Patent Description:
The present disclosure also relates to a system for a comminution apparatus, a method of manufacturing a wear sensing liner for a comminution apparatus and a comminution apparatus comprising the wear sensing liner or the wear sensing system.

Crushers are used in the mining and construction industries for reducing large rocks into smaller rocks, gravel, or grit. Typically, crushers hold rock material between two parallel or angled rigid crushing surfaces and apply force to bring the surfaces together to fracture or deform the rock material. Crushers take various forms including jaw crushers, gyratory crushers, cone crushers, horizontal shaft impactors and vertical shaft impactors.

The crushing surfaces are subjected to rapid wear because of the inherently abrasive action of the rock material. Consequently, each crushing surface is generally lined with at least one wear liner formed from a hardened, wear resistant material. Necessarily, the wear liner is also subjected to wear and must be replaced on a regular basis, leading to process downtime while the crusher undergoes maintenance which results in reduced productivity.

Due to the unpredictable nature of wear rate, it is necessary to monitor ongoing wear of the wear liner during its operational life. Such monitoring requires the cessation of operation of the crusher to conduct a visual inspection of wear. This is a time consuming task that also leads to lost productivity and revenue. A wear sensing liner for a comminution apparatus comprising a liner body and a sensor to sense wear of the liner body is disclosed in document <CIT>.

According to a first aspect of the disclosure, there is provided a wear sensing liner for a comminution apparatus, the wear sensing liner comprising:.

wherein the insert is configured to receive the rigid sleeve of the at least one sensor when the at least one sensor is mounted to the liner body.

In some embodiments, a distal end of the at least one sensor is aligned with the wear surface of the liner body.

In some embodiments, the output signal corresponds to a physical parameter associated with the liner body, the physical parameter being representative of the wear of the wear surface side of the liner body.

In some embodiments, the physical parameter is a depth of the liner body in a region of the at least one sensor.

In some embodiments, the at least one sensor is an optical fibre sensor.

In some embodiments, the at least sensor comprises an optical fibre core.

In some embodiments, the wear sensing liner further comprises an electromagnetic radiation source configured to generate light that is directed through the optical fibre core of the at least one sensor.

In some embodiments, the optical fibre core of the at least one sensor comprises at least one dielectric mirror located at a known position along a length of the optical fibre core.

In some embodiments, the signal output by the at least one sensor comprises reflected light.

In some embodiments, the at least one dielectric mirror is configured to reflect a specified wavelength of the light, thereby producing the reflected light.

In some embodiments, the at least one sensor comprises a plurality of dielectric mirrors arranged at spaced intervals along the optical fibre core.

In some embodiments, the specified wavelength of each dielectric mirror is different to each other specified wavelength.

In some embodiments, the at least one sensor comprises a printed circuit board comprising a sensing circuit configured to wear with wear of the liner body.

In some embodiments, the sensing circuit comprises a plurality of impedance elements arranged in parallel and positioned at known positions along a length of the at least one sensor.

In some embodiments, the at least one sensor is configured to be received within an opening defined by the liner body.

In some embodiments, the sleeve is configured to mount the at least one sensor to the liner body with a mechanical connection.

In some embodiments, the at least one sensor is configured to be connected to the liner body with an adhesive.

In some embodiments, the insert is configured to be positioned with respect to the liner body during fabrication of the wear sensing liner.

In some embodiments, the insert is configured to melt at a higher temperature than the material(s) constituting the liner body, such that the insert can be positioned in the liner body when the liner body is formed.

In some embodiments, the wear sensing liner comprises a plurality of sensors, wherein the plurality of sensors are arranged in an array with respect to the liner body so as to indicate mechanical degradation across the liner body.

In some embodiments, the wear sensing liner comprises a data recorder configured to communicate with the at least one sensor, the data recorder comprising:.

According to a second aspect of the disclosure, there is provided a wear sensing system for a comminution apparatus, comprising:.

In some embodiments, the computing device is configured to determine an indication of wear of the wear sensing liner.

In some embodiments, the computing device is configured to determine a wear rate of the wear sensing liner.

In some embodiments, the computing device is configured to determine an estimated remaining lifetime of the wear sensing liner.

In some embodiments, the computing device is configured to generate an alarm when the determined wear is equal to or less than a wear threshold.

In some embodiments, the computing device is configured to generate an alarm when the wear rate is equal to or greater than a wear rate threshold.

In some embodiments, the computing device is configured to generate an alarm when the estimated remaining lifetime is equal to or less than a lifetime threshold.

In some embodiments, the computing device is configured to transmit the control signal to a comminution controller of the comminution apparatus when the determined wear is equal to or less than a wear threshold, thereby deactivating the comminution apparatus, or changing the comminution apparatus operating parameter.

In some embodiments, the computing device is configured to transmit the control signal to a comminution controller of the comminution apparatus when the wear rate is equal.

to or greater than a wear rate threshold, thereby deactivating the comminution apparatus, or changing the comminution apparatus operating parameter.

In some embodiments, the computing device is configured to transmit the control signal to a comminution controller of the comminution apparatus when the estimated remaining lifetime is equal to or less than a lifetime threshold, thereby deactivating the comminution apparatus, or changing the comminution apparatus operating parameter.

According to a third aspect of the disclosure, there is provided a comminution apparatus comprising the wear sensing liner as defined above, or the wear sensing system as defined above.

In an example there is provided a wear sensing liner for a comminution apparatus, the wear sensing liner comprising;.

In some embodiments, the fibre sensor comprises an optical fibre having one or more fibre Bragg gratings.

In some embodiments, the fibre sensor is provided with a rigid sleeve for housing a portion of the fibre sensor.

In some embodiments, the rigid sleeve may have a distal end located at or proximal to the rear surface of the liner body.

In some embodiments, the rigid sleeve may be configured to be threadedly engaged with a threaded recess in the liner body.

In some embodiments, the rigid sleeve may be configured to be inserted into a recess in the liner body and retained therein with an adhesive material.

In some embodiments, the rigid sleeve may comprise a material having a higher melting point than a castable material from which the liner body is cast, thereby allowing the rigid sleeve to be embedded in the liner body when the liner body is cast.

