo various processes and stages, including mining, sorting, and recovery, either by pyrometallurgical or hydrometallurgical means. The first of these stages or processes consists of mechanical crushing or grinding to separate the valuable mineral material as efficiently as possible, separating it from the waste material.

[0008] The crushing process begins at the excavation, either in a mine or on the surface, then a crushing stage follows, followed by a grinding stage to reach a fine material size suitable for the mineral extraction process, using pyrometallurgy or hydrometallurgy processes. The latter depends on the properties of the mineral, that is, its composition, sulfides or oxides, as well as the grinding technique to be used, there are multiple options that are mainly aimed at obtaining the particle size according to the process in question, said size ranges between 150 pm and 20.32 mm (8 inches) for coarser material and between 150 pm and 220 pm for finer material.

[0009] Grinding or pulverizing is a continuous process involving primary equipment, such as conveyor belts, mills, and hydrocyclones, and accessories such as water pumps, valves, motors, grinding balls, bars, or the mineral itself, which directly or indirectly influence the efficiency of the process.The result of the operation of these equipments is determined by the hardness and aggressiveness characteristics of each type, and even the batch of mineral to be processed, the design and materiality of internal linings, hardness, quantity of grinding media, with grinding balls or grinding bars, or the filling speed / energy available in the process, operating conditions that, in addition to being highly complex, also have a wide variability, conditioning the result of the process, as well as the operational life of grinding inputs such as lining, grinding media, grinding bars, lifters), bolts, nuts, washers, flange, crown, as well as the number of incidents or failures in the equipment that cause both scheduled and unscheduled stops, higher consumption of inputs, water and energy, in other words, it is applicable to wet grinding and dry grinding.

[0010] Therefore, the efficiency of the grinding or mining process is related, among other variables, to the time it takes to process the material TPH (Tons per Hour), the associated energy consumption, the use of inputs such as water, lime, grinding media, grinding bars, lifters, bolts, nuts, washers, flange, crown, the durability of these components, as well as the correct operation of pumping equipment, motors and valves, reducing operational incidents such as scheduled and unscheduled stops, failures or malfunctions of mills or inefficient operation, conveyor belts or hydrocyclones, forming a set of variables that condition or impact the processing cost, and therefore the profitability of mineral exploitation.

[0011] In this sense, the efficiency of this type of complex industrial processes, such as the grinding and pulverizing of minerals, is determined by a large number of variables: those related to the physical / chemical characteristics of the mineral to be processed, which directly affect the operating parameters of each piece of equipment involved in the grinding process, the use of water and energy, as well as the optimal operating capacities or the correct integration of the different accessory equipment, which are, as a whole, a technological challenge that must be solved with a detailed survey by capturing data corresponding to the phenomena that occur in said process from multiple points and variables, being analyzed and processed in real time by analysis tools, such as artificial intelligence, in order to reduce human error or the inability to analyze large volumes of data, variabilities and interrelationships that can be measured.obtain and determine the complex process. This variability and interrelationship between the different equipment that make up a comminution / grinding system has not been sufficiently covered by the state of the art, being incipiently through developments of application of sensors applied, mainly, within the grinding or pulverization system, addressed by grinding media and / or linings that incorporate sensors through which they have attempted to determine with a certain degree of accuracy the location of the grinding media and the impacts received in order to determine the consumption of steel and / or polymeric material, the filling levels of the mill (through the estimation of the kidney shape that the mineral charge has during the grinding process), and eventually the weight of the material being processed,That is why the objective is to cover the need through a system and method of obtaining real-time data on physical / chemical variables inside the equipment associated with comminution / grinding that, through the analysis of the load behavior, allows to determine its operation and anticipate failures of said equipment, where the obtaining method includes obtaining the data by emitting information by a set of micro components that make up the TX section (data sending end), an integral part of the Capture and transmitter PCB board comprising a microcontroller, capacitors, crystals, resistors, accelerometer, gyroscope, thermocouple, battery and transmitter and receiver by a set of micro components that make up the RX section (Data receiving end through antennas) an integral part of the Receiving and integrating PCB board made up of 3 or more microcontrollers, antenna routers, resistors, regulators, crystals, capacitors,Diodes, inductors, UFL ports and various types of connectors that allow integration through specially designed ports to mini computers such as Raspberry or Toradex, finally these are connected via Ethernet port or wireless to a router which allows via WIFI or 4G connection to send and receive information to the platform arranged in a Cloud architecture as well as send and receive information to the SCADA / DCS / PLC system of the mining company through Ethernet port. This set of components is known as Gateway. The receiving antennas are positioned at the entrance and exit of the mill with a variation in the SAG mills, which are shown in figure 6.,

[0012] STATE OF THE ART

[0013] Currently, in the mining industry, data processing and capture presents the disadvantage of not knowing the exact real-time operation of the phenomena occurring inside the grinding and / or comminution equipment. Therefore, it is necessary to know the physical / chemical variables in said equipment accurately and in real time, and to reduce the delay time from 14 days to 2 days for the set-up of said equipment to a stable operating regime (set point). In the state of the art, various solutions have been found that partially resolve the technical problem posed.

[0014] There are a number of known methods, apparatus and systems for grinding or pulverizing, using certain conventional methods and apparatus involving the use of horizontal grinding mills including: autogenous (where grinding is performed using the grinding of the mineral material itself); semi-autogenous (where grinding is performed by both the mineral material itself as well as grinding media (typically steel balls); and conventional (where grinding is performed exclusively by grinding media (typically steel balls or bars).

[0015] Within the mineral processing industry, the crushing of ore material generally takes place in three primary ways. First, by impact, which is the collision of the falling ore material against a substructure or against the material itself (e.g., a SAG mill). Second, by attrition, which is most common in rod and ball mills (e.g., conventional mills) and in autogenous mills (under favorable conditions). Attrition refers to the process of smaller ore pieces being crushed by pressure and shear between larger ore pieces and / or between surfaces under pressure. Third, by abrasion, where crushing occurs as a result of the surfaces of the ore pieces rubbing against each other.

[0016] Among the known patent applications is US20100024518A1, called instrumental ball, which discloses a metal ball composed of two halves that are assembled together, maintaining a hollow space inside to house electronic circuits with different sensors. However, this document does not disclose the incorporation of a wear sensor and does not solve the technical problem of anticipating failures in the grinding equipment.Another document is the patent application CL2015003741, which discloses a real-time monitoring system for phenomena occurring inside SAG mills, consisting of an instrumental ball with a built-in comprehensive monitoring system, measurement sensors, protection systems, receiving and transmitting antennas, data storage system and an expert information technology system, but this document does not disclose the incorporation of a wear sensor and does not solve the technical problem of anticipating failures in the grinding equipment.

[0017] Another document is patent application PCT / AU2019 / 050376 which discloses a freely moving grinding media adapted to measure one or more physical characteristics of a grinding apparatus during operation or a load thereon. The grinding media comprises a freely moving grinding body. A sensor body is configured to be received in the bore. The sensor body comprises a rigid sleeve, a resilient core, and a sensor system integrated into the resilient core. Also disclosed is a system for optimizing the performance of a grinding circuit. The system comprises a grinding apparatus in response to one or more physical characteristics of the grinding apparatus or the load contained therein measured during operation of the grinding apparatus, but this document does not disclose the incorporation of a wear sensor and does not solve the technical problem of anticipating grinding equipment failures.

[0018] Another document is patent application WO2022109126 which discloses apparatus, systems and methods for detecting and modeling the behavior of a mill load, in which on the one hand a mill sensor system is provided in which the mill sensor system may include a plurality of housing sensor assemblies. On the other hand, it provides a method for monitoring crushing operating conditions. The method may include receiving detection data from a plurality of housing sensor assemblies during operation of a crushing mill. Each of the plurality of housing sensor assemblies may include at least one sensor or set of sensors, at least one power source and at least one antenna.Each of the plurality of housing sensor assemblies may be coupled to a grinding compartment of a comminution mill at spaced-apart positions to provide a plurality of measurement zones within the mill interior. The method may also include determining a two-dimensional process map, a three-dimensional process map, or both, based on the sensing data, but this document does not disclose the incorporation of a wear sensor and does not address the technical problem of anticipating grinding equipment failures. In summary, these documents indicate that while there are developments for monitoring and optimizing the grinding process, the incorporation of specific wear sensors and the anticipation of failures remain unsolved challenges.

