Systems, methods, and storage media for monitoring real-time stress and strain of a chain link joiner

Abstract

Systems, methods, and storage media for monitoring real-time stress and strain of a chain link joiner are disclosed. Exemplary implementations may: collect strain data about at least one instrumented chain link joiner by a remotely deployable wireless sensor device in the instrumented chain link joiner; and generate, by a computing a device, a report comprising analysis of the strain data.

Description

SYSTEMS, METHODS, AND STORAGE MEDIA FOR MONITORING REAL-TIME STRESS AND STRAIN OF A CHAIN LINK JOINERFIELD OF THE DISCLOSURE

[0001] The present disclosure relates to systems, methods, and storage media for monitoring real-time stress and strain of a chain link joiner.BACKGROUND

[0002] An ongoing trend in longwall mine planning is to demand longer, higher capacity and lower profile armored face conveyors (AFC). AFC failure accounts for up to 27% of total longwall equipment failure and is known to cause serious production delays and associated costs for longwall operators. A large majority of these failures can be attributed to incorrect chain tension. To replace / repair a failed AFC chain during a panel is an exercise that can take several production shifts to complete and can represent a significant negative impact to the profitability of the longwall operation.Furthermore, chain replacement / repair can introduce additional occupational health and safety risk to personnel conducting the labor to replace and / or repair the AFC chain.

[0003] Currently, two techniques are used for continuous monitoring of AFC chain tensions. The first records AFC drive motor currents to infer chain tension. While this is better than nothing, it provides a very “averaged” record of the chain’s loading at a single point. The second deploys an arm that measures the force required to deflect the chain. This is typically done at a single location and like the first method only measures tension at a single point on the conveyor.SUMMARY

[0004] One aspect of the present disclosure relates to a system configured formonitoring real-time stress and strain of a chain link joiner. The system may include one or more hardware processors configured by machine-readable instructions. The processor(s) may be configured to collect strain data about at least one instrumented chain link joiner by a remotely deployable wireless sensor device in the instrumented chain link joiner. The instrumented chain link joiner may include a strain gauge configured to measure and collect the strain data for the at least one instrumented chain link joiner, a microcontroller unit configured to receive and store the strain data in a storage medium, and a wireless link configured to receive requests for and transmit the strain data to a remote gateway. The remote gateway may include a wireless chain link joiner configured to transmit and receive the strain data, a microcomputer for processing the strain data, and a gateway storage medium for storing the strain data. The processor(s) may be configured to generate, by a computing a device, a report including analysis of the strain data.

[0005] In some implementations of the system, the machine-readable instructions may collect strain data about a plurality of instrumented chain link joiners.

[0006] In some implementations of the system, the instrumented chain link joiner may further include a sensor device configured to measure at least one of the vibration, incline, and acceleration data of the at least one instrumented chain link joiner.

[0007] In some implementations of the system, the processor(s) may be configured to allow users to reconfigure the sensor device and enable it to monitor at least two of the vibration, incline, and acceleration data of the at least one instrumented chain link joiner.

[0008] In some implementations of the system, the processor(s) may be configuredto allow users to reconfigure the sensor device and enable it to monitor each of the vibration, incline, and acceleration data of the at least one instrumented chain link joiner.

[0009] In some implementations of the system, the sensor device may be internal battery powered and encapsulated.

[0010] In some implementations of the system, the strain data may be for a conveyor chain.

[0011] In some implementations, the system may further comprise a ‘shelf mode’ wherein the one or more hardware processors are further configured by machine- readable instructions to disable selected features of the instrumented chain link joiner to conserve power while maintaining Bluetooth discoverability, the disabled features including one or more of an accelerometer, strain gauge measurement, and gateway broadcast capabilities.

[0012] In some implementations, the system may further comprise entering a ‘shelf mode’ to conserve power in the instrumented chain link joiner by disabling selected features while maintaining Bluetooth discoverability, the disabled features including one or more of an accelerometer, strain gauge measurement, and gateway broadcast capabilities.

[0013] Another aspect of the present disclosure relates to a method for monitoring real-time stress and strain of a chain link joiner. The method may include collecting strain data about at least one instrumented chain link joiner by a remotely deployable wireless sensor device in the instrumented chain link joiner. The instrumented chain linkjoiner may include a strain gauge configured to measure and collect the strain data for the at least one instrumented chain link joiner, a microcontroller unit configured to receive and store the strain data in a storage medium, and a wireless chain link joiner configured to receive requests for and transmit the strain data to a remote gateway. The remote gateway may include a wireless chain link joiner configured to transmit and receive the strain data, a microcomputer for processing the strain data, and a gateway storage medium for storing the strain data. The method may include generating, by a computing a device, a report including analysis of the strain data.

