TORQUE MONITORING OF HYDRAULIC SHOVELS WITHIN MINING OPERATIONS WITH LPWAN AND CLOUD-BASED LATEST TECHNOLOGY

Abstract

ABSTRACT This invention provides a cloud-integrated torque monitoring system for hydraulic shovels in mining operations, utilizing TMS_MOTMote for real-time data acquisition and TMS_MOTCMote for dual-channel communication and feedback. The system features ATmega328 Boards, LoRa and WiFi connectivity, Torque Sensor, Optical Encoder, RTC Module, HMI Display, and Power Supply, allowing for seamless data transfer, remote access, and on-site monitoring. This solution supports predictive maintenance, enhances operational control, and minimizes downtime through continuous torque analysis and alerts for early issue detection in hydraulic shovels.

Specification

Description:FIELD OF THE INVENTION
This invention relates to Torque Monitoring of Hydraulic Shovels within Mining Operations with LPWAN and Cloud-Based Latest Technology.
BACKGROUND OF THE INVENTION
This state-of-the-art torque monitoring system integrates cloud-based IoT capabilities and sophisticated sensor technology for use with hydraulic shovels in mining operations. It provides instantaneous insights into the torque performance of the apparatus. During operation, the system collects and analyzes torque data in a smooth manner, guaranteeing maximum efficiency and early detection of possible problems. Low-power wireless communication makes it possible to monitor continuously, even in far-off mining regions. The intuitive interface, accessible both on-site and via an online dashboard, makes it simple for operators and pertinent authorities to obtain important data.
Effectively managing the torque performance of hydraulic shovels during operations is a major difficulty faced by the mining industry. The integration of cutting-edge technology into current monitoring systems is often lacking, which results in limited real-time insights and delayed identification of possible concerns. This shortcoming raises the possibility of unplanned downtime and costly repairs, which has a negative effect on operational efficiency.RU2049861C1 - The device has an arm with two bucket members and is fitted in arm eyes on one hinge axle. The first bucket member is made in front of a narrow (relative to the width of the trench to be dug) bucket, and the other is made in the form of two separate extreme buckets with common traction leverage connected to hydraulic rams installed on the arm, providing turning of the bucket member. The narrow bucket member has a rear wall and is arranged in the space between extreme buckets furnished with side walls adjoining the central bucket. Radii of digging of all buckets are equal to each other, and cutting members of the buckets (their teeth) fill the entire width of the trench excavated by the machine. LoRa and Cloud-based Technology for Torque Monitoring in mining operations is the novelty of the system.
CN101649627B - The invention discloses a multifunctional tipping-bucket hydraulic excavator bucket, comprising a tipping bucket connected with an extension arm of an excavator by pulling back a bidirectional hydrocylinder. The multifunctional tipping-bucket hydraulic excavator bucket is characterized in that a multifunctional shovel plate is arranged at the front end of the tipping bucket; a fixed hole in the middle of the multifunctional shovel plate is connected with the tipping bucket via a connecting rod; the middle of the connecting rod is connected to one end of the two bidirectional hydrocylinders respectively; and the other ends of the two bidirectional hydrocylinders are connected with the tipping bucket and the multifunctional shovel plate respectively. By adopting a structure combining the tipping bucket with the multifunctional shovel plate, the invention can excavate and shovel excavated objects by using the multifunctional shovel plate and has a large capacity for a single bucket, reducing the falling of excavated objects during excavation. LoRa and Cloud-based Technology for Torque Monitoring in mining operations is the novelty of the system.
SUMMARY OF THE INVENTION
This summary is provided to introduce a selection of concepts, in a simplified format, that are further described in the detailed description of the invention.
This summary is neither intended to identify key or essential inventive concepts of the invention and nor is it intended for determining the scope of the invention.
The ATmega328 Board, Lora Module, Torque Sensor, Optical Encoder, RTC Module, and Power Supply equipped TMS_MOTMote is used to acquire torque data in real time from hydraulic shovels using sophisticated sensors, enabling low-power wireless communication through LoRa, and guaranteeing smooth transmission to the cloud for extensive analysis and monitoring.
