WO2016008059A1 - Monitoring system for the detection of ferromagnetic elements in mineral loads - Google Patents

Monitoring system for the detection of ferromagnetic elements in mineral loads Download PDF

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Publication number
WO2016008059A1
WO2016008059A1 PCT/CL2015/000037 CL2015000037W WO2016008059A1 WO 2016008059 A1 WO2016008059 A1 WO 2016008059A1 CL 2015000037 W CL2015000037 W CL 2015000037W WO 2016008059 A1 WO2016008059 A1 WO 2016008059A1
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WO
WIPO (PCT)
Prior art keywords
monitoring system
detection
ferromagnetic elements
magnetic field
automatic monitoring
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PCT/CL2015/000037
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Spanish (es)
French (fr)
Inventor
Tomás Ángel GLARIA LÓPEZ
Rodolfo Andrés KÖCK SCHULMEYER
Félix Alberto LEAMAN WEIFFENBACH
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Cadatech S.A.
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Publication of WO2016008059A1 publication Critical patent/WO2016008059A1/en

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Classifications

    • E—FIXED CONSTRUCTIONS
    • E02—HYDRAULIC ENGINEERING; FOUNDATIONS; SOIL SHIFTING
    • E02F—DREDGING; SOIL-SHIFTING
    • E02F3/00—Dredgers; Soil-shifting machines
    • E02F3/04—Dredgers; Soil-shifting machines mechanically-driven
    • E02F3/28—Dredgers; Soil-shifting machines mechanically-driven with digging tools mounted on a dipper- or bucket-arm, i.e. there is either one arm or a pair of arms, e.g. dippers, buckets
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01V—GEOPHYSICS; GRAVITATIONAL MEASUREMENTS; DETECTING MASSES OR OBJECTS; TAGS
    • G01V3/00—Electric or magnetic prospecting or detecting; Measuring magnetic field characteristics of the earth, e.g. declination, deviation
    • G01V3/08—Electric or magnetic prospecting or detecting; Measuring magnetic field characteristics of the earth, e.g. declination, deviation operating with magnetic or electric fields produced or modified by objects or geological structures or by detecting devices
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01V—GEOPHYSICS; GRAVITATIONAL MEASUREMENTS; DETECTING MASSES OR OBJECTS; TAGS
    • G01V3/00—Electric or magnetic prospecting or detecting; Measuring magnetic field characteristics of the earth, e.g. declination, deviation
    • G01V3/15—Electric or magnetic prospecting or detecting; Measuring magnetic field characteristics of the earth, e.g. declination, deviation specially adapted for use during transport, e.g. by a person, vehicle or boat
    • G01V3/165—Electric or magnetic prospecting or detecting; Measuring magnetic field characteristics of the earth, e.g. declination, deviation specially adapted for use during transport, e.g. by a person, vehicle or boat operating with magnetic or electric fields produced or modified by the object or by the detecting device
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01V—GEOPHYSICS; GRAVITATIONAL MEASUREMENTS; DETECTING MASSES OR OBJECTS; TAGS
    • G01V3/00—Electric or magnetic prospecting or detecting; Measuring magnetic field characteristics of the earth, e.g. declination, deviation
    • G01V3/18—Electric or magnetic prospecting or detecting; Measuring magnetic field characteristics of the earth, e.g. declination, deviation specially adapted for well-logging
    • G01V3/26—Electric or magnetic prospecting or detecting; Measuring magnetic field characteristics of the earth, e.g. declination, deviation specially adapted for well-logging operating with magnetic or electric fields produced or modified either by the surrounding earth formation or by the detecting device
    • G01V3/28—Electric or magnetic prospecting or detecting; Measuring magnetic field characteristics of the earth, e.g. declination, deviation specially adapted for well-logging operating with magnetic or electric fields produced or modified either by the surrounding earth formation or by the detecting device using induction coils

Definitions

  • the transport of the ore from the mine to the crusher is done with the help of shovels or loaders of different types and trucks.
  • the loaders fill a bucket with the fragmented material of the mine and unload it into the truck hopper as many times as necessary until it is filled. Once the hopper is filled, the vehicle travels to the location of the discharge area to the crusher, where its cargo is emptied.
  • the present technology corresponds to a system for monitoring the loading of ore when it is loaded or unloaded from a container, or passes through it.
  • the system comprises magnetic field sensors to detect automatically and in real time the disturbances of the local magnetic field, produced by the entrance of a ferromagnetic body to the container.
  • it can be applied in a bucket or shovel bucket to detect hidden inchancables in a mineral load. In this way, instead of depositing that load with inchancable in the hopper of a truck, it is deposited in an alternative zone.
  • the system can be applied for mineral monitoring and detection of ferromagnetic bodies in mobile equipment (front loaders, trucks), semi-mobile (shovels) or static (chutes, crushers, belts or others).
  • the magnetometer sensors allow the local magnetic field to be measured and delivered in the 3 directions of space, so when a Ferromagnetic element is placed or passed near the sensor, its reading shows fluctuations that depend on the mass, volume, geometry, orientation and proximity to the ferromagnetic element.
  • a sample (2.A) of the noticeable fluctuation in the sensor reading is presented in Figure 2 when a bucket is filled with ore containing an inchancable; on the other hand, in the sample (2.B), the sensor reading is presented when the bucket is filled with unreachable ore, observing that the reading only has small variations.
