Patent Description:
Underground mining machines operate in challenging environments and are typically subjected to significant forces and stress. Accordingly, such mining machines comprise replaceable wear parts that may be optimised for durability and are capable of being replaced when warned or damaged. For example, typically a bucket of an underground loader is fitted with a plurality of GETs in the form or interchangeable teeth secured to the front lip or edge of the bucket. Initially, the GETs were welded onto the bucket lip and on expiry of their service lifetime, removal from the lip was achieved via a time and labour intensive cutting process.

More recently, mechanical connection systems have been proposed to facilitate the interchange of warn GETs as described in <CIT> and <CIT>. However, it is not uncommon for existing mechanical connections to wear prematurely or be damaged due to high impact loading forces resulting in detachment of a GET. In such situations, normal operation is halted as a manual search is often undertaken to try and locate the lost GET. Additionally, further time and effort is required to reattach or install a new GET at the heavy machinery.

A particular problem with lost and unidentified GETs is the contamination of the bulk material that is being extracted and subsequently processed (by a crusher for example). As will be appreciated, the introduction of an uncrushable GET into a crusher can cause significant damage and machine downtime. Accordingly, systems have been proposed for the detection of detached GETs to try and prevent disruption to downstream material processing. In particular, <CIT> describes a detection system for detecting loss of a GET component from a mining or earth moving machine. The system comprises a radio frequency identification (RFID) tag securable to the GET component. One or more tag reading stations are provided at exit gates surrounding the site such that GET contaminated bulk material passing through a gate is scanned to allow GET identification and removal prior to onward processing. Further example GET detection systems are described in <CIT>; <CIT>; <CIT>; <CIT>; <CIT>, <CIT> and <CIT>.

However, existing GET detection systems are limited to the detection of detached GETs. In particular, a GET embedded deeply within extracted bulk material may not be readily identifiable and may pass downstream undetected. Additionally, such systems do not address the problem of the labour and time required to repair and/or reattach a lost GET at the heavy machinery. Accordingly, what is required is a GET detection/monitoring system that addresses the above problems.

It is an objective of the present invention to provide a monitoring system for monitoring a status of attachment of a ground engaging tool (GET) at a mining, earth moving or rock processing machine configured to output a status of attachment of the GET at the heavy machinery in real-time (i.e., as the machinery is in use). It is a further specific objective to provide a monitoring system that is sensitive to the attachment status of a GET so as to alert personnel to the loosening or partial failure of a mechanical connection of the GET to the heavy machinery. Accordingly, it is a general objective of the present invention to provide a system to avoid undesirable damage to the attachment mechanism of a GET and the unintentional GET detachment at a mining, earth moving or rock processing machine.

The objectives are achieved by providing a GET attachment status monitoring system in which a proximity sensor is provided at the GET and is configured to sense a proximity of a GET relative to a region of the mining, earth moving or rock processing machine to which the GET is mounted. Such a sensor is configured to transmit real-time data to a suitable receiver so as to provide live connection status monitoring. Such status monitoring may be qualitative or quantitative relative to a predetermined and desirable connection status. The subject invention may be implemented via RFID type technology in which an RFID tag coupled to a GET is capable of transmitting sensor data to a receiver for direct output to personnel and/or onward communication to a network or central hub.

The present system may be configured as a local network or localised GET attachment status monitoring system specific to a particular machine such as an underground loader. In particular, a set of GETs mounted at a lip of a loader bucket may be respectively paired with a single receiver mountable in the cab of the loader with each GET comprising an RFID tag capable of single or two way communications with the cab mounted receiver. Pairing of the receiver and tags (implemented for example by password or code communication) is advantageous in that each individual loader machine comprises a 'self-contained' GET connection status monitoring system that is independent of other operating machines within the same environment. This type of machine specific local network configuration is advantageous to optimise the sensitivity of the monitoring/detection system and to provide a reliable and efficient system with regard to the working components, their function and communication pathways.

The subject invention is further advantageous via the configuration of the machine/localised GET monitoring system in that each system is capable of being configured to be sensitive to detached GETs of other machines if required. That is, by configuration of the machine specific receivers of a plurality of machines, multiple machines can be configured to be sensitive to detached GETs of neighbouring machines and increase the likelihood of recovery. The present invention may be advantageously implemented using RFID type technology in which individual GETs are capable of transmitting status sensor data via wireless communication to an electronic receiver within desired and optimised radio frequency ranges fitting with a working environment such as a mine.

According to a first aspect of the present invention there is provided a monitoring system according to claim <NUM>, for monitoring a status of attachment of a ground engaging tool (GET) at a mining, earth moving or rock processing machine, the system comprising: at least one GET detachably mountable at a mount region of a mining, earth moving or rock processing machine; at least one proximity sensor provided at the GET and configured to sense a proximity of the GET relative to the mount region of the mining, earth moving or rock processing machine to which the GET is mountable; and a transmitter provided at the GET to transmit wirelessly proximity data to a receiver located remote from the GET.

Optionally, the GET comprises a first part of a mechanical connection and the mount region comprises a second part of the mechanical connection, the GET capable of being detachably mounted at the mount region via a mating of the first part and the second part. The first part may comprise a generally solid body having an internal cavity region that defines a 'shroud' capable of at least partially extending over the mount region. The second part may comprise a boss, body or projection capable of being received within the cavity or shroud. The first part and second part may be mated together via a mechanical connection mechanism as described in <CIT>.

Such a mechanical connection is advantageous to allow convenient mounting and interchange of GETs at the mount region.

