Apparatus and method for gate or splitter positioning in bulk material separation

Abstract

An apparatus for material separation is disclosed, including apparatus examples (5, 105, 205, 305, 405, 505) for use with a sorting structure (12, 212, 312, 412, 512) adapted to sort material according to one or more physical characteristics to provide sorted material, and a gate / separator (10, 210, 360, 410, 510) positioned to provide a separation point. The gate / separator (10, 210, 360, 410, 510) carries a sensor arrangement (14, 214, 314, 414, 514), movable with the gate / separator, and configured to provide a signal indicative of at least one physical characteristic or attribute of the sorted material proximate a separation edge. A control and actuation system (600) and corresponding control method (700) are also disclosed.

Description

Apparatus and Method for Gate or Splitter Positioning in Bulk Material SeparationRelated Applications

[0001] This application claims priority from Australian provisional patent application no. 2025900570 filed on 27 February 2025, the contents of which are incorporated by reference.Technical Field

[0002] The invention relates to an apparatus and a method for gate or splitter positioning in bulk material separation. In particular, the invention relates to an apparatus and a method for the automation of a gate or splitter position in bulk material separation, such as the separation of a mined bulk material.Background

[0003] Bulk material separation is commonly required to sort a bulk material into two or more parts such as a first stream that may be a product stream and a second stream that may be a waste stream. In some cases, there may also be a third stream such as a middlings stream. Such bulk materials may include, but not limited to, farmed goods such as grapes, recyclables, manufactured materials, construction materials and mined materials such as coal and sands.

[0004] Bulk materials are generally sorted or grouped by exploiting one or more characteristic of the material to separate the material into two or more parts. These characteristics may be, but not limited to, the size, shape, colour, density, resistivity, EMF response of particles of the bulk material.

[0005] In all these applications, there is some kind of physical separation means is utilised to separate the sorted material such as, but not limited to, a gate or splitter which may be positioned to physically separate the sorted bulk material into the one or more streams. The position of the gate may be moved to alter the separation point betweenthe streams and, of course, determines the quantity of the bulk material ends up in, for example, the first and second streams.

[0006] One type of bulk material which is required to be separated is mineral sands. Such mineral sands include important minerals such as rutile, magnetite, ilmenite, zircon and monazite. A known method to sort such mineral sands includes a spiral separator in which a slurry of the mineral sand flows down a spiral.

[0007] Due to different properties of the mineral sands such as density, the composition of the mineral sands changes from the inner part of the spiral to the outer part of the spiral, thereby sorting or grouping the material. Inefficiencies in the sorting process, changes in feeds and constitutions, and non-homogeneous particulate may not fully report to the correct attribute stream, this forms a misreport zone or middlings band between the said streams. This band typically transitions in constitution across the band with greatest concentration of with attribute particles closest to the attributed sorted stream and conversely the leased attributed particles close to the non-attributed or waste stream. A gate may then be positioned within the middlings band between the inner and outer part of the spiral to “split” the mineral sands into the sorted inner and outer fractions one of which includes the preferred concentration of desired attributed particles within the stream and the other does not.

[0008] The position of such gates is generally manually positioned during calibration and may be manually adjusted overtime. Gates may also be controlled to move the location of the “split” position during operation of the spiral. However, a problem persists with determining the position of the “split” and optimising this position within the middlings to obtain the best separation result. As the middlings band, by nature is entrapped between the sorted streams, inspection of middlings band constitution change is often obscured by the sorted streams, and by the middlings band. This problem is compounded when, for example, the material feed changes over time and therefore the constitution and optimum separator location of the “split” within the middlings band also changes.

[0009] The invention disclosed herein seeks to overcome one or more of the above identified problems or at least provide a useful alternative.Summary

[0010] In accordance with a first aspect there is provided an apparatus for material separation. The apparatus includes or may be fitted to a sorting structure adapted to sort or distribute the material according to one or more physical characteristics of the material relative to the sorting structure to provide a sorted material; a gate or separator positioned at a separation point relative to the sorting structure to separate the sorted material into at least two parts, a control and actuation system adapted to move the gate to change the separation point, wherein the gate or separator carries a sensor arrangement moveable with the gate, the sensor arrangement being adapted to provide an signal indicative of at least one physical characteristic of the sorted material proximate the gate or separator within the middlings stream, and, wherein the control and actuation system is adapted to receive the signal and move the gate or separator based on a predetermining separation criteria to change the separation point.

[0011] In an aspect, the sensor arrangement includes at least two sensors.

[0012] In yet another aspect, the at least two sensors are arranged to detect the concentration of particulate displaying one or more physical characteristics of the sorted material flow at different locations.

[0013] In yet another aspect, the at least two sensors are arranged to face or have a field of view at least partially opposing one another.

[0014] In yet another aspect, the sensor arrangement includes non-contacting sensors.

[0015] In yet another aspect, the at least two sensors are angled at least partly away from one another.

[0016] In yet another aspect, the at least two sensors are spaced apart from the material.

[0017] In yet another aspect, the at least two sensors are located above or along side the material.

[0018] In yet another aspect, wherein the gate has a separation edge and the sensor arrangement is located on opposing sides of the separation edge.

[0019] In yet another aspect, wherein the gate has a separation edge and one of the at least two sensors is located on at or on a surface of the gate on opposing sides of the separation edge.

[0020] In yet another aspect, the different locations include different lateral locations across the sorted material flow.

[0021] In yet another aspect, the different locations include upstream and downstream locations relative to a separation edge of the gate.

[0022] In yet another aspect, the two sensors include optical sensors. Other examples may include, but not limited to, magnetic sensors, temperature sensors.

[0023] In yet another aspect, the optical sensors include one or more cameras or infrared sensors.

[0024] In yet another aspect, the sorting structure is a density spiral and the gate is positionable width wise of a section of the spiral.

[0025] In yet another aspect, the sorting structure is a vibrating table.

[0026] In yet another aspect, the sorting structure, is a particulate conduction to a grounded drum.

[0027] In yet another aspect, the material is a mined material.

[0028] In yet another aspect, the mined material is mineral sand.

[0029] In yet another aspect, the gate includes a gate body to which the sensor arrangement is fitted.

[0030] In yet another aspect, wherein the gate body includes at least two surfaces on opposing sides of a separation edge, and wherein and the one of the at least two sensors is located on each of the opposing sides.

[0031] In yet another aspect, the control and actuation system include an actuator adapted to move the gate and a controller adapted to provide a control signal to the actuator based at least in part on the received signal.

[0032] In yet another aspect, the one or more physical characteristics of the material include, but not limited to, density, colour, and magnetic properties of the material.

[0033] In yet another aspect, wherein the signal indicative an attribute of the one or more physical characteristics of the material.

[0034] In yet another aspect, wherein the attribute is one or more of optical and thermal characteristics.

[0035] In yet another aspect, the attribute is one or more of one or more of colour, temperature and texture.

[0036] In yet another aspect, the sensor arrangement comprises a single sensor or a plurality of sensors configured to sense the sorted material at respective opposing sides of a separation edge of the gate.

[0037] In accordance with a second aspect there is provided, an apparatus for material separation. The apparatus including or being fitted to a sorting structure adapted to sort or group the material according to one or more physical characteristics of the material relative to the sorting structure to provide a sorted material; a gate positioned at a separation point relative to the sorting structure to separate the sorted material into at least two streams, a control and actuation system adapted to move the gate to change the separation point between the sorted streams, wherein the gate carries a sensor arrangement, the sensor arrangement being adapted to provide a signal indicative of an attribute of at least one physical characteristic of the sorted material proximate the gate, and wherein the control and actuation system is adapted to receive the signal and move the gate based on a predetermining attribute concentration separation criteria to change the separation point between the sorted streams, the sensor arrangement being movable with the gate thereby increasing the swath of the sensor field of view arrangement relative to the sorted material.