[0019] The integration of external sensors installed in the mill casing and internal sensors in the grinding media, capable of measuring various physical parameters of the mill, provides a comprehensive view of both the internal and external dynamics of the mill. This configuration provides detailed information on the physical and chemical characteristics of the internal process and grinding media wear.

[0020] For the operation of the system, a plurality of mill measurement zones are considered. This comprises at least three axial measurement zones, within the outer grinding compartment of the crushing mill, located between a feed end of the mill's grinding compartment, the center and a discharge end of the mill's grinding compartment, where a first radial zone includes an open portion of a mill charge; a second radial zone includes a tip portion of a mill charge; and a third radial zone includes a portion of the mill charge (the internal cross-sectional shape of the charge inside an operating mill, where the base of the kidney is called the charge foot and the upper part of said kidney (FR) is called the charge shoulder) of a mill charge.

[0021] The comminution processes to be used in a given mining operation are determined by the physical characteristics of the mineral, classified according to certain competence intervals to select the crushing technique. It is possible to identify "competent" ore, or minerals with sufficient mechanical strength to form an active grinding charge in themselves, making them highly suitable for autogenous grinding techniques; "incompetent" ore, or minerals that require the addition of grinding media, such as steel balls, to allow their crushing, making them highly suitable for semi-autogenous or conventional grinding techniques. Finally, "over-competent" ore, or minerals with very high mechanical strength, whose crushing in an autogenous grinding process requires a very high energy input.

[0022] Conventional grinding involves the use of steel bars or balls in mills, preceded by comminution to achieve a more stable grinding process due to the heterogeneity of the material in terms of both weight and composition. However, this conventional technique is also the most expensive of the grinding techniques used, in terms of both initial capital investment and ongoing operating expenses, so any measure or improvement to optimize and reduce the cost of this process is relevant. An autogenous mill is a type of relatively large-diameter drum mill in which the ore material itself forms the grinding elements. However, such autogenous mills may also include a limited proportion of additional grinding media, such as steel grinding balls, to assist with the grinding process.This latter type of grinding operation is commonly known as a semi-autogenous or SAG mill.

[0023] Often, with the use of crushing techniques involving conventional or semi-autogenous grinding, especially drum mills incorporating steel bars and steel balls as grinding media, it is necessary to monitor the operation of these mills to optimize the feed rate, both within the drum and in the rest of the equipment and systems that together comminute the mineral.

[0024] The grinding rate and aggressiveness are relevant, as they are established from a stable and known parameter of grinding elements, in this case the metal balls, and / or sensorized polymeric balls, it constitutes reference and correlation information to define and optimize the adopted grinding technique, considering the consumption of water, lime, material, energy and optimal grinding elements required for the processing of a certain mineral, thus comparing this base data to the grinding properties and / or its "crushing resistance" of the mineral.

[0025] The ability to maintain a constant total feed volume in a mill at the required feed rate can be an important control requirement, where automation can make a significant difference in overall process efficiency and costs. Indeed, the ratio of energy consumption to mill feed can be affected by changes in mill density resulting from changes in feed viscosity and fluidity. These variables can be analyzed by applying sensors to all the equipment and components involved. For example, weight can be determined by sensors placed on the conveyor belts, corroborated by triangulation with sensor application systems placed on the mill, balls or bars, and mill landings.

[0026] In other areas and innovative applications of the developed sensor application system, it is possible to monitor all mill bolts, nuts, and retaining washers to determine, through bolt vibration and nut movement, when the assembly is loosening or shearing, in order to avoid emergency shutdowns, whether scheduled or unscheduled. These retention problems can be corrected as much as possible during scheduled shutdowns, while simultaneously achieving greater reliability in the application of sensors to the balls and rock-like components inside the mill. Sensors can also be applied to the mill shafts or landings, or to the rollers of the conveyor belts through pressure sensor inserts, or to rollers made of polymer to accurately determine the weight of the ore inside the drum and on the conveyor belt, respectively.Another application is the use of vibration sensors in water pumps, motors, and conveyor belts to determine both their performance under normal operating conditions and for early detection of faults.

[0027] Therefore, the present invention is related to sensor application systems, measurement and real-time monitoring of the phenomena that occur both outside and inside grinding or pulverizing equipment of high operational complexity, as well as accessory systems such as water pumps, belt or selection systems such as hydrocyclones, responding to the need for a system that can monitor and / or model the comminution process as a whole, considering it as a continuous integrated process that must be automated as far as possible, capable of detecting and maintaining optimal operating conditions and that anticipates equipment failures, through a system for obtaining real-time data on physical / chemical variables inside mining equipment.

[0028] SOLUTION TO THE TECHNICAL PROBLEM

[0029] In order to solve the problem posed, a system and method for obtaining real-time data on physical / chemical variables within a mining comminution / grinding system is presented, through the behavior of the load to anticipate failures of said mining comminution / grinding system, the data obtaining system comprising: data capture means comprising: a single structural body with an interior space sized for the location of at least one electronic wear measurement circuit;said electronic circuit including at least 3 sacrificial electrical resistors operatively connected to one another by three connection paths for measuring wear, wherein at least one of said three connection paths is a verification path, signal channeling means between an outer cover of the interior space and the at least one electronic circuit, hard and dielectric fixing means, which fix the electronic circuit with the signal channeling means; a processor configured to: measure the total electrical resistance of the at least 3 sacrificial resistors, supply at least one verification signal via at least one verification path, receive at least one response signal to a verification signal; and determine wear based on the measurement of the total electrical resistance and / or the at least one response signal;wireless communication means operatively connected to the processor, said wireless communication means configured to emit a channeled signal through the signal channeling means, said channeled signal being indicative of the wear measurement determined by the processor; and power supply means that feed the processor, said at least one electronic circuit and the wireless communication means; wherein the data acquisition system additionally comprises information capture means, configured to receive the signal emitted by the wireless communication means and send said signal to a computer;and a computer system comprising a customized user interface configured to display a status of a comminution / milling process, of at least one component of the comminution / milling mining system, or of a combination thereof in response to the signal received from the information capture means.;

[0030] BRIEF DESCRIPTION OF THE FIGURES

[0031] Figure 1 shows data capture means (100) in the shape of a ball or sphere, which can be metallic.

[0032] Figure 2 shows data capture means (100) with an amorphous shape to simulate a stone.

[0033] Figures 3 and 4 show data capture means (100) without the electronic circuits (106).

[0034] Figure 5 shows data capture means (100) in the form of a bar, with at least one electronic circuit (106). Figure 6 shows a ball mill with data capture means (100) communicated with the information capture means (200), configured to receive the signal emitted by the wireless communication means (500) and send said signal to a computer (201), through a data cloud (202).

[0035] Figure 7. Shows the average daily percentage wear of grinding media per day.

[0036] Figures 8 A, B and C show the record of critical impacts in three areas of the mill, where Fig. 8A corresponds to the loading area (Z1), Fig. 8B to the central area (Z2) and Fig. 8C to a discharge area (Z3).

[0037] Figure 9 shows the load and ball fill levels, as well as the foot and shoulder angles, exhibiting irregular behavior after scheduled stops, compared to the periods before and after these events.

[0038] Figure 10 shows a preferred configuration of an electronic circuit with sacrificial electrical resistors (103) operatively connected to each other by three connection paths for wear measurement, with accelerometer, gyroscope, thermocouple, operatively connected to a processor.

[0039] Figure 11 shows a preferred configuration of an electronic circuit with sacrificial electrical resistors (103) operatively connected to each other by three connection paths for wear measurement.

[0040] Figure 12 shows a preferred configuration of complete mining comminution / grinding systems in parallel format comprising at least one ball mill (1002), a SAG mill (1001), a rod mill, an ISA-MILL, conveyor belts (1004), screens with or without a vibration system, mineral recirculation subsystems, a hydrocyclone battery (1003) or a mixture thereof. In addition, the present technology is for wet mills and is also applied in dry grinding systems with or without chambers, which are applied in cement plants and / or in the aggregates industry.

