MORE TRUCKS

DESCRIPTION

PRIOR RELATED APPLICATIONS

[0001] This application claims priority to US Serial No. 63/140,504, filed January 22, 2021, incorporated by reference in its entirety for all purposes.

TECHNICAL FIELD

[0002] The invention relates to a system and method for monitoring the operation of one or more trucks at worksites, preferably one or more mining trucks at mine sites.

[0003] The main object of the invention is to provide an online platform that addresses underproduction and inefficiencies at mine sites, implementing Industry 4.0 concepts to include mine analytics and performance monitoring on mining trucks, particularly on its hoppers or trays. The main approach of this invention is to be able to monitor the truck’s performance in terms of payload, cycle efficiency, availability, fuel consumption, wear analysis, fatigue analysis, asset tracking and speed control. For this purpose, the highest technology in terms of sensors, data transmission and analytics is implemented.

BACKGROUND

[0004] Monitoring and controlling operations at worksites are major objects of most industries. Characterizing a productive operation through data collection can result in early identification of operational issues that reduce operating efficiency. In addition, such characterization can help identify possible operational improvements that lower operating costs, reduce operational risks, and/or increase worksite productivity. This is particularly true in the monitoring and control of a fleet of trucks, which operation has a high potential for implementing improvements in terms of truck routes, fuel efficiency, fleet availability, operation cycles, maintenance and payload capacity. [0005] Different monitoring and controlling solutions have been implemented for the management of truck fleets, mostly directed to monitor key truck operational parameters to improve the availability of the fleet. For instance, publication US2019019167A1 discloses a solution for the monitoring, control and optimization of a waste pickup service based on a fleet of trucks. Then, the publication discloses a waste measurement device directed to obtain waste volume data and use the truck capacity as key input for managing the fleet, including data about traveled distance, fuel expenses, emissions and working hours.

[0006] The implementation of the solution above is relatively simple since the key operational parameter is limited to the waste volume being transported by the trucks, for which volume sensors are implemented. However, said approach is not direct for managing more complex operations like pay load transport at mine sites, wherein multiple key operational parameters are involved in the operation of the truck fleet.

[0007] The operation of mining trucks is ruled by several key parameters not only related to payload, operation cycles and fuel consumption, but also to wear and fatigue due to harsh mine site operation conditions. Different monitoring and controlling solutions have been implemented for improving operation of mine trucks, mostly directed to identifying specific operation issues and proposing solutions to the same. For instance, publication US6157889A discloses a load distribution system for mine trucks, wherein weight sensors coupled to the bed of a truck measure the weight applied to each tire strut as the truck is being loaded. Then, the exact position of the center of gravity of the load in the truck’s bed can be calculated and displayed on a monitor relative to a target position deemed optimal for uniform weight distribution. Based on this information, the operator of the loading machine can complete the loading operation in such a way as to shift the center of gravity toward the chosen target position.

[0008] The implementation of the solution above solves the problem of payload distribution, which improves operation efficiency and reduces safety risks regarding unevenly distributed payloads. However, said solution only considers one operational parameter of the truck, and is not useful for determining a complete overview of the whole truck operation, from its loading point to its discharge point. Besides, specific solutions like the one in publication US6157889A requires special equipment that, in most cases, should be included when manufacturing the truck components. Therefore, are difficult to implement in existing operations, resulting not only in increasing manufacturing costs, but also in productivity inefficiencies due to high downtimes.

[0009] Other many solutions, like the one in publication US2015285650A1, are directed to monitoring and controlling the navigation of mining vehicles, providing directions on the best route to follow by the operators based on the location of the vehicle. Said solutions can be implemented using location sensors like GPS, and are intended to improve fleet management in terms of geolocation. However, no other operational parameters are considered, and a holistic overview of the truck operation cannot be determined.

[0010] Based on the above, there is a need to provide a monitoring solution able to provide a complete overview of the truck operation, considering multiple operational parameters directed to a holistic management of truck fleets. In addition, the solution should be assembled easily, preferably in the form of a kit, reducing installation downtimes, and substantially reducing the implementation of special equipment. The main difference between this invention and current solutions is that it does not depend on the OEM (Original Equipment Manufacturer) of the truck because it does not intervene the truck at any point, not requiring authorization from a third party to implement it. This means that the invention is proposed in the form of an enclosure, which can be installed in the truck’s dump body with minor interventions. This allows for a quick installation, reducing the downtime of the trucks when the system is being installed and during maintenance processes. Besides, the enclosure being installed in the dump body of trucks is independent of the type of truck, meaning that it is possible to adapt the same to any truck in the industry. The enclosure can be presented as part of a kit, with minimum intervention to existing trucks or its dump bodies.

