System and method for remote monitoring of drilling equipment

• US 9,657,567 B2
• Filed: 01/30/2013
• Issued: 05/23/2017
• Est. Priority Date: 01/30/2012
• Status: Active Grant

• Current Assignee: Joy Global Surface Mining Inc. (Mitsui & Company Limited)
• Original Assignee: Harnischfeger Technologies Inc. (Mitsui & Company Limited)
• Inventors: Malayappalayam Shanmugam, Saravana Manickam, Rikkola, Michael J.
• Primary Examiner(s): Edwards, Jerrah
• Assistant Examiner(s): WALLACE, DONALD JOSEPH
• Application Number:
  US13/754,082
• Publication Number:
  US 20130197737A1
• Time in Patent Office: 1,574 Days
• CPC Class Codes: E02F 3/30 with a dipper-arm pivoted on a cantilever beam , i.e. boom
• CPC Class Codes: E02F 3/46 with reciprocating digging or scraping elements moved by cables or hoisting ropes ; Drives or control devices therefor E02F3/205, E02F3/905 take precedence
• CPC Class Codes: E02F 9/264 Sensors and their calibration for indicating the position of the work tool
• CPC Class Codes: E02F 9/267 Diagnosing or detecting failure of vehicles
• CPC Class Codes: E21B 44/00 Automatic control systems specially adapted for drilling operations, i.e. self-operating systems which function to carry out or modify a drilling operation without intervention of a human operator, e.g. computer-controlled drilling systems; Systems specially adapted for monitoring a plurality of drilling variables or conditions
• CPC Class Codes: E21C 47/00 Machines for obtaining or the removal of materials in open-pit mines obtaining peat E21C49/00
• CPC Class Codes: E21F 17/18 Special adaptations of signalling or alarm devices for mine lifts B66B; gas-sensitive devices per se G01N
• CPC Class Codes: G07C 5/008 communicating information to a remotely located station transmission systems for measured values G08C

Abstract

A system and method for capturing information related to mining machine performance and making the information accessible to remote maintenance staff. The information can be used to generate alarms, determine a state of the machine, determine performance statistics for the machine, and identify problems with the machine that may require attention. The information can be provided in a state message and the data can be packaged as XML data or in a string format. The data associated with a message can be particular to the current state or context of the mining machine. That is, in the case of a rope shovel, different data may be included in a message generated in a swing state versus a message generated in a tuck state. In some instances, a message is generated when progress thresholds are satisfied, such as for each foot of drilling performed by a mining drill.

Claims

1. A method of monitoring a mining machine, the method comprising:

determining that the mining machine is operating in a first operation state of a plurality of defined operation states of the mining machine;

detecting, by a processor of the mining machine, a transition of the mining machine from the first operation state to a second operation state of the plurality of defined operation states;

monitoring, by the processor, using at least one sensor, mining machine parameters of the mining machine;

generating, by the processor, a state exit message indicating an end of the first operation state, wherein the state exit message includes a first set of the mining machine parameters associated with the first operation state; and

generating, by the processor, a state start message indicating a start of the second operation state, wherein the state start message includes a second set of the mining machine parameters associated with the second operation state,

wherein the first set of the mining machine parameters are a different portion of the mining machine parameters than the second set of the mining machine parameters.

2. The method of claim 1, wherein generating the state exit message includes structuring the first set of the mining machine parameters as markup language data, and generating the state start message includes structuring the second set of the mining machine parameters as markup language data.

3. The method of claim 1, wherein the first operation state is selected from the group consisting of a jacks-up state, propel state, level state, jacks-down state, pre-drill state, drill state, and retract state, and the second operation state is a different one of the jacks-up state, propel state, level state, jacks-down state, pre-drill state, drill state, and retract state.

4. The method of claim 1, wherein the first operation state is selected from the group consisting of a dig state, swing state, and tuck state, and the second operation state is a different one of the dig state, swing state, and tuck state.

5. The method of claim 1, wherein the mining machine is selected from the group consisting of a drill, a rope shovel, dragline, wheel loader and dozer, conveyor, continuous miner, longwall shearer, longwall mining roof support, shuttle car, flexible conveyor train, and mobile mining crusher.

6. The method of claim 1, wherein the mining machine is a drill, the method further comprising generating a plurality of drill context messages while drilling a hole with the drill, each drill context message being generated based on a depth of the drill in the hole.

7. The method of claim 1, wherein the mining machine is a drill, the method further comprising:

drilling a hole with the drill;

monitoring progress of the drill in drilling the hole;

determining when the drill reaches a plurality of progress thresholds while drilling the hole; and

generating a drill context message each time the drill is determined to reach one of the progress thresholds.

8. The method of claim 7, wherein the drill context message includes values for a third set of the mining machine parameters associated with a drilling context.

9. The method of claim 1, further comprising:

performing calculations, with a pre-processor on the mining machine, on a series of data values collected over a period of time for a parameter of the mining machine parameters, the calculations generating calculated data;

generating a processed-data message including the calculated data; and

outputting the processed-data message to a remote device via a network.

10. The method of claim 9, wherein the calculations are selected from the group consisting of an average computation, maximum determination, minimum determination, root mean squared (RMS) calculation, and a Fourier transform.

