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A SYSTEM FOR DATA COLLECTION

BACKGROUND OF THE INVENTION

THIS invention relates to a system for digital data collection particularly to data relating to mining assets such as, but not limited to, conveyors installed in an operation, peripheral assets such as scrapers or cleaners on the conveyor as well as to assets such as electric motors and pumps also used in operations.

Information relating to assets is very important for the owner of the asset to properly manage the asset, particularly where the asset has a high capital value and is in use in an operation when it is subject to wear and tear and/or the potential theft or misuse of the asset. With proper information, the asset can be tracked and located, properly maintained and the life of the asset extended. End users such as mine owners can also monitor the warranty periods of assets and take steps to ensure that warranties are claimed and losses, if any, are reduced.

The present invention seeks to address this.

SUMMARY

According to a first embodiment there is provided a system for data collection including:

a data reader for reading item data from a data storage device associated with an item, the item data including an identification of the item to which the data storage device is associated;

a data input module coupled to the data reader for capturing operating conditions data being data describing the operating conditions in which the item operates; and

a communications module coupled to the data reader and the data input module for communicating read item data and entered operating conditions data to an external computer.

The communications module may be able to receive data transmitted to the data reader.

In one example embodiment the system further includes:

a server in communication with the data reader for receiving item data and operating conditions data;

a memory associated with the server for storing received item data and operating conditions data; and

a user access module to allow a user to access data stored in the memory.

The server is typically geographically remote from the data reader.

The data storage device may be an RFID tag and the data reader may be an RFID tag reader.

The data input module may also be used for capturing data describing the physical status and condition of the item.

An example item is a conveyor roller in which case the item data includes at least one of job number, manufacturer date, destination mine, destination shaft, destination conveyor, bearing detail, roller seal, roller type, roller material, warranty duration and measurement units.

The operating conditions data may include at least one of material type conveyed, material lump size conveyed, humidity, spillage, moisture, noise, frame condition, conveyor speed and roller condition and asset location.

The data reader may be included in a handheld device.

The data input module may also able to receive maintenance data being at least one of maintenance request data or maintenance performed data.

The maintenance request data may include data relating to a request for maintenance to be performed on an item and wherein the maintenance performed data includes data relating to maintenance already performed on an item.

The maintenance request data may include an identity of the item on which maintenance is to be carried out, the type of maintenance which is to be carried out and the date of logging of the request and the maintenance performed data may include an identity of the item on which maintenance has been carried out, the type of maintenance that was carried out, the date when the maintenance was carried out and an identity of the individual carrying out the maintenance.

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Typically, the maintenance request data or maintenance complete data is input into the data reader and is transmitted from the data reader to the centra! server.

According to another embodiment there is provided a method for data collection including:

reading item data from a data storage device associated with an item, the item data including an identification of the item to which the data storage device is associated;

capturing operating conditions data being data describing the operating conditions in which the item operates; and

communicating read item data and entered operating conditions data to an external computer.

BRIEF DESCRIPTION OF THE DRAWINGS

Figure 1 shows an example system to implement the methods described herein.

DESCRIPTION OF PREFERRED EMBODIMENTS

Although the systems and methodologies described below can be applied to numerous types of assets, for purposes of this description, the assets will be referred to as a conveyor.

Conveyors are used in many different kinds of applications such as in the mining industry. Conveyors, and particularly conveyor rollers, are high capital value items. Engineers looking after the conveyors need as much information as possible to properly look after the conveyors to extend the life of these items.

A system and methodology are provided to capture the relevant information relating to these items and to store these in a manner in which they are readily accessible to a user. The system is also intended to collate data in such a way as to facilitate the selection of the most appropriate equipment for a particular environment.

According to a first embodiment there is provided a system for data collection including a hand held device 10. The hand held device 10 includes a data reader 22 for reading item data from a data storage device 12 associated with an item 14.

The hand held device 10 also includes a data input module 24. The hand held device 10 could take any one of a number of forms including a handheld computer, PDA, cellular telephone with an appropriate application operating thereon or any other form.

In the illustrated embodiment, the item 14 is a roller for a conveyor and the data storage device 12 is a radio frequency identification (RFiD) tag. The data storage device 12 could be any similar micro data storage device.

Thus the hand held device 10 needs to be a robust, intrinsically safe (rated for underground mining use) handheld computer with an RFID reader. In the example embodiment the device 10 is operating at 13.56mhz but not limited to this frequency.

