Robotic Mill Liner Changing With Coordinated Internal-External Manipulators
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Solution Overview
Problem
The existing methods for changing mill liners in the mining industry are inefficient, time-consuming, and pose significant risks to maintenance staff due to the need for manual intervention, high operational complexity, and the requirement for multiple personnel to perform tasks that involve heavy tools and equipment, leading to prolonged downtime and potential accidents.
Innovation Solution
An automated system utilizing robotic manipulators with at least six degrees of freedom, both inside and outside the mill, controlled by a processor-based system that allows for remote command operation, enabling precise and automated manipulation of tools for loosening, removing, and replacing liners without direct human intervention, thereby reducing the need for manual handling and minimizing risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual intervention and multiple personnel are used for changing mill liners, then the process allows for flexible handling and guidance of liners, but it increases safety risks to maintenance staff and extends maintenance downtime
Solution Approach 1:
The system enables self-service operation where the robotic manipulators autonomously perform liner removal and installation tasks without requiring human operators to physically intervene in the hazardous zone. The robotic system serves itself by automatically positioning, manipulating tools, and coordinating the entire liner changing process
Solution Approach 2:
Manual mechanical operations performed by maintenance staff are replaced with an automated robotic mechanical system. The robotic manipulators use automated control systems, sensors, and programmed sequences to perform tasks that previously required human operators to manually handle heavy tools and equipment inside the mill
2Reliability
If traditional hydraulic manipulation equipment with remote control is used, then operators can control the process from a distance, but it still requires staff to be positioned inside and outside the mill creating high-risk situations
Solution Approach 1:
The robotic manipulators are equipped with integrated sensors, control systems, and automated decision-making capabilities that allow them to autonomously navigate and perform operations without continuous human guidance. The system handles its own positioning, tool selection, and operation execution
Solution Approach 2:
The robotic manipulators are designed as multi-functional devices capable of performing various operations including liner removal, bolt manipulation, waste removal, and new liner installation. A single robotic system replaces multiple specialized tools and operations that previously required different equipment and coordination
3Productivity
If the mill is rotated multiple times during liner changing, then all liners can be accessed and replaced, but it reduces effective working time and requires lockout-tagout procedures
Solution Approach 1:
The robotic manipulator operates continuously without interruption to rotate the mill and replace liners. The automated system maintains constant operation throughout the liner changing process, eliminating idle time associated with manual repositioning, tool changes, and coordination breaks that occur in traditional methods
Solution Approach 2:
The system performs preliminary positioning and preparation actions automatically before each liner removal operation. The robotic manipulator pre-positions itself, pre-selects tools, and pre-coordinates mill rotation timing to optimize the sequence of operations and minimize total maintenance downtime
4Measurement precision
If robotic manipulators with six degrees of freedom are used, then precise automated manipulation is achieved, but the system complexity and initial setup requirements increase
Solution Approach 1:
The six-degree-of-freedom robotic manipulator is designed as a universal platform that can perform multiple liner changing operations with a single device. The same manipulator handles different tools, different liner positions, and different operational phases, making the complexity worthwhile by eliminating the need for multiple specialized devices
Solution Approach 2:
The system uses parameter changes in the form of programmable control sequences and adjustable operational parameters to adapt to different liner positions and removal requirements. Rather than physical reconfiguration, the robotic system changes its behavior through software parameter adjustments, maintaining precision while managing complexity
Data Source
AI summary
The invention relates to a system and method for the robotic and automated, coordinated, collaborative changing of mill liners, the configuration thereof allowing the full robotic and automated manipulation of the method, by means of a remote command entered by an operator by means of a processor of a control system. The system of the invention comprises: at least one robotic manipulator (2) located outside of the mill; at least one robotic manipulator (3) located inside the mill; a control system; and a series of tools that are taken and manipulated automatically by the robotic manipulators (2, 3), such that the control system sends a command to operate the at least one external manipulator (2) and the at least one internal manipulator (3) to carry out the steps of changing at least one liner of the mill in a coordinated manner with collaboration between at least the two robotic manipulators.