[0014] Yet another aspect of the present disclosure relates to a non-transient computer-readable storage medium having instructions embodied thereon, the instructions being executable by one or more processors to perform a method for monitoring real-time stress and strain of a chain link joiner. The method may include collecting strain data about at least one instrumented chain link joiner by a remotely deployable wireless sensor device in the instrumented chain link joiner. The instrumented chain link joiner may include a strain gauge configured to measure and collect the strain data for the at least one instrumented chain link joiner, a microcontroller unit configured to receive and store the strain data in a storage medium, and a wireless chain link joiner configured to receive requests for and transmit the strain data to a remote gateway. The remote gateway may include a wireless chain link joiner configured to transmit and receive the strain data, a microcomputer for processing the strain data, and a gateway storage medium for storing the strain data. The method may include generating, by a computing a device, a report including analysis of the straindata.

[0015] In some embodiments, the computer-readable storage medium further comprises instructions for entering a ‘shelf mode’ to conserve power in the instrumented chain link joiner by disabling selected features while maintaining Bluetooth discoverability, the disabled features including one or more of an accelerometer, strain gauge measurement, and gateway broadcast capabilities.

[0016] These and other features, and characteristics of the present technology, as well as the methods of operation and functions of the related elements of structure and the combination of parts and economies of manufacture, will become more apparent upon consideration of the following description and the appended claims with reference to the accompanying drawings, all of which form a part of this specification, wherein like reference numerals designate corresponding parts in the various figures. It is to be expressly understood, however, that the drawings are for the purpose of illustration and description only and are not intended as a definition of the limits of the invention. As used in the specification and in the claims, the singular form of 'a', 'an', and 'the' include plural referents unless the context clearly dictates otherwise.BRIEF DESCRIPTION OF THE DRAWINGS

[0017] FIG. 1 illustrates an example joiner having a strain gauge and encapsulated electronics.

[0018] FIG. 2 illustrates an example conveyor with active and out of range joiners implementing a strain gauge and encapsulated electronics, in accordance with one ormore implementations.

[0019] FIG. 3 illustrates example communications between a joiner and a gateway implementing a strain gauge and encapsulated electronics, in accordance with one or more implementations.

[0020] FIGS. 4 and 5 illustrate an example chain link for implementing a strain gauge and encapsulated electronics, in accordance with one or more implementations.

[0021] FIG. 6 illustrates an example chain link battery cover for implementing a strain gauge and encapsulated electronics, in accordance with one or more implementations.

[0022] FIG. 7 illustrates a system configured for monitoring real-time stress and strain of a chain link joiner, in accordance with one or more implementations.

[0023] FIGS. 8A, 8B, and / or 8C illustrate a method for monitoring real-time stress and strain of a chain link joiner, in accordance with one or more implementations.

[0024] FIG 9 illustrates a method for monitoring real-time stress and strain or a chain link joiner, in accordance with one or more implementations.DETAILED DESCRIPTION

[0025] Systems, methods, and storage media for monitoring real-time stress and strain of a chain link joiner are disclosed. Exemplary implementations may provide an armored face conveyor chain link joiner system. To achieve the additional requirements for higher equipment reliability it is clear that mining chain designs must improve. This may include manufacturing to higher quality standards and potential changes to chain shapes. All this means higher replacement chain costs. Particularly in large mining blocks, an incremental improvement in chain life is meaningless. Until the operatingcompany can be assured that the risk of reusing a chain for an entire additional block is acceptable, many 'fit for purpose' chains will be disposed of prematurely. Conversely, overly optimistic estimation of remaining life will result in significant downtime. At present the industry understanding of the relationship between chain life and operating parameters is limited.

[0026] Multiple instrumented chain link joiners acquire acceleration and strain data as the conveyor operates. The acquired data represents the vibration, impact, and tension events the chain has experienced and can help predict its remaining useful life. As a joiner passes in close proximity to the gateway, data is wirelessly exchanged. The Gateway is capable of storing the data. The data can be retrieved over WIFI or Ethernet.

[0027] FIG. 1 illustrates an example joiner 100 having a strain gauge 110 and encapsulated electronics 120. The example joiner 100 may have any joiner structure 102 suitable for joining a chain, e.g., including openings 104 and 106 for connecting additional chain links (not shown), such as opposite ends of a chain loop and / or as intermediary chain sections. In an example, the joiner 100 is implemented as an armored face conveyor (AFC) chain link joiner, such as those in the mining industry including but not limited to use with armored face conveyors (AFC) for longwall mining operations.

[0028] The example joiner 100 may include a strain gauge 110 configured to measure strain within the structure 102 of the joiner 100. The strain gauge 110 may be implemented as one or more sensor. Example sensors 110 which are suitable for the joiner 100 include, but are not limited to, electronic sensors whose resistance varieswith force. The sensor 110 and / or the electronics 120 convert applied force (e.g., pressure, tension, weight) into an electrical resistance which can be measured to determine stress and / or strain on the joiner 100.

[0029] The strain gauge 110 may be operatively associated with electronics 120. The electronics 120 may be encapsulated within the structure 102 of the joiner 100.One or more battery or other power source 122 may be provided for the electronics 120. The power source 122 may also be provided within the structure 102 of the joiner 100.In an example, the electronics 120 and / or the power source 122 may be provided within a flameproof enclosure to reduce or altogether prevent a fire hazard.

