Ultrasonic sensing wear life of ground engaging tools

• US 10,371,669 B2
• Filed: 02/02/2017
• Issued: 08/06/2019
• Est. Priority Date: 02/02/2017
• Status: Active Grant

• Current Assignee: Caterpillar Incorporated
• Original Assignee: Caterpillar Incorporated
• Inventors: Plouzek, John Michael
• Primary Examiner(s): West, Paul M.
• Application Number:
  US15/423,247
• Publication Number:
  US 20180217108A1
• Time in Patent Office: 915 Days
• CPC Class Codes: E02F 9/2808 Teeth
• CPC Class Codes: E02F 9/2883 Wear elements for buckets or implements in general
• CPC Class Codes: G01N 17/006 of metals
• CPC Class Codes: G01N 17/04 Corrosion probes
• CPC Class Codes: G01N 2291/011 Velocity or travel time
• CPC Class Codes: G01N 2291/0258 Structural degradation, e.g. fatigue of composites, ageing of oils
• CPC Class Codes: G01N 29/07 by measuring propagation velocity or propagation time of acoustic waves
• CPC Class Codes: G01N 29/223 Supports, positioning or alignment in fixed situation mounting transducers per se G10K11/004
• CPC Class Codes: G01N 29/2475 Embedded probes, i.e. probes incorporated in objects to be inspected
• CPC Class Codes: G01N 29/4445 Classification of defects
• CPC Class Codes: G01N 29/4454 Signal recognition, e.g. specific values or portions, signal events, signatures

Abstract

A wear life sensing system may use nondestructive testing techniques to determine when ground engaging tools (GETs) are worn down and reach the ends of their useful wear lives. The wear life sensing system may include a wear sensing body and a wear sensor assembly embedded within the body of the GET. The wear sensing body is positioned proximate a maximum wear point of the GET and is fabricated from a material having a different material density than the material of the GET body. The wear sensor assembly outputs distance sensor signals in the direction of the wear sensing body and determines the presence or absence of the wear sensing body based on the reflected distance sensor signals received at the wear sensor assembly. The wear sensor assembly may transmit a GET replacement message when it no longer detects the presence of the wear sensing body.

Claims

1. A ground engaging tip of a ground engaging tooth assembly for an implement of a work machine that engages a work material with a base edge of the implement to dig into the work material, the ground engaging tip comprising:

a tip body having an exterior surface shaped to penetrate the work material into which the base edge of the implements digs, an adapter cavity surface defining an adapter cavity for receiving an adapter nose of an adapter of the ground engaging tooth assembly to mount the ground engaging tip on the adapter, and a first wear sensor cavity surface defining a first wear sensor cavity within the ground engaging tip, wherein the tip body is fabricated from a ground engaging tool (GET) body material having a GET body material density;

a first wear sensing body embedded in the tip body at a first location indicative of a first maximum GET wear point of the ground engaging tip, wherein the first wear sensing body is fabricated from a wear sensing body material having a wear sensing body material density that is not equal to the GET body material density; and

a first wear sensor assembly disposed within the first wear sensor cavity, the first wear sensor assembly comprising;

a first distance sensor for transmitting output distance sensor signals and for receiving reflected distance sensor signals that are reflected from an object or a surface of the tip body, and

a first sensor assembly controller operatively connected to the first distance sensor, the first sensor assembly controller being configured to;

cause the first distance sensor to transmit the output distance sensor signals,

detect receipt of the reflected distance sensor signals at the first distance sensor,

determine whether the first wear sensing body is still embedded in the tip body proximate the first maximum GET wear point based on a value of the reflected distance sensor signals, and

cause a GET replacement message to be transmitted from the first wear sensor assembly in response to determining that the first wear sensing body is no longer embedded in the tip body.

2. The ground engaging tip of claim 1, comprising:

a first conductive gelatinous substance disposed within the first wear sensor cavity and suspending the first wear sensor assembly within the first wear sensor cavity, wherein the first conductive gelatinous substance is a conductive medium for propagating the output distance sensor signals and the reflected distance sensor signals through the first wear sensor cavity between the first distance sensor and the tip body; and

a first wear sensing cavity cap covering a first wear sensor cavity opening to retain the first wear sensor assembly and the first conductive gelatinous substance within the first wear sensing cavity.

3. The ground engaging tip of claim 1, wherein the first wear sensor assembly comprises a first sensor assembly power source operably coupled to the first sensor assembly controller and the first distance sensor.

4. The ground engaging tip of claim 1, wherein the first wear sensor assembly comprises a first sensor assembly communications module operably coupled to the first sensor assembly controller, wherein the first sensor assembly controller is configured to cause the first sensor assembly communications module to transmit the GET replacement message in response to determining that the first wear sensing body is no longer embedded in the tip body.

