Productivity monitoring in machines that reduce or separate materials

Abstract

A method of operating a material reduction or separation machine includes operating the machine with power from a power system to produce a stream at a material outlet. A volume of the stream at the material outlet is monitored as a consumption of the power system from operation of the material reduction or separation machine. A productivity measure is calculated at an on-board controller of the material reduction or separation machine as unit volume per unit consumption. The productivity measure is displayed on an operator display during operation of the material reduction or separation machine to produce a stream at the material outlet.

Description

[Technical field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims the benefit of priority to co-pending U.S. Provisional Patent Application No. 63 / 335,395, filed April 27, 2022, the entire contents of which are incorporated herein by reference. [Background technology]

[0002] The present invention relates to mobile processing machines such as grinders or material separators (e.g., screening machines such as rotary trommels). Grinders and separators receive a load or stream of input material and then process the material to produce one or more output streams. These machines may have many adjustable operating parameters or configurations and are primarily controlled by human operators who must use their knowledge and control the machine to achieve various performance metrics such as production rate, efficiency, etc. These machines include operator control stations with detailed displays that allow the operator to monitor several parameters. However, it is still difficult for the operator to observe all of the available data and adjust their control strategies for the desired performance or for the operator to know how close the current performance is to optimal. Furthermore, the machines may be operated by several different operators. Manufacturer suggestions for machine setup and control strategies, along with some automatic control programs, can be helpful in at least avoiding poor performance. Summary of the Invention [Means for solving the problem]

[0003] In one aspect, the present invention provides a mobile processing machine, such as a grinder or material separator, and a method of operation that provides an operator with a dynamic learning experience to control the productivity of the machine while in use in the field. This can be accomplished in some aspects by providing the operator with a real-time display of productivity measures in terms of volume of output material per unit consumption.

[0004] The productivity measures on the display may change in real time and respond to changes made by the operator to the machine's operating settings or configurations in a manner that indicates the impact of the operator's changes on productivity directly to the operator via the display.

[0005] In another aspect, the invention provides a method of operating a material reduction or separation machine, comprising operating the machine with power from a power system to produce an outlet stream of material. The volume of the outlet stream of material is monitored as a function of power system consumption from operation of the material reduction or separation machine. A productivity measure is calculated at an on-board controller of the material reduction or separation machine as unit volume per unit consumption. The productivity measure is displayed on an operator display during operation of the material reduction or separation machine to produce an outlet stream of material.

[0006] In another aspect, the present invention provides a material reduction or separation machine including a power system and a processing unit operable by the power system to process material fed into the material reduction or separation machine. An exit conveyor is configured to receive processed material from the processing unit. A first sensor is operable to monitor a volume of material along the exit conveyor. A second sensor is operable to monitor consumption of the power system from operation of the material reduction or separation machine. An on-board controller of the material reduction or separation machine is in communication with the first sensor and the second sensor and is programmed to calculate a productivity measure as unit volume per unit consumption from data provided by the first sensor and the second sensor. An operator display is in communication with the controller and configured to display the productivity measure during operation of the processing unit.

[0007] In yet another aspect, the present invention provides a method of operating a machine for reducing or separating materials. A processing unit of the machine for reducing or separating materials is operated with power from a power system for a first duration to create a flow at an outlet of the material, the processing unit having a first replaceable component. The first replaceable component is detected with an on-board RFID reader. During the first duration, a volumetric productivity of the processing unit per unit consumption of the power system is monitored and displayed with a controller and a display. Operation of the processing unit is stopped and the processing unit is modified to include a second replaceable component in place of the first replaceable component. The second replaceable component is detected with an on-board RFID reader. The processing unit is operated with the second replaceable component installed for a second duration. During the second duration, an updated volumetric productivity measure per unit consumption is monitored and a contrast between the volumetric productivity of the first duration and the updated volumetric productivity of the second duration is displayed. [Brief description of the drawings]

[0008] [Figure 1]FIG. 1 is a perspective view of a rotary screening trommel machine for material separation according to one embodiment of the present disclosure. [Diagram 2] FIG. 2 is a perspective view of a screen drum assembly of the rotary screening trommel machine of FIG. [Diagram 3] FIG. 3 is a perspective view of one removable screen of the screen drum assembly of FIG. 2. [Figure 4] FIG. 2 is a perspective view of a material exit conveyor of the rotary screening trommel machine of FIG. 1 including a lidar sensor configured to detect the volume of output material. [Diagram 5] FIG. 5 is a detailed view of the lidar sensor of FIG. 4. [Figure 6] FIG. 1 is a perspective view of a horizontal grinder according to one embodiment of the present disclosure. [Figure 7] FIG. 7 is a detailed view of a portion of the horizontal grinder of FIG. 6 with a portion of the housing removed to show its grinding mechanism. [Figure 8] FIG. 8 is a side elevational view of a portion of the horizontal grinder of FIG. 7. [Figure 9] FIG. 7 is a perspective view of a removable screen of the horizontal grinder of FIG. [Figure 10] FIG. 1 is a perspective view of a tab grinder according to one embodiment of the present disclosure. [Figure 11] 10 is an exemplary display configuration for an operator control station display for either the rotary screening trommel of FIG. 1, the horizontal grinder of FIG. 6, or the tub grinder of FIG. [Figure 12] 10 is an exemplary operator control panel for either the rotary screening trommel of FIG. 1, the horizontal grinder of FIG. 6, or the tab grinder of FIG. [Figure 13] 1 is an exemplary graph of productivity versus time for an operator control station display in which the graph plot represents productivity loss over time due to component wear. [Figure 14] 1 is an exemplary graph of productivity versus time for an operator control station display where the graph plot represents the productivity difference between operators. [Figure 15] 1 is an exemplary graph of productivity versus time for an operator control station display where the graph plots represent productivity changes due to input material changes and due to machine parameter / component changes. [Figure 16] 1 is an exemplary graph of productivity versus time for an operator control station display where the graph plot represents productivity changes due to multiple changes in machine parameters / components. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0009] Before describing any embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings, as the invention is capable of other embodiments and of being practiced or carried out in various ways.

