Rock Processing Feed Planning for Discontinuous Buffer Loading

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Solution Overview

Problem

Existing rock processing apparatuses struggle with efficient operation during discontinuous material feed, leading to unpredictable output and inefficiencies due to reliance on operator response times, which can result in overloading or undersupply, especially when material buffers run empty or underfilled.

Innovation Solution

A control unit in the rock processing apparatus uses sensors to detect operating parameters and predict future material feed times, providing time information to ensure timely loading, even with discontinuous material input, by integrating input devices and data processing to adjust loading operations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If operator personnel manually decide on loading the material buffer, then the operation depends on operator abilities and experiences, but the loading timing becomes unpredictable and can lead to overloading or undersupply

Engineering Contradiction:

ImproveManual loading decision processVSAvoidLoading timing accuracy

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The rock processing apparatus performs self-monitoring and self-scheduling of material feeds autonomously. The control unit detects operating parameters, determines future material feed times, and triggers loading operations without requiring continuous manual intervention, enabling the system to serve itself in terms of material feed coordination.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The system continuously monitors operating parameters such as material buffer fill level, crusher load, and conveyor status. This feedback information is processed by the control unit to dynamically adjust and optimize the timing of future material feeds, creating a closed-loop control system that improves loading reliability.

Inventive Principle:

Principle #23Feedback

2Productivity

If the material buffer is kept filled to ensure continuous operation, then the rock processing apparatus can operate without interruption, but the loading apparatus may need to perform frequent or rushed loading operations

Engineering Contradiction:

ImproveContinuous operation capabilityVSAvoidLoading operation timing

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The control unit calculates and schedules future material feeds in advance based on predicted consumption rates and buffer fill levels. By planning loading operations ahead of time, the system prepares material feeds proactively, allowing the loading apparatus to operate at optimal pacing rather than reacting to urgent buffer levels.

Inventive Principle:

Principle #10Preliminary action

3Productivity

If the conveying capacity of the conveyor belt is adjusted to match rock processing apparatus output, then the system operates efficiently, but the adjustment must be made precisely to avoid material buffer overflow or emptying

Engineering Contradiction:

ImproveConveying capacity matchingVSAvoidConveying capacity adjustment precision

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The system dynamically adjusts the conveying capacity of the conveyor belt based on real-time operating conditions and predicted material feed timing. The control unit modulates conveyor speed and capacity to match the rock processing apparatus output, creating a flexible adaptive system that maintains precision without requiring manual calibration.

Inventive Principle:

Principle #15Dynamics

4Reliability

If sensors and control units are added to predict material feed times, then loading operations can be optimized, but the device complexity increases

Engineering Contradiction:

ImproveMaterial feed coordinationVSAvoidControl system components

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The control unit serves multiple functions: it monitors operating parameters, predicts material consumption rates, calculates future feed times, coordinates loading operations, and adjusts conveying capacity. By consolidating these diverse functions into a single multi-functional control system, the patent reduces overall complexity compared to having separate dedicated systems for each function.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS12508602B2Mobile rock processing apparatus with improved planning of a discontinuous material feed

Publication Date: 2025.12.30 KLEEMANN

AI summary

A rock processing apparatus is provided for crushing and/or sorting granular mineral material according to size. The rock processing apparatus comprises a material feeding apparatus including a material buffer, at least one working unit of at least one crushing apparatus and at least one screening apparatus, at least one conveyor apparatus for conveying material between two apparatus components, a control unit for controlling apparatus components, at least one sensor for detecting at least one operating parameter, the sensor being connected to the control unit for transmitting a detection signal, at least one output device for outputting information and connected to the control unit. The control unit is designed to ascertain, in an operation with discontinuous material feed, and based on the at least one detection signal, time information about a future material feed, wherein the output device is designed to output the ascertained time information.