Movable Sensor Scanning for Mining Equipment Inspection

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Solution Overview

Problem

Current inspection methods for mining equipment face challenges in acquiring complete and accurate data, particularly due to the presence of mining materials and structural protrusions, which lead to incomplete scans and increased inspection duration. Additionally, traditional methods require the equipment to be powered down and cleaned, extending downtime and safety risks for inspection staff.

Innovation Solution

The proposed solution involves a system and method for inspecting mining equipment using a movable sensor that can acquire point-cloud data while the equipment is in operation, eliminating the need for shutdown and cleaning. This system includes data acquisition during operation, virtual inspection capabilities, and a human-machine guidance process to ensure comprehensive and accurate data collection.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Area of stationary object

If inspection is performed with stationary scanner positioned at center, then scanning coverage is maximized, but scanning shadows from protrusions and incomplete data increase

Engineering Contradiction:

Improvescanning coverageVSAvoiddata completeness

Core Design Contradiction:

Area of stationary objectVSMeasurement precision

Solution Approach 1:

The patent transforms the stationary scanner into a movable scanner that can dynamically reposition itself within the mining equipment. The scanner moves along a path that allows it to capture data from multiple angles and positions, eliminating scanning shadows caused by protrusions and ensuring complete surface coverage without requiring the equipment to be stationary.

Inventive Principle:

Principle #15Dynamics

2Object-affected harmful factors

If equipment is powered down and decontaminated for inspection, then inspection safety is improved, but inspection duration and equipment downtime increase

Engineering Contradiction:

Improveinspection staff safetyVSAvoidequipment downtime

Core Design Contradiction:

Object-affected harmful factorsVSLoss of time

Solution Approach 1:

The patent enables continuous operation of the mining equipment during inspection by using a movable scanner that can safely operate in the hostile environment. The scanner is protected from mining materials and harsh conditions through robust design and positioning, allowing data collection to continue while the equipment remains operational, thus eliminating the need for shutdowns.

Inventive Principle:

Principle #20Continuity of useful action

3Stability of the object's composition

If scanner is rigidly attached to prevent position changes, then measurement stability is improved, but adaptability to complex geometries and complete surface scanning deteriorate

Engineering Contradiction:

Improvescanner position stabilityVSAvoidsurface scanning capability

Core Design Contradiction:

Stability of the object's compositionVSAdaptability or versatility

Solution Approach 1:

The patent employs a movable scanner that dynamically adjusts its position and orientation to adapt to complex internal geometries of mining equipment. The scanner moves along predetermined paths or is guided by navigation systems, maintaining stable measurement conditions at each position while covering the entire surface area, including hard-to-reach regions.

Inventive Principle:

Principle #15Dynamics

4Productivity

If inspection is performed quickly to minimize downtime, then productivity is improved, but data completeness and inspection accuracy deteriorate

Engineering Contradiction:

Improveinspection speedVSAvoidwear assessment accuracy

Core Design Contradiction:

ProductivityVSMeasurement precision

Solution Approach 1:

The patent replaces traditional manual inspection methods with an automated movable scanner system. The scanner automatically navigates, captures data, and maps surfaces without requiring manual intervention, enabling rapid and comprehensive inspection that maintains high accuracy while minimizing equipment downtime.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This approach significantly reduces inspection duration, enhances safety for inspection staff, and minimizes equipment downtime. It ensures complete and accurate data acquisition, allowing for more effective assessment of wear and damage, and enables virtual inspection for remote and on-site users, improving collaboration and efficiency.

Implementation Method 1

a sensor (30) configured to sense a distance to a surface (520) inside the mining equipment (500) by use of time of flight

Methodology Applied

Scientific EffectTime of flight: Time of Flight

Data Source

PatentUS12283040B2Mining equipment inspection system, mining equipment inspection method, and mining equipment inspection device

Publication Date: 2025.04.22 METSO OUTOTEC FINLAND OY

AI summary

A computer-implemented point-cloud data acquisitioning method for acquiring point-cloud data of the inside of a mining equipment. The method includes the step of acquiring from a sensor, a first dataset and a second dataset, wherein each dataset includes datapoints at coordinates. The method extracts features from the first and second dataset and aligns the first and second dataset using the extracted features. The first and second dataset are aligned into a point-cloud data. The geometry of the mining equipment is estimated based on the point-cloud data and the point-cloud data is used to identify a region of the estimated geometry indicating insufficient data.