[0011] It is another object of the invention to implement a sensor for metal/uncrushable early detection. At the moment, the mining industry is highly impacted by metal fragments that breach the operation when the ore is being processed. The invention can implement metal detector sensors and/or cameras in order to identify these metal fragments before it damages the crusher or the conveyor belt, affecting the entire operation.

[0012] The applicant is developing first-class technology for cycle monitoring and timing improvement. In this regard, one of the key characteristics of the invention is its online technology and real time data processing, using 3G, 4G or 5G. Non-invasive sensors monitor the performance of the truck in real time, giving relevant information for improving the productivity of the operations.

SUMMARY OF INVENTION

[0013] As indicated above, the invention is related to a system and method for monitoring the operation of one or more trucks at worksites, preferably one or more mining trucks at mine sites. For performing said monitoring, the system and method are implemented in a hardware-software environment, directed to monitor, process and display data, including calculation of specific operational parameters.

[0014] According to its general aspects, the hardware related features of the invention are directed to monitor operational data of the trucks or trays, storing said operational data and communicating said data to an online platform. Alternatively, the hardware related features can also preprocess the operational data, e.g. calculating operational parameters from raw operational data, debugging the operational data or preparing tables or graphs with the captured data, providing pre-processed operational data to one or more users.

[0015] Then, the monitored, stored and/or preprocessed operational data is communicated to an online platform for processing, obtaining operation information and statistics of all the trucks at one or more worksites. The online platform is software-implemented, providing different tools for analyzing the operational data according to preferences of end users. Besides, this platform provides a clear visualization of the data through a user interface, which can be displayed in different user equipment.

[0016] According to a main embodiment of the invention a system for monitoring the operation of one or more trucks comprises: at least one truck with a tray; an inertial measurement unit (IMU) arranged on a first surface of the tray, configured to characterize the movement of the tray, obtaining real-time movement data of the tray; a location sensor configured to track the location of the tray, obtaining real-time location data of the tray; at least one processing unit configured to process the movement and location data, obtaining processed data; at least one server configured to receive the real-time movement and location data and/or the processed data; at least one communication unit configured to communicate the real-time movement and location data and/or the processed data from the at least one truck to the at least one server; and a display interface configured to display the real-time movement and location data and/or the processed data to a user.

[0017] The at least one server is further configured to obtain truck operation information from the real-time movement and location data and/or the processed data, said operation information including at least one or a combination of truck status information, truck payload information, truck travel information, truck efficiency information, truck cycle information and truck availability information. The display interface is further configured to display said truck operation information.

[0018] According to a main embodiment of the invention a method for monitoring the operation of one or more trucks comprises: providing at least one truck with a tray; characterizing the movement of the tray by means of an inertial measurement unit (IMU) arranged on a first surface of the tray, obtaining real-time movement data of the tray; tracking the location of the tray by means of a location sensor, obtaining real-time location data of the tray; processing the movement and location data by means of at least one processing unit, obtaining processed data; receiving the real-time movement and location data and/or the processed data by at least one server, wherein said real-time movement and location data and/or the processed data is communicated from the at least one truck to the at least one server by at least one communication unit; obtaining, by the at least one server, truck operation information from the realtime movement and location data and/or the processed data, said operation information including at least one or a combination of truck status information, truck payload information, truck travel information, truck efficiency information, truck cycle information and truck availability information; and displaying the real-time movement and location data and/or the processed data to a user by means of a display interface, wherein the display interface also displays said truck operation information.

[0019] According to a main embodiment of the invention a monitoring kit for monitoring the operation of a truck comprises: at least one processing unit; an inertial measurement unit (IMU) in communication with the at least one processing unit; a location sensor in communication with the at least one processing unit; at least one communication unit in communication with the at least one processing unit; at least one data storage unit in communication with the at least one processing unit; and at least one power source.