  • the monitoring system requires at least one magnetometer node, which is arranged in the perimeter of the area to be monitored.
  • the nodes In the case of metal or ferromagnetic containers, the nodes must go inside. In the case of containers that do not interfere with the magnetic field, the nodes can go outside. Regardless of their position, these magnetometer sensors are located inside plastic capsules, which are located within protections specially adapted to withstand the impacts of the mineral load, which adhere to the equipment to be monitored.
  • the material of the protections is designed depending on the operating conditions, which can be made of steel, polymer, ceramic, composite material or a combination of them. Depending on the protection material, these may be welded, bolted or glued to the container.
  • the sample (4.A) corresponds to the magnetometer reading during a rotation of a container and the sample (4.B) corresponds to the reading of the IMU during the same rotation. It is noted Clearly there is a correlation between both readings.
  • the sample (4.C) the magnetometer reading is observed during the entry of an inchancable and in the sample (4.D) the parallel reading of the IMU is observed, observing that in this case there is no correlation any.
  • the accelerometer (s) are used equivalently to compensate for bumps and sudden movements of the container.
  • the benefits of this technology are related to the simplicity and flexibility of operation, since it is based on the measurement of the magnetic field of the environment in some area of interest. Nor does it require the use of expert or specialized personnel, since the system takes the data, processes it through a detection software and determines whether or not an inchancable was loaded autonomously. In addition, the installation of the system does not require significant detentions of the production process, nor does it require changing the way of operating, which facilitates its implementation in practice.

Abstract

The invention relates to a monitoring system for the detection of ferromagnetic elements concealed in a mineral load during the loading and/or unloading of a container, said system comprising: at least one magnetic field sensor for the automatic and real-time detection of disturbances in the local magnetic field; a computer that compiles and processes data using software; a wired or wireless short-range communication channel located between the nodes and the computer; a display incorporating a light and/or sound alarm; a wired or wireless long-range communication channel between the user and the computer; a portable battery type power source or a connection to a fixed and/or mobile power supply; and optionally auxiliary sensors.

Description

SISTEMA DE MONITOREO PARA LA DETECCION DE ELEMENTOS FERROMAGNETICOS EN LA CARGA DE MINERAL.  MONITORING SYSTEM FOR THE DETECTION OF PHERROMAGNETIC ELEMENTS IN THE MINERAL LOAD.
Sector técnico Technical sector
La tecnología está orientada al área minera, más específicamente, corresponde a un sistema de monitoreo automático para la detección de elementos ferromagnéticos ocultos en la carga de mineral. The technology is oriented to the mining area, more specifically, it corresponds to an automatic monitoring system for the detection of hidden ferromagnetic elements in the mineral load.
Técnica Anterior La extracción de minerales, por lo general, incorpora una primera fase en la fragmentación de roca en la mina mediante el uso de explosivos y el transporte del material fragmentado hasta un dispositivo denominado chancador, que se encarga de reducir el tamaño del mineral a un tamaño más uniforme y especificado por el proceso. Desde ahí continúa hacia otras fases del proceso productivo. Prior Art Mineral extraction generally incorporates a first phase in rock fragmentation in the mine by using explosives and transporting fragmented material to a device called a crusher, which is responsible for reducing the size of the mineral to a more uniform size and specified by the process. From there it continues towards other phases of the productive process.
v  v
El transporte del mineral de la mina al chancador se realiza con la ayuda de palas o cargadores de diferente tipo y camiones. Los cargadores llenan un balde con el material fragmentado de la mina y lo descargan en la tolva del camión tantas veces como sea necesario hasta llenarla. Una vez llena la tolva, el vehículo se desplaza hasta la ubicación de la zona de descarga al chancador, donde se procede a vaciar su carga.  The transport of the ore from the mine to the crusher is done with the help of shovels or loaders of different types and trucks. The loaders fill a bucket with the fragmented material of the mine and unload it into the truck hopper as many times as necessary until it is filled. Once the hopper is filled, the vehicle travels to the location of the discharge area to the crusher, where its cargo is emptied.
El material proveniente de la mina no sólo contiene mineral sino que también puede contener elementos metálicos de diversos orígenes como dientes de pala quebrados, barras de perforación, estructuras de vehículos, etc. Estos elementos, denominados "inchancables" no pueden ser triturados por el chancador, y dependiendo de su tamaño, es necesario detener el equipo para retirarlos con la consiguiente detención de la producción. The material from the mine not only contains mineral but can also contain metal elements of various origins such as broken blade teeth, drill rods, vehicle structures, etc. These elements, called "inchancables" can not be crushed by the crusher, and depending on their size, it is necessary to stop the equipment to remove them with the consequent production stop.
A la fecha no existe un equipo que logre detectar la presencia de los elementos inchancables, que están ocultos entre la carga de mineral antes de la descarga al chancador. Si tal sistema de detección existiese se podría descartar esa carga de mineral del proceso antes de que produzca algún efecto adverso al equipo. To date there is no equipment that manages to detect the presence of the inchancable elements, which are hidden between the ore load before discharge to the crusher. If such a detection system existed, that mineral load could be discarded from the process before it produces any adverse effect on the equipment.