The device 10 also includes a communications module coupled to the data reader 22 and the data input module 24 for communicating read item data and entered operating conditions data to an external computer.

The communication module can communicate by any one of a number of know methods including one or more of wireless networking capability, Bluetooth protocol or by being hardwired to an external computing device such as by using a LJSB connection or docking station, for example.

The device 10 also includes a screen for displaying information to a user.

The data input module 24 is used to receive information input by the user. The data input module may take any practical form and may include one or more of a keyboard, one or more input buttons and a touch screen to name but a few examples,

RFiD tags are welf known and typically include a memory thereon onto which data can be written to and read from.

During production of the roller 14, an RFID tag 12 is attached to the roller 14. The RFID tag may also be attached to the roller or capital asset retrospectively allowing data capture post installation. Item data is then written to the RFID tag which includes data describing the roller and various aspects of the manufacture of the roller and other characteristics of the roller. Pertinent data regarding design _λ client and destination may be written to the RFID tag at manufacturing stage using a factory ready RFID reader.

In the example embodiment, the item data includes at least one of job number, manufacturer date, destination mine, destination shaft, destination conveyor, bearing detail, roller seal, roller type, roller materia!, warranty duration and measurement units.

Where the item is not a roller the item data will include data specific to the item type.

Capturing information relating to destination allows a database search to be conducted on the data to retrieve all the information relating to a conveyor belt.

In the illustrated example, this data is transmitted from the device 10 to a geographically remote server 16 via a communications network 18. This will be described in more detail below.

The server 16 has an associated memory in the form of a database 20 and the data is stored in the database 20.

With the RFID tag 12 attached to the roller, the roller is installed on site.

Once the rollers are installed at the target mine, information about the operating environment is inspected and associated against a specific roller using a device 22.

In particular, the data input module 24 is used for capturing operating conditions data being data describing the operating conditions in which the item operates. In the example of a roller in a mine, the operating conditions data may include at least one of material type conveyed, material lump size conveyed, humidity, spillage, moisture, noise, frame condition, conveyor speed and roller condition.

The data input module 24 may also capture data describing the physical status and condition of the item.

The device 10 of the prototype operates a software package specifically written to encompass the mining and hard asset operating environment.

Thus in one example embodiment, data input module 24 includes software that prompts the user to choose and capture from tables prepared in the software. These tables may be increased in scope and disseminated across all users.

As described above, the device 10 is in communication with the server 16 either directly using Bluetooth, Wifl or similar communication methods or via a docking station depending on the nature of the device 10.

In the case of a docking station, the docking station is connected to a computer remote from the server 16 but in communication with the server 16 via a data communication network. This data communication network

may be the Internet for example so that the remote computer transmits data from the device 10 to the server 16 over the Internet. In other forms the user could nominate to use an in house intranet as the data communication network.

Thus, in the prototype of the present invention, the inspection data that is stored on the device 10 is uploaded to the server 16 via a computer synchronization application running on a desktop or laptop computer, for example, and the Internet.

The communication enabled is also two way in that data (including new data in terms of tables or additions to drop downs ) can be downloaded from the central server 16 to the device 10. In addition, all devices linked to the central database or communication network are updated in this way ensuring that the collation of reporting and performance data is uniform and error free. Where the communication between the two is via an intermediate computer, the data will be communicated from the central server 16 to the intermediate computer and wilf then be downloaded to the handheld device 10 when it is docked and communicating with the intermediate computer.

In any event, the server 16 receives data from the device 10 and stores the data in the associated memory 18.

The server may include a user access module to allow a user to access data stored in the memory 18.

In the example embodiment the user access module allows a user to access the server 16 via a communications network, for example in the form of the Internet.

Thus a user wishing to obtain information regarding their installation and particularly the conveyor rollers in their installation will log on to the server,

provide a user name and password, and if authorised will be provided with the latest information regarding the rollers.

The website serves as the central data repository for all uploaded information and allows comprehensive historic reports and notifications to be drawn from this information.

The reports and notifications include at least some of:

Current Rollers to be replaced;

Extreme Environmental conditions;

Average Roller life span per shaft;

Environmental and condition variances that are common in roller's that are replaced;

Roller replacement average per shaft;

Comparison of roller lifespan by manufacturer, component manufacturer, seal design;

Roller construction - type of material used-(HDPE, Steel, aluminium, PVC)

Bearing type and shaft diameter;

Thus it will be appreciated that the system allows:

• The capture of manufacturing details - date of components such as bearings, type of seals, material of manufacture and end user.

