Patent Description:
In earth working activities (e.g., mining and construction), ground engaging products are commonly provided on all kinds of earth working equipment to protect the underlying equipment from undue wear and, in some cases, also perform other functions such as breaking up the ground ahead of a digging edge. Ground engaging products include, for example, teeth and shrouds that are secured to the lip of a bucket.

Heavy loading and abrasive conditions can cause ground engaging products to become separated from the earth working equipment. The operators of earth working equipment are not always able to see when a ground engaging product has separated. A separated ground engaging product may cause damage to downstream processing equipment. For example, if a separated ground engaging product is fed into a crusher, the product may be ejected and cause a hazard to workers, or it may become jammed and cause costly crusher downtime. A jammed crusher requires shutting down the machine and having an operator dislodge the part, which at times may be a difficult, time-consuming and/or hazardous process. Additionally, continuing to operate the excavating equipment with missing ground engaging products can decrease overall productivity, and may cause the base, upon which the product was secured, to experience premature wear.

There are prior systems that have been proposed to determine when a wear part has been lost. For example, the missing tooth detection system sold by Motion Metrics uses an optical camera mounted on the boom of the excavating equipment to determine when wear parts are lost. Likewise, <CIT> discloses a system that relies on a video camera mounted to the boom of an excavating machine for detecting damaged or missing wear members. In <CIT>, a springloaded switch is provided between wear part components so that when the components separate, the switch activates a radio transmitter alerting the operator that a wear part has separated. In <CIT>, an actuator is secured to a wear part component to provide a smoke or radio signal when the wear part has fallen off.

Alma'Aitah Abdallah et AI: "Utilizing Sprouts WSN platform for Equipment Detection and Localization in Harsh Environments" discloses a wear assembly with a magnetic field sensor that senses the magnetic field from a magnet. However, this prior art reference does not teach the characterizing portion of claim <NUM> of the instant application and even not completely the preamble portion.

<CIT> discloses a wear assembly for earth working equipment, the wear assembly comprising:.

The wear assembly of this prior art reference does not teach a monitoring device which is adapted to monitor ground-engaging products to identify characteristics such as wear and presence and which is secured in the wear part.

The problem at the origin of the invention of the instant case was to improve protection of non-movables components within the monitoring device and provide greater assurance, a remote device to receive the signal from the monitoring device indicating that the wear part has separated.

To this end, the application relates to a wear assembly for earth working equipment as claimed in claim <NUM>.

The proximity device is a magnet, and preferably at least one filler material at least partially fills the hole in the base.

Advantageously, the lock includes a leading end movable to be received in and out of the hole in the base, and the monitoring device is located within the hole adjacent the leading end of the lock when the leading end is received into the hole.

The present disclosure pertains to devices and systems for monitoring characteristics of ground-engaging wear parts for use on earth working equipment. The monitored characteristics may include, for example, presence, part identification, condition, performance and/or usage of ground-engaging products on the earth working equipment. As examples, the devices and systems can be used to monitor ground-engaging products secured to dozers, loaders, dragline machines, cable shovels, face shovels, hydraulic excavators, dredge cutters, buckets, lips, rippers, shear drums, continuous miners, crushers, etc. Examples of wear parts for such ground-engaging products include points, base adapters, intermediate adapters, shrouds, upper and lower wing shrouds, runners, picks, wear plates, tips, etc. Some of the example wear parts (e.g., base adapters or intermediate adapters) can also be considered a base because they in turn support other components.

Relative terms such as front, rear, top, bottom and the like are used for convenience of discussion. The terms front or forward are generally used to indicate the usual direction of travel of the ground engaging product relative to the earthen material during use (e.g., while digging), and upper or top are generally used as a reference to the surface over which the material generally passes when, for example, it is gathered into a bucket. Nevertheless, in the operation of various earth working equipment, the ground engaging products may be oriented in various ways and move in all kinds of directions during use.

For ease of discussion, the monitoring of ground engaging products secured to an excavating bucket is generally discussed herein, and in particular the monitoring of specific kinds of teeth and shrouds. However, the monitoring systems of the present disclosure could be used to monitor other kinds of teeth, other kinds of ground engaging products, and products on various types of earth working equipment. As examples only, the monitoring system may monitor a point on an adapter (intermediate or base), an intermediate adapter on a base adapter or integral cast nose, a shroud on a lip or base, a wear runner on a bucket, teeth on a dredge cutter head, picks on a shearer drum, liners on a chute or truck tray, tips in a roll crusher, and the like. The ground engaging products may be attached to various equipment and may be secured by various mechanical attachments including different locks and the like.

Referring to <FIG>, a mining excavator <NUM> is equipped with a boom <NUM>, a stick <NUM>, and a bucket <NUM> for gathering earthen material while digging. The bucket <NUM> includes a frame or shell <NUM> defining a cavity <NUM> for gathering material during the digging operation (<FIG>). Shell <NUM> includes a top wall <NUM> having attachment supports <NUM> to attach the bucket <NUM> to excavator <NUM>, a bottom wall <NUM> opposite the top wall <NUM>, a rear wall <NUM>, and a pair of opposing sidewalls <NUM>. Multiple configurations of buckets are known and variations in bucket geometry exist for excavating buckets and, of course, other excavating machines. For example, the bucket may not have a top wall as in a dragline bucket, the bottom wall may be hinged as in a dipper bucket, or a portion of the side walls may be hinged as in a hydraulic face shovel. The specific geometry of the bucket is not intended to be limiting as the present system can be used with various types of buckets and with various types of ground engaging products used on the buckets or other earth working equipment.

In the illustrated example, bucket <NUM> has a digging edge <NUM> (<FIG> and <FIG>). The digging edge <NUM> is that portion of the equipment that leads the contact with the ground and in an excavator bucket is generally formed by a lip. Sidewalls <NUM> of a bucket <NUM> commonly also form a portion of the digging edge and at times include wear parts. Teeth and/or shrouds are often secured to the digging edge to protect the edge, break up the ground ahead of the bucket <NUM> and/or gather material into the bucket. Multiple teeth <NUM> and/or shrouds <NUM>, such as disclosed in <CIT> and <CIT>, which are each incorporated by reference in its entirety, may be attached to lip <NUM> of bucket <NUM>.

