Industrial wear indicator and wear monitoring system

Abstract

Provided is a wear monitoring system (24) comprising a scanner (26) arrangeable to monitor an industrial wear indicator or liner (10). The scanner (26) is configured to scan variations in surface spectral reflectance of an exposed surface or stratum of an ablative material of said liner. Also included is a processing system (28) arranged in signal communication with the scanner (26) and configured to analyse such sensed variations in surface spectral reflectance over time, compare such temporal analysis to a preconfigured model (44) of predetermined surface spectral reflectance, and predict a remaining lifespan of said wear indicator or liner (10) based on the comparison. In this manner, the wear monitoring system is (24) able to facilitate proactive or predictive maintenance for an industrial process including such an industrial wear indicator or liner (10).

Description

INDUSTRIAL WEAR INDICATOR AND WEAR MONITORING SYSTEMTECHNICAL FIELD

[0001] This invention relates broadly to wear indication in industrial processes, and more specifically to an industrial wear indicator, an industrial wear liner and an associated wear monitoring system.BACKGROUND ART

[0002] The following discussion of the background art is intended to facilitate an understanding of the present invention only. The discussion is not an acknowledgement or admission that any of the material referred to is or was part of the common general knowledge as at the priority date of the application.

[0003] Many industrial processes require wear linings or liners, generally being sacrificial linings, covers or layers of material that are typically, but not exclusively, found in bulk material handling processes. Such wear linings or liners are typically used to reduce friction, impact, noise and degradation of bulk material during handling and transport thereof and are typically installed in material transfer chutes, spouts, hoppers, transfer points, conveyors and other applications subjected to wear. For example, in mining processes, where bulk materials are transported, wear liners are extensively used in conveyor transfer chutes, conveyor belts, hoppers, and the like.

[0004] Similarly, some industrial processes rely on machine parts and tools that wear away over time, such as haul truck bodies and trays, ground-engaging tools (GET) , excavator buckets, tyres, brake pads and lining, cutting discs, conveyor rollers, conveyor belts, and the like. Such machine parts and tools, whilst notnecessarily including specific wear linings or liners, are periodically replaced when worn, effectively acting as wear liners themselves .

[0005] Conventional methods for monitoring such wear on industrial equipment with or without wear liners generally rely on periodic visual inspection and / or measurement using tools such as ultrasonic thickness testers or wear sensors. These conventional processes are time-consuming, labour-intensive and often inaccurate, as they are subject to the diligence of the person performing the test, which typically leads to reactive maintenance, unplanned downtime and increased operational costs.

[0006] Such conventional predictive maintenance practices using electronic sensors, such as vibration, temperature, ultrasonic, or the like, to detect wear conditions, have other shortcomings such as sensor malfunctions due to harsh environments (dust, heat, moisture, impact) , connectivity and power dependency necessary to communicate with control systems, and high costs and complexity typically making them unsuitable for remote or extreme operating conditions .

[0007] In light of such conventional wear monitoring practices, the Applicant has identified a need in the art for accurate, user- friendly and elegant wear monitoring that enables predictive maintenance, and the current invention was conceived with this goal in mind.SUMMARY OF THE INVENTION

[0008] As known in the art, the electromagnetic spectrum is the full range of electromagnetic radiation, organised by frequency or wavelength. The electromagnetic spectrum is divided into separate bands, with different names for the electromagnetic waves within each band. From low to high frequency these are radio waves,microwaves, infrared, visible light, ultraviolet, X-rays, and gamma rays. The electromagnetic waves in each of these bands have different characteristics, such as how they are produced, how they interact with matter, and their practical applications.

[0009] The reflectance of the surface of a material is its effectiveness in reflecting radiant electromagnetic spectrum energy, i.e. the fraction of incident electromagnetic power that is reflected at the boundary of such material. Reflectance is a component of the response of the electronic structure of the material to the incoming electromagnetic spectrum and is, in general, a function of the frequency, or wavelength, of the incoming electromagnetic signal, its polarization, and the angle of incidence. The dependence of reflectance on the wavelength is called a reflectance spectrum.

