Crushing Plant Optical Analysis for Autonomous Size Control
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Solution Overview
Problem
Modern material crushing plants lack efficient, autonomous methods to maintain consistent product quality by adjusting crushing parameters without operator intervention, despite having advanced open-loop control systems.
Innovation Solution
An optical analysis system integrated with a neural network autonomously adjusts crushing unit parameters based on real-time image analysis of crushed material, determining geometric properties and comparing them to target specifications, iteratively correcting deviations to achieve desired material distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If autonomous control is implemented using optical analysis systems, then manufacturing precision and productivity are improved, but device complexity increases
Solution Approach 1:
The system continuously monitors crushed material properties using optical analysis systems and feeds this information back to the control unit, which automatically adjusts crushing parameters. This closed-loop feedback mechanism enables autonomous control that maintains product quality consistency without requiring complex manual intervention systems.
Solution Approach 2:
The control system is designed to autonomously adjust crushing parameters based on real-time material analysis. The system serves itself by automatically detecting deviations from target specifications and correcting them without external operator intervention, thereby improving manufacturing precision while managing complexity through automation.
2Productivity
If manual operator intervention is reduced, then productivity and efficiency are improved, but measurement precision requirements increase
Solution Approach 1:
Manual measurement and monitoring methods are replaced with optical analysis systems that automatically measure material properties. This substitution enables continuous, high-precision monitoring of crushed material distribution without requiring manual sampling or inspection, thereby improving productivity while maintaining measurement precision through advanced optical sensors and image analysis.
Solution Approach 2:
The system creates digital copies of the crushed material through optical imaging and analyzes these representations to determine material distribution. This copying approach allows for precise, non-contact measurement of material properties, enabling accurate monitoring that supports autonomous control decisions without manual intervention.
3Manufacturing precision
If real-time autonomous adjustment is implemented, then manufacturing precision is improved, but loss of time for analysis and adjustment increases
Solution Approach 1:
The optical analysis system operates continuously to monitor crushed material properties without interruption. This continuous monitoring enables real-time detection of deviations from target specifications, allowing the control system to make continuous small adjustments rather than waiting for periodic manual inspections, thereby maintaining manufacturing precision while minimizing time loss through uninterrupted operation.
Solution Approach 2:
The system performs preliminary analysis of material properties continuously and prepares adjustment decisions in advance. By analyzing material distribution trends and predicting when adjustments will be needed, the system can execute adjustments more efficiently with less real-time delay, maintaining precision while reducing the time loss associated with analysis and adjustment cycles.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Ensures consistent product quality by autonomously optimizing crushing processes, reducing the need for manual operator intervention and enhancing accuracy, efficiency, and flexibility in material crushing operations.
Implementation Method 1
taking an image of the crushed material on the conveyor belt using an optical analysis system
Data Source
AI summary
The disclosure relates to a method for operating a material crushing plant having at least one crushing unit to which material to be crushed is continuously fed and at least one conveyor belt by means of which the material crushed by the at least one crushing unit is transported away. The method involves taking an image of the crushed material on the conveyor belt using an optical analysis system. The image taken is then analyzed, wherein geometric properties of the crushed material are determined during the analysis process and a current material distribution of different material sizes in the crushed material is calculated on the basis of the determined geometric properties using the optical analysis system. A difference between the calculated and current material distribution and a target material distribution specified by an operator is then calculated using the optical analysis system, wherein at least one operating parameter of the crushing unit is then adjusted autonomously while the material crushing plant is operating by means of the optical analysis system if the calculated difference lies outside a specified tolerance range for a specified period of time.