Referring to <FIG>, the illustrated tooth <NUM>, provided only as an example, includes a base adapter <NUM> welded to lip <NUM>, an intermediate adapter <NUM> mounted on adapter <NUM>, and a point (also called a tip) <NUM> mounted on intermediate adapter. Point <NUM> includes a rearward-opening cavity <NUM> to receive nose <NUM>, and a front end or bit portion <NUM> to penetrate the ground (<FIG>). A lock opening <NUM> is formed in the point <NUM> and a hole <NUM> in the base <NUM> to receive a lock <NUM> that holds the point <NUM> to the base <NUM>. For example, locks (also called retainers) <NUM> are used to secure point <NUM> to intermediate adapter <NUM>, and intermediate adapter <NUM> to a nose <NUM> of the adapter <NUM>. In this example, the locks <NUM> are all the same but they would not need to be. When a ground engaging product becomes unexpectedly separated from the base, the ground engaging product is preferably replaced soon so production does not decrease and the base, upon which the ground engaging product is attached, does not experience premature wear.

Referring to <FIG>, the lock <NUM> may include a pin <NUM> threaded into a collar <NUM>. In one example, the collar <NUM> is secured in opening <NUM> in the tip <NUM>, and a pin <NUM> is threaded through the collar <NUM> for inward and outward movement between hold and release positions, respectively; i.e., the pin <NUM> has a leading end <NUM> that is movable in and out of hole <NUM> in the base <NUM> to secure and release the wear part, respectively. In this example, lugs <NUM>, <NUM> secure the collar into opening <NUM> bayonet style, and a clip <NUM> is used to prevent rotation and release of the collar from the opening; the collar could be secured in opening <NUM> in other ways. The pin <NUM> could also be secured without a collar; for example, the opening could include threads. A latch <NUM> in pin <NUM> is provided to secure the pin in the hold and release positions but other securing arrangements could be used, or the pin could be infinitely adjustable between positions where the point is secured, and the point can be released. In the hold position, a leading end <NUM> of the pin <NUM> is received into a hole <NUM> in the nose <NUM> to secure the point <NUM> onto the nose <NUM>. In the illustrated example, the pin <NUM> includes a head <NUM> and a threaded shank <NUM> but other arrangements are possible. A recess <NUM> opens in an outside face <NUM> of the head <NUM> for receiving a tool (not shown) for turning the pin <NUM> for securing and releasing point <NUM>. This is provided simply as an example; other locking arrangements (threaded or not) could be used to secure the point (or other wear part) to the adapter (or other base).

Referring to <FIG>, a monitoring system <NUM> includes a monitoring device <NUM> situated within a base hole <NUM> adjacent a lock <NUM>. A tooth <NUM> is shown having a ground engaging product situated over a base (e.g. the illustrated point <NUM> is situated over an adapter <NUM>), and a lock <NUM> to secure the wear part to the base. As can be seen, lock <NUM> is situated in both the grounding-engaging product lock opening <NUM> and the base hole <NUM> to secure the wear part to the base. Alternatively, a mounting portion of the wear part could set adjacent or otherwise complement a recess in the base.

In certain examples, monitoring system <NUM> includes a sensor(s) in the base and optionally a tag(s) or the like in and/or on the lock. Wear parts typically separate from a machine due to such things as impacts, high loads, fatigue, wear, etc. The wear part typically pulls the lock from the base during separation. If the lock <NUM> fails, the wear part will not ordinarily remain with the base during use of the earth working equipment. Accordingly, regardless of the reason for the separation, the lock ordinarily stays with the wear part (e.g., with locks integrally secured to the wear part) or is cast entirely out of the wear assembly due to the force on the wear part, breakage of the wear part, etc., when the wear part separates from an earth working machine. Since the lock is not normally retained in the lock-receiving hole in the base when the wear part separates from the machine, the sensor in the base can detect the absence of the lock to identify that the wear part has separated from the base. The monitoring device can also be used to determine if the base has separated from the earth working equipment, and thus also the wear part and lock associated with that base. In such a circumstance, the loss of a signal from the sensor(s) can identify that the base has separated from the earth working equipment.

Earth working equipment is commonly used in arduous environments where the survival of sensors is at risk. Having the monitoring device within a hole in the base supporting the wear part tends to provide improved protection for the components within the monitoring device (e.g., a sensor(s) and a communication device) as compared to being mounted in the wear part or the lock because it can be sheltered by a combined assembly of, e.g., the wear part, the lock, and the base. In some constructions, the hole within the base provides more room for the use of cushioning fillers for improved protection as compared to systems where a monitoring device is provided in the wear part or lock. Securing the monitoring device in the base as opposed to the wear part or the lock provides greater assurance the remote device to receive the signal from the monitoring device (i.e., indicating that the wear part has separated) will receive the signal, i.e., because the base ordinarily remains with the machine when the wear part is lost whereas the wear part or lock (if containing the sensor) could remain in the ground or be otherwise farther separated from the remote device when the wear part separates making it more likely the signal may not be received.

In the illustrated examples (<FIG>), the point <NUM> includes an external surface <NUM> having a top surface <NUM>, a bottom surface <NUM> and side surfaces <NUM>. Monitoring device <NUM> is positioned in hole <NUM> in base <NUM> so as to be adjacent the leading end <NUM> of pin <NUM> of lock <NUM> when the components of tooth <NUM> are assembled together (<FIG> and <FIG>). In one example, the monitoring device <NUM> is received in hole <NUM> in base <NUM> prior to the installation of the lock <NUM>, i.e., in the portion of hole <NUM> not to be occupied by pin <NUM> when the pin secures point <NUM> to adapter <NUM>. In this position (i.e., in hole <NUM>), the monitoring device <NUM> can be protected during the earth working operations, can provide reliable detection of characteristics of the wear part and/or base, can be used to monitor successive wear parts secured to the base, and/or can eliminate the need for batteries in the more quickly consumed wear parts. That is, by positioning the sensor(s) in the base, the more frequently replaced wear parts can be free of batteries and can be more easily discarded and/or recycled. By placing the monitoring device <NUM> in the base, the components have a better chance of survival by not being in direct contact with the environment. The monitoring device <NUM> may be installed in hole <NUM> as a part of the manufacturing process, in a shop and/or in the field. When the monitoring device <NUM> is installed in hole <NUM> at the time of manufacture, it may optionally be used to track shipping progress, inventory levels of the ground engaging products (e.g., adapters <NUM>), and/or when ground engaging products are removed from inventory for use. In addition, the monitoring device <NUM> may optionally be able to detect if the ground engaging product experienced a condition (e.g., a high impact) that has the potential to damage the ground engaging product during shipping and/or use. Alternatively, monitoring device <NUM> may be installed after the manufacturing process and may, for example, be installed in hole <NUM> while in inventory or at the time of installation of a new ground engaging product on the earth working equipment.