La mayor parte de los esfuerzos tecnológicos se han centrado en detectar y evitar la producción de inchancables. Entre ellos se encuentran los sistemas para detectar la caída de dientes de palas. Sin embargo, estos sistemas no evitan o detectan otros tipos de elementos inchancables. Además, una vez que se detecta la caída el diente no siempre es posible encontrarlo en el sitio. Most of the technological efforts have focused on detecting and avoiding the production of inchancables. Among them are the systems for detecting the falling of blade teeth. However, these systems do not prevent or detect other types of unreachable elements. In addition, once the fall is detected the tooth is not always possible to find on the site.
Algunos documentos vinculados con la presente innovación, se detallan a continuación: Some documents linked to this innovation are detailed at continuation:
1- Solicitud de patente CL200001092 (Carrandi Muñoz, Luis), denominada "Sistema de paso de elementos no triturables o de alivio de cámara de chancado, para chancadores de cono, en donde, entre cada cilindro hidráulico y acumulador de presión, se tiene una válvula hidráulica antirretorno". Los chancadores de roca del tipo de cono, siempre cuentan con un dispositivo que permite ceder cuando el chancador excede la magnitud de la fuerza desarrollada para triturar rocas. Dentro de la variedad de elementos con que se alimentan usualmente los chancadores, también se encuentran presentes trozos de madera, trozos de goma, trozos de fierro, todos ellos denominados elementos inchancables o no triturables. Cuando cualquiera de estos elementos ingresa al chancador, requiere que el exceso de fuerza desarrollado al tratar de triturar lo que no se puede triturar, sea liberado mediante el dispositivo denominado sistemas de alivio de cámara de chancado o sistema de paso de inchancables. Una modificación de este sistema se propone en esta solicitud, de manera que el comportamiento del sistema proteja mejor al chancador, amortiguado o atenuado los efectos no deseables del paso de materiales no triturables, con un claro efecto sobre los costos de mantención del chancador.  1- Patent application CL200001092 (Carrandi Muñoz, Luis), called "System of passage of non-crushing elements or relief of crushing chamber, for cone crushers, where, between each hydraulic cylinder and pressure accumulator, there is a hydraulic check valve ". Cone crusher rock crushers always have a device that allows them to yield when the crusher exceeds the magnitude of the force developed to crush rocks. Within the variety of elements that crushers usually feed on, there are also pieces of wood, pieces of rubber, pieces of iron, all of them called unbreakable or non-shreddable elements. When any of these elements enters the crusher, it requires that the excess force developed when trying to crush what cannot be crushed be released by means of the device called crushing chamber relief systems or inchancables passage system. A modification of this system is proposed in this application, so that the behavior of the system better protects the crusher, cushioned or attenuated the undesirable effects of the passage of non-crushable materials, with a clear effect on the maintenance costs of the crusher.
2.- Patente de invención US 8,284,096 (Martínez Godoy et al.), denominada "System and method of detection of uncrushable metallic pieces in mineral loads". Se resguarda un sistema y método para detectar piezas metálicas ocultas dentro de una carga de mineral, directamente en un medio de transporte hacia un chancador primario. Para el análisis, el transporte se hace pasar a través de un portal a una velocidad de 5 a 50 km/h; para luego efectuar la detección cuando la carga mineral se encuentra bajo el portal; se activa el scanner del radar; se generan los pulsos electromagnéticos controlados que penetran la carga mineral; se analiza la información y se envía a un procesador digital, luego se repiten los pasos anteriores, para generar una imagen tomográfica de toda la carga mineral. Esta tecnología tiene un alcance limitado y las pruebas de campo no han sido satisfactorias ya que no ha logrado detectar elementos a poca profundidad en la tolva del vehículo. 3.- Solicitud de patente WO 2013/153283 (Salonen) denominada "A system and method for monitoring and controlling a crusher, a crusher and a method for adjusting crusher". En esta solicitud se protege un método y un sistema para el monitoreo de un chancador giratorio o de cono. Particular, pero no exclusivamente, se resguarda al chancador del material incrustable, donde la carga del chancador es monitoreada con un sistema de monitoreo en las posiciones de rotación del eje principal del chancador, y donde esta información es usada para ajusfar un evento del chancador. Dicho ajuste puede llevarse a cabo por medio de la acción de un operador o en forma automática. Entre los objetivos del ajuste se tiene: una carga uniforme en todas las posiciones de rotación del eje de rotación, una carga suficientemente alta para asegurar un evento de chancado eficiente y la detección de incrustables o materiales muy duros antes de dañar el chancador. En base a los antecedentes descritos, es que se hace necesario el desarrollo de tecnologías que permitan detectar en forma segura, rápida y confiable la presencia de inchancables previos a la alimentación al chancador. 2.- US Patent 8,284,096 (Martínez Godoy et al.), Called "System and method of detection of uncrushable metallic pieces in mineral loads". A system and method for detecting hidden metal parts within a mineral load, directly in a means of transport to a primary crusher, is protected. For the analysis, the transport is passed through a portal at a speed of 5 to 50 km / h; soon to realize the detection when the mineral load is under the portal; the radar scanner is activated; the controlled electromagnetic pulses that penetrate the mineral charge are generated; The information is analyzed and sent to a digital processor, then the previous steps are repeated, to generate a tomographic image of the entire mineral load. This technology has a limited scope and the field tests have not been satisfactory since it has failed to detect elements at a shallow depth in the vehicle hopper. 3.- Patent application WO 2013/153283 (Salonen) called "A system and method for monitoring and controlling a crusher, a crusher and a method for adjusting crusher". This method protects a method and a system for monitoring a rotating crusher or cone. Particularly, but not exclusively, the crusher is protected from the embeddable material, where the crusher load is monitored with a monitoring system in the rotation positions of the main crusher shaft, and where this information is used to adjust a crusher event. Said adjustment can be carried out through the action of an operator or automatically. The objectives of the adjustment include: a uniform load in all rotational positions of the rotation axis, a sufficiently high load to ensure an efficient crushing event and the detection of encrustables or very hard materials before damaging the crusher. Based on the background described, it is necessary to develop technologies that allow the presence of inchancables before feeding the crusher in a safe, fast and reliable way.