The TMS_MOTCMote serves as the communication hub and user interface and is outfitted with an ATmega328 Board, a Lora Module, an ESP01 WiFi Board, an HMI Display, and a Power Supply. This allows for dual communication channels via LoRa for seamless connectivity in remote mining areas and WiFi for internet access. Additionally, it features an easy-to-use HMI Display for on-site torque monitoring and real-time feedback, all of which improve operational efficiency and maintenance management.
The ATmega328 Board, which is integrated into both motes, serves as the system's central processing unit. It oversees data gathering, processing, and communication tasks to make sure torque data is efficiently coordinated and transmitted throughout the system.
The LoRa Module, which is also included in each of the motes, allows the TMS_MOTMote and TMS_MOTCMote components to communicate wirelessly over long distances and at low power, which guarantees the smooth transfer of torque data in real time during mining operations.
The optical encoder and torque sensor, which are both included into TMS_MOTMote, are used to precisely record torque values in real time from hydraulic shovels while they are in use. This data is crucial for analysis and monitoring in order to improve the performance of the gear in mining operations.
In order to enable smooth contact with the cloud server and to provide an extra channel for the remote monitoring and administration of torque data from hydraulic shovels in mining operations, the ESP01 WiFi Board, which is attached in TMS_MOTCMote, is utilized to support internet connectivity.
This innovation's user-friendly interface is provided by the HMI Display, which is interfaced on TMS_MOTCMote. It also gives on-site staff real-time torque monitoring and system status feedback for hydraulic shovels, improving operational awareness and enabling quick decision-making in mining operations.
The Power Supply, which plugs into both motes, is used to supply the energy required to support data acquisition, processing, communication, and display functionalities in the torque monitoring system for hydraulic shovels in mining operations. This ensures the consistent and dependable operation of both TMS_MOTMote and TMS_MOTCMote components.
To further clarify advantages and features of the present invention, a more particular description of the invention will be rendered by reference to specific embodiments thereof, which is illustrated in the appended drawings. It is appreciated that these drawings depict only typical embodiments of the invention and are therefore not to be considered limiting of its scope. The invention will be described and explained with additional specificity and detail with the accompanying drawings.
TMS_MOTMote and TMS_MOTCMote are the two primary parts of the Torque Monitoring System for Hydraulic Shovels in Mining Operations, which makes use of LoRa LPWAN and cloud-based IoT technology. The data acquisition device is TMS_MOTMote, which is outfitted with an ATmega328 Board, LoRa Module, Torque Sensor, Optical Encoder, RTC Module, and Power Supply. When the hydraulic shovel is operating, the Torque Sensor and Optical Encoder work together to measure and record the torque values in real time. The ATmega328 Board processes the data and the timestamp information from the RTC Module before wirelessly transmitting it over the LoRa Module to provide effective low-power communication over great distances. TMS_MOTCMote manages the user interface and communication simultaneously. Its twin communication channels are enabled by its ATmega328 Board, LoRa Module, ESP01 WiFi Board, HMI Display, and Power Supply. While the ESP01 WiFi Board provides internet connectivity, the LoRa Module guarantees connectivity with TMS_MOTMote, providing smooth communication even in remote mining locations.

BRIEF DESCRIPTION OF THE DRAWINGS
The illustrated embodiments of the subject matter will be understood by reference to the drawings, wherein like parts are designated by like numerals throughout. The following description is intended only by way of example, and simply illustrates certain selected embodiments of devices, systems, and methods that are consistent with the subject matter as claimed herein, wherein:
FIGURE 1: SYSTEM ARCHITECTURE
The figures depict embodiments of the present subject matter for the purposes of illustration only. A person skilled in the art will easily recognize from the following description that alternative embodiments of the structures and methods illustrated herein may be employed without departing from the principles of the disclosure described herein.
DETAILED DESCRIPTION OF THE INVENTION
The detailed description of various exemplary embodiments of the disclosure is described herein with reference to the accompanying drawings. It should be noted that the embodiments are described herein in such details as to clearly communicate the disclosure. However, the amount of details provided herein is not intended to limit the anticipated variations of embodiments; on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the scope of the present disclosure as defined by the appended claims.