[0038] In accordance with a third aspect there is provided, a method for material separation, the method including: sorting material according to one or more physical characteristics of the material relative to a sorting structure to provide a sorted material streams; positioning a gate or other suitable separator at a separation point between the sorted streams relative to the sorting structure to separate the sorted material streams into at least two parts, detecting an attribute of the one or more physical characteristics of the sorted material proximate the gate with a sensor arrangement carried by the gate, moving the gate based the concentration of the detected attribute to change the separation point and the field of view of the sensors.

[0039] In accordance with a fourth aspect there is provided, a method for material separation, the method including: distributing material according to one or more physical characteristics of the material relative to a sorting structure to provide a sorted material; positioning a gate at a separation point relative to the sorting structure to separate the sorted sort material into at least two parts, detecting the one or more attributes indicative of the physical characteristics of the sorted material proximate the gate with a sensor arrangement carried by the gate, moving the gate based the concentration of detected the one or more attributes of the sorted material to change the separation point, the movement of the gate increasing the swath of the sensor arrangement relative to the sorted material.

[0040] In accordance with a fifth aspect there is provided, a system for material separation, the system including: a sorting structure configured to sort a bulk material according to one or more physical characteristics of the bulk material to provide a sorted material distribution; a movable separator configured to define a separation edge at a separation point relative to the sorting structure to separate the sorted material distribution into at least two parts; a sensor set carried by, mounted to, or movable with the movable separator, the sensor set configured to output at least one signal indicative of an attribute of the one or more physical characteristics of the sorted material proximate the separation edge; an actuator coupled to the movable separator and configured to move the movable separator to change the separation point; and a controller in communication with the sensor set and configured to: (i) receive the at least one signal, (ii) compare the at least one signal to a predetermined separationcriterion, and (iii) control the actuator to move the movable separator based on the comparison to change the separation point.

[0041] In accordance with a sixth aspect, there is provided an apparatus for bulk material separation, the apparatus comprising: a separator member defining a separation edge for dividing a sorted bulk material distribution into at least two streams; a sensor arrangement supported by the separator member and configured to detect an attribute of the bulk material at or adjacent the separation edge; and a controller configured to automatically reposition the separator member in response to the detected attribute so as to maintain the separation edge at a target condition corresponding to a predetermined grade or attribute concentration.

[0042] In accordance with a seventh aspect, there is provided an apparatus for controlling a separation edge in a bulk material separator, the apparatus comprising: a movable separation edge member; a first sensor configured to sense a first attribute level on a first side of the separation edge; a second sensor configured to sense a second attribute level on a second side of the separation edge; and a control system configured to reposition the separation edge member until the first attribute level satisfies a predetermined criterion and the second attribute level satisfies an offset criterion relative to the predetermined criterion.

[0043] In accordance with an eighth aspect, there is provided a bulk material separation system comprising: a movable separator defining a separation point; a sensor set movable with the separator and configured to generate measurement signals from respective locations proximate the separation point; and a processor configured to execute an iterative control routine comprising repeatedly (i) sampling the measurement signals, (ii) determining a direction of movement of the separator based on a comparison of at least one of the measurement signals to a predetermined threshold, and (iii) stepping the separator in the determined direction, thereby adaptively maintaining the separation point.

[0044] In accordance with a ninth aspect, there is provided a method of controlling a separator in a bulk material separation apparatus, the method comprising: obtaining at least two sensor measurements from different locations proximate a separation edge, the sensor measurements being indicative of an attribute correlated with a physicalcharacteristic used to separate the bulk material; comparing the sensor measurements to a predetermined target condition; and moving the separator in a first direction or a second direction based on the comparison such that the separation edge is maintained at or proximate a desired cut point within a middlings region.

[0045] In accordance with a tenth aspect, there is provided an apparatus for material sorting optimisation, the apparatus including: a sorting structure adapted to sort the material according to one or more physical characteristics of the material relative to the sorting structure to provide a sorted material; a gate positioned to provide a separation point relative to the sorting structure to separate the sorted material into at least two parts; a control and actuation system adapted to move the gate to change the separation point; wherein the gate carries a sensor arrangement moveable with the gate, the sensor arrangement being positioned proximate a separation edge of the gate and being adapted to provide a signal indicative of at least one physical characteristic of the sorted material; wherein the sensor arrangement is configured to sense the sorted material at opposing or juxtaposed positions relative to the separation edge; and wherein the control and actuation system is adapted to receive the signal and move the gate based on a predetermining separation criteria to change the separation point.

[0046] The apparatus, system or method of any preceding aspect, wherein the sensor arrangement comprises at least two sensors having fields of view that are opposed, at least partly opposed, or juxtaposed about the separation edge.

[0047] The apparatus, system or method of any preceding aspect, wherein the at least two sensors are configured to sense at least two different locations comprising one or more of (i) different lateral locations across a material flow, (ii) upstream and downstream locations relative to the separation edge, and (iii) locations on opposed sides of the separation edge.

[0048] The apparatus, system or method of any preceding aspect, wherein the controller is configured to converge on the desired cut point by performing stepwise repositioning of the separator and reducing a step size as a deviation from the predetermined target condition decreases.

[0049] The apparatus, system or method of any preceding aspect, wherein the predetermined target condition corresponds to a sensor response representing a target grade or attribute concentration, and wherein the controller positions the separator so that a first sensor response corresponds to the target grade or attribute concentration and a second sensor response corresponds to a grade or attribute concentration lower than the target grade or attribute concentration.

[0050] The apparatus, system or method of any preceding aspect, wherein movement of the separator increases a swath or coverage of the sensor arrangement relative to the bulk material by scanning across a region including a middlings band.

[0051] The apparatus, system or method of any preceding aspect, wherein the sensor arrangement comprises an optical sensor arrangement including one or more of an infrared emitter / sensor pair, an infra-red camera, a visible-light camera, or a multi-element imaging device, and wherein the detected attribute is an optical response correlated to density and / or mineral concentration.

[0052] The apparatus, system or method of any preceding aspect, wherein the sensor arrangement comprises one or more of a magnetic sensor, a thermal sensor, a conductive sensor, an inductive sensor, an acoustic sensor, an ultrasonic sensor, an X-ray sensor, or an isotopic sensor.

[0053] The apparatus, system or method of any preceding aspect, further comprising a gate position sensor configured to provide a signal indicative of a position of the separator, and wherein the controller uses the position signal to confirm movement and / or implement limits or homing.

[0054] The apparatus, system or method of any preceding aspect, wherein the sorting structure comprises one or more of: a spiral separator, an electrostatic drum separator, a magnetic separator, or a vibratory table separator.

[0055] The apparatus, system or method of any preceding aspect, wherein the bulk material comprises mined material including mineral sands, and wherein the method is configured to maintain a target grade of a mineral concentrate stream.

[0056] The apparatus, system or method of any preceding aspect, further comprising local storage / processing and / or cloud storage / processing configured to store one or more of sensor data, gate position data, calibration correlations, setpoints, alarms, or maintenance logs, and to provide one or more local, remote, or maintenance user interfaces.

[0057] The apparatus, system or method of any preceding aspect, wherein the sensor arrangement comprises a single sensor configured to sense respective regions on opposed sides of the separation edge.

[0058] The apparatus, system or method of any preceding aspect, wherein the single sensor comprises a multi-element sensor having a field of view spanning the separation edge so as to provide respective signals for different locations relative to the separation edge.

[0059] The apparatus, system or method of any preceding aspect, wherein the single sensor comprises a camera, line-scan sensor, line array, or imaging sensor configured to derive separate measurements corresponding to opposed sides of the separation edge.