[0010] Accordingly, the skilled addressee is to appreciate that reference herein to 'surface spectral reflectance' is used in a broad manner to generally denote such reflectance spectrum of a material, irrespective of a frequency of the electromagnetic radiation involved and reflected from said material. As such, the surface spectral reflectance of a material, as used herein, may include reflectivity of visible light, including different frequencies or colours thereof, as well as non-visible electromagnetic radiation which is detectable by means of sensors, such as infrared, ultraviolet, etc., including detectable variations on frequencies within such frequency bands. Similarly, other visible cues such as colour gradients, reflection patterns and surface textures are also apposite.

[0011] The skilled addressee is further to appreciate that reference herein to an 'industrial wear liner' includes broad reference to materials and linings that are specifically applied as sacrificial materials on top of machine parts and tools, butmay also include separate machine parts and tools , such as groundengaging tools ( GET ) , excavator buckets , loader buckets , chute liners or vehicle tyres , that wear away over time via an intended use thereof .

[0012] According to a first aspect of the invention there is provided an industrial wear indicator comprising : a support configured for supporting the wear indicator in, on and / or proximate an industrial wear liner ; a first ablative material having a predetermined first surface spectral reflectance and supported by said support ; and at least one secondary ablative material having a predetermined second surface spectral reflectance and layered on the first ablative material ; wherein the industrial wear indicator comprises strata of ablative materials of di f ferent surface spectral reflectances locatable relative to the wear liner, so that ablation over time of the wear liner is identi fiable via analysis of a surface spectral reflectance of an exposed stratum .

[0013] In an embodiment , the support comprises a mechanical contrivance configured for supporting the wear indicator in, on and / or proximate an industrial wear liner .

[0014] In an embodiment , the mechanical contrivance is selectable from a group consisting of a threaded fastener, a nail , a friction- fit insert , and a rivet .

[0015] In an embodiment , the support comprises an overall shape and dimension of the strata of ablative materials formed via a process selectable from a group consisting of sintering, pressing, moulding, additive manufacturing, adhesion, casting, forming, j oining, spraying, deposition, machining, curing and vulcanisation .

[0016] In an embodiment, each stratum of ablative material comprises a predetermined thickness.

[0017] In an embodiment, each stratum of ablative material comprises a predetermined material property selectable from a group consisting of corrosion resistance, durability, hardness and toughness .

[0018] In an embodiment, the ablative material is selectable from a group consisting of a metal, a polymer, a ceramic, a crystal, a refractory, a wood, a glass, and a fibre (natural and / or synthetic) .

[0019] In an embodiment, the ablative material includes a phosphorescent material, such as strontium aluminate, to facilitate identifying of ablation in low-light environments.

[0020] According to a second aspect of the invention there is provided an industrial wear liner comprising at least one industrial wear indicator supported in and / or on said wear liner, and comprising: a first ablative material having a predetermined first surface spectral reflectance; and at least one secondary ablative material having a predetermined second surface spectral reflectance and layered on the first ablative material; wherein the layered ablative materials form strata of different surface spectral reflectances, so that ablation over time of the wear liner is identifiable via analysis of a surface spectral reflectance of an exposed stratum.

[0021] In an embodiment, each stratum of ablative material comprises a predetermined thickness.

[0022] In an embodiment , each stratum of ablative material comprises a predetermined material property selectable from a group consisting of corrosion resistance , durability, hardness and toughness .

[0023] In an embodiment , the ablative material is selectable from a group consisting of a metal , a polymer, a ceramic, a crystal , a refractory, a wood, a glass , and a fibre (natural and / or synthetic ) .

[0024] According to a third aspect of the invention there is provided an industrial wear indicator or liner comprising : a support configured for supporting the wear indicator in, on and / or proximate an industrial wear liner ; and an ablative material configured to define a gradually changing surface spectral reflectance along a length thereof and supported by said support ; wherein the industrial wear indicator comprises gradually changing spectral reflectance surface relative to the wear liner, so that ablation over time of the wear liner is identi fiable via analysis of a surface spectral reflectance of the exposed surface .

[0025] In an embodiment , the support comprises a mechanical contrivance configured for supporting the wear indicator in, on and / or proximate an industrial wear liner .