In some embodiments, a plurality of fibre sensors are arranged in an array with respect to the liner body so as to monitor mechanical degradation across the wear surface during operation of the comminution apparatus.

In some embodiments, the wear sensing liner further comprises a data recorder configured to record the signal(s) from the one or more fibre sensors.

In some embodiments, the data recorder may be configured to record the signal(s) from the one or more fibre sensors in real time or near real time.

In some embodiments, the wear sensing liner further comprises an antenna configured to transmit the signal(s) to a remote device.

In some embodiments, the antenna may be configured to transmit the signal(s) from the one or more fibre sensors in real time or near real time.

According to another example, there is provided a wear monitoring system for monitoring wear of a wear liner for a comminution apparatus, the wear monitoring system comprising:.

In some embodiments, the extent of wear and/or the wear rate may be displayed on a graphical user interface display of the remote device.

In some embodiments, the remote device may be further configured to receive the signal(s) in a real time or near real time.

In some embodiments, the remote device may be further configured to determine and display the one or more physical parameters related to the extent of wear and/or the wear rate of the wear surface.

In some embodiments, the remote device may be further configured to determine and display an estimated time to failure of the wear sensing liner.

In some embodiments, the remote device may be further configured to generate an alarm when the extent of wear reaches a predetermined wear threshold.

According to a further example, there is provided a method of monitoring wear of a wear liner for a comminution apparatus, the method comprising:.

In some embodiments, the method further comprises predicting time to failure from the extent of wear and/or the wear rate.

In some embodiments, of the method further comprises replacing the wear sensing liner prior to the predicted time to failure.

In some embodiments, the method further comprises displaying the extent of wear and/or wear rate as a graphical representation.

In some embodiments, the receiving and displaying steps may be performed in real time or near real time.

Embodiments of the disclosure will now be described by way of example with reference to the accompanying drawings in which:.

<FIG> illustrate a first embodiment of a sensor <NUM> for use in monitoring wear of a wear sensing liner, as will be described in greater detail below. The sensor <NUM> is configured to sense a physical parameter and to produce a signal indicative of the physical parameter being sensed. Examples of the physical parameter sensed include a depth of the wear sensing liner in which the sensor is mounted in use, strain, temperature, pressure, vibration or the like.

In all cases, the sensor <NUM> monitors the physical parameter at a distal end <NUM> of the sensor <NUM>. As will be described in greater detail below, the sensor <NUM> is a sacrificial sensor and degrades over time by being shortened as the wear sensing liner in which the sensor <NUM> is mounted wears in use. Thus, it will be appreciated that the distal end <NUM> of the sensor <NUM> will transit up towards a proximal end of the sensor <NUM> with time, i.e. the effective length of the sensor <NUM> is shortened.

In the embodiment shown in <FIG> of the drawings, the sensor <NUM> is a fibre optic sensor and comprises an optical fibre core <NUM>. The optical fibre core <NUM> is configured to transmit and reflect electromagnetic radiation between a first end and a second end of the optical fibre core <NUM>. The optical fibre core <NUM> may be an elongate length of transparent silica or polymer, for example.

The optical fibre core <NUM> is radially surrounded by a protecting portion, or sheath <NUM>. The sheath <NUM> comprises one or more of a cladding with a lower index of refraction than the optical fibre core <NUM>, a coating, a strengthening portion configured to provide strength and/or rigidity to the optical fibre core, and an outer jacket.

The sensor <NUM> comprises a rigid sleeve <NUM> surrounding the sheath <NUM>. The sleeve <NUM> houses at least a portion of the sensor <NUM>. The sleeve <NUM> is configured to facilitate mounting of the sensor <NUM> within a bore of the wear sensing liner. The sleeve <NUM> has an external thread to enable it to be threadedly engaged with the correspondingly, internally threaded bore of the wear sensing liner. In other embodiments (not shown), the sleeve <NUM> is configured to be a press fit or a snap fit in the bore of the wear sensing liner. Further, in some embodiments (not shown), the sleeve is <NUM> is mounted in the bore of the wear sensing liner and retained in the bore with an adhesive.

The sensor <NUM> is configured to be connected to an electromagnetic radiation source (not shown) in the form of a light source. The light may be in the form of visible light. The light source generates light and directs the light through the optical fibre core <NUM>.

The sensor <NUM> comprises a plurality of dielectric mirrors <NUM> arranged at longitudinally spaced intervals within the optical fibre core <NUM>. Each dielectric mirror <NUM> may be in the form of an electromagnetic radiation filter, light filter or, instead, a distributed reflector. The dielectric mirrors <NUM> are positioned at known, spaced positions along the length of the optical fibre core <NUM>. In other words, the spacing between adjacent dielectric mirrors <NUM> is known.

The dielectric mirrors <NUM> are evenly spaced along the length of the optical fibre core <NUM>, as illustrated in <FIG>. In another embodiment (not shown), the dielectric mirrors <NUM> may be irregularly spaced along the length of the optical fibre core <NUM>. For example, a density of the dielectric mirrors <NUM> towards the distal end <NUM> (a distal density) may be greater than a density of the dielectric mirrors <NUM> towards the other, proximal end (a proximal density). Alternatively, the density of the dielectric mirrors <NUM> towards the distal end <NUM> may be less than the density of the dielectric mirrors <NUM> towards the other, proximal end. Increasing the density of dielectric mirrors <NUM> improves the resolution of the sensor <NUM>.

Each dielectric mirror <NUM> is configured to reflect a specified wavelength, or a specified range of wavelengths of light, whilst transmitting the remaining wavelengths, thereby producing reflected light. In some embodiments, the wavelength, or range of wavelengths of light associated with each dielectric mirror <NUM> (that is, the wavelength, or range of wavelengths reflected by that dielectric mirror <NUM>), differs from the wavelengths, or range of wavelengths, of light associated with any other dielectric mirror <NUM> of the sensor <NUM>. In other words, each of the dielectric mirrors <NUM> is configured to reflect a different specified wavelength or specified range of wavelengths.

When the light source directs light through the optical fibre core <NUM>, each dielectric mirror <NUM> reflects a portion of that light. The reflected light forms at least a part of the signal produced by the sensor <NUM>. The reflected light comprises a superposition of the wavelengths of light reflected by each dielectric mirror <NUM>. The resolution of the sensor <NUM> therefore corresponds with the separation of adjacent dielectric mirrors <NUM>.