The monitoring device <NUM> can, when installed, detect the presence and/or absence of the lock <NUM> (e.g., the pin of the lock in the illustrated embodiment) received in hole <NUM> when securing the wear part to the base. The monitoring device <NUM> may also optionally monitor other characteristics of the wear part and/or base such as the usage, condition and/or performance of the wear part and/or base, and/or part identification such as disclosed in <CIT>. The monitoring device can also detect one or more of these other characteristics instead of the presence and/or absence of the lock and/or wear part. The monitoring of separation as well as other characteristics can be accomplished in a number of different ways. When absence of the lock is detected, the sensor can send a wireless alert signal to a remote device to alert the operator, maintenance personnel, manager, contractor, etc. that a wear part has separated from the machine.

In the illustrated example of <FIG>, monitoring system 27B includes a proximity device 51B secured to (i.e., in and/or on) the lock 21B and a sensor 35B in the base that can detect the presence of the proximity device 51B. In the illustrated example, the proximity device may be secured to or near the leading end <NUM> of pin 150B, and the monitoring device <NUM> placed in hole 49B so as to be adjacent the leading end <NUM> of pin <NUM> when the lock secures the wear part to the base. Alternatively, the proximity device could be located in the collar <NUM> (e.g., in the body or lugs <NUM>, <NUM> of the collar <NUM>). The monitoring device <NUM> could also alternatively be located in a hole offset but in communication with hole 49B so as to position monitoring device <NUM> adjacent a side of pin 150B and/or adjacent the collar <NUM>. This position may have the advantage of utilizing the spacing in-between the wear member and the base for communications. Other variations are possible for the illustrated lock as well as other kinds of locks that may be used.

In one example, the proximity device 51B is a magnet, and the sensor <NUM> is a Hall effect sensor to detect the presence and/or absence of the magnet (e.g., locking pin <NUM> with magnet 51B). The Hall effect sensor 35B generates a current and measures a change in the electric potential due to an introduced static magnetic field. The static magnetic field may be generated by a magnet 51B but can be generated by other means. The Hall effect sensor 35B acts as a switch when detecting changes in Hall voltage as affected by the presence and/or absence of the magnet (e.g. changes in the electric field along a gradient, direction of electric field, etc.). If the magnet 51B is no longer in position to be detected by sensor 35B, then this indicates that the lock 21B has become dislodged or lost, and that the wear part has separated from the machine. The sensor 35B may have a predetermined set value for either the electric field (V/M) and/or the magnetic field (mT). The predetermined set value determines how sensitive (e.g. loss versus pre-loss or dislodging) the sensor 35B is to a distance D the magnet 51B is away from the sensor 35B. The predetermined set value may be static or dynamic (e.g. set between <NUM> mT to <NUM> mT). The sensor 35B does not suffer from vibration or contact bounce as a solid mechanical contact sensor would. The sensor 35B can generally be used in severe conditions without being affected by environmental contaminants and costs less than a mechanical switch. The sensor 35B can measure a wide range of magnetic fields.

In another example, the proximity device 51B is an RFID tag and/or other short-range detectable element can be secured to the lock <NUM> (e.g., to and/or in the leading end <NUM> of the pin <NUM>). The RFID tag 51B is then detected by an RFID receiver sensor 35B (i.e., as part of the monitoring device <NUM>) in hole <NUM> of base <NUM>. When the wear part and lock separate from the base, sensor <NUM> loses signal with the RFID tag 51B. This loss of signal identifies that the wear part has separated from the base. In another example, the RFID receiver sensor <NUM> may keep track of each new RFID tag introduced so as to monitor inventory and replacement timing for the wear parts.

Other kinds of sensors could be used to detect the presence and/or absence of the pin <NUM> in hole <NUM>, and/or detect other characteristics of the ground-engaging product. For example, the sensors may include a temperature sensor, a digital inclinometer unit, a digital compass, an accelerometer, a timer, a proximity sensor, a position sensor, a hall effect sensor, a flux magnetometer, a magnetometer, a magnetoresistance sensor, an inductive sensor, RFID tag and/or reader, IR receiver, ultrasonic and/or other sensors that can detect the presence and/or absence of the lock securing the ground engaging product to the base and/or other characteristics of the wear part and/or base. Some sensors involve the use of a proximity device on the lock and/or wear part (e.g., an RFID tag, magnet, and the like) and some do not involve such use of a tag or other proximity device on the lock and/or wear part). Although the use of a proximity sensor to detect a proximity device on the lock has been discussed above, other kinds of sensors could be used in lieu of or in addition to a proximity sensor. While monitoring devices that are free of moving parts are disclosed in various embodiments (e.g., Hall effect sensors), the monitoring device could include a sensor with a contact switch that contacts the lock or wear part and moves when the lock or wear part separates so as to identify the presence and/or absence of a lock and/or wear part. Monitoring devices free of such moving parts have less risk of failure due to accumulation of fines, damage caused by impacts, and the like. Monitoring devices free of such moving parts can also be encased and more securely protected by a body or filler material.

