Active Load Weight Calculation for Mining Excavators
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Solution Overview
Problem
In large-scale surface mining operations, existing systems for determining the net weight of material in mining shovel buckets often lead to increased excavation cycle times and safety hazards when the load exceeds required weight, resulting in higher labor and maintenance costs.
Innovation Solution
The method involves scanning the excavation surface using laser scanners to determine the surface shape and excavating path, calculating the volume of material excavated, and then calculating the weight based on density factors, allowing for active determination of load weight in real-time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If existing weight determination systems are used to measure load weight, then weight measurement capability is provided, but excavation cycle time increases and safety hazards occur when load exceeds required weight
Solution Approach 1:
The system performs preliminary scanning of the excavation surface and calculates the volume of material to be excavated before the actual excavation occurs. By determining the expected load weight in advance based on the calculated volume and material density, the system enables operators to adjust excavation parameters proactively, preventing overloading and avoiding unnecessary dump cycles, thus reducing overall excavation cycle time while maintaining accurate weight measurement capability
Solution Approach 2:
The invention replaces traditional mechanical weight measurement systems (such as load cells and force sensors) with a volumetric calculation system that uses laser scanning and 3D modeling to determine material volume, then converts this to weight using material density. This substitution eliminates the need for direct mechanical weighing during excavation, thereby reducing measurement time and avoiding the safety hazards associated with post-measurement detection of overload conditions
2Measurement precision
If existing weight determination systems are used, then load weight can be determined, but safety hazards and increased maintenance costs occur due to overloading
Solution Approach 1:
The system calculates the volume of material to be excavated and estimates the load weight before excavation occurs. This preliminary assessment allows operators to adjust excavation parameters in advance to ensure the load will not exceed the bucket's safe capacity, preventing overloading conditions that lead to safety hazards and equipment damage, thereby improving operational reliability while maintaining accurate weight determination
Solution Approach 2:
By replacing mechanical weight measurement systems with volumetric calculation and density-based weight estimation, the system provides reliable weight determination without the safety risks associated with mechanical overload detection. The volumetric method inherently prevents overloading by allowing pre-calculation of material volume and weight, eliminating the need for post-excavation weight verification and reducing safety hazards related to equipment overloading
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
This approach reduces excavation cycle times, enhances safety by preventing overloading, and decreases overall operational costs by accurately measuring material weight in real-time.
Implementation Method 1
an excavation surface can be scanned, an excavation surface shape can be determined based on scanned excavation surface
Data Source
AI summary
Provided is a method in which an excavation surface is scanned, the excavation surface shape is determined based on scanned excavation surface, an excavating path is identified from a mining excavation equipment, a volume of a material excavated by the mining excavation equipment is actively calculated based at least on the excavation surface shape and the excavating path of the mining excavating equipment, and a weight of the material excavated by the mining excavating equipment is actively calculated based on at least one density factor.