Digital Twin Screening Control for Variable Earth Material Feed
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing vibratory screening devices in mineral processing plants often overlook operational context variations, leading to inefficiencies in screening processes, particularly in earth material processing where conditions can change, affecting performance metrics such as particle size distribution, energy consumption, and velocity.
Innovation Solution
A method and apparatus utilizing a digital twin (DT) to predict and control screening processes by obtaining input data from upstream and downstream devices, performing simulations, and adjusting operations based on machine learning models to optimize performance metrics like particle size distribution, feed rate, and material properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional screening devices operate without considering operational context variations, then device complexity is reduced, but screening efficiency and performance metrics deteriorate
Solution Approach 1:
The patent creates a digital twin (virtual copy) of the screening device that replicates its operational behavior and responses. This digital replica allows for simulation and prediction of screening performance under various conditions without adding physical complexity to the actual screening device, thereby improving screening efficiency while maintaining simple physical hardware.
Solution Approach 2:
The system performs preliminary simulations using the digital twin to predict how the screening device will respond to different operational contexts and material properties before actual screening occurs. This advance prediction allows optimization of screening parameters and proactive adjustments, improving efficiency without requiring complex real-time control systems.
2Reliability
If screening processes do not adapt to changing operational conditions, then device complexity is minimized, but performance metrics such as particle size distribution and energy consumption worsen
Solution Approach 1:
The patent implements a feedback mechanism where the digital twin continuously receives data from sensors monitoring actual screening performance and operational context. The system compares predicted versus actual performance, and uses this feedback to refine predictions and guide adjustments to screening parameters, ensuring consistent performance while adapting to changing conditions.
Solution Approach 2:
The system dynamically adjusts screening parameters based on real-time operational context and material properties. The digital twin models the dynamic behavior of the screening device under varying conditions, enabling the system to optimize performance consistently across different operating scenarios without requiring manual intervention or complex mechanical adjustments.
3Measurement precision
If digital twin simulations are implemented for predicting screening performance, then screening efficiency and performance prediction accuracy improve, but device complexity and computational requirements increase
Solution Approach 1:
The patent creates a digital twin (virtual copy) of the screening device that replicates its operational behavior and responses. This digital replica allows for simulation and prediction of screening performance under various conditions without adding physical complexity to the actual screening device, thereby improving screening efficiency while maintaining simple physical hardware.
4Use of energy by moving object
If proactive control based on digital twin predictions is implemented, then energy consumption and screening process efficiency improve, but device complexity increases
Solution Approach 1:
The system performs preliminary simulations using the digital twin to predict how the screening device will respond to different operational contexts and material properties before actual screening occurs. This advance prediction allows optimization of screening parameters and proactive adjustments, improving efficiency without requiring complex real-time control systems.
Solution Approach 2:
The digital twin system autonomously predicts performance and recommends optimal parameter adjustments without requiring complex external control systems. The system essentially serves itself by using its own simulation capabilities to guide operational decisions, reducing the need for additional complex control hardware and software while still achieving energy optimization.
Data Source
Figure 1~2
Figure 3
Figure 4
AI summary
Disclosed is a method (300) of operating a screening device (118) configured to carry out a screening process, the method comprising: obtaining input data indicative of the earth material process (S302), the input data representing at least one of a first type of information and a second type of information, the first type of information is indicative of operation of one or more of the set of devices (116, 118, 120) respectively arranged, relative the screening process, in one of an up-stream part and a down-stream part of the earth material process, the second type of information is indicative of earth material properties of the earth material respectively processed, relative the screening process, in one of an upstream part and a down-stream part of the earth material process; based on the input data, predicting (S304) one or more performance metrics of the screening process by performing one or more simulations using a digital twin (DT).