Monitoring device <NUM> can optionally include more than one sensor to increase the reliability of detecting the presence and/or absence of the lock and, hence, the presence and/or absence of the wear part mounted on the base. As one example only, monitoring device <NUM> can include a first sensor to sense a proximity device (e.g., a magnet, RFID tag and the like) on the lock as discussed above, and a second sensor to detect temperature changes. Continued digging with, e.g., a tooth after the point has separated will typically result in a temperature sensor in the base detecting an increase in temperature. The monitoring device <NUM> could transmit a signal when either sensor detects separation or only when both (or all if more than two are used) sensors detect separation or when some (if more than two sensors are provided) of the sensors detect separation. For example, the communication device may send a signal when the first sensor detects the wear part or lock is absent and/or when the second sensor detects that a threshold level temperature or increase in temperature is reached. Also, a programmable logic device receiving the transmitted signals could assess the information received from the sensors (e.g., the amount of temperature change, the amount of time that has lapsed since receiving a signal regarding the proximity device, etc.) and make a determination as to whether the wear part has separated from the base.

Including monitoring device <NUM> in base <NUM> can also optionally detect if the base has separated from the earth working equipment. As one example, the monitoring device could include an accelerometer and transmit signals about the movement of the base. Then, if the base separates from the equipment, it would have no movement (e.g., if in or on the ground) or a different movement (e.g., if gathered as part of the load). In either case, an alert could be provided to indicate the base had separated. Separation of the base would, of course, also mean separation of the wear part and lock securing the wear part to the base.

Referring to <FIG>, the illustrated monitoring system <NUM> includes a monitoring device <NUM>, a support <NUM>, a body <NUM>, and a proximity device <NUM> (e.g., secured to the lock). The monitoring device <NUM> includes a sensor <NUM> to detect at least one characteristic of the wear assembly (e.g., the presence and/or absence of proximity device <NUM>), a communication device <NUM> (e.g., a transmitter and/or receiver) for wirelessly communicating information (e.g., a signal indicating the wear part has separated from the machine) to and/or from a remote device <NUM> (<FIG>) to receive the signal, and a battery <NUM>. These can be different components working together or they may be combined (e.g., the sensor <NUM> and communication device <NUM> may be the same component). Monitoring devices <NUM> also could have other constructions and/or other components. For example, monitoring devices <NUM> can include multiple sensors for redundancy and/or sensing other characteristics (e.g., high impact events, digging cycles, etc.), storage mediums for holding data (e.g., the part ID, software, firmware, etc.), a GPS device, and/or a microprocessor for processing data or other information.

In one example, the electronics or components of monitoring device <NUM> are positioned in a housing <NUM> (<FIG>). The housing <NUM> is illustrated as a cup with an open top <NUM> but it could have other forms. The housing <NUM> can aid in supporting the monitoring device components, positioning the sensor <NUM> relative to the lock and/or providing protection for the monitoring device <NUM>. The housing <NUM> may be situated to fit within the hole <NUM>, such that the outer surface of the housing <NUM> engage the inner surfaces of the hole <NUM>. In one example, the hole <NUM> converges toward one end, and the housing <NUM> converges generally in parallel with the inner surfaces of the hole <NUM> (e.g., <NUM>° ±<NUM> degrees of convergence). The housing <NUM>, though, could be secured in hole <NUM> in other ways; for example, the hole could be secured by adhesive, fasteners, friction, supports, etc. The monitoring device <NUM> may also be fit in hole <NUM> without contacting the walls of the hole; for example, a body or filler material <NUM> may be included in and/or around housing <NUM>. The housing <NUM> could also be omitted.

In another example, the monitoring system <NUM> may include a support <NUM> in hole <NUM> for positioning monitoring device <NUM>. Support <NUM> is illustrated (<FIG>) with a grate configuration but other kinds of supports could be used. The support <NUM> can provide tolerance in examples using a complementary tapering of the housing <NUM> and walls of hole <NUM> to ensure the desired positioning of the monitoring device. The support <NUM> can also position the monitoring device in hole <NUM> without tapering walls. In the illustrated example, the support <NUM> may include of a plurality of cross beams <NUM>. The height of the individual plurality of cross beams <NUM> may aid in better positioning of the sensor <NUM> within hole <NUM>. The support <NUM> may bite into the inner walls of hole <NUM> to act as a grip and/or be secured in other ways such as by adhesive, fasteners, etc. Alternatively, housing <NUM>, body <NUM> or other component of the monitoring device <NUM> could be secured to the walls of hole <NUM> without a separate support such as by friction, adhesive, fasteners, etc..

In the illustrated example, the body <NUM> is a material that envelopes the sensor <NUM> and the housing <NUM> and the empty space of the hole <NUM>, but it could be used to cover and/or fill less than these components and/or spaces. The body <NUM> can protect the sensor <NUM> from water, fines, corrosive material and the like, and/or from impacts, strains and the like that may occur during use. The body <NUM> may be a filler material in the form of resin, polymer, polyurethane, or other suitable material that plugs the hole <NUM>. The body <NUM> may be a dielectric material to improve transmission of the wireless signals. The body <NUM> may be composed of elastomers, thermoplastics, thermosets, and/or other non-conductive materials.

The body <NUM> may optionally be made up of two (or more) different materials. In one example, the body <NUM> may be composed of different gauged durometer hardness scale materials including, e.g., a first portion <NUM> and a second portion <NUM>. In the illustrated embodiment, the first portion <NUM> is located farther from the lock. In an example such as shown in <FIG> and <FIG>, the first portion <NUM> may come into contact with the inner walls of the cavity <NUM> of the point (i.e., opposite hole <NUM>). Contact with the inner walls of the point cavity can, e.g., cause impacts applied to the point <NUM> during use to be translated to the monitoring device <NUM>. In such an arrangement, the first portion <NUM> can be made of a softer material than the second portion <NUM> to better absorb these impacts and provide enhanced protection for monitoring device <NUM>. While the first softer portion <NUM> is illustrated in <FIG> as being on one side of the monitoring device opposite lock <NUM>, a softer portion <NUM> could have other configurations. For example, a softer portion of the body could surround the entire firmer portion of the body. The second portion <NUM> can be of a firmer material that better holds and supports the monitoring device; for example, a firmer second portion <NUM> can alleviate a risk of the housing <NUM> compressing into the softer first portion <NUM> and becoming undesirably spaced from proximity device <NUM> and/or lock <NUM>. Other arrangements besides harder and softer could be used when relying on more than one body material. As one example, the second section <NUM> may be a dielectric for improving the transmission of signals from and/or to communication device <NUM> and the first section not a dielectric material (e.g., chosen for a different purpose such as for improve protection). Multiple purposes could, of course, be considered when choosing the material(s) for the body <NUM>.