[0020] The at least one processing unit, the IMU, a first part of the location sensor, a first part of the at least one communication unit, the at least one data storage and the at least one power source are housed within a Sensor Signal Processing Cabinet or enclosure, said enclosure being arranged on the first surface of the tray.

[0021] An embodiment of the invention further comprises at least one power source that can be configured to energize the IMU, the location sensor, the at least one processing unit and/or the at least one communication unit. When the invention is presented as a kit, the at least one power source can be comprised in said kit, within the enclosure.

[0022] According to an embodiment of the invention at least part of the location sensor and/or at least part of the at least one communication unit can be arranged on a second surface of the tray, facing sky. When the invention is presented as a kit, first parts of the location sensor and communication unit are comprised by the kit, within the enclosure. Then, a second part of the location sensor and a second part of the at least one communication unit are arranged on a second surface of the tray, facing sky, wherein said second parts are in data communication with said first parts wirelessly or by means of a data cable. Commonly, said second parts are one or more antennas of the location sensor and communication unit. Preferably, all the components of the location sensor and communication unit, including the antennas, are housed inside the enclosure, which is possible when said arrangement does not jeopardize the location and communication data acquisition by the system.

[0023] According to an embodiment of the invention, the IMU, the at least one processing unit and the at least one power source can be housed within the enclosure, said enclosure being arranged on the first surface of the tray. The enclosure can comprise at least one data storage unit in communication with the at least one processing unit.

[0024] According to an embodiment of the invention, the system and kit can further comprise wear sensors arranged on wear surfaces of the tray. Said wear sensors, forming a wear sensor arrangement, can be configured to obtain real-time thickness data of the tray, which can be used by the at least one server to calculate and display tray lifetime information. The wear sensors can be in data communication with the at least one processor of the system and kit by means of data cables or wirelessly. The data cables can be embedded in the structure of the tray, inside columns/beams, or wired over said structure.

[0025] Alternatively, the wear sensors are implemented in fixing elements used for fixing one or more plates forming the tray or for fixing one or more wear plates to working surfaces of the tray. Said wear sensors can form a mesh of wear sensors communicating the thickness data of the tray wirelessly through the mesh, from multiple sensing points to the at least one processing unit. According to this embodiment each wear sensor is capable of sensing thickness data and communicating the same to neighboring wear sensors, propagating the thickness data of each sensor through the mesh and towards the at least one processing unit, for further processing.

[0026] According to an embodiment of the invention, the system and kit further comprise weight sensors arranged on predetermined locations of the tray and/or of a chassis of the at least one truck. Said weight sensors are configured to obtain real-time weight data of the payload in the tray. The weight sensors, the IMU and the location sensor comprise a cycle timing sensor arrangement. Similarly, to the wear sensors, the weight sensors can be in data communication with the at least one processor of the system and kit by means of data cables or wirelessly. The data cables can be embedded in the structure of the tray and/or truck chassis, inside columns/beams, or wired over said structures.

[0027] The cycle timing sensor arrangement obtains real-time movement, location and weight data of the tray. Said data is communicated to the at least one processor and/or to the at least one server to identify and count timing of the truck on each of the following operation cycle stages: queuing to load stage, defined as a stage in which a truck is waiting for being loaded; loading stage, defined as a stage in which a truck is being loaded at a load site; to dump or returning stage, defined as a stage in which a truck is loaded and in movement from the load site to a dump site; queuing to dump stage, defined as a stage in which a truck is waiting for dumping the load; dumping stage, defined as a stage in which a truck is dumping the load at the dump site; to load stage, defined as a stage in which a truck is returning to the load site from the dump site; fueling stage, defined as a stage in which a truck is being fueled; other stages, defined as a stage that is not part of an operation cycle, like a service stage.

[0028] Then, the cycle timing sensor arrangement can obtain a time it takes a truck to complete the above operation cycle stages, allowing complete characterization of the operation cycle.

[0029] According to the embodiment above, the queuing to load stage is identified when: the real-time movement data from the IMU indicates that a speed of the tray is approximately zero, that a tilt angle of the tray is approximately zero and that an acceleration/impact indicator of the tray is approximately zero; the real-time location data from the location sensor indicates that the tray is within an area near the load site; the real-time weight data from the weight sensors indicates that the weight of the pay load is approximately zero; and a previous operation cycle stage was the to load stage.

