Excavator Boom Ore Sensing for Damage-Resistant Grade Analysis
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Solution Overview
Problem
Existing XRF-based ore sensing technologies for mining are limited to surface measurements, vulnerable to damage during operation, and lack the capability to measure mineralogy and physical properties, restricting their application to scanning during excavation.
Innovation Solution
Implementing laser-induced breakdown spectroscopy (LIBS) and active hyperspectral sensing (AHS) sensors on an excavator's boom, spaced from the bucket, to scan ore properties remotely and determine grade and mineralogy, with imaging for texture analysis.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If XRF sensors are mounted inside the mining bucket for close proximity sensing, then measurement capability is improved, but the sensors become vulnerable to damage from rocks during loading
Solution Approach 1:
The sensor is extracted from the vulnerable bucket interior and relocated to a protected position on the excavator boom, allowing the sensing function to be separated from the high-risk loading zone while maintaining operational effectiveness
Solution Approach 2:
The excavator boom serves as an intermediary structure that positions the sensor at an optimal distance from the bucket, providing both protection from damage and sufficient proximity for accurate ore composition measurement during excavation
2Measurement precision
If sensors are positioned close to the bucket for accurate ore measurement, then measurement accuracy is improved, but the sensors are exposed to harmful factors during operation
Solution Approach 1:
The sensor is extracted from the hazardous zone near the bucket opening and repositioned on the boom structure, removing it from direct exposure to falling rocks and debris while preserving its ability to measure ore properties during the excavation cycle
3Productivity
If conventional on-belt sensors are used for bulk ore sorting, then waste ore rejection is enabled, but the sensors can only measure surface properties limiting representativity
Solution Approach 1:
Ore composition is measured during the excavation phase before the ore enters the processing stream, enabling early identification and rejection of waste material while establishing a foundation for more sophisticated value-based sorting approaches downstream
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
Enables accurate, damage-resistant measurement of chemical compositions and mineralogy of the ore during excavation, allowing for real-time decision making and optimizing the cost expended per tonne of metal produced. Ensuring the energy intensity of the mining process and optimising the cost expended per tonne of metal produced.
Implementation Method 1
Implementing laser-induced breakdown spectroscopy (LIBS) and active hyperspectral sensing (AHS) sensors on an excavator's boom
Implementation Method 2
EP 2 844 987 relates to a system and method of sorting mineral streams, for example laterite mineral ores, into appropriately classified valuable and waste streams for maximum recovery of value from the mineral stream. The method includes receiving response data indicating reflected, absorbed or backscattered energy from a mineral sample exposed to a sensor, where the mineral sample is irradiated with electromagnetic energy.
Data Source
AI summary
A method of analysing ore, wherein the method includes, during excavation, scanning/sensing ore, by using a sensor. The sensor is located at a position which is (i) spaced from a bucket/shovel of an excavator and (ii) operatively higher relative to the bucket/shovel. The sensor is also directed towards the bucket/shovel, so that the sensor can scan/sense operatively downwardly towards/into the bucket/shovel. The sensor may be secured to, or mounted on, an excavator at a position which is spaced from a bucket/shovel of the excavator.