[0010] FIG. 1 shows a rotary screening trommel machine 100 for material separation, or simply "screening machine 100". The screening machine 100 can have basic functions and features consistent with conventionally known machines, in addition to one or more features that are the subject of this disclosure. Conventional features of the rotary trommel 100, also briefly addressed herein, can be found in U.S. Pat. No. 10,118,197 or U.S. Patent Application Publication No. 2018 / 0340593, both of which are incorporated herein by reference in their entirety. The screening machine 100 can be a mobile machine configured to be towed by a vehicle to one or more work sites. Thus, the screening machine 100 can include a trailer support device having wheels 102 for ground support and a hitch 103 configured to be attached to a towing vehicle. Alternatively, the screening machine 100 can be self-propelled, including a ground drive system, such as a set of tracks, that allows the screening machine 100 to be self-propelled around the work site. The screening machine 100 has an on-board power system 104, a rotating trommel screen 106 or "screen drum," an entrance conveyor 108, an exit conveyor 110, a front side conveyor 112, and a rear side conveyor 114. The screening machine 100 is configured to separate the agglomerated material into separate component products (e.g., based on component sizing) that are delivered via the exit conveyor 110 and the side conveyors 112, 114. As will become apparent from the description below, the side conveyors 112, 114 are "fine" conveyors configured to receive relatively small component sized material, and the exit conveyor 110 is an "overs" conveyor configured to receive relatively large component sized material.

[0011] The power system 104 provides power to the screening machine 100 during operation. In some examples, the power system 104 includes an internal combustion engine. In some examples, the power system 104 is an electric powered system. In some examples, the power system includes a fuel cell, such as a battery. In some embodiments, the engine is a diesel engine. Additionally, the power system 104 includes a hydraulic system. In some embodiments, the power system 104 and the screening machine 100 can be operated in their entirety, remotely, or by a control panel 130 that can be operated by a human operator and communicates with the power system 104. The control panel 130 forms part of the screening machine 100 and can be built-in (e.g., integrated and hardwired) or removable (e.g., removable and configured to communicate wirelessly). In particular, the control panel 130 can be or include any one or combination of a touch screen, a remote control (e.g., having a touch screen or other input selector), or a display with corresponding physical inputs such as buttons, switches, etc. Figure 5 illustrates diagrammatically the on-machine control panel 130 including an operator control unit 133 and a display portion 130A. An additional remote control unit 135 is shown separately in Figure 5, which may have some or all of the same control functions as the on-machine control panel 130. Similarly, it will be appreciated that the power system 104 may be self-contained and thus transported on the trailer support apparatus, or alternatively may be remote, for example, in the form of a pulling vehicle engine (e.g., a hydraulic connection to the pulling vehicle engine which may provide driving force to power the screening machine 100).

[0012] The rotating trommel screen 106 is configured to receive and filter the agglomerated material. The rotating trommel screen 106 includes an inlet 116, an outlet 118, and a number of screen sections 120. In some embodiments, the rotating trommel screen 106 is generally cylindrical. The rotating trommel screen 106 has an overall length measured from the inlet 116 to the outlet 118. In general, the rotating trommel screen 106 is configured to separate smaller materials from larger materials just prior to the inlet 116, and the larger materials are removed just prior to or from the outlet 118. During operation, the rotating trommel screen 106 rotates about its longitudinal axis, which causes the contained material to be agitated and sieved by the rotating trommel screen 106. Additionally, in some embodiments, the rotating trommel screen 106 is mounted such that the rotating trommel screen 106 slopes downwardly from the inlet 116 to the outlet 118. Such a slope encourages the material to move from the inlet 116 to the outlet 118 during operation. Brushes 126 may be provided along the outer surface of the rotating trommel screen 106, for example at a fixed upper position, for blowing or brushing the exterior of the rotating trommel screen 106 as it rotates.

[0013] The inlet 116 of the rotary trommel screen 106 is configured to receive the agglomerated material. In some embodiments, the agglomerated material may be fed to the inlet 116 of the rotary trommel screen 106 by the inlet conveyor 108. The material may be introduced to the inlet conveyor 108 via a material hopper 124. In other embodiments, the material may be fed to the inlet 116 directly by the material hopper 124 without the inlet conveyor 108. The outlet 118 of the rotary trommel screen 106 is configured to provide an opening for material that is not removed from the rotary trommel screen 106 by passing through the screen portion 120 ("oversized material"). The outlet conveyor 110 is configured to move the material received from the outlet 118 of the rotary trommel screen 106 to a discharge location away from the screening machine 100. In the embodiment shown, the outlet conveyor 110 is positioned longitudinally relative to the rotary trommel screen 106. In some embodiments, the entrance conveyor 108 and the exit conveyor 110 are belt conveyors. The exit conveyor 110 can have various operating positions. The exit conveyor 110 can also be folded and stored over the screening machine 100 in a storage position. When in the storage position, the screening machine 100 can be transported. The side conveyors 112, 114 can be similarly configured.

[0014] As shown in FIG. 2, the rotary trommel screen 106 is in the shape of a hollow cylinder or drum and can be composed of multiple screen sections 120. At a longitudinal end having an inlet 116, the rotary trommel screen 106 includes a drive sprocket 128 configured to be driven by the power system 104 to rotate the rotary trommel screen 106. As shown, each screen section 120 forms a 180 degree semicircle such that each longitudinal section of the rotary trommel screen 106 (of which there are four in the illustrated embodiment) is composed of a pair of screen sections 120. All of the screen sections 120 can be identical to one another so as to be interchangeable, and one exemplary screen section 120 is shown in FIG. 3. Two opposing, longitudinally extending ends 132 (e.g., flanged ends) of the arcuate screen sections 120 can be configured to fasten or otherwise secure to a portion of a drum frame 134 (FIG. 2) of the rotary trommel screen 106.