Optionally, the proximity sensor comprises any one or a combination of the following set of: an inductor component; a capacitor component; a proximity sensor component. Preferably, the inductor component comprises an inductance sensor that may include electronic components such as at least one capacitor, at least one inductor, at least one proximity sensor and/or a load cell or strain gauge configured to measure strain at a GET. Where the sensor comprises a strain gauge, the subject invention is capable of outputting a calculated stress based on stain monitoring.

The GET comprises an electronic tag, wherein the proximity sensor is provided at the tag. Preferably, the tag comprises any one or a combination of the following set of: a PCB; a processor; a data storage utility; a transceiver; an antenna. Optionally, the transceiver comprises a radio frequency transceiver and/or a Bluetooth transceiver. Preferably, the present system utilises RFID tag technology to provide a system adaptable to suit different working environments with regard to operating frequency and range of frequency transmission.

The system further comprises an activator having a PCB, a processor and a transceiver, the activator configured for wireless communication with the electronic tag. Preferably, the activator is a hand-held device capable of being located in close proximity to the electronic tag so as to activate the tag for use and in particular to convert the tag from an initial 'manufacturing mode' to a fully functional 'operational mode'. Preferably, the activator and the electronic tag are configured for UHF (radio frequency) and/or Bluetooth communication. Preferably, the activator is configured for wired or wireless communication with auxiliary computer entities such as a computer, personal digital assistant (PDA) and the like. Preferably, the activator is configured to receive data via Bluetooth communication and then to transmit data to the tag via UHF communication. Optionally, the electronic tag may be configured for any mode of wired or wireless communication. Such wireless communication may include any type of electromagnetic wireless technology encompassing radio frequency and other types of communication such as long-term evolution (LTE), LTE-advanced, Wi-Fi and Bluetooth. The tag may also operate with radio frequency communication technology including any of the ITU radio bands for example VLF, LF, MF, HF, VHF, UHF, SHF, EHF or THF. Accordingly, where the present invention comprises a receiver and optionally an activator, such components may be similarly configured for these types of wireless communication via their electronic components and in particular their communication components such as transceivers.

Optionally, the activator may be an auxiliary computer entity such as a computer, PDA, a mobile phone and the like. Optionally, the activator may be an electronic component positionable in the communication pathway intermediate the GET (tag) and an auxiliary computer entity such as a PDA.

Preferably, the electronic tag is encapsulated within a housing, a shell, an encapsulating material or specifically a polymer based material so as to protect the tag from abrasive wear or impact related damage and to provide a sealed coating to prevent moisture ingress. Optionally, the polymer based material comprises a silicone material or an epoxy adapted to seal, house and protect the electronic components from moisture in addition to bonding the tag to the GET.

Preferably, the receiver comprises a PCB, a processor, a transceiver and a data storage utility. More preferably, the receiver further comprises an accelerometer, a display screen and an antenna. The receiver may further comprise additional electronic components to provide wired or wireless communication between the receiver and other components of a larger network or computer entities such as a server, computer, PDA etc. Preferably, the receiver further comprises a user interface comprising a display screen to output the proximity data (or information based on the proximity data) and optionally additional sensor data or information based on one of the sensors mounted at the machine. Such sensor data may include accelerometer data including in particular accelerometer data relating to part of the machine to which a GET is mounted including movement in elevation, horizontal/vertical motion, angular rotation and acceleration or deceleration of a machine part to which the GET is attached. In particular, the user interface (or display screen) is configured to output an angular orientation of a GET corresponding to an inclination or declination of a machine part to which a GET is attached.

Optionally, the mount region is a leading edge of an excavation bucket of an earth moving machine. Optionally, the mount region is a region of a hammer component, a drill component, a crushing component forming part of a mining, quarrying, rock processing or crushing apparatus. Optionally, the status monitoring tag according to the subject invention may be mounted at any region or component of ground engaging or rock processing apparatus including for example mounting at an excavation bucket, a vehicle, a motor, a gear box, a hopper, a conveyor, a protective liner, a wear plate, a crushing shell, a drill rod, a drill shank adaptor, a drill head, a drive sub, a drill casing or other intermediate drill component forming part of a drill string.

Optionally, the GET further comprises any one or a combination of the following set of: a temperature sensor; a GET wear status sensor; an accelerometer; a voltage sensor.

Optionally, the wear status sensor comprises a resistive wire or film capable of being fully or at least partially embedded within the GET. Optionally, the wear status sensor comprises a resistance wire or foil extending through the body of the GET from external facing surface to an internal region or internal facing surface (i.e., at a cavity region of the GET). Optionally, the wear status sensor may comprise an ultrasonic sensor configured to identify a relative thickness and/or body profile of a GET to allow determination of a wear status. Such an ultrasonic sensor may be operated according to time periods being independent of the operation of other sensors so as to provide power saving. Optionally, the ultrasonic sensor may be operated in a period twice a day, once a day or once every two or three days. Such a configuration is advantageous to provide wear status data as the volume of material that forms the GET is reduced, as the GET wears during normal use.

According to a second aspect of the present invention there is provided a method according to claim <NUM>, of monitoring a status of attachment of a ground engaging tool (GET) at a mining, earth moving or rock processing machine, the method comprising: providing a proximity sensor at a GET detachably mountable at the mining, earth moving or rock processing machine; sensing the proximity of the GET relative to a mount region of the mining, earth moving or rock processing machine to which GET is mounted; transmitting wirelessly proximity data generated by the sensor to a receiver located remote from the GET; and storing, outputting and/or processing the proximity data at the receiver to monitor the attachment status of the GET based on the proximity data.