5. The ground engaging tip of claim 4, wherein the first sensor assembly controller is configured to detect receipt at the first sensor assembly communications module of a wear test request message from an external GET wear test device, and to cause the first distance sensor to transmit the output distance sensor signals in response to detecting receipt of the wear test request message.

6. The ground engaging tip of claim 1, comprising a second wear sensing body fabricated from the wear sensing body material and embedded in the tip body at a second location indicative of a partial GET wear point of the ground engaging tip, wherein the first sensor assembly controller is configured to:

determine whether the second wear sensing body is still embedded in the tip body proximate the partial GET wear point based on the value of the reflected distance sensor signals, and

cause a GET partial wear message to be transmitted from the first wear sensor assembly in response to determining that the second wear sensing body is no longer embedded in the tip body and the first wear sensing body is still embedded in the tip body.

7. The ground engaging tip of claim 1, wherein the tip body has a second wear sensor cavity surface defining a second wear sensor cavity within the tip body, the ground engaging tip comprising:

a second wear sensing body embedded in the tip body at a second location indicative of a second maximum GET wear point of the ground engaging tip, wherein the second wear sensing body is fabricated from the wear sensing body material; and

a second wear sensor assembly disposed within the second wear sensor cavity, the second wear sensor assembly comprising;

a second distance sensor for transmitting output distance sensor signals and for receiving reflected distance sensor signals that are reflected from an object or a surface of the tip body, and

a second sensor assembly controller operatively connected to the second distance sensor, the second sensor assembly controller being configured to;

cause the second distance sensor to transmit the output distance sensor signals,

detect receipt of the reflected distance sensor signals at the second distance sensor,

determine whether the second wear sensing body is still embedded in the tip body proximate the second maximum GET wear point based on the value of the reflected distance sensor signals, and

cause the GET replacement message to be transmitted from the second wear sensor assembly in response to determining that the second wear sensing body is no longer embedded in the tip body.

8. A wear life sensing system, comprising:

the ground engaging tip of claim 1; and

an external GET wear test device, comprising;

an input device, and

a test device controller operatively connected to the input device, wherein the test device controller is configured to;

detect input of a GET wear test request command at the input device, and

transmit a wear test request message to the first wear sensor assembly in response to detecting the GET wear test request command at the input device,

wherein the first sensor assembly controller is configured to;

receive the wear test request message transmitted by the external GET wear test device, and

cause the first distance sensor to transmit the output distance sensor signals in response to receiving the wear test request message.

9. The wear life sensing system of claim 8, wherein the external GET wear test device comprises an output device operatively connected to the test device controller, wherein the test device controller is configured to:

receive the GET replacement message transmitted by the first wear sensor assembly, and

cause the output device to output a sensory perceptible output indicating that the ground engaging tip is worn to the first maximum GET wear point in response to receiving the GET replacement message.

10. A method for sensing an amount of wear in a ground engaging tool for an implement of a work machine that engages a work material to dig into the work material, the method comprising:

transmitting output distance sensor signals through a ground engaging tool (GET) body of the ground engaging tool from a first distance sensor of a first wear sensor assembly disposed within a first wear sensor cavity within the GET body, wherein the GET body is fabricated from a GET body material having a GET body material density, and wherein a first wear sensing body is embedded in the GET body at a first location indicative of a first maximum GET wear point of the ground engaging tool, and the first wear sensing body is fabricated from a wear sensing body material having a wear sensing body material density that is not equal to the GET body material density;

receiving reflected distance sensor signals at the first distance sensor that are reflected from one of an object or a surface of the GET body;

determining at the first wear sensor assembly whether the first wear sensing body is still embedded in the GET body proximate the first maximum GET wear point based on a value of the reflected distance sensor signals; and

transmitting a GET replacement message from the first wear sensor assembly in response to determining that the first wear sensing body is no longer embedded in the GET body.

11. The method of claim 10, comprising:

receiving a wear test request message at the first wear sensor assembly; and

transmitting the output distance sensor signals in response to receiving the wear test request message.

12. The method of claim 11, comprising transmitting the wear test request message from an external GET wear test device.

13. The method of claim 12, comprising:

receiving the GET replacement message at the external GET wear test device; and

outputting a sensory perceptible output at the external GET wear test device indicating that the ground engaging tool is worn to the first maximum GET wear point in response to receiving the GET replacement message at the external GET wear test device.

14. The method of claim 11, comprising waiting for additional wear test request messages to be received at the first wear sensor assembly in response to determining that the first wear sensing body is still embedded in the GET body.