[0030] FIG. 2 illustrates a conveyor system 200, in accordance with one or more implementations. The conveyor system 200 includes a conveyor 250 with an active joiner 210 and out of range joiners 211 , 212, and 213 interconnecting chain links 220. The joiners 210 and 211 , 212, and 213 each implement a strain gauge and encapsulated electronics as described above with reference to Figure 1 .

[0031] The active joiner 210 may include wireless communications capabilities (e.g., a wireless link such as BLUETOOTH TM or other suitable wireless communications capabilities) to transfer information from the electronics of the active joiner 210 to a gateway 230. Strain data may be collected for the out of range joiners 211 , 212, and 213, and this data communicated with the gateway 230 when the out of range joiners 211 , 212, and 213 come physically into range with the gateway 230.

[0032] In an example, the gateway 230 is powered by a direct current (DC) link 232, although other suitable power source(s) may be provided. The gateway 230 communicates with the active joiner 210 and transmits or otherwise generates output.The output may be communicated to any suitable output device(s) (not shown) via a wired connection (e.g., Ethernet link 234) and / or via a wireless connection (e.g., WiFi link 236, telecommunications link such as 4G, 5G or satellite, etc.). Suitable output devices include, but are not limited to a mobile device executing a mobile app, such as a mobile phone device or other computing device. Output devices are not limited, and may also include dedicated devices, such as a display and / or digital readout at or near the conveyor 205.

[0033] FIG. 3 illustrates example communications 300 between a joiner 310 and a gateway 330 implementing a strain gauge 312 and electronics encapsulated in a cavity 315, in accordance with one or more implementations. In an example, the joiner 310 include a strain gauge 312 and may also include additional sensors 314 (e.g., vibration, inclinometer, accelerometer). The electronics are powered by a battery or other power source 316, which may be provided within a flameproof enclosure 318 that may be the same or separate from the cavity 315.

[0034] The electronics of the joiner 310 may include a power converter 320, a processor 322, and a wireless communications link 325. The electronics receive data from the strain gauge 312 and / or sensor(s) 314. The data may be raw data and / or data which is preprocessed by processor 322. The electronics communicate the data via the wireless link 325 to the gateway 330.

[0035] The gateway 330 may include a wireless link 332 configured to receive data from the joiner 310. A processor 335 handles the data, e.g., by processing and / or preprocessing the data for communications from the gateway 330. The processor 335 may be powered by any suitable power source (e.g., DC supply 336 and powerconverter 338). The processor 335 may store data in data storage 340 (e.g., memory) prior to communicating the data. The processor 335 may communicate the data to any suitable device (e.g., a mobile phone app or other display device) via wired connection 342 such as Ethernet and / or wireless connection 344 such as WiFi.

[0036] FIGS. 4 and 5 are various views 400 and 500 illustrating an example chain link configured as a joiner 405 for implementing a strain gauge 410 and electronics 420 encapsulated in a cavity 420 of the joiner 405, in accordance with one or more implementations. The joiner 405 may be manufactured of any suitable material. In an example, the joiner 405 is manufactured of a metal sufficient to perform as a chain link and withstand the stress, strain, and tension of a conveyor chain, e.g., for a longwall mining operation. The joiner 405 may have any suitable shape, and is configured with the cavity 420 in a portion of the joiner 405 with sufficient strength to provide the cavity 420 therein.

[0037] FIG. 6 are views 600 illustrating an example chain link battery cover 605 for implementing a strain gauge and encapsulated electronics, in accordance with one or more implementations. In an example, the battery cover 605 may include a mating cavity 610 to mate with the cavity formed in the joiner to encapsulate the electronics and / or power source.

[0038] FIG. 7 illustrates a system 700 configured for monitoring real-time stress and strain of a chain link joiner, in accordance with one or more implementations. In some implementations, system 700 may include one or more computing platforms 702. Computing platform(s) 702 may be configured to communicate with one or more remote platforms 704 according to a client / server architecture, a peer-to-peer architecture,and / or other architectures. Remote platform(s) 704 may be configured to communicate with other remote platforms via computing platform(s) 702 and / or according to a client / server architecture, a peer-to-peer architecture, and / or other architectures. Users may access system 700 via remote platform(s) 704.

[0039] Computing platform(s) 702 may be configured by machine-readable instructions 706. Machine-readable instructions 706 may include one or more instruction modules. The instruction modules may include computer program modules. The instruction modules may include one or more of strain data collection module 708, report generating module 710, user allowing module 712, and / or other instruction modules.

[0040] Strain data collection module 708 may be configured to collect strain data about at least one instrumented chain link joiner by a remotely deployable wireless sensor device in the instrumented chain link joiner. Strain data may include any suitable data collected by one or more sensor such as a strain gauge. Data may include raw data (e.g., electrical resistance) and / or data which is preprocessed (e.g., to indicate a failure condition) prior to transmitting to the gateway. By way of non-limiting example, the instrumented chain link joiner may further include a sensor device configured to measure at least one of the vibration (e.g., oscillating or other movement to indicate a disturbance), incline (e.g., a slope of a surface or plane), and acceleration (e.g., capacity to gain speed or increase the rate of motion) data of the at least one instrumented chain link joiner. The strain data may be for a conveyor chain. The conveyor chain may be for an armored face conveyor. The conveyor chain may be for a longwall mining operation. Longwall mining is a type of underground mining (e.g., tomine for coal), where the substrate being extracted (e.g., coal) is mined in a single slice or “longwall panel.”. However, other types of mining may also implement conveyors. Indeed, the joiner described herein may be suitable for implementation in any of a variety of end-uses which include a chain, such as a timing belt on a gas engine, a motorcycle chain, etc.