In the example shown in <FIG>, the first portion <NUM> has a height H that can create a support for the housing <NUM> to set against and be positioned in hole <NUM> (with or without support <NUM>). The positioning of sensors <NUM> by the first portion <NUM>, support <NUM>, housing <NUM> and/or other means to a particular location in hole <NUM> can improve the operation of the sensor <NUM>, i.e., by setting the sensor a desired distance D away from the lock and/or a proximity device 51B secured to the lock <NUM>. Positioning monitoring device <NUM> in hole <NUM> at a desired location can also alleviate the potential interference between the monitoring device <NUM> and the lock <NUM>. The support <NUM> can optionally act as a barrier such that the sensor <NUM> does not penetrate into the lower level <NUM>.

As noted above, the second portion <NUM> can be made from a dielectric material and may be a harder or firmer material than the first portion <NUM> (e.g. 85A). In the illustrated example, the first portion <NUM> fills the area above the second portion <NUM> but other arrangements are possible. The first portion can fill the space between the support <NUM> (if included) and potted into the open top <NUM> of the housing <NUM>.

The monitoring device <NUM> can be secured in hole <NUM> by any suitable means including, for example, bolts, adhesive, brackets, taper fit, friction, etc. The components of the monitoring device can optionally be encased in a housing <NUM> and/or the hole <NUM> may be filled in with a filler or body <NUM> as will be further discussed below. Alternatively, the monitoring device <NUM> may not include a housing <NUM> or body <NUM>, and/or hole <NUM> may not be filled in. Securing the components of the monitoring device <NUM> in a housing and/or body, and/or filling the hole <NUM> (i.e., outside of where the lock is received when securing the wear part to the base) with a suitable material may provide greater protection for the device <NUM> from water, fines, vibration, impact, etc. as the ground engaging product engages the material to be excavated or is otherwise worked. The use of a suitable body <NUM> material may optionally function to secure the monitoring device in hole <NUM>. Monitoring device <NUM> can be constructed to be removably secured in hole <NUM> within the base, though it could be permanently secured. Removably securing the monitoring device <NUM> allows the device <NUM> to be temporarily installed in the ground engaging product, replaced when it breaks and/or when the battery is depleted, and/or removed at the end of life of the adapter <NUM>. Removal of device <NUM> with its battery <NUM> may enable easier shipping, and/or conventional recycling of the bases when removed from the equipment. Removal may also permit successive use in other wear parts.

In one example of installing the monitoring system <NUM>, a body <NUM> encasing monitoring device <NUM> may be formed in mold in the shape of the hole <NUM> so the monitoring device <NUM> can be installed as a unit into hole <NUM>. Although at times the body has been referred to as an element in addition to the monitoring device, in this arrangement, the body could be considered a part of the monitoring device <NUM>. In another example of installing monitoring system <NUM>, the first portion material may be injected into mold to form a first portion <NUM> of body <NUM>. The support <NUM> may be inserted into mold adjacent the first portion of the shell <NUM>. The housing <NUM> with sensor <NUM> may be installed against support <NUM>. In this example, housing <NUM> does not engage the first portion of the body. A second portion <NUM> of the body may be injected into the mold to completely surround and envelop the area above the first portion <NUM>. The mold may be placed into a furnace to set the material(s) of the first and second portions <NUM>, <NUM>. The molded together body portions <NUM>, <NUM>, support <NUM> and monitoring device <NUM> are installed in hole <NUM> as a unit. In this arrangement, the body <NUM> and support <NUM> could be considered part of the monitoring device. When the monitoring system <NUM> is installed into the hole, if the first portion <NUM> passes through the bottom opening of the hole <NUM>, then when the ground engaging part is placed over the nose of the underlying ground engaging part, the lower level <NUM> will be pushed up into the hole <NUM> and will be positioned correctly. As another example, the body <NUM>, support <NUM> and/or monitoring device <NUM> could be installed directly into hole <NUM> and instead of being formed first in a mold. These are intended as examples; the monitoring device could be installed in the base in a wide variety of ways and using many different materials.

In the illustrated example of <FIG>, the monitoring system <NUM> includes a monitoring device <NUM> that includes a sensor to detect the presence and/or absence of the lock in hole <NUM>, which in this case is the leading end of pin <NUM>, without the use of a proximity device on the lock. Otherwise, this monitoring system can include the variations disclosed above in regard to the example of <FIG>.

Referring to <FIG>, an alternative tooth <NUM>' is provided as another example. The alternative tooth <NUM>' includes an adapter <NUM>' welded to the lip <NUM>' and a point <NUM>' mounted on the adapter <NUM>'. Point <NUM>' includes a rearward-opening cavity <NUM>' to receive a nose <NUM>', and a front end <NUM>' to penetrate the ground. A lock <NUM> is situated into an opening <NUM>' formed on one side of the point <NUM>' and at least one hole <NUM>' in the adapter <NUM>'. Hole <NUM>' is aligned with lock opening <NUM>' to receive a leading end <NUM> of lock <NUM> to secure the point <NUM>' to the adapter <NUM>'. Although not shown, the monitoring device <NUM> could be positioned adjacent the leading end <NUM> of lock <NUM> such as shown in <FIG> and <FIG> to detect the presence and/or absence of the lock <NUM>.