[0030] According to the embodiment above, the loading stage is identified when: the real-time movement data from the IMU indicates that a speed of the tray is approximately zero, that a tilt angle of the tray is approximately zero and that an acceleration/impact indicator of the tray is positive; the real-time location data from the location sensor indicates that the tray is within an area near the load site; the real-time weight data from the weight sensors indicates that the weight of the pay load is increasing; and a previous operation cycle stage was the to load stage or queuing to load stage.

[0031] According to the embodiment above, the to dump or returning stage is identified when: the real-time movement data from the IMU indicates that a speed of the tray is above zero, that a tilt angle of the tray is approximately zero and that an acceleration/impact indicator of the tray is zero or positive; the real-time location data from the location sensor indicates that the tray is within a road area; the real-time weight data from the weight sensors indicates that the weight of the pay load is above zero; and a previous operation cycle stage was the loading stage. [0032] According to the embodiment above, the queuing to dump stage is identified when: the real-time movement data from the IMU indicates that a speed of the tray is approximately zero, that a tilt angle of the tray is approximately zero and that an acceleration/impact indicator of the tray is approximately zero or negative; the real-time location data from the location sensor indicates that the tray is within an area near the dump site; the real-time weight data from the weight sensors indicates that the weight of the pay load is above zero; and a previous operation cycle stage was the to dump or returning stage.

[0033] According to the embodiment above, the dumping stage is identified when: the real-time movement data from the IMU indicates that a speed of the tray is approximately zero, that a tilt angle of the tray is above zero and that an acceleration/impact indicator of the tray is positive; the real-time location data from the location sensor indicates that the tray is within an area near the dump site; the real-time weight data from the weight sensors indicates that the weight of the pay load is decreasing; and a previous operation cycle stage was the queuing to dump or to dump stage.

[0034] According to the embodiment above, the to load stage is identified when: the real-time movement data from the IMU indicates that a speed of the tray is above zero, that a tilt angle of the tray is approximately zero and that an acceleration/impact indicator of the tray is zero or positive; the real-time location data from the location sensor indicates that the tray is within the road area; the real-time weight data from the weight sensors indicates that the weight of the pay load is approximately zero; and a previous operation cycle stage was the dumping stage. [0035] According to the embodiment above, the fueling stage is identified when: the real-time movement data from the IMU indicates that a speed of the tray is approximately zero, and that an acceleration/impact indicator of the tray is approximately zero; and the real-time location data shows that the truck is within a fueling area.

[0036] Finally, the at least one communication unit is configured to communicate all data to a communication system of the at least one truck and/or to wirelessly communicate said data to the at least one server, for instance, by means of a wireless network.

BRIEF DEFINITION OF THE FIGURES

[0037] As part of the present invention, the following representative figures thereof are presented, which teach preferred embodiments of the invention and, therefore, should not be considered as limiting the definition of the claimed matter.

Fig. 1 is a graph of the Truck Operation Cycle from sensor data, according to an embodiment of the invention.

Fig. 2a and Fig. 2b are a representation of the payload sensor arrangement with pressure sensors in the tire struts, according to an embodiment of the invention.

Fig. 3a is a representation of wire loops inside wear bolts or cylinders installed on critical locations of the tray, according to an embodiment of the invention.

Fig. 3b is a representation of an internal perspective of a wear bolt or cylinder implementing the tray wear sensor, according to a first embodiment of the invention.

Fig. 3c is a representation of an external perspective of wear bolts or cylinder implementing the tray wear sensor, according to the first embodiment of the invention.

Fig. 3d is an exploded view of a wear cylinder implementing the tray wear sensor, according to a second embodiment of the invention.

Fig. 3e is a cross-section view of the wear cylinder of Fig. 3d.

Fig. 3f is a perspective view of a wear cylinder implementing the tray wear sensor, according to a third embodiment of the invention. Fig. 3g is a cross-section view of the wear cylinder of Fig. 3f.

Fig. 3h is a perspective view of a wear cylinder implementing the tray wear sensor, according to a fourth embodiment of the invention.

Fig. 3i is a cross-section view of the wear cylinder of Fig. 3h.

Fig. 3j is a perspective view of a wear cylinder implementing the tray wear sensor, according to a fifth embodiment of the invention.

Fig. 3k is a first cross-section view of the wear cylinder of Fig. 3j.