[0041] Figure 13 shows a preferred configuration of complete mining comminution / grinding systems in a production line comprising at least a primary crusher (1000), a SAG mill (1001), a ball mill (1002), a classifier, mineral recirculation subsystems, a hydrocyclone battery (1003). Figure 14 shows a cross-sectional view of the internal shape of the ball mill charge in operation, where the base of the kidney is called the charge foot and the upper part of said kidney (FR) is called the charge shoulder, of a ball mill charge with data capture means (100).

[0042] Figure 15 shows a detail of a preferred configuration of an electronic circuit with sacrificial electrical resistors (103) operatively connected to each other by three connection paths for wear measurement.

[0043] Figure 16 shows a distribution of the acceleration and rotation sensors in communication with the information capture means (300) in the different parts of the mill, start, middle and end.

[0044] Figure 17 A shows a preferred configuration of external sensors (400) that are positioned on the cover or mantle of the mill that is part of the comminution / grinding system, where a loading zone (Z1), central zone (Z2) and a discharge zone (Z3) are shown.

[0045] Figure 17 B shows an external sensor (400) that is located in at least one nut / bolt and communicates with the information capture means (200) fixed by a preferred configuration of auxiliary fixing means (401).

[0046] Figure 18 shows the information capture means (200) of the present technology applied in a hydrocyclone.

[0047] Figure 19 shows a router (Gateway), comprising an antenna (RX), configured to receive the signal emitted by the information capture means (200) inside a cabinet (501) and send said signal to a computer (201).

[0048] Figure 20 shows the reservoir of the data capture means (100), and other data capture means (100) are in a lining to measure the wear of said lining.

[0049] Figure 21 shows an RX card of information capture means (200) with an antenna (RX), for receiving the wireless transmission. DETAILED DESCRIPTION OF THE INVENTION

[0050] As shown schematically and as a preferred embodiment in Figures 1 to 10, the present invention provides a system for obtaining real-time data on physical / chemical variables within a mining comminution / grinding system, through the behavior of the load to anticipate failures in said mining comminution / grinding system, the data obtaining system comprising: data capture means (100) comprising: a single structural body with an interior space sized for the location of at least one electronic circuit (106) for measuring wear;said electronic circuit including at least 3 sacrificial electrical resistors (103) operatively connected to each other by three connection paths for wear measurement, wherein at least one of said three connection paths is a verification path, wherein the sized interior space of the grinding ball is made by electro erosion to maintain the structural technical characteristics of the balls. signal channeling means (104) between an outer cover of the interior space and the at least one electronic circuit (106), hard and dielectric fixing means, which fix the electronic circuit with the signal channeling means (104);a processor (105) configured to: measure the total electrical resistance of the at least 3 sacrificial resistors (103) through the consumption of the sacrificial electrical resistors (103), input at least one verification signal via the at least one verification path, receive at least one response signal in response to the at least one verification signal; and determine a wear based on the measurement of the total electrical resistance and / or the at least one response signal; wireless communication means operatively connected to the processor (105), said wireless communication means configured to output a channeled signal through the signal channeling means, said channeled signal being indicative of the wear measurement determined by the processor; and power supply means feeding the processor (105), said at least one electronic circuit and the wireless communication means;wherein the data acquisition system additionally comprises information capture means (200), configured to receive the signal emitted by the wireless communication means and send said signal to a computer (201); and the computer (201) comprising a user interface configured to display a status of a comminution / milling process, of at least one component of the comminution / milling mining system, or of a combination thereof in response to the signal received from the information capture means (200).;

[0051] In the context of the present invention, without limiting its scope, verification paths shall be understood as one or more electrical connection paths that can be used by the processor to verify that the electrical connection is effectively interrupted, for example, by sending a verification signal from the processor.

[0052] In a preferred embodiment, the three connection paths may also be verification paths.

[0053] In another preferred embodiment, without limiting the scope of the present invention, the at least one electronic circuit may comprise more than 3 sacrificial electrical resistors (103), preferably more than 5 sacrificial electrical resistors (103). In a more preferred embodiment, the at least one electronic circuit may comprise at least 15 or at least 18 sacrificial electrical resistors (103) separated from each other by a distance within the range of between 0.3 mm and 5 mm.

[0054] In a preferred embodiment, the at least one electronic circuit may further comprise sensors other than the sacrificial electrical resistors (103). For example, and without limiting the scope of the present invention, the at least one electronic circuit may further comprise a microcontroller, capacitors, crystals, an accelerometer, a gyroscope, a thermocouple, a battery, an electromagnetic signal transmitter, a pH meter, a humidity meter, as well as a combination thereof.

[0055] The shape of the single structural body does not limit the scope of the present invention and may depend, for example, on the application of the data acquisition system that is the subject of the present invention. For example, in a preferred embodiment and without limiting the scope of the present invention, the single structural body may have a shape selected from the group consisting of balls, bars, or an amorphous stone shape. In a more preferred embodiment, without limiting the scope of the present invention, the single structural body has an amorphous stone shape, also known as a clast.

[0056] Furthermore, the materials from which the single structural body is manufactured do not limit the scope of the present invention and may depend, for example and without limiting the scope of the present invention, on the specific application of the data acquisition system that is the object of the present invention. For example, in a preferred embodiment and without limiting the scope of the present invention, the single structural body may be manufactured from a material selected from the group consisting of metal, solid polymeric compounds, or a combination thereof.

[0057] In a preferred embodiment, without limiting the scope of the present invention, the single structural body can be manufactured with a solid polymeric composite formed by a combination of at least one polymeric matrix and solids bonded within the polymeric matrix. In a more preferred embodiment, the bonded solids can be selected from the group consisting of metals, crystals, ceramics, carbon in the form of macro-, micro-, or nanomaterials, structured or unstructured, as well as a combination thereof. In another preferred embodiment, without limiting the scope of the present invention, the bonded solids can be selected from the group consisting of metal and shot, as well as a combination thereof.

[0058] In a preferred embodiment, without limiting the scope of the present invention, wireless communication means comprise at least one transmitting (TX) and receiving (RX) antenna.

[0059] In another preferred embodiment, without limiting the scope of the present invention, the data acquisition system that is the object of the present invention may comprise a plurality of data capture means (100). In a more preferred embodiment, without limiting the scope of the present invention, the information capture means (200) can receive information from the wireless communication means of the plurality of data capture means (100) and send it to the computer (201).

[0060] In a preferred embodiment, without limiting the scope of the present invention, the single structural body may have an apparent density between 450.84 and 500.80 lb / ft3, a Rockwell C (HRC) hardness between 50 and 70 and / or a predetermined configuration value, as well as a combination thereof. In a preferred embodiment, without limiting the scope of the present invention, once the shape, size and composition of the single structural body have been defined, it is possible to manufacture said single structural body in series, thus generating a large number of sensing components with exactly the same characteristics given by said shape, size and composition.

[0061] In a preferred embodiment, without limiting the scope of the present invention, the processor and / or computer (201) are configured to determine the load behavior at a rate of at least one ton processed per hour (TPH), wear and / or consumption of steel and / or polymer of the grinding or lining media and / or data capture transport, said determination being made, additionally, based on at least one operating parameter of the comminution / grinding process and / or at least one operating parameter of at least one component of the comminution / grinding mining system.In a more preferred embodiment, without limiting the scope of the present invention, the single structural body is manufactured from a solid polymer composite and in that the processor and / or computer (201) are configured to determine the tons processed per hour, wear and / or consumption of steel or polymeric material and / or a mixture thereof, of the grinding and / or lining and / or transport media for the single solid polymeric body based on at least one piece of equipment that is a component of the comminution / grinding mining system. In any of the preferred embodiments previously set forth, the tons processed per hour, load behavior and a rate of wear and / or consumption of steel and / or polymeric material of the grinding and / or lining and / or transport media are additionally determined based on at least one sensor incorporated in the single structural body or positioned in the at least one component of the comminution / grinding mining system.