Divulgación de ia Invención Disclosure of the Invention
La presente tecnología corresponde a un sistema de monitoreo de la carga de mineral cuando ésta se carga o descarga de un contenedor, o pasa a través de él. El sistema comprende sensores de campo magnético para detectar en forma automática y en tiempo real las perturbaciones del campo magnético local, producidas por la entrada de un cuerpo ferromagnético al contendedor. En particular, puede ser aplicada en un balde de cargador o de pala para detectar elementos inchancables ocultos en una carga de mineral. De esta manera, en lugar de depositar esa carga con inchancable en la tolva de un camión, ésta se deposita en una zona alternativa. The present technology corresponds to a system for monitoring the loading of ore when it is loaded or unloaded from a container, or passes through it. The system comprises magnetic field sensors to detect automatically and in real time the disturbances of the local magnetic field, produced by the entrance of a ferromagnetic body to the container. In particular, it can be applied in a bucket or shovel bucket to detect hidden inchancables in a mineral load. In this way, instead of depositing that load with inchancable in the hopper of a truck, it is deposited in an alternative zone.
Dado que el mineral tiene un contenido ferroso muy bajo, el sistema no se ve afectado por el propio mineral, y como la mayor parte de los elementos inchancables están constituidos de material ferromagnético, este sistema logra detectar las variaciones de intensidad que se produce en el campo magnético natural del entorno (cercano) al contenedor al introducir un elemento adicional ferromagnético. La ventaja de detectar el inchancable en el momento de la carga del balde, es que esa carga es desechada inmediatamente, no es cargada en el vehículo y no es transportada hasta el chancador, lo que disminuye el costo operativo respecto de cualquier sistema de detección una vez que la carga ya se encuentra en el vehículo. Since the mineral has a very low ferrous content, the system is not affected by the mineral itself, and since most of the unreachable elements are made of ferromagnetic material, this system manages to detect the intensity variations that occur in the Natural magnetic field of the environment (close) to the container when introducing an additional ferromagnetic element. The advantage of detecting the inchancable at the time of loading the bucket, is that this load is immediately discarded, is not loaded into the vehicle and is not transported to the crusher, which decreases the operating cost with respect to any detection system. Once the load is already in the vehicle.
Ventajosamente el sistema se puede aplicar para el monitoreo del mineral y detección de cuerpos ferromagnéticos en equipos móviles (cargadores frontales, camiones), semi-móviles (palas) o estáticos (chutes, chancadores, correas u otros). Advantageously, the system can be applied for mineral monitoring and detection of ferromagnetic bodies in mobile equipment (front loaders, trucks), semi-mobile (shovels) or static (chutes, crushers, belts or others).
Para una mejor compresión de la tecnología se toma como referencia la Figura 1 , donde se presenta un esquema del sistema y de las partes que lo componen: donde (1.A) corresponde a un contenedor que contiene sensores (nodos) de campo magnético y sensores (nodos) auxiliares; (1.B) un canal de comunicación de corto alcance, entre los nodos y un computador coordinador, que puede ser del tipo cableado o inalámbrico; (1.C) un computador coordinador que recopila y procesa los datos mediante un software especializado; (1.D) un canal de comunicación de largo alcance, entre el usuario y el computador, del tipo cableado o inalámbrico; (1.E) un visualizador que incorpora una alarma luminosa y/o sonora, además de información respecto del estado del sistema; y (1.F) una fuente de energía del sistema que puede ser una batería portable o una conexión a alimentación fija y/o móvil.  For a better understanding of the technology, Figure 1 is taken as a reference, where a scheme of the system and its component parts is presented: where (1.A) corresponds to a container containing magnetic field sensors (nodes) and auxiliary sensors (nodes); (1.B) a short-range communication channel, between the nodes and a coordinating computer, which can be of the wired or wireless type; (1.C) a coordinating computer that collects and processes the data through specialized software; (1.D) a long-range communication channel, between the user and the computer, of the wired or wireless type; (1.E) a display that incorporates a light and / or audible alarm, as well as information regarding the status of the system; and (1.F) a system power source that can be a portable battery or a fixed and / or mobile power connection.