It is also to be understood that various arrangements may be devised that, although not explicitly described or shown herein, embody the principles of the present disclosure. Moreover, all statements herein reciting principles, aspects, and embodiments of the present disclosure, as well as specific examples, are intended to encompass equivalents thereof.
The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of example embodiments. As used herein, the singular forms "a"," "an" and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms "comprises," "comprising," "includes" and/or "including," when used herein, specify the presence of stated features, integers, steps, operations, elements and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components and/or groups thereof.
It should also be noted that in some alternative implementations, the functions/acts noted may occur out of the order noted in the figures. For example, two figures shown in succession may, in fact, be executed concurrently or may sometimes be executed in the reverse order, depending upon the functionality/acts involved.
In addition, the descriptions of "first", "second", "third", and the like in the present invention are used for the purpose of description only, and are not to be construed as indicating or implying their relative importance or implicitly indicating the number of technical features indicated. Thus, features defining "first" and "second" may include at least one of the features, either explicitly or implicitly.
Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which example embodiments belong. It will be further understood that terms, e.g., those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.
TMS_MOTMote and TMS_MOTCMote are the two primary parts of the Torque Monitoring System for Hydraulic Shovels in Mining Operations, which makes use of LoRa LPWAN and cloud-based IoT technology. The data acquisition device is TMS_MOTMote, which is outfitted with an ATmega328 Board, LoRa Module, Torque Sensor, Optical Encoder, RTC Module, and Power Supply. When the hydraulic shovel is operating, the Torque Sensor and Optical Encoder work together to measure and record the torque values in real time. The ATmega328 Board processes the data and the timestamp information from the RTC Module before wirelessly transmitting it over the LoRa Module to provide effective low-power communication over great distances. TMS_MOTCMote manages the user interface and communication simultaneously. Its twin communication channels are enabled by its ATmega328 Board, LoRa Module, ESP01 WiFi Board, HMI Display, and Power Supply. While the ESP01 WiFi Board provides internet connectivity, the LoRa Module guarantees connectivity with TMS_MOTMote, providing smooth communication even in remote mining locations.
A local interface for real-time torque monitoring and system status feedback is provided via the HMI Display. The data gathered is transmitted by both parts to a cloud server specifically designed for this breakthrough. The cloud server evaluates the incoming torque data using pre-programmed algorithms. On-site staff can then monitor the torque performance of the hydraulic shovel by viewing the results in real-time on the HMI Display of TMS_MOTCMote. In addition, the web dashboard that runs on the cloud provides an extensive overview for remote management and monitoring. The system sends email notifications to the operator and appropriate authorities in the event of anomalies or specified threshold breaches. This ensures that any concerns are promptly addressed and makes repair or intervention possible on time.
BEST METHOD OF WORKING
The TMS_MOTMote system equipped with an ATmega328 Board, LoRa Module, Torque Sensor, Optical Encoder, RTC Module, and Power Supply for real-time torque data acquisition in hydraulic shovels, enabling low-power wireless communication through LoRa and seamless transmission to the cloud for comprehensive analysis and monitoring in mining operations.
The TMS_MOTCMote comprising an ATmega328 Board, LoRa Module, ESP01 WiFi Board, HMI Display, and Power Supply, facilitating dual communication channels through LoRa and WiFi, supporting remote monitoring, data transmission, and on-site feedback for hydraulic shovel operations.
An ATmega328 Board integrated into both TMS_MOTMote and TMS_MOTCMote, serving as the central processing unit, coordinating data collection, processing, and communication to ensure efficient transmission of torque data across the system.
A LoRa Module in both TMS_MOTMote and TMS_MOTCMote, providing long-range, low-power wireless connectivity, enabling real-time data transfer between components and ensuring seamless operation in remote mining environments.
A Torque Sensor and Optical Encoder in TMS_MOTMote, precisely measuring torque values in real time from hydraulic shovels during operation, providing critical data for performance monitoring and efficiency improvement.
An ESP01 WiFi Board in TMS_MOTCMote, enabling internet connectivity, allowing for cloud-based remote monitoring and management of torque data, enhancing accessibility and operational control in mining environments.
