Wear Liner Tile Perimeter Sensor Integration
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Solution Overview
Problem
Existing wear liners in high wear environments, such as bulk material chutes, require costly shutdowns for maintenance due to limited real-time monitoring capabilities and high manufacturing and installation costs of traditional wear sensor probes, which also compromise the integrity of the ceramic tiles.
Innovation Solution
A wear liner system with inductive wear sensors mounted to the perimeter face of wear-resistant tiles, providing high-resolution wear detection through a microprocessor and wireless communication, integrated with a backing plate and intermediate layer for secure and efficient monitoring without compromising the tiles' integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If wear sensor probes are installed through holes in wear tiles to provide real-time monitoring, then wear monitoring capability is improved, but the integrity of the wear liner is compromised
Solution Approach 1:
The invention extracts the wear sensing function from the bulk material flow path and relocates it to the perimeter face of the wear tile. By mounting sensors on the perimeter face rather than inserting them through the tile, the system obtains wear measurements while preserving the structural integrity and continuity of the wear liner material.
Solution Approach 2:
The perimeter face of the wear tile serves as an intermediary surface that exposes wear information without requiring penetration of the tile structure. The wear pattern on the perimeter face indirectly indicates the wear state of the entire tile, allowing measurement without direct intrusion into the tile's interior.
2Measurement precision
If traditional wear sensor probes are used for real-time monitoring, then wear detection is enabled, but manufacturing and installation costs increase
Solution Approach 1:
The invention employs cost-effective sensor mounting solutions on the perimeter face of wear tiles, using simpler sensor configurations that do not require expensive custom probe manufacturing or complex installation procedures. The sensors are mounted in a manner that leverages existing tile structures rather than requiring additional expensive components.
3Productivity
If wear sensor probes are installed through wear tiles, then real-time monitoring is achieved, but installation complexity and disruption increase
Solution Approach 1:
The invention segments the wear monitoring function to be performed at the perimeter regions of wear tiles rather than requiring through-tile installation. This segmentation allows sensors to be mounted on accessible surface areas, simplifying installation while maintaining the ability to monitor wear across the tile structure.
Solution Approach 2:
The wear information is preliminarily available on the perimeter face of the tile during normal operation, allowing sensors to be mounted and begin monitoring without requiring shutdown or removal of existing tile structures. The perimeter face naturally exposes wear patterns that can be immediately detected.
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
Enables real-time, high-resolution wear detection with reduced costs and minimal disruption to operations, allowing for continuous monitoring and effective process control in abrasive material handling environments.
Implementation Method 1
the wear sensor is an inductive wear sensor including an inductive coil loop mounted directly to the perimeter face of the corresponding wear resistant tile
Data Source
AI summary
The present invention relates broadly to a wear liner module (10) for equipment in a high wear environment, said module (10) comprising a back plate (12) and a wear liner (11) including one or more tiles (14a) to (14f) formed of wear resistant material, and one or more sensors such as (16a) mounted to the wear resistant tile such as (14a). The wear sensor (16a) is mounted to a perimeter face of the corresponding wear resistant tile (14a). The wear sensor (16a) is electrically coupled to a microprocessor mounted to a rear face of the tile (14a). The microprocessor is configured to process data received from the wear sensor (16a) to provide a wear signal represented of wear in the wear sensor (16a). The microprocessor (24a) transmits the wear signal to a wireless receiver (34a) mounted to the backing plate (12).