[0041] By way of non-limiting example, the data may represent the vibration, impact, and tension events the conveyor chain has experienced and can help predict remaining useful life of the conveyor. A “tension event” as that term is used herein, refers to a change in a state of tension (or stretched tight) of the chain. For example, a tension event may indicate a loosening of the chain (e.g., due to wear and tear of the chain link(s)). The term “useful life” as that term is used herein, refers to the duration for which a chain may be safely utilized (e.g., including a factor of safety or FOS) for its intended operation, before needing to be repaired or replaced. A closed loop quasi real time longwall chain model is generated based on the strain data from the at least one instrumented chain link joiner. The term “closed loop quasi real time” as that term is used herein, refers to a mechanical-electronic system that automatically regulates the conveyor system to maintain a desired state or set point of the conveyor. In an example, human interaction is reduced or altogether not necessary. The term “quasi” refers to any delay between detecting a strain condition and transmitting that data via the gateway. Real time field data from the at least one instrumented chain link joiner may be coupled with a corresponding dynamic response computer model at both the system and chain link joiner level to monitor and control key variables that give rise to chain failure. The term “response computer model” as that term is used herein, refers to a model forresponding to a strain event, such as shutting down the conveyor and / or alerting an inspection and / or repair crew. By way of non-limiting example, the instrumented chain link joiner may include a strain gauge configured to measure and collect the strain data for the at least one instrumented chain link joiner, a microcontroller unit configured to receive and store the strain data in a storage medium, and a wireless chain link joiner configured to receive requests for and transmit the strain data to a remote gateway. Any suitable strain gauge may be implemented, e.g., as described above. Any suitable microcontroller unit may be implemented, which fits within the cavity of the joiner and is capable of at least being able to transmit data from the strain gauge to the gateway. The term “remote gateway” refers to any communications hub which is wirelessly linked to the joiner and able to transmit data from the joiner to one or more endpoints for processing and / or output. By way of non-limiting example, the remote gateway may include a wireless chain link joiner configured to transmit and receive the strain data, a microcomputer for processing the strain data, and a gateway storage medium for storing the strain data. Any suitable microcomputer and gateway storage medium may be implemented which meets the size constraints of the joiner and wireless communications protocol implemented for transmitting the data for further processing and / or output.

[0042] Report generating module 710 may be configured to generate, by a computing a device, a report including analysis of the strain data.

[0043] User allowing module 712 may be configured to allow users to reconfigure the sensor device and enable it to monitor at least two of the vibration, incline, and acceleration data of the at least one instrumented chain link joiner. Reconfiguring mayinclude resetting the sensor device after the conveyor chain has been inspected and / or repaired / replaced.

[0044] User allowing module 712 may be configured to allow users to reconfigure the sensor device and enable it to monitor each of the vibration, incline, and acceleration data of the at least one instrumented chain link joiner.

[0045] In some implementations, the machine-readable instructions may collect strain data about a plurality of instrumented chain link joiners. In some implementations, the sensor device may be internal battery powered and encapsulated. Any battery or other power source may be provided, such that it meets the size constraints. Additional considerations may include operating environment and safety requirements. In some implementations, a chain remaining useful life may be determined in cycles of operation or shears using a stress and strain-based approach. Cycles of operation and shears (e.g., stress which is coplanar to a cross-section of the chain) are typically determined based on number of rotations of the chain through the conveyor and may be modified (e.g., increased or decreased) based on load. For example, empty or partial loads may be utilized for more cycles of operation than full loads. These considerations may be included in a computer model and / or other calculation to determine useable life of the chain based on stress and strain. In some implementations, a likelihood or probability of cracks initiation (e.g., cracks forming in the chain in any of the links and / or joiner) at the instrumented chain link joiner may be determined using a stochastic approach (e.g., a prediction which may or may not be based on actual cracks in the chain) for a fluctuating tension distribution and stress field. The tension distribution and stress field may be based on actual measurements of other conveyor systems, such as conveyorsystems which have exhibited degradation as compared with new conveyor chains or chains which have not experienced any significant wear and tear. In some implementations, by way of non-limiting example, a basis for fault detection, diagnosis algorithms, and predictive models may be determined for a chain and drive train components. Drive train components may include the sprockets driving the chain and / or the motor assembly, which may also impact stress and strain calculations for the conveyor.

