AU2018220056B2 - Pump data system - Google Patents

Abstract

A module which collects and stores, in a memory, data relating to the operation of an emulsion pump, and which transmits that data to a receiver, and wherein the module is powered by energy generated by movement of a part of the pump.

Description

PUMPDATASYSTEM BACKGROUND

[0001] This disclosure relates to a system for capturing data relating to the operation of

a pump, in a mobile or portable charging unit, which is used for the loading of an emulsion

explosive into a blast hole.

[0002] An emulsion explosive includes a base emulsion which is mixed with a sensitizer

to render the resulting mixture explosive. Typically a mobile charging unit draws emulsion

from a cassette or silo underground. A portable charging unit, which has a small pump

on board, is replenished, as required, from a portable bag of base emulsion which is

supplied to the pump. The portable charging unit, which has a small pump on board, is

used at a work site to place the aforementioned explosive mixture into boreholes for

blasting purposes.

[0003] The pump on the portable charging unit is designed to mix the base emulsion with

the sensitizer in a predetermined and controlled ratio and then to place the resulting

mixture in a blasting location, typically into a borehole.

[0004] Each mobile charging unit is regarded, from a legal point of view, as a mobile

explosive factory and therefore is subject to tight control. The use of each mobile charging

unit is permitted in terms of a licence from the appropriate authorities. It is therefore

necessary from a regulatory point of view to be able to ascertain with certainty the physical

location of each mobile charging unit. It should also be possible, with ease, to ascertain the physical location of each mobile charging unit and to formulate a schedule which facilitates the carrying out of preventative maintenance on each unit.

[0005] If information is available on the usage of each mobile charging unit then the task

of exercising stock control on the base emulsion and on the sensitizer is more readily

effected.

[0006] Information and data of the aforementioned kind can be gathered using manual

techniques. Inevitably this type of approach, which is laborious, difficult to implement and

control, is subject to human error.

[0007] An object of the present disclosure is to address, at least to some extent, the

aforementioned factors.

SUMMARY

[0008] The disclosure provides, in the first instance, a data collection module for use with

an emulsion pump for loading an emulsion explosive into a blast hole, the module

including at least one sensor, responsive to actuation of the pump, to generate data

relating to the volume of emulsion explosive delivered by the emulsion pump, a memory

unit in which said data is stored, a power source and a transmitter, powered by the power

source, for transmitting at least said data to a receiver which is located on a user wearable

item , characterised in that the data collection module includes a RFID tag which, in

response to receiving an interrogating signal which is sent by an environmentally placed

sensor upon detecting proximity of the RFID tag to the environmentally placed sensor, transmits identity data on the pump to the environmentally placed sensor which upon receipt of the identity data on the pump transmits the identity data to a surface location via a communication link to track the position of the data collection module..

[0009] The power source, in one embodiment of the disclosure, may be an on-board

battery provided for the purpose. Alternatively the power source may include a generator

which is driven by movement of a part of the pump to generate electrical energy which is

preferably then stored in a battery.

[0010] The part of the pump which drives the generator may vary from pump type to

pump type. For example if the pump is a reciprocating pump then upon reciprocating

action of a component of the pump, one or more magnets could be caused to move

relatively to a coil arrangement in order to generate electrical energy. If the pump is based

on rotatable movement then a coil could be rotated through a magnetic field, or vice versa.

A pneumatically driven electrical generator could alternatively be used to produce the

electrical energy which is required for charging the battery. The disclosure is not limited

in respect of the battery charging technique which can be used.

[0011] The module may include any appropriate circuit for monitoring the strength, e.g.

the voltage, of the battery. The battery voltage data comprises an important parameter

relating to the functioning of the module for it can be analysed to explain why the

associated module is not generating information. This can be due to diverse reasons e.g.

the pump may be faulty, the battery may require replacement or the generator may be

defective.

[0012] The energy generator may include a rectifier and a smoothing circuit which

processes the electrical output of the energy generator and makes it suitable for

recharging a battery.

[0013] The module may include a RFID tag or a similar device which, in response to an

interrogating signal, transmits pump identity data to a receiver or which otherwise makes

pump identity data available to a transmitter which thereafter transmits such pump identity

data together with data relating to the operation of the pump to the receiver.

