Self-Cleaning Sensor Window for Mining Equipment
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Solution Overview
Problem
Sensors at mining sites face significant challenges due to harsh environments, which lead to occlusion and diminished performance, often resulting in the need for full sensor replacement due to dust, dirt, and debris accumulation, especially on equipment like mining shovel buckets.
Innovation Solution
A self-cleaning sensor window system integrated into sensor enclosures or as standalone devices, featuring a cleaning assembly operably coupled to a controller, which automatically removes debris from the sensor window using wipers, nozzles, or movable films, ensuring continuous operation without manual intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If sensors are deployed at mining sites on equipment like shovel buckets, then they can monitor mining operations in real-time, but they accumulate dust and debris that occludes transmissivity and diminishes performance
Solution Approach 1:
The sensor system performs self-cleaning through integrated cleaning assemblies (wipers, nozzles, or movable films) that automatically remove debris from the sensor window, allowing the sensor to maintain its own transmissivity without external intervention. This resolves the contradiction by enabling the sensor to sustain its monitoring capability while operating in harsh mining environments.
Solution Approach 2:
The cleaning assembly is activated preemptively based on predetermined criteria (time intervals, distance traveled, or detected transmissivity thresholds) before complete occlusion occurs. This preliminary cleaning action prevents performance degradation rather than merely responding to it, maintaining reliability while preserving productivity.
2Ease of operation
If sensors are exposed to harsh mining environments, then they can be positioned on mining equipment for direct monitoring, but they require frequent manual cleaning or replacement
Solution Approach 1:
The system eliminates manual cleaning requirements by incorporating self-cleaning mechanisms that automatically maintain the sensor window. The cleaning assembly, controlled by a controller that monitors transmissivity or operates on schedules, enables the sensor to serve itself, dramatically reducing maintenance frequency while keeping the sensor positioned on mining equipment for direct monitoring.
Solution Approach 2:
The cleaning system operates dynamically, adjusting its activity based on actual contamination levels, time intervals, or distance metrics. This dynamic operation allows the sensor to remain positioned on equipment while adapting cleaning frequency to actual needs, reducing unnecessary maintenance while ensuring performance.
3Duration of action of stationary object
If sensors operate in harsh conditions with dust and debris, then they can monitor mining operations continuously, but transmissivity occlusion renders them inoperable
Solution Approach 1:
The self-cleaning mechanism ensures continuous useful action by maintaining sensor transmissivity throughout operation. The cleaning assembly operates periodically or on-demand to remove debris, preventing complete occlusion and ensuring the sensor remains inoperable-free, thereby extending continuous operation duration without interruption for manual intervention.
Solution Approach 2:
The system incorporates feedback through transmissivity monitoring that detects when cleaning is needed. The controller receives feedback about window condition and activates the cleaning assembly accordingly, creating a closed-loop system that maintains reliability by responding to actual transmissivity levels rather than operating on fixed schedules alone.
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
The self-cleaning sensor window system effectively maintains sensor transmissivity, preventing performance degradation and extending sensor lifespan by automatically cleaning the window, thus reducing maintenance needs and ensuring continuous operation in harsh mining environments.
Implementation Method 1
cleaning assembly operably coupled to a controller that causes the cleaning assembly to clean debris from the exterior surface of the window
Data Source
AI summary
Self-cleaning sensor window devices for mine site equipment and associated systems and methods are disclosed herein. In some embodiments, a self-cleaning sensor system includes a sensor housing having an opening, a sensor carried by the sensor housing, a self-cleaning window device coupled to the sensor enclosure and positioned at least partially within the opening. The self-cleaning window device comprises a window positioned forward of the sensor to allow the sensor to transmit and/or receive signals through the window, a cleaning assembly directed toward the window and configured to clean debris from the front surface of the window, and a controller operably coupled to the cleaning assembly. The controller can transmit control signals to the cleaning assembly to initiate cleaning of the front surface of the window.