Mobile Surge Conveyor Feeder for Bulk Material Handling
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Solution Overview
Problem
Conventional static plate feeders are inefficient in truck-shovel loading systems due to batch-process nature, leading to suboptimal truck fill efficiencies and processing rates, as they are not well-suited for monitoring material flow and fill levels in real-time.
Innovation Solution
A mobile surge conveyor feeder with a material flow monitoring device that measures volume and weight of material passing along the conveyor, enabling real-time monitoring and improved fill efficiency by converting batch supplies into continuous flow, facilitating more accurate and efficient truck loading.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional static plate feeders are used in truck-shovel loading systems, then the structure is simple and robust, but the truck fill efficiency is suboptimal and processing rates are limited due to batch-process operation
Solution Approach 1:
The patent transforms the static plate feeder into a mobile unit with wheeled or tracked construction, allowing it to move dynamically within the loading area. This mobility enables the feeder to adapt to different truck positions and maintain optimal loading configurations, thereby increasing processing rates without requiring complex automated positioning systems.
Solution Approach 2:
The patent introduces a surge hopper that accumulates material in continuous supply, allowing the feeder to operate continuously even when trucks are being positioned or loaded. This surge capacity eliminates idle time between loading cycles, maintaining continuous useful action and improving overall productivity without adding complex scheduling systems.
2Productivity
If conventional plate feeders operate in batch process, then the structure is simple, but the truck fill efficiency is suboptimal and cannot achieve near 100% load levels
Solution Approach 1:
The patent incorporates sensors and monitoring systems that detect material flow rates, hopper fill levels, and truck loading status. This feedback information is used to automatically adjust feeder speed, control discharge rates, and optimize loading patterns, enabling the system to achieve near 100% truck fill efficiency through real-time adjustments rather than fixed batch operations.
Solution Approach 2:
The patent replaces manual or mechanical batch-control methods with electronic sensing and control systems. Load cells, optical sensors, and flow meters substitute for mechanical gauges and manual monitoring, providing precise measurement of material quantity and flow characteristics that enable optimized loading efficiency.
3Reliability
If material is dumped directly onto the feeder, then the receiving process is simple, but the shock load damages the feeder and disrupts continuous flow
Solution Approach 1:
The patent incorporates a surge hopper that serves as a buffer between the material source and the feeder. This hopper absorbs shock loads from material dumping by temporarily storing excess material, then releasing it at a controlled rate to the feeder. This beforehand cushioning protects the feeder from damage while maintaining continuous operation without requiring complex shock absorption mechanisms.
4Ease of operation
If mobile surge conveyor feeder is implemented, then continuous operation is enabled and fill efficiency improves, but the device complexity increases with monitoring and transport components
Solution Approach 1:
The patent designs the mobile feeder unit to perform multiple functions: material reception, surge storage, continuous conveying, and automated monitoring. The integrated control system manages both transport operations and material flow optimization, allowing a single device to handle tasks that would otherwise require separate systems, thereby reducing overall system complexity while enabling continuous operation.
Data Source
AI summary
The disclosure relates to a feeder apparatus, system and method applied to the movement of bulk material and in particular for the movement of bulk run of mine material from a working site. In particular, a feeder (5) is disclosed comprising: a feed device having a material receiving end for receiving material; a material discharge end (11) distal of the material receiving end; an endless conveyor disposed to define a conveying surface (9) between the material receiving end and the discharge end (11) movable in use to cause material received at the material receiving end to be conveyed to the material discharge end (11), wherein the endless conveyor comprises a plurality of successively arrayed metal plates, pans or flights; a material flow monitoring device disposed in association with the feed device and adapted to obtain in use a measurement representative of a quantity of material passing along the conveying surface (9) of the endless conveyor; wherein the feed device is conformed as a surge conveyor; the feeder further comprises