[0026] In an embodiment , the mechanical contrivance is selectable from a group consisting of a threaded fastener, a nail , a friction- fit insert , and a rivet .

[0027] In an embodiment , the support comprises an overall shape and dimension of the strata of ablative materials formed via a process selectable from a group consisting of sintering, pressing,moulding, additive manuf cturing, adhesion, casting, forming, joining, spraying, deposition, machining, curing and vulcanisation .

[0028] In an embodiment, the ablative material comprises a predetermined thickness with the gradually changing surface spectral reflectance along said thickness thereof.

[0029] In an embodiment, the ablative material comprises a predetermined material property along a thickness thereof, said material property selectable from a group consisting of corrosion resistance, durability, hardness and toughness.

[0030] In an embodiment, the ablative material is selectable from a group consisting of a metal, a polymer, a ceramic, a crystal, a refractory, a wood, a glass, and a fibre (natural and / or synthetic) .

[0031] In an embodiment, the ablative material includes a phosphorescent material, such as strontium aluminate, to facilitate identifying of ablation in low-light environments.

[0032] According to a fourth aspect of the invention there is provided a wear monitoring system comprising: a scanner arrangeable to monitor an industrial wear indicator or an industrial wear liner, in accordance with the first or second aspects of the invention, said scanner configured to scan variations in surface spectral reflectance of an exposed surface or stratum of an ablative material of said liner; and a processing system arranged in signal communication with the scanner and configured to: i. analyse such sensed variations in surface spectral reflectance over time;ii . compare such temporal analysis to a preconfigured model of predetermined surface spectral reflectance ; and iii . predict a remaining li fespan of said wear indicator or liner based on the comparison; wherein the wear monitoring system is able to facilitate proactive maintenance for an industrial process .

[0033] In an embodiment , the scanner comprises a camera for capturing surface spectral reflectance of electromagnetic radiation from said wear indicator or liner .

[0034] In an embodiment , the scanner comprises an electromagnetic radiator configured to radiate or emit electromagnetic radiation of predetermined frequency at the wear indicator or wear liner to facilitate sensing of surface spectral reflectance of an exposed stratum of an ablative material .

[0035] The processing system may comprise any suitable processing system or microcontroller configured to receive input , perform logical and arithmetical operations on a suitable instruction set , and provide output , as well as transitory and / or non-transitory electronic storage .

[0036] In an embodiment , the processing system is configured to analyse variations in surface spectral reflectance over time by pre-processing captured images from the scanner to enhance image quality and remove noise or distortions .

[0037] In an embodiment , the processing system is configured to analyse sensed variations in surface spectral reflectance by digitising a scanned surface spectral reflectance into a colour model , such as RGB, CMY, CMYK, or the like .

[0038] In an embodiment , the preconfigured model of predetermined surface spectral reflectance comprises surface spectral reflectance values for the di f ferent ablative materials according to a thickness and / or composition of such materials .

[0039] In an embodiment , the processing system is configured to predict a remaining li fespan of the wear indicator or liner based on the comparison of a time-averaged sensed surface spectral reflectance with the model of predetermined surface spectral reflectance values .

[0040] In an embodiment , the processing system is configured to predict a remaining li fespan of the wear indicator or liner based on the comparison of a time-averaged sensed surface spectral reflectance with a predetermined thickness and / or material property of the ablative materials .

[0041] In an embodiment , the processing system is configured to apply machine learning to the sensed surface spectral reflectance and / or model of predetermined surface spectral reflectance to compensate for variations in ambient lighting, relative positions between the scanner and wear indicator or liner, and / or environmental factors proximate the wear indicator or liner , in order to improve accuracy of remaining li fespan prediction .

[0042] The skilled addressee is to appreciate that reference herein to 'machine learning' generally refers to the application and / or use of algorithms and statistical models by a processing system or processing system to ef fectively perform a speci fic task without using explicit instructions , but rather via reliance on patterns and inference .