[0062] In a preferred embodiment, without limiting the scope of the present invention, the only structural body may be a bipolymeric ball (with two polymers) configured to emulate a ball or grinding media inside a grinding equipment of the mining grinding / comminution system with a weight of at least 0.5 kg and a diameter of at least 50.8 mm (2 inches).

[0063] In another preferred embodiment, without limiting the scope of the present invention, the data capture means (100) additionally comprise a polymeric coating that protects the at least one electronic circuit, said polymeric coating being transparent to the wireless signals generated by the at least one electronic circuit.In another preferred embodiment, without limiting the scope of the present invention, the data capture means (100) comprise at least one inertial sensor operatively connected to the processor, wherein the processor and / or the computer (201) are configured to trace a trajectory of the load inside a mill / conveyor belt / cyclone that forms part of the comminution / grinding system in response to at least one measurement of said inertial sensor, wherein the data capture means (100) comprise at least one height sensor operatively connected to the processor, wherein the processor and / or the computer (201) are configured to determine a level of the load inside a mill / conveyor belt / cyclone that forms part of the comminution / grinding system in response to at least one measurement of said height sensor.Furthermore, the data capture means (100) may comprise at least one load quantity / weight sensor operatively connected to the processor, wherein the processor and / or the computer (201) are configured to determine a quantity of the load within a mill / conveyor belt / cyclone that forms part of the comminution / grinding system in response to at least one measurement of said load quantity sensor.

[0064] In another preferred embodiment, the data capture means (100) may comprise at least one inertial sensor of the MEMs (MicroElectroMechanical Systems) type operatively connected to the processor, where the processor and / or the computer (201) may be configured to trace a path of the load inside a mill / conveyor belt / cyclone that forms part of the comminution / grinding system in response to at least one measurement of said inertial sensor.

[0065] In another preferred embodiment, without limiting the scope of the present invention, the only structural body has a grinding ball shape and because the processor and / or the computer (201) are configured to determine grinding ball wear inside a mill that is part of the comminution / grinding system.

[0066] In another preferred embodiment, the data acquisition system may further comprise at least one sensor positioned on at least one loading ring, and / or a central ring and / or a discharge ring of a mill that is part of the comminution / grinding system, wherein at least one sensor is located on the loading ring, the central ring and / or the discharge ring in equal and equidistant quantities from each other.

[0067] In a further preferred embodiment, the data acquisition system may additionally comprise at least one external sensor (400) that is located in at least one nut / bolt, managing to sensorize said nut / bolt and are in communication with the information capture means (200), said at least one nut / bolt are positioned in a mill that is part of the comminution / grinding system. Wherein the external sensor (400) that fixes the nut / bolt through auxiliary fixing means (401), wherein the auxiliary fixing means (401) may be a clamp, an external sensor (400) printed to fit the nut, high adhesion magnets such as neodymium and / or fixed with glue.

[0068] In another preferred embodiment, the wireless communication means also comprise pseudolites that communicate with each other to form a network of pseudolites generating communication between the wireless communication means, where the information capture means (200) receive information from the plurality of data capture means (100) and / or external sensor (400) from at least one of the wireless communication means and send them to the computer (201), managing to improve the communication between the plurality of data capture means (100) with the information capture means (200), which in turn, that is to say the information capture means (200), communicate with the external sensor (400), managing to know the behavior of the load to anticipate failures, wear status and operation of the complete mining comminution / grinding system.

[0069] In another preferred embodiment, the computer (201) uses the information processed to calibrate various types of grinding and comminution devices that are part of the mining comminution / milling system and integrates said information into virtualization computer systems. For example, and without limiting the scope of the present invention, said virtualization computer systems may be digital twins and / or SCADA / DCS / PLC industrial automation systems.

[0070] In another preferred embodiment, the data acquisition system may additionally comprise means for determining the entry and / or exit of the data capture means (100) towards and / or from the interior of a mill that forms part of the comminution / grinding system.

[0071] In any of the preferred embodiments previously set forth, the processor and / or the computer (201) are configured to determine a residence time of the load inside the mill by means of a clock operatively connected to the processor.

[0072] In a preferred embodiment, without limiting the scope of the present invention, the data acquisition system may additionally comprise at least one pressure and / or vibration sensor in communication with the information capture means (200), said at least one pressure and / or vibration sensor being positioned on a roller of a conveyor belt that forms part of the comminution / grinding system. In a more preferred embodiment, without limiting the scope of the present invention, the computer (201) may be configured to determine a weight of material loaded or transported by the conveyor belt in response to at least one measurement of the at least one pressure and / or vibration sensor.

[0073] In another preferred embodiment, without limiting the scope of the present invention, the data acquisition system may additionally comprise at least one vibration sensor in communication with the information capture means (200), said at least one vibration sensor being positioned in a motor and / or in a pump that forms part of the comminution / grinding system.

[0074] In a preferred embodiment, without limiting the scope of the present invention, the data acquisition system may additionally comprise at least one vibration sensor in communication with the information capture means (200), said at least one vibration sensor being positioned in a hydrocyclone that forms part of the comminution / grinding system, to obtain real-time data on physical / chemical variables within a mining comminution / grinding system, through the analysis of the harmonics of the vibration of the structure of the idlers and / or in the conveyor belt, and of the information capture means (200).

[0075] In a preferred embodiment, without limiting the scope of the present invention, the wireless communication means (500) operatively connected to the processor (105), wherein said wireless communication means configured to emit a channeled signal, so that the computer (201) receives a signal from the information capture means (200), comprises a signal with the same bandwidth in a range of 400 Hz to 5.4 GHz, (Example 2.4 GHz) with signal ID codes for group identification if they are a Ball, clasts, epoxy balls, mill vibration sensors, conveyor belt base vibration, hydrocyclone vibration, amero vibration, crusher vibration and in another preferred configuration the wireless communication means (500) operatively connected to the processor (105), wherein said wireless communication means configured to emit a channeled signal,so that the computer (201) receives a signal from the information capture means (200), it comprises a signal range between 400 Hz to 5.4 GHz, especially at 2.4 GHz, for each equipment where each equipment is a Ball, clasts, epoxy balls, mill vibration sensors, conveyor belt base vibration, hydrocyclone vibration, amero vibration, crusher vibration, to identify the group of equipment to which it belongs.,

[0076] In another preferred configuration, a signal range between 432 Hz to 5.4 GHz, (Example 2.4 GHz) for each equipment where each equipment is a Ball, clasts, epoxy balls, mill vibration sensors, conveyor belt base vibration, hydrocyclone vibration, amero vibration, crusher vibration and signal ID codes for group identification if they are a Ball, clasts, epoxy balls, mill vibration sensors, conveyor belt base vibration, hydrocyclone vibration, amero vibration, crusher vibration.

[0077] In another preferred configuration, at least one acceleration sensor in communication with the information capture means (300), in the structure of the idlers of the conveyor belts and / or in the conveyor belt, where, the information of the acceleration sensor in communication with the information capture means (300), of the structure of the idlers of the conveyor belts is complemented with the information of the information capture means (200), to obtain real-time data of physical / chemical variables within a mining comminution / grinding system, through the analysis of the harmonics of the vibration of the structure of the idlers and / or in the conveyor belt, and of the information capture means (200).

[0078] Wherein the data capture means (100) the data capture means (100) are inside: a ball, a clast, a bar, a conveyor belt, a caterpillar of a means of transport and / or mining equipment, a lining (crusher, chute, truck hopper, bucket or shovel bucket, amero, hydrocyclone base (Apex) and / or lifter).

[0079] In another preferred configuration, the interior space sized for the location of at least one electronic circuit (106) in the only structural body of the data capture means (100), when the only structural body is a grinding ball, is generated by electroerosion in said grinding balls, which allows maintaining the structural and physical characteristics of said balls before incorporating the at least one electronic circuit (106). (Since, if the grinding balls are drilled, micro fractures are generated that weaken the ball and the wear measurement to obtain the load behavior to anticipate failures of said comminution / grinding mining system, would be altered)

[0080] In another preferred configuration, it additionally comprises at least one receiving antenna positioned on the outside and / or inside of the inlet and / or outlet of at least one mining comminution / grinding system, such as a mill, hydrocyclone, conveyor belts, sieves supporting conveyor belts, mineral transport equipment (backhoes, transport trucks, trains, etc.), sieves with or without a vibration system, mineral recirculation subsystems, crushers, trucks and / or backhoes, among others.