In the example as shown in <FIG>, the monitoring system <NUM>' is situated in a hole <NUM>" separate from the lock-receiving hole <NUM>'. In the illustrated example, hole <NUM>" is in the side of the base opposite the side receiving the lock <NUM>. However, hole <NUM>" could be provided in other surfaces and other locations. A plug or insert <NUM>' may be optionally received in hole 48a to set adjacent monitoring device <NUM>'. In this example, the plug <NUM>' sets opposite lock <NUM>. Hole <NUM>" is shown in <FIG> to have a unique shape but it could have other shapes such as matching the shape of hole <NUM>' so the lock and plug can be reversed to permit reversing of the wear part, a simple cylindrical shape, etc. The plug <NUM>' may optionally include a proximity device (e.g., an RFID tag, magnet <NUM>', etc.). The plug <NUM>' may be made from the same or different materials as disclosed for body <NUM>. For example, a dielectric material may be used to aid in signal transmission. Alternatively, the monitoring device <NUM>' could detect the presence and/or absence of a portion of the wear part without a plug and/or proximity device. In this arrangement, the body <NUM> can fill to the height of the inner walls of the hole <NUM> and fully plug the hole but it can have other arrangements. Also, the holes 48a and/or <NUM>" could optionally have other additional purposes; e.g. holes 48a and/or <NUM>" could be provided to alternatively receive a lifting eye or other attachment. As another alternative, a plurality of monitoring devices could be provided to redundantly detect separation of the wear part and/or other characteristics of the wear assembly to increase the reliability of the system.

In the illustrated example of <FIG>, the monitoring device <NUM>' includes a sensor <NUM>', a transceiver, and a battery. The sensor <NUM>' may be a Hall effect sensor that functions with a magnet <NUM>'. The monitoring device <NUM>' could be located in a hole <NUM>" in the base that is or is not for receiving a lock but is disclosed with reference to hole <NUM>". The housing <NUM>' of the monitoring device <NUM>' may include one or more retainers <NUM>' to frictionally hold the body <NUM>' within hole <NUM>" though other arrangements are possible. The retainers <NUM>' may be formed as ribs that generally extend around the sides of the outer edges to contact the surfaces of hole <NUM>". The body <NUM>' can be secured within a complementary hole recess via an interference fit so that the ribs of retainers <NUM>' contact the sides of the recess to secure the body <NUM>' within the hole <NUM>". Other retainers are possible, and the ribs are only one example of a retainer that may be used to secure the body within the recess. Other ways of securing the body within the hole <NUM>" are possible. For example, the retainer may be a series of helical ridges that correspond to grooves in the recess. The body may be threaded or otherwise rotated so that the retainer engages the corresponding grooves in hole <NUM>". Alternatively, as an example, one or more latches could be used to secure the body in place. Further, retainers could be formed in the hole instead of or in addition to retainers on the body. Other means for securing the monitoring device <NUM>' in hole <NUM>" could be used such as adhesive, fasteners, friction, etc. One or both ends of the monitoring device can have a removal feature (e.g., a loop or head) to remove the monitoring device from the hole. When the hole receiving the monitoring device is a through-hole, the monitoring device may be removed by pressing upwards from the bottom of hole.

Referring to <FIG>, the illustrated shroud assembly includes a shroud <NUM> mountable onto a lip <NUM>. In this example, the shroud fits over a boss <NUM> of lip <NUM> but other arrangements are possible. Shroud <NUM> includes an opening <NUM>" to receive a lock <NUM>" that holds the shroud <NUM> to the lip <NUM>. The shroud and lock could have a construction such as disclosed in <CIT> or <CIT>, which are each incorporated herein by reference. The shroud could alternatively mount to a sidewall of a bucket as an upper and/or a lower wing shroud (not shown). Monitoring device <NUM>" is positioned in hole <NUM>" formed in boss <NUM> so as to be adjacent a portion of shroud <NUM> (See <FIG>). Alternatively, hole <NUM>" and monitoring device <NUM>" could be located in a sidewall of boss <NUM>, e.g., perpendicular to the lip. Alternatively, the hole <NUM>" could be re-oriented <NUM>° so the monitoring device detected the presence and/or absence of the lock <NUM>" when the shroud is installed on the boss <NUM> and lock <NUM>" is inserted in hole <NUM>". In another example, the monitoring device <NUM> may be located in a thrust block, which may, e.g., abut a rear and/or side of a wing shroud. The monitoring device <NUM>" would, then, detect the presence and/or absence of the lock as discussed earlier in regard to the other examples. Alternatively, hole <NUM>" and monitoring device <NUM>" could be provided in the lip to underlie the lock or a different portion of shroud <NUM> to detect the presence and/or absence of the lock or shroud, respectively. The lock <NUM>" may or may not have a proximity device (e.g., a magnet, RFID tag, etc.) to work with the monitoring device <NUM>". The monitoring device could also monitor the presence and/or absence of shroud <NUM> with or without a plug and/or proximity device in the shroud.

Monitoring device <NUM> (or any of the other examples) may communicate with a remote device <NUM>, which simply means a device remote from the monitoring device <NUM>. The remote device <NUM> can, for example, be secured to one or more of the bucket <NUM> (<FIG>, <FIG>, and <FIG>), the boom <NUM> (<FIG>), the stick <NUM> (<FIG>), the cab <NUM> of the digging machine <NUM> (<FIG>), a service truck (<FIG>), a drone, a handheld device <NUM> (<FIG>), a station, etc. The remote device <NUM> can be a single component or a collection of components working together or separately. For example, a remote device <NUM> may include one or more of a processor <NUM> (PC, microprocessor, etc.), memory <NUM>, a database <NUM>, a transmitter, a receiver, a transceiver <NUM>, etc. (<FIG>). The remote device <NUM> may include one or more receivers (e.g., antennae) to receive the wireless signals <NUM> from the monitoring device(s) <NUM>, a transmitter(s) to transmit signals, or a transceiver <NUM>, a processor(s) to process information received from the monitoring device(s), a database(s) to store information, a human-machine interface(s), etc. The remote device <NUM> may communicate with additional sensors on the ground engaging product, other ground engaging products, multiple ground engaging products, earth working equipment <NUM> and/or with a database(s) and/or computer(s). The remote device <NUM>, for example, may be a wireless device or a wired device. The term remote device <NUM> herein encompasses all such variations. Various examples may locate one or more components of the remote device <NUM> at predetermined points on the digging machine <NUM> and/or other vehicles <NUM> and pieces of equipment and/or in office space. Various examples may include mobile and handheld devices <NUM> as components of the remote device (<FIG>). Examples may provide electronic canvassing of the sensors and/or communication devices to inventory the data collected. The data may be combined with previously known data and/or data collected from other locations. One or more programmable logic device may be utilized to manipulate the data into various machine usable and human usable formats, and/or to make various assessments.