As previously described, the sensor <NUM> is configured to detect wear along its length <NUM>. As the sensor <NUM> wears along its length <NUM>, the dielectric mirrors <NUM> will also be sequentially worn away. As each dielectric mirror <NUM> is worn away, the reflected light representative of the superposition of the wavelengths of light reflected by each dielectric mirror <NUM> of the sensor <NUM> will change. The absence of the specified wavelength(s) associated with a particular dielectric mirror <NUM> contributing to the superposition, and the known position of that dielectric mirror <NUM> along the length of the optical fibre core <NUM> indicates wear of the sensor <NUM> at least to that known position. The wear rate of the sensor <NUM> can also be determined by associating the wear between two or more dielectric mirrors <NUM> with a measured time frame.

In an embodiment, each dielectric mirror <NUM> is in the form of a fibre Bragg grating. That is, the optical fibre core <NUM> of each sensor <NUM> contains a plurality of longitudinally spaced fibre Bragg gratings positioned at known locations along the length of the optical fibre core <NUM>. The inclusion of fibre Bragg gratings in the optical fibre core <NUM>, causes the reflection of particular wavelengths of light (the superposition of which forms a Bragg wavelength) while allowing the transmission of the remaining wavelengths. A reflected peak is measured and compared to a control peak for variations that can be attributed to the physical parameter and/or changes in the physical parameter (e.g. depth or thickness of the wear sensing liner, temperature, strain, pressure, vibration, or the like).

The physical parameter and changes in the physical parameter can be determined by measuring the signal comprising the reflected light. The physical parameter changes can be determined by measuring the changes in the wavelengths of the reflected light, or changes in the superposition of the reflected light, for example, shifts in the Bragg wavelength. These changes in the wavelengths of the reflected light, or changes in the superposition of the reflected light can then be converted to values representing the physical parameter. In an example, the superposition of the reflected light shifts when the respective sensor <NUM> encounters a change in temperature, such as an increase in temperature. This shift can be detected, and used to determine the change in temperature.

When multiple fibre Bragg gratings are included in each optical fibre core <NUM>, each fibre Bragg grating is configured to reflect different wavelengths of electromagnetic radiation as previously described, producing a multiplexed signal. In an example, as the sensor <NUM> is worn away and reduces in length, fibre Bragg gratings are consecutively destroyed from the distal end <NUM> of the optical fibre core <NUM> of the sensor <NUM>. This leads to a cessation of their respective reflected Bragg wavelengths. As the spacing between each fibre Bragg grating is known, the extent of wear of the sensor <NUM> may be easily determined. Additionally, the wear rate may be easily determined by associating the extent of wear with a measured time frame.

The sensor <NUM> is advantageously resistant to electromagnetic and radio frequency interference. Furthermore, the sensor <NUM> is resistant to chemicals, radioactivity, corrosion, and lightning. The sensor <NUM> has a high sensitivity, produces a high resolution signal and is highly responsive. The sensor <NUM> can be manufactured in a small form-factor, and can be easily connected to other components. The sensor <NUM> advantageously allows for the measurement of wear, temperature, strain and/or pressure via a reduction in the length <NUM> of the sensor <NUM>.

<FIG> illustrates a cross section of another embodiment of the sensor <NUM> to sense the physical parameter. With reference to <FIG>, like reference numerals refer to like parts unless otherwise specified.

The sensor <NUM> comprises a printed circuit board (PCB) <NUM>. The PCB <NUM> carries a sensing circuit <NUM> comprising a plurality of electrical impedance elements, each in the form of a resistor, <NUM>, arranged in parallel. Opposed ends <NUM>, <NUM> of the sensing circuit <NUM> are connected to conductors <NUM>, <NUM>, respectively, for connection to a signal processing module <NUM> (illustrated in <FIG>). In some embodiments, the PCB <NUM> is in the form of a flexible printed circuit. The sensor <NUM> may comprise a power source (not shown), for example, a battery, that is configured to power the sensor <NUM> and to allow the determination of a characteristic of the sensing circuit <NUM>.

Each resistor <NUM> has a known impedance. The impedance of each resistor <NUM> may be the same as each other resistor <NUM>. Alternatively, the impedances of the resistors <NUM> may differ from one another. Each resistor <NUM> is positioned at a known position along the length of the sensor <NUM>. Furthermore, the spacing between adjacent resistors <NUM> is known.

The resistors <NUM> are evenly spaced along the length of the PCB <NUM>, as illustrated in <FIG>. In another embodiment (not shown), the resistors <NUM> may be irregularly spaced along the length of the PCB <NUM>. For example, a density of the resistors <NUM> towards the distal end <NUM> (a distal density) may be greater than a density of the resistors <NUM> towards the other, proximal end (a proximal density) of the PCB <NUM>. Alternatively, the density of the resistors <NUM> towards the distal end <NUM> may be less than the density of the resistors <NUM> at the other end. Increasing the density of resistors <NUM> improves the resolution of the sensor <NUM>.

The sensor <NUM> comprises the rigid sleeve <NUM> housing an elongate portion of the PCB <NUM>. As with the previous embodiment, the sleeve <NUM> facilitates mounting of the sensor <NUM> within a bore of the wear sensing liner. The sleeve <NUM> has an external thread to enable it to be threadedly engaged with the correspondingly, internally threaded bore of the wear sensing liner. In other embodiments (not shown), the sleeve <NUM> is configured to be a press fit or a snap fit in the bore of the wear sensing liner. Further, in some embodiments (not shown), the sleeve is <NUM> is mounted in the bore of the wear sensing liner and retained in the bore with an adhesive.