Los sensores (nodos) magnetómetros permiten medir y entregar la lectura el campo magnético local en las 3 direcciones del espacio, por lo que cuando un elemento ferromagnético se sitúa o pasa cerca del sensor, la lectura de éste muestra fluctuaciones que dependen de la masa, volumen, geometría, orientación y cercanía al elemento ferromagnético. A modo de referencia se presenta en la Figura 2, una muestra (2.A) de la notoria fluctuación de la lectura del sensor cuando se llena un balde con mineral conteniendo un inchancable; en cambio en la muestra (2.B) se presenta la lectura del sensor cuando se llena el balde con mineral sin inchancable, observándose que la lectura sólo tiene pequeñas variaciones. El sistema de monitoreo requiere de al menos un nodo magnetómetro, el cual se dispone en el perímetro de la zona que se desea monitorear. En el caso de que se requiera más de uno, estos se disponen preferente pero no exclusivamente, en forma equidistante en el perímetro que se desea monitorear. En la Figura 3 se presentan, a modo de referencia y que no restringen la tecnología, diferentes arreglos sobre la distribución de los sensores magnetometros en los equipos de monitoreo, donde (3.A) corresponde a la disposición cuando se utiliza con 1 sensor; (3.B) cuando se utilizan 2 sensores; (3.C) con 4 sensores; (3.D) con 6 sensores; y (3.E) la distribución con 8 sensores. La cantidad total de nodos magnetometros a utilizar dependerá de la longitud del perímetro a monitorear, de la aplicación y del tamaño de los inchancables que se requiera detectar. Dependiendo del material del contenedor los sensores pueden ser ubicados por el exterior o interior. En el caso de contenedores metálicos o ferromagnéticos, los nodos deben ir por el interior. En el caso de contendedores que no interfieren el campo magnético, los nodos pueden ir por fuera. Independiente de su posición, estos sensores magnetometros se ubican al interior de cápsulas de plástico, las cuales se ubican dentro de unas protecciones especialmente acondicionadas para soportar los impactos de la carga del mineral, las cuales se adhieren al equipo a monitorear. El material de las protecciones se diseña dependiendo de las condiciones de operación, pudiendo ser de acero, polímero, cerámica, material compuesto o una combinación de ellos. Dependiendo del material de la protección, estas podrán ser soldadas, apernadas o pegadas al contenedor. The magnetometer sensors (nodes) allow the local magnetic field to be measured and delivered in the 3 directions of space, so when a Ferromagnetic element is placed or passed near the sensor, its reading shows fluctuations that depend on the mass, volume, geometry, orientation and proximity to the ferromagnetic element. As a reference, a sample (2.A) of the noticeable fluctuation in the sensor reading is presented in Figure 2 when a bucket is filled with ore containing an inchancable; on the other hand, in the sample (2.B), the sensor reading is presented when the bucket is filled with unreachable ore, observing that the reading only has small variations. The monitoring system requires at least one magnetometer node, which is arranged in the perimeter of the area to be monitored. In the event that more than one is required, these are arranged preferentially but not exclusively, in an equidistant manner in the perimeter that is to be monitored. Figure 3 shows, as a reference and that does not restrict technology, different arrangements on the distribution of magnetometer sensors in monitoring equipment, where (3.A) corresponds to the arrangement when used with 1 sensor; (3.B) when 2 sensors are used; (3.C) with 4 sensors; (3.D) with 6 sensors; and (3.E) distribution with 8 sensors. The total number of magnetometer nodes to be used will depend on the length of the perimeter to be monitored, the application and the size of the inchancables that are required to be detected. Depending on the material of the container the sensors can be located on the outside or inside. In the case of metal or ferromagnetic containers, the nodes must go inside. In the case of containers that do not interfere with the magnetic field, the nodes can go outside. Regardless of their position, these magnetometer sensors are located inside plastic capsules, which are located within protections specially adapted to withstand the impacts of the mineral load, which adhere to the equipment to be monitored. The material of the protections is designed depending on the operating conditions, which can be made of steel, polymer, ceramic, composite material or a combination of them. Depending on the protection material, these may be welded, bolted or glued to the container.
