GET Wear Sensor Assembly for Wireless Replacement Timing

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Solution Overview

Problem

Existing methods for determining the condition and replacement timing of ground engaging tool (GET) components in mining machinery are inefficient, prone to human error, and do not account for varying designs of GETs across different machines.

Innovation Solution

A sensor system comprising a battery, cushioning element, temperature sensor, accelerometer, and a metal disc antenna, which is designed to be impact-resistant and capable of transmitting data wirelessly to a remote receiver, allowing for real-time monitoring of GET component wear and condition.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If traditional manual inspection methods are used to determine GET component wear, then operational simplicity is maintained, but measurement precision and reliability of wear assessment deteriorate

Engineering Contradiction:

Improvewear assessment accuracyVSAvoidmonitoring system complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The patent replaces manual visual inspection and physical measurement methods with an automated sensor-based monitoring system. Sensors embedded in or attached to GET components continuously collect data on wear, impact, and operational conditions, transmitting this information wirelessly to a central system for analysis, thereby eliminating human error and subjectivity in wear assessment.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The monitoring system enables GET components to self-report their condition through embedded sensors that automatically detect wear levels, impact forces, and operational parameters. The system requires minimal human intervention, with sensors continuously monitoring and transmitting data without manual calibration or inspection, allowing the components to essentially monitor themselves.

Inventive Principle:

Principle #25Self-service

2Reliability

If frequent inspection and replacement of GET wear components is performed, then reliability of digging operations is improved, but loss of time and productivity deteriorate due to unnecessary downtime

Engineering Contradiction:

Improvedigging operation reliabilityVSAvoidmining operation productivity

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent implements a feedback-based condition monitoring system where sensors continuously collect data on GET component wear and operational conditions, transmit this information to a central system, and trigger replacement alerts only when predetermined wear thresholds are approached. This feedback loop enables proactive scheduling of replacements based on actual component condition rather than fixed intervals, optimizing the balance between reliability and productivity.

Inventive Principle:

Principle #23Feedback

3Adaptability or versatility

If GET wear components are monitored using fixed replacement schedules, then ease of operation is maintained, but adaptability to varying wear rates and designs deteriorates

Engineering Contradiction:

Improveaccommodation of varying GET designs and wear ratesVSAvoidmonitoring and data management complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent employs a universal monitoring platform that can accommodate multiple types of GET components with varying designs and wear characteristics. The system uses standardized sensor interfaces and wireless communication protocols that work across different component types, while the central processing system adapts analysis parameters and thresholds based on specific component identities and operational conditions, enabling one system to serve multiple functions.

Inventive Principle:

Principle #6Universality (Multi-functionality)

4Measurement precision

If advanced sensor systems with multiple components are used to monitor GET conditions, then measurement precision and reliability improve, but weight of the monitored component increases

Engineering Contradiction:

Improvewear and condition detection accuracyVSAvoidGET component weight

Core Design Contradiction:

Measurement precisionVSWeight of moving object

Solution Approach 1:

The patent strategically places sensors at specific locations on GET components where they can maximize measurement effectiveness while minimizing added weight. Rather than uniformly distributing sensors across entire components, the system positions sensors at critical stress points and wear zones where measurements provide the most diagnostic value, ensuring high measurement precision with minimal mass addition.

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS12203244B2Apparatus, methods, and systems of monitoring the condition of a wear component

Publication Date: 2025.01.21 CQMS RAZER

AI summary

Apparatus, methods, and systems of monitoring the condition of a wear component, including a sensor system for monitoring the condition of a wear component comprising: an outer casing bottom portion having a closed bottom end; at least one battery situated inside the outer casing bottom portion; at least one cushioning element interposed between the at least one battery and at least one sensor component; at least one metal disc antenna positioned at a distance above the at least one sensor component; at least one metal connector element configured to join the metal disc antenna to the sensor component; and an outer casing top portion adapted to fit over at least the metal disc antenna, wherein the outer casing top portion is adapted to substantially connect with the outer casing bottom portion.