Fig. 31 is a second cross-section view of the wear cylinder of Fig. 3j.

Fig. 3m is a view of the installation system of the wear cylinder of Fig. 3j on the tray.

Fig. 4 is a representation of the location of the location sensor (GPS) and communication antenna on a surface of the tray, according to an embodiment of the invention.

Fig. 5 is a representation of the Sensor Signal Processing Cabinet or enclosure, according to an embodiment of the invention.

Fig. 6a is a representation of the location of the enclosure at the front of the tray, according to an embodiment of the invention.

Fig. 6b is a representation of the location of the enclosure at the front of the tray according to Fig. 6a.

Fig. 7 is a scheme of the system arrangement on the tray (enclosure and external sensor/devices), according to an embodiment of the invention.

Fig. 8 is a representation of the system arrangement on the cabin of the truck, according to an embodiment of the invention.

Fig. 9 is a representation of the system arrangement with the integration of the wear cylinder and the mesh network system.

DEFINITION OF THE PREFERRED EMBODIMENTS

[0038] The preferred embodiments of the invention can be defined in connection to its hardware and software related features as described below. Hardware related features

Sensors

[0039] The invention implements different types of sensors, with specific aims. The main sensors being installed are described below, as implemented in connection to a single truck or tray.

Cycle Timing Sensors

[0040] The named Cycle Timing Sensors are a set of sensors directed to identify the truck operation cycle stages. These sensors count timing of the truck on each of the following stages: returning or to dump, dumping, queuing to dump, to load, loading, queuing to load, fueling, and other unknown activity. The cycle timing sensors provide the time it takes a truck to complete the loading, travelling and dumping processes, allowing complete characterization of the operation cycle.

[0041] The cycle timing sensors are formed by a set of sensors allowing timing calculation, such as:

Location sensor: This sensor is for tracking the tray location, for instance tracking its latitude and longitude, and its speed with standard GPS accuracy. Jointly with the online platform, the data from the location sensor is able to provide 3D visualization of tray data overlaid on aerial view of the worksite or mine site. According to a preferred embodiment, the sensor for this purpose is a GNSS (Global Navigation Satellite System).

IMU (Inertial Measurement Unit): This sensor is for tracking impacts in the tray, inclination angle, acceleration and speed. The IMU uses a combination of accelerometers, gyroscopes, and sometimes magnetometers, directed to obtain data with the aim of characterize the movement of the tray.

Pressure/weight sensor: This sensor is for tracking the weight of the payload or changes in the weight of the tray.

[0042] The logic behind the procedure or algorithm for determining the stage of the operation cycle can be visualized in connection to Fig. 1, showing the output of the sensors, or sensor data, in connection to the main stages of the truck operation cycle. As can be seen in Fig. 1, the output of the sensors is a clear indication operational changes, which in combination allow for clear determination of the cycle stages identified above.

[0043] In addition, the data in Table 1 also shows how the data from the sensors can be used for determining the stage of the operation cycle.

Table 1: Truck Operation Cycle from sensor data.

[0044] For example, to determine when the truck is being loaded, the sensors will have to show: speed is zero (“0”) or approximately 0, weight is increasing and is greater than 0, angle of the tray is 0 and the tray is receiving impacts, though is increasing or positive. Through these four insights can be concluded that the truck is being loaded. It is important to note that some variations can be occur in connection to the data in Table 1. For instance, the accelerations/impact can output zero (or negative) or positive during the to load task, to dump or returning tasks, being expected to receive a continuous oscillation between zero and positive reads during said tasks, due to the smoothness or roughness of the truck path. Said oscillations are not affecting the determination of the task due to the other data received from the sensors (location, speed, pay load weight, title angle and previous task).

Payload Weight Sensor

[0045] For measuring the weight of the payload, two approaches are proposed:

Pressure Sensors installed in the tire struts of the truck. Pressure sensors can measure the pressure inside the struts, which are connected to specific locations of the chassis of the truck and have a response to the weight of the payload. Different approaches can be implemented to calculate payload weight from various algorithms. For instance, pressure measurements from sensors in the tire struts can be converted to payload weight from a correlation between pressure inside each strut and weight of the pay load being loaded into the tray. Fig. 2a and 2b show a scheme of the payload sensor arrangement, with pressure sensors in the struts that are connected to the chassis, according to an embodiment of the invention.