Opcionalmente, se pueden utilizar sensores (nodos) de tipo auxiliar. Preferente, pero no exclusivamente, estos sensores pueden ser unidades de medición inercial (IMU), acelerómetros, galgas extensiométricas, codificadores rotatorios, giroscopios, inclinómetros, manómetros, voltímetros u otros. Los nodos auxiliares proporcionan información adicional al sistema, correspondiente a datos de posición, vibración, presión, velocidad, voltaje, señales de control, deformación y/o otros. El objetivo de usar estos nodos auxiliares es hacer más efectiva la detección. Particularmente en el sistema de monitoreo, una IMU se puede localizar en un contenedor para medir la posición relativa de éste y diferenciar los cambios en las lecturas de los magnetometros producto de los cambios de posición del contenedor versus la entrada de un inchancable. En la Figura 4 se presentan a modo de referencia gráficas con respuestas de diferentes sensores. Específicamente la muestra (4.A) corresponde a la lectura del magnetómetro durante una rotación de un contenedor y la muestra (4.B) corresponde a la lectura de la IMU durante la misma rotación. Se observa claramente que existe una correlación entre ambas lecturas. En cambio, en la muestra (4.C) se observa la lectura del magnetómetro durante la entrada de un inchancable y en la muestra (4.D) se observa la lectura en paralelo de la IMU, observándose que en este caso no existe correlación alguna. El o los acelerómetros se utilizan de forma equivalente para compensar los golpes y movimientos bruscos del contenedor. Los nodos auxiliares también pueden ser usados para medir parámetros adicionales como posición, vibración, presión, velocidad, voltaje, señales de control, deformación, temperaturas, imágenes, sonido y/o otros, de la máquina, estructura, ambiente u operación para optimizar el funcionamiento del sistema en aspectos tales como: autonomía energética, continuidad operacional, facilidad de uso u otras. En cada caso, los nodos auxiliares deberán posicionarse en o los lugares indicados para medir la variable objetivo, los que podrían ser en el mismo contenedor, un gabinete eléctrico, una estructura de soporte de la máquina, un computador u otro. Optionally, auxiliary type sensors (nodes) can be used. Preferably, but not exclusively, these sensors may be inertial measurement units (IMU), accelerometers, strain gauges, rotary encoders, gyroscopes, inclinometers, manometers, voltmeters or others. The auxiliary nodes provide additional information to the system, corresponding to position, vibration, pressure, speed, voltage, control, deformation and / or other data. The objective of using these auxiliary nodes is to make detection more effective. Particularly in the monitoring system, an IMU can be located in a container to measure its relative position and differentiate changes in magnetometer readings due to changes in the position of the container versus the entrance of an inchancable. Figure 4 shows graphical references with responses from different sensors. Specifically, the sample (4.A) corresponds to the magnetometer reading during a rotation of a container and the sample (4.B) corresponds to the reading of the IMU during the same rotation. It is noted Clearly there is a correlation between both readings. On the other hand, in the sample (4.C) the magnetometer reading is observed during the entry of an inchancable and in the sample (4.D) the parallel reading of the IMU is observed, observing that in this case there is no correlation any. The accelerometer (s) are used equivalently to compensate for bumps and sudden movements of the container. Auxiliary nodes can also be used to measure additional parameters such as position, vibration, pressure, speed, voltage, control signals, deformation, temperatures, images, sound and / or others, of the machine, structure, environment or operation to optimize the operation of the system in aspects such as: energy autonomy, operational continuity, ease of use or others. In each case, the auxiliary nodes must be positioned at or in the places indicated to measure the objective variable, which could be in the same container, an electrical cabinet, a support structure of the machine, a computer or another.
Las señales de los sensores son transmitidas mediante un canal de comunicación interno hacia un computador que recopila y procesa los datos mediante un software especializado. El procesamiento de los datos en tiempo real determina en cada momento e indica si un elemento inchancable entró a la zona de control. En caso positivo, se activa una alarma luminosa y/o sonora para avisar al operador, encargado y/o analista que se ha cargado un inchancable y que se debe proceder a descartar la carga actual de mineral. El procesamiento de los datos se basa en un software que permite que el sistema sea capaz por sí solo de reconocer si una carga de mineral contiene o no un inchancable. Además, el computador cuenta con canales de comunicación externos para acceder a la información y configuración. Estos canales pueden ser de carácter local y/o de acceso remoto. The sensor signals are transmitted through an internal communication channel to a computer that collects and processes the data through specialized software. The real-time data processing determines at any time and indicates whether an unreachable item entered the control zone. In positive case, a light and / or audible alarm is activated to notify the operator, manager and / or analyst that an inchancable has been loaded and that the current mineral load must be discarded. The data processing is based on software that allows the system to be able to recognize whether or not a mineral load contains an unreachable. In addition, the computer has external communication channels to access information and configuration. These channels can be local and / or remote access.
Los beneficios que presenta esta tecnología están relacionados a la sencillez y flexibilidad de operación, ya que se basa en la medición del campo magnético del entorno en alguna zona de interés. Tampoco requiere del uso de personal experto o especializado, ya que el sistema toma los datos, los procesa mediante un software de detección y determina si se cargó o no un inchancable de forma autónoma. Además, la instalación del sistema no requiere detenciones considerables del proceso productivo, y tampoco requiere modificar la forma de operar, lo que facilita su implementación en la práctica. The benefits of this technology are related to the simplicity and flexibility of operation, since it is based on the measurement of the magnetic field of the environment in some area of interest. Nor does it require the use of expert or specialized personnel, since the system takes the data, processes it through a detection software and determines whether or not an inchancable was loaded autonomously. In addition, the installation of the system does not require significant detentions of the production process, nor does it require changing the way of operating, which facilitates its implementation in practice.
El sistema de monitoreo ventajosamente presenta una eficiencia del 90% en la detección de inchancables en condiciones de terreno, con lo cual se evita detener la faena y perder el costo de oportunidad de producción, evitar daños en la maquinaria y/o estructuras del chancador u otras como correas de transporte de mineral y evitar posibles fuentes de riesgo para la seguridad del personal. Ejemplo de aplicación The monitoring system advantageously has an efficiency of 90% in the detection of inchancables in terrain conditions, which avoids stopping the work and losing the cost of production opportunity, avoiding damage to the machinery and / or crusher structures or others such as ore transport belts and avoid possible sources of risk for personnel safety. Application example
Ejemplo 1. Detección de elementos inchancables en baldes de cargadores frontales. Para verificar la efectividad del sistema de monitoreo, se instaló en un cargador frontal de gran tamaño de una minera del Norte de Chile. La instalación fue realizada durante 1 día de trabajo en faena, luego se probó el sistema de monitoreo con el cargador trabajando en condiciones reales durante 1 ,5 días de faena. Example 1. Detection of unreachable elements in buckets of front loaders. To verify the effectiveness of the monitoring system, it was installed in a large front loader of a mining company in Northern Chile. The installation was carried out during 1 day of work on site, then the monitoring system was tested with the charger working in real conditions for 1.5 days of work.