[0046] In some implementations, by way of non-limiting example, effects on chain performance may be analyzed upon changes in operational parameters associated with equipment upgrades (e.g., a new chain, drive motor, etc. which change the dynamics of the conveyor) and / or operational conditions including at least one of face length, inclination, and cutting rate. In some implementations, real-time stress and strain monitoring data (e.g., continuously monitoring stress and strain) may be analyzed and the at least one instrumented chain link joiner modal response and vibration are continuously updated to a simulation model (e.g., a computer model to simulate useful life and / or other events) for interrogation or checking of a condition of a chain to predict failure. In some implementations, dynamic response of a tension profile (e.g., average force per unit of chain section) may be monitored along a chain and drive train components. In some implementations, inherent imbalances on the system (e.g., due to loading conditions) may be monitored leading to potential extension of the remaining useful life and enable throughput increases. In some implementations, by way of nonlimiting example, the data per chain link joiner may be analyzed along a length of a conveyor and information to retrofit to a tension control algorithm is provided forcontrolling inherent imbalances of the system and thus extending the life cycle of the Chain, sprockets, and motors or other drivetrain components In some implementations, triaxial acceleration (acceleration in three orthogonal directions such as an X-Y-Z axis) and / or mono axial acceleration (acceleration along one axis such as acceleration in the X-direction in an X-Y coordinate plane) may be analyzed inside the chain link joiner and staggered along the chain length to get the full breadth of the dynamic response.

[0047] In some implementations, movement within a tolerance of 1 millimeters may be analyzed to measure elongation at the chain link joiner level. Of course, any suitable tolerance(s) may be defined based on operating conditions, safety, materials, etc. In some implementations, humidity or moisture in the air may be analyzed to account for humidity changes over the life of the Chain. For example more humid conditions may result in the formation of rust and shortening the useful life of metal components of the conveyor system. In some implementations, corrosion may be analyzed to measure material loss and the effect of tension over the elongation as the cross-sectional area of the conveyor chain is reduced. In some implementations, reduction in the cross- sectional area (e.g., as the metal thins and stretches) may be tied back to fatigue or wear and serves as input for a remaining life cycle count (e.g., duration of useful life) on the instrumented link. In some implementations, temperature may be analyzed. In some implementations, a load cell may be analyzed to measure tension directly. A load cell is a transducer which converts force into a measurable electrical output.

[0048] In some implementations, the chain link joiner modal response is continuously updated for the interrogation of a condition of the chain to predict failure. In some implementations, the condition of the chain may be monitored and an online lifecycleassessment is conducted to determine remaining useable life. The online lifecycle assessment may include rotations of the conveyor chain through which the conveyor chain may be safely operated based on load and other operating conditions. In some implementations, a close loop quasi real time longwall chain model may be determined based on the input data (e.g., stress and strain data) from the instrumented links or joiners described herein. In some implementations, the chain remaining useful life may be determined in cycles of operation or shears using a stress and strain-based approach. In some implementations, a likelihood of cracks initiation at the instrumented chain link joiner level may be determined using a stochastic approach for a fluctuating tension distribution and stress field. In some implementations, by way of non-limiting example, a control algorithm may be implemented that controls the safe operating range of the system and grows throughout a life cycle from deployment, repairs, upgrades, and end of life.

[0049] In some implementations, computing platform(s) 702, remote platform(s) 704, and / or external resources 714 may be operatively linked via one or more electronic communication links. For example, such electronic communication links may be established, at least in part, via a network such as the Internet and / or other networks. It will be appreciated that this is not intended to be limiting, and that the scope of this disclosure includes implementations in which computing platform(s) 702, remote platform(s) 704, and / or external resources 714 may be operatively linked via some other communication media.

[0050] A given remote platform 704 may include one or more processors configured to execute computer program modules. The computer program modules may beconfigured to enable an expert or user associated with the given remote platform 704 to interface with system 700 and / or external resources 714, and / or provide other functionality attributed herein to remote platform(s) 704. By way of non-limiting example, a given remote platform 704 and / or a given computing platform 702 may include one or more of a server, a desktop computer, a laptop computer, a handheld computer, a tablet computing platform, a NetBook, a Smartphone, a gaming console, and / or other computing platforms.

[0051] External resources 714 may include sources of information outside of system 700, external entities participating with system 700, and / or other resources. In some implementations, some or all of the functionality attributed herein to external resources 714 may be provided by resources included in system 700.

[0052] Computing platform(s) 702 may include electronic storage 716, one or more processors 718, and / or other components. Computing platform(s) 702 may include communication lines, or ports to enable the exchange of information with a network and / or other computing platforms. Illustration of computing platform(s) 702 in FIG. 7 is not intended to be limiting. Computing platform(s) 702 may include a plurality of hardware, software, and / or firmware components operating together to provide the functionality attributed herein to computing platform(s) 702. For example, computing platform(s) 702 may be implemented by a cloud of computing platforms operating together as computing platform(s) 702.