[0014] The module may include a timing mechanism which generates time and date

information relating to operation of the pump. Such information may be logged, e.g.

stored in a memory unit, and may be included in data which is transmitted to said receiver.

[0015] The module may include a controller, for example a processor, to control

operation of elements or components of the module.

[0016] The module, if included in or added to a mobile or portable charging unit, enables

data pertaining to the operation of the pump to be ascertained.

[0017] In order to make use of the data which is collected by a module, data may be

transferred from the module to an appropriate receiver. The way in which this is done

may vary according to requirement. A miner, for example, is required by law to carry a

cap lamp and thus each miner, in an underground position, has an energy source. It is

possible to add to the cap lamp a transmitter-receiver unit which can interrogate a module

of the aforementioned kind and which can then receive data which is transmitted by the module. The miner, with the respective cap lamp, may return to surface or to a different control location at an appropriate time and, upon the miner entering into a defined region, data may be transferred from the cap lamp arrangement to a secondary receiver.

[0018] The present disclosure may also comprise a data collection module which

includes a RFID tag which, in response to receiving an interrogating signal which is sent

by a sensor upon detecting proximity of the RFID tag to the sensor, transmits identity data

on the pump to the sensor which upon receipt of the identity data on the pump transmits

the identity data to a surface location via a communication link to track the position of the

data collection module and which receives data pertaining to the sensor and which makes

the data pertaining to the sensor available to the transmitter which thereafter transmits

such data together with data relating to the operation of the pump to the receiver which

is located on the user wearable item thereby to allow validation of the position of the data

collection module.

[0019] Variations on the aforementioned procedure may be implemented. For example

a miner may be issued with a wrist watch or another user-wearable item which carries out

a function similar to that which has been envisaged to be carried out by equipment added

to a cap lamp. The disclosure is not limited in this respect.

[0020] Preferably data collected in the described manner is transferred from a collection

location, e.g. on surface, to a data bank, or to a supervisor, or is processed into graphical

form to be made available to a supervisor, other control personnel or to a supplier of the

explosive material.

[0021] It is also possible to collect other information relating to a mobile or portable

charging unit, or particularly to an environment in which the unit is positioned. Such

information may include a licence number or identity number for the charging unit, timing

information relating to its use, positional information relating to a location in which the

charging unit is in operation and the like. The disclosure is not limited in this respect.

Additionally, data pertaining to the identity of the operator of the charging unit may be

collected.

BRIEF DESCRIPTION OF THE DRAWINGS

[0022] The disclosure is further described by way of example with reference to the

accompanying drawings in which :

Figure 1 is a schematic illustration of an underground mine in which a pump data

collection system, according to the disclosure, is implemented,

Figure 2 illustrates in block diagram form components of a module according to the

disclosure which is attached to, or included in, a miner's cap lamp,

Figure 3 is a block diagram of some components of an emulsion charging unit which

includes a module according to the disclosure,

Figure 4 depicts a possible sequence of movements during which data generated

underground is conveyed to a surface or control location, and

Figure 5 depicts the possible construction of a record which contains data collected in the

data system of the disclosure.

DESCRIPTION OF PREFERRED EMBODIMENT

[0023] Figure 1 of the accompanying drawings illustrates, schematically, an arrangement

of an underground mine 10 which includes a shaft 12 which extends from surface 18 to a

number of underground levels 20, 22, 24 etc.

[0024] A store 26 is located at the surface 18. A number of sensors S1 to SN are

positioned at strategic locations at the mine. Thus, by way of example only, a sensor S1

is at an entry to the shaft 12 from the surface 18. A sensor S2 is positioned in the level

20 extending from the shaft 12 to a first working area 30. A sensor S3 is installed in the

level 22. A sensor S4 is installed in the level 24 which extends to a second working area

34.

[0025] A portable emulsion charging unit 40, which includes a pump 42, is located in the

working area 30. Another portable charging unit 44, which has a pump 46, is in the

working area 34. Each unit 40, 44 is operated by means of a respective operator (not

shown).

[0026] Figure 2 schematically depicts a miner's cap lamp system 48 which includes a

data handling module 50, according to the disclosure.