[0081] The present invention further comprises a method for obtaining real-time data on physical / chemical variables within a comminution / grinding mining system, through load behavior to anticipate failures of said comminution / grinding mining system, the data obtaining system comprising the following steps: entering data capture means (100) of claim 1 into a ball mill; operating the ball mill if it is at rest, if it is in operation, keeping said ball mill in operation; a.-obtaining at least one resistance value (LENS) of the at least 3 sacrificial electrical resistors (103) operatively connected to each other by three connection paths in at least one electronic circuit (106) for measuring wear; for measuring wear; b. -verifying, through the processor (105), the resistance value by at least one of said three connection paths, c.-receiving at least one response signal in response to the at least one verification signal; and d. -determining a wear of the at least 3 sacrificial electrical resistors (103) through the consumption of the sacrificial electrical resistors (103); based on the measurement of the total electrical resistance and / or the at least one response signal; e. -emitting a radio frequency (TX) signal through wireless communication means operatively connected to the processor (105) and through signal channeling means (104) between an outer cover of the interior space and the at least one electronic circuit (106), said channeled signal being indicative of the wear measurement determined by the processor, f.-receive a radio frequency signal through information capture means (200) (an antenna (RX), configured to receive the signal emitted by the wireless communication means (500) and send said signal to a computer (201) where the receiving antenna is located outside the mill; g. -process the signal emitted by the wireless communication means (500) in the computer (201) to transform the signal into processed data; to display a status of a grinding process, of at least one comminution / grinding mining system, to anticipate failures of said comminution / grinding mining system and h. -store said processed data.

[0082] The present invention further comprises in step g.- processing the signal emitted by the wireless communication means (500) in the computer (201) to transform the signal into processed data; it also comprises: sending said processed data to a second processor, via wire or wireless, to display a status of a grinding process, of at least one mining comminution / grinding system, to anticipate failures of said mining comminution / grinding system, h.- storing said processed data.

[0083] In another preferred configuration, they are repeated from stage a.- to stage h.- until the last sacrificial electrical resistance (103) is consumed.

[0084] In another preferred configuration, they are repeated from stage a.- to stage h.- for each second.

[0085] In another preferred configuration, the method further comprises entering a plurality of data capture means (100) for a predefined period of time.

[0086] In another preferred configuration, the method further comprises, the predefined period of time is from 5 to 30 days.

[0087] In another preferred configuration, the method further comprises the plurality of data capture means (100) per week, in the range of between 40 and 1000 balls.

[0088] In another preferred configuration, the method further comprises, in step g.- of processing the signal emitted by the wireless communication means (500) in the computer (201) to transform the signal into processed data and thereby analyze the movement and / or displacement and / or trajectory of the mineral along the at least one mining comminution / milling system. In another preferred configuration, the method further comprises, in step g.-to process the signal emitted by the wireless communication means (500) in the computer (201) to transform the signal into a processed data and thereby analyze the wear of the steel consumption inside the mill, the expected wear of the grinding components, wear of the at least one lifter and / or internal mill linings and / or hydrocyclone lining and / or lining of a bucket of the at least one backhoe, of the lining of the at least one hopper of a lifting truck, and / or wear of the conveyor belt, as well as the materials that make up the comminution and / or grinding system, as well as determining the physical conditions of the material together with the analysis of the energy consumption used by the at least one comminution / grinding mining system.

[0089] In a more preferred embodiment, without limiting the scope of the present invention, the polymeric coating may not require a rigid case or other additional protection measures to those provided by the single structural body inside which the electronic components of the at least one electronic circuit will be arranged, in particular the protection provided by the polymeric material(s) of said single structural body.

[0090] The present invention can integrate sensor application systems, together with triangulation and processing by advanced computing of the data obtained from multiple devices arranged or applied in different equipment and components involved in mineral grinding, whether in main units such as mills and hydrocyclones, as well as secondary ones such as conveyor belts, water pumps, pressure gauges, fastening bolts to the outside of the mills, drive motors, mill drum support, and in grinding inputs such as balls, bars or sensors arranged in rocks, or polymeric simulations in shape and weight of these.

[0091] Among the differentiating applications of the present invention, the sensor application system stands out to determine a “tons processed per hour, wear and / or consumption of steel of the grinding media” of the mineral load inside grinding or pulverizing mills, using for such purposes, for example and without limiting the scope of the present invention, solid polymer grinding balls similar in density, weight and functionality to a conventional steel ball under operating conditions and thereby obtaining real-time data on physical / chemical variables inside a grinding equipment that, through the behavior of the load, anticipates failures of said equipment.These polymer ball units can be manufactured in series, presenting the same composition and physical characteristics, and therefore a unique behavior during grinding, carrying inside a sensor specially designed to measure wear, specifically an electronic circuit with at least 3 sacrificial electrical resistors (103) connected in parallel for measuring wear. In addition, it can measure a trajectory, impact among other parameters, these units being in functionality and behavior comparable to that of conventional steel balls used in the grinding process. In contrast, conventional balls currently perforated and sensorized, have dissimilar hardness / duration qualities depending on the composition of the metal and the quenching-tempering process with which they are manufactured.Therefore, they fail to accurately represent the grinding process occurring inside the mill, nor do they serve as an objective reference for the abrasive level of the ore batch or the wear of the steel balls arranged inside the mill. It is important to note that the abrasive level may depend on the composition of the minerals comprising the material to be ground, as well as the geometric shape of said rocks. For example, and without limiting the scope of the present invention, very sharp or pointed rocks cause greater wear on the balls or data capture means (100).

[0092] Another type of trajectories that can be obtained with these data capture means (100) is the trajectory from the bucket or ladle of the backhoe machine, passing through the trajectory of the mineral transport truck, primary crusher, conveyor belts, grinding media, such as mills, SAG or others, to the hydro cyclones.

[0093] These balls or data capture media (100) can be perforated by machining and more preferably by electroerosion, which allows maintaining the structural characteristics of the balls without a sensor. Since, if the grinding balls are perforated with a drill, micro fractures are generated that weaken the ball and the measurement of wear to obtain the load behavior to anticipate failures of said comminution / grinding mining system, would be altered.

[0094] This is why these data capture means (100) can be assimilated to conventional balls within the grinding or pulverizing equipment, compared to sensorized balls of conventional material, constituting a fixed variable with respect to the heterogeneous variables of the grinding process, thus being able to determine a "tons processed per hour, wear and / or steel consumption of the grinding media" on which to compare the operation and durability of components such as balls, linings, as well as the energy / speed conditions used in the grinding process, and the water load suitable for this process.

[0095] Considering the state of the art, there are instrumented metal balls between two parts or halves, generating the interior space for the electronic components, which do not wear out and therefore do not incorporate wear sensors or an electronic circuit with at least 3 sacrificial electrical resistors (103) connected in parallel for measuring wear, or perforated steel balls to house sensors in a polymeric capsule or inside a rigid case to be inserted into the cavity, but which also do not integrate the capacity to measure wear, and if they did, it would even be unrepresentative considering that it would generate information on the wear of the batch of balls used, which tends to be highly variable in hardness and quality.On the operational side, state-of-the-art sensors are a foreign material to grind, which is not accepted by many mining or grinding companies, which are very strict about introducing elements other than the mineral to be ground and the balls or bars that assist in said grinding.

[0096] That is why the present invention uses components accepted in the grinding processes, which are the balls and bars intended for this purpose, with sensors or with the electronic circuit with at least 3 sacrificial electrical resistors (103) connected in parallel for the measurement of wear that are deployed within the grinding or pulverizing equipment, allowing to determine with wear sensors, together with other sensors arranged in the nuts of the bolts that fasten the lifters, linings and crown of the mill, the tons processed per hour, wear and / or steel consumption of the grinding media of the grinding process in each batch, generating objective, reliable and representative information of the grinding or pulverizing from a component standardized in hardness and behavior with respect to the conventional balls used.