[0060] The apparatus, system or method of any preceding aspect, wherein the sensor arrangement comprises a scanning sensor configured to obtain measurements from opposed sides of the separation edge by time-based scanning, beam steering, mechanical scanning, or sequential sampling.

[0061] The apparatus, system or method of any preceding aspect, wherein the sensor arrangement comprises two or more discrete sensors arranged to provide respective signals corresponding to different locations relative to the separation edge.

[0062] The apparatus, system or method of any preceding aspect, wherein the sensor arrangement is mounted to the gate such that movement of the gate provides at least part of the scanning or sequential sampling function for a single sensor or multi-element sensor.Brief Description of the Figures

[0063] The invention is described, by way of non-limiting example only, by referenceto the accompanying figures, in which;

[0064] Figures 1 A and IB are explanatory views respectively illustrating an ideal and typical actual separation of a bulk material using a sorting apparatus with a separator such as a gate;

[0065] Figures 1C and ID are conceptual views of a first example an apparatus respectively illustrating operation of a sensor arrangement moveable with the gate for separating the sorted bulk material;

[0066] Figure 2A is a top view illustrating an example of spiral separator including the apparatus having sensors fitted to the gates;

[0067] Figure 2B is a side perspective view illustrating the spiral separator including the apparatus having sensors fitted to the gates and means such as actuators to move the gates;

[0068] Figure 2C is a close-up perspective view illustrating the gates and the sensor arrangement fitted thereto;

[0069] Figure 2D is a top perspective view illustrating a sensor unit for fitting with a gate;

[0070] Figure 2E is an underside perspective view illustrating the sensor unit for fitting with the gate;

[0071] Figure 2F is another perspective view illustrating the sensor unit fitted with the gate;

[0072] Figure 3 A is a top view illustrating another example of spiral separator including the apparatus having sensors fitted to the gate thereof;

[0073] Figure 3B is a perspective view illustrating the spiral separator including the apparatus having sensors fitted to the gate and means to actuate the gate;

[0074] Figure 3C is a close-up perspective view illustrating the gate and the sensorarrangement fitted thereto;

[0075] Figure 3D is a close-up perspective end view illustrating a sensor configuration of the gate; and,

[0076] Figure 3E is a close-up perspective end view illustrating the gate coupled to an actuation means for linear actuation of the gate;

[0077] Figure 4A is side view illustrating an example of electrostatic separator including the apparatus having sensors fitted to the gates thereof;

[0078] Figure 4B is a close-up perspective view illustrating the electrostatic separator, the gates and the sensor arrangement fitted thereto;

[0079] Figure 5A is a top perspective another example of a separator in the form of a vibratory table separator;

[0080] Figure 5B is a top view of another example of the separator in the form of a vibratory table separator;

[0081] Figure 5C is a detailed part perceptive view illustrating a launder arrangement of the vibratory table separator;

[0082] Figure 5C is a detailed perspective view of a first gate of the launder arrangement;

[0083] Figure 5D is a detailed perspective view of a second gate of the launder arrangement;

[0084] Figure 6 is a block diagram of a system for material separation such as separation of the bulk material, the system being applicable to the separation apparatus examples disclosed herein; and,

[0085] Figure 7 is a block diagram of a method for operating the system of the separation apparatus examples disclosed herein.Detailed DescriptionFirst “Concept” Example

[0086] Referring to Figure 1A there is shown a conceptual example of an ideal separation of a presorted bulk material “MB” in which some form of separation means or separator, in this example a gate 10, is used to separate the bulk material sorted streams based on some kind of material attribute based on the physical characteristics of the material.

[0087] The material passes a sorting structure 12 such as, but not limited to a spiral, laser, X-ray, or static sorter, which assists to initially sorts the material toward or into one or more streams, indicated here as “SI” and “S2” with SI having material with a first attribute “Al” and S2 having material with a second attribute “A2”.

[0088] The material attribute may be, but not limited to, colour, size, type, density, optical properties and magnetic properties. These may be indicative of, for example, the type of mineral present. For example, a cut or separation point “CP” could be determined with Al material having a density below a threshold CP level and A2 material have a density above the threshold CP level. Such as cut or separation point “CP” is typically determined via lab testing and / or on-site calibration.

[0089] Referring additional to Figure IB, whilst the clear-cut sorting as shown in Figure 1 is desirable, in practice such a clean sort is difficult to achieve and typically as “SI” and “S2” will have a mixture of material having both of the first and second attributes which may be referred to as middlings “S3”. One reason for this is that the ideal separation point may change over time as, for example, the feed material may change, or other variable may change such as flow rate. As such, the quality of the sort and hence “grade” of the output, relative to the gate position, may vary or degrade over time which may cause a reduction in product quality and call for recalibration of the separation gate position.

[0090] Referring to Figure 1C and IB, there is shown a first example of apparatus 5 for the separation of a bulk material in which the gate 10 of Figures 1A and IB is fitted with a sensor arrangement 14 which in this example two sensors 18a and 18a carriedand moveable with the gate 10. The gate 10 may also be coupled to a control and actuation system (not shown) adapted to move the gate 10 to change the separation point “CP” defined by a separation or leading edge 22 of the gate 10. The sensors 18A and 18b may be arranged such as by angling to have a field of view (FOV) opposing or at least partly opposing one another, although in some examples the FOV may at least partially overlap. The arrangement of the sensors 18a and 18b may be considered juxtaposed.

[0091] The sensor arrangement 14 is adapted to provide a signal indicative of at least one detectable attribute the sorted material proximate the gate 10 and more specifically proximate and, in some examples, up and cross stream of a leading edge 22 of the gate 10. The detectable attribute may be indicative of the concentration of physical characteristic particles of the material flow passing the sensors. For example, denser material may be darker in colour and a detectable attribute may be the optical signature of that material which is therefore indicative of the physical characteristic of density for which the material is being sorted.

[0092] As such, if the sensors 18a and 18b detect a non-optimal separation of the material such as that shown in Figure 1C, the control and actuation system can be configured to move the gate 10 to change the cut point and sensor field of view to that shown, for example, in Figure ID. This allows the cut point to be dynamically changed to seek to optimate the cut point.

[0093] More specifically, sensors 18a and 18b may detect difference in middlings S3 material constitution passing either side of the separation edge 22 of the gate 10. Sensor 18a may be consider a “with-attribute” sensor and sensor 18b may be considered a “without-attribute” sensor.

[0094] The signal responses of sensors 18a and 18b may be compared against preset or predetermined signal response level pertaining to desired grade level. Disparity of the signals may be used to move the gate 10 via an actuation means (not shown) of the control and actuation system a predetermined distance and direction, changing the position of the edge thus changing the separation point within the middlings S3 flow.

[0095] Response from sensors 18a and 18b at the new position within the middling flow S3 are again compared to desired grade response and gate 10 position may be again changed, accordingly. As the measured response reduces in disparity in comparison to the desired condition, the gate 10 movement step distance withing the middlings band S3 is reduced. Steps are repeated until preferably the with-attribute sensor 18A response equates to desired grade response level, and the without-attribute sensor 18B response is slightly lower than the desired grade response level.Second Example

[0096] Referring to Figures 2A to 2C there is shown a second example of the apparatus 105 for material separation such as separation of the bulk material in which like sequences of numerals (i.e 10, 210) are used to denote like parts. In this example, the bulk material may be, but not limited to, mineral sands.

[0097] In this example, the apparatus 205 is fitted to or part of the spiral separator 230 such spiral separators are well-known and include a sorting structure 212 in the form of a spiral 232 adapted to sort the material according to one or more attributes such as physical characteristics of the material relative to the sorting structure 212 to provide a sorted material. The separated material may be discharge via one or more discharges 238.