Preferably, the system further comprises outputting at the receiver the proximity data or information based on the proximity data. Optionally, the proximity data may be transmitted to the receiver according to single or multiple sensing events of the order of one event per millisecond, per second or per minute. Optionally, the system is configured such that sensor data is transmitted to the receiver in a range one to five times a second to one to five times every thirty seconds. Optionally, the sensor is configured to generate proximity sensor data in a range one event per second to one event per ten seconds.

The electronic tag is configured to transmit tag ID data to the receiver such that the electronic tag and the receiver are communication paired; wherein in a normal use mode, the receiver accepts exclusively transmission of proximity data from the electronic tag associated with the mining, earth moving or rock processing machine and not from non-associated electronic tags on different mining, earth moving or rock processing machines. Reference within the specification to 'communication paired' encompasses pass-code or password related data transmission such that data from the sensor is received and processed, stored or output at the receiver only if the sensor data is accompanied by a recognised tag ID data that confirms the electronic tag is associated with a GET at the mining, earth moving or rock processing machine that is within the designated 'local network' of the mining, earth moving or rock processing machine with such a network comprising at least one GET and a communication paired receiver. Preferably, and in one implementation, the communication pairing between the electronic tag and the receiver is achieved via a lock and key code based system in which each data packet transmitted from a GET includes code data that is recognised by the receiver.

The method further comprises prior to generating the proximity data, activating the electronic tag using an activator configured for wireless communication with the electronic tag. Preferably, the wireless communication between the activator and the electronic tag is Bluetooth or UHF communication. Optionally, the wireless communication with the tag utilises adaptive frequency hopping (AFH) to provide low energy communication and a means of avoiding or minimising communication interference.

Optionally, the step of activating the electronic tag comprises transferring activation data to the electronic tag, the activation data comprising any one or a combination of the following set of: ID data relating to the GET, the environment within which the GET is to be operative and/or the machine to which the GET is mountable; a position of the GET at the machine to which the GET is mounted; communication parameter data to enable the electronic tag to communicate with the receiver; configuration data to set a working configuration of the electronic tag. Such data exchange may comprise wireless or wired communication between an electronic tag, an activator and/or a third data storage or transmission component such as a computer, a network, a cloud architecture, a hub, a PDA.

Preferably, the method further comprises providing at the GET any one or a combination of the following set of: a temperature sensor; a GET wear status sensor; an accelerometer; a voltage sensor; and sensing at the GET and transmitting to the receiver any one or a combination of the following set of: a temperature of the GET; a wear status of the GET; an inclination/declination of the GET; an acceleration/deceleration of the GET; a tilt angle of the GET; GET movement in a horizontal/vertical plane; a strain or stress at the GET; an impact status of a GET; a voltage at any one or a combination of the sensors.

Preferably, the method further comprises outputting the proximity data or information based on the proximity data to a network or data storage utility such as a cloud architecture via wired or wireless communication. Preferably, the proximity data is processed by the processor on board the receiver such that the system comprises raw proximity data and processed proximity data with the processed proximity data preferably being output at the receiver. The output proximity data may be expressed visually, audibly or tactilely. Preferably the data is output graphically and/or numerically indicating a status of attachment of the GET at the machine.

Preferably, the method is further configured such that in response to a mechanical detachment of the GET from the mount region, the receiver is configured to transmit to at least one neighbouring receiver (in the same working environment) a signal to enable said neighbouring receiver(s) to receive and process a signal transmitted from the GET that is detached. Preferably, the neighbouring receivers are configured to communicate with the receiver of the machine from which the GET has been detached and to notify the receiver when a signal has been received from the detached GET. Such a system is advantageous to identify and locate a detached GET as quickly as possible by utilising neighbouring machines to receive data from the detached GET. Such a system is described herein with reference to the generation of an SOS signal and process.

According to a further aspect of the present invention there is provided a monitoring system for monitoring a status characteristic of each of a set of ground engaging tools (GETs) mountable at a mining, earth moving or rock processing machine, the system comprising: a plurality of GETs mountable to respective mount regions of a mining, earth moving or rock processing machine; a set of RFID tags, each tag having at least one sensor for sensing a status characteristic of each respective GET; a receiver to receive data from the RFID tags; each of the RFID tags comprising ID data to associate the RFID tags with a specific mining, earth moving or rock processing machine; wherein the receiver and the RFID tags are configured to be communication paired such that in a normal use mode said receiver accepts exclusively data transmission from said RFID tags associated with said mining, earth moving or rock processing machine and not from non-associated RFID tags.

According to a further aspect of the present invention there is provided a method of monitoring a status characteristic of each of a set of ground engaging tools (GETs) mountable at a mining, earth moving or rock processing machine, the method comprising: providing a plurality of GETs mountable to respective mount regions of a mining, earth moving or rock processing machine; providing each GET of the set of GETs with an RFID tag, each having at least one sensor; sensing a status characteristic of each of the GETs via each respective sensor; each RFID tag transmitting GET status data to a receiver that is communication paired with the RFID tags so as to receive GET status data from said RFID tags and to ignore data from non-communication paired RFID tags in a normal use mode. According to a further aspect of the present invention there is provided a monitoring system for monitoring a status characteristic of a ground engaging tool (GET) at a mining, earth moving or rock processing machine, the system comprising: a GET mechanically attachable to a mount region of the mining, earth moving or rock processing machine; at least one tag provided at the GET, the tag having at least one sensor, a processor and a transmitter to transmit wireless GET status data based on signals generated by the sensor; a receiver configured to receive wirelessly the GET status data from the tag; at least the tag comprising ID data to associate the tags with the receiver such that the receiver and the tag are communication paired and the receiver is configured to receive exclusively in normal use GET status data from the tag having a recognised ID and to ignore GET status data from other tags.