[0015] 4 and 5, the screening machine 100 includes a scanner in the form of a lidar sensor 140, otherwise known as a laser profiler, along the exit conveyor 110. In one non-limiting example, the lidar sensor 140 can be a Bulkscan® LMS511-20190 flow sensor from SICK AG of Waldkirch, Germany. The lidar sensor 140 is mounted in an upward position and aimed at the material receiving surface 142 of the exit conveyor 110. According to the illustrated embodiment, the lidar sensor 140 is supported on a generally triangular bracket 144 positioned at the exit end of the exit conveyor 110. However, in other configurations, the lidar sensor 140 can be positioned further upstream. Additionally, the lidar sensor 140 can be mounted on or adjacent to the exit conveyor 110 in other ways, such as on a separate arm. Bracket 144 centers lidar sensor 140 along the width W of exit conveyor 110. Lidar sensor 140 is configured to view the entire width of material receiving surface 142. Thus, during operation, lidar sensor 140 is supported on exit conveyor 110 and has a complete view of material conveyed thereby. Lidar sensor 140 is an example of a production volume sensor.

[0016] The side conveyors 112, 114 can be configured with a lidar sensor 140 similar to that of the exit conveyor 110 described above. Thus, the screening machine 100 is configured to measure the total material output (volume ratio) from the rotating trommel screen 106, including both the "fines" passing through the screen portion 120 to the side conveyors 112, 114 and the "overs" exiting the rotating trommel screen 106 through the exit 118. The lidar sensor 140 is connected for data communication with a controller 150, as shown diagrammatically in FIG. 5. In some configurations, the controller 150 can be embedded or incorporated into a rugged PC on the machine 100. The controller 150 is also connected for data communication with the power system 104 and the control panel 130. In some configurations, the controller 150 communicates with the power source 104 (e.g., an internal combustion engine) via a CAN bus protocol. This communication may include data provided to the controller 150 regarding consumption (e.g., fuel consumption) by the power system 104. For example, the power system 104 may include a sensor 105 (e.g., fuel flow) configured to measure the power system consumption. If the power source 104 is instead a power source, the sensor 105 may measure consumption (i.e., power consumption in kilowatt-hours or joules). In some embodiments, the controller 150 may calculate or convert the power consumption to an alternative unit, such as kWh. Along with the consumption data, the controller 150 also tracks the volumetric output of the screening machine 100 via the lidar sensor 140, and the controller 150 is programmed to calculate a productivity measure as unit volume per unit consumption. Although time may be taken into account when creating the productivity measure (e.g., calculating via a current volume rate and a current consumption rate), the productivity measure is not a rate measure. In other words, the productivity measure does not inherently increase with faster volume rate production on the conveyors 110, 112, 114. In fact, productivity measures may decline if consumption increases more dramatically than volumetric output rates.Productivity measures are therefore measures of overall efficiency that measure total output against the consumption required to produce that output.

[0017] The controller 150 communicates with the control panel 130 (e.g., its display screen 130A) during operation of the screening machine 100 and displays the productivity measures for the operator to view. The productivity measures can be displayed to the operator in real time. In some configurations, the productivity measures can also be stored and / or downloaded. The controller 150 can include one or more electronic processors and one or more memory devices. The controller 150 can be communicatively connected to one or more sensors or other inputs, such as those described herein. The electronic processor can be implemented as a programmable microprocessor, an application specific integrated circuit (ASIC), one or more field programmable gate arrays (FPGAs), a group of processing components, or with other suitable electronic processing components. The memory device (e.g., a non-transitory computer-readable medium) includes one or more devices (e.g., RAM, ROM, flash memory, hard disk storage, etc.) for storing data and / or computer code for completing or facilitating various processes, methods, layers, and / or modules described herein. The memory device may include database components, object code components, script components, or other types of code and information to support the various activities and information structures described herein. According to one example, the memory device may be communicatively connected to an electronic processor and include computer code for performing one or more processes described herein. The controller 150 may further include an input-output ("I / O") module. The I / O module may be configured to directly interface with one or more devices, such as a power source, a sensor, a display, etc. In one embodiment, the I / O module may utilize a general purpose I / O (GPIO) port, an analog input / output, a digital input / output, etc.

[0018] With respect to FIG. 5, it should be noted that the components in this schematic may have internal / integrated controller and / or memory functions. The functions or operations of the controller 150 may be centralized or distributed among multiple physical controllers (e.g., chips or microprocessors), generally referred to herein as “controllers 150” for simplicity. For example, the scanner 140 may include an integrated controller and memory. The scanner 140 may connect with the controller 150 via Ethernet. The encoder 168 is used to determine the conveyor speed and is connected to the scanner 140 (e.g., directly as opposed to being connected to the controller 150). The operator control unit 133, the display 130A, and / or the remote control 135 may have buttons, touch screens, controls, switches, etc., to adjust machine and display settings. The telematics control unit (TCU) 170 may transmit and / or receive data from an external source 172, such as an office or cloud-based storage system. The ability of the TCU 170 to transmit or receive data may depend on connectivity to cellular service / external sources 172. When the TCU 170 is in a state where it cannot transmit or receive data (no cellular service), the data is stored in a memory device on the machine. The fuel data may be provided from the TCU 170 to the controller 150 in some configurations.

[0019] Before returning to discuss additional detailed features related to the productivity measures, reference is first made to Figures 6-9 for the horizontal grinder 200 and Figure 10 for the tub grinder 300, each of which can be configured to calculate and display productivity measures, similar to the screening machine 100. Each different type of machine has a different type of material handling unit for reducing or screening the material provided to the machine.