11. The method of claim 1, further comprising:

detecting, by the processor, a preceding transition from a preceding operation state to the first operation state; and

generating, by the processor, a preceding state exit message indicating an end of the preceding operation state and a state start message indicating a start of the first operation state.

12. A mining machine monitor for monitoring a mining machine, the mining machine monitor comprising:

a memory;

a processor coupled to the memory and configured to

monitor mining machine parameters of the mining machine using at least one sensor;

determine that the mining machine is operating in a first operation state of a plurality of defined operation states of the mining machine;

detect a transition of the mining machine from the first operation state to a second operation state of the plurality of defined operation states;

generate a state exit message indicating an end of the first operation state, wherein the state exit message includes a first set of the mining machine parameters associated with the first operation state; and

generate a state start message indicating a start of the second operation state, wherein the state start message includes a second set of the mining machine parameters associated with the second operation state,

wherein the first set of the mining machine parameters are a different portion of the mining machine parameters than the second set of the mining machine parameters.

13. The mining machine monitor of claim 12, wherein the state exit message includes the first set of the mining machine parameters structured as markup language data or string data.

14. The mining machine monitor of claim 12, wherein the first operation state is selected from the group consisting of a jacks-up state, propel state, level state, jacks-down state, pre-drill state, drill state, and retract state, and the second operation state is a different one of the jacks-up state, propel state, level state, jacks-down state, pre-drill state, drill state, and retract state.

15. The mining machine monitor of claim 12, wherein the first operation state is selected from the group consisting of a dig state, swing state, and tuck state, and the second operation state is a different one of the dig state, swing state, and tuck state.

16. The mining machine monitor of claim 12, wherein the mining machine is selected from the group consisting of a drill, a rope shovel, dragline, wheel loader and dozer, conveyor, continuous miner, longwall shearer, longwall mining roof support, shuttle car, flexible conveyor train, and mobile mining crusher.

17. The mining machine monitor of claim 12, wherein the mining machine is a drill and the processor is further configured to generate a plurality of drill context messages while drilling a hole with the drill, each drill context message being generated based on a depth of the drill in the hole.

18. The mining machine monitor of claim 12, wherein the mining machine is a drill and the processor is further configured to:

drill a hole with the drill;

monitor progress of the drill in drilling the hole;

determine when the drill reaches a plurality of progress thresholds while drilling the hole; and

generate a drill context message each time the drill is determined to reach one of the progress thresholds.

19. The mining machine monitor of claim 18, wherein the drill context message includes values for a third set of the mining machine parameters associated with a drilling context.

20. The mining machine monitor of claim 12, further comprising a pre-processor on the mining machine, the pre-processor

performing calculations on a series of data values collected over a period of time for a parameter of the mining machine parameters, the calculations generating calculated data;

generating a processed-data message including the calculated data; and

outputting the processed-data message to a remote device via a network.

21. The mining machine monitor of claim 20, wherein the calculations are selected from the group consisting of an average computation, maximum determination, minimum determination, root mean squared (RMS) calculation, and a Fourier transform.

22. A mining machine monitor for monitoring a mining machine, the mining machine monitor comprising:

a memory storing monitoring instructions, state machine instructions, and message generating instructions;

a processor that is coupled to the memory and that

executes the monitoring instructions to thereby monitor mining machine parameters of the mining machine;

executes the state machine instructions to thereby

determine that the mining machine is operating in a first operation state of a plurality of defined operation states of the mining machine, and

detect a transition of the mining machine from the first operation state to a second operation state of the plurality of defined operation states; and

executes the message generating instructions to thereby

generate a state exit message indicating an end of the first operation state, wherein the state exit message includes a first set of the mining machine parameters associated with the first operation state, and

generate a state start message indicating a start of the second operation state, wherein the state start message includes a second set of the mining machine parameters associated with the second operation state,

wherein the first set of the mining machine parameters are a different portion of the mining machine parameters than the second set of the mining machine parameters.

23. The mining machine monitor of claim 22, further comprising at least one sensor, wherein the monitoring instructions are used to monitor mining machine parameters of the mining machine using the at least one sensor.

24. The mining machine monitor of claim 22, wherein the state exit message includes the first set of the mining machine parameters structured as markup language data or string data.

25. The mining machine monitor of claim 22, wherein the mining machine is selected from the group consisting of a drill, a rope shovel, dragline, wheel loader and dozer, conveyor, continuous miner, longwall shearer, longwall mining roof support, shuttle car, flexible conveyor train, and mobile mining crusher.

26. The mining machine monitor of claim 22, wherein the mining machine is a drill and the processor is further configured to generate a plurality of drill context messages while drilling a hole with the drill, each drill context message being generated based on a depth of the drill in the hole.

27. The mining machine monitor of claim 22, further comprising a pre-processor on the mining machine, wherein the memory stores pre-processor instructions;

and

the pre-processor is coupled to the memory and executes the pre-processor instructions to thereby

perform calculations on a series of data values collected over a period of time for a parameter of the mining machine parameters, the calculations generating calculated data;

generate a processed-data message including the calculated data; and

output the processed-data message to a remote device via a network.

28. The mining machine monitor of claim 27, wherein the calculations are selected from the group consisting of an average computation, maximum determination, minimum determination, root mean squared (RMS) calculation, and a Fourier transform.