As previously described, the sensor <NUM> is configured to produce a signal indicative of the physical parameter. As the sensor <NUM> is worn down by abrasion of the wear sensing liner in which it is mounted, the distal most resistor <NUM> will also be destroyed by being worn away. As each distal resistor <NUM> is worn away, the impedance of the sensing circuit <NUM> changes. The impedance of the sensing circuit <NUM> is therefore indicative of the length of the sensor <NUM> and is therefore also indicative of wear of the sensor <NUM>. Thus, when the impedance of the sensing circuit <NUM> indicates that a particular resistor <NUM> has been worn away, it is able to be inferred that the length of the sensor <NUM> has worn to at least that known position. The resolution of the sensor <NUM> therefore corresponds with the separation of adjacent resistors <NUM>. The wear rate of the sensor <NUM> can be determined by associating the wear between two or more resistors <NUM> with a measured time frame.

In an embodiment, particularly where the sensor <NUM> is to communicate wirelessly, the sensor <NUM> comprises a power source (not shown), for example, a battery. As will be described in greater detail below, the sensor <NUM> communicates with a signal processing module and, optionally, a wireless communications system. The sensor <NUM> may wirelessly transmit a data set generated by the sensor <NUM>. The complete data set may comprise a representation of the signal over time. In order to reduce power consumption, the sensor <NUM> may transmit an indication of a change in the signal and/or the physical parameter when detected, rather than transmitting the complete data set generated by the sensor <NUM>. Advantageously, this significantly reduces the amount of data transmitted, and the power consumption of the sensor <NUM>.

In an embodiment, the sensor <NUM> is configured to sense an alternative physical parameter. For example, the physical parameter sensed may comprise temperature, strain, vibration, pressure, or the like. Each impedance element <NUM> may be in the form of a thermistor, a strain gauge, a vibration sensor, or a pressure sensor. Alternatively, the sensor <NUM> comprises one or more sensing elements in addition to the impedance elements <NUM>. The sensing circuit <NUM> may comprise each sensing element. Each of the sensing elements is positioned at a known position along the length of the sensor <NUM>, as described with reference to the impedance elements, and therefore, the sensing elements provide an indication of the physical parameter along the length <NUM> of the sensor <NUM>.

The described sensor <NUM> advantageously allows for the provision of a wireless sensor <NUM> that can be used in difficult to access areas, or components. For example, the sensor <NUM> may comprise an antenna for wireless communication with remote units. The battery powers the sensing circuit <NUM> and the antenna, and provides, for example, a <NUM> to <NUM> month lifespan, allowing the sensor to operate without maintenance for an extended period of time.

A wear liner is designed and manufactured to be sacrificially worn instead of the crushing surface of a comminution apparatus. It is useful for an operator or a site supervisor to monitor the extent of wear and/or the wear rate of the wear liner during its operational life and to determine when the wear liner requires replacement. Additionally, it is useful to be informed of physical parameters that may affect the extent of wear and/or the wear rate of the wear liner. It will be appreciated by those skilled in the art that a reference to a wear liner as used herein may also apply to a wear plate.

<FIG> shows a first embodiment of a wear sensing liner <NUM>. The wear sensing liner <NUM> is configured as a wear plate for a hopper. The wear sensing liner <NUM> includes a liner body <NUM>. The wear sensing liner <NUM> also includes a plurality of sensors <NUM>, as described above. The wear sensing liner <NUM> may comprise, for example, a plurality of the sensors <NUM> described with reference to <FIG>, a plurality of the sensors <NUM> described with reference to <FIG>, or some combination thereof.

The liner body <NUM> comprises a plurality of rigid tiles <NUM>. In general, the tiles <NUM> are polygonal, such as rectangular, triangular, hexagonal, or another shape. The liner body <NUM> comprises a base <NUM>. Each sensor <NUM> is received within a hole <NUM> or opening. Each hole <NUM> is located at a corner of abutting tiles <NUM>. The plurality of holes <NUM> are formed during fabrication of the liner body <NUM> (e.g. by casting) or, instead, are formed, for example, by drilling, after the fabrication of the liner body <NUM>. Each sensor <NUM> is received in its associated hole <NUM> from an operatively rear surface of the base <NUM>. In this particular embodiment, each sensor <NUM> extends substantially through the entire depth of the liner body <NUM>.

<FIG> shows an embodiment of a wear sensing liner <NUM> for a comminution apparatus <NUM> (<FIG>) in the form of a cone crusher. More particularly, the wear sensing liner <NUM> is for a bowl or shell of the cone crusher. The wear sensing liner <NUM> comprises a liner body <NUM>. The liner body <NUM> comprises a wear surface side <NUM> and an operatively rear surface side <NUM>. The wear surface side <NUM> defines a wear surface <NUM> and the rear surface side <NUM> defines a rear surface <NUM>.

The body <NUM> of the wear sensing liner <NUM> defines a plurality of holes <NUM>. Each of the plurality of holes <NUM> spans at least a portion of a depth of the liner body <NUM>. In the illustrated embodiment, each of the plurality of holes <NUM> spans the entire depth of the liner body <NUM>. That is, each of the plurality of holes <NUM> extends from the wear surface side <NUM> to the rear surface side <NUM> of the liner body <NUM>. Once again, the holes <NUM> are formed during fabrication, for example during casting, of the liner body <NUM> or, instead, are formed, for example, by drilling, after fabrication.

An insert <NUM> is received in each hole <NUM> of the liner body <NUM> of the wear sensing liner <NUM>. In an embodiment, each insert <NUM> is threadedly inserted into a respective hole <NUM> of the liner body <NUM>. Each insert <NUM> thus provides a securing point for a respective sensor <NUM>. A wear surface end (e.g. a distal end) of each insert <NUM> is flush with the wear surface <NUM> of the liner body <NUM>. As illustrated, one or more of the inserts <NUM> partially spans the depth of the liner body <NUM>, the relevant insert/s <NUM> terminating short of the rear surface <NUM> of the liner body. Instead, one or more of the inserts <NUM> may span the entire depth of the liner body <NUM>. That is, the relevant insert <NUM> may extend from the wear surface side <NUM> of the liner body <NUM> to the rear surface side <NUM>. Therefore, those inserts <NUM> may also be flush with the rear surface <NUM> of the liner body <NUM>.