[0098] In this example, the spiral 232 is arranged to sort or group the material based on density of the material. In this example, heavier density particles move to the inside of the spiral 232 while lighter particles move to the outside. The desired material could be on either on the inside or outside of the spiral. For example purposes only the arbitrary selection of the desired attribute being “greater density” was selected, thus the inside of the spiral is considered the with-attribute SI flow and outside material is considered the without-attribute S2 flow.

[0099] The apparatus 205 includes a gate 210 and a control and actuation system 216 adapted to move the gate 210. The movement of the gate 210 is arranged to change the separation point “CP” relative to the sorting 212 structure to separate the sorted material into at least two parts SI and S2. There may be more than one gate 210, and, in this example, there are two gates 210a and 210b. Each or both gates 210a and 210b maycarry and be fitted with a sensor arrangement 214 moveable with the gates 210a and 210b. The sensor arrangement 214 is adapted to provide a signal indicative of at least one attribute of the sorted material proximate the gates 210a and 210b.

[0100] In this example, the attribute of the material detected by the sensor arrangement 214 is an optical response and an example of suitable sensor is, but not limited to, an IR 940 nm Emitter and Sensor. Other suitable sensors could include: Short and long IR, UV, Visible (i.e a camera), Magnetic hall effect, isotopic, conductive. Further details of a specific working arrangement are provided below.

[0101] Similar to the first example, in this second example, the sensors 218a and 218b may be mounted upon the gates 210a and 210b and may be posited on opposing sides of the separation edge 222. Each Sensor 218a and 218b of each gate 210a, 210b have field of view forward looking and opposed to one another. There may be some overlap within the middlings band S3 such as between the gates 110a and 110b.

[0102] A signal associated with each sensor 218a and 218b is communicated with the control and actuation system 216 that includes a controller or computer system 600, shown in Figure 6, adapted to process the signals. The control and actuation system 216 performs a comparison of the signals relative to a desired or predetermined grade level and a control signal is sent to an actuator 234 of control and actuation system 216.

[0103] The actuator 234 then moves the respective gates 210a and 110b toward a condition of improved grade. It is noted that in this example, there may be two actuators 234a and 234b each independently associated with each of the gates 210a and 210b. An example of the method 700 of operation and control is provided in Figure 7.

[0104] The movement of the respective gates 210a and 210b thereby moves the separation edges 222a, 222b which in turn changes the grade of the material passing the separation edges 222a, 222b. The sensors 218a and 218b are also moved during this movement which, in effect, provides a scanning function to increase field of view or swath of the sensors 218a and 218b.

[0105] The measured disparity between desired grade response level and the sensors 218a and 218b is processed by the control and actuation system 216 whichcontinues to send an actuator signal the actuator 234a and 234b until the sensors 218a and 218b signal response equal or are at a desired response level.

[0106] In the example of a mineral sand, the mineral has a density attribute which also correlates with an optical IR (Infra-Red) response. In other words, density which is the physical characteristic and basis for sorting by the spiral structure, the ideal separation point of the density sorted bulk material can be detected based the optical response.

[0107] In this example, the dense materials move toward the centre of the spiral and less-dense material move to the outside. The sorting structure 212 is performing its separation based the on density.

[0108] However, the sensors 218a and 218b are configured to provide a signal based on the detectable attribute correlating to the density attribute, in this case infrared signature, which is indicative of density. From magnetite has a density of 5.18 g / cm3and quartz 2.32g / cm3. The infrared signature of magnetite may be is low as highly absorptive at 940nm and quartz is highly reflective at 940nm allowing a correlation to be established between magnetite concentration sorted by density and measured by optical intensity.

[0109] A 100% concentration of Magnetite irradiated by 940nm illumination would absorb most illuminated light and provide a low signal. In the middlings a 90% grade or 90% magnetite (absorptive) and 10% silica (reflective) thus by example the 10% particles of silica would reflect producing a return illumination higher level than that of 100% magnetite. By reason the highest signal would be that of 100% silica. By iterative means a plot of measured illumination response to grade by density sorted means can be developed across the middlings band.

[0110] By measuring current intensity response to plot, provides indication which direction to move the separation gate towards preferred grade response. Preferred grade cut position is obtained when one sensor is at the preferred grade level response and the second sensor is just measuring a response equivalent to a grade just lower than the desired grade. An acceptable grade may be, for example, 80% Magnetite which may be the cut point. The sensor nearest the sorted magnetite stream would equal theresponse for 80% magnetite and the opposing sensor would read by example 79% magnetite, indicating that the gate is on the cut point of 80% magnetite.

[0111] Referring now to Figures 2D, 2E and 2F there is shown an example of a sensor unit 240 for the sensor arrangement 214 which is adapted for retrofitting onto existing gates 210a, 210b etc of existing spiral separators 230. It is noted that whilst in this example the sensor unit 240 is a separate part coupled to the gates 210a, 210b, in other examples, the sensor unit 240 and the gates 210a, 210b may be integrated and may be a single part as has been shown in Figures 2A to 2C.

[0112] The sensor unit 240 includes a housing body 242 which supports and locates the sensors 218a and 218b. In this example, the housing body 242 includes two recesses 244a, 244b in which each of the sensors 218a and 218b are located. The recesses 244a, 244b serve the orient the sensors 218a, 218b and also allow recessing of the sensors 218a, 218b to assist to protect the sensors 218a, 218b from the separation material environment.

[0113] The housing body 242 extends forward of and about the separation edge 222a, 222b to generally position the sensors 218a, 218b forward of and above the relevant separation edge 222a, 222b. The orientation of the sensors 218a, 218b allows them to be focused at or toward the relevant separation edge 222a, 222b. Specifically, the sensors 218a, 218b are located on opposing sides of the relevant separation edge 222a, 222b and oriented so that the field of view forward looking and opposed to one another.

[0114] The sensor unit 240 may also house and generally protect one or more components of the control and actuation system 216 such as a control and communication circuit and power source (not shown) for the sensors 218a and 218b. The unit 240 may be hardwired or wirelesses connected to the control system 600.Third Example

[0115] Referring to Figures 3A to 3C there is shown a third example of the apparatus 305 for material separation such as separation of the bulk material in whichlike sequences of numerals (i.e 10, 310) are used to denote like parts. In this example, the bulk material may be, but not limited to, mineral sands.

[0116] In this example, the apparatus 305 is fitted to or part of the spiral separator 330 with side splitter gates 360 and include a sorting structure 312 in the form of a spiral 332 adapted to sort the material according to one or more attributes such as physical characteristics of the material relative to the sorting structure 312 to provide a sorted material. Such spiral separators 330 are well-known and not described here in any further detail.

[0117] In this example, the side splitter gates 360 slide in-and-out from the centre of the spiral by an actuation means 324 associated with the control and actuation system 316. The actuation means 324 in the form an actuator 334 moves the side splitter gates 360 to provide an adjustable gap “G”.

[0118] When the side splitter 360 is completely closed the gap is completely filled and the material flow continues down the spiral unabated. When the side splitter 360 is slid open by the actuator 334 the gap is formed with automated intent to set a desired distance within the middlings band S3 to allow the with-attribute particles SI to flow into the gap and be piped away whilst the without-attribute particles S2 of particles continue unabated.

[0119] As best shown in Figures 3B and 3C, the sensors 318a and 318b mounted or otherwise fitted on the gate 360 and may be opposed or juxtaposed relative the separation edge 322. One example of this fitment is shown in Figure 3D. In this arrangement, one of the sensors 318a is focused on the attribute particles SI within the gap and the other is focussed toward the middlings S3 and / or without attribute particulars S2. This provides two signals representative of different locations with the bulk material that may be used to optimise the location of the gate 360 and hence separation.