An HMI Display integrated into TMS_MOTCMote, offering an intuitive interface for on-site operators, providing real-time monitoring, system status, and feedback, thus enhancing situational awareness and decision-making.
A Power Supply attached to both TMS_MOTMote and TMS_MOTCMote, ensuring continuous operation of the torque monitoring system, supporting reliable data acquisition and transmission for hydraulic shovel management in mining.
ADVANTAGES OF THE INVENTION
1. This innovation's data gathering unit, the TMS_MOTMote, uses sophisticated sensors to collect torque data in real time from hydraulic shovels. It makes low-power wireless communication possible with LoRa and guarantees smooth transmission to the cloud for extensive monitoring and analysis.
2. The TMS_MOTCMote functions as the communication hub and user interface, providing WiFi for internet access and dual communication channels via LoRa for seamless connectivity in remote mining regions. It offers a user-friendly HMI Display for real-time feedback and on-site torque monitoring, which improves maintenance management and operating efficiency.
3. By facilitating long-range, low-power wireless communication between the TMS_MOTMote and TMS_MOTCMote components, the LoRa Module is essential to this invention. It guarantees the smooth transfer of torque data in real time during mining operations.
4. This invention's Torque Sensor and Optical Encoder are essential for precisely recording torque readings from hydraulic shovels in real time while they are in use. They supply vital information for tracking and evaluating, improving the efficiency of mining equipment.
5. This innovation's ESP01 WiFi Board makes it easier for the TMS_MOTCMote to connect to the internet, allowing for smooth communication with the cloud server. In mining operations, it offers an extra channel for the remote management and monitoring of torque data from hydraulic shovels.
6. This invention uses an HMI Display as a user-friendly interface to give on-site staff feedback on the state of the hydraulic shovel system and real-time torque monitoring. In mining operations, it improves operational awareness and speeds up decision-making.
, Claims:We Claim:
1. A system of Torque Monitoring of Hydraulic Shovels within Mining Operations with LPWAN and Cloud-Based Latest Technologycomprises TMS_MOTMote system equipped with an ATmega328 Board, LoRa Module, Torque Sensor, Optical Encoder, RTC Module, and Power Supply for real-time torque data acquisition in hydraulic shovels, enabling low-power wireless communication through LoRa and seamless transmission to the cloud for comprehensive analysis and monitoring in mining operations.
2. The system as claimed in Claim 1, wherein an ATmega328 Board, LoRa Module, ESP01 WiFi Board, HMI Display, and Power Supply, facilitating dual communication channels through LoRa and WiFi, supporting remote monitoring, data transmission, and on-site feedback for hydraulic shovel operations.
3. The system as claimed in Claim 1, wherein the ATmega328 Board integrated into both TMS_MOTMote and TMS_MOTCMote serves as the central processing unit, coordinating data collection, processing, and communication to ensure efficient transmission of torque data across the system.
4. The system as claimed in Claim 1, wherein the LoRa Module in both TMS_MOTMote and TMS_MOTCMote provides long-range, low-power wireless connectivity, enabling real-time data transfer between components and ensuring seamless operation in remote mining environments.
5. The system as claimed in Claim 1, wherein the Torque Sensor and Optical Encoder in TMS_MOTMote precisely measure torque values in real time from hydraulic shovels during operation, providing critical data for performance monitoring and efficiency improvement.
6. The system as claimed in Claim 1, wherein the ESP01 WiFi Board in TMS_MOTCMote enables internet connectivity, allowing for cloud-based remote monitoring and management of torque data, enhancing accessibility and operational control in mining environments.
7. The system as claimed in Claim 1, wherein the HMI Display integrated into TMS_MOTCMote offers an intuitive interface for on-site operators, providing real-time monitoring, system status, and feedback, thus enhancing situational awareness and decision-making.
8. The system as claimed in Claim 1, wherein the Power Supply attached to both TMS_MOTMote and TMS_MOTCMote ensures continuous operation of the torque monitoring system, supporting reliable data acquisition and transmission for hydraulic shovel management in mining.

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