Drilling the holes <NUM> in the liner body <NUM> can result in localised regions of weakness. Therefore, in some embodiments, each insert <NUM> is positioned with respect to the liner body <NUM> during fabrication of the wear sensing liner <NUM>. For example, the liner body <NUM> may be cast from a castable liner body material. Each insert <NUM> may be positioned within a liner body mould before the liner body <NUM> is cast. Each insert <NUM> is configured to melt at a higher temperature than the liner body material. For example, each insert <NUM> may comprise tungsten carbide which has a greater than the melting point of the liner body <NUM> material. The liner body <NUM> is therefore able to be cast with each insert <NUM> in-situ.

The wear sensing liner <NUM> comprises a plurality of sensors <NUM> which are carried by the liner body <NUM>. Each sensor <NUM> is configured to sense wear of the wear surface side <NUM> of the liner body <NUM> in a region of the respective sensor <NUM>. Each sensor <NUM> is further configured to degrade in response to wear of the wear surface side <NUM> of the liner body <NUM> and, thus, each sensor <NUM> functions as a sacrificial sensor.

The sensors <NUM> are arranged in an array with respect to the liner body <NUM>, so as to monitor mechanical degradation across the wear surface side <NUM> of the liner body <NUM>. It is understood that, being arranged in an array, may comprise the sensors <NUM>, for example, being positioned in known positions across the liner body <NUM>. The positioning of each sensor <NUM> in the array may be regular, (e.g. a spacing between adjacent sensors <NUM> may be consistent), or may be irregular. For example, a higher density of sensors <NUM> may be positioned in regions of the liner body <NUM> that are expected to experience the greatest wear, so that those regions are able to be better monitored. For example, a lower portion density of the sensors <NUM>, being the density of the sensors <NUM> in an operatively lower portion of the liner body <NUM>, may be greater than a higher portion density of the sensors <NUM>, being the density of the sensors <NUM> in an operatively higher portion of the liner body <NUM>, or vice versa.

As described above, each sensor <NUM> comprises a rigid sleeve <NUM> housing at least a portion of the respective sensor <NUM>. Each sleeve <NUM> mounts its respective sensor <NUM> to the liner body <NUM> by being received in an associated insert <NUM>. In an embodiment, the rigid sleeve <NUM> has an external thread to enable it to be threadedly engaged within its associated insert <NUM>. In other embodiments (not shown), each sleeve <NUM> may connect to its associated insert <NUM> with a press fit or a snap fit. Further, in some embodiments (not shown), each sleeve <NUM> may be secured within its associated insert <NUM> with an adhesive.

Each sensor <NUM> is inserted into the liner body <NUM> from the operatively rear surface side <NUM> of the liner body <NUM> by threading the rigid sleeve <NUM> into its associated insert <NUM>. Each sensor <NUM> is inserted such that a wearing end (i.e., the distal end <NUM>) of each sensor <NUM> is aligned with the wear surface <NUM> of the liner body <NUM>. The length of each sensor <NUM> substantially spans the depth of the liner body <NUM>. Each sleeve <NUM> has a proximal end located at, or towards, the rear surface side <NUM> of the liner body <NUM>. The proximal end of each sleeve <NUM> may lie substantially flush with the rear surface <NUM> of the liner body <NUM>.

As previously described, each sensor <NUM> is operative to produce a signal representative of wear of the wear surface side <NUM> of the liner body <NUM> by monitoring a depth of the liner body <NUM> in a region of the respective sensor <NUM>. A change in the signal output by any one of the sensors <NUM> results from mechanical degradation of the wear surface side <NUM> around the sensor <NUM> and, likewise, the respective sensor <NUM>, during operation of the comminution apparatus <NUM>.

As previously described, in an embodiment, the wear sensing liner <NUM> carries a plurality of the sensors <NUM> of <FIG> of the drawings. Each of the sensors <NUM> is connected to the light source. Each sensor <NUM> is positioned at a known position with respect to the liner body <NUM>. Therefore, the position of each dielectric mirror <NUM> with respect to the liner body <NUM> is known, as is the position of each dielectric mirror <NUM> with respect to the wear surface <NUM>. The sensor <NUM> is responsive to wear along its length and, therefore, is configured to detect wear of the liner body <NUM> when carried by the liner body <NUM>.

As each dielectric mirror <NUM> is worn away with wear of the wear surface side <NUM> of the liner body <NUM>, the specified wavelength, or range of wavelengths, reflected by that dielectric mirror <NUM> will no longer be reflected. The reflected light, being the superposition of the wavelengths of light reflected by each dielectric mirror <NUM> of the sensor <NUM> will therefore also change. The known position of that dielectric mirror <NUM> along the length of the optical fibre core <NUM> results in the sensor outputting a signal indicative of wear of the liner body <NUM> at least to that known position. The wear rate of the liner body <NUM> can also be determined by associating the wear between two or more dielectric mirrors <NUM> with a measured time frame. As the liner body <NUM> comprises a plurality of sensors <NUM>, the wear of the liner body <NUM> can be mapped across the wear surface side <NUM>.

In another example, the superposition of the reflected electromagnetic radiation (e.g. the Bragg wavelength) shifts when the respective sensor <NUM> encounters a change in temperature, such as an increase in temperature. The change in temperature may then be associated with an external force acting upon the wear sensing liner <NUM>. This external force is indicative of mechanical degradation of the liner body <NUM>. Furthermore, the superposition of the reflected electromagnetic radiation changes when the sensor <NUM> is exposed to a change in pressure, such as an increase in pressure. The change in pressure may be determined and may be associated with an external force acting upon the wear sensing liner <NUM>. This external force is again indicative of mechanical degradation of the liner body <NUM>. Additionally, the superposition of the reflected light changes when a force is applied to the sensor <NUM> causing strain. The strain may be determined, and may be associated with the force acting upon the wear sensing liner <NUM>. This force is also indicative of mechanical degradation of the liner body <NUM>.

As previously described, in another embodiment, the wear sensing liner <NUM> comprises a plurality of the sensors <NUM> of <FIG> of the drawings. Each sensor <NUM> is positioned at a known position with respect to the liner body <NUM>. Therefore, the position of each resistor <NUM> with respect to the liner body <NUM> is known, as is the position of each resistor <NUM> with respect to the wear surface <NUM>.