[0120] The control and actuation system 316 may be configured to receive and perform a comparison of the signals from the sensors 318a and 318b which may be used to determined or estimate a measured grade. The measured grade may be compared to a target grade that may be predetermined or preset.

[0121] The control and actuation system 316 may then be configured to move the side splitter gates 360 in or out using the actuator 334 to change the location of the leading or separation edge 322. The measured difference between desired grade response level and the sensor responses continue to send a drive signal the gate actuator 334 until the desired grade is achieved. A way this may be achieved is moving the gate 330 until the with-attribute sensor 318A equals the desired response level and the without-attribute sensor 318B is lower.

[0122] In this example, the bulk material may be, but not limited to a mineral sand. An example sensor may be, but not limited to, an IR sensor which provides a signal indicative of density. Such as sensor and its function are descried above in relation to the second example are not again described here.

[0123] Referring now more specifically to Figures 3D and 3E there is shown more examples of the side splitter gates 360 and the actuation means 324. In this example, the side splitter gates 360 are adapted to be retrofitted onto existing spirals separates. However, in other examples, such side splitter gates 360 may be integrated at the time of manufacture.

[0124] In this example, the existing gate 310 may be modified about its separation edge 322 to allow greater material dwell time upon sensor 318a without impacting the 322 separation edge purpose. Specifically, the sensor 318a is located at a chamfered or angled separation edge 323a which is adjacent to the free end surface 323b. Sensor 318a is located on a top surface top surface 325 proximate to but spaced apart from the free end surface 323b and the sensor 318b located at the chamfered or angled separation edge 323a.

[0125] The sensors 318a and 318b are within or embedded within gate 310 and are juxtaposed about separation edge 322 with each sensor 318a, 318b facing at least partly away from the other so as to measure properties of different parts or portions of the bulk material passing the separation edge 322. Specifically, the sensors 318a, 318b may be embedded within gate 310 such as in aperture and then a covering such as a clear polymer may be set to, in effect, provide a protective lens over the sensors 318a,

[0126] As sensors 318a and 318b may require local control, power, signal conditioning, and actuation. The control circuits (not shown) and actuator 334 are housed within body 362. Although, in some examples, the control circuits may be embedded into the side splitter gates 360 themselves. Figure 6 provides an example of a system 600 suitable to operate such side splitter gates 360 and sensors 318a, 318b carried thereby.

[0127] In this example, the attribute of the material detected by the sensor arrangement 314 is an optical response and an example of suitable sensors 318a, 318b may be, but not limited to, an IR 940 nm Emitter and Sensor. Other suitable sensors could include: Short and long IR, UV, Visible (i.e a camera), Magnetic hall effect, isotopic, conductive. Further details of a specific working arrangement are provided belowFourth Example

[0128] Referring to Figures 4A to 4B there is shown a fourth example of the apparatus 405 for material separation such as separation of the bulk material in which like sequences of numerals (i.e 10, 410) are used to denote like parts. In this example, the bulk material may be, but not limited to, mineral sands.

[0129] In this example, the apparatus 405 is fitted to or part of a magnetic separator unit 470 including a sorting structure 412 in the form of a corona electrostatic drum separator 472 adapted to sort the material according to one or more attributes such as physical characteristics of the material relative to the sorting structure 412 to provide a sorted material. In this example, the physical characteristic of the material upon which separation is based is the magnetic properties of the particles of the material.

[0130] Particles of the material are fed across the drum surface 474. As the drum 472 rotates, particles pass an electrostatic field where nonconductive particles charge and conductive particles loose charge to the drum. The charge is provided by a corona wire arrangement 476. Charged particles are attracted to the drum surface 474, where conductive particles loose charge to the drum surface 474 and fall away from the drum 472. Attracted particles preferably maintain upon drum surface 474 until they areremoved by a brush 478 or the like. Nonhomogeneous particles (middlings) may only partly conduct relative to the percentage conductive material, these middling particles may release from drum at different rotational arc points to the preferred uncharged conductive particulate forming middlings band S3.

[0131] The apparatus 405 includes one or more gates or separators 410 which are used to separate the material. The relative paths of the particles are best shown in Figure 4A in which the attribute (conductive) particles path SI is desirably passed on an outer side of the gate 410a and the non-conductive particle stream S2 and generally middling passings on the inside of the gate 410a. The non-conductive particle stream S2 carried by the drum 472 may be removed by the brush 478 removed and may pass a further pass gate 110b on the opposing side.

[0132] Similarly to the above examples, in this example, one or multiples of the gates 410 may include sensors 418a and 418b. For example, gate 410a may include sensors 418a and 418b arranged to detect attributes of the particles path SI and the middlings steam S3. The control and actuation system 416 may be configured to receive signals from the sensors 418a and 418b and move a separation edge 422a using an actuation means 424a using a rotary actuator 480. The sensor 418a may be focused or arranged to detect an attribute of the SI stream and sensor 18b may be focused to detect an attribute of the S3 stream.

[0133] In this example, further gates or separators 410b and 410c may also be provides which also carry sensors 418a and 418b and are movable via the control and actuation system 416. These may function similarly to gate 410a which the overall configuration seeking to optimise the grade of the with-attribute material SI.

[0134] The detectable attribute may be optical properties, conductance, magnetics, inductance, Xray or any other suitable attribute. However, again, similar to the second example, the detectable attribute is preferably the reflective response from particles measurable as an IR signature using an infrared sensor as outlined above. Accordingly, the material type and sensor function are not again described here.

[0135] Accordingly, in this example, the material will be fast moving and free flowing and the attributes of the material may be measured using the reflective responsefrom particles mixed and measuring the relative response relative using the sensors 418a and 418b, which as noted above may be IR sensors in this example, to the percentage of the mix. Each gate 410a to 410c can work independently, each with potentially different detectors / sensors, parameters and setpoints with the goal of each to automatically find the optimum position based on the material presented either side of the gate. Noting material will be different in type and or concentration at each gate 410a to 410c.Fifth Example

[0136] Referring to Figures 5A to 5E there is shown a fifth example of the apparatus 505 for material separation such as separation of the bulk material in which like sequences of numerals (i.e 10, 510) are used to denote like parts. In this example, the bulk material may be, but not limited to, mineral sands.

[0137] In this example, the apparatus 505 is fitted to or part of the vibratory table separator 530, with side launder gates 510 (also known as sliders). The vibratory table separator 530 includes a ribbed sorting structure 512 in the form of a latterly ribbed tilted table 532 adapted to sort the material according to one or more attributes such as physical characteristics of the material relative to the sorting structure 512 to provide a sorted material.

[0138] In this arrangement, generally heavier particulate moves laterally across the table 532 as unable to overcome height of lateral ribs of the table 523, forming material SI and passes into launder 560a whilst lighter particulate S2 passes over the rib formation 512 and pass into launder 560b.

[0139] Particles near the density of the heavier particulate S3 pass into the middlings launder 560c likely containing both desired and undesired material for further separation practices. Such table separators 530 are well-known and not described here in any further detail.

[0140] In this example, the launder gates 510a and 510b slide respectively along the launder 560a, 560b by an actuation means 524 associated with the control and actuation system 516. The actuation means 524 in the form an actuator 534 moves theside splitter gates 510a to provide an adjustable alignment and between the preferred cut of SI and S3 and also S2 and S3 for 510b. More specifically, actuators 534 may be coupled to each of the launder gates 510a and 510b via a rod (not shown) or the like to linearly move the launder gates 510a and 510b by extension or retraction relative to the actuator 534.

[0141] As best shown in Figures 5B and 5C, the sensors 518a and 518b mounted or otherwise fitted on the gate 510a and 510b and may be opposed or juxtaposed relative the separation edge 522. In this arrangement, one of the sensors 518a is focused on the attribute particles SI within the gap and the other is focussed toward the middlings S3 and / or without attribute particulars S2. This provides two signals representative of different locations with the bulk material that may be used to optimise the location of the gate 510 and hence separation.