The monitoring device <NUM> and/or remote device <NUM> may, for example, include a transceiver <NUM>, for example, a radio frequency communication device, an electromagnetic wave receiver and/or transmitter, a mechanical wave receiver and/or transmitter, and/or Global Positioning System (GPS). The electromagnetic waves may have a wavelength outside of the visible spectrum (e.g., infrared, microwave, or Radio Frequency [RF]), and may be in the ultrasonic spectrum. As one example, the communication device could transmit a Bluetooth signal at <NUM> Gigahertz, but other means and other frequencies could be used.

The monitoring device <NUM> sends a wireless signal <NUM> regarding the detected characteristic(s) to the remote device <NUM> (<FIG>). The signal <NUM> may, e.g., be continual, intermittent, batch, event driven, etc. In the illustrated example, the signal <NUM> is received by a transceiver <NUM> (e.g., an antenna) of remote device <NUM> mounted on the boom <NUM> of the excavator <NUM> (<FIG>). An antenna <NUM> can be provided in other positions and/or mounted on different supports (e.g., on the bucket <NUM>, near the cab <NUM>, etc.) in lieu of or in addition to the antenna on the boom. The antenna <NUM> on the cab <NUM> in this example is shown wired <NUM> to a processor <NUM> having memory <NUM> in the cab <NUM> but could have a different connection or location. For example, an antenna <NUM> or other receiver could be mounted near the cab, on a service truck, on a handheld device <NUM>, etc. The antenna <NUM> could be coupled to a wireless transmitter such that the information received from the monitoring device <NUM> and sent to the remote device <NUM> in the cab, may be provided to and/or combined with data from a handheld device <NUM>, cloud database <NUM>, other data sources, etc. to provide helpful information and/or analysis. Multiple antennas <NUM> could be used to increase the reliability of picking up the signal if desired or needed for the operation.

In cases where signals can only be received at certain times, monitoring device <NUM> and/or remote device <NUM> may transmit only during certain times (e.g., when the bucket is oriented in a particular way, when a trigger signal is received, etc.) or may continue to transmit continually. The monitoring device <NUM> may optionally transmit only when sensor detects the lock and/or wear part has separated from the base. Further, multiple remote devices and/or antennas could be used to receive information from the monitoring device continually or during longer periods even if the signal can only be accessed by the antenna on the boom <NUM> during certain intervals. A component of the remote device <NUM> may receive a signal <NUM> from a monitoring device <NUM> and relay the signal <NUM> to a second or third component of the remote device (<FIG>). Any number of remote device components may be used to relay the signals as needed. The movement of the digging machine <NUM>, including the individual articulated components thereof, and/or other vehicles at the worksite may tend to establish and reestablish the interrelationships of the sensors and communication devices. In this way, various and numerous communication paths may be established despite the great number of potentially shielding surfaces at the worksite.

In examples detecting separation, the loss of the lock <NUM> and/or the overlaying wear part, tends to lessen the signal blocking effects, which has the effect of increasing the likelihood of the remote device <NUM> receiving the signals from the monitoring device <NUM>, which thus may increase the reliability of the system. The monitoring device <NUM> could operate only when the wear part separates, or it could operate continually. Continual operation provides the added benefit of ensuring the monitoring device is still operating and/or sensing other characteristics. A monitoring device may optionally increase the magnitude and/or speed of repetition of the signal it transmits when absence of the lock and/or wear part are detected so as to increase the likelihood the remote device <NUM> receives the signal indicating the wear part has separated from the base. Increasing the likelihood, the remote device receives the signal can improve the reliability of the monitoring system. As a lost wear part may not include a tracking device, the location of the wear member may be unknown upon separation. In such situations, the advantage of receiving the identifying signal at the moment of separation increases the likelihood of locating the lost wear part. The monitoring device <NUM> may optionally include additional sensors (e.g., one or more of a GPS, accelerometer, inclinometer, etc.) located in the base, which can determine the path of the last digging cycle or bucket payload to determine the area of where the lost wear part may be found. In the illustrated tooth <NUM> of <FIG>, a first monitoring device <NUM> may be located in hole <NUM> of the base adapter <NUM> adjacent lock <NUM> securing the intermediate adapter <NUM> to base adapter <NUM>, and a second monitoring device <NUM> in hole <NUM> of the intermediate adapter <NUM> adjacent lock <NUM> securing point <NUM> to intermediate adapter <NUM>. In such an implementation, if the point <NUM> and the intermediate adapter <NUM> are lost together, the intermediate adapter may include a sensor that signals the location of the intermediate adapter <NUM>. Other tags, sensors, etc. could also optionally be included in the wear part (e.g., as disclosed in <CIT>).

The remote device <NUM> and/or the monitoring device <NUM> may on their own, collectively, and/or with other devices, and/or software applications, and the like (e.g., data <NUM> from a database <NUM> in, for example, a cloud database, other processors, etc.), store, process and/or communicate information or data <NUM> related to a characteristic of the wear part. Monitoring device <NUM> may along with detecting separation also optionally (or in lieu of detecting separation) include one or more sensors for identifying other characteristics of the wear assembly besides separation of the wear part including, for example, part ID, usage, strain, temperature, acceleration, inclination, etc. of a ground engaging product such as tooth <NUM>, shroud <NUM> or other wear assembly for earth working equipment. Information related to the part ID can include such things as ground engaging product type, part number, customer, brand name, trademark, manufacturer, bill of materials, etc. The part ID may be used as search criteria in order to retrieve additional information regarding the specific ground engaging product. The search criteria may be used to query one or more relational databases and/or broader data structures. Information related to usage can include such things as the kind of machine to which the ground engaging product is secured, time the ground engaging product went into service, how many digging cycles the ground engaging product has experienced, average time of the digging cycles, location of the ground engaging product on the machine, impact events, etc. These monitored characteristics are given as examples only and are not intended to be limiting. Information may be shared with, i.e., sent to and/or received from, various other machines including programmable logic, other networks, and used with various software applications, and routines.