[0053] Electronic storage 716 may comprise non-transitory storage media that electronically stores information. The electronic storage media of electronic storage 716 may include one or both of system storage that is provided integrally (i.e. , substantiallynon-removable) with computing platform(s) 702 and / or removable storage that is removably connectable to computing platform(s) 702 via, for example, a port (e.g., a USB port, a firewire port, etc.) or a drive (e.g., a disk drive, etc.). Electronic storage 716 may include one or more of optically readable storage media (e.g., optical disks, etc.), magnetically readable storage media (e.g., magnetic tape, magnetic hard drive, floppy drive, etc.), electrical charge-based storage media (e.g., EEPROM, RAM, etc.), solid- state storage media (e.g., flash drive, etc.), and / or other electronically readable storage media. Electronic storage 716 may include one or more virtual storage resources (e.g., cloud storage, a virtual private network, and / or other virtual storage resources). Electronic storage 716 may store software algorithms, information determined by processor(s) 718, information received from computing platform(s) 702, information received from remote platform(s) 704, and / or other information that enables computing platform(s) 702 to function as described herein.

[0054] Processor(s) 718 may be configured to provide information processing capabilities in computing platform(s) 702. As such, processor(s) 718 may include one or more of a digital processor, an analog processor, a digital circuit designed to process information, an analog circuit designed to process information, a state machine, and / or other mechanisms for electronically processing information. Although processor(s) 718 is shown in FIG. 7 as a single entity, this is for illustrative purposes only. In some implementations, processor(s) 718 may include a plurality of processing units. These processing units may be physically located within the same device, or processor(s) 718 may represent processing functionality of a plurality of devices operating in coordination. Processor(s) 718 may be configured to execute modules 708, 710, and / or712, and / or other modules. Processor(s) 718 may be configured to execute modules 708, 710, and / or 712, and / or other modules by software; hardware; firmware; some combination of software, hardware, and / or firmware; and / or other mechanisms for configuring processing capabilities on processor(s) 718. As used herein, the term “module” may refer to any component or set of components that perform the functionality attributed to the module. This may include one or more physical processors during execution of processor readable instructions, the processor readable instructions, circuitry, hardware, storage media, or any other components.

[0055] It should be appreciated that although modules 708, 710, and / or 712 are illustrated in FIG. 7 as being implemented within a single processing unit, in implementations in which processor(s) 718 includes multiple processing units, one or more of modules 708, 710, and / or 712 may be implemented remotely from the other modules. The description of the functionality provided by the different modules 708, 710, and / or 712 described below is for illustrative purposes, and is not intended to be limiting, as any of modules 708, 710, and / or 712 may provide more or less functionality than is described. For example, one or more of modules 708, 710, and / or 712 may be eliminated, and some or all of its functionality may be provided by other ones of modules 708, 710, and / or 712. As another example, processor(s) 718 may be configured to execute one or more additional modules that may perform some or all of the functionality attributed below to one of modules 708, 710, and / or 712.

[0056] FIGS. 8A, 8B, and / or 8C illustrates a method 800 for monitoring real-time stress and strain of a chain link joiner, in accordance with one or more implementations. The operations of method 800 presented below are intended to be illustrative. In someimplementations, method 800 may be accomplished with one or more additional operations not described, and / or without one or more of the operations discussed. Additionally, the order in which the operations of method 800 are illustrated in FIGS. 8A, 8B, and / or 8C and described below is not intended to be limiting.

[0057] In some implementations, method 800 may be implemented in one or more processing devices (e.g., a digital processor, an analog processor, a digital circuit designed to process information, an analog circuit designed to process information, a state machine, and / or other mechanisms for electronically processing information). The one or more processing devices may include one or more devices executing some or all of the operations of method 800 in response to instructions stored electronically on an electronic storage medium. The one or more processing devices may include one or more devices configured through hardware, firmware, and / or software to be specifically designed for execution of one or more of the operations of method 800.

[0058] FIG. 8A illustrates method 800, in accordance with one or more implementations.

[0059] An operation 802 may include collecting strain data about at least one instrumented chain link joiner by a remotely deployable wireless sensor device in the instrumented chain link joiner. The instrumented chain link joiner may include a strain gauge configured to measure and collect the strain data for the at least one instrumented chain link joiner, a microcontroller unit configured to receive and store the strain data in a storage medium, and a wireless link configured to receive requests for and transmit the strain data to a remote gateway. The remote gateway may include a wireless link configured to transmit and receive the strain data, a microcomputer forprocessing the strain data, and a gateway storage medium for storing the strain data. Operation 802 may be performed by one or more hardware processors configured by machine-readable instructions including a module that is the same as or similar to strain data collection module 708, in accordance with one or more implementations.

[0060] An operation 804 may include generating, by a computing a device, a report including analysis of the strain data. Operation 804 may be performed by one or more hardware processors configured by machine-readable instructions including a module that is the same as or similar to report generating module 710, in accordance with one or more implementations.

[0061] FIG. 8B illustrates method 800, in accordance with one or more implementations.

[0062] An operation 806 may include allowing users to reconfigure the sensor device and enable it to monitor at least two of the vibration, incline, and acceleration data of the at least one instrumented chain link joiner. Operation 806 may be performed by one or more hardware processors configured by machine-readable instructions including a module that is the same as or similar to user allowing module 712, in accordance with one or more implementations.

