Real-time monitoring and estimation system for wear in rubber liners and lifter bars utilized in ore grinding mills

A system that enables real-time monitoring of wear and tear occurring in rubber liners and lifter bars used in an internal structure of ore grinding mills, in addition to obtaining estimations as to replacement times of worn parts by evaluating the estimations according to different ore types by employing artificial intelligence approaches, the system comprising:

• sensing modules positioned inside the rubber liners and the lifter bars that sense the wear and tear occurring over time in the rubber liners and lifter bars in the internal structure of the ore grinding mills, as well as temperature and pressure, wherein the sensing modules comprise electromechanical and acoustic sensors;
• data collection nodes positioned outside of a mill that reads measurement data from the sensing modules, wherein a command is transmitted and energy is provided to the sensing modules;
• a communication coordinator that transfers data from the data collection nodes to a cloud/internet, wherein the measurement data from the sensing modules are wirelessly transferred to the communication coordinator;
• a data collection monitoring and estimation center that stores data from the communication coordinator via the cloud/internet, and instantly monitors the data, and makes analyses and estimations with an artificial intelligence approach by using the data;
• and
• a reporting and user interface that allows users to access real-time monitoring data, analysis, and estimation results.

A method of operating a system that enables real-time monitoring of wear and tear occurring in rubber liners and lifter bars used in an internal structure of ore grinding mills, in addition to obtaining estimations as to replacement times of worn parts by evaluating the estimations according to different ore types by employing artificial intelligence approaches, the method comprising:

• instantly measuring wear level, temperature, and pressure in the rubber liners and the lifter bars by sensing modules;
• transferring data coming from the sensing modules to data collection nodes that are positioned outside of a mill;
• wirelessly transferring data read by the data collection nodes to a communication coordinator;
• transferring data received at the communication coordinator to a data collection monitoring and estimation center through a cloud/internet;
• storing and monitoring data gathered at the data collection monitoring and estimation center in real-time;
• creating estimation models based on monitored data with artificial intelligence approaches comprising time-series estimation models;
• estimating wear and tear of the rubber liners and lifter bars for different ores;
• and
• accessing data, analysis, and estimation results in the data collection monitoring and estimation center through a reporting and user interface.