[0020] As shown in Figures 6-9, the horizontal grinder 200 includes many general similarities with the screening machine 100, but is recognized as two different types of material processing machines that differ in the way they convert input materials into processed output materials. The horizontal grinder 200 can have basic functions and features consistent with conventionally known machines, in addition to one or more features that are the subject of this disclosure. Conventional features of the horizontal grinder 200, also briefly addressed herein, can be found in U.S. Pat. No. 9,192,964 or U.S. Pat. No. 9,254,492, both of which are incorporated herein by reference in their entirety. The horizontal grinder 200 can be a mobile machine configured to be towed by a vehicle to one or more work sites. Thus, the horizontal grinder 200 can include a trailer support device having wheels 202 for ground support and a hitch configured to be attached to a towing vehicle. Alternatively, the horizontal grinder 200 can be self-propelled, including a ground drive system, such as a set of tracks, that allows the horizontal grinder 200 to be self-propelled around a work site. The horizontal grinder 200 has an on-board power system 204, a grinding mechanism 206, an inlet conveyor 208, and an outlet conveyor 210. The horizontal grinder 200 is configured to break down or reduce the input material into smaller pieces or "chips" that are discharged via the outlet conveyor 210. The power system 204 provides power to the horizontal grinder 200 during operation. The power system 204 can take a variety of forms as described with respect to the screening vehicle power system 104, including an internal combustion engine. In some embodiments, the power system 204 and the horizontal grinder 200, in their entirety, can be operated by a control panel (not shown) that can follow the general description of the control panel 130 above.

[0021] The grinding mechanism 206 is configured to receive the material to be reduced from a horizontally extending inlet conveyor 208. Additionally, the upper feed roller 216 can cooperate with the inlet conveyor 208 to transport the material to a material reduction chamber including a rotating component 218 or drum to which a number of chipping knives 226 are fixed. The upper feed roller 216 can be mounted on a movable arm 216A that pivots at 216B to adjust the pressing force on the material between the upper feed roller 216 and the inlet conveyor 208. The rotating component 218, which can be driven by the power system 204 to rotate about a horizontal axis, operates to press the knives 226 against a fixed anvil to reduce the material into smaller pieces. One or more screen sections 220 having sizing openings that selectively allow the passage of reduced material from the material reduction chamber to the outlet conveyor 210 partially surround the rotating component 218. The exit conveyor 210 may include one or more belt sections operable to remove the reduced volume material from the grinder 200. Although not shown, the exit conveyor 210 may be configured like the exit conveyor 110 of the screening machine 100 to include a lidar sensor 140, the functionality of which generally corresponds to that described for the screening machine 100. In other words, the lidar sensor 140 is mounted in an upper position, aimed at the material receiving surface of the exit conveyor 210, and in data communication with the controller to track the volumetric output of the horizontal grinder 200. As described in the previous embodiment, the controller is programmed to calculate the productivity measure as unit volume per unit consumption.

[0022] As shown in FIG. 10, the tub grinder 300 includes many general similarities with the screening machine 100 and the horizontal grinder 200, but is recognized as two different types of material processing machines that differ in the way they convert input materials into processed output materials. The tub grinder 300 can have basic functions and features consistent with conventionally known machines, in addition to one or more features that are the subject of this disclosure. Conventional features of the tub grinder 300, also briefly addressed herein, can be found in U.S. Pat. No. 9,505,007, the entire contents of which are incorporated herein by reference. The tub grinder 300 can be a mobile machine configured to be towed by a vehicle to one or more work sites. Thus, the tub grinder 300 can include a trailer support device having wheels 302 for ground support and a hitch configured to be attached to a towing vehicle. Alternatively, the tub grinder 300 can be self-propelled, including a ground drive system, such as a set of tracks, that allows the tub grinder 300 to be self-propelled around the work site. The tub grinder 300 has an on-board power system 304, a grinding mechanism 306, and an exit conveyor 310. The tub grinder 300 is configured to comminute or reduce input material into smaller pieces or "chips" that are discharged via the exit conveyor 310. The power system 304 provides power to the tub grinder 300 during operation. The power system 304 can take a variety of forms as described with respect to the screening machine power system 104, including an internal combustion engine. In some embodiments, the power system 304 and the tub grinder 300, in their entirety, are operable by a control panel (not shown) that can follow the general description of the control panel 130 above.

[0023] On the tub grinder 300, the material is introduced into the grinding mechanism 306 via a rotating tub 316 rotatable about a vertical axis. At the bottom of the rotating tub 316 is a floor 328 with an opening through which the rotating component or drum is partially exposed. A plurality of hammers with corresponding cutters are fixed to the rotating component. The rotating component, which can be driven by a power system 304 to rotate about a horizontal axis, operates such that the combined action of the rotation of the tub 316 and the rotation of the rotating component reduces the material into smaller pieces. Partially surrounding the rotating component are one or more screen sections with sizing openings that selectively allow the passage of reduced material from the material reduction chamber to the exit conveyor 310. As shown on the left of FIG. 10, the exit conveyor 310 can be configured like the exit conveyor 110 of the screening machine 100 to include the lidar sensor 140, and its functions generally correspond to those described for the screening machine 100. In other words, the lidar sensor 140 is mounted in an upper position and aimed at the material receiving surface of the exit conveyor 310 and is in data communication with the controller to track the volumetric output of the tub grinder 300. As described in the previous embodiment, the controller is programmed to calculate a productivity measure as unit volume per unit consumption.