As shown in Fig. 2b, the Pressure Sensors can be located in connection to each tire strut of the truck and, by means of testing the response of the struts during loading operations, a correlation between payload weight and pressure measurement in each strut can be defined. Said correlation is useful for obtaining payload weight data in trucks with similar strut configuration, meaning that different correlations may be required depending on the model of the truck.

When applicable, depending on the configuration of the truck and the struts, pressure sensors in two struts of the back tires of the truck are implemented, and the gathered pressure data is communicated to a Sensor Signal Processing Cabinet or Enclosure, by means of sensor connection cables or Bluetooth where possible, as represented in Fig. 2a. From said cabinet or enclosure, the data can be processed to obtain payload weight and/or transmitted wirelessly to further processing.

Data transmission from the Dump Truck Payload Meter. When the trucks are already having a Payload Meter, the information can be obtained from the truck through a wired connected device or wirelessly, if applicable.

Wear and Fatigue Analysis Sensor

[0046] For obtaining data directed to a mechanical wear or fatigue analysis of the trays, a wear sensor is proposed.

[0047] The tray wear sensor measures the thickness of the wear floor plate, using said information to determine the end of the tray life. In particular, the proposed approach measures the reduction on the tray thickness over time to schedule tray replacement on time, implementing wear bolts or cylinders with wire loops to be electronically monitored. For instance, Fig. 3a, Fig. 3b and Fig. 3c show how the proposed approach works, implementing special wear cylinders including an electrical circuit inside, wherein the wear of the plates will break the electrical circuit indicating wear depth and though predict beforehand when plates should be replaced. [0048] According to an embodiment of the invention, the wear sensor considers the design and fabrication of a device directly installed in the tray, with an independent power system through batteries and independent communication that goes directly to the enclosure. The evaluation of the thickness of the tray will be carried out every 1mm of wear, with a range of up to 50mm.

[0049] The communication of the thickness data to the enclosure can be over a mesh network system through wireless communication, like Bluetooth, between the sensors itself and a mesh gateway included in the system of the invention.

[0050] According to an embodiment, the wear sensors can implement a special configuration as shown in Figs. 3b-l. Figs. 3b and 3c are representing an embodiment using wired sensors, which are connected to the processing unit by means of data cable. Said cables are also energizing the sensors from a power source in the enclosure. Alternatively, the wear sensors can communicate thickness data wirelessly, and can be presented as independent units with its own power source, as shown in Figs. 3d-l. According to said wireless embodiment of the wear sensors, the same can be distributed in multiple measurement points of the tray forming the mesh network system or sensor mesh, communicating the thickness data to the processing unit through said mesh. This approach allows using low energy wireless network, allowing that the data from the furthest wear sensor reach the data processing unit with low energy consumption. This means that the data of the furthest sensors reach the processing unit by a wireless communication with the closest sensors. As indicated above, the mesh network system contemplates that each wear sensor is a mesh node and includes a mesh gateway that can be implemented in the enclosure as another component of the system of the invention, for retrieving the wear data from each node.

[0051] Figs. 3d and 3e represent a first embodiment of the wireless wear sensor, in which power, communication and sensing units are attached to an existing wired sensing wear cylinder, converting the same to wireless sensing wear cylinder. The power unit and the communication unit, jointly with related circuitry, are housed in a wear sensor enclosure that can be fixed to the head of the existing sensing wear cylinder, having a lid for accessing to the components without requiring removal of the wear cylinder. Fig. 3e shows a cross-sectional view of this embodiment, wherein the wear cylinder is fixing a wear plate to a surface of the tray. [0052] Figs. 3f and 3g represent a second embodiment of the wireless wear sensor, similar to the first embodiment but in which the wear sensor enclosure housing the power unit, communication unit and related circuitry is integrated to the head of the wear bolt or cylinder.

[0053] Figs. 3h and 3i represent a third embodiment of the wireless wear sensor, similar to the second embodiment but in which the wear sensor enclosure housing the power unit, communication unit and related circuitry is the head of the wear bolt or cylinder.