[0097] The disclosed systems and methods of the present invention may further include sensing systems for sensing and / or modeling mill load behavior during comminution, as well as monitoring operating conditions of the grinding mill. In various aspects, the systems and methods disclosed herein may include a plurality of housing sensor assemblies that are coupled to the grinding compartment of the grinding mill and that may provide sensing and information related to a mill load during comminution. In aspects, this information may be transmitted outside of the grinding compartment of the grinding mill and may be used to provide two- and / or three-dimensional process maps or models of mill load behavior during crushing / grinding.In several aspects, the systems and methods described can provide tons processed per hour, wear and / or steel consumption of the grinding media using sensorized solid polymeric balls, whose data and processed information can be considered as a base antecedent or central axis to determine the suitability of the comminution process as a whole, which will be contrasted and coordinated with information generated before, in conveyor belts, during the processing of the mineral inside the mill and then in the selection stage in hydrocyclones for reprocessing, which together with other sensorized systems monitor and / or detect in real time a mill load and / or crushing operating conditions that can lead to an improved operation of the mill load.

[0098] APPLICATION EXAMPLE

[0099] A 2.5" (63.5 mm) grinding media of Fig. 1 was introduced with data capture means (100) of Fig. 10, which has a radial wear measurement sensor that sends information in real time detected by antennas in the 2.4GHz band (Bluetooth® Low Energy), which are arranged in the entrance and exit area of ​​the mill. The electronic circuit (106) was built with an nRF52832 microcontroller, with dimensions of 32 mm long, 10 mm wide and 1.6 mm thick of the PCB board. The grinding media, to measure radial wear, consists of a resistive mesh (Fig. 10), which is composed of 27 resistors in total, of which only 15 are the sacrificial electrical resistors (103) that are intended for the detection of impedance changes (5K1 Q), 8 are protection resistors (22Q) and 4 resistors connected in “pull down” to generate a 0 voltage in rows of the wear matrix (5K1 Q), as shown in Fig. 10.What was used was an electronic circuit (106) of Fig. 10 where said electronic circuit (106) or sensor was inserted into a grinding medium containing a resistive mesh that allows measuring radial wear. In addition, it contains a gyroscope and accelerometer that allows measuring critical movement and impacts, respectively.

[0100] In terms of the sensor battery capacity, within the physical parameters we can mention it has a nominal voltage of 3V and a capacity of 160 mAh (see Table 1).

[0101] This system was implemented at Nexa Resources' Cerro Lindo mine in Peru, where lead, zinc, and copper ores are processed. The sensors were installed in the METSO 1 ball mill, whose specifications are: Dimensions: 16.5' x 24' (5.029 meters x 7.315 meters); Processing capacity: Up to 580 tph (Tons per hour); Installed power: 3000 kW; F80: 6500 pm; and P80: 440 pm; Grinding balls: 2.5” (63.5 mm) mono size.

[0102] The data is captured and displayed on the user platform as shown in Table 2. The table shows the data collected by wear sensors, which was the radial wear of steel balls, where the data received by each sensor is identified (MAC). The date and time of the reading, along with the firmware version (Fw), are recorded. On the other hand, the data from the accelerometer is displayed in the columns of Force Gx, Force Gy and Force Gz, with their respective Acceleration Module. In addition, it is possible to record the values ​​of the gyroscope coordinates (Radian x, Radian , Radian z) with the angular velocity module, providing additional information on the dynamics of the movement. The radial wear value in millimeters (Wear) is the key metric delivered by this system, along with the operational status of the sensor (Status), the type of service (Service) and the revolutions per minute of the mill (RPM).

[0103] Table 2 Table 2 (Continued) Table 2 (Second continuation)

[0104] As can be seen in Table 2, from data received from the electronic circuit sensors (106). The Wear column corresponds to the value in mm of the wear plate, with a maximum value of 13 mm.

[0105] The balls, which were sensorized by the data capture means (100), provided information on the magnitude of their radial wear. Fig. 7 shows that the wear becomes more significant from the third day onwards and increases continuously. This information allows adjusting the input of new sets of balls, controlling steel consumption and evaluating ball quality. It also made it possible to know the state of the grinding inside the mill without having to stop production.

[0106] Mill motion and internal dynamics

[0107] External sensors (400) attached to the mill casing provide information on mill motion via a gyroscope and critical impacts detected by an accelerometer. The results presented are based on the analysis of data provided by the external sensors (400) and specific operational data requested from the plant (expost data from the PL System or online data). The external sensors (400) in conjunction with the internally located data capture media (100) transmitted an average of 400,000 data and 3,000 data per day, respectively.This data provided information on mill movement and asset health at all times, facilitating proactive and early decision-making to avoid unscheduled shutdowns, achieving more precise operational control, anticipating equipment failures, improving mineral processing, and determining mill wear, steel consumption, and the consumption of polymeric materials incorporated into the mill.

[0108] SPECIFIC RESULTS

[0109] Angular Velocity and Critical Impacts:

[0110] The angular velocity data obtained with the external sensors (400) indicated values ​​of 1.5 rad / s, which translates into 14.5 rpm and a critical speed percentage of 70%.

[0111] The magnitude of the critical impacts detected varies depending on the level of wear of the lining in each of the mill zones (see Fig. 8), where Fig. 8A corresponds to the loading zone (Z1), Fig. 8B to the central zone (Z2) and Fig. 8C to a discharge zone (Z3).

[0112] Figure 8. Critical impact records in three areas of the mill. The impact records closest to the center indicate greater magnitude. The arrow indicates the mill's rotational direction. 9T and 9S indicate the toe and shoulder angle values, respectively.

[0113] Filling levels and seating angles

[0114] The information captured by external sensors provides crucial insights into the mill's internal dynamics. Using power models, such as the Morrell power model, both sensor-captured and operational data from the concentrator plant are incorporated. Charge and ball fill levels, as well as foot and shoulder angles, show irregular behavior after scheduled shutdowns, compared to the periods before and after these events (see Fig. 6).

[0115] In the area delimited by the green dotted lines in Fig. 6, more violent and sustained behavior is observed, indicating possible irregularities in the grinding process. These irregularities can be caused by a decrease in power, prolonged processing times for fine material, or a longer than normal ramp-up period.

[0116] Continuous monitoring helps maintain optimal operational levels, avoiding unscheduled downtime and contributing to operational improvement and efficient asset use.

[0117] Figure 9 shows the fill levels of the charge and ball, as well as the toe and shoulder angles, which show irregular behavior after scheduled shutdowns, compared to the periods before and after these events. Monitoring of critical parameters of the grinding process is shown in:

[0118] Top panel: Load fill levels (blue) and ball fill levels (red).

[0119] Bottom panel: Foot angle (blue) and shoulder angle (blue).

[0120] The panels highlight planned shutdowns (gray areas) and minor reported incidents (gray dotted lines). The area between the green lines indicates the period of interest due to the sudden change in parameters.

[0121] In the context of this application, without limiting its scope, "at least one" shall be understood as one or more of the elements referenced. Consequently, the number of elements referenced does not limit the scope of this application. Additionally, if more than one element is provided, said elements may or may not be identical to each other, without limiting the scope of this application.

[0122] In the context of this application, without limiting its scope, "plurality" shall be understood as two or more of the elements referred to. Consequently, the number of elements of the plurality referred to does not limit the scope of this application as long as it is greater than or equal to two. Additionally, said elements of the plurality may or may not be identical to each other without limiting the scope of this application. Throughout this specification, the word "comprise" or variations thereof such as

[0123] "comprises" or "comprising" shall be deemed to imply the inclusion of a specified element, integer, or stage, or group of elements, integers, or stages, but not the exclusion of any other element, integer, or stage, or group of elements, integers, or stages.

[0124] Different options described for different technical characteristics may be combined with each other, or with other options known to a person normally versed in the art, without limiting the scope of this application.