[0063] FIG. 8C illustrates method 800, in accordance with one or more implementations.

[0064] An operation 808 may include allowing users to reconfigure the sensor device and enable it to monitor each of the vibration, incline, and acceleration data of the at least one instrumented chain link joiner. Operation 808 may be performed by one ormore hardware processors configured by machine-readable instructions including a module that is the same as or similar to user allowing module 712, in accordance with one or more implementations.

[0065] FIG. 9 illustrates a method 900 for monitoring real-time stress and strain of a chain link joiner, in accordance with one or more implementations. The operations of method 900 presented below are intended to be illustrative. In some implementations, method 900 may be accomplished with one or more additional operations not described, and / or without one or more of the operations discussed. Additionally, the order in which the operations of method 900 are illustrated in FIG. 9 and described below is not intended to be limiting.

[0066] In some implementations, method 900 may be implemented in one or more processing devices (e.g., a digital processor, an analog processor, a digital circuit designed to process information, an analog circuit designed to process information, a state machine, and / or other mechanisms for electronically processing information). The one or more processing devices may include one or more devices executing some or all of the operations of method 900 in response to instructions stored electronically on an electronic storage medium. The one or more processing devices may include one or more devices configured through hardware, firmware, and / or software to be specifically designed for execution of one or more of the operations of method 900.

[0067] In some implementations, the method 900 may include a 'shelf mode' feature designed to conserve power when the instrumented chain link joiner is not in active use. In 'shelf mode', various features of the device are disabled to reduce power consumption, while maintaining the device's ability to be discovered via Bluetooth (asshown at step 902) for future activation or data retrieval. The disabled features in 'shelf mode' may include, but are not limited to: (i) the accelerometer, which is typically used to measure vibration, incline, and acceleration data of the instrumented chain link joiner (as part of the additional sensors 314; (ii) the strain gauge 312 measurement functionality, which is responsible for collecting strain data indicative of stress and strain experienced by the chain link joiner; and (iii) the gateway 330 broadcast capability, which involves transmitting the collected data to a remote gateway 330 for further processing and analysis.

[0068] The 'shelf mode' can be activated manually by a user or automatically after a predetermined period of inactivity. Reactivation from 'shelf mode' can occur through a specific command received via the Bluetooth connection or by detecting a condition indicative of the chain link joiner returning to active use. When not in ‘shelf mode’, or when emerging from ‘shelf mode’, the instrumented chain link joiner defaults to ‘active’ mode 920.

[0069] In some implementations, the system may be configured to offer a range of options 902 that are configurable via a mobile device (such as, for example, a mobile phone). This configurability enhances the flexibility and user interaction with the system, allowing for adjustments to be made conveniently in the field.

[0070] One such configurable option is the ‘verbose’ gateway data output mode 910, which is primarily used for debugging purposes. When enabled, this mode 910 facilitates the transmission of comprehensive data from the strain gauge 312 and / or accelerometer to the gateway 330 at either a specific set time or at predetermined time intervals. This mode is instrumental in providing detailed insights for system diagnosticsand troubleshooting.

[0071] Another configurable option is the 'idle timeout' setting 912, which allows users to specify a desired period of time after which the instrumented chain link joiner will automatically revert to sleep mode if no motion is detected. The ‘idle timeout’ is designed to conserve battery life by ensuring that the instrumented chain link joiner is not actively monitoring or transmitting data during periods of inactivity. The timeout duration is initiated from the moment the instrumented chain link joiner ceases to detect any motion (via the accelerometer), and upon expiration of the set period, the device enters sleep mode until motion is once again detected or another condition for reactivation is met.

[0072] Another configurable option relates to a suite of device-specific settings and firmware options 914, which include, but are not limited to, hardware serial number, current time, firmware version, and battery voltage. This level of configurability ensures that users can maintain an accurate and up-to-date record of each instrumented chain link joiner's operational status and identity. Furthermore, the system supports firmware updates 916, which can be conveniently performed via a user’s mobile device (and using, for example, Nordic Semiconductor's nRF smartphone application technology or similar wireless communication technologies). This capability allows for seamless and efficient updates to the firmware, ensuring that the instrumented chain link joiners benefit from the latest features and security enhancements without the need for physical retrieval or manual intervention.

[0073] Another configurable option is the ‘epoch logging time’ setting 918, whichallows users to define the internal clock interval for logging information within the instrumented chain link joiner. The ‘epoch logging time’ determines the frequency at which the instrumented chain joiner records and stores data before sending back to the gateway 330. This feature is particularly useful for creating a consistent and human- readable timeline of events and data points, which can be invaluable for analysis and historical record-keeping. By adjusting the ‘epoch logging time’, users can balance the granularity of the logged data with storage and power consumption considerations.

[0074] Although the present technology has been described in detail for the purpose of illustration based on what is currently considered to be the most practical and preferred implementations, it is to be understood that such detail is solely for that purpose and that the technology is not limited to the disclosed implementations, but, on the contrary, is intended to cover modifications and equivalent arrangements that are within the spirit and scope of the appended claims. For example, it is to be understood that the present technology contemplates that, to the extent possible, one or more features of any implementation can be combined with one or more features of any other implementation.

