Crusher Feed Sequencing Using Predictive Truck Arrival Analytics

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Solution Overview

Problem

Conventional methods for sequencing trucks to avoid prohibited material processing at crushers are inefficient and wasteful, often leading to crusher breakdowns due to unpredictable material qualities, and lack effective use of predictive analytics to prevent such sequences.

Innovation Solution

A system comprising machines and a control system that uses predictive analytics to monitor and manage the sequence of material processing, determining a predicted sequence of arrival and processing based on telemetry data, material attributes, and destination queue data to avoid prohibited sequences, and sends commands to machines to adjust operations accordingly.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional sequencing techniques (park-up locations, diverting to stockpiles, holding at intersections) are used to manage truck sequences, then crusher breakdowns from prohibited material sequences are avoided, but productive capacity is wasted and scalability is limited due to space constraints

Engineering Contradiction:

Improvecrusher reliabilityVSAvoidproductive capacity

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The system performs preliminary sequencing of trucks based on predictive analytics before they arrive at the crusher. By analyzing telemetry data, material attributes, and destination queue data in advance, the system determines optimal sequences that avoid prohibited combinations, allowing trucks to proceed directly to the crusher without needing park-up locations or diversion to stockpiles.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent replaces physical sequencing infrastructure (park-up locations, stockpiles, intersection holding areas) with a digital control system that uses predictive analytics and telemetry data to manage truck sequences. This substitution eliminates the need for additional physical space while maintaining crusher reliability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If conventional sequencing techniques divert trucks to stockpiles or park-up locations, then prohibited material sequences are avoided, but fuel consumption increases and material re-handling costs increase

Engineering Contradiction:

Improvecrusher reliabilityVSAvoidfuel consumption

Core Design Contradiction:

ReliabilityVSLoss of energy

Solution Approach 1:

The system enables trucks to service themselves by providing real-time guidance on optimal dumping sequences through the control system. Trucks receive instructions on when and where to dump based on predictive analytics, eliminating the need for diversion to stockpiles or park-up locations and reducing fuel consumption associated with these detours.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The control system continuously monitors telemetry data from trucks, material attributes, and crusher status to provide real-time feedback on optimal sequencing. This feedback loop allows dynamic adjustment of truck sequences to avoid prohibited combinations without requiring physical diversion, thereby reducing fuel consumption and material re-handling costs.

Inventive Principle:

Principle #23Feedback

3Productivity

If real-time monitoring and predictive analytics are implemented to avoid prohibited sequences, then crusher downtime is reduced and operational efficiency is improved, but system complexity increases

Engineering Contradiction:

Improveoperational efficiencyVSAvoidsystem complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The control system performs multiple functions using a single integrated platform: it collects telemetry data from trucks, analyzes material attributes, predicts future sequences, generates optimization recommendations, and provides real-time guidance to truck operators. This multi-functionality reduces the need for separate systems for each function, thereby managing complexity while improving operational efficiency.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent introduces an intermediary control system that acts as a mediator between trucks, material attributes, and the crusher. This intermediary processes information and provides guidance without requiring direct complex interactions between all system components, thereby managing system complexity while enabling real-time predictive analytics and sequencing optimization.

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS12572864B2Avoiding prohibited sequences of materials processing at a crusher using predictive analytics

Publication Date: 2026.03.10 CATERPILLAR INC

AI summary

A method may include receiving, from at least one first machine, telemetry data. The at least one first machine may be operable to transport materials from at least one material source location to at least one material destination location. The method may further include sending at least one command to at least one machine based on whether a predicted sequence of processing of materials by at least one second machine at the at least one material destination location violates at least one prohibited sequence of processing. The predicted sequence of processing may be based on at least one of: a predicted sequence of arrival of the at least one first machine at the at least one material destination location, material attribute data, destination queue data, or a score for the predicted sequence of arrival.