Each sensor <NUM> is positioned, in use, in the liner body <NUM> such that a distal end of the PCB <NUM> of the sensor <NUM> is aligned with the wear surface <NUM> of the liner body <NUM>. The PCB <NUM> is configured to wear with wear of the sensor <NUM>, and, in particular, wear of the wear surface side <NUM> of the liner body <NUM>. The sensor <NUM> is responsive to wear along its length and, therefore, is configured to detect wear of the liner body <NUM>. As previously described, each sensor <NUM> may also be configured to sense one or more of temperature, strain, pressure or vibration. Therefore, each sensor <NUM> is configured to detect the temperature, strain, pressure or vibration associated with the liner body <NUM> in the region of the sensor <NUM>. This measurement is indicative of wear of the liner body <NUM> in the region of the respective sensor <NUM>.

The sensing circuit <NUM> is monitored by, for example, measuring a potential difference, current and/or impedance between the ends <NUM> and <NUM> of the sensing circuit <NUM>. As the sensor <NUM> degrades in response to wear of the wear surface side <NUM> of the liner body <NUM>, the sensing circuit <NUM> also degrades. In particular, the resistors <NUM> are sequentially worn away altering the overall impedance of the circuit <NUM> as each resistor <NUM> is destroyed. Therefore, the change in the impedance indicates degradation of the respective sensor <NUM>, and thus wear of the wear surface side <NUM> of the liner body <NUM>. The wear rate of the liner body <NUM> can be determined by associating the wear between two or more resistors <NUM> with a measured time frame. As the liner body <NUM> comprises a plurality of sensors <NUM>, the wear of the liner body <NUM> can be mapped across the wear surface side <NUM>.

The wear sensing liner <NUM> is associated with a data recorder <NUM> (shown in <FIG>). Each sensor <NUM> is connected to the data recorder <NUM>. The data recorder <NUM> is configured to record the signal from each sensor <NUM> for transmission to a computing device <NUM> which may be a remote device.

The data recorder <NUM> comprises a processor <NUM>, for processing software instructions, and a memory <NUM>. The processor <NUM> is configured to execute instructions <NUM> stored in the memory <NUM> to cause the data recorder <NUM> to perform certain functionality, as described in more detail below. The instructions <NUM> may be in the form of program instructions or instruction program code. The processor <NUM> comprises a microprocessor, central processing unit (CPU), application specific instruction set processor (ASIP), application specific integrated circuit (ASIC) or another processor capable of reading and executing instructions. The memory <NUM> comprises one or more volatile or non-volatile memory types for storing recorded data. For example, memory <NUM> may comprise one or more of random access memory (RAM), read-only memory (ROM), electrically erasable programmable read-only memory (EEPROM) or flash memory.

The data recorder <NUM> is further configured to be ruggedized, allowing the data recorder <NUM> to operate reliably in harsh environments and conditions. Furthermore, the data recorder <NUM> may be configured to receive and record the signal from each sensor <NUM> in real time or near real time. This allows for the provision of a continuous data stream that is representative of in situ use of the wear sensing liner <NUM>, as well as a set of historic data for reference.

The data recorder <NUM> comprises a network interface <NUM>. The network interface <NUM> allows the data recorder <NUM> to communicate with the computing device <NUM> over a communications network <NUM>. Examples of a suitable communications network <NUM> include a cloud server network, wired or wireless connection (such as an Internet connection), Bluetooth™, Zigbee, or other near field radio communication technology, and/or physical media such as USB.

In an embodiment, the network interface <NUM> comprises an antenna (not shown). The antenna is configured to wirelessly transmit the signal from each sensor <NUM> to the computing device <NUM>. In such embodiments, the computing device <NUM> is a remote, wireless device. The antenna is configured to transmit the signal according to any one of the wireless technology standards, such as Bluetooth®, Zigbee, IEEE <NUM>. 11ac, or the like.

As illustrated in <FIG>, and as described above, the data recorder <NUM> comprises a signal processing module <NUM> forming a part of the processor <NUM>. The signal processing module <NUM> processes signals output by each sensor <NUM> to enable the processor <NUM> to determine the wear rate of the wear surface side <NUM> of the wear sensing liner <NUM>.

It will be appreciated by persons skilled in the art that the wear sensing liner <NUM> may be configured to be used with different types of comminution apparatuses (e.g. crushers), or for different portions of comminution apparatuses. For example, the wear sensing liner <NUM>, as described with reference to <FIG>, may be used as a wear sensing liner of a jaw crusher. <FIG> shows a wear sensing liner <NUM> configured as a mantle liner for a cone crusher. <FIG> shows a wear sensing liner <NUM> configured as a jaw liner for a jaw crusher. <FIG> shows a wear sensing liner <NUM> configured as a concave liner for a gyratory crusher.

A comminution apparatus <NUM> typically includes two crushing surfaces, one defined by a stationary component and the other defined by a movable component which is displaceable relative to the stationary component. Each component carries wear sensing liners <NUM>, of the type described, to protect the components against wear. This may be the case, for example, with jaw crushers, cone crushers and gyratory crushers. For example, in the case of a cone crusher, the stationary component is the outer bowl or shell and the movable component is the cone which rotates eccentrically within the shell.

Generally, the stationary component of the comminution apparatus <NUM> is easier to access. Thus, the wear sensing liners <NUM> carried by the stationary component contain sensors <NUM> as described above with reference to <FIG> of the drawings to be connected directly to the light source and associated signal processing circuitry. Conversely, the movable component of the comminution apparatus <NUM> is generally more difficult to access. The wear sensing liners <NUM> associated with the movable component may thus contain sensors <NUM> as described above with reference to <FIG> of the drawings. The sensors <NUM> associated with the movable component of the comminution apparatus <NUM> are able to communicate wirelessly with the relevant signal processing circuitry.

<FIG> illustrates an embodiment of a wear sensing system <NUM> which is operable to monitor the extent of wear and/or wear rate of the wear sensing liner <NUM>.

The wear sensing system <NUM> comprises the wear sensing liner <NUM> and a computing device <NUM>. In the illustrated embodiment, the computing device <NUM> is in the form of a remote device. It will be appreciated however, that the computing device <NUM> may be directly connected to the wear sensing liner <NUM> (e.g. by one or more wired connections). The wear sensing liner <NUM>, as described above, is arranged to cover or line a crushing surface of a comminution apparatus <NUM>. Each sensor <NUM> of the wear sensing liner <NUM> is configured to produce a signal representative of wear of the wear surface <NUM> of the liner body <NUM>. Thus, a change in the signal output by each sensor <NUM> in response to mechanical degradation of the wear surface <NUM> during operation of the comminution apparatus <NUM> is representative of a change in the wear surface of the liner body <NUM>.