Claims

What is claimed is:1 . A system configured for monitoring real-time stress and strain of a chain link joiner, the system comprising: one or more hardware processors configured by machine-readable instructions to: collect strain data about at least one instrumented chain link joiner by a remotely deployable wireless sensor device in the instrumented chain link joiner, the instrumented chain link joiner comprising a strain gauge configured to measure and collect the strain data for the at least one instrumented chain link joiner, a microcontroller unit configured to receive and store the strain data in a storage medium, and a wireless chain link joiner configured to receive requests for and transmit the strain data to a remote gateway, the remote gateway comprising a wireless chain link joiner configured to transmit and receive the strain data, a microcomputer for processing the strain data, and a gateway storage medium for storing the strain data; and generate, by a computing a device, a report comprising analysis of the strain data.

2. The system of claim 1 , wherein the machine-readable instructions collect strain data about a plurality of instrumented chain link joiners.

3. The system of claim 1 , wherein the instrumented chain link joiner further comprises a sensor device configured to measure at least one of the vibration,27incline, and acceleration data of the at least one instrumented chain link joiner.

4. The system of claim 3, wherein the one or more hardware processors are further configured by machine-readable instructions to: allow users to reconfigure the sensor device and enable it to monitor at least two of the vibration, incline, and acceleration data of the at least one instrumented chain link joiner.

5. The system of claim 3, wherein the one or more hardware processors are further configured by machine-readable instructions to: allow users to reconfigure the sensor device and enable it to monitor each of the vibration, incline, and acceleration data of the at least one instrumented chain link joiner.

6. The system of claim 1 , wherein the sensor device is internal battery powered and encapsulated.

7. The system of claim 1 , wherein the strain data is for a conveyor chain.

8. A method for monitoring real-time stress and strain of a chain link joiner, the method comprising: collecting strain data about at least one instrumented chain link joiner by a remotely deployable wireless sensor device in the instrumented chain link joiner,the instrumented chain link joiner comprising a strain gauge configured to measure and collect the strain data for the at least one instrumented chain link joiner, a microcontroller unit configured to receive and store the strain data in a storage medium, and a wireless chain link joiner configured to receive requests for and transmit the strain data to a remote gateway, the remote gateway comprising a wireless chain link joiner configured to transmit and receive the strain data, a microcomputer for processing the strain data, and a gateway storage medium for storing the strain data; and generating, by a computing a device, a report comprising analysis of the strain data.

9. The method of claim 8, wherein the machine-readable instructions collect strain data about a plurality of instrumented chain link joiners.

10. The method of claim 8, wherein the instrumented chain link joiner further comprises a sensor device configured to measure at least one of the vibration, incline, and acceleration data of the at least one instrumented chain link joiner.

11. The method of claim 10, further comprising: allowing users to reconfigure the sensor device and enable it to monitor at least two of the vibration, incline, and acceleration data of the at least one instrumented chain link joiner.

12. The method of claim 10, further comprising: allowing users to reconfigure the sensor device and enable it to monitor each of the vibration, incline, and acceleration data of the at least one instrumented chain link joiner.

13. The method of claim 8, wherein the sensor device is internal battery powered and encapsulated.

14. The method of claim 8, wherein the strain data is for a conveyor chain.

15. A non-transient computer-readable storage medium having instructions embodied thereon, the instructions being executable by one or more processors to perform a method for monitoring real-time stress and strain of a chain link joiner, the method comprising: collecting strain data about at least one instrumented chain link joiner by a remotely deployable wireless sensor device in the instrumented chain link joiner, the instrumented chain link joiner comprising a strain gauge configured to measure and collect the strain data for the at least one instrumented chain link joiner, a microcontroller unit configured to receive and store the strain data in a storage medium, and a wireless chain link joiner configured to receive requests for and transmit the strain data to a remote gateway, the remote gateway comprising a wireless chain link joiner configured to transmit and receive the strain data, a microcomputer for processing the strain data, and a gatewaystorage medium for storing the strain data; and generating, by a computing a device, a report comprising analysis of the strain data.

16. The computer-readable storage medium of claim 15, wherein the machine- readable instructions collect strain data about a plurality of instrumented chain link joiners.

17. The computer-readable storage medium of claim 15, wherein the instrumented chain link joiner further comprises a sensor device configured to measure at least one of the vibration, incline, and acceleration data of the at least one instrumented chain link joiner.

18. The computer-readable storage medium of claim 17, wherein the method further comprises: allowing users to reconfigure the sensor device and enable it to monitor at least two of the vibration, incline, and acceleration data of the at least one instrumented chain link joiner.

19. The computer-readable storage medium of claim 17, wherein the method further comprises: allowing users to reconfigure the sensor device and enable it to monitor each of the vibration, incline, and acceleration data of the at least oneinstrumented chain link joiner.

20. The computer-readable storage medium of claim 15, wherein the sensor device is internal battery powered and encapsulated.

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