Reference within this specification to 'a status characteristic' of a GET encompasses a temperature of the GET; a wear status of the GET; movement of the GET; movement of the GET in a horizontal/vertical plane; an inclination/declination of the GET; an acceleration/deceleration of the GET; a tilt angle of the GET; a strain or stress at the GET; an impact status of a GET; a voltage through a sensor at an electronic tag provided at a GET and/or any other physical or mechanical characteristic.

According to a further aspect of the present invention there is provided a ground engaging tool (GET) according to claim <NUM>, mountable at a mining, earth moving or rock processing machine, the GET comprising: a main body having a ground engaging region to engage the ground and an attachment region to attach the GET at a mining, earth moving or rock processing machine; an RFID tag attached to the GET, the tag comprising: a PCB; a processor; an antenna; a battery; at least one sensor comprising a proximity sensor to sense a proximity of the GET relative to a region of the mining, earth moving or rock processing machine to which the GET is mountable.

The subject invention provides a system enabling the active monitoring of the mechanical connection of a wear part to heavy machinery so as to detect in real-time any loosening, partial or complete detachment of the wear part from its region of attachment. The subject invention accordingly provides apparatus and method focused towards preventing undesirable detachment and loss of wear parts in an environment such as a mine or quarry. The subject invention seeks to avoid the disadvantages associated with such undesirable detachment including in particular damage to down-stream processing apparatus and the time and effort needed to locate lost wear parts. One implementation of the subject invention may exemplified via the configuration of an underground mining loader, commonly referred to as a load haul dumper (LHD) <NUM>. The loader <NUM> comprises a mainframe or chassis <NUM>, an operated cab <NUM> and a pivot mounted excavator bucket <NUM> that in turn mounts a plurality of ground engaging teeth (GETs) <NUM> attached respectively to a leading edge or lip <NUM> of the bucket <NUM>. As will be appreciated, the loader <NUM> is independently powered by a motor unit so as to be a mobile unit operative autonomously within an underground mine environment.

Referring to <FIG>, the bucket lip <NUM> is formed at the leading edge of a generally platelike base of bucket <NUM>. Lip <NUM> is accordingly dimensioned so as to accommodate a set of GETs with each GET being detachably mounted at lip <NUM> via a releasable mechanical mounting. The mounting comprises a shroud indicated generally by reference <NUM> configured to at least partially envelope the lip (leading edge) <NUM> at the mount region of the GET. A boss <NUM> (formed from a weld component) is securely attached to lip <NUM> at the region of mounting of each GET. A lock pin assembly <NUM> is releasably mountable at/within shroud <NUM> to provide a mechanical lock for attachment of the GET <NUM> to the lip <NUM> via the cooperative engagement of the boss <NUM> according to the components and attachment mechanism described within <CIT>. In particular, shroud <NUM> comprises an internal cavity 18a within which the lock and pin assembly <NUM> is mounted to abut against boss <NUM>. An RFID tag <NUM> is secured to GET <NUM> by mounting internally within a forward region of shroud cavity 18a. According to the specific implementation, tag <NUM> comprises electronic components (as described with reference to <FIG> and <FIG>) and is bonded to the GET <NUM> via an encapsulating material. In particular, tag <NUM> is preferably encapsulated within the material that firstly acts as an adhesive to attach tag <NUM> to the forward region of shroud cavity 18a and secondly provides a moisture protective housing for tag <NUM>.

The present system also comprises a portable electronic 'activator' <NUM> primarily configured to activate and configure the set of RFID tags <NUM> for operation according to the subject invention. Activator <NUM> (described further referring to <FIG> and <FIG>) is configured for wireless communication <NUM> with the RFID tags <NUM> in addition to separate wireless communication <NUM> with a portable computer or suitable electronic device such as a personal digital assistant (PDA) <NUM>. As will be described in detail below, activator <NUM> and PDA <NUM> are configured to initially activate the tags <NUM> in situ within the working environment and in particular on initial installation and mounting of the GETs <NUM> at the bucket lip <NUM> prior to first use.

Referring to <FIG>, the subject invention may also be considered to comprise a receiver <NUM> also configured for wireless communication <NUM> independently with each of the bucket mounted GETs <NUM>. Receiver <NUM> comprising the electronic components and function described further with reference to <FIG>, <FIG> and <FIG> is additionally adapted for coupled communication with a hub or network <NUM> so as to exchange GET related data with the hub/network <NUM>. Any such uploaded data may then be configured for onward transmission <NUM> to one or a plurality of storage units or further data processing utilities (not shown) as will be appreciated.

Referring to <FIG> and <FIG>, each RFID tag <NUM> comprises a printed circuit board (PCB) <NUM> mounting a plurality of circuits 25a, b, c and d. PCB <NUM> further mounts a battery <NUM>; an antenna <NUM>; a microchip base processor <NUM>; a radio frequency transceiver <NUM>; and a suitable data storage <NUM> comprising RAM and flash memory <NUM>, <NUM> respectively. Each tag <NUM> comprises a sensor unit <NUM> that includes a plurality of different types of sensor each configured for real-time status monitoring of the respective GET <NUM> and in particular the environment within which the GET <NUM> is located and is operative. In particular, sensor unit <NUM> comprises, according to the specific implementation, an inductance sensor <NUM>, a thermometer <NUM>, a resistance wire/film <NUM>, an accelerometer <NUM>, a voltage sensor <NUM> and a strain gauge <NUM>. Optionally the tag architecture <NUM> may comprise an additional communication transceiver <NUM>. The additional communication transceiver <NUM> may be configured for implementation with any additional communication types including any type of wireless communication not restricted to radio frequency and in particular UHF, VHF, Bluetooth etc. Similar additional or auxiliary communication transceivers <NUM> may be implementer as part of the activator architecture <NUM> and receiver architecture <NUM>. The sensor unit <NUM> and in particular the electronic components <NUM> of the tag <NUM> are all encapsulated within a suitable silicone polymer based encapsulating material <NUM> (such as an epoxy) that both protects the components <NUM> and provides a means of attachment of the tag <NUM> to the GET <NUM>.

