3D Volume Rate Controller for Bucket-Wheel Reclaimer
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Solution Overview
Problem
Current reclaim rate controllers for slewing bucket-wheel reclaimers are unable to accurately control the volume rate, leading to inefficiencies and fluctuations, as they rely on implied measurements that are affected by product characteristics and bucket-wheel cutting efficiency, and fail to account for changes in the stockpile shape during operation.
Innovation Solution
A 3D volume rate control system using 3D image sensors to provide accurate measurements of the stockpile bench face, calculating the reclaim cut volume rate based on the measured change in volume and the shape of the excavation tool, allowing for precise control of the reclaim rate independent of product characteristics and bucket-wheel cutting characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If power-based reclaim rate controllers are used, then the control system is simple to implement, but the measurement precision of reclaim rate is poor due to inability to directly measure volume rate
Solution Approach 1:
The patent replaces the mechanical/power-based measurement system with an optical sensing system. 3D image sensors (cameras) capture visual data of the stockpile face, and this optical information is processed to directly measure the volume rate of material being reclaimed, eliminating the need for power-based indirect measurement.
Solution Approach 2:
The patent introduces 3D image sensors as an intermediary between the reclaiming process and the control system. These sensors capture 3D images of the stockpile face, which are then processed to calculate the volume of material removed, providing an accurate intermediate measurement that links the physical reclaiming action to the control system.
2Reliability
If implied measurement techniques are used, then the device complexity is reduced, but the reliability of rate control deteriorates due to rate fluctuations and inability to account for stockpile shape changes
Solution Approach 1:
The patent implements a feedback control system where 3D image sensors continuously monitor the stockpile face during reclaiming operations. The measured volume rate is fed back to the control system, which adjusts the reclaimer's operation to maintain the desired reclaim rate, accounting for real-time changes in stockpile shape and material properties.
Solution Approach 2:
The patent transitions from 2D or power-based measurements to 3D volumetric measurement. By capturing 3D images of the stockpile face and calculating the actual volume of material removed, the system obtains measurement data in three dimensions, providing comprehensive information about the reclaiming process that accounts for stockpile shape changes.
3Ease of operation
If power-based controllers with correction parameters are used, then some adaptation to different conditions is achieved, but the ease of operation deteriorates due to requirement for custom correction parameters and manual adjustments
Solution Approach 1:
The patent enables the control system to automatically adapt to different products and conditions without requiring manual intervention. The 3D image sensors continuously capture the actual reclaiming process, and the system automatically calculates and adjusts the volume rate based on real-time observations, eliminating the need for operators to input correction parameters or make manual adjustments for different materials.
Solution Approach 2:
The patent dynamically changes the measurement parameters from fixed power-based values to variable 3D volumetric measurements. The system continuously updates the volume rate calculation based on changing conditions such as stockpile shape, material properties, and reclaimer operation, automatically adapting to different products and operational scenarios without requiring parameter adjustments by the operator.
Data Source
AI summary
A 3D volume rate control method and apparatus (10) for a slewing bucket-wheel stockpile reclaimer 16 is described. The apparatus (10) comprises four 3D image sensors (12) mounted adjacent a bucket-wheel (14) of the (reclaimer 16), which are adapted to provide 3D images of a stockpile bench face. The apparatus includes a data processor (20) for: (i) processing the 3D images produced by the 3D image sensors (12) to generate a 3D stockpile bench face profile, (ii) calculating a reclaim cut volume rate at which material is being cut from the stockpile face based on a measured change in volume of the 3D stockpile bench face profile in the area abutting the excavation tool, (iii) calculating a reclaim cut volume of material that will be cut from the stockpile face based on the shape of the excavation tool and the 3D stockpile bench face profile to determine a feed forward reclaim cut volume rate profile, and (iv) calculating an operating parameter for the reclaimer based on a desired reclaim cut volume rate compared to the measured reclaim cut volume rate and the feed forward reclaim cut volume rate profile. The method and apparatus provide accurate reclaim volume measurement so that the reclaim volume rate becomes independent of the product characteristics, stockpile bench face shape and bucket-wheel cutting parameters.