Face Shovel Bucket Pivot Control for Stable Material Discharge
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Solution Overview
Problem
Face shovels face challenges in maintaining stable operation due to the large volume and weight of the bucket, leading to potential instability and damage during dumping, and require precise manual control to avoid material sliding and wear, which is inefficient and labor-intensive.
Innovation Solution
A control system for face shovels that automates the dumping sequence, including predefined movements to pivot the rear part of the bucket to specific orientations before and after opening, optimizing the dumping trajectory and reducing mechanical stress on the bucket components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the bucket volume is increased to handle large-scale mining operations, then productivity is improved, but stability and mechanical stress resistance deteriorate
Solution Approach 1:
The bucket is divided into two independently controllable parts: the front part (clam) and the rear part (rear wall). This segmentation allows the front part to be opened for dumping while the rear part maintains structural support and stability, enabling large bucket volumes without compromising operational reliability
Solution Approach 2:
The bucket configuration is made dynamic through independent control of the front and rear parts. The front part can be opened to a first position for dumping material while the rear part remains closed to maintain structural integrity. This dynamic configuration allows the system to adapt between maximizing productivity (open front) and maintaining stability (closed rear)
2Duration of action of stationary object
If manual control is used to prevent material sliding and wear, then bucket surface durability is improved, but operational efficiency deteriorates
Solution Approach 1:
The control system receives feedback from sensors that detect the positions of the front and rear bucket parts, the angle of the rear part, and the presence of material in the bucket. This feedback enables automatic adjustment of the dumping sequence to optimize both efficiency and bucket surface protection
Solution Approach 2:
The control system automatically executes the dumping sequence based on sensor feedback without requiring continuous manual intervention. The system self-regulates the opening/closing of the front part and the angling of the rear part to achieve optimal dumping while minimizing wear, thereby improving productivity without sacrificing bucket surface durability
3Productivity
If automated control is implemented to improve efficiency, then productivity is improved, but system complexity increases
Solution Approach 1:
The control system integrates multiple functions into a single automated sequence: it controls the opening and closing of the front part, angles the rear part to the correct position, monitors material presence, and manages the dumping trajectory. This multi-functionality achieves high productivity while limiting complexity growth through functional integration
Data Source
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AI summary
A digging machine (1) such as a face shovel is controlled in an automated dumping sequence in which the bucket (10, 10') is pivoted to a first angular orientation before opening and, optionally, re-orienting to a second, slightly more forwardly inclined angular orientation. The first orientation may relieve the front part (20) of the bucket from the load while the second orientation is selected to discharge the load at an optimal trajectory. The bucket may move to a third angular orientation before closing the front part (20) against gravity.