Stockpile Model Update via Physics Simulation
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Solution Overview
Problem
Existing bulk goods handling systems rely on expensive measuring devices for generating and updating three-dimensional stockpile models, which are not cost-effective for smaller systems and fail in dusty environments.
Innovation Solution
A deterministic, dynamic physics simulation is used to update the stockpile model, eliminating the need for measuring devices by simulating bulk goods movement during stacking and dumping, with a data model dividing the stockpile into a horizontal grid and assigning parameters to each layer for realistic and efficient operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If expensive measuring devices (laser scanners) are used to generate and update the three-dimensional stockpile model, then measurement precision and reliability are improved, but device complexity and cost increase significantly
Solution Approach 1:
The patent creates a virtual copy (digital twin) of the stockpile through physics simulation rather than using physical measuring devices. The simulation model replicates the stockpile's geometry and bulk good distribution by calculating physical processes, eliminating the need for expensive laser scanners while maintaining model accuracy.
Solution Approach 2:
The patent replaces mechanical/optical measuring systems (laser scanners) with a computational physics simulation system. Instead of physically scanning the stockpile surface, the system uses deterministic physics equations to simulate and predict stockpile geometry based on stacking and dumping operations, substituting mechanical measurement with computational modeling.
2Measurement precision
If optical measuring systems are used to record the heap surface, then measurement capability is improved, but reliability deteriorates in dusty environments with dusty bulk goods
Solution Approach 1:
The patent replaces optical measurement systems that fail in dusty environments with a physics-based simulation system. The simulation uses deterministic physics equations to model bulk good behavior during stacking and dumping, completely avoiding optical sensors and making the system reliable in dusty conditions where laser scanners cannot operate.
Solution Approach 2:
The system uses its own operational data (stacking and dumping process parameters) to automatically update the stockpile model without external measurement. The physics simulation self-corrects and updates the model based on process data, eliminating dependence on external optical measuring systems that would fail in dusty environments.
3Loss of information
If a detailed three-dimensional stockpile model is maintained through measurement, then stockpile composition knowledge is improved, but loss of time for measurement and processing increases
Solution Approach 1:
The patent performs preliminary action by predicting stockpile geometry through physics simulation before actual stacking and dumping operations complete. The simulation continuously calculates the evolving stockpile model in advance based on process parameters, eliminating the need for post-measurement model updates and reducing time loss.
Solution Approach 2:
The physics simulation runs continuously during stacking and dumping operations, continuously updating the stockpile model without interruption. This continuous computational process replaces discrete measurement cycles, maintaining real-time stockpile composition knowledge without the time loss associated with stopping operations for measurement.
4Measurement precision
If measuring devices are integrated with the bucket wheel device for continuous scanning, then measurement capability is improved, but device complexity and cost increase
Solution Approach 1:
The patent creates a virtual representation of the continuous scanning function through physics simulation rather than physical scanning devices. The simulation model continuously replicates stockpile geometry changes by calculating physical processes, providing the same information as continuous optical scanning would without requiring integrated measuring hardware.
Solution Approach 2:
The patent substitutes mechanical scanning systems (laser scanners mounted on bucket wheel devices) with a computational physics simulation system. The simulation continuously updates the stockpile model by calculating bulk good behavior during stacking and dumping, replacing the need for integrated optical-mechanical measurement systems.
Data Source
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AI summary
The invention relates to a system for operating a stockpile (1), comprising a conveyor device (2) for piling and/or unpiling bulk materials, a guiding technology device (3) which is connected to the conveyor device (2) in order to automatically control the conveyor device (2), and a control computer (4) which is connected to the guide technology device (3) and which controls the piling and/or unpiling processes on the basis of a three-dimensional stockpile model. The invention addresses the problem of providing an improved system which can measure the geometry of stockpiles without a measurement device. The invention solves this problem by providing the control computer (4) for performing a deterministic, dynamic physical simulation that simulates the movement of the bulk materials during piling and unpiling, and thus updates the stockpile model in accordance with the amount of bulk materials that have been piled and/or unpiled. The invention further relates to a method for operating a stockpile (1).