The monitoring device <NUM> and/or remote device <NUM> can use programmable logic to process information generated from, e.g., monitoring device(s) <NUM> and/or the remote device(s) <NUM> for monitoring characteristics such as the part ID, presence, condition, performance, and/or usage of the ground engaging product being monitored and/or providing alerts to the operator. Processors (e.g., microprocessors), using programmable logic may be part of monitoring device <NUM> and/or a remote device <NUM>. The programmable logic included in a remote device <NUM> may, for example, use information received from monitoring device <NUM> to identify that the ground engaging product is still secured to the base. When the ground engaging product has unexpectedly been separated from the base, the monitoring device <NUM> may send an alert signal indicating a change in the condition of the ground-engaging product. In another example, the processor may use information about the geology of the mine site in combination with usage information from monitoring device <NUM> to determine, e.g., the estimated wear life remaining for the ground engaging product. For example, the programmable logic may use the number of digging cycles and/or the duration that a ground engaging product has been in service to determine the estimated wear life remaining. The programmable logic may be programed to produce a precautionary alert that a specific ground engaging product is close to needing replacement. The alert may be, for example, a visual alert, haptic feedback, and/or an audio alert. The devices <NUM> and/or <NUM> may provide the alerts to devices for access by the operator or others such as maintenance personnel, mine site managers, or the like. In addition, the programmable logic may be programed to produce an alert if the condition indicates, e.g., that the ground engaging product has been unexpectedly separated from the base.

In one implementation, the results and alerts from the process may be sent to at least one Human-Machine Interface (HMI) <NUM>. The HMI could, e.g., be a handheld device <NUM> as shown in <FIG>, mounted in a cab of a vehicle such as a digging machine or haul truck, or in an on-site or off-site location. The features, events, data or the like detected by the monitoring device can be processed with other collected or stored data by programmable logic to determine a wide variety of factors that may influence the machine operator. The system may make determinations by including outside factors such as the hardness or abrasiveness of the earthen material being worked, the material composition of the ground engaging product being monitored, etc. Also, as discussed earlier, the system may be coordinated with a ground-engaging inventory and supply system. The system may also be coordinated with other kinds of information such as scheduled maintenance to determine the most efficient time to replace or maintain the ground engaging product being monitored. In turn, the HMI <NUM> can on the basis of the detected features and/or processed information provide alerts, data, expected wear lives, and the like for more efficient use of the earth working equipment.

The HMI <NUM> may be hard wired or may be a wireless device, may be integrated with a display system currently in the excavating equipment (e.g., with the OEM display), integrated with a new display system within the excavating equipment, and/or may be in a remote location. The HMI <NUM> may be configured to provide a graphical display of the current condition of the ground engaging product. The HMI <NUM> may, for example, provide visual alerts (e.g., text and/or pictorial images), haptic feedback (e.g., vibrations), and/or audio alerts regarding each ground engaging product. The visual alert may be, for example, a graphical picture displaying each ground engaging product and the condition of each ground engaging product (i.e., absent/present, needing maintenance, etc.). The HMI <NUM> may be designed to display a history chart so that an operator can determine when an alert happened so that an operator can take the necessary actions if a ground engaging product is unexpectedly separated. The HMI <NUM> may include a display <NUM>. The display <NUM> may include various visual indicators including but not limited to: photographs or real time images of, for example, similar ground engaging products from a database; photographs taken with camera at the worksite, such as with camera <NUM> on boom <NUM> (<FIG>); remaining wear life; bucket configuration; etc..

In one example, a camera could be attached to, e.g., the bucket <NUM>, the boom <NUM>, the stick <NUM>, the machine <NUM>, drone, service truck <NUM>, or other support to provide a visual double check for the operator. In the illustrated example, a camera <NUM> is secured to the boom <NUM> to capture (at least part of the time) a visual image of the ground engaging products attached to the bucket <NUM>. When the machine display (or another) receives an alert that, e.g., a ground engaging product has separated, a display showing the visual image within the cab can be checked to ensure the noted ground engaging product is actually missing from the bucket. The checking may use computer vision, which has been programmed to look for ground engaging products in a specific location. This backup system can reduce false alarms that cause the operator to stop operation of the machine.

In another example, systems involving cameras such as used in prior art systems or as disclosed in <CIT> can be used in combination with the monitoring systems described in this application. The information received from the camera-based systems can be used as a backup double check to reduce the number of false alarms. Alternatively, the monitoring devices <NUM> disclosed herein could be a backup double check for the camera-based monitoring systems. Further, the data collected by both a camera-based monitoring system and a non-camera based monitoring system (such as disclosed herein) could be collectively processed to determine, e.g., the part ID, presence, usage, condition and/or performance of the ground engaging product. The full data received by both systems could lead to more reliable conclusions and assessments. The performance of the ground engaging product could be related to the number of digging cycles and/or the length of said digging cycles. Digging cycles may be measured from the time of impact with the ground to the next impact with the ground. Digging cycles may also be measured as operational cycles, which is the amount of time required to fill a load container.

The monitoring device <NUM> may also communicate with other computer systems, wirelessly or through a cable, the specific ground engaging product(s) needing maintenance either because the ground engaging product is separated or because there is an indication that the ground engaging product may need maintenance. The monitoring device may store all the results from the process.

Claim 1:
A wear assembly for earth working equipment (<NUM>), the wear assembly comprising:
a base (<NUM>';13B) securable to the earth working equipment (<NUM>), and including a mounting portion (<NUM>) and a hole (<NUM>";49B) that opens in the mounting portion;
a wear part (<NUM>';15B) including a cavity (18B) receiving the mounting portion (<NUM>) of the base (13B);
a lock (<NUM>;21B) to secure the wear part (<NUM>';15B) to the base (<NUM>';13B);
characterized in that the wear assembly further comprises
a proximity device (<NUM>';51B) on the wear part (<NUM>';15B) or the lock (<NUM>;21B), wherein the proximity device is a magnet; and
a monitoring device (<NUM>';25B) in the hole (<NUM>';49B) in the base (<NUM>';13B) having a sensor (<NUM>', 35B) to detect the presence and/or absence of a magnetic field of the proximity device (<NUM>';51B), and a communication device (<NUM>) to send a wireless signal when the proximity device (<NUM>';51B) is absent.