[0043] According to a further aspect of the invention there is provided an industrial wear indicator, an industrial wear linerand an associated wear monitoring system, substantially as herein described and / or illustrated .BRIEF DESCRIPTION OF THE DRAWINGSThe description will be made with reference to the accompanying drawings in which :Figures 1A and IB are diagrammatic representations of one embodiment of an industrial wear indicator, in accordance with aspects of the invention;Figures 2A and 2B are diagrammatic representations of another embodiment of an industrial wear indicator, in accordance with aspects of the invention;Figures 3A and 3B are diagrammatic representations of a yet further embodiment of an industrial wear indicator, in accordance with aspects of the invention;Figure 4 is a diagrammatic overview representation of one embodiment of an industrial wear liner comprising at least one industrial wear indicator, in accordance with aspects of the invention;Figure 5 is a diagrammatic overview representation of a wear monitoring system, in accordance with aspects of the present invention; andFigure 6 is a diagrammatic overview representation of one embodiment of the processing system of the wear monitoring system of Figure 5 .DETAILED DESCRIPTION OF EMBODIMENTS

[0044] Further features of the present invention are more fully described in the following description of several non-limiting embodiments thereof . This description is included solely for the purposes of exempli fying the present invention to the skilledaddressee. It should not be understood as a restriction on the broad summary, disclosure or description of the invention as set out above .

[0045] In the figures, incorporated to illustrate features of the example embodiment or embodiments, like reference numerals are used to identify like parts throughout. Additionally, features, mechanisms and aspects well-known and understood in the art will not be described in detail, as such features, mechanisms and aspects will be within the understanding of the skilled addressee.

[0046] Additionally, the accompanying figures do not represent engineering or design drawings, but provide a functional overview of the invention only. As a result, features and practical construction details required for various embodiments may not be indicated in each figure, but such construction requirements will be within the understanding of the skilled addressee.

[0047] Broadly, the present invention provides for an industrial wear indicator 10, as well as an associated wear liner 14 and wear monitoring system 24, whereby accurate, user-friendly and elegant wear monitoring is facilitated, as described herein.

[0048] With reference now to the accompanying figures, there is shown various different possible embodiments of such an industrial wear indicator 10. In general, the wear indicator 10 comprises a support 12 which is configured for supporting the wear indicator 10 in, on and / or proximate an industrial wear liner 14. As described, such an industrial wear liner 14 may include materials and linings that are specifically applied as sacrificial materials on top of machine parts and tools, but may also include machine parts and tools, such as haul truck bodies and trays, groundengaging tools (GET) , excavator buckets, loader buckets, chute liners, and vehicle tyres, and the like, that wear away over timevia an intended use thereof. Additionally, the support 12 may be configured to support the wear indicator 10 in, on and / or proximate the wear liner 14, i.e. proximate the wear liner 14, within a portion of the wear liner 14, on a surface of the wear liner 14, etc .

[0049] Accordingly, in one embodiment, the support 12 comprises a mechanical contrivance configured for supporting the wear indicator in, on and / or proximate an industrial wear liner. For example, in one embodiment, the mechanical contrivance may comprise a threaded fastener, such as a bolt, a nail, a friction- fit insert, a rivet, and / or the like.

[0050] Importantly, in one embodiment, the support 12 may also comprises an overall shape, configuration and / or dimension of the wear indicator 10 itself, examples of which are shown in Figures 2 and 3. For example, the embodiment of the wear indicator 10 shown in Figure 2 comprises a friction-fit insert, which is insertable into a suitable aperture 16 in the wear liner 14. Similarly, the embodiment of the wear indicator 10 shown in Figure 3 comprises an overall shape and configuration of a threaded fastener which is insertable into a complementarily threaded aperture 16 in the wear liner. Of course, variations hereon are possible and expected.

[0051] The wear indicator 10 further comprises a first ablative material 18 having a predetermined first surface spectral reflectance and which is supported by the support 12, as well as at least one secondary ablative material 20 having a predetermined second surface spectral reflectance and layered on the first ablative material 18. In the exemplified embodiments, the wear indicator 10 comprises a tertiary ablative material 22, but of course additional layers of tertiary, quaternary, quinary, etc. ablative materials are possible, as per requirements.