En la Figura 5 se muestra la disposición de los componentes del sistema de monitoreo en la máquina, donde (A) corresponde a un nodo magnetómetro ubicado por el interior del balde, (B) a un nodo auxiliar del tipo IMU ubicado por afuera del balde, (C) a un nodo auxiliar del tipo acelerómetro, ubicado por afuera del balde, (D) al computador coordinador con 4 antenas para comunicación inalámbrica y (E) a una alarma luminosa y sonora. La ubicación de los nodos magnetómetros se realizó de forma equiespaciada en el borde interno del balde para abarcar la máxima área posible. Previamente se confirmó con pruebas manuales que este número y disposición de nodos magnetómetros era suficiente para detectar inchancables de tamaño promedio (largo 40 cm, ancho 20 cm y alto 10 cm) como los mostrados en la Figura 6: donde (6.A) corresponde a una horquilla grande, (6.B) a una horquilla pequeña, (6.C) a uña de pato, (6.D) a un tricono, (6.E) a uña ancha, y (6.F) a un adaptador barra. Figure 5 shows the arrangement of the components of the monitoring system in the machine, where (A) corresponds to a magnetometer node located inside the bucket, (B) to an auxiliary node of the IMU type located outside the bucket , (C) to an auxiliary accelerometer type node, located outside the bucket, (D) to the coordinating computer with 4 antennas for wireless communication and (E) to a light and audible alarm. The location of the magnetometer nodes was performed equally in the inner edge of the bucket to cover the maximum possible area. It was previously confirmed with manual tests that this number and arrangement of magnetometer nodes was sufficient to detect inchancables of average size (length 40 cm, width 20 cm and height 10 cm) as shown in Figure 6: where (6.A) corresponds to a large fork, (6.B) to a small fork, (6.C) to a duck's claw, (6.D) to a tricone, (6.E) to a wide toe, and (6.F) to A bar adapter.
En la Figura 7 se presenta una imagen con los nodos instalados en el balde. Los sensores se ubicaron dentro de unas cápsulas de plástico que fueron insertadas a presión dentro de unas protecciones cilindricas de acero soldadas al balde, capaz de soportar los impactos de la carga de mineral. Los nodos auxiliares se instalaron en la parte posterior del balde, en donde no se encontraban sometidos directamente a impactos y/o golpes de la carga. El computador se montó dentro de un gabinete metálico, el cual iba atornillado sobre una pletina que era parte de la estructura del techo del cargador. Las antenas se montaron mediante el uso de bases magnéticas sobre la estructura metálica. Este montaje se puede apreciar en la Figura 8. An image with the nodes installed in the bucket is presented in Figure 7. The sensors were located inside plastic capsules that were inserted under pressure into cylindrical steel protections welded to the bucket, capable of withstanding the impacts of the mineral load. The auxiliary nodes were installed in the back of the bucket, where they were not directly subjected to impacts and / or blows of the load. The computer was mounted inside a metal cabinet, which was screwed onto a plate that was part of the roof structure of the loader. The antennas were mounted by using magnetic bases on the metal structure. This assembly can be seen in Figure 8.
El ensayo consistió en que cada vez que el operador realizó una operación de carga o descarga de mineral, el sistema adquirió los datos de los nodos, los cuales fueron procesados por el software instalado en el computador. En cada operación el sistema reconocía si la carga de mineral contenía o no un inchancable. En caso afirmativo, se activaba la alarma luminosa y sonora para advertir al operador. Se realizaron un total de 50 ensayos (25 con un elemento inchancable oculto y 25 sin inchancable) con mineral de diferentes granulometrías. En la Figura 9 se puede observar el cargador frontal en trabajo.  The test was that every time the operator performed an operation to load or unload ore, the system acquired the data of the nodes, which were processed by the software installed on the computer. In each operation the system recognized whether or not the ore load contained an inchancable. If so, the light and audible alarm was activated to warn the operator. A total of 50 trials (25 with a hidden inchancable element and 25 without unreachable) were carried out with ore of different particle sizes. In Figure 9 you can see the front loader at work.
Los resultados de los ensayos permitieron demostrar la efectividad del sistema en la detección de los inchancables, detectando oportunamente hasta el 90% de los casos. The results of the trials allowed to demonstrate the effectiveness of the system in the detection of the inchancables, timely detecting up to 90% of the cases.

