Excavator Dipper Trajectory and Spillage Detection in Mining
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Solution Overview
Problem
Mining operations face inefficiencies due to suboptimal dipper trajectories, spillage, carry-back material, and deviations from the mine plan, leading to increased energy consumption, reduced productivity, and potential hazards.
Innovation Solution
Implementing a system with LIDAR scanners and a processor to measure volumes of material removed, carried, and deposited, and determine optimal dipper trajectories, alerting operators to spillage or carry-back conditions, and optimizing digging efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the dipper dig trajectory is not ideal, then the dipper bucket is less than optimally filled and more time is required to fill haul trucks, but increasing the digging speed may cause asymmetric dumping and reduced truck stability
Solution Approach 1:
The system uses LIDAR scanners to continuously monitor the volume of material in the bucket and the volume deposited in the truck tray, providing real-time feedback to the operator through alerts when spillage or carry-back conditions are detected. This enables dynamic adjustment of digging parameters to maintain optimal trajectory and filling efficiency while preventing asymmetric dumping that would compromise truck stability.
Solution Approach 2:
The patent replaces manual operator judgment and mechanical measurement methods with optical LIDAR scanning systems that use laser ranges and 3D point cloud processing to automatically measure material volumes. This substitution provides precise, objective data on bucket fill levels and dump accuracy, enabling operators to optimize trajectories without relying on subjective assessment or trial-and-error mechanical adjustments.
2Productivity
If LIDAR scanners are mounted on the excavator to measure material volumes and provide real-time feedback, then spillage and carry-back conditions can be detected, but the device complexity increases
Solution Approach 1:
The LIDAR system serves multiple functions: it measures the volume of material in the bucket, monitors the volume deposited in the truck tray, detects spillage and carry-back conditions, and provides real-time feedback to the operator. By consolidating these measurement and monitoring functions into a single integrated system, the patent reduces overall system complexity compared to using separate devices for each function.
Solution Approach 2:
The system automatically processes LIDAR scan data to calculate material volumes and detect anomalies without requiring manual intervention. The processor autonomously compares measured volumes against expected values and generates alerts when spillage or carry-back conditions are detected, enabling the system to self-monitor and self-report issues without additional operational complexity.
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
Improves mining productivity by ensuring closer adherence to optimal dipper trajectories, reducing energy expenditure, and minimizing material loss, thereby enhancing throughput and safety.
Implementation Method 1
Laser Imaging, Detection And Ranging (LIDAR) systems have been used for several different purposes in mining environments
Data Source
AI summary
A method for improving the efficiency of a mining operation includes obtaining measurements of at least two of: a volume of mined material removed from terrain by an excavator; a volume of the mined material carried in a bucket of the excavator after removal of the material from the terrain; and a volume of the mined material deposited by the bucket in a truck tray. The method includes alerting an operator of the excavator to a possible spillage or carry-back condition if a difference between the at least two volume measurements exceeds a threshold value. Another method includes determining an optimum dipper trajectory in response to measurements of a height and radial profile of a terrain bank, a position of the excavator relative to the bank and a target volume of material to be extracted into a bucket of the dipper during the dig cycle.