• Recording of dates of inspections of conveyors as the handheld computer with the RFiD reader allows data on the conveyor equipment to be read and developments including maintenance requests to be recorded both on the handheld and on the capital item. It will be appreciated that most engineers do not know when their equipment is inspected. They thus do not know what equipment is failing and why.

• Reporting on the data captured as the user logs on to the website, enters their password and gains access to their summarized information including failures and reorders. The user can also be

provided access to entire body of summarized data and is able to compare their data to the community data.

• A user can find out what manufacturer to use and what components will best suit his application by using the filters in the reporting to drill down in terms of dimensions, equipment, components and even design.

The system also allows the capture and management of maintenance requests and other maintenance related information thus creating an audit trail of the maintenance environment including actions taken, assets replaced , inspection intervals and responsible individuals.

This information can be captured both via the data input module 24 on the device 10 or entered to the server 16 and then transmitted back and forth between the device 10 and the server 16 depending on where it is entered.

For example, a person inspecting a conveyor identifies a problem with a particular roller can scan the identity of the roller and then input information relating to the identified problem. This translates to a maintenance request.

In the prototype of the present invention, the data input module 24 includes a touch screen of the device 10 to access drop down menus for example. The drop down menus are populated with maintenance requests from which the user can select a relevant maintenance request.

Thus scanning the roller causes the identity of the roller to display on the screen of the device 10 and then the user can access a maintenance requests section to input maintenance data.

The maintenance data is at least one of maintenance request data or maintenance complete data. The maintenance request data includes data relating to a request for maintenance to be performed on an item which may include an identity of the item on which maintenance is to be carried

out, the type of maintenance which is to be carried out and the date of logging of the request.

The maintenance performed data includes data relating to maintenance already performed on an item and may include an identity of the item on which maintenance has been carried out, the type of maintenance that was carried out, the date when the maintenance was carried out and an identity of the individual carrying out the maintenance.

Maintenance data entered is transmitted, together with any other type of data entered, from the device 10 to the central server 16.

Alternatively maintenance requests can be entered directly into server 16, typically by accessing server 16 via a communications network such as the Internet. These requests are then downloaded to the handheld devices 10.

In addition, where the maintenance request is captured by one handheld device 10 it can be transmitted to another handheld device 10 used on the same conveyor installation either via the intermediate computer or via the server 16.

Maintenance requests together with the other data can be viewed via the communications network that accesses the centra! server 16. These can be ordered using selected criteria such as by date, time and frame, for example and viewed as required.

Maintenance personnel can use the device 10 when carrying out maintenance. For example, the outstanding maintenance requests for a particular conveyor can be downloaded to a device 10. The maintenance personal walk along the conveyor scanning in the rollers and other elements of the conveyor and any element with a maintenance request outstanding against it will have the maintenance request shown on the screen of the handheld device 10.

Wheπ a maintenance request is shown on the screen of the handheld device, the maintenance personal attends to the maintenance request and updates on the handheld maintenance completion information. This will include for example what maintenance was carried out, when it was carried out and by whom it was carried out.

It wil! be appreciated that this maintenance completion information will be uploaded to the server 16 as described above.

In this manner a complete record of all outstanding and completed maintenance requests can be stored in the database and accessed remotely.

It will also be appreciated that the system addresses certain important objectives such as:

The performance of individual conveyor rollers and their components can be tracked allowing better and longer lasting components to be installed over time.

• The performance of the installed base can be measured against the global population and informed choices can be made about future purchases in terms of the manufacturer, bearings, seals, roll material - ie. plastic, steel or aluminium or any other material .

• The location of a roller to a conveyor and then to a specific frame on a conveyor can be tracked. In this way an area on a conveyor that continuously exhibits high wear activity can be addressed and remedied.

Removing a roller from the conveyor requires in field analysis of the cause of failure. The cause of failure can be recorded.

New rollers installed in the field will have their new data read to an attached RFID tag during installation.

Problem areas on a conveyor, for example broken/bent frames, cleaner blades status, spillage and water can be pinpointed. • All maintenance requests are recorded and stored and accessible via the Internet at any time.

Outstanding maintenance issues are highlighted and emailed to relevant parties.

Outstanding maintenance issues are downloaded to the handheld for action and cannot be cleared or made to disappear until resolved. ^■ When the maintenance issue is resolved, the 'rectifying action' and the 'person responsible' is recorded.