Mine Hoist Monitoring System

Abstract

A mine hoist monitoring system (102) for monitoring a mine hoist (100) comprising a hoist drum (120), the mine hoist monitoring system (102) comprising a hoist controller (150) configured for controlling the mine hoist (100); a plurality of strain gauges (144) mounted on the hoist drum (120); and at least one drum data node (140) mounted on the hoist drum (120), the plurality of strain gauges (144) being coupled to the at least one drum data node (140), wherein the at least one drum data node (140) is configured for determining strain signals indicative of strain in the hoist drum (120) using the plurality of strain gauges (144); wherein the at least one drum data node (140) is configured for transmitting the strain signals to the hoist controller (150); wherein the hoist controller (150) is configured for determining a strain distribution in the hoist drum (120) based on the strain signals received from the at least one drum data node (140), and wherein the hoist controller (150) is configured for visualizing the strain distribution.

Claims

1. A mine hoist monitoring system for monitoring a mine hoist including a hoist drum, the mine hoist monitoring system comprising: a hoist controller for controlling the mine hoist; a plurality of strain gauges configured to be mounted on the hoist drum; and at least one drum data node configured to be mounted on the hoist drum, the plurality of strain gauges being coupled to the at least one drum data node, wherein the at least one drum data node determines strain signals indicative of strain in the hoist drum using the plurality of strain gauges; wherein the at least one drum data node transmits the strain signals to the hoist controller; wherein the hoist controller determines a strain distribution in the hoist drum based on the strain signals received from the at least one drum data node, wherein the hoist controller visualizes the strain distribution; and wherein the hoist controller determines a current loading condition of the hoist drum from the strain distribution in the hoist drum, and wherein the hoist controller further tracks a consumed fatigue life over time based on the current loading condition.

2. The mine hoist monitoring system according to claim 1, wherein each of the at least one drum data node comprises a transmitter configured for transmitting the strain signals to the hoist controller using wireless transmission.

3. The mine hoist monitoring system according to claim 1, wherein at least one strain gauge of the plurality of strain gauges is arranged at an inner drum joint, wherein the inner drum joint joins a radial structural member of the hoist drum and a shaft flange of a drive shaft of the hoist drum, or wherein the inner drum joint joins a radial structural member and a shaft sleeve of the hoist drum, the shaft sleeve being mounted to a drive shaft of the hoist drum.

4. The mine hoist monitoring system according to any claim 1, wherein at least one strain gauge of the plurality of strain gauges is arranged at a cylinder joint joining a radial structural member of the hoist drum and a drum cylinder of the hoist drum, the radial structural member being positioned radially between a drive shaft of the hoist drum and the drum cylinder.

5. The mine hoist monitoring system according to claim 1, wherein the at least one drum data node comprises an energy storage device for supplying power to the at least one drum data node.

6. The mine hoist monitoring system according to claim 1, wherein the hoist controller is configured for generating an alarm if the strain signals and/or the strain distribution are indicative of a strain in the hoist drum being equal or greater than a strain threshold.

7. The mine hoist monitoring system according to any claim 1, wherein the hoist controller is configured for controlling the mine hoist based on the current loading condition.

8. The mine hoist monitoring system according to any claim 1, wherein determining the strain distribution by the hoist controller includes determining a partial strain distribution for each of the strain signals and determining the strain distribution based on the partial strain distributions.

9. The mine hoist monitoring system according to claim 8, wherein the partial strain distributions are determined based on a model of the hoist drum.

10. A method of monitoring a mine hoist including a hoist drum, the method comprising: determining, by at least one drum data node mounted on the hoist drum, strain signals indicative of strain in the hoist drum, wherein the at least one drum data node determines the strain signals using a plurality of strain gauges coupled to the at least one drum data node, the plurality of strain gauges being mounted on the hoist drum; transmitting, by the at least one drum data node, the strain signals to a hoist controller, the hoist controller being configured for controlling the mine hoist; determining, by the hoist controller, a strain distribution in the hoist drum based on the strain signals; and visualizing the strain distribution; determining a current loading condition of the hoist drum from the strain distribution in the hoist drum; and tracking, by the hoist controller, a consumed fatigue life over time based on the current loading condition.

