Rock Reinforcement Mixture Flow Control
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Solution Overview
Problem
Current rock reinforcement methods in the mining industry face challenges in ensuring the quality of the multi-component mixture injected into rock holes, leading to inconsistent reinforcement and potential collapse risks due to deviations in the volume ratio of components.
Innovation Solution
A system with separate channels and pumps for each component, equipped with flow meters and a control unit that continuously compares and adjusts the flow to maintain a pre-defined volume ratio, ensuring the mixture's quality even under dynamic conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If multi-component mixture is injected for rock reinforcement, then rock strength is improved, but volume ratio consistency deteriorates
Solution Approach 1:
The system divides the mixture injection into separate channels for each component (resin and hardener), with individual pumps controlling the flow of each component. This segmentation allows independent control of each component's flow rate, ensuring precise volume ratio consistency while maintaining rock reinforcement strength.
Solution Approach 2:
The system incorporates flow meters in each channel that continuously measure the flow rate of individual components. The control unit receives this feedback information and adjusts the pump operations to maintain the desired volume ratio, correcting any deviations in real-time to ensure consistent mixture quality.
2Manufacturing precision
If flow comparison and pump control are implemented, then mixture quality is improved, but system complexity increases
Solution Approach 1:
The control unit serves multiple functions: it receives flow meter signals from both channels, processes the flow comparison data, and controls both pumps simultaneously. This multi-functionality consolidates the control architecture, reducing overall system complexity while maintaining precise mixture quality through integrated management of monitoring and actuation.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system ensures a consistent volume ratio of the components, enhancing the quality and strength of the rock reinforcement, reducing the risk of collapse and maintaining optimal mixture properties despite potential obstructions or pump deterioration.
Implementation Method 1
The respective channel comprises a pump and a container intended for the respective component. The respective component is pumped from the respective container through the respective channel.
Implementation Method 2
The respective channel comprises a pump and a container intended for the respective component. When pumping, the flow of the first component in the first channel is continuously compared with the flow of the second component in the second channel.
Implementation Method 3
The pumps are controlled individually, based on the comparison of the flows, in such a way that a deviation from a pre-defined volume ratio between the first component and the second component in the mixture is below a pre-defined first threshold.
Implementation Method 4
The first component and the second component are intended to be mixed with each other when injected in the rock hole, such that a mixture is created. The components are mixed in the mixer before, or at the same time as, they are brought into the hole.
Implementation Method 5
When the components have been mixed together a reaction occurs in the resin which is triggered by the hardener and which leads to cross-links being created in the resin resulting in the mixture hardening.
Data Source
AI summary
A method for ensuring the quality of a multi-component mixture in a system for rock reinforcement is described herein. The system comprises a first and a second channel for a respective first and second component intended for injection in a rock hole. The respective channel comprises a pump and a container intended for the respective component. The method comprises the steps of pumping of the respective component from the respective container through the respective channel and continuously comparing the flow of the first component in the first channel with the flow of the second component in the second channel. The method further comprises the step of controlling the pumps individually, based on the comparison of the flows, in such a way that a deviation from a pre-defined volume ratio between the first component and the second component in the mixture is below a pre-defined first threshold.