Claims

MODIFIED CLAIMS received by the International Bureau on 21 February 2025 (21.02.2025) 1- A system for obtaining real-time data on physical / chemical variables within a comminution / grinding mining system, through the behavior of the load to anticipate failures of said comminution / grinding mining system, the data obtaining system, CHARACTERIZED in that it comprises: data capture means (100) comprising: a single structural body with an interior space sized for the location of at least one electronic circuit (106) for measuring wear;said electronic circuit including at least 3 sacrificial electrical resistors (103) operatively connected to one another by three connection paths forming a resistive mesh for wear measurement, wherein at least one of said three connection paths is a verification path, signal channeling means (104) between an outer cover of the interior space and the at least one electronic circuit (106), hard and dielectric fixing means, which fix the electronic circuit with the signal channeling means (104); a processor (105) configured to: measure the total electrical resistance of the at least 3 sacrificial resistors (103), through the consumption of the sacrificial electrical resistors (103), feed at least one verification signal through the at least one verification path, receive at least one response signal in response to the at least one verification signal;and determining a wear based on the measurement of the total electrical resistance and / or the at least one response signal; wireless communication means operatively connected to the processor (105), said wireless communication means configured to output a channeled signal through the signal channeling means (104), said channeled signal being indicative of the wear measurement determined by the processor; and power means feeding the processor (105), said at least one electronic circuit and the wireless communication means; wherein the data acquisition system additionally comprises information capture means (200), configured to receive the signal emitted by the wireless communication means (500) and send said signal to a computer (201); and the computer (201) comprising a user interface configured to display a status of a comminution / milling process, of at least one component of the comminution / milling mining system, or of a combination thereof in response to the signal received from the information capture means (200). 2- The data collection system according to claim 1, CHARACTERIZED because the three connection paths are also verification paths. 3- The data acquisition system according to claim 1, CHARACTERIZED in that the electronic circuit comprises at least 15 sacrificial electrical resistors (103) separated from each other by a distance within the range of between 0.3 mm and 3 mm. 4- The data acquisition system according to claim 3, CHARACTERIZED in that the at least one electronic circuit further comprises: microcontroller, capacitors, crystals, accelerometer, gyroscope, thermocouple, battery, electromagnetic signal transmitter, a pH meter, a humidity meter, as well as a combination thereof. 5- The data collection system according to claim 1, CHARACTERIZED in that the only structural body has a shape that is selected from the group consisting of balls, bars or amorphous stone shapes. 6- The system of claim 5, CHARACTERIZED in that the only structural body has an amorphous stone shape. The data acquisition system according to claim 1, CHARACTERIZED in that the only structural body is manufactured with a material that is selected from the group consisting of metal, solid polymeric compounds, or a combination thereof. 8- The data acquisition system according to claim 1, CHARACTERIZED in that the only structural body is manufactured with a solid polymeric compound formed by a combination of at least one polymeric matrix and solids agglutinated in the polymeric matrix. 9- The system of claim 8, CHARACTERIZED in that the agglutinated solids are selected from the group consisting of metals, crystals, ceramics, carbon in the form of macro, micro or nanomaterials, structured or not, as well as a combination thereof. 10- The data collection system of claim 8, CHARACTERIZED in that the agglutinated solids are selected from the group consisting of metal and shot, as well as a combination thereof. 11 - The data acquisition system according to claim 1, CHARACTERIZED in that the wireless communication means comprise at least one transmitting (TX) and receiving (RX) antenna. 12- . The data acquisition system according to claim 1, CHARACTERIZED in that it comprises a plurality of data capture means (100); wherein the information capture means (200) receive information from the wireless communication means of the plurality of data capture means (100) and send them to the computer (201). 13- The data acquisition system according to claim 1, CHARACTERIZED in that the only structural body has an apparent density between 450.84 and 500.80 Ib / p¡e3, a Rockwell C (HRC) hardness between 50 and 70 and / or a predetermined configuration value, as well as a combination thereof. 14- The data acquisition system according to claim 1, CHARACTERIZED in that the processor and / or the computer (201) are configured to determine the behavior of the load at a rate of at least one ton processed per hour (TPH), wear and / or consumption of steel and / or polymer of the grinding or lining media and / or data capture transport, said determination being carried out, additionally, based on at least one operating parameter of the comminution / grinding process and / or at least one operating parameter of at least one component of the comminution / grinding mining system. 15- The data acquisition system according to claim 14, CHARACTERIZED in that the only structural body is manufactured from a solid polymeric compound and in that the processor and / or the computer (201) are configured to determine the tons processed per hour, wear and / or consumption of steel or polymeric material and / or mixture thereof, of the grinding and / or coating and / or transport media for the only polymeric body. massif as a function of at least one piece of equipment that is a component of the comminution / grinding mining system. 16- The data acquisition system according to claim 14 or 15, CHARACTERIZED in that the tons processed per hour, load behavior and a rate of wear and / or consumption of steel and / or polymeric material of the grinding and / or lining and / or transport media are additionally determined based on at least one sensor incorporated in the sole structural body or positioned in at least one component of the comminution / grinding mining system. 17- The data acquisition system according to claim 1, CHARACTERIZED in that the only structural body is a sensored bipolymer ball configured to emulate a grinding ball or medium inside a grinding equipment of the grinding / comminution mining system with a weight of at least 0.5 kg and a diameter of at least 50.8 mm (2 inches). 18- The data acquisition system according to claim 1, CHARACTERIZED in that the data capture means (100) additionally comprise a polymeric coating that protects the at least one electronic circuit, said polymeric coating being transparent to the wireless signals generated by the at least one electronic circuit. 19- The data acquisition system according to claim 1, CHARACTERIZED in that the data capture means (100) comprise at least one inertial sensor operatively connected to the processor, wherein the processor and / or the computer (201) are configured to trace a trajectory of the load inside a mill / conveyor belt / cyclone that is part of the comminution / grinding system in response to at least one measurement of said inertial sensor. 20- The data acquisition system according to claim 1, CHARACTERIZED in that the data capture means (100) comprise at least one height sensor operatively connected to the processor, wherein the processor and / or the computer (201) are configured to determine a level of the load inside a mill / conveyor belt / cyclone that is part of the comminution / grinding system in response to at least one measurement of said height sensor. 21 - The data acquisition system according to claim 1, CHARACTERIZED in that the data capture means (100) comprise at least one load quantity / weight sensor operatively connected to the processor, wherein the processor and / or the computer (201) are configured to determine a quantity of the load inside a mill / conveyor belt / cyclone that is part of the comminution / grinding system in response to at least one measurement of said load quantity sensor. 22- The data acquisition system according to claim 1, CHARACTERIZED in that the only structural body has a grinding ball shape and in that the processor and / or the computer (201) are configured to determine grinding ball wear inside a mill that is part of the comminution / grinding system. 23- The data acquisition system according to claim 1, CHARACTERIZED in that it further comprises at least one sensor positioned in at least one loading ring, and / or a central ring and / or a discharge ring of a mill that is part of the comminution / grinding system, wherein at least one sensor is located in the loading ring, the central ring and / or the discharge ring in equal and equidistant quantities from each other. 24- The data acquisition system according to claim 1, CHARACTERIZED in that it additionally comprises at least one external sensor (400) that is located in at least one nut / bolt, managing to sensorize said nut / bolt and are in communication with the information capture means (200), said at least one nut / bolt are positioned in a mill that is part of the comminution / grinding system. 25- The data acquisition system according to claim 1, 23 or 24, CHARACTERIZED in that with the information processed by the computer (201) it calibrates various types of grinding and comminution devices that are part of the mining comminution / grinding system and integrates said information into virtualization computer systems. 26- The data collection system according to claim 1, CHARACTERIZED because it additionally comprises means to determine the entry and / or exit of the data capture means (100) towards and / or from the interior of a mill that is part of the comminution system. 27- The monitoring system according to claim 1 or 26, CHARACTERIZED in that the processor and / or the computer (201) are configured to determine a residence time of the load inside the mill by means of a clock operatively connected to the processor. 