11. The method according to claim 10, wherein transmitting the strain signals to the hoist controller includes a wireless transmission of the strain signals.

12. The method according to claim 10, further comprising: generating, by the hoist controller, an alarm if the strain signals or the strain distribution are indicative of a strain in the hoist drum being equal or greater than a strain threshold.

13. (canceled)

14. The method according to claim 10, wherein determining the strain distribution comprises determining a partial strain distribution for each of the strain signals and determining the strain distribution based on the partial strain distributions.

15. The method according to claim 14, wherein the partial strain distributions are determined based on a model of the hoist drum.

16. A mine hoist comprising a mine hoist monitoring system including a hoist controller configured for controlling the mine hoist; a plurality of strain gauges configured to be mounted on the hoist drum; and at least one drum data node configured to be mounted on the hoist drum, the plurality of strain gauges being coupled to the at least one drum data node, wherein the at least one drum data node determines strain signals indicative of strain in the hoist drum using the plurality of strain gauges; wherein the at least one drum data node transmits the strain signals to the hoist controller; wherein the hoist controller determines a strain distribution in the hoist drum based on the strain signals received from the at least one drum data node, wherein the hoist controller visualizes the strain distribution; and wherein the hoist controller determines a current loading condition of the hoist drum from the strain distribution in the hoist drum, and wherein the hoist controller further tracks a consumed fatigue life over time based on the current loading condition.

17. The mine hoist monitoring system according to claim 2, wherein at least one strain gauge of the plurality of strain gauges is arranged at an inner drum joint, wherein the inner drum joint joins a radial structural member of the hoist drum and a shaft flange of a drive shaft of the hoist drum, or wherein the inner drum joint joins a radial structural member and a shaft sleeve of the hoist drum, the shaft sleeve being mounted to a drive shaft of the hoist drum.

18. The mine hoist monitoring system according to claim 2, wherein at least one strain gauge of the plurality of strain gauges is arranged at a cylinder joint joining a radial structural member of the hoist drum and a drum cylinder of the hoist drum, the radial structural member being positioned radially between a drive shaft of the hoist drum and the drum cylinder.

19. The mine hoist monitoring system according to claim 2, wherein the at least one drum data node comprises an energy storage device for supplying power to the at least one drum data node.

20. The mine hoist monitoring system according to claim 2, wherein the hoist controller is configured for generating an alarm if the strain signals and/or the strain distribution are indicative of a strain in the hoist drum being equal or greater than a strain threshold.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0041] The accompanying drawings relate to embodiments of the disclosure and are described in the following:

[0042] FIG. 1 schematically illustrates a mine hoist and a mine hoist monitoring system according to embodiments described herein;

[0043] FIGS. 2A-2B each schematically illustrate a hoist drum according to embodiments;

[0044] FIG. 3 schematically illustrates a flow diagram of a method according to embodiments; and

[0045] FIGS. 4A-4B schematically illustrate a visualization of a hoist drum according to embodiments of the present disclosure.

DETAILED DESCRIPTION

[0046] Reference will now be made in detail to the various embodiments of the disclosure, one or more examples of which are illustrated in the figures. Within the following description of the drawings, the same reference numbers refer to same components. Generally, only the differences with respect to individual embodiments are described. Each example is provided by way of explanation of the disclosure and is not meant as a limitation of the disclosure. Further, features illustrated or described as part of one embodiment can be used on or in conjunction with other embodiments to yield yet a further embodiment. It is intended that the description includes such modifications and variations.

