Stockpile Conveyor Control System for Precise Placement
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Solution Overview
Problem
Conventional stockpile systems are inaccurate and imprecise in placing and locating stockpiles, do not allow for repeating previous patterns, are difficult to use, rely on timed events for equipment location, and fail to maximize stockpile capacity and desegregation.
Innovation Solution
A stockpile control system comprising sensors, limit switches, and a microprocessor that measures and controls the movement of a conveyor to accurately place and locate stockpiles, allows for pattern repetition, and continuously calculates and controls stockpile boundaries and conveyor movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional timed event control is used to determine equipment location, then the system is simple to implement, but the placement precision and location accuracy of stockpiles deteriorates
Solution Approach 1:
The patent replaces the conventional timed event control mechanism with a sensor-based detection system. Sensors mounted on the stockpile conveyor detect the actual position of the stockpile in real-time, substituting mechanical timing assumptions with direct optical or electronic measurement. This substitution dramatically improves location accuracy while the modular sensor architecture keeps the added complexity manageable.
Solution Approach 2:
The patent implements continuous feedback loops where sensors monitor stockpile position and conveyor location, feed this data back to the control system, which then adjusts control signals to maintain precise positioning. This closed-loop feedback mechanism resolves the contradiction by providing real-time correction that improves accuracy without requiring overly complex predictive algorithms.
2Manufacturing precision
If conventional stockpile systems are used, then the system structure is simple, but the manufacturing precision and placement accuracy of stockpiles deteriorates
Solution Approach 1:
The patent employs a multi-functional control system that simultaneously performs multiple tasks: sensing stockpile position, determining conveyor location, calculating boundary intersections, controlling conveyor speed and direction, and storing pattern data. This universal system approach improves placement precision by integrating all control functions into a coordinated platform rather than adding separate complex subsystems for each function.
Solution Approach 2:
The patent implements preliminary action by pre-storing stockpile patterns in the control system's memory and pre-calculating boundary intersections before material deposition begins. This allows the system to execute precise placement operations based on pre-planned trajectories, improving manufacturing precision while avoiding the need for complex real-time calculations during active stockpiling.
3Adaptability or versatility
If conventional systems without pattern storage are used, then the device complexity is low, but the ability to repeat previous stockpile patterns is lost
Solution Approach 1:
The patent implements pattern copying functionality by storing digital representations of successful stockpile patterns in memory and reproducing them by replaying the stored control sequences. This copying mechanism enables exact repetition of previous patterns while keeping the added complexity minimal, as it relies on digital data storage and retrieval rather than complex mechanical replication systems.
4Productivity
If conventional systems without continuous boundary calculation are used, then the system is simpler, but the stockpile capacity maximization and desegregation control deteriorates
Solution Approach 1:
The patent implements dynamic boundary calculation that continuously adapts to the changing geometry of the stockpile as it grows. The control system dynamically recalculates boundary intersections and adjusts conveyor control parameters in real-time based on current stockpile dimensions and material flow characteristics. This dynamic adaptation maximizes stockpile capacity by optimizing the use of available space while maintaining proper desegregation, without requiring overly complex static pre-programming.
Data Source
AI summary
A stockpile control system adapted for use on a stockpile conveyor comprising a sensor that is disposed on the stockpile conveyor, a limit switch that is disposed on the stockpile conveyor, a pile probe that is disposed on the stockpile conveyor, and a microprocessor that is in operative communication with the limit switch and the sensor. The stockpile conveyor is adapted to move, the sensor is adapted to measure the location of the stockpile conveyor, the limit switch is adapted to limit the movement of the stockpile conveyor, the pile probe is adapted to measure a distance between the stockpile conveyor and a stockpile, and the microprocessor is adapted to control the movement of the stockpile conveyor. A method for controlling the production of a stockpile comprising providing a stockpile control system, calculating one or more stockpile boundaries, and controlling the movement of the stockpile conveyor.