Processor <NUM> may typically comprise a master processor in addition to a small power efficient processor (not shown) for initial activation of the master processor. Processor <NUM> is configured to run a suitable real-time operating system so as to provide tag operator functionality as described referring to <FIG> with the tag operators <NUM> implemented as software.

Referring to <FIG>, voltage sensor <NUM> is configured to monitor the voltage at tag <NUM> and provide real-time monitoring of battery <NUM>. Accelerometer <NUM> is configured to monitor a variety of different characteristics of bucket <NUM> (and optionally loader <NUM>) including bucket movement generally and in particular a bucket elevation, horizontal/vertical motion, angular rotation and an acceleration/deceleration of bucket <NUM> including in particular bucket lip <NUM>. Thermometer <NUM> accordingly provides temperature monitoring at the region of each GET <NUM>. According to the specific implementation, the resistive wire/film sensor <NUM> is formed as a foil or rigid PCB attached to the main PCB board <NUM>. Each GET <NUM> comprises a cast borehole (not shown) extending through the GET body and into the shroud cavity 18a. The resistive foil extends through the cast hole so as to protrude from an underside of the GET <NUM>. The hole may be filed with an encapsulating resin such as an epoxy sealant so as to fix the resistive coil in place and to form a composite GET. Accordingly, as the GET <NUM> wears the length of the resistive foil is gradually decreased and a wear status monitoring of the GET <NUM> is provided.

The present GET status monitoring system according to the subject invention is specifically configured to monitor and output a status of mechanical attachment of each GET <NUM> at the bucket lip <NUM>. In particular, via the sensor unit <NUM> and in particular inductance sensor <NUM>, a GET-lip distance is capable of being monitored. In particular, via sensor <NUM>, a separation distance between tag <NUM> and boss <NUM> is monitored continuously in real-time so as to output proximity data to receiver <NUM>. Such a system, as will be described, is advantageous to identify progressive partial separation or loosening of a GET <NUM> at the bucket lip <NUM> during use and in particular prior to complete mechanical detachment of GET <NUM>. According to the specific implementation, inductance sensor <NUM> is formed as a proximity sensor being a transducer operating according to the Hall effect in which an output voltage is varied in response to an induced magnetic field so as to provide the proximity sensing between tag <NUM> and the metallic boss <NUM> (for example formed by a weld component). As will be appreciated, inductance sensor <NUM> may be implemented as a variety of different types of sensor mountable at PCB <NUM> and configured to provide GET-to-bucket lip proximity data which is then capable of wireless transmission <NUM> to receiver <NUM> via the tag mounted radio frequency transceiver <NUM>. Transceiver <NUM> is capable of operation within a broad frequency range typically ranging from <NUM> to <NUM>.

In use, each tag <NUM> via the electronic component <NUM> is associated with a plurality of different data sets <NUM> processable by processor <NUM> and stored at data storage <NUM>, <NUM>, <NUM>. In particular, sensors <NUM> to <NUM> are configured to output GET-lip separation data <NUM>, temperature data <NUM>, wear data <NUM>, bucket angle (and acceleration/deceleration) data <NUM> and battery voltage data <NUM>, respectively with such data <NUM> to <NUM> being bucket sensor data <NUM>. Each tag <NUM> via data storage <NUM>, <NUM> and/or <NUM> is configured with GET and/or loader specific ID data <NUM>. Such data <NUM> includes machine assignment number data <NUM> (being the assigned operating number of the low loader <NUM>); position data <NUM> (being the position of a specific GET <NUM> at the lip <NUM> relative to other GETs <NUM> of the set mounted at the same loader <NUM>) and bucket number data <NUM> (corresponding to the specific ID number assigned to the bucket <NUM> mounted at loader <NUM>). The tag data <NUM> also comprises communication data <NUM> including in particular an operating frequency setting <NUM> being the designated operating frequency of a mine in which the loader <NUM> may be operative. At least some or all of the data sets <NUM> are capable of being communicated to and/or from tag <NUM> via wireless communication <NUM>, <NUM> with the respective activator <NUM> and/or receiver <NUM>.

Referring to <FIG>, the portable activator <NUM> is implemented as a handheld device having electronic components <NUM> including in particular a PCB <NUM>; a battery <NUM>; a processor <NUM>; an antenna <NUM>; a radio frequency transceiver <NUM>; a Bluetooth transceiver <NUM>, a power-up emitter <NUM> and a communication transceiver <NUM>. Activator <NUM> may also comprise a suitable display screen (not shown) for displaying information to user. Alternatively, activator <NUM> may not comprise a display (or output components) other than wireless or wired communication components to provide the desired communication pathways <NUM>, <NUM> between tag <NUM> and PDA <NUM>. Accordingly and referring to <FIG>, activator <NUM> is configured for use with a plurality of activator data sets <NUM> including in particular tag ID data <NUM>. Tag ID data <NUM> includes machine assignment number data <NUM>; GET mounting position data <NUM>; date of set-up data <NUM> and loader bucket number data <NUM>. Activator data <NUM> further comprises communication data <NUM> including in particular a designated operating frequency data <NUM>.