[0047] FIG. 1 schematically illustrates a mine hoist 100 for underground mining including a mine hoist monitoring system 102 according to embodiments described herein. The mine hoist 100 includes a hoist drum 120, the hoist drum 120 having a drive shaft supported by bearings 118 of the mine hoist 100. The hoist drum 120 can be rotated by a mine hoist drive (not shown). The hoist drum 120 includes a rope support surface for supporting one or more ropes 114. Each end of the rope 114 is connected to a conveyance 116 of the mine hoist 100, the conveyances being configured for receiving mined material, mining equipment and/or mining personnel. In FIG. 1, the rope 114 is redirected by a diverter pulley 112. The mine hoist 100 is configured to move the conveyances 116 in a mine shaft 110 by rotating the hoist drum 120.

[0048] The mine hoist monitoring system 102 includes a plurality of strain gauges 144 and a drum data node 140. The plurality of strain gauges 144 and the drum data node 140 are mounted on the hoist drum 120. Each of the plurality of strain gauges 144 is coupled to the drum data node 140 via a sensor connection 146. In FIG. 1, each strain gauge 144 of the plurality of strain gauges 144 is particularly coupled to a single drum data node 140 by a sensor connection 146 being provided as a wired connection. The drum data node 140 is configured for determining strain signals indicative of strain in the hoist drum 120 using the plurality of strain gauges 144. The drum data node 140 includes a transmitter for transmitting the strain signals by wireless transmission 142.

[0049] The mine hoist monitoring system 102 includes a hoist controller 150 or hoist control system. The hoist controller 150 is positioned off the hoist drum 120, particularly not on the hoist drum 120. In FIG. 1, the hoist controller 150 inter alia includes a receiver gateway 154, a control cabinet 152 and a local or remote operator station 156. The receiver gateway 154 is positioned within a transmission range of the drum data node 140. The receiver gateway 154 is configured for receiving the strain signals from the drum data node 140 by wireless transmission 142. The receiver gateway 154 is communicatively coupled to the control cabinet 152 and transmits the strain signals to the control cabinet 152, which is configured for determining a strain distribution in the hoist drum 120 based on the strain signals. It should be understood that in further embodiments the strain distribution may be determined for example by any local or remote computer or server of the hoist controller 150 or hoist control system. The hoist controller 150 is configured for visualizing the strain distribution on a local or remote operator station 156, particularly on a display of the operator station 156.

[0050] FIG. 2A schematically illustrates an axial section of a hoist drum 120 with a plurality of strain gauges 144 and a drum data node 140 mounted on the hoist drum 120. The hoist drum 120 includes a drum cylinder 132 having a rope support surface 133 for supporting the ropes 114 of the mine hoist. The drum cylinder 132 is arranged coaxially with a drive shaft 122 of the hoist drum 120 around a rotational axis 124 of the hoist drum 120. The configuration of the hoist drum 120 illustrated in FIG. 2A is often referred to as clutched drum. The hoist drum 120 includes shaft sleeves 126 mounted on the drive shaft 122. Radial structural members 128, in FIG. 2A an annular disk, extends radially between each of the shaft sleeves 126 and the drum cylinder 132. The radial structural members 128 are configured for transmitting loads between the drum cylinder 132 and the drive shaft 122. The radial structural members 128 are each joined to one of the shaft sleeves 126 by an inner drum joint 130. The radial structural members 128 are each joined to the drum cylinder 132 by a cylinder joint 134. In the example of FIG. 2A, the inner drum joints 130 and the cylinder joints 134 are formed as a welded joint.

[0051] In FIG. 2A, strain gauges 144 of the plurality of strain gauges 144 are mounted at each of the inner drum joints 130 and the cylinder joints 134. In particular, six circumferentially spaced strain gauges 144 are mounted at each of the inner drum joints 130 and the cylinder joints 134. The drum data node 140 is mounted to one of the radial structural members 128. It should be understood that in further embodiments, the drum data node may be mounted to another part of a hoist drum, e.g., the drum cylinder, a shaft sleeve or a location suitable for wireless data transmission towards an receiver gateway of the hoist controller. Each of the plurality of strain gauges 144 is connected to the drum data node 140 by a sensor connection 146. The drum data node 140 includes a battery for supplying power to the drum data node 140 and to the plurality of strain gauges 144. The battery is configured to supply the drum data node 140 and the plurality of strain gauges 144 with energy over months or more than year.

