Material Comminution Control Through Optical Size Distribution Feedback
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Solution Overview
Problem
Existing material comminution systems lack efficient and precise methods for optimizing the comminution process without requiring operator intervention, leading to inconsistent product quality.
Innovation Solution
An optical analysis system integrated with a neural network, such as a convolutional neural network (CNN), autonomously adjusts operating parameters of the comminution unit based on real-time image analysis of the shredded material, determining geometric properties and deviations from target distributions, and making adjustments to achieve consistent product quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual operator intervention is used to adjust operating parameters, then flexibility and adaptability are maintained, but productivity and consistency are reduced due to interruptions and human error
Solution Approach 1:
The system performs self-adjustment by automatically detecting deviations in material distribution and autonomously modifying operating parameters of the comminution unit, eliminating the need for manual operator intervention and enabling continuous uninterrupted operation
Solution Approach 2:
The optical analysis system continuously monitors the material distribution on the conveyor belt and provides real-time feedback to the control system, which automatically adjusts operating parameters when deviations from target distribution are detected, creating a closed-loop control system
2Measurement precision
If advanced control systems with sensors are implemented, then measurement precision and control accuracy are improved, but device complexity increases
Solution Approach 1:
The patent replaces complex mechanical sensing and measurement systems with an optical analysis system that uses cameras and image processing algorithms to analyze material distribution, simplifying the overall system structure while maintaining high measurement precision
Solution Approach 2:
The system creates visual copies (images) of the material distribution on the conveyor belt and analyzes these digital representations using image processing algorithms, substituting physical measurement devices with optical copying and digital analysis
3Reliability
If autonomous adjustment is implemented, then productivity and consistency are improved, but device complexity increases due to integration of optical analysis and control systems
Solution Approach 1:
The control system is designed to perform multiple functions: it receives data from the optical analysis system, processes information, compares actual distribution with target distribution, and automatically adjusts operating parameters, reducing the need for separate dedicated components
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 continuous optimization of the comminution process, ensuring high accuracy, efficiency, and flexibility by autonomously adjusting operating parameters to maintain target specifications, reducing the need for manual operator intervention.
Implementation Method 1
Creating an image of the shredded material on the conveyor belt with the aid of an optical analysis system
Data Source
AI summary
The invention relates to a method for operating a material comminution plant comprising at least one comminution unit, to which material to be comminuted is continuously fed, and at least one conveyor belt, from which the material comminuted by the at least one comminution unit is transported away. In the method, an image of the comminuted material on the conveyor belt is created using an optical analysis system. The created image is then analyzed. During the analysis, geometric properties of the comminuted material are determined, and a current material distribution of different material sizes in the comminuted material is calculated using the optical analysis system based on the determined geometric properties.Then, a deviation between the calculated and current material distribution and a target material distribution specified by an operator is calculated with the aid of the optical analysis system, wherein at least one operating parameter of the shredding unit is then adjusted autonomously during ongoing operation of the material shredding system with the aid of the optical analysis system if the calculated deviation lies outside a specified tolerance range for a specified period of time.