Referring to <FIG>, receiver <NUM>, configured for wireless communication <NUM>, <NUM> with each GET <NUM> and a suitable hub/network <NUM> is implemented as a fixed-mounted or portable unit mountable within loader cab <NUM> and configured primarily for receiving sensor data <NUM> from GETs <NUM> in normal use. Receiver <NUM> is implemented via electronic component <NUM> including in particular a PCB <NUM>, that mounts at least one processor <NUM>; data storage utility <NUM>; a UHF transceiver <NUM>; a Bluetooth transceiver <NUM>; an Ethernet out <NUM>; an accelerometer <NUM>, an antenna <NUM> and a communication transceiver <NUM>. The receiver components <NUM> further comprise a visual display screen <NUM>; human interface or input component <NUM> (such as a keyboard); an audio output <NUM> and a powered status indicator light <NUM>. Receiver <NUM> via the electronic components <NUM> is adapted for operation with a variety of different data sets referred to herein as receiver data <NUM>. Such receiver data <NUM> includes generally active sensor data <NUM>; GET status library data <NUM>; tag configuration data <NUM>; communication data <NUM> and identification data <NUM> referring to <FIG> and <FIG>. In particular, the active sensor data includes temperature data <NUM>; bracket acceleration/deceleration and angle data <NUM>; tooth-lip separation data <NUM>; wear status data <NUM> with such data being generated by sensor unit <NUM> and received at receiver <NUM> via wireless communication pathway <NUM>. The GET status library data set includes a temperature range data <NUM>; bucket range data <NUM>; separation range data <NUM> and wear range data <NUM>. Such library data <NUM> may be loaded onto receiver <NUM> via communication pathway <NUM> so to enable on-board processing of the active sensor data <NUM> with reference to a corresponding library data set. Such library data <NUM> may be utilised to calculate and enable output reporting of the status of the GET at the lip <NUM> based on historic or desired performance parameters such as a desired operating temperature, bucket acceleration/deceleration; a GET-lip maximum separation threshold and a predefined wear characteristic or threshold to identify when a warn GET <NUM> requires replacement prior to an exceeded maximum wear limit.

Tag configuration data <NUM> includes machine assembly number data <NUM>; GET position at lip data <NUM>; operating frequency data <NUM>; initial calibration or set up data <NUM> and assigned bucket number data <NUM>. Such tag configuration data <NUM> is capable of being received from each tag <NUM> (at each respective GET <NUM>) in parallel to the receipt of the active sensor data <NUM> so as to correlate sensor data <NUM> with a particular tag <NUM>. In particular, code data <NUM> enables transmission and receipt of sensor data <NUM> at receiver <NUM> such that receiver <NUM> receives exclusively active sensor data <NUM> from the GETs <NUM> mounted at the lip <NUM> of appropriate loader mounted bucket <NUM>. That is, signals from other GETs <NUM> mounted on different loaders <NUM> are effectively ignored by receiver <NUM> so as to provide a 'closed network' of communication <NUM> between the relevant GETs <NUM> mounted at the required 'local' bucket <NUM>.

Communication data <NUM> includes in particular network information data <NUM> that is relevant for identifying receiver <NUM> within a hub/network <NUM> of multiple independent local networks formed by multiple mining machines (loaders <NUM>) operating within the environment. The receiver ID data <NUM> includes receiver assignment number <NUM>; machine assignment number data <NUM>; mine related data <NUM>; country related data <NUM>; company related data <NUM>; and operator related data <NUM>. Such data sets <NUM> are used to identify the relevant receiver, machine etc., within a mining environment in addition to identifying the mine, country, company and machine operator within which a GET <NUM> is or has been operative within a larger network such as a company database containing information of heavy machinery in a large number of mines and operative environments across a plurality of countries.

As indicated, tag mounted processor <NUM> is configured to process tag data <NUM>. Such processing is preferably implemented by software. The term 'operators' used herein encompasses software implemented routines and functionality with such operators being implemented by tag processor <NUM>; activator processor <NUM> and receiver processor <NUM>.

Tag operators <NUM> include software implemented for receiving tag data <NUM>; transmitting sensor and other tag related data <NUM>; processing signals from the sensors <NUM> and initial calibration and activation <NUM>. Such operators function to control the data flow <NUM>, <NUM> from the activator <NUM> through the tag <NUM> during initial set-up of a tag <NUM> immediately prior to use within a mine environment as described referring to <FIG>. The operators <NUM> are also configured for the control of the processing of the data generated by sensor unit <NUM> and the onward transmission of data packets to the receiver <NUM> via communication pathway <NUM>.

Similar software implemented operators <NUM> are associated with the activator <NUM> and include in particular data receipt <NUM>; data transmission <NUM>; calibration and activation <NUM>; tag communication <NUM> and receiver communication <NUM>. Such operators, as described with the tag operators <NUM> control transmission of data between the activator <NUM> and the respective tags <NUM> and PDA <NUM> in addition to the management of the various data sets <NUM> and <NUM> at the activator <NUM>.