[0052] FIG. 2B shows a hoist drum 120 of a different configuration than in FIG. 2A, in particular a configuration often referred to as fixed drum. The drive shaft 122 includes shaft flanges 136 protruding in a radially outward direction from the drive shaft 122. Each of the radial structural members 128 is joined to one of the shaft flanges 136 by a flange joint. In particular, the radial structural members 128 each include a flange portion at the inner radial end of the radial structural member 128. The flange portion of each of the radial structural members 128 is joined by bolts 138 to a shaft flange 136, forming an inner drum joint 130 of the hoist drum 120. The plurality of strain gauges 144 and the drum data node 140 are mounted similarly as in FIG. 2A.

[0053] FIG. 3 schematically illustrates a flow diagram of a method 300 of monitoring a mine hoist 100, particularly a mine hoist 100 as described herein. At block 310, the drum data node 140 determines strain signals indicative of strain in the hoist drum 120 using the plurality of strain gauges 144. At block 320, the drum data node 140 transmits the strain signals to the hoist controller 150 by wireless transmission. The hoist controller 150 receives the strain signals via a receiver gateway 154 of the hoist controller 150.

[0054] At block 330, the hoist controller 150 determines a partial strain distribution for each of the strain signals, wherein each of the partial strain distributions is determined based on a strain signal associated with a strain gauge and based on a spatial distribution of strain factors corresponding to the strain gauge. For each strain gauge 144, a corresponding spatial distribution of strain factors is based on a previously run finite element analysis of a loading condition of the hoist drum 120. The hoist controller 150 further determines a strain distribution in the hoist drum 120 based on the partial strain distributions, particularly by superposing the partial strain distributions. At block 330, the hoist controller 150 further tracks a consumed fatigue life based on the strain signals. In particular, the hoist controller 150 increases the consumed fatigue life depending on the loading condition experienced by the hoist drum 120, the loading condition being indicated by the strain signals. At block 330, the hoist controller 150 further generates an alarm if the strain signals or the strain distribution are indicative of a strain in the hoist drum being equal or greater than a strain threshold.

[0055] At block 340, the hoist controller 150 visualizes the strain distribution, the consumed fatigue life and/or the remaining fatigue life on a display of an operator station 156. Further, if an alarm was generated at block 330, the hoist controller 150 visualizes the alarm on the display of the operator station. Additionally or alternatively, the hoist controller 150 may generate an alarm sound.

[0056] FIGS. 4A and 4B schematically illustrate visualizations of strain distributions by the hoist controller 150. In FIGS. 4A and 4B, the visualizations include a visualized hoist drum 420 having a visualized drive shaft 422, visualized shaft sleeves 426, visualized radial structural members 428 and a visualized drum cylinder 432. The visualizations correspond to a type of hoist drum as illustrated for example in FIG. 2A. It should be understood that a similar visualization may be provided for a hoist drum as illustrated in FIG. 2B or other configurations of hoist drums. FIG. 4A illustrates a strain distribution of a hoist drum 120 under little or no load. FIG. 4B shows a visualized hoist drum 420 corresponding to a hoist drum 120 under high load. In FIG. 4B, the strain intensities of the strain distribution are visualized as local deformations of the visualized hoist drum 420. In further embodiments, the strain intensities of the strain distribution may be additionally or alternatively visualized, e.g., by color-coding. Embodiments of the present disclosure can enable the generation of a digital twin model of the hoist drum based on an analysis, visualization, logging and/or tracking of strain conditions in the hoist drum. Such a digital twin model may enable monitoring and controlling of the mine hoist to increase the safety or efficiency of mine hoist operation, avoid mine hoist failures or reduce downtime costs or maintenance costs of the mine hoist.

[0057] While the foregoing is directed to embodiments of the disclosure, other and further embodiments of the disclosure may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims that follow.