The computing device <NUM> may be in the form of a desktop computer or a tablet computer, for example. The computing device <NUM> comprises a computing device processor <NUM> and a computing device memory <NUM>. The computing device processor <NUM> is configured to execute computing device instructions <NUM> stored in the computing device memory <NUM> to cause the computing device <NUM> to perform certain functionality, as described in more detail below. The computing device instructions <NUM> may be in the form of program instructions or instruction program code. The computing device processor <NUM> comprises a microprocessor, central processing unit (CPU), application specific instruction set processor (ASIP), application specific integrated circuit (ASIC) or another processor capable of reading and executing instructions.

The computing device memory <NUM> comprises one or more volatile or non-volatile memory types. For example, the computing device memory <NUM> may comprise one or more of random access memory (RAM), read-only memory (ROM), electrically erasable programmable read-only memory (EEPROM) or flash memory.

The computing device <NUM> comprises a computing device network interface <NUM> which may be in the form of a wireless receiver. The computing device network interface <NUM> allows the computing device <NUM> to communicate with the data recorder <NUM> over the communications network <NUM>. Where applicable, the computing device network interface <NUM> also allows the computing device <NUM> to communicate with the comminution apparatus <NUM> over the communications network <NUM>.

The computing device <NUM> comprises a user interface <NUM> via which a user enters inputs to the computing device <NUM> and via which the user is able to monitor wear of the wear sensing liner <NUM>. Thus, the user interface <NUM> comprises one or more user interface components, such as one or more of a display device, a haptic display, a keyboard, a mouse, a camera, a microphone, buttons, switches, discernible warning elements (such as audible or visual warning devices), or the like.

As illustrated in <FIG>, the computing device <NUM> comprises a parameter module <NUM>. The parameter module <NUM> is configured to determine a rate of change of the physical parameter using the data produced by each sensor <NUM>. That is, the parameter module <NUM> is configured to determine the wear rate of the wear sensing liner <NUM>. The parameter module <NUM> is configured to determine an estimated remaining lifetime, or time to failure, of the wear sensing liner <NUM> using the data received from the data recorder <NUM>.

The computing device <NUM> further comprises an output module <NUM>. The output module <NUM> is configured to generate one or more outputs obtained from processing the data. For example, the output module <NUM> is configured to generate a visual representation of the physical parameter, rate of change of the physical parameter, and/or the estimated remaining lifetime, or time to failure, of the wear sensing liner <NUM>, as will be described in more detail below. The output module <NUM> is further configured to generate an alarm based on the determined physical parameter, rate of change of the physical parameter, and/or estimated remaining lifetime, or time to failure, of the wear sensing liner <NUM>. Still further, the output module <NUM> is configured to generate a control signal based on the determined physical parameter, rate of change of the physical parameter, and/or estimated remaining lifetime, or time to failure, of the wear sensing liner <NUM>.

In an embodiment, the comminution apparatus <NUM> includes the wear sensing liner <NUM>, as shown in <FIG>. The comminution apparatus <NUM> thus comprises the wear sensing system <NUM>. The comminution apparatus <NUM> comprises a comminution apparatus controller <NUM>. The comminution apparatus controller <NUM> controls the comminution apparatus <NUM>. In particular, the comminution apparatus controller <NUM> controls one or more operating parameters of the comminution apparatus <NUM> (e.g. its throughput). The comminution apparatus controller <NUM> operates under the control of the computing device <NUM>, which may activate and/or deactivate the comminution apparatus <NUM> upon instruction. The comminution apparatus <NUM> is configured to communicate with the computing device <NUM> and/or the data recorder <NUM> using the communications network <NUM> if necessary.

As previously described, each sensor <NUM> is connected to the data recorder <NUM>, and the data recorder <NUM> is configured to record the signal from each sensor <NUM>. In particular, the data recorder <NUM> is configured to receive the signal from one or more of the sensors <NUM> as an input. The data recorder <NUM> generates wear data from the signal of each sensor <NUM> and stores the data in the memory <NUM>. The data recorder <NUM> transmits the data to the computing device <NUM> over the communications network <NUM>. The computing device <NUM> stores the data in the computing device memory <NUM>.

The computing device <NUM> determines the wear rate of the liner body <NUM> from the data extracted from each signal. To determine the wear rate, the computing device processor <NUM> determines the depth, or thickness, of the liner body <NUM> in a region of a particular sensor <NUM> at a first time using the data. The computing device processor <NUM> executes the parameter module <NUM> to determine the depth of the liner body <NUM> using the data.

The computing device processor <NUM> compares the data to signal reference data to determine the depth of the liner body <NUM>. The signal reference data is stored in the computing device memory <NUM>. The signal reference data may comprise a signal look-up table. The signal look-up table may comprise known signals, or known signal reference information, and corresponding values of the depth of the liner body <NUM>. Thus, when a particular signal is detected, the data is compared to the signal reference data to determine the depth of the liner body <NUM>. The computing device processor <NUM> stores the determined depth of the liner body <NUM> in the computing device memory <NUM>.

The computing device <NUM> generates a visual representation of the determined depth of the liner body <NUM> at the first time. The visual representation of depth may, for example, be displayed on the user interface <NUM>. More particularly, the output module <NUM> generates the visual representation of the depth.

The computing device processor <NUM> then determines the depth in the region of the sensor <NUM> at a second time using the data, as previously described with reference to the depth determined at the first time.

The computing device <NUM> generates a visual representation of the determined depth of the liner body <NUM> at the second time which, once again, may be displayed on the user interface <NUM>.

The computing device processor <NUM> determines the wear rate of the liner body <NUM>, and therefore of the wear sensing liner <NUM> in the region of the sensor <NUM> by comparing the depth determined at the first time to the depth determined at the second time. The computing device <NUM> generates a visual representation of the determined wear rate of the liner body <NUM> which may be displayed on the user interface <NUM>.