[0142] The control and actuation system 516, further described with reference to Figure 6, may be configured to receive and perform a comparison of the signals from the sensors 518a and 518b from each gate 510a and 510b respectively which may be used to determined or estimate a measured grade. The measured grade may be compared to a target grade that may be predetermined or preset.

[0143] The control and actuation system 516 may then be configured to move the launder gates 510a, 510b in or out using the actuator 534 to change the location of the leading or separation edge 522. The measured difference between desired grade response level and the sensor responses continue to send a drive signal the gate actuator 534 until the desired grade is achieved. A way this may be achieved is moving the gate 510 until the with-attribute sensor 518a equals the desired response level and the without-attribute sensor 518b is lower.

[0144] In this example, the bulk material may be, but not limited to a mineral sand. An example sensor may be, but not limited to, an IR sensor which provides a signal indicative of density. Such as sensor and its function are descried above in relation to the second example are not again described here.Further Examples

[0145] Suitable sensors (18, 118, 218, 318, 418, 518 etc) may take various forms and may comprise multiple sensors or a single sensor that is configured to provide the same or similar signal output which as described above generally comprises two contracting signals looking at slightly different points or segments of a bulk material proximate to its point of separation.

[0146] For example, a single sensor with multiple sensor elements with a FOV (Field of View) across the separation edge such that said sensor is able to capture information relating to the difference in particulate flow constitution and use such information to move the gate to a preferred separation position. This may be a camera, line array, hall effect, or other multielement device capable of the above prescribed. Such a sensor or sensor arrangement is contemplated herein.

[0147] In yet another example, the sensor or sensor arrangement could include a single sensor or multiple sensors capable of a scanning means such that the sensor may be time base or other means detect either side of the separation edge such that said scanning sensor is able to capture information relating to the difference in particulate flow constitution and use such information to move the gate to a preferred separation position.

[0148] Preferably this could include the movement of the gate to produce a scan like result. This could also include time-based scanning using by example magnetic, acoustic, microwaves or other means to pass preferably through or either side of the gate to perform a scan like response. This may be a scanning laser, Mazer, radio, isotopic, Xray, ultrasonic, or other device capable of the above prescribed.

[0149] In yet another examples, the sensor arrangement itself could undertake some movements, for example, single sensor could be configured to and regularly move, such as jiggling, across the cut point to ensure on the best cut line. In such examples, the gate itself may not move, but the sensor arrangement may be or simulate movement to provide the same or similar output. Such an arrangement could be considered as time slicing the single sensor to be both sides of the gate by moving position, in effect, acting like two sensors with data half the time. All such arrangements and configurations of the sensor arrangement are contemplated herein.

[0150] The provided examples may find application with a wide variety of bulk materials that a preferably mined materials such as minerals sands, rock and coal. However, the provided examples and variations thereof may also be suitable for a wide range of other bulk materials including, but not limited to, fruit, packages, mail, baggage etc or any other material or items that needs to be sorted to provide separated outputs and on some kind of detectable attribute.

[0151] In this specification, unless the context requires otherwise, the term “gate” is used for convenience to refer to any movable separation member that defines, forms, or presents a separation edge (or separation boundary) at a separation point for dividing a sorted bulk material into two or more streams. A gate may be implemented as, or may include, one or more of a splitter, knife-edge, divider plate, wedge, blade, skimmer, deflector, plough, chute, lip, weir, baffle, shutter, valve element, slide / slider, louvre, flap, paddle, or any other structure arranged to physically influence, intercept, divert, collect, or separate material flow based on position relative to the sorted material distribution.

[0152] A gate may be linearly and / or rotationally moveable (including by translation, pivoting, sliding, stepping, oscillation, or combinations thereof) and may be moved continuously or in increments. The gate may be a single-piece member or a multi-part assembly (including opposed gates forming a variable gap), and may be integrated with the separator at manufacture or provided as a retrofit assembly.

[0153] References herein to a gate “position” and to movement of the gate are to be understood as referring to movement of the separation edge or separation boundary presented by the gate relative to the sorted material distribution, such that the separation point (cut-point) between streams is altered.System and Control Method

[0154] Referring now to Figure 6, there is shown an example system 600 for controlling positioning of a movable separator, such as a gate or splitter, in bulk material separation. The system 600 is general and applicable to each of the apparatus examples described herein, including the embodiments of Figures 1A-1D, Figures 2A-2F, Figures 3 A-3E, Figures 4A-4B, and Figures 5A-5E. For clarity, the functional blocksshown in Figure 6 represent logical components which may be implemented in various physical forms depending on the separator type and gate arrangement.

[0155] In the illustrated example, the system 600 includes apparatus module 605 comprising a movable gate 610 and associated sensing. The gate 610 defines a separation point (for example a cut point within a middlings band) and is movable relative to a sorting structure so as to change the separation point between at least two sorted streams.

[0156] The apparatus module 605 includes a sensor set 618 arranged to detect at least one attribute indicative of one or more physical characteristics of the sorted material proximate the separation point. The sensor set 618 shown in Figure 6 is representative of the sensor arrangements described throughout this specification, including (by way of example) sensor arrangement 14 and sensors 18a, 18b (Figures 1C-1D), sensor arrangement 214 and sensors 218a, 218b (Figures 2A-2F), sensor arrangement 314 and sensors 318a, 318b (Figures 3A-3E), sensor arrangement 414 and sensors 418a, 418b (Figures 4A-4B), and sensor arrangement 514 and sensors 518a, 518b (Figures 5A-5E).

[0157] Accordingly, the sensor set 618 may comprise one sensor, or two or more sensors, including opposed or juxtaposed sensors arranged to observe different locations relative to a separation edge, or a single multi-element sensor (for example a camera or line array) configured to provide corresponding information indicative of attribute concentration on opposed sides of the separation point.

[0158] The apparatus module 605 further includes a gate position arrangement 680 configured to provide a signal indicative of a current position of the gate 610. The gate position arrangement 680 may comprise one or more of an encoder, potentiometer, linear transducer, actuator stroke feedback, limit switches, or other suitable position feedback devices. The position signal may be used to verify commanded movement, determine absolute or relative gate position, and / or implement safety limits and homing routines.

[0159] Signals from the sensor set 618 and gate position arrangement 680 are communicated to a processor 682. The processor 682 may comprise a microcontroller,PLC, industrial computer, embedded controller, or other computing device configured to execute control logic for adjusting the position of the gate 610. In use, the processor 682 receives one or more sensor signals indicative of the detected attribute(s) and receives the position signal indicative of gate position.

[0160] The processor 682 is configured to determine whether a predetermined separation criterion is satisfied. The predetermined separation criterion may include a target grade, a target attribute concentration, a target signal level, a target relationship between two sensor signals, and / or a permitted range or tolerance around any of the foregoing. In some examples, the processor 682 may determine an inferred grade or attribute concentration by applying one or more stored correlations between sensor response and grade / attribute concentration (for example a calibration curve or lookup table derived from commissioning tests).

[0161] Based on the received signal(s) and the predetermined separation criterion, the processor 682 outputs one or more control signals to an actuator 684 coupled to the gate 610. The actuator 684 is operable to move the gate 610 to change the separation point. The actuator 684 may be a linear actuator (lead screw, servo, pneumatic, hydraulic), a rotary actuator, or any other suitable drive arrangement depending on the separator type and gate geometry.

[0162] In one example mode of operation, where the sensor set 618 includes at least two sensors arranged to observe different locations relative to the separation edge, the processor 682 compares the respective sensor responses to one another and / or to one or more stored threshold values. The processor 682 determines a direction of movement of the gate 610 that is expected to increase or decrease the sensed attribute concentration at the separation point toward the predetermined separation criterion, and commands movement of the gate 610 accordingly.