[0052] The skilled addressee is to appreciate that spectral reflectance generally refers to the measurement of how much light a surface reflects at different wavelengths across the electromagnetic spectrum. This measurement is crucial for understanding the properties of materials and surfaces, including their colour, and for applications like remote sensing.

[0053] In this manner, the industrial wear indicator 10 comprises strata of ablative materials 18, 20, 22, etc. each having different surface spectral reflectances. As the wear indicator 10 is operatively locatable relative to the wear liner 14, ablation over time of the wear liner 14 is identifiable via analysis of a surface spectral reflectance of an exposed stratum as the wear indicator commensurately wears together with the wear liner 14.

[0054] Accordingly, in one embodiment, each stratum of ablative material 18, 20, 22, etc. typically comprises a predetermined thickness. Similarly, in one embodiment, each stratum of ablative material 18, 20, 22, etc. typically comprises a predetermined material property selectable from a group consisting of corrosion resistance, durability, hardness and toughness. In this manner, a wear rate or wear characteristic of each stratum of ablative material may be matched to suit the wear liner 14 and operating environment thereof, or the like. As such, the ablative material of each layer may comprise similar or different materials, such as a metal, a polymer, a ceramic, a crystal, a refractory, a wood, a glass, a fibre (natural and / or synthetic) , etc. In one embodiment, the ablative material may include a phosphorescent material, such as strontium aluminate, to facilitate identifying of ablation in low-light environments.

[0055] For example, depending on requirements, the wear indicator 10 may comprise first, secondary and tertiary layers 18, 20 and 22 of ablative materials each having a different surfacespectral reflectance , e . g . di f ferently-coloured ceramic materials , or the like . Similarly, the wear indicator 10 may comprise a single layer of ablative material configured to define a gradually changing surface spectral reflectance along a length thereof , e . g . a continuous colour gradient shi ft along the thickness of the layer, with such gradually changing spectral reflectance similarly detectable as a multi-layered configuration .

[0056] The wear indicator 10 may be inserted into a suitable aperture 16 in the wear liner 14 , typically so that the wear indicator 10 lies flush with an outer surface of the wear liner . As the wear liner 14 ablates during normal use thereof , the wear indicator ablates or wear commensurately, so that , depending on configuration of the wear indicator 10 , a particular layer or stratum of ablative material is exposed according to an amount of material which has ablated from the wear liner 14 and installed wear indicator 10 . In this manner, the surface spectral reflectance of the exposed ablative material is indicative of wear or ablation of the wear liner 14 with installed wear indicator 10 .

[0057] For example , the wear indicator 10 may comprise a first red layer 18 of ablative material , with then an orange or yellow layer of secondary ablative material 20 , followed by a green layer of tertiary ablative material 22 , with the wear indicator countersunk into an aperture 16 of a wear liner 14 . As mentioned, the respective thicknesses of the layers 18 , 20 and 22 may be predetermined or pre-selected according to requirements . As the wear liner 14 with installed wear indicator 10 ablates or wears down over time with normal use , the surface spectral reflectance of the exposed ablative material will change from green to orange / yellow to red, indicating that the wear liner 14 has almost worn through .

[0058] As described above , the overall shape and dimension of the wear indicator 10 may also function as the support . For example , the strata of ablative materials may be formed via a process such as sintering, pressing, moulding, additive manufacturing, adhesion, casting, forming, j oining, spraying, deposition, machining, curing, vulcanisation, etc . into a speci fic shape for insertion into the wear liner 14 , or the like . Again, variations hereon are possible and expected .

[0059] With reference to Figure 4 of the accompanying drawings , there is shown an embodiment of an industrial wear liner 14 , which may comprise a machine part or tool , which comprises at least one industrial wear indicator 10 supported in and / or on the wear liner 14 . As described, the layered ablative materials 18 , 20 and 22 form strata of di f ferent surface spectral reflectances , so that ablation over time of the wear liner 14 is identi fiable via analysis of a surface spectral reflectance of an exposed stratum .