[0027] The lamp system 48 includes a lamp 52 which, in normal usage, is mounted to a

protective helmet of a miner (not shown). The lamp 52 is powered by means of a battery

54 which, typically, is tied to a belt of the miner. The battery has connections 56 which

enable the battery to be recharged, automatically, after each shift when the cap lamp is

returned to a cap lamp battery system.

[0028] The module 50 includes at least one sensor 58, a processor 60, a memory unit

62 and a transmitter-receiver unit 64.

[0029] Figure 3 depicts, in block diagram form, elements of a data collection system 66

associated with a portable charging unit (40 or 44 as the case may be) and an associated

pump (42 or 46 as the case may be).

[0030] In Figure 3 the pump is labelled 70. Typically the pump 70 is powered by means

of a motive source 72 such as a source of compressed air or a source of pressurised

hydraulic fluid. The pump 70 is designed to pump metered quantities of a base emulsion

and a sensitizer from a supply source 76 and to discharge a resulting mixture 78 into a

usage point (not shown). As may be necessary the supply source 76 is replenished from

a silo or bagged emulsion unit 80.

[0031] If the motive source 72 comprises a source of compressed air or a pressurised

source of hydraulic fluid then, inevitably, the pump 70 or the associated portable charging

unit (40, 42) does not have an independent electrical power supply. In accordance with

one embodiment of the present disclosure an appropriate battery is included in the system

66 for this purpose. In a different form of the disclosure, the pump 70 has an energy

generator 82 which includes a component 84 (see the inset drawing to Figure 3) which is

movable when the pump 70 is operated by the motive source 72. The component 84 may

be rotated or reciprocated. The disclosure provides that, for example, when the

component 84 moves, a coil 86 is caused to pass through a magnetic field created by

magnets 88. Electrical energy produced by the energy generator 82 is fed via a rectifier

90 and a smoothing capacitor 92 to a battery 94 to ensure that the battery 94 is kept fully charged. The battery 94 is used to power a processor 96, a sensor or sensors 98, a memory unit 100 and a transmitter-receiver 102.

[0032] The processor 96 has an on-board time and date keeping system 104. Coupled

to or included in the system 66 is a RFID tag 106. The memory unit 100 is loaded with

reference data 108.

[0033] The sensor or sensors 98 are intended to monitor chosen aspects of operation of

the pump 70. A basic requirement in this respect is to monitor or record the amount of

mixed emulsion delivered by the pump, in use. As the pump 70 is designed to work within

a predetermined degree of accuracy then, by way of example only, it is known that for

each cycle of pump operation a fixed quantity of mixed emulsion is delivered for example

if the pump is a reciprocating pump then for each forward and return stroke, the pump 70

delivers a known quantity of the mixed emulsion. If the number of reciprocating strokes

is counted, for example by means of appropriate limit switches, then the product of the

number of strokes and the volume of emulsion pumped per stroke is easily ascertainable.

The time and date keeping system 104 gives an indication of the time periods during

which the pump is in operation.

[0034] The various sensors S1 to SN, shown in Figure 1, are used to detect the passage

of a pump 70 or, more particularly, of the RFID tag 106, which is associated with the

emulsion charging unit which contains the pump. Information gathered in this respect

can be generated in two ways. Firstly, when the pump 70 is moved past a sensor (S1 to

SN) the sensor can detect the passage of the pump, e.g. by means of an interrogating

signal, and then transmit data pertaining to the sensor to the transmitter-receiver unit 102 in the system 66. In a variation, the sensor (S1 to SN) detects the passage of the pump

70 and, in response to an interrogating signal, sent by the particular sensor, the RFID tag

106 outputs information which identifies the pump, and that information is collected by the

same sensor.

[0035] The various sensors S1 to SN can be coupled by means of any suitable

communication link to a surface location so that on an ongoing basis the position of each

charging unit in the underground mine 10 is known. That information can be validated by

collecting information, stored in the various pumps, and then, at chosen intervals,

transferring that information from each pump to a data collection point.

[0036] The reference data 108, shown in the block diagram in Figure 3, can be included

in each record 110 of information (see Figure 5) assembled in the memory unit 100. The

charging unit or pump can have an identity number 112 and, also, is normally licensed

for use in a particular location. Data 114 pertaining to such licence is included in the

reference data 108. Data 116 identifying the mine in which the charging unit is used, is

recorded. The time and date information, produced by the unit 104, is inserted, when

required, into a field 118 in the record 110. Data 120 relating to the use of the pump, e.g.

the measured volume of emulsion delivered by the pump, or the number of pump cycles

is assembled and updated, as the count of volume delivered increases.

