Mobile Surge Feeder for Continuous Mining Material Loading
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Solution Overview
Problem
Truck-shovel loading in open-cast mining is inefficient due to batch processing and difficulty in achieving 100% fill efficiency, as shovels are not well adapted for distributing overburden or mineral evenly and require trucks to reverse, leading to suspended shoveling operations and reduced volume processing rates.
Innovation Solution
A mobile surge feeder apparatus with a material receiving apron and continuous conveyor positioned between the shovel and truck, allowing for continuous material supply and even loading, enabling the feeder to move alongside the shovel and truck for optimal positioning and operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If truck-shovel loading is used for material removal, then flexibility in removal operations is improved, but fill efficiency and volume processing rates deteriorate due to batch processing and operational suspensions
Solution Approach 1:
The patent introduces a mobile surge feeder as an intermediary device between the shovel and truck. This feeder receives material from the shovel via a receiving apron and continuously discharges it to the truck, mediating the batch process into a continuous flow. The surge feeder buffer capacity absorbs the discontinuities in shovel loading cycles, maintaining continuous material flow to the truck and eliminating operational suspensions.
Solution Approach 2:
The mobile surge feeder is positioned and prepared in advance at the loading location. Its buffer capacity is pre-established to store material ahead of time, allowing the truck to be filled continuously without waiting for each shovel load. This preliminary buffering action enables the system to maintain high productivity while preserving the flexibility of truck-shovel operations.
2Device complexity
If a shovel loads trucks directly in batch process, then operational simplicity is maintained, but fill efficiency deteriorates due to difficulty in achieving 100% fill levels
Solution Approach 1:
The mobile surge feeder converts the discontinuous batch loading process into a continuous material flow. The shovel loads the feeder buffer continuously, and the feeder continuously discharges material to the truck at a controlled rate. This continuous action ensures uniform distribution of material throughout the truck volume, maximizing fill efficiency to near 100% while the shovel maintains its simple batch loading operation.
3Adaptability or versatility
If trucks reverse into position for loading, then positioning flexibility is improved, but operational time and productivity deteriorate due to periodic suspension of shoveling
Solution Approach 1:
The mobile surge feeder acts as a stationary intermediary receiving station that the truck does not need to reverse to. The shovel continuously loads the feeder, and the truck can be positioned once and fed continuously from the feeder's discharge end. This eliminates the need for trucks to reverse into position repeatedly, reducing operational time while maintaining positioning flexibility through the feeder's mobile capability.
Data Source
AI summary
A feeder is described for the conveyance of material such as overburden or mineral from a working site, the feeder comprising a feed device having a material receiving end having a material receiving apron suitable for receiving material such as overburden or mineral at a working site; a material discharge end distal of the material receiving end; an endless conveyor disposed between the material receiving apron and the discharge end so as in use to cause material received at the material receiving apron to be conveyed to the material discharge end; a chassis supporting the feed device; a transport carriage supporting the chassis and adapted to cause the feeder to be movable across a surface for deployment in use. A system A system and method for the movement of material from a working site for example via transport trucks are also described.