[0060] With reference now to Figure 5 of the drawings , there is shown an embodiment of an associated wear monitoring system 24 . Such a wear monitoring system generally comprises a scanner 26 which is arrangeable to monitor an industrial wear indicator 10 or an industrial wear liner 14 , as described above . In the exempli fied embodiment , the wear liner 14 comprises a mining haul truck body having wear indicators 10 instal led therein, as described above , but variations are possible and anticipated . The scanner 26 is further configured to sense variations in surface spectral reflectance of an exposed stratum of an ablative material .

[0061] In one embodiment , the scanner 26 comprises a camera for capturing surface spectral reflectance of electromagnetic radiation from the wear indicator 10 or liner 14 . In one embodiment , the scanner 26 may also comprise an electromagnetic radiator, such as a light or infrared emitter, which is configuredto radiate or emit electromagnetic radiation of predetermined frequency at the wear indicator 10 or wear liner 14 in order to facilitate sensing of surface spectral reflectance of an exposed stratum of an ablative material .

[0062] The skilled addressee is to appreciate that the scanner 26 may take various forms , with such form adaptable according to requirements . For example , scanner 26 may include a fixed installation, such as a camera monitoring an industrial process , or a hand scanner whereby a user is able to scan speci fic articles or pieces of equipment , or a mobile scanner, such as a drone , whereby machinery is monitorable on demand on an industrial site , or the like . Variations hereon are possible and expected .

[0063] The wear monitoring system 24 also includes a processing system 28 which is arranged in signal communication with the scanner 26 by means of a suitable communications network 30 . Such communications network 30 may include both wired and wireless communications techniques , as generally known in the art of communications . The processing system 28 is generally configured to analyse the sensed variations in surface spectral reflectance over time ; to compare such temporal analysis to a preconfigured model 44 of predetermined surface spectral reflectance ; and to predict a remaining li fespan of the wear indicator 10 or liner 14 based on such a comparison .

[0064] The processing system 28 may also be configured to communicate with a mobile device 32 , typically via communications network 30 , in order to provide information on the sensed variations in surface spectral reflectance over time , the comparison of the temporal analysis to the preconfigured model , and / or the prediction of the remaining li fespan of the wear indicator 10 or liner 14 . In this manner, the wear monitoringsystem 24 is able to facilitate proactive maintenance for an industrial process.

[0065] For example, the mobile device 32 may include a mobile phone or tablet of a maintenance supervisor responsible for maintaining industrial equipment using the wear indicator 10 or liner 14. Via regular updates, the maintenance supervisor may monitor the current wear of the indicator 10 and / or liner 14 and the processing system 28 predicts when the indicator 10 and / or liner 14 will be worn through, so that proactive maintenance of the industrial equipment can be performed to avoid unplanned outages and breakdowns.

[0066] The processing system 28 may comprise any suitable processing system or microcontroller configured to receive input, perform logical and arithmetical operations on a suitable instruction set, and provide output, as well as transitory and / or non-transitory electronic storage. As shown in Figure 6, processing system 28 generally includes at least one processor 34, or processing unit or plurality of processors, memory 36, at least one input and output device 38, coupled together via a bus or group of buses 40, and non-transitory storage device 42, or the like.

[0067] In one embodiment, the processing system 28 is configured to analyse variations in surface spectral reflectance over time by pre-processing captured images from the scanner 26 to enhance image quality and remove noise or distortions, e.g. dust and dirt on the indicator 10 and / or wear liner 14, or the like.

[0068] In one embodiment, the processing system 28 is configured to analyse sensed variations in surface spectral reflectance by digitising a scanned surface spectral reflectance into a colour model, such as RGB, CMY, CMYK, or the like. For example, using an RGB colour model, 16,777,216 possible colours orshades of spectral reflectance is possible across the di f ferent RGB colour values , i . e . each RGB ( red, green, and blue ) parameter in the RGB colour model defines a colour spectral reflectance with a value between 0 and 255 in an 8-bit per parameter model , or 24- bit for the overall colour model . As such, this means that there are 256 x 256 x 256 = 16 , 777 , 216 possible colours representable , providing a level of spectral reflectance sensitivity and discernment that is extremely accurate .