[0054] Finally, Figs. 3j, 3k, 31 and 3m represent a fourth embodiment of the wireless wear sensor, in which the wear sensor is not implemented in an existing bolt, being a completely different sensing unit that includes a first portion and a second portion. The first portion is an elongated probe that projects towards the wear plates, having the sensing means within. The second portion is a probe head that houses the power unit, communication unit and related circuitry. Said second portion is fixed to the tray from outside, by common fixing bolts, and the first portion is inserted into a perforation of said tray and related wear plate. Fig. 3m shows how the wear sensor can be installed on the tray.

Other Sensors

[0055] The invention also contemplates other sensors per truck or tray, for instance:

Time sensor: the aim of this sensor is to precisely record all operational data that is collected against time, and to collect raw data that will enable the classification of time, location, speed, vibration, acceleration, angle and height. Allows for accurate time stamping of all collected data from each of the trucks. The system is able to time stamp all incoming data and system actions which allows for accurate data comparisons to be made across all devices. Allows for global pinpointing when events occur on the data.

Uncrushable/metal detector: at least one metal detector sensor and/or one or more cameras can be implemented in order to detect uncrushable or metal fragments inside the tray (payload). If those fragments get to the crusher and/or conveyor belt, may affect and stop the entire operation. Uncrushable/metal detectors (sensors and/or cameras) are installed facing the load area of the tray, at one or more heights, detecting metal uncrushable within the load. Fuel sensor: the invention is also able to obtain fuel level data from the truck’ s fuel sensor or from a specific sensor arranged in connection to fuel tanks.

Sensor Signal Processing Cabinet or Enclosure

[0056] All the information obtained from the sensors is gathered in a special device named Sensor Signal Processing Cabinet or enclosure. Said enclosure is strategically fixed to the tray of each truck, housing most of the sensors and connected to all the sensors at the tray. In this regard, some sensors/devices may be required to be external to the enclosure. For instance, the location sensor (e.g., GPS) and the communication antenna may need to be installed at the top of the tray, facing the sky, preferably at the top of the tray canopy for improving location accuracy and communication fidelity (see Fig. 4). Said sensor/devices are named external sensor/devices. Other main sensors, like the IMU, can be implemented inside the enclosure, which is presented as a hardcase housing enclosing electronics and circuitry (see Fig. 5). However, current technologies in location and communication antennas allow implementing the location sensor and/or the communication antenna inside the enclosure, without substantially jeopardizing the operation of the system.

[0057] It should be understood that other additional sensors, like the weight sensor, uncrushable/metal detector and fuel sensor, need to be installed in clear connection to the measured object, meaning that said sensors will be most likely installed remote from the enclosure, like the GPS if needed, falling within the definition of external sensor/devices. In said cases, the information from/to the external sensors/devices travels to the enclosure via small and non-invasive cables, from the different components/locations of the tray in which the sensors/devices are installed. Said cables may be integrated into the structure of the tray, encased by the same structure, but the most preferred option is to facilitate its installation over the external surface of the tray, allowing integration of the invention to existing trays and reducing the required intervention. In this regard, when wireless sensors can be used, the same are implemented in data wireless communication with the enclosure.

[0058] The enclosure can be located at the front wall of the tray, where possible, for ease of access. For instance, Fig. 6a and Fig. 6b show a preferred location of the enclosure at the front side of the tray, facing the driver access of the truck.

[0059] The information processed in the enclosure can be sent directly to the online platform or through an internal system on the cabin of the truck via Bluetooth, were further data collection, storage and/or processing can be made, as well as data displaying for the driver’s consideration.

[0060] The configuration of the enclosure with internal sensor/devices and the arrangement of the external sensor/devices in data communication with the enclosure, being self-energized, conforms a monitoring kit that can be easily installed in existing trays without interference to the operation. If data cables are used for said data communication, the same can be arranged in the external structure of the tray and/or truck chassis, with minor structural interference that does not affect the operation of the tray.