[0024] 11 and 12, the control panel 130 (for any one of the screening machine 100, horizontal grinder 200, tub grinder 300, or any number of additional material processing machines such as industrial chippers or crushers) is shown in further detail. In particular, FIG. 11 shows an exemplary display representation for a display portion 130A of the control panel 130. One or more gauges (e.g., yd 3 / hour volume rate, and yd 3In addition to the units of volume, the display portion 130A is controlled by the controller 150 to display the production data in tabular form on the right. In configurations where the machine has more than one conveyor configured to receive processed material, the production data table can be conveyor specific and the display portion 130A can be cycled to change the production data table to correspond to a conveyor. In some configurations, the data table can represent production data from multiple conveyors, up to and including all of the conveyors receiving processed material. The top row of data is displayed in units of volume (e.g., yd 3 ) total production. This data can be parsed to show key-on total production, job total production, and life total production separately. The next data line corresponds to a total volume / time unit (e.g., yd 3 This data can be parsed to show separate key-on, job, and life production rates. The next data line corresponds to the unit volume per unit consumption (e.g., yd 3 / gal.) productivity. This data can be parsed to display key-on productivity, job productivity, and life productivity separately. Aspects of the present disclosure may also encompass configurations or embodiments where the volumetric input of material fed into the machine is known. When known, that volumetric input can be compared to the volumetric output of material. This can be useful for calibrating sensors and determining the fraction of material. For example, in a trommel with multiple discharge conveyors, the percentage of the total input leaving each conveyor can be determined.

[0025] As noted above, the data can be configured to be updated in real time, or at least during ongoing or in-progress material processing operations, for operator observation during use. In some configurations, the data is updated with virtually no delay (i.e., only the delay required for the computer to process the data) to provide immediate feedback. On the other hand, updating at pre-determined timing intervals can establish consistent material flow, resulting in smooth and reliable data representation. In some configurations, the data update interval is 1 to 10 minutes. In some configurations, the data update interval is 10 to 20 minutes. In some configurations, the data update interval is 20 to 30 minutes. Thus, an operator can observe the impact on productivity after manual changes to the machine's operating settings or configuration. In some situations, the operating settings can be changed in-situ, for example, to adjust the feed rate of input material or to adjust the operating speed of a processing mechanism, such as a rotating trommel screen or a rotating crushing or crushing component. However, an operator can also gain useful insight by noting the productivity values ​​during one period of operation compared to another subsequent period of operation when the machine's physical configuration is changed mid-way. One such example is a screen change (e.g., screen portion 120, 220), e.g., replacing a screen portion with an alternative screen portion having openings of different sizes. At the time of machine reconfiguration outages, one or more knives or cutters may also be replaced. In other situations, an operator may simply be replaced by another operator without any physical changes to the machine. The subsequent operator may change one or more control parameters for operating the machine and may achieve a different productivity measure. Individual periods of machine use may also vary depending on the type of material fed to the machine, resulting in a change in productivity that is displayed to the operator. Real-time productivity feedback allows the operator to know the effect of various changes and allows the operator to further adjust towards optimizing productivity, if that is the desired objective.

[0026] In addition to simply displaying numerical values ​​as in FIG. 11, graphical productivity information can be provided by the controller 150 and displayed on the control panel 130. Such information can also be stored in memory and / or transmitted (e.g., via wireless communication) to another device for viewing. FIGS. 13-16 show several specific examples of graphical productivity displays, each of which corresponds to a different specific scenario. In FIG. 13, the plot of productivity versus time starts at a high, consistent level, which corresponds to the beginning of a component life cycle (e.g., cutter, knife, screen) on the machine. As time progresses with continued operation of the machine, productivity begins a visually observable decline. In this case, the decline starts at a low rate and then the rate of decline increases. Thus, an operator can visually observe the effect of worn components on productivity. The operator can determine when during the decline to stop operation and replace components. In FIG. 14, the plot of productivity versus time starts at a first level, which corresponds to control of the machine by a first operator. At a particular time, there is an operator change from a first operator to a second operator. Other aspects of the machine may remain the same (e.g., type of material input, component configuration of the machine). The operator change may include stopping operation of the machine as indicated by productivity trending towards zero for a period of time. In other configurations, the operator may be changed in place. In either case, from the operator change time onwards, the productivity plot will continue to display the productivity of the first operator next to the productivity of the second operator, giving the operator an opportunity to compare productivity between the operators. In this way, operators who are less skilled at optimizing the productivity of the machine can be identified and further trained.

[0027] The system may be configured for one or both of the following options: The first option is manual comparison by an operator, where the user can compare changes (e.g., operator changes, machine component changes, setting changes, etc.) between different operating scenarios. The second option is for a computer program (on-board or external) to compare results for durations from different operating scenarios. Alarms can be set, which can be preset and adjustable, to notify the operator if productivity levels are within or outside a certain range.

[0028] In FIG. 15, the plot of productivity versus time begins at a first level corresponding to a machine processing a first material. During a first period, the first material continues to be processed and the machine's operating parameters and physical configuration are maintained and not adjusted. At a particular time, there is a change from the first material to a second material, as shown in FIG. 15. The productivity plot tracks the change in productivity directly attributable to the material change and gives the operator an opportunity to compare productivity between the first and second materials. For example, the operator may observe a drop in productivity due to the second material being processed with the initial machine settings. After processing the second material for a period of time, the operator may adjust the machine (operating parameters, or physical configuration via component changes) in an attempt to increase the productivity value, for example. Machine operation may be stopped by the operator, as indicated by a short period of zero productivity, or changes may be made in situ. As indicated by the final period on the plot of FIG. 15, the changes made have resulted in increased productivity above the first and second productivity values. The operator may choose to make multiple adjustments at once, but it is also possible to make two or more sequential adjustments, one at a time, so that the direct results of each can be seen in terms of productivity effect. In FIG. 16, the productivity plot shows an operating time elapsed including three machine changes made by the operator (e.g., with optional respective stops in between). From the initial productivity, the first change results in a slight productivity increase. The second change results in a productivity decrease, in this case even less than the initial productivity. The third change results in a productivity increase that exceeds the productivity value after the first change.

[0029] With reference to FIG. 12, the control panel 130 provides a number of operator input selectors (e.g., buttons, or levers, dials, sliders, etc.) to change the operating parameters of the screening or material reduction machine. In other words, this allows the operator to change the adjustable settings of the machine from one setting to a different setting. The input selectors can provide one or more preset modes. In particular, input selectors 1-4 can correspond to four different factory preset modes. The preset modes, which may correspond to different material types, can reduce or eliminate the need for the operator to make individual control selections. Additional input selectors in the operator control unit 133 are configured to allow the operator to control individual operating parameters for the machine. Specific examples for some of the machine types disclosed herein are provided below. All of those disclosed modes and details are non-limiting examples.