[0037] Data relating to the time and date at which operation of a pump is commenced

and the time and date at which operation of a pump ceases, during each pump cycle say,

from day to day, or date relating to the time and date of information transfer into the record

110 (as described hereinbefore), is stored in a field 122.

[0038] As the pump is moved through the mine 10 data transmitted from each of the

sensors (S1 to SN) which the pump passes, can be collected in a field 124 when can thus

contain a full history of pump movement as recorded by passage of the pump past the

various sensors. The actual location, or working position, of a charging unit, to the extent

that it is not ascertainable from sensor information, can be pre-recorded in a field 128,

and data 130 which identifies the operator who is handling the pump can be pre-recorded.

This data can be obtained by means of an input signal which the miner in question is

required to give to the module 50 via an appropriate keyboard or other input device (not

shown). Alternatively the cap lamp 48 which carries the module 50 is encoded with a

unique identity number and that identity number is held in the memory 62 and transferred,

as appropriate, to the memory unit 100.

[0039] The structure of the record 110 shown in Figure 5 is exemplary and additional

information can be added as may be required, or certain fields can be omitted. By way

of example, environmental factors such as readings of prevailing humidity and

temperature levels at an installation site may be logged.

[0040] Figure 4 illustrates a sequence of operations which relates to the data collection

system of the disclosure.

[0041] Each miner is required after each shift to have the battery 54 of his cap lamp

system recharged at a surface store or location 26 (see Figure 1). When the cap lamp

system is drawn from the store information on the time and date of withdrawal is

generated by the processor 60 and transferred to the memory unit 62.

[0042] The miner, as indicated, may have an identity number which is also stored in the

memory unit 62. As the miner moves through the underground workings the miner passes

some of the sensors S1 to SN. At each sensor data 140 is generated which thus indicates

the position of the miner. That data may be accumulated in the memory unit 62. Thus

the position of the miner is logged at all times.

[0043] Once the miner is in possession of a mobile charging unit or pump at a working

area the miner is in a position to commence operation, generally in the manner which has

been described, for the pumping of the emulsion. Information 142 relating to the working

of the pump 70 is then generated and accumulated in the memory unit 100. Depending

on the nature of the system 66, further information pertaining to the working of the pump,

its position and, optionally, environmental data is generated and recorded. If the emulsion

charging unit is moved past a sensor (S1 to SN) then that event is detected by the

respective sensor and transmitted to surface. Additionally, positional data which identifies

the sensor in question, is transferred to the memory unit 100.

[0044] The charging unit is used in the normal mannerforthe placing of a mixed emulsion

product. Energy which is required for the reading or transmission of data is produced by

the energy generator 82 which ensures, as well, that the processor 96 is kept updated.

[0045] During a working shift the data referred to in connection with Figure 5 is

transferred on an on-going basis to the memory 62 which is associated with the cap lamp

worn by the miner. At the end of a shift the miner returns to surface 144 and engages

the cap lamp with the charging system in the surface store 26. The return data and time

are logged (146).

[0046] The data which is carried in the memory unit 62 is transferred (150) to a data bank

or directly to a user together with the relevant time and date information (146) which

relates to this event.

[0047] With each transfer of data which takes place to the memory 62, whether from a

memory unit 100 or from one or more of the sensors S1 to SN, the accuracy of the data

transfer is confirmed. Thus when data is sent in one direction, a return signal transfers

data in the return direction for validation and correction procedures. Coding and error

rectification techniques known in the art for the transmission of data can be employed, as

appropriate, to minimise errors.

[0048] A benefit of the disclosure lies in the fact that the emulsion charging unit which

carries the pump monitoring system is used in the normal manner. No deviation from

standard operating procedures is required. Data collected during operation of a pump,

stored in the associated memory unit 100, is automatically transferred to the memory 62

in a module 50 when the operator who carries the module 50 with his cap lamp 48 is in

the vicinity of the pump. The miner, upon returning to surface, carries that data with him

and once the cap lamp has been placed into a cap lamp battery bank, the transferred

data is available for use or further transmission etc. at a surface location.