[0163] The control may be executed iteratively. For example, the processor 682 may: (i) sample the sensor signal(s), (ii) determine a disparity between the measured condition and the desired condition, (iii) command movement of the gate 610 by a predetermined step size and direction, (iv) confirm movement using the gate position arrangement 680, and (v) re-sample the sensor signal(s) after the movement. In some examples, as the measured condition approaches the desired condition, the processor682 reduces the step size of gate movement so as to converge on the desired separation point within the middlings band.

[0164] In a preferred convergence condition for a “with-attribute” and “without-attribute” sensor arrangement, the processor 682 positions the gate 610 such that a first sensor response corresponds to a desired target grade / attribute concentration and a second sensor response corresponds to a grade / attribute concentration slightly lower than the desired target, thereby indicating that the separation edge is positioned at or near an intended cut point. In other examples, the convergence condition may be defined by a threshold difference between two sensor signals, a ratio, a minimum / maximum bound, or another suitable decision function.

[0165] Movement of the gate 610 by the actuator 684 correspondingly moves the sensor set 618 where the sensor set 618 is carried by the gate 610. Accordingly, the sensor set 618 may scan across a region proximate the separation point as the gate 610 is moved, increasing the effective swath or field-of-view coverage relative to the sorted material and improving detection of changes in the location and constitution of a middlings band.

[0166] The system 600 optionally includes cloud storage / processing 686 communicatively coupled with the processor 682. The cloud storage / processing 686 may receive operational data (including sensor signals, inferred grades, and gate position histories) and may perform remote monitoring, analytics, trending, reporting, diagnostics, and / or optimisation processing. A remote user interface 692 may be coupled with the cloud storage / processing 686 to allow authorised users to view operating status and performance and, in some implementations, to adjust configuration settings or setpoints subject to permissions and safety constraints.

[0167] The system 600 optionally includes on-premises storage / processing 688 communicatively coupled with the processor 682. The on-premises storage / processing 688 may store configuration profiles, calibration correlations between sensor response and grade / attribute concentration, target setpoints, alarm thresholds, and historical logs. A local user interface 694 may be coupled with the on-premises storage / processing 688 to permit operator interaction at the separation apparatus, including display of current operating parameters, manual override functions, and setpoint entry.

[0168] The system 600 may further include a maintenance user interface 690 coupled with the processor 682. The maintenance user interface 690 may provide maintenance and commissioning functions including sensor calibration routines, actuator stroke tests, gate homing and limit setting, inspection prompts, fault code display, software / firmware update routines, and retrieval / export of event logs.

[0169] It will be appreciated that the division of functionality between the processor 682, the cloud storage / processing 686 and the on-premises storage / processing 688 may vary between implementations. For example, in some arrangements the on-premises storage / processing 688 may be integrated with the processor 682, while in other arrangements some processing (such as trending and diagnostics) may be performed remotely in the cloud storage / processing 686, with the processor 682 performing local real-time control of the actuator 684.

[0170] In each of the separator embodiments described herein, the system 600 thereby enables adaptive control of the separation point by moving the gate 610 based on attribute sensing proximate the separation edge, maintaining or optimising separation performance notwithstanding changes in feed composition, flow conditions, and / or the location and constitution of the middlings band.

[0171] It is noted that sensor elements (18, 218, 318, 418, 518) may differ between apparatus embodiments and further selection to bulk material constitution sensitivity to such sensor type. The sensor set 18 may be or include a single or multiple EMF sensing element or other detection element such as an optical sensor. One example of suitable sensor is an optical BPW20RF IR (Infra-red) photodiode which is commercially available from Vishay™ Semiconductors. These may be a coupled emission source to the sensor as part of the sensor set, providing for particulate interaction and subsequent detection by a further sensor, that may be, for example, a high-speed, high-power Infrared (IR) Emitting Diode such as a VSLY5940 also commercially available from Vishay™ Semiconductors.

[0172] However, as noted above, the sensor sets may also be multi-element, by example camera , CCD (Charge-Coupled Device), CID (Charge-Injection Devic), line array or other such sensing device or combination thereof. The emission source mayalso be multielement and multi spectral. All such sensors and combinations thereof and contemplated herein.

[0173] Referring now to Figure 7, there is shown an example method 700 for automatically positioning a gate or splitter in a bulk material separator. The method 700 may be performed by the system 600 described with reference to Figure 6, and is applicable to each separator embodiment described herein. In general, the method 700 iteratively processes sensor measurements obtained from a sensor arrangement carried by the gate and moves the gate in one of at least two directions until a desired separation condition is achieved.

[0174] At 702, a desired sensor threshold is defined. The desired sensor threshold may correspond to a target grade, target attribute concentration, or target sensor-response level associated with a preferred cut-point within a middlings band. The desired sensor threshold may be predetermined from commissioning tests and / or derived from stored calibration correlations between sensor response and grade / attribute concentration.

[0175] At 704, a sensor set measurement is obtained from the sensor arrangement carried by the gate. The sensor set provides at least two measurement signals SI and S2. In one example, SI corresponds to a measurement biased toward the stream intended to contain a higher concentration of the desired attribute (a “withattribute” measurement), and S2 corresponds to a measurement biased toward an opposing stream (a “without-attribute” measurement), each being taken proximate the separation edge. The measurements may be obtained substantially concurrently or sequentially, and may be filtered, averaged, or otherwise signal-conditioned.

[0176] At 706, the control logic determines whether SI equals the threshold (or is within an acceptable tolerance band about the threshold). If SI equals the threshold (Y), the method proceeds to 708. If SI does not equal the threshold (N), the method proceeds to 714.

[0177] At 708, the control logic determines whether S2 equals the threshold (or is within an acceptable tolerance band). If S2 equals the threshold (Y), the methodproceeds to 710. If S2 does not equal the threshold (N), the diagram indicates the condition that S2 is slightly higher than the threshold and the method proceeds to 712.

[0178] At 710, the method implements a no gate movement condition. This represents a steady-state condition in which the gate position is considered acceptable under the applied criterion. The method may continue to monitor the sensor set measurements by returning to 704 at a sampling rate suitable for the separator.

[0179] At 714, the control logic determines whether SI is lower than the threshold. If SI is lower than the threshold (Y), the method proceeds to 712. If SI is not lower than the threshold (N) (i.e., SI is higher than the threshold), the method proceeds to 716.

[0180] At 712, the system commands a step movement of the gate in direction 2. Direction 2 is selected to drive the measured condition toward the desired threshold under the circumstances leading to step 712. For example, where SI is lower than the threshold, moving in direction 2 may shift the gate and associated sensing region toward a portion of the middlings band having a higher concentration of the desired attribute such that SI increases toward the threshold. Where the method reaches 712 via 708 (i.e., SI is at threshold and S2 is slightly higher than the threshold), moving in direction 2 may shift the gate such that S2 is reduced toward the desired relationship while maintaining SI at or near the threshold.

[0181] At 716, the system commands a step movement of the gate in direction 1, opposite to direction 2. For example, where SI is higher than the threshold, moving the gate in direction 1 may shift the sensing region and separation point toward a portion of the middlings band having a lower concentration of the desired attribute such that SI decreases toward the threshold.

[0182] Following either step movement 712 or 716, the method returns to 704 to obtain updated SI and S2 sensor measurements and repeats the decision process. In this manner, the method 700 provides an iterative closed-loop positioning routine that converges on a gate position which satisfies the desired separation criterion.