Claims

Reivindicaciones Claims
1 .- Un sistema de monitoreo automático para la detección de elementos ferromagnéticos ocultos en la carga de mineral, CARACTERIZADO porque actúa durante la carga o descarga de un contenedor y comprende los siguientes componentes: 1 .- An automatic monitoring system for the detection of hidden ferromagnetic elements in the loading of ore, CHARACTERIZED because it acts during the loading or unloading of a container and comprises the following components:
a. al menos un sensor de campo magnético para detectar en forma automática y en tiempo real las perturbaciones del campo magnético local en las tres direcciones del espacio; to. at least one magnetic field sensor to detect automatically and in real time the disturbances of the local magnetic field in the three directions of space;
b. un computador que recopila y procesa los datos mediante un software especializado; b. a computer that collects and processes the data through specialized software;
c. un canal de comunicación de corto alcance, cableado o inalámbrico, que se localiza entre los nodos y el computador; C. a short-range, wired or wireless communication channel that is located between the nodes and the computer;
d. un visualizador que entrega información del estado del sistema de monitoreo, y que incorpora una alarma luminosa y/o sonora; d. a display that delivers information on the status of the monitoring system, and that incorporates a light and / or audible alarm;
e. un canal de comunicación de largo alcance entre el usuario y el computador, del tipo cableado o inalámbrico; and. a long-range communication channel between the user and the computer, wired or wireless;
f. una fuente de energía del tipo batería portable o una conexión a alimentación fija y/o móvil; y F. a portable battery type power source or a fixed and / or mobile power connection; Y
g. opcionalmente, sensores auxiliares. g. optionally, auxiliary sensors.
2 - Un sistema de monitoreo automático para la detección de elementos ferromagnéticos ocultos en la carga de mineral, según reivindicación 1 CARACTERIZADO porque los sensores de campo magnético se disponen en forma equidistante en el perímetro de la zona a monitorear. 2 - An automatic monitoring system for the detection of hidden ferromagnetic elements in the ore load, according to claim 1 CHARACTERIZED because the magnetic field sensors are arranged equidistant on the perimeter of the area to be monitored.
3. - Un sistema de monitoreo automático para la detección de elementos ferromagnéticos ocultos en la carga de mineral, según reivindicación 1 CARACTERIZADO porque los sensores de campo magnético se ubican al interior o exterior del equipo a monitorear. 3. - An automatic monitoring system for the detection of hidden ferromagnetic elements in the ore load, according to claim 1 CHARACTERIZED because the magnetic field sensors are located inside or outside the equipment to be monitored.
4. - Un sistema de monitoreo automático para la detección de elementos ferromagnéticos ocultos en la carga de mineral, según reivindicación 1 CARACTERIZADO porque los sensores de campo magnético, independiente de la posición, se ubican al interior de cápsulas de plástico que se insertan dentro de protecciones especiales que se adhieren al equipo a monitorear. 4. - An automatic monitoring system for the detection of hidden ferromagnetic elements in the ore load, according to claim 1 CHARACTERIZED because the magnetic field sensors, independent of position, are located inside plastic capsules that are inserted into special protections that adhere to the equipment to be monitored.
5.- Un sistema de monitoreo automático para la detección de elementos ferromagnéticos ocultos en la carga de mineral, según reivindicaciones 1 y 4 CARACTERIZADO porque las protecciones de los sensores de campo magnético son elaboradas de acero, polímero, cerámica, material compuesto o una combinación de ellos, y se sueldan, apernan o pegan en el equipo a monitorear. 5.- An automatic monitoring system for the detection of hidden ferromagnetic elements in the ore load, according to claims 1 and 4 CHARACTERIZED because the protections of the magnetic field sensors are made of steel, polymer, ceramics, composite material or a combination of them, and they are welded, bolted or glued on the equipment to be monitored.
6.- Un sistema de monitoreo automático para la detección de elementos de ferromagnéticos ocultos en la carga de mineral, según reivindicación 1 CARACTERIZADO porque los sensores auxiliares corresponden a unidades de medición inercia!, acelerómetros, galgas extensiométricas, codificadores rotatorios, giroscopios, inclinómetros, manómetros y voltímetros. 6. An automatic monitoring system for the detection of hidden ferromagnetic elements in the ore load, according to claim 1 CHARACTERIZED because the auxiliary sensors correspond to inertial measurement units !, accelerometers, strain gauges, rotary encoders, gyroscopes, inclinometers, manometers and voltmeters.
7.- Un sistema de monitoreo automático para la detección de elementos de ferromagnéticos ocultos en la carga de mineral, según reivindicación 1 CARACTERIZADO porque los sensores auxiliares miden posición, vibración, presión, velocidad, voltaje, señales de control, deformación, temperaturas, imágenes, sonido de la máquina, estructura, ambiente u operación. 7. An automatic monitoring system for the detection of hidden ferromagnetic elements in the ore load, according to claim 1 CHARACTERIZED because the auxiliary sensors measure position, vibration, pressure, speed, voltage, control signals, deformation, temperatures, images , machine sound, structure, environment or operation.
8.- Un uso del sistema de monitoreo automático de elementos ferromagnéticos según reivindicación 1 CARACTERIZADO porque se utiliza en equipos móviles del tipo cargadores frontales y camiones; en equipos semi-móviles como palas; o equipos estáticos como chutes, chancadores y correas. 8. A use of the automatic monitoring system of ferromagnetic elements according to claim 1 CHARACTERIZED because it is used in mobile equipment of the type front loaders and trucks; in semi-mobile equipment such as shovels; or static equipment such as chutes, crushers and belts.
PCT/CL2015/000037 2014-07-18 2015-07-14 Monitoring system for the detection of ferromagnetic elements in mineral loads WO2016008059A1 (en)

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