Rock Processing Stockpile Control via Sensor Feedback
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Solution Overview
Problem
Existing rock processing devices face challenges in optimally managing stockpiles to prevent material loss and operational disruptions, particularly due to the need for timely dismantling before stockpiles grow large enough to impede conveyor operation, and ensuring dismantling does not compromise stability or lead to material loss in adverse weather conditions.
Innovation Solution
A rock processing device equipped with a control system that uses sensors to detect stockpile parameters, determining a predicted mining time based on growth rates and shape changes, allowing for timely and controlled material removal to prevent overflow and ensure stability, with output devices providing actionable information for operators or automated systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If material is continuously conveyed to the stockpile, then productivity increases, but the stockpile grows too large and impedes conveyor operation
Solution Approach 1:
The control device performs preliminary action by determining mining time information before the stockpile actually impedes conveyor operation. Based on detection signals from stockpile sensors and growth rate calculations, the system predicts when the stockpile will reach critical size and schedules mining operations in advance, preventing operational disruptions before they occur.
2Volume of stationary object
If material is removed from the stockpile too much, then stockpile size is reduced, but stability is compromised and material loss occurs in adverse weather
Solution Approach 1:
The system implements feedback control by continuously monitoring stockpile parameters through sensors and adjusting mining operations accordingly. The control device receives detection signals, calculates current stockpile state and growth rate, and determines optimal mining timing to maintain stockpile within safe size limits while preventing excessive removal that would cause instability or material loss in adverse weather conditions.
3Loss of substance
If mining operation is delayed, then material loss from wind is reduced, but the stockpile grows large enough to block conveyor operation
Solution Approach 1:
The control device performs preliminary action by calculating mining time information in advance based on current stockpile parameters and growth rate projections. This allows the system to schedule mining operations optimally - early enough to prevent conveyor blockage but not so early as to cause material loss in adverse weather, thereby resolving the timing conflict between these two opposing requirements.
4Device complexity
If manual monitoring of stockpile size is used, then device complexity is reduced, but timely detection of critical stockpile growth is delayed
Solution Approach 1:
The system implements automated feedback control through stockpile sensors that continuously monitor stockpile parameters and transmit detection signals to the control device. This automated monitoring eliminates the delays inherent in manual observation, enabling timely detection of critical stockpile growth and immediate calculation of appropriate mining time information without increasing operational complexity for the operator.
Data Source
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AI summary
The present invention relates to a rock processing device (12) for crushing and/or sorting granular mineral material (M) by size, comprising: - a material feed device (22) with a material buffer (24), - at least one working unit consisting of at least one crushing device (14) and at least one screening device (16, 18), - at least one conveying device (26, 32) for conveying material between two device components, - at least one discharge conveying device (29, 42, 46) for conveying processed material onto a stockpile (30, 44, 48), - a control device (60), - at least one stockpile sensor (96, 98) for detecting at least one state and/or a change in the size of the stockpile (30, 44, 48) over time, wherein the stockpile sensor (96, 98) is connected to the control device (60), - at least one output device (66) for outputting information,wherein the output device (66) is connected to the control device (60). According to the invention, the control device (60) is configured to determine, in an operation with discontinuous removal of the at least one stockpile (30, 44, 48), a removal time information about the execution time of a future removal of the stockpile (30, 44, 48) based on the at least one detection signal, wherein the output device (66) is configured to output the determined removal time information.