[0183] In some examples, the step size used for gate movement at 712 and 716 is constant. In other examples, the step size is adaptive and may be reduced as themeasured values approach the desired threshold (for example based on the magnitude of deviation of SI and / or S2 from the threshold) to improve stability and reduce oscillation about the cut-point. The method may also implement time delays, averaging windows, deadbands, and / or confidence checks to accommodate fluctuating flows and particle statistics.

[0184] While Figure 7 illustrates threshold comparisons using SI and S2, it will be appreciated that the method may be implemented using any suitable decision function derived from SI and S2, including differences, ratios, weighted combinations, or mapped grade estimates using stored calibration correlations, while still operating to step the gate in direction 1 or direction 2 and iteratively re-measuring until a desired condition is achieved.Advantages

[0185] Advantageously there has been disclosed an apparatus system and methods provide automatic, adaptive positioning of a gate or splitter to maintain or optimise a separation cut-point as operating conditions change, including changes in feed composition, flow rate and the location / constitution of a middlings band. This can reduce reliance on manual calibration and operator judgement, supporting more consistent separation performance and product grade.

[0186] Preferably the sensor arrangement is carried by and moveable with the gate, sensing is performed proximate the separation edge and thus is directly indicative of conditions at or about the cut-point. Movement of the gate correspondingly moves the sensor arrangement, providing an effective scanning / swath-increasing function across the middlings band without requiring separate scanning equipment.

[0187] The use of a plurality of sensor measurements taken at different locations relative to the separation edge enables robust control based on a predetermined grade or attribute concentration criterion, with iterative stepwise adjustment for stable convergence. The system is adaptable across separator types (including spirals, electrostatic drums and vibratory tables) and sensor modalities (optical / IR, magnetic, thermal and others), and may be implemented as a retrofit with optional local and / or cloud monitoring, diagnostics and optimisation.

[0188] Throughout this specification and the claims which follow, unless the context requires otherwise, the word "comprise", and variations such as "comprises" and "comprising", will be understood to imply the inclusion of a stated integer or step or group of integers or steps but not the exclusion of any other integer or step or group of integers or steps.

[0189] The reference in this specification to any known matter or any prior publication is not, and should not be taken to be, an acknowledgment or admission or suggestion that the known matter or prior art publication forms part of the common general knowledge in the field to which this specification relates.

[0190] While specific examples of the invention have been described, it will be understood that the invention extends to alternative combinations of the features disclosed or evident from the disclosure provided herein.

[0191] Many and various modifications will be apparent to those skilled in the art without departing from the scope of the invention disclosed or evident from the disclosure provided herein.

Claims

The claims defining the Invention are as follows:

1. An apparatus for material sorting optimisation, the apparatus including:a sorting structure adapted to sort the material according to one or more physical characteristics of the material relative to the sorting structure to provide a sorted material;a gate positioned at a separation point relative to the sorting structure to separate the sorted material into at least two parts,a control and actuation system adapted to move the gate to change the separation point,wherein the gate carries a sensor arrangement moveable with the gate, the sensor arrangement being adapted to provide a signal indicative of at least one physical characteristic of the sorted material proximate the gate, andwherein the control and actuation system is adapted to receive the signal and move the gate based on a predetermining separation criteria to change the separation point.

2. The apparatus according to claim 1, wherein the sensor arrangement includes at least two sensors.

3. The apparatus according to claim 2, wherein the at least two sensors are arranged to detect an attribute indicative of the one or more physical characteristics of the sorted material at different locations.

4. The apparatus according to claim 3, wherein the different locations include different lateral locations across the sorted material.

5. The apparatus according to claim 3, wherein the different locations include upstream and downstream locations relative to the sorted material.

6. The apparatus according to claim 2, wherein the two sensors include optical sensors.

7. The apparatus according to claim 6, wherein the optical sensors include one or more cameras or infra-red sensors.

8. The apparatus according to claim 1, wherein the sorting structure is a spiral and the gate is positionable width wise of a section of the spiral.

9. The apparatus according to claim 1, wherein the material is a mined material.

10. The apparatus according to claim 9, wherein the mined material is mineral sands.

11. The apparatus according to claim 1, wherein the gate includes a gate body to which the sensor arrangement is fitted.

12. The apparatus according to claim 1, wherein the control and actuation system includes an actuator adapted to move the gate and a controller adapted to provide a control signal to the actuator based at least in part on the received signal13. The apparatus according to claim 1, wherein, the one or more physical characteristics of the material include, but not limited to, density, colour, and magnetic properties of the material.

14. The apparatus according to claim 1, wherein the signal indicative an attribute of the one or more physical characteristics of the material.

15. The apparatus according to claim 14, the attribute is one or more of optical and thermal characteristics.

16. The apparatus according to claim 14, wherein the attribute is one or more of one or more of colour, temperature and texture.

17. The apparatus according to claim 1, wherein the sensor arrangement comprises a single sensor or a plurality of sensors configured to sense the sorted material at respective opposing sides of a separation edge of the gate.

18. An apparatus for material separation, the apparatus including:a sorting structure adapted to sort the material according to one or more physical characteristics of the material relative to the sorting structure to provide a sorted material;a gate positioned at a separation point relative to the sorting structure to separate the sorted material into at least two parts,a control and actuation system adapted to move the gate to change the separation point,wherein the gate carries a sensor arrangement, the sensor arrangement being adapted to provide a signal indicative of at least one physical characteristic of the sorted material proximate the gate, andwherein the control and actuation system is adapted to receive the signal and move the gate based on a predetermined separation criteria to change the separation point, the sensor arrangement being movable with the gate thereby increasing the swath of the sensor arrangement relative to the sorted material.

19. A method for material separation, the method including:distributing material according to one or more physical characteristics of the material relative to a sorting structure to provide a sorted material;positioning a gate at a separation point relative to the sorting structure to separate the sorted material into at least two parts,detecting the one or more physical characteristics of the sorted material proximate the gate with a sensor arrangement carried by the gate, moving the gate based the detected the one or more physical characteristics of the sorted material to change the separation point.

20. A method for material separation, the method including:distributing material according to one or more physical characteristics of the material relative to a sorting structure to provide a sorted material;positioning a gate at a separation point relative to the sorting structure to separate the sorted material into at least two parts,detecting the one or more physical characteristics of the sorted material proximate the gate with a sensor arrangement carried by the gate, moving the gate based the detected the one or more physical characteristics of the sorted material to change the separation point, the movement of the gate increasing the swath of the sensor arrangement relative to the sorted material.

1. A system for material separation, the system including:a sorting structure configured to sort a bulk material according to one or more physical characteristics of the bulk material to provide a sorted material distribution;a movable separator configured to define a separation edge at a separation point relative to the sorting structure to separate the sorted material distribution into at least two parts;a sensor set carried by, mounted to, or movable with the movable separator, the sensor set configured to output at least one signal indicative of an attribute of the one or more physical characteristics of the sorted material proximate the separation edge;an actuator coupled to the movable separator and configured to move the movable separator to change the separation point; anda controller in communication with the sensor set and configured to: (i) receive the at least one signal,(ii) compare the at least one signal to a predetermined separation criterion, and(iii) control the actuator to move the movable separator based on the comparison to change the separation point.

22. An apparatus for material sorting optimisation, the apparatus including:a sorting structure adapted to sort the material according to one or more physical characteristics of the material relative to the sorting structure to provide a sorted material;a gate positioned to provide a separation point relative to the sorting structure to separate the sorted material into at least two parts;a control and actuation system adapted to move the gate to change the separation point;wherein the gate carries a sensor arrangement moveable with the gate, the sensor arrangement being positioned to view sorted material proximate a separationedge of the gate and being adapted to provide a signal indicative of at least one physical characteristic of the sorted material; andwherein the control and actuation system is adapted to receive the signal and move the gate based on a predetermined separation criteria to change the separation point.

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