[0069] In one embodiment , the preconfigured model 44 of predetermined surface spectral reflectance comprises surface spectral reflectance values for the di f ferent ablative materials according to a thickness and / or composition of such materials . In one embodiment , the processing system 28 is configured to predict a remaining li fespan of the wear indicator 10 or liner 14 based on the comparison of a time-averaged sensed surface spectral reflectance with the model of predetermined surface spectral reflectance values . Similarly, in one embodiment , the processing system 28 is configured to predict a remaining li fespan of the wear indicator 10 or liner 14 based on the comparison of a time- averaged sensed surface spectral reflectance with a predetermined thickness and / or material property of the ablative materials , as described .

[0070] In one embodiment , the processing system 28 is configured to apply machine learning to the sensed surface spectral reflectance and / or model 44 of predetermined surface spectral reflectance to compensate for variations in ambient lighting, relative positions between the scanner 26 and wear indicator 10 or liner 14 , and / or environmental factors proximate the wear indicator 10 or liner 14 , in order to improve accuracy of remaining li fespan prediction . Such machine learning techniques may include , but are not limited to , supervised learning, unsupervised learning, and reinforcement learning algorithms . These algorithmsmay be trained on a dataset of images or reflective data collected under various conditions to learn a relationship between the visual wear indicators and the actual wear depth, enabling the system to adapt to di f ferent environments and provide accurate wear assessments .

[0071] Applicant believes it particularly advantageous that the present invention provides for a wear indicator 10 , wear liner 14 and wear monitoring system 24 able to realise real-time wear monitoring to allow proactive maintenance to reduce unplanned downtime , thereby leading to increased productivity and cost savings . The invention also provides improved accuracy and eliminates the need for manual wear measurement and reduces the risk of human error, ensuring more reliable wear data . The invention further provides cost savings and extends the lifespan of wear components and optimises maintenance schedules , resulting in signi ficant cost reductions over time .

[0072] The invention also enables data-driven insights and facilitates data collection and analysis for predictive maintenance and wear pattern identi fication, enabling data-driven decision-making to further optimise operations . The invention also facilitates versatility in wear monitoring and is applicable to various wear components and materials , including haul truck trays , chutes , conveyor deflectors , tyres , and other industrial equipment , of fering a comprehensive wear management solution . The present invention accommodates for digitising and analysing of such colour-based wear indicators to provide Al-driven predictive insights without requiring active electronic wear sensors . The system 24 is substantially fail-safe , power- free , and scalable across industries where traditional scanner-based systems are unreliable .

[0073] In the example embodiments, well-known processes, well- known device structures, and well-known technologies are not described in detail, as such will be readily understood by the skilled addressee. Optional embodiments of the present invention may also be said to broadly consist in the parts, elements and features referred to or indicated herein, individually or collectively, in any or all combinations of two or more of the parts, elements or features. Where specific integers are mentioned herein which have known equivalents in the art to which the invention relates, such known equivalents are deemed to be incorporated herein as if individually set forth.

[0074] It is to be appreciated that reference to "one example" or "an example" of the invention, or similar exemplary language (e.g., "such as") herein, is not made in an exclusive sense. Various substantially and specifically practical and useful exemplary embodiments of the claimed subject matter are described herein, textually and / or graphically, for carrying out the claimed subject matter. Accordingly, one example may exemplify certain aspects of the invention, whilst other aspects are exemplified in a different example. These examples are intended to assist the skilled person in performing the invention and are not intended to limit the overall scope of the invention in any way unless the context clearly indicates otherwise.

[0075] Variations (e.g. modifications and / or enhancements) of one or more embodiments described herein might become apparent to those of ordinary skill in the art upon reading this application. The inventor (s) expects skilled artisans to employ such variations as appropriate, and the inventor (s) intends for the claimed subject matter to be practiced other than as specifically described herein.

[0076] The use of the terms "a", "an", "said", "the", and / or similar referents in the context of describing various embodiments(especially in the context of the claimed subject matter) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. The terms "comprising, " "having, " "including, " and "containing" are to be construed as open-ended terms (i.e., meaning "including, but not limited to,") unless otherwise noted. As used herein, the term "and / or" includes any and all combinations of one or more of the associated listed items. No language in the specification should be construed as indicating any non-claimed subject matter as essential to the practice of the claimed subject matter.