15. The method of claim 11, comprising:

transmitting output distance sensor signals through the GET body from a second distance sensor of a second wear sensor assembly disposed within a second wear sensor cavity within the GET body, wherein a second wear sensing body is embedded in the GET body at a second location indicative of a second maximum GET wear point of the ground engaging tool, and wherein the second wear sensing body is fabricated from the wear sensing body material;

receiving reflected distance sensor signals at the second distance sensor that are reflected from one of an object or a surface of the GET body;

determining at the second wear sensor assembly whether the second wear sensing body is still embedded in the GET body proximate the second maximum GET wear point based on the value of the reflected distance sensor signals; and

transmitting a GET replacement message from the second wear sensor assembly in response to determining that the second wear sensing body is no longer embedded in the GET body.

16. The method of claim 10, wherein a second wear sensing body fabricated from the wear sensing body material is embedded in the GET body at a second location indicative of a partial GET wear point of the ground engaging tool, the method comprising:

determining whether the second wear sensing body is still embedded in the GET body proximate the partial GET wear point based on the value of the reflected distance sensor signals; and

transmitting a GET partial wear message from the first wear sensor assembly in response to determining that the second wear sensing body is no longer embedded in the GET body and the first wear sensing body is still embedded in the GET body.

17. A ground engaging tool for an implement of a work machine that engages a work material to dig into the work material, the ground engaging tool comprising:

a ground engaging tool (GET) body having an exterior surface shaped to penetrate the work material into which the implements digs, and a first wear sensor cavity surface defining a first wear sensor cavity within the GET body, wherein the GET body is fabricated from a GET body material having a GET body material density;

a first wear sensing body embedded in the GET body at a first location indicative of a first maximum GET wear point of the ground engaging tool, wherein the first wear sensing body is fabricated from a wear sensing body material having a wear sensing body material density that is not equal to the GET body material density; and

a first wear sensor assembly disposed within the first wear sensor cavity, the first wear sensor assembly comprising;

a first distance sensor for transmitting output distance sensor signals and for receiving reflected distance sensor signals that are reflected from an object or a surface of the GET body, and

a first sensor assembly controller operatively connected to the first distance sensor, wherein the first sensor assembly controller is configured to;

cause the first distance sensor to transmit the output distance sensor signals,

detect receipt of the reflected distance sensor signals at the first distance sensor,

determine whether the first wear sensing body is still embedded in the GET body proximate the first maximum GET wear point based on a value of the reflected distance sensor signals, and

cause a GET replacement message to be transmitted from the first wear sensor assembly in response to determining that the first wear sensing body is no longer embedded in the GET body.

18. The ground engaging tool of claim 17, comprising a second wear sensing body fabricated from the wear sensing body material and embedded in the GET body at a second location indicative of a partial GET wear point of the ground engaging tool, wherein the first sensor assembly controller is configured to:

determine whether the second wear sensing body is still embedded in the GET body proximate the partial GET wear point based on the value of the reflected distance sensor signals, and

cause a GET partial wear message to be transmitted from the first wear sensor assembly in response to determining that the second wear sensing body is no longer embedded in the GET body and the first wear sensing body is still embedded in the GET body.

19. The ground engaging tool of claim 17, wherein the GET body has a second wear sensor cavity surface defining a second wear sensor cavity within the GET body, the ground engaging tool comprising:

a second wear sensing body embedded in the GET body at a second location indicative of a second maximum GET wear point of the ground engaging tool, wherein the second wear sensing body is fabricated from the wear sensing body material; and

a second wear sensor assembly disposed within the second wear sensor cavity, the second wear sensor assembly comprising;

a second distance sensor for transmitting output distance sensor signals and for receiving reflected distance sensor signals that are reflected from an object or a surface of the GET body, and

a second sensor assembly controller operatively connected to the second distance sensor, wherein the second sensor assembly controller is configured to;

cause the second distance sensor to transmit the output distance sensor signals,

detect receipt of the reflected distance sensor signals at the second distance sensor,

determine whether the second wear sensing body is still embedded in the GET body proximate the second maximum GET wear point based on the value of the reflected distance sensor signals, and

cause the GET replacement message to be transmitted from the second wear sensor assembly in response to determining that the second wear sensing body is no longer embedded in the GET body.

20. A wear life sensing system, comprising:

the ground engaging tool of claim 17; and

the external GET wear test device, comprising;

an input device,

an output device,

a wear test device communications module, and

a test device controller operatively connected to the input device, the output device and the wear test device communications module, wherein the test device controller is configured to;

detect input of a GET wear test request command at the input device,

cause the wear test device communications module to transmit a wear test request message to the first wear sensor assembly in response to detecting the GET wear test request command at the input device,

detect receipt at the wear test device communications module of the GET replacement message by the first wear sensor assembly, and

cause the output device to output a sensory perceptible output indicating that the ground engaging tool is worn to the first maximum GET wear point in response to receiving the GET replacement message.