Corresponding software implemented operators <NUM> include receiver implemented software for controlling and processing receiver data <NUM> (data sets <NUM>, <NUM>, <NUM>, <NUM> and <NUM>). Such receiver operators <NUM> include in particular calibration and activation processing <NUM>; data receipt <NUM>; data transmission <NUM>; sensor data operators <NUM> including in particular, operators <NUM>, <NUM>, <NUM>, <NUM>, <NUM> for processing of data relating to temperature, bucket status, GET-to-lip separation; GET wear and battery voltage, respectively. The receiver operators <NUM> further comprise diagnostic operators <NUM>; network communication operators <NUM> and alert signalling operators <NUM>. Alert signalling operators <NUM> include in particular, operators for alerting that a tag has been detached <NUM>; a tag is lost <NUM>; a tag includes a signal error <NUM>; a receiver <NUM> is malfunctioning <NUM>; an activator <NUM> is malfunctioning <NUM> and a calibration status <NUM> of the tags <NUM>.

Via the architecture, data and operators as described referring to <FIG>, an initial configuration of the tags <NUM> may be performed and is described referring to <FIG>. To facilitate transportation of the tags <NUM> bonded to a respective GET <NUM>, the tags <NUM> are transported in a 'sleeping' or 'manufacturing' mode. Once a GET <NUM> is mounted at a bucket lip <NUM> on-site, the tag <NUM> requires processing through an activation process <NUM> and in particular configuration or operation within the designated mining environment and in particular when attached to a particular bucket <NUM> of a specific piece of heavy machinery <NUM>. At step <NUM>, tag <NUM> is installed at lip <NUM> in its 'manufacturing' mode. Tag <NUM> is configured to 'sleep' for one minute at stage <NUM> and to 'listen' for transmission from activator <NUM>. Tag <NUM> and activator <NUM> are configured for UHF or Bluetooth communication via the respective transceivers <NUM> and <NUM>. Accordingly communication pathway <NUM> is initiated and maintained so as to allow download of information from activator <NUM> to each of tags <NUM> at the lip <NUM>. If no activation signal is received at stage <NUM>, stages <NUM> and <NUM> are cycled. If a signal is received, tag <NUM> responds with a unique ID at stage <NUM>. The tag <NUM> then waits for configuration data at stage <NUM>. At stage <NUM>, if no configuration data is received after ten seconds (stage <NUM>) tag <NUM> continues to wait and stage <NUM> is repeated. If configuration data is received at stage <NUM>, processing of the data exchanged initiates (stage <NUM>) including in particular the setting of the tag ID data <NUM> including in particular changing the frequency range at stage <NUM>. Once the data exchange is complete, the activator <NUM> via operators <NUM> continues to stage <NUM> to confirm tag <NUM> as fully operational. Once fully operational, the tag <NUM> exits manufacturing mode at stage <NUM> and is capable of beginning sensor data transmission at stage <NUM>. The tag initial configuration data may be selected and customised via user input at PDA <NUM> for communication to the activator <NUM> via pathway <NUM>. As will be appreciated, the operating power of the activator <NUM> and in particular the transmission strength from the activator <NUM> may be regulated so as to control and in particular to restrict the localised transmission of data from activator <NUM> to a target tag <NUM> at the bucket lip <NUM>.

Once the initial calibration of each tag <NUM> is complete according to stages <NUM> to <NUM>, activator <NUM> is generally inactive as part of the real-time GET status monitoring. However, activator <NUM> may be used subsequently for diagnostic investigation and in particular to confirm a functioning status of a tag <NUM> should there be any error with data transmission for example.

A normal operating processing according to the subject invention will now be described referring to <FIG>. In particular, the normal operating process <NUM> involves RFID tag <NUM> transmitting sensor data at stage <NUM>. Such data includes sensor data <NUM> including in particular data relating to the proximity or linear separation of tag <NUM> relative to weld component <NUM>; the temperature at tag <NUM>; a wear status of the GET (based on a volume of resistive wire/film present within the GET <NUM>); an acceleration/deceleration and angle of the bucket lip <NUM> in use and a voltage at the tag <NUM>. Such data transmission <NUM> occurs in real-time and is received at receiver <NUM> at stage <NUM>. Receiver <NUM> also receives the tag ID data <NUM> in parallel to the sensor data <NUM>. Receiver mounted processor <NUM> is then configured to process the received sensor data <NUM> at stage <NUM>. Information based on the processed sensor data may then be output at stage <NUM> via the receiver mounted display screen <NUM>.

Additionally, such processed sensor data is also capable of being stored at the receiver storage utility <NUM> at stage <NUM>. At stage <NUM>, the processed sensor data may also be output to hub/network <NUM> via wireless communication pathway <NUM> for subsequent onward transmission <NUM> or processing referring to <FIG>. As noted in <FIG>, the raw data from tag <NUM> may also be stored at receiver data storage utility <NUM> without receiver processing.

Accordingly, 'live' proximity data is capable of being transmitted and received between tag <NUM> and receiver <NUM> with this information being displayed at the machine cab <NUM>. Accordingly, an operator is fed real-time GET status information. In the event that a GET <NUM> appears to becoming loose, action may be taken prior to complete mechanical detachment and undesirable loss of a GET <NUM> from a mounted position at bucket <NUM>. Via the receiver held GET status library <NUM>, a GET status check can be performed at stage <NUM> so as to confirm that a GET <NUM> has not warn beyond threshold limits or has not become loose beyond a predetermined threshold. Accordingly, at stage <NUM>, the operating status of the GET is assessed. If any physical or mechanical characteristic that is being monitored by sensor unit <NUM> is outside of a desired range, an alert signal is generated at stage <NUM>. Such an alert signal may be local at the receiver <NUM> via display screen <NUM>, audio output <NUM> and/or status indicator light <NUM>. Alternatively and in addition, an alert signal may be transmitted to hub/network <NUM>. If a sensor is outputting data within a desired range, the sensing operation continues at stage <NUM>. The transmission, receipt and processing of data and information through stages <NUM> to <NUM> is primarily localised between the bucket mounted tags <NUM> and the receiver <NUM> located at loader <NUM>. Via the transmission of the ID data and in particular code data <NUM>, <NUM>, data from tags <NUM> mounted on other mobile units <NUM> is effectively ignored. That way, an operator of the specific loader <NUM> is notified exclusively of the status of attachment, wear status, the temperature etc., of those GETs <NUM> at the loader specific bucket <NUM>.

