Topographic wear monitoring system for ground engaging tool

Patent metadata

Field	Value
Publication number	US-9714923-B2
Application number	US-201514707173-A
Country	US
Kind code	B2
Filing date	May 8, 2015
Priority date	May 8, 2015
Publication date	Jul 25, 2017
Grant date	Jul 25, 2017

Abstract

A system for measuring topography of the surface of a ground engaging tool is disclosed. The system may include a machine and the ground engaging tool. A phased array ultrasonic sensor may be associated with the ground engaging tool and configured to create ultrasonic pulses within the ground engaging tool. A communication device may be associated with the phased array ultrasonic sensor. A monitoring component may communicate with the phased array ultrasonic sensor via the communication device, and may be configured to receive signals from the phased array ultrasonic sensor and monitor the topography of the ground engaging tool.

First claim

What is claimed is:

1. A system for measuring topography of the surface of a ground engaging tool, comprising:
a machine including an on-board station and the ground engaging tool;
a phased array ultrasonic sensor mounted within the ground engaging tool of the machine and configured to create ultrasonic pulses within the ground engaging tool;
a communication device associated with the phased array ultrasonic sensor; and
a monitoring component associated with the on-board station and communicating with the phased array ultrasonic sensor via the communication device, and configured to receive signals from the phased array ultrasonic sensor and monitor the topography of the surface of the ground engaging tool.

2. The system of claim 1 , wherein the phased array ultrasonic sensor is attached within a cavity in the ground engaging tool.

3. The system of claim 1 , wherein the ground engaging tool is a multi-piece tooth assembly including an adapter and a wear tip, and wherein the phased array ultrasonic sensor is mounted within a cavity in the wear tip.

4. The system of claim 1 , wherein the phased array ultrasonic sensor is mounted interiorly of the ground engaging tool and is configured to direct ultrasonic pulses in at least one general direction within the ground engaging tool.

5. The system of claim 4 , further including multiple phased array ultrasonic sensors mounted interiorly of the ground engaging tool, and wherein each of the multiple phased array ultrasonic sensors is configured to direct ultrasonic pulses in different general directions within the ground engaging tool.

6. The system of claim 5 , wherein the multiple phased array ultrasonic sensors include at least three sensors, and wherein each of the three sensors is configured to direct ultrasonic pulses generally in one of three mutually perpendicular directions.

7. The system of claim 1 , wherein the phased array ultrasonic sensor is configured to create ultrasonic pulses within the ground engaging tool at a timing consistent with an expected rate of wear of the tool.

8. The system of claim 1 , wherein the communication device is a wireless communication device, and a battery is associated with the phased array ultrasonic sensor and the wireless communication device, and wherein the battery, the phased array ultrasonic sensor, and the wireless communication device are mounted together within a cavity formed interiorly of the ground engaging tool.

9. The system of claim 1 , wherein the monitoring component is configured to:
determine the topography of the surface of the ground engaging tool; make a comparison of the determined topography with a threshold topography; and generate a signal based on the result of the comparison.

10. The system of claim 9 , wherein the signal is one of an audible and a visual signal proximate the on-board station and is generated when the comparison indicates a change in topography consistent with a predetermine difference from an original topography of the ground engaging tool.

11. The system of claim 9 , wherein the monitoring component is configured to communicate the results of the comparison and the signal to an off-board facility.

12. The system of claim 9 , wherein the monitoring component is configured to shut down the machine when the comparison indicates a change in topography that is consistent with a predetermined change that is indicative of substantial failure of the ground engaging tool.

13. The system of claim 9 , wherein the monitoring component includes a controller configured to make decisions, based on the received signals, whether to give a warning based on the comparison, shut down the machine based on the comparison, and/or shut down a crusher associated with the machine.

14. The system of claim 13 , wherein the warning is coupled with a signal indicating a time period within which the machine should be inspected for servicing.

15. A ground engaging tool for a machine, comprising:
a ground contacting surface surrounding a volume;
a cavity within the ground engaging tool; and
at least one phased array ultrasonic sensor located within the cavity and configured to sweep a beam of ultrasonic pulses through at least a portion of the volume of the ground engaging tool in at least one general direction to at least a portion of the ground contacting surface, and configured to receive echoes from the surface portion indicative of the topography of the surface portion.

16. The ground engaging tool of claim 15 , further including a second phased array ultrasonic sensor located within the cavity and configured to sweep a beam of ultrasonic pulses through a second portion of the volume of the ground engaging tool in a second general direction different from the first general direction to a second portion of the ground contacting surface, and configured to receive echoes from the second surface portion indicative of the topography of the second surface portion.

17. The ground engaging tool of claim 16 , further including a third phased array ultrasonic sensor located within the cavity and configured to sweep a beam of ultrasonic pulses through a third portion of the volume of the ground engaging tool in a third general direction different from the first and second general directions to a third portion of the ground contacting surface, and configured to receive echoes from the third surface portion indicative of the topography of the third surface portion.

18. The ground engaging tool of claim 17 , wherein, the first, second, and third general directions are mutually perpendicular, and the echoes from the first, second, and third surface portions are indicative of the topography of substantially the entire ground engaging surface.

19. A machine, comprising:
an implement operatively associated with the machine;
a ground engaging tool on the implement and including a ground engaging surface;
a cavity within the ground engaging tool;
at least three phased array ultrasonic sensors located within the cavity and configured to sweep beams of ultrasonic pulses through the ground engaging tool, with each of the three phased array ultrasonic sensors located and arranged to sweep beams in three generally, mutually perpendicular directions toward surface portions of the ground engaging tool located in the three directions, and configured to receive echoes from the surface portions giving an indication of the topography of the ground engaging surface;
a wireless communication device located in the cavity, and at least one battery configured to power the wireless communication device and the three phased array ultrasonic sensors; and
a monitoring system configured to determine the topography of the surface of the ground engaging tool, make a comparison of the determined topography with a threshold topography, and generate a signal based on the result of the comparison.

20. The machine of claim 19 , wherein the generated signal produces at least one of a visual indication, an audible indication, an electronic record, and a topographic three-dimensional map image on a display, and the monitoring system is configured to shut down the machine when the comparison indicates a change in topography from the threshold topography that is consistent with substantial failure of the ground engaging tool.

Assignees

• Caterpillar Inc

Inventors

• Behmlander Matthew Jacob
• Atkinson Terri Lynn
• Hammar Jeremy Roe

Classifications

• G01N2291/0258

  Structural degradation, e.g. fatigue of composites, ageing of oils · CPC title

• G01N29/262

  by electronic orientation or focusing, e.g. with phased arrays (phased arrays per se G10K11/34) · CPC title

• G01N2291/106

  one or more transducer arrays · CPC title

• G01N2291/044

  Internal reflections (echoes), e.g. on walls or defects · CPC title

• E02F9/268

  with failure correction follow-up actions · CPC title