[0077] Spatially relative terms, such as "inner," "outer," "beneath, " "below, " "lower, " "above, " "upper, " and the like, may be used herein for ease of description to describe one element or feature's relationship to another element (s) or feature (s) as illustrated in the figures. Spatially relative terms may be intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the contrivance in the figures is turned over, elements described as "below" or "beneath" other elements or features would then be oriented "above" the other elements or features. Thus, the example term "below" can encompass both an orientation of above and below. The contrivance may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly .

[0078] Any method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. It is also to be understood that additional or alternative steps may be employed .

Claims

CLAIMS1 . A wear monitoring system comprising : a scanner arrangeable to monitor an industrial wear indicator or liner, said scanner configured to scan variations in surface spectral reflectance of an exposed surface or stratum of an ablative material of said liner ; and a processing system arranged in signal communication with the scanner and configured to : i . analyse such sensed variations in surface spectral reflectance over time ; ii . compare such temporal analysis to a preconfigured model of predetermined surface spectral reflectance ; and iii . predict a remaining li fespan of said wear indicator or liner based on the comparison; wherein the wear monitoring system is able to facilitate proactive maintenance for an industrial process including such an industrial wear indicator or liner .2 . The wear monitoring system of claim 1 , wherein the industrial wear indicator or liner comprises a plurality of layers or stratum of ablative material , each layer having a predetermined surface spectral reflectance , wherein the industrial wear indicator comprises strata of ablative materials of di f ferent surface spectral reflectances so that ablation over time of the wear indicator or liner is identi fiable via analysis of a surface spectral reflectance of an exposed stratum .3 . The wear monitoring system of either of claims 1 or 2 , wherein the industrial wear indicator or liner comprises an ablative material configured to define a gradual ly changing surface spectral reflectance along a length thereof , so thatablation over time of the wear indicator or liner is identi fiable via analysis of a surface spectral reflectance of an exposed surface .4 . The wear monitoring system of any of claims 1 to 3 , wherein the scanner comprises a camera for capturing surface spectral reflectance of electromagnetic radiation from said wear indicator or liner .5 . The wear monitoring system of any of claims 1 to 4 , wherein the scanner comprises an electromagnetic radiator configured to radiate or emit electromagnetic radiation of predetermined frequency at the wear indicator or liner to facilitate sensing of surface spectral reflectance of an exposed stratum or surface of an ablative material .6 . The wear monitoring system of any of claims 1 to 5 , wherein the processing system is configured to analyse variations in surface spectral reflectance over time by preprocessing captured images of the industrial wear indicator or liner from the scanner to enhance image quality and remove noise or distortions .7 . The wear monitoring system of any of claims 1 to 6 , wherein the processing system is configured to analyse sensed variations in surface spectral reflectance by digitising a scanned surface spectral reflectance into a colour model , such as RGB, CMY, CMYK, or the like .8 . The wear monitoring system of any of claims 1 to 7 , wherein the preconfigured model of predetermined surface spectral reflectance comprises surface spectral reflectance values for the di f ferent ablative materials according to a thickness and / or composition of such materials .9 . The wear monitoring system of any of claims 1 to 8 , wherein the processing system is configured to predict a remaining li fespan of the wear indicator or liner based on the comparison of a time-averaged sensed surface spectral reflectance with the model of predetermined surface spectral reflectance values .10 . The wear monitoring system of any of claims 1 to 9 , wherein the processing system is configured to predict a remaining li fespan of the wear indicator or liner based on the comparison of a time-averaged sensed surface spectral reflectance with a predetermined thickness and / or material property of the ablative materials .11 . The wear monitoring system of any of claims 1 to 10 , wherein the processing system is configured to apply machine learning to the sensed surface spectral reflectance and / or model of predetermined surface spectral reflectance to compensate for variations in ambient lighting, relative positions between the scanner and wear indicator or liner, and / or environmental factors proximate the wear indicator or liner, in order to improve accuracy of remaining li fespan prediction .

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