However, the present local-network GET status monitoring is capable of being extended beyond individual and independent mobile processing machines <NUM>. In particular, and referring to <FIG>, the GET status monitoring system is configured to generate alerts <NUM> during normal operation <NUM> as described referring to alert signalling step <NUM>. In particular, should a GET <NUM> become detached from its mounted position at the lip <NUM> as illustrated in <FIG>, the alert sequence is initiated at stage <NUM> by receiver <NUM>. This process of alter signalling <NUM> involves interrogation of the library data <NUM> via sensor and/or alert operators <NUM> and <NUM>. If an RFID tag status is within the various different desired operating ranges via a status check at stage <NUM>, normal operation is followed via stage <NUM> corresponding to the operating procedure <NUM> detailed in <FIG>. If a GET (via its respective tag <NUM>) is identified as having sensor parameters outside of a predetermined operating range, the alert sequence is activated via an initial confirmatory check (stage <NUM>). Confirmation of detachment at stage <NUM> may be achieved exclusively via the output proximity sensor data <NUM>, <NUM> or in combination with the accelerometer sensor data <NUM>, <NUM> of each GET <NUM> of the same bucket <NUM> i.e., were a particular detached GET <NUM> is identified as stationary whilst the remainder of the set of GETs attached to the same bucket <NUM> are identified as mobile. Such a situation would initiate generation of an SOS signal at stage <NUM>. According to the specific implementation, a detached GET <NUM> is configured to generate the SOS signal at stage <NUM> (based on an exceeded proximity threshold value). All multiple independent receivers <NUM> (mounted within neighbouring loaders <NUM> operative in the same working environment) are programed to listen for an SOS signal. This tag-generated SOS signal or code will also include broadcast of tag ID data <NUM> including in particular machine assignment number ID data <NUM> so as to identify the loader <NUM> from which the GET <NUM> is detached.

Optionally, according to a further specific implementation, the receiver <NUM> may be configured to generate the SOS signal. As part of this, receiver <NUM> enables multiple independent receivers <NUM> (mounted within neighbouring loaders <NUM>) to be configured to receive data from the detached GET <NUM>. Stage <NUM> for example comprises transmission of code data <NUM> and <NUM> to the neighbouring receivers <NUM> within the local environment. All cab mounted receivers <NUM> are then enabled to continually scan and receive data from a tag <NUM> of a detached GET <NUM> transmitting an SOS signal.

Optionally, the SOS signal may be based on sensor data <NUM> that is outside of a predefined range (or beyond a threshold value) as would be expected from a 'detached' GET. For example, such an SOS signal could be based on the accelerometer data <NUM> in that a detached GET will be stationary. Such data transmission may be clarified by corresponding inductance data <NUM> where the separation between tag <NUM> and boss <NUM> has exceeded the threshold indicating detachment.

Once location of a lost GET has been identified at stage <NUM> (for example by a neighbouring loader <NUM>) an output signal is generated at stage <NUM>. In response to the output signal <NUM>, the tag generated SOS signal is stopped at stage <NUM>. In one implementation, this may be achieved by manually attaching a steel block or bar to the inside face of a GET <NUM> once recovered, that would in turn change the environment of the inductance sensor <NUM> and in turn effectively deactivate the SOS signal at stage <NUM>. According to a further variation, the activator <NUM> may be operated to disarm the tag <NUM> and terminate the SOS signal.

Claim 1:
A monitoring system for monitoring a status of attachment of a ground engaging tool (GET) (<NUM>) at a mining, earth moving or rock processing machine (<NUM>), the system comprising:
at least one GET (<NUM>) detachably mountable at a mount region of a mining, earth moving or rock processing machine (<NUM>);
at least one proximity sensor (<NUM>) provided at the GET (<NUM>) and configured to sense a proximity of the GET (<NUM>) relative to the mount region of the mining, earth moving or rock processing machine (<NUM>) to which the GET (<NUM>) is mountable; and
a transmitter provided at the GET (<NUM>) to transmit wirelessly proximity data (<NUM>) to a receiver (<NUM>) located remote from the GET (<NUM>);
wherein the GET comprises an electronic tag (<NUM>) provided with the proximity sensor (<NUM>);
characterized in that the system further comprises an activator (<NUM>) having a PCB (<NUM>), a processor (<NUM>) and a transceiver (<NUM>, <NUM>), wherein the activator (<NUM>) is configured for wireless communication with the electronic tag (<NUM>), and
in that the electronic tag (<NUM>) is configured to transmit tag ID data (<NUM>) to the receiver (<NUM>) such that the electronic tag (<NUM>) and the receiver (<NUM>) are communication paired;
wherein in a normal use mode, the receiver (<NUM>) accepts exclusively transmission of proximity data (<NUM>) from the electronic tag (<NUM>) associated with the mining, earth moving or rock processing machine (<NUM>) and not from non-associated electronic tags on different mining, earth moving or rock processing machines.