Parallel Wear Gauge for Mill Liner Monitoring
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Solution Overview
Problem
Existing wear measurement devices for mill liners lack sufficient resolution, making it difficult to determine when the liner needs to be replaced before damage occurs.
Innovation Solution
A wear gauge system with an elongate substrate featuring two rows of electronic components connected in parallel, where the removal of components from the distal end changes an electrical parameter measured at a port, allowing for precise wear monitoring, including a housing that embeds into the liner and electronic circuitry for data transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional wear measurement devices are used, then wear monitoring is provided, but the measurement resolution is insufficient for precise wear detection
Solution Approach 1:
The wear gauge is segmented into multiple discrete electronic components (resistors) arranged in two rows along the substrate. Each resistor represents a discrete measurement point, allowing the system to detect wear at multiple locations along the gauge length. This segmentation enables precise wear measurement by determining which specific resistors remain connected, providing high resolution wear detection without requiring a continuous complex sensing mechanism.
Solution Approach 2:
The invention transitions from conventional single-point or low-resolution wear measurement to a two-dimensional array of electronic components arranged in rows along the substrate. This spatial arrangement in multiple dimensions allows the system to detect wear patterns across the entire gauge length, providing comprehensive high-resolution measurement data about wear distribution and progression.
2Reliability
If the liner is not monitored precisely, then operational continuity is maintained, but damage occurs due to excessive wear
Solution Approach 1:
The wear gauge provides preliminary warning by continuously monitoring liner thickness and detecting when wear approaches critical levels before actual damage occurs. The discrete electronic components are strategically positioned to detect wear at predetermined intervals, allowing operators to schedule liner replacement proactively rather than reactively, thus preventing shell damage while maintaining operational planning.
Solution Approach 2:
The system establishes a feedback loop where wear measurements are continuously taken through the electrical connection status of resistors, processed to determine remaining liner thickness, and used to trigger alerts or warnings. This feedback mechanism enables real-time monitoring and decision-making, allowing operators to balance operational continuity with preventive maintenance scheduling to avoid catastrophic failures.
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
Provides continuous, precise wear readings, enabling timely replacement of mill liners and preventing damage, with improved resolution compared to existing systems.
Implementation Method 1
the electronic components of the first and second rows being electrically connected to one another in an electrical connection having a port, the arrangement being such that an electrical parameter relating to the connection as measured at the port changes as electronic components are removed from the connection from the distal end of the substrate
Data Source
AI summary
A wear gauge 10 comprises an elongate substrate 12 having a proximal end 14 and a distal end 16. At least a first row 18 of spaced electronic components 22.1, 22.3 . . . 22.n and a juxtaposed second row 20 of spaced electronic components 22.2, 22.4 . . . 22.n−1 are provided on the substrate. The first and second rows extend in a direction from the proximal end towards the distal end of the substrate. The electronic components 22.2 to 22.n−1 in the second row are spatially interposed between adjacent electronic components 22.1 to 22.n in the first row. The electronic components of the first and second rows are electrically connected in parallel by conductive tracks 19. An electrical parameter relating to the parallel connection as measured at a port 24 of the parallel connection towards the proximal end, changes as electronic components are removed from the connection from the distal end, to provide an indication of the extent of wear, as indicated by the arrow A.