[0030] For the screening machine 100, there may be material preset modes that provide multiple (e.g., four) combinations of machine functions and speed settings available for screening different types of materials. These preset modes are programmable and adjustable to allow customization for screening different types of products. The same may be true for other types of screening machines or grinders (e.g., horizontal grinder 200 and tub grinder 300). The operator may switch from one material preset to another during operation. The various presets may be modified by the operator (e.g., based on observed productivity increases) and saved in their modified state for future use. The drum may be reversed as needed (used only when the screen stalls, which is rarely done). It is also possible to choose between the remote control 135 and the ground station control 130. Values ​​displayed on the display 130A may include: Preset engine speed (per selected mode): displays range of 1000~2400 rpm Presets drum forward speed (per selected mode): displays range 0 to 22 rpm in 0.5 rpm increments. Speed ​​setting applies to forward direction in normal operation. Presets the Hopper Conveyor forward speed (per selected mode): displays a range of 0 to 18 fpm (feet per minute) in increments of 0.5 fpm. The speed setting applies to the forward direction in normal operation. Preset oversize and rear fines conveyor speeds (per selected mode): displays range from 10 to 100% in 10% increments. Speed ​​settings apply to the forward direction in normal operation. Drum Pressure (per selected mode): Displays a range of 8963-19,995 kPa (1300-2900 psi) in 690 kPa (100 psi) increments. This setting will stop the hopper conveyor when the pressure in the drum hydraulic circuit reaches the set value for 3 seconds. This acts as a smart feed control and helps avoid drum stalls. This setting is used in conjunction with the "Hopper Conveyor Restart" feature. (Hopper Conveyor Restart selects the pressure change required in the drum to allow the hopper conveyor to return to forward motion after it has been stopped due to the drum pressure reaching its maximum setting. The range is 690 to 3,447 kPa (100 to 500 psi) in increments of 690 kPa (100 psi). For example, if the drum pressure is set to 10,342 kPa (1500 psi) on the main display and the Hopper Conveyor Restart Pressure is set to 1,379 kPa (200 psi), the hopper conveyor will stop when the drum pressure reaches or exceeds 10,342 kPa (1500 psi) for three consecutive seconds. It will restart when the drum pressure drops below 8963 kPa (1300 psi). Preset Front Fine Conveyor / Auxiliary (per selected mode): Displays a range of 10-100% in 10% increments if a front fine or auxiliary circuit is present. Current Engine Speed: Displays the current engine rpm. Allows comparison of the actual / current engine speed compared to the preset engine speed (first bullet point above).

[0031] For the horizontal grinder 200, the control panel 130 may allow adjustment of the infeed control as follows: Auto Feed On / Off - When active (A), shown on the display with "S" Smart Grind or "Rev" (Auto Reverse). Auto Feed grind mode will be the default grind mode currently selected. For Smart Grind control operation (such as Grind Mode 3 below), the feed rollers and infeed conveyor will change engine speed, will stop feeding material when the engine RPM drops below the preset droop, and will automatically restart when the engine speed exceeds the droop speed. If Auto Reverse is active (such as Grind Modes 1 and 2 below), the infeed speed will remain constant until the engine drops below the droop speed (or until a predictive algorithm is met). The infeed will then reverse for a period of time (e.g., adjustable / programmable) or until the engine returns to droop speed. In some configurations, this period may be 0.5 to 2 seconds. In some configurations, this period may be 2-5 seconds. In still other configurations, this period may be 5-10 seconds. Feed will resume forward motion as soon as engine speed is restored. Suggested auto feed modes are as follows: Select Auto Reverse (such as Grinding Modes 1 and 2 below) for grinding large, heavy items or when material is difficult to feed into the mill. This non-proportional plunging mode grinds large, heavy items more efficiently by keeping material away from the cutting action until the mill is back up to speed between each feed cycle. Select SmartFeed (grinding mode 3) to regrind. This proportional feed mode maintains a steady feed. When adjusting, feed roller and infeed conveyor speeds of approximately 100% are suggested as a good initial setting to achieve an efficient grinding operation. Adjust the speeds up or down in 5% increments until the optimum efficiency is determined.

[0032] Auto Feed has an automatic feature that will reverse the feed rollers and feed table if either exceeds its maximum operating pressure for a specified time. An infeed stall message will be shown on the display. If the infeed conveyor stalls due to maximum pressure, the infeed will reverse and show a message on the display. Auto Feed will operate the feed rollers and feed conveyor in forward motion, increase engine speed to high idle (approximately 2030 rpm), lower the charge defector, start the discharge conveyor, and engage the clutch to allow the power source to rotate the rotor / drum / cutter. Auto Feed Grind Modes 1-3 are factory defaults but can be changed if desired. Crush Mode 1 (Aggressive Crush) Default Settings: Droop speed: 1600 rpm Supply Type: Automatic Reversing Feed table speed: 100% Supply roller speed: 100% Crushing mode 2 (general crushing) default settings: Droop speed: 1700 rpm Supply Type Automatic Reversal Feeding table speed: 70% Supply roller speed 83% Crushing mode 3 (re-crushing) default settings: Droop speed: 1700 rpm Supply Type:Smart Supply Feed table speed: 100% Supply roller speed: 83%

[0033] By pressing button 4, values ​​for droop, feed table, feed roller speed, and auto feed type can be adjusted: Droop speed: 1400-1800 rpm, feed table speed: 10-100%, feed roller speed: 10-100%, feed type: smart feed or auto reverse. From the above options, it can be seen that choosing the correct machine option can be important for efficient operation. Additionally, buttons on the operator control unit 133 allow manual adjustment of the following controls and can override some aspects of the auto mode discussed above: Feed roller forward / reverse switch - manual control of the feed roller rotation in forward or reverse direction; Feed roller up (crushing), down switch, and feed roller lock switch - manual control of the feed roller up and down (crushing force). The "auto feed" setting can affect the feed roller control switch. Applying downward pressure to the feed roller can help draw material into the mill / drum. The infeed conveyor control allows the infeed conveyor to move in a forward or reverse direction. The discharge conveyor speed can be adjusted.

