Bulk Material Reclaimer Control System for Flow Stability
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Solution Overview
Problem
Reclaimer automation systems face challenges such as unstable flow control due to delays in bucket wheel operations, variability in reclaiming flow, and inefficiencies in translation and turning step adjustments, leading to potential overflows and reduced productivity, as well as difficulties in accurately assessing pile features and reclaimer position.
Innovation Solution
A control system utilizing PID controllers, Extended Least Square Method, and Reinforcement Learning to estimate and optimize reclaiming flow, combined with IDDR and IATR sensors for accurate pile feature detection and reclaimer positioning, enabling simultaneous step and turning processes and predictive control to maintain consistent flow and prevent collisions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual adjustment of translation step and turning speed is used, then the operator can control the reclaimer operation, but the reclaiming flow becomes unstable and variability increases
Solution Approach 1:
The system implements automatic feedback control by continuously monitoring the actual reclaiming flow and comparing it with the target flow, then adjusting the translation step and turning speed automatically to eliminate deviations. This replaces manual operator adjustments with an automated closed-loop control system that maintains stable flow despite variations in stack conditions.
Solution Approach 2:
The reclaimer system performs self-adjustment of its operational parameters (translation step and turning speed) based on real-time flow measurements. The control system autonomously optimizes the reclaiming process without requiring continuous manual intervention, enabling the system to adapt to changing conditions while maintaining stable flow.
2Productivity
If the translation step amount is increased to improve productivity, then the reclaiming rate increases, but overflowing occurs
Solution Approach 1:
The system dynamically adjusts the translation step and turning speed based on real-time flow conditions rather than using fixed predetermined values. When the approach to the stack indicates risk of overflow, the system automatically reduces the translation step or turning speed to maintain optimal flow rates, enabling high productivity without overflowing.
Solution Approach 2:
The control system changes operational parameters (translation step distance and turning speed) based on measured flow rates and stack conditions. By continuously adjusting these parameters to match actual conditions, the system maximizes reclaiming rate while preventing overflow through automatic parameter optimization.
3Reliability
If the translation step amount is decreased to prevent overflowing, then the reclaiming flow becomes more stable, but productivity decreases
Solution Approach 1:
The system uses dynamic adjustment of translation step and turning speed based on real-time conditions rather than fixed small steps. When conditions allow, the system increases the translation step to maintain high productivity; when approaching overflow risk, it automatically reduces the step size. This dynamic approach achieves both stability and high productivity simultaneously.
4Productivity
If simultaneous turning and translation step movements are performed, then productivity increases, but control complexity increases
Solution Approach 1:
The control system merges the control of turning motion and translation step motion into a single coordinated control algorithm. By combining these movements and controlling them simultaneously through integrated feedback, the system achieves continuous reclaiming operation without interruption, maximizing productivity while managing complexity through unified control logic.
5Measurement precision
If the reclaimer performs translation step movements frequently to maintain position, then positioning accuracy improves, but reclaiming flow stability deteriorates
Solution Approach 1:
The system performs translation step adjustments only when necessary to maintain optimal positioning relative to the stack, rather than frequent adjustments. The control algorithm determines the minimum necessary adjustments to maintain positioning accuracy while minimizing disruptions to the reclaiming flow, achieving both position accuracy and flow stability.
Data Source
AI summary
The present invention refers to a control system for bulk material reclaimers that comprises an automated control of turning speed and translation step variables, the turning speed being controlled by estimating the reclaiming flow and the translation step being adjusted in function of distance.