System arrangement

[0061] Regarding the arrangement of the system of the invention, it is important to note that the information is transmitted from the sensors to the cloud or online platform via the system arrangement on the tray, which main components are the enclosure and sensors, as shown in Fig. 7. According to an embodiment of the invention, internal components like a processor, an IMU, a data storage and a power supply (battery pack), as represented in Fig. 7, are housed inside the enclosure, jointly with circuitry related to data communication (3G/4G, Bluetooth), positioning (GPS), and power management, among others. According to the embodiment of Fig. 7, external components are represented by dots in the perimeter of Fig. 7, arranged outside the enclosure to send/receive data from/to the enclosure. For instance, the external components in the represented embodiment are: an antenna arranged to send/receive data to/from the online platform, establishing data communication within the enclosure and the online platform; an antenna arranged to receive location related data (GPS); and/or one or more external sensors, located in the truck but remote the enclosure, for instance, the fuel and/or pay load related sensors. It is important to note that, thanks to current technologies, some location and communication antennas can be arranged inside the enclosure without jeopardizing the reception of location and communication data, meaning that most of the components of the system can be arranged inside the enclosure.

[0062] According to the preferred embodiment, all the information gathered in the enclosure can be sent via Bluetooth to the internal system arrangement installed in the cabin of the truck. From the cabin, the information can be uploaded to the cloud for analysis through the online platform, as show in Fig. 8. As in Fig. 7, Fig. 8 also shows dots at the perimeter of the figure, representing external existing components that would be related to the internal system arrangement installed in the cabin of the truck. According to an embodiment of the invention, said external existing components might be a truck computer, providing truck information to the payload system; and/or a truck alternator/generator/batteries, as power source to the components of the invention.

[0063] Finally, Fig. 9 shows an embodiment of the system arrangement according to Fig. 7 and integrating the wear cylinder and the mesh network system. As shown in Fig. 9, a Mesh Gateway can be implemented as an internal component within the enclosure, said gateway in wireless communication with remote sensors that need to be arranged at different points of the tray, like the wear sensors that are also nodes of the mesh network system. Alternatively, other remote sensors with similar communication capabilities can be implemented, like the pressure sensors for obtaining weight data and/or uncrushable/metal detectors.

Software related features

[0064] The aim of the software related features is to create a platform to gather all the information mentioned above, for instance, using a WEB service Front-end with HMI (human machine interface) approach.

[0065] The main features of this component of the invention are:

Data storage: all data is remotely communicated using a cloud server from the pit, in real time. The purpose of the data storage is to store data to upload to the cloud while disconnected, as well as ensure record keeping in case upload is not possible.

Cloud storage: this feature has the ability to automatically count the number of loads/cycles and report results. The cloud server will be used to transmit all the data obtained from the sensors and transmit it to the display interface. Different algorithms process the data to generate relevant information.

Report Generator: Generate reports for evaluating different operational parameters. For instance, issue operational reports on each one of the trays with the following information: GPS location, cycle status, speed and inclination, payload, efficiency, availability, real time monitor, impact loads, time between loads, fuel usage, wear analysis, and impacts on stress zones Display Interface: Display all available tray sensor information in online tools that can be accessed anywhere. Besides, the display interface can be useful for visualizing the location of tray using a map visualization platform like Google Maps. For instance, the display interface can:

■ Show the last route of the truck and display speed of tray around the mine and tray cycle times.

■ Provide 3D visualization of the tray data overlaid on an aerial view of the mine.

■ Generate different statistics and parameters that will enable the mine operator to evaluate performance over time. The system will offer comparisons between one truck over time, different trucks at the same time, and different trucks over time, grouped by fleet, loading zones, truck routes, time shift, among others.

[0066] Besides, the online platform has the following capabilities: support integration with a third-party data, support all trays sending data to the cloud, can use the processor on the phone/desktop/laptop, generate reports from any device for qualified operators, provide manual data analysis via a data processor like Excel, automatically classify data collected from the tray into cycle times, and remotely communicate with cloud server from the pit in real time.

[0067] As indicated above, the display interface is the key component for user interaction, providing access to the online platform and to the gathered information for the end users, mine site operators an any other relevant user duly registered for access.

[0068] Using the online platform, users are able to select a truck, display current location and previous path on an open map. Also, users are able to see graphs and information displaying wear, payload, cycle timing, fuel consumption, efficiency, availability, speed, fueling, wear and fatigue, impacts on stress zones, and all data provided by the sensors. In addition, the online platform is also capable of comparing data in connection to the truck’ s performance, driver’s performance or full mine site, as well as by specific data requirements such as payload comparison by truck, timing comparison by truck, fuel consumption and any combinations from the above. [0069] Upon mine site requests, the online platform can be connected to the mine site previous hardware system, meaning that the software is independent from the hardware and it can be used with any sensors or data recollection system.