[0034] For the tub grinder 300, the controls can be similar to the horizontal grinder 200, but there is no infeed conveyor or infeed roller control, since there is instead a rotating tub with speed control. The parameters are as follows: Auto feed type: Stop, Reverse, or Smart Stop - The tub rotation speed will remain constant until the engine drops below droop speed. The rotation will resume forward motion as soon as engine speed recovers. Reverse - Tub rotation speed will remain constant until the engine drops below droop speed. Rotation will then reverse for 2-5 seconds (adjustable / programmable) or until the engine returns to droop speed. Rotation will resume forward motion as soon as engine speed recovers. Smart - Tub rotation speed will vary with engine speed and will stop feeding material when engine RPM drops below a preset droop and will automatically restart when engine speed exceeds the droop speed. Droop speed: 1400~1800rpm (high idle approx. 2030rpm) Tab Speed: 0~100%

[0035] Auto-feed modes for the tub grinder 300 can include: Crushing mode 1 (aggressive crushing) Automatic supply type: Automatic stop (stop) Droop speed: 1400 rpm Tab speed: 90% Crushing mode 2 (general crushing) Automatic feed type: Automatic reverse (reverse) Droop speed: 1400 rpm Tab speed: 60% Grinding mode 3 (re-grinding) Automatic supply type: Smart supply (Smart) Droop speed: 1400 rpm Tab speed: 35%

[0036] Although not explicitly shown, aspects of the present invention may be applied to processing machines other than those explicitly shown in the drawings. These may be different types of processing machines, such as modifications or improvements to trommels or grinders, or slow speed crushers, an example of which is provided in U.S. Patent No. 11,484,886 to Vermeer Manufacturing Co., the entire contents of which are incorporated herein by reference.

[0037] Processing machines (such as tub grinders, horizontal grinders, trommels, and / or crushers) have multiple screen configurations, all resulting in different efficiencies and yields depending on the type of material being reduced and the desired characteristics of the output product (chip size and shape). Output product characteristics may change as parts wear, which may result in undesirable and / or unusable output. Using worn components (screens) may result in a change in efficiency of the processing machine. Additionally, changing screen types may result in a more desirable output product and / or improved efficiency of the processing machine. In one aspect, each of the machines disclosed above may optionally incorporate a component identification system. The component identification system may be an internal system that is uniquely coded and includes removable components that are scanners or readers. The component identification system may be in data communication with the controller 150, may be integrated into a productivity display, and / or may store information regarding productivity performance.

[0038] In some configurations, the component identification system can utilize RFID technology, e.g., high frequency RFID, which can optionally utilize the IO-Link network communication protocol (or CAN bus protocol). At least one component of the machine (e.g., screen, cutter, knife, etc.) is provided with an ID tag (e.g., RFID tag) that contains coded identifying information about the component. See, for example, Figures 2 and 3, where the screen portion 120 of the screening machine 100 includes a respective RFID tag 160. Also, in the horizontal grinder 200, the screen portion 220 is shown with an RFID tag 260 in Figures 7-9. The RFID tags 160, 260 can be located on the screen portions 120, 220 (e.g., on an outer rail or flange) so as to be positioned at the outer edge of the processing unit. Thus, the RFID tags 160, 260 can be in a position to be detected by the respective RFID readers (see, for example, RFID reader 164 of the screening machine 100 in FIG. 1 and RFID reader 264 of the horizontal grinder 200 in FIGS. 6-8). The RFID reader 264 is mounted to the cutter mill housing in the illustrated embodiment. In some configurations, the identification system can utilize other standardized identification systems, including but not limited to bar codes and bar code readers, or QR codes and QR readers. In some configurations, any intervening components between the reader and the ID tag can include an aperture to create a line of sight between the reader and the ID tag. However, RFID advantageously does not require a direct line of sight to function properly and can be read through foreign objects that accumulate on or near components of the identification system. The components detected by the RFID reader can be individually replaceable or replaceable as a set of two or more similar components.

[0039] The RFID reader identifies components that have unique physical and performance characteristics compared to other interchangeable versions of the component. The component information is collected by the control system and displayed to the operator. Additionally, the data may be sent external to the machine via telematics (e.g., to a job management entity and / or manufacturer) for data collection and analysis. In some configurations, the component identification information is transferred to a rugged PC or other controller on the machine that may have memory. By reviewing this data, customers can understand the most efficient way to set up each machine. Collecting and storing the data also provides valuable information regarding the best set up. Component identification (e.g., serial number and / or part number), hours of use, recommended usage (e.g., mulching, general grinding, construction waste reduction), and physical characteristics (e.g., screen hole diameter, shape, etc.) are examples of other data that may be recorded. This data may be utilized to track screen life and other component life (e.g., tracking knives or cutters in other material processing machines). Although not required, the component identification information may be integrated with productivity data. In some configurations with integration, productivity data can be displayed alongside the screen identification. Additionally, a display contrasting productivity for two different periods of operation with two different replaceable components (e.g., screens) can be displayed along with information identifying the first and second replaceable components.

[0040] Changes may be made in the above methods and systems without departing from their scope. Also, aspects of the various embodiments may be combined unless expressly prohibited. It should therefore be noted that the matter contained in the above description or shown in the accompanying drawings should be interpreted as illustrative and not in a limiting sense. The following claims are intended to encompass all the general specific features described herein, as well as all descriptions of the scope of the present methods and systems, which may be said to fall therebetween as a matter of language.