[0049] The data which is collected allows for the reliability of each pump to be

ascertained and for its work cycle to be closely monitored. Maintenance and updating

procedures can be facilitated. If the energy generator system 82 is responsive to pump

movement then no on-board battery is required. It is possible though to place a battery

on the charging unit and thereby dispense with the energy generator.

[0050] The disclosure has been described in the context of the module 50 being

associated with a cap lamp. This is not necessarily the case. Any usable wearable item

such as a watch or body belt may incorporate a device which is an equivalent to the

module 50. Data generated and captured during the use of the module can be transferred

to any chosen destination e.g. an emulsion supplier, a mine official or a regulatory

authority.

[0051] It will be understood that the term "comprise" and any of its derivatives (eg

comprises, comprising) as used in this specification is to be taken to be inclusive of

features to which it refers, and is not meant to exclude the presence of any additional

features unless otherwise stated or implied.

[0052] The reference to any prior art in this specification is not, and should not be taken

as, an acknowledgement of any form of suggestion that such prior art forms part of the

common general knowledge.

[0053] It will be appreciated by those skilled in the art that the disclosure is not restricted

in its use to the particular application described. Neither is the present disclosure

restricted in its preferred embodiment with regard to the particular elements and/or

features described or depicted herein. It will be appreciated that various modifications can

be made without departing from the principles of the disclosure. Therefore, the disclosure

should be understood to include all such modifications in its scope.

Claims (14)

1 A data collection module for use with an emulsion pump for loading an emulsion

explosive into a blast hole, the module including at least one sensor, responsive to

actuation of the pump, to generate data relating to the volume of emulsion explosive

delivered by the emulsion pump, a memory unit in which said data is stored, a power

source and a transmitter, powered by the power source, for transmitting at least said

data to a receiver which is located on a user wearable item, characterised in that

the data collection module includes a RFID tag which, in response to receiving an

interrogating signal which is sent by an environmentally placed sensor upon

detecting proximity of the RFID tag to the environmentally placed sensor, transmits

identity data on the pump to the environmentally placed sensor which upon receipt

of the identity data on the pump transmits the identity data to a surface location via

a communication link to track the position of the data collection module.

2. A data collection module according to claim 1 wherein the RFID tag receives data

pertaining to the environmentally placed sensor and makes the data pertaining to

the environmentally placed sensor available to the transmitter which thereafter

transmits such data together with data relating to the operation of the pump to the

receiver which is located on the user wearable item thereby to allow validation of

the position of the data collection module.

3. A data collection module according to claim 1 wherein the power source is an on

board battery.

4. A data collection module according to claim 1 wherein the power source includes a

generator which is driven by movement of a part of the pump to generate electrical

energy which is stored in a battery.

5. A data collection module according to claim 4 wherein the pump is a reciprocating

pump and upon reciprocating action of a component of the pump, one or more

magnets move relatively to a coil arrangement in order to generate electrical energy.

6. A data collection module according to claim 3 wherein the pump includes a

pneumatically driven electrical generator which produces electrical energy which is

required for charging the battery.

7. A data collection module according to claim 4 wherein the power source includes a

rectifier and a smoothing circuit which processes the electrical output of the

generator and makes it suitable for recharging the battery.

8. A data collection module according to claim 1 which includes a timing mechanism

which generates time and date information relating to operation of the pump.

9. A data collection module according to claim 8 wherein such time and date

information is stored in a memory unit, and is included in data which is transmitted

to the receiver.

10. A data collection module according to claim 1 which includes a processor to control

operation of at least the memory unit, the transmitter, or the at least one sensor.

11. A data collection module according to claim 1 wherein the user wearable item is a

cap lamp or a wrist watch.

12. A combination which includes a data collection module according to claim 1, said

user wearable item and a data handling module which includes a memory unit, a

power source and a first transmitter-receiver module, powered by the power source,

for receiving and transferring the data which is sent from the transmitter of said

collection module to the memory unit.

13. A combination according to claim 12 which includes a second transmitter-receiver

unit which interrogates and receives data transmitted by the first transmitter-receiver

module from the memory unit of the data handling module.

14. A combination according to claim 12 or 13 wherein the user wearable item is a cap

lamp or a wrist watch.