28- The data acquisition system according to claim 1, CHARACTERIZED in that it additionally comprises at least one pressure and / or vibration sensor in communication with the information capture means (200), said at least one pressure and / or vibration sensor being positioned on a roller of a conveyor belt that forms part of the comminution / grinding system. 29- The data acquisition system according to claim 28, CHARACTERIZED in that the computer (201) is configured to determine a weight of material loaded or transported by the conveyor belt in response to at least one measurement of the at least one pressure and / or vibration sensor. 30- The data acquisition system according to claim 1, CHARACTERIZED in that it additionally comprises at least one vibration sensor in communication with the information capture means (200), said at least one vibration sensor being positioned in a motor and / or in a pump that forms part of the comminution / grinding system. 31 - The data acquisition system according to claim 1, CHARACTERIZED in that it additionally comprises at least one vibration sensor in communication with the information capture means (200), said at least one vibration sensor being positioned in a hydrocyclone that forms part of the comminution / grinding system. 32- The data acquisition system according to claim 1, CHARACTERIZED in that the wireless communication means (500) are operatively connected to the processor (105), wherein said wireless communication means are configured to emit a channeled signal, so that the computer (201) receives a signal from the information capture means (200), comprises a signal with the same bandwidth in a range of 400 Hz to 5.4 GHz, with signal ID codes for group identification if they are a Ball, Glastos, epoxy balls, mill vibration sensors, conveyor belt base vibration, hydrocyclone vibration, amero vibration, crusher vibration. 33- The data collection system according to claim 1, CHARACTERIZED because the wireless communication media (500) connected operatively to the processor (105), wherein said wireless communication means configured to emit a channeled signal, so that the computer (201) receives a signal from the information capture means (200), comprises a signal range between 400 Hz to 5.4 GHz, for each equipment where each equipment is a Ball, Glastos, epoxy balls, mill vibration sensors, conveyor belt base vibration, hydrocyclone vibration, amero vibration, crusher vibration, to identify the group of equipment to which it belongs. 34- The data acquisition system according to claims 32 and 33, CHARACTERIZED in that it comprises a signal range between 432 Hz to 5.4 GHz, for each piece of equipment where each piece of equipment is a Ball, Glastos, epoxy balls, mill vibration sensors, conveyor belt base vibration, hydrocyclone vibration, amero vibration, crusher vibration and signal ID codes for group identification if they are a Ball, Glastos, epoxy balls, mill vibration sensors, conveyor belt base vibration, hydrocyclone vibration, amero vibration, crusher vibration. 35- The data acquisition system according to claim 1, CHARACTERIZED in that it additionally comprises at least one acceleration sensor in communication with the information capture means (300), in the structure of the idlers of the conveyor belts and / or in the conveyor belt. 36- The data acquisition system according to claim 35, CHARACTERIZED in that the information from the acceleration sensor in communication with the information capture means (300), of the structure of the idlers of the conveyor belts is complemented with the information from the information capture means (200), to obtain real-time data on physical / chemical variables within a mining comminution / grinding system, through the analysis of the harmonics of the vibration of the structure of the idlers and / or in the conveyor belt, and of the information capture means (200). 37- The data collection system according to claim 1, CHARACTERIZED in that the data capture means (100) are inside: a ball, a Glasto, a bar, a conveyor belt, a caterpillar of a means of transport and / or mining equipment, a lining of: a crusher, a chute, a truck hopper, a bucket or shovel bucket, amero, a hydrocyclone base (Apex) and / or a lifter. 38- The data acquisition system according to claim 1, CHARACTERIZED in that the interior space is sized for the location of at least one electronic circuit (106) in the only structural body of the data capture means (100), When the only structural body is a grinding ball, it is generated by electroerosion in said grinding balls, which allows maintaining the structural and physical characteristics of said balls before incorporating at least one electronic circuit (106). 39- The data acquisition system according to claim 1 or 11, CHARACTERIZED in that it additionally comprises at least one receiving antenna positioned on the outside and / or inside of the inlet and / or outlet of at least one mining comminution / grinding system, such as a mill, hydrocyclone, conveyor belts, crushers, trucks and / or backhoes. 40- The data acquisition system according to claim 24, CHARACTERIZED in that the at least one external sensor (400) is fixed to the nut / bolt through auxiliary fixing means (401), wherein the auxiliary fixing means (401) comprises a clamp, high adhesion magnets, such as neodymium, fixed with glue, and / or an external sensor (400) is printed so that it fits the nut. 41 - The data acquisition system according to claim 1, CHARACTERIZED in that the wireless communication means also comprise pseudolites that communicate with each other to form a network of pseudolites generating communication between the wireless communication means, wherein the information capture means (200) receive information from the plurality of data capture means (100) and / or external sensor (400) from at least one of the wireless communication means and send them to the computer (201). 42- A method for obtaining real-time data on physical / chemical variables within a mining comminution / grinding system, through load behavior to anticipate failures of said mining comminution / grinding system, the data obtaining system, CHARACTERIZED in that it comprises: entering data capture means (100) of claim 1, into a ball mill; operating the ball mill if it is at rest, if it is in operation, keeping said ball mill in operation; a.-obtaining at least one resistance value (LENS) of at least 3 sacrificial electrical resistors (103) operatively connected to each other by three connection paths forming a resistive mesh for measuring wear, in at least one electronic circuit (106) for measuring wear; for measuring wear; b.-verify, through the processor (105), the resistance value for at least one of said three connection paths, c.-receive at least one response signal in response to the at least one verification signal; and d. -determine a wear of the at least 3 sacrificial electrical resistors (103) through the consumption of the sacrificial electrical resistors (103); based on the measurement of the total electrical resistance and / or the at least one response signal; e.-emit a radio frequency signal (TX) through wireless communication means operatively connected to the processor (105) and through the signal channeling means (104) between an outer cover of the interior space and the at least one electronic circuit (106), said channeled signal being indicative of the wear measurement determined by the processor, f.-receive a radio frequency signal through information capture means (200) (an antenna (RX), configured to receive the signal emitted by the wireless communication means (500) and send said signal to a computer (201) where the receiving antenna is located outside the mill; g. -process the signal emitted by the wireless communication means (500) in the computer (201) to transform the signal into processed data; to display a status of a grinding process, of at least one comminution / grinding mining system, to anticipate failures of said comminution / grinding mining system and h. -store said processed data. 43- The method of claim 42, CHARACTERIZED in that in step g.- of processing the signal emitted by the wireless communication means (500) in the computer (201) to transform the signal into processed data; it also comprises: sending said processed data to a second processor, via wire or wireless, to display a status of a grinding process, of at least one mining comminution / grinding system, to anticipate failures of said mining comminution / grinding system, h.- storing said processed data. 44- The method of claim 42 or 43, CHARACTERIZED in that step a.- to step h.- are repeated until the last sacrificial electrical resistance (103) is consumed. 45- The method of claim 42 or 43, CHARACTERIZED in that step a.- to step h.- are repeated for each second. 46- The method of claim 42, CHARACTERIZED in that: entering a plurality of data capture means (100) for a predefined period of time. 47- The method of claim 42, CHARACTERIZED in that: the predefined period of time is from 5 to 30 days. 48- The method of claim 42, CHARACTERIZED in that: the plurality of data capture means (100) per week is in the range of between 40 and 1000 balls. 49- The method of claim 42, CHARACTERIZED in that in step g.-of processing the signal emitted by the wireless communication means (500) in the computer (201) to transform the signal into processed data and thereby analyze the movement and / or displacement and / or trajectory of the mineral along the at least one mining comminution / grinding system. 50- The method of claim 42, CHARACTERIZED in that in step g.-of processing the signal emitted by the wireless communication means (500) in the computer (201) to transform the signal into a processed data and thereby analyze the wear of the steel consumption inside the mill, the expected wear of the grinding components, wear of the at least one lifter and / or internal mill linings and / or hydrocyclone lining and / or lining of a bucket of the at least one backhoe, of the lining of the at least one lifting truck hopper, and / or wear of the conveyor belt, as well as the materials that make up the comminution and / or grinding system, as well as determining physical conditions of the material together with the analysis of the energy consumption used by the at least one comminution / grinding mining system.

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