Claims

1. 1. A method of operating a machine for reducing or separating materials, comprising: operating a machine that reduces or separates the material with power from the power system to produce a flow at an outlet of the material; monitoring a flow volume at an outlet of the material; monitoring consumption of said power system from operation of a machine that reduces or separates said material; Calculating a productivity measure as unit volume per unit consumption in an on-board controller of a machine that reduces or separates the material; displaying said productivity measure on an operator display during operation of the machine to reduce or separate said material to create a flow at an outlet of said material; The method includes:

2. The method of claim 1 , wherein the power system includes an internal combustion engine and the consumption is monitored in terms of volume of fuel consumed.

3. The method of claim 1 , wherein the power system is an electric power system and the consumption is monitored as an electrical consumption.

4. The method of claim 1 , wherein the flow volume at the material outlet is monitored with a lidar sensor.

5. The method of claim 4 , wherein the lidar sensor is operative to emit a laser output from an exit conveyor mount downwardly toward an exit conveyor that moves the flow of material at the exit.

6. 2. The method of claim 1, further comprising monitoring a volume of a flow at an outlet of at least one additional material produced from operation of a machine that reduces or separates the material, and wherein the productivity measure is calculated using the flow at the outlet of the material and the volume of the flow at the at least one additional material outlet.

7. 2. The method of claim 1, wherein the productivity measure is displayed as a numeric readout that is updated in real time on the operator display during operation of a machine that reduces or separates the material to create a flow at an outlet of the material.

8. 2. The method of claim 1, wherein the productivity measure is displayed as a graph plotted in real time on the operator display during operation of a machine that reduces or separates the material to create a flow at an outlet of the material.

9. the material reduction or separation machine is operated with adjustable operating parameters at a first setting for a first duration; the controller responding to an operator input to change the adjustable operating parameter from the first setting to a second setting; calculating, at the controller, an updated productivity measure for a second duration corresponding to the second setting, as unit volume per unit consumption; and displaying the productivity measure for the first duration and the updated productivity measure for the second duration simultaneously in graphical form on the operator display.

10. the material reduction or separation machine is operated with a first replaceable component installed for a first duration, the first replaceable component directly interacting with materials being processed by the material reduction or separation machine; deactivating a machine for reducing or separating the material and replacing the first replaceable component with a second replaceable component; restarting operation of the material reduction or separation machine with the second replaceable component installed; and calculating, at the controller, an updated productivity measure for a second duration corresponding to the second replaceable component, as unit volume per unit consumption; and displaying the productivity measure for the first duration and the updated productivity measure for the second duration simultaneously in graphical form on the operator display.

11. In machines for reducing or separating materials, The power system, a processing unit operable by said power system to process material fed into a machine for reducing or separating said material; an exit conveyor configured to receive processed material from the processing unit; a first sensor operable to monitor a volume of material along the exit conveyor; a second sensor operable to monitor consumption of the power system from operation of a machine that reduces or separates the material; an on-board controller of the material reduction or separation machine in communication with the first sensor and the second sensor and programmed to calculate a productivity measure from data provided by the first sensor and the second sensor as unit volume per unit consumption; an operator display coupled to the controller and configured to display the productivity measure during operation of the processing unit; A machine for reducing or separating materials.

12. 12. The material reduction or separation machine of claim 11, wherein the power system includes a fuel burning internal combustion engine.

13. The material reduction or separation machine of claim 11 , wherein the first sensor comprises a lidar sensor.

14. 14. The material reduction or separation machine of claim 13, wherein the lidar sensor is positioned on a mount above the exit conveyor and aimed downward toward the exit conveyor.

15. 14. The material reduction or separation machine of claim 13, further comprising an additional exit conveyor and a third sensor operable to monitor a volume of material along the additional exit conveyor, and wherein the controller is programmed to calculate the productivity measure from data provided from the first sensor, the second sensor, and the third sensor.

16. 12. The material reduction or separation machine of claim 11, wherein the operator display is configured to display the productivity measure as a numerical readout.

17. 12. The material reduction or separation machine of claim 11, wherein the operator display is configured to display the productivity measure as a graph against time.

18. 1. A method of operating a machine for reducing or separating materials, comprising: operating a processing unit of a machine for reducing or separating a material with power from a power system for a first duration to produce a flow at an outlet of the material, the processing unit having a first replaceable component; Detecting the first replaceable component with an on-board RFID reader; monitoring and displaying, during said first duration, with a controller and a display, a volumetric productivity of said processing unit per unit consumption of said power system; deactivating the processing unit and modifying the processing unit to include a second replaceable component in place of the first replaceable component; detecting the second replaceable component with the on-board RFID reader; operating the processing unit with the second replaceable component installed for a second duration; monitoring an updated volumetric productivity measure per unit consumption during the second duration and displaying a contrast between the volumetric productivity for the first duration and the updated volumetric productivity for the second duration; The method includes:

19. 20. The method of claim 18, further comprising: detecting a third replaceable component with an additional on-board RFID reader; modifying the processing unit to include a fourth replaceable component in place of the third replaceable component; and detecting the fourth replaceable component with the additional on-board RFID reader.

20. 20. The method of claim 19, wherein operation of the processing unit during the first duration includes operation with the third replaceable component installed, and operation of the processing unit during the second duration includes operation with the fourth replaceable component installed.

21. 20. The method of claim 18, wherein the first replaceable component and the second replaceable component are screens through which processed material passes to reach an exit conveyor.

22. 20. The method of claim 18, wherein the displayed contrast between the volumetric productivity for the first duration and the updated volumetric productivity for the second duration includes information identifying the first replaceable component and the second replaceable component.

23. 20. The method of claim 18, wherein the volumetric productivity is measured with a lidar sensor along an outlet conveyor that moves the flow of material at the outlet.

24. Each of the first replaceable component and the second replaceable component includes an RFID tag encoded with data corresponding to the respective replaceable component, and the RFID reader, upon detection, communicates the data to the controller, the data comprising: Identification number, physical properties, Recommended Use, and Number of hours used 20. The method of claim 18, selected from the group consisting of:

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