When the wear or wear rate of the liner body <NUM> reaches, or breaches, a threshold level, the computing device <NUM> generates an alarm, via the output module <NUM>. The alarm is a discernible alarm and may comprise a visual alarm output, for example, displayed on the user interface <NUM> and/or an audio alarm. The computing device processor <NUM> thus compares the determined wear and/or wear rate to the relevant threshold level and causes the alarm to be generated when the wear is equal to or less than a wear threshold level or the wear rate is equal to or greater than a wear rate threshold level.

The wear of the liner body <NUM> may correspond to the determined depth of the liner body <NUM>, and the threshold level may be a minimum allowable depth of the liner body <NUM>. If the liner body <NUM> were to be allowed to wear beyond the minimum allowable depth, damage may be caused to the comminution apparatus <NUM> on which the wear sensing liner <NUM> is installed. Therefore, by generating the alarm when the wear is equal to or less than the wear threshold, the computing device <NUM> notifies the user that the liner body <NUM> depth is equal to or less than the wear threshold. Furthermore, by generating the alarm when the wear rate is equal to or greater than the wear rate threshold, the computing device <NUM> notifies the user that the wear rate of the liner body <NUM> will result in a reduced lifetime of the wear sensing liner <NUM>. The user may, for example, deactivate the comminution apparatus <NUM>, or adjust an operating parameter of the comminution apparats <NUM> based on this alarm, thereby mitigating damage to the comminution apparatus <NUM>.

Wear sensing liners <NUM> may be difficult to acquire on short notice, and may require significant planning to replace. This is because the comminution apparatus <NUM> is shut down to facilitate replacement of the wear sensing liner <NUM>. By generating the alarm, the computing device <NUM> provides advance notice that the wear sensing liner <NUM> is going need to be replaced. This can allow the user sufficient time to plan a shutdown of the comminution apparatus <NUM> to replace the wear sensing liner <NUM>. This minimises the operational disruption of the deactivation, by allowing the user to redirect rock material to other comminution apparatuses, or stockpile rock material efficiently during the deactivation.

In addition, or instead, the computing device <NUM> generates and transmits a control signal configured to control the comminution apparatus <NUM> when the wear and/or wear rate reaches, or breaches, the relevant threshold level. The computing device <NUM> may transmit the control signal to the comminution apparatus controller <NUM>. The control signal may deactivate the comminution apparatus <NUM>. Alternatively, the control signal may adjust an operating parameter of the comminution apparatus <NUM>. For example, the control signal may be configured to cause a reduction in the throughput of the comminution apparatus <NUM>. As previously described, this advantageously mitigates damage to the comminution apparatus <NUM>.

The computing device <NUM> is configured to determine an estimated remaining lifetime of the liner body <NUM>, and therefore of the wear sensing liner <NUM>. The estimated remaining lifetime may also be referred to as the estimated time to failure of the wear sensing liner <NUM>. The computing device <NUM> uses the determined wear and/or wear rate of the liner body <NUM> to determine the estimated remaining lifetime of the wear sensing liner <NUM>.

The computing device <NUM> generates a visual representation of the estimated remaining lifetime of the wear sensing liner <NUM> which is displayed on the user interface <NUM>. Further, the computing device <NUM> generates an alarm based on the determined estimated remaining lifetime. The computing device <NUM> generates the alarm when the determined estimated remaining lifetime is equal to or less than a lifetime threshold. The alarm may comprise a visual alarm output, for example, displayed on the user interface <NUM> and/or an audio alarm. In an embodiment, the computing device <NUM> generates and transmit a control signal to control the comminution apparatus <NUM> when the determined estimated remaining lifetime is equal to or less than the lifetime threshold. In particular, the computing device <NUM> may transmit the control signal to the comminution apparatus controller <NUM> either to deactivate the comminution apparatus <NUM> or to adjust an operating parameter of the comminution apparatus <NUM>. For example, the control signal may be configured to cause a reduction in the throughput of the comminution apparatus <NUM>. As previously described, this advantageously mitigates damage to the comminution apparatus <NUM>.

Although determining the depth of the liner body <NUM> in the region of the sensor <NUM>, the wear of the liner body <NUM>, the wear rate of the liner body <NUM> and the estimated remaining lifetime of the liner body <NUM> have been described with reference to the signal produced by the sensor <NUM> being representative of the length of the sensor <NUM>, it will be appreciated that one or more of these can also be determined where the signal produced by the sensor <NUM> is indicative of the temperature at the distal end <NUM> of the sensor <NUM> or at an intermediate portion along the sensor's <NUM> length, the strain at the distal end <NUM> of the sensor <NUM> or at an intermediate portion along the sensor's <NUM> length, the pressure at the distal end <NUM> of the sensor <NUM>, the pressure at an intermediate portion along the sensor's <NUM> length, vibration at the distal end <NUM> of the sensor <NUM>, or vibration at an intermediate portion along the sensor's <NUM> length.

Claim 1:
A wear sensing liner (<NUM>) for a comminution apparatus (<NUM>), the wear sensing liner (<NUM>) comprising:
a liner body (<NUM>) comprising;
a wear surface side (<NUM>) defining a wear surface;
an opposed, operatively rear surface side (<NUM>); and
at least one sensor (<NUM>) carried by the liner body (<NUM>), the at least one sensor being carried by the liner body to sense wear of the wear surface side (<NUM>) of the liner body (<NUM>), the at least one sensor (<NUM>) being configured to degrade in response to wear of the wear surface side of the liner body and to output a signal representative of the wear of the wear surface side of the liner body;
wherein the at least one sensor (<NUM>) comprises a rigid sleeve (<NUM>) configured to mount the at least one sensor to the liner body, and characterised in that:
the liner body (<NUM>) comprises an insert (<NUM>) which partially spans the depth of the liner body or span the entire depth of the liner body, wherein the liner body (<NUM>) is formed of a castable material cast around the insert and wherein the insert (<NUM>) has a higher melting temperature than the material(s) constituting the liner body;
wherein the insert (<NUM>) is configured to receive the rigid sleeve (<NUM>) of the at least one sensor (<NUM>) when the at least one sensor (<NUM>) is mounted to the liner body.