Method for controlling and/or regulating the feed of material to be processed to a crushing and/or screening plant of a material processing device

Abstract

The invention relates to a method for controlling and/or regulating the feed of material to be processed, in particular rock material, to a crushing and/or screening plant of a material processing device, wherein a conveyor device is used to guide the material to be processed to the crushing and/or screening plant, wherein a characteristic of the material to be processed is determined, and/or wherein a volume flow of the material to be processed is determined, and wherein a conveying speed of the conveyor device is controlled and/or regulated taking into account the characteristic and/or the volume flow of the material to be processed. The invention also relates to a material processing device designed to perform such a method.

Claims

1-17. (canceled)

18. A method for controlling and/or regulating a feed of material to be processed to a crushing and/or screening plant of a material processing apparatus, the apparatus including a conveyor configured to guide the material to be processed to the crushing and/or screening plant, the method comprising: determining a characteristic of the material to be processed and/or a volumetric flow rate of the material to be processed; and controlling and/or regulating a conveying speed of the conveyor based at least in part on the characteristic of the material to be processed and/or the volumetric flow rate of the material to be processed.

19. The method of claim 18, wherein: the characteristic includes a feed size of the material to be processed and/or a type of the material to be processed.

20. The method of claim 18, further comprising: determining a speed of the material to be processed; determining a layer thickness on the conveyor of the material to be processed; and determining the volumetric flow rate of the material to be processed based at least in part on the determined layer thickness, the determined speed of the material to be processed and a geometry of the conveyor.

21. The method of claim 20, wherein: the characteristic and/or the layer thickness is determined by at least one sensor.

22. The method of claim 21, wherein: the at least one sensor is an imaging sensor selected from the group consisting of a camera, a stereo camera, a time-of-flight camera and a laser scanner.

23. The method of claim 21, wherein: the determining of the characteristic and/or the determining of the layer thickness includes: capturing images with the at least one sensor; and evaluating the images using at least one image recognition algorithm and/or at least one object recognition algorithm to determine at least one target variable, the at least one target variable including the characteristic and/or the layer thickness of the material to be processed.

24. The method of claim 23, wherein: the at least one target variable is subdivided into classes and the evaluating of the images results in assignment of an image to one of the classes of the target variable.

25. The method of claim 23, wherein: the at least one image recognition algorithm and/or at least one object recognition algorithm is performed at least in part by at least one artificial neural network.

26. The method of claim 25, wherein: the at least one artificial neural network includes: a first artificial neural network to evaluate the layer thickness; a second artificial neural network to evaluate a type of material to be processed; and a third artificial neural network to evaluate a feed size of the material to be processed.

27. The method of claim 26, wherein: the first, second and third artificial neural networks are operated in parallel.

28. The method of claim 27, wherein: the first, second and third artificial neural networks are each operated on its own computing unit.

29. The method of claim 20, wherein: the speed of the material to be processed is measured with a speed sensor selected from the group consisting of a radar-based speed sensor, an ultrasound-based speed sensor and a laser-based speed sensor.

30. The method of claim 18, further comprising: predicting a dwell time of the material to be processed in the crushing and/or screening plant or in a region of the crushing and/or screening plant based at least in part on the characteristic of the material to be processed and the volumetric flow rate of the material to be processed; and wherein the controlling and/or regulating the conveying speed of the conveyor is based at least in part on the predicted dwell time.

31. The method of claim 30, wherein: the predicting of the dwell time is based at least in part on a drive speed of the crushing and/or screening plant.

32. The method of claim 18, further comprising: monitoring a capacity utilization of the screening and/or crushing plant; and wherein the controlling and/or regulating the conveying speed of the conveyor is based at least in part on the monitoring of the capacity utilization.

33. The method of claim 18, further comprising: determining at least one further characteristic of the material to be processed selected from the group consisting of: a layer thickness of the material to be processed on a pre-screen and/or on the screening plant; a filling level of the crushing plant; a mechanical stress of the crushing plant; a mechanical stress of the pre-screen; and a drive power of a drive motor of the crushing plant and/or the screening plant and/or the pre-screen; and wherein the controlling and/or regulating the conveying speed of the conveyor is based at least in part on the at least one further characteristic.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0034] The invention is explained in greater detail below based on an exemplary embodiment shown in the drawings. In the Figures:

[0035] FIG. 1 shows a lateral, partially cut schematic representation of a material processing device and

[0036] FIG. 2 shows a schematic drawing of the data processing equipment including an exemplary block diagram of a parallel evaluation of images by artificial neural networks.

DETAILED DESCRIPTION

[0037] FIG. 1 shows a lateral, partially cut schematic representation of a material processing device 10. The material processing device 10 can be designed as a mobile unit having a chassis 11 and for instance a chain drive 13. The material processing device 10 may comprise a crushing plant 50 and/or a screening plant 30.

[0038] A hopper 21, which may have hopper walls 22, may further be provided at the material processing device 10, in particular at a feed unit 20. The hopper 21 may be used to receive feed material 70 from an upstream conveyor, such as an excavator, wheel loader, or belt conveyor, and direct it onto a conveyor device 23. Conveyor device 23 may also be referred to as conveyor 23.

[0039] The crushing plant 50 and/or the screening plant 30 can be supplied with feed material 70 for processing in a conveying direction F by means of the conveyor device 23. In this case, the conveyor device 23 is designed as a vibratory feeder. However, other embodiments of a conveyor device 23, in particular as a conveyor belt, are also conceivable.

[0040] The screening plant 30 may, for instance, be connected upstream of the crushing plant 50 as a pre-screen unit. The pre-screen unit may comprise a heavy-duty double-deck screen 31, which may have an upper deck 32 designed as a coarser screen and a lower deck 34 designed as a finer screen. A drive 33 causes it to vibrate in a circular motion. The upper deck 32 can separate a fine fraction 71 and a medium fraction 72 from the material to be crushed 73. The lower deck 34 can separate the fine fraction 71 from the medium fraction 72. The fine fraction 71 can optionally be discharged from the material crusher plant 10 or be fed to the medium fraction 72 for instance by setting a bypass flap accordingly. The medium fraction 72 can be routed to a crusher discharge conveyor 40 past the crusher 50 via a bypass. The material to be crushed 73 is routed to the crusher 50 via a crusher inlet at the end of the pre-screen unit. The pre-screen unit may be part of the conveyor device 23.

[0041] The material processing device 10 may comprise a crushing plant 50 configured as a jaw crusher. However, it is also conceivable to provide other types of crushing plants 50, for instance impact crushers, gyratory crushers or cone crushers. The crushing plant 50 may comprise a stationary crushing jaw 51 and a moving crushing jaw 52, which may be oriented to converge at an angle such that a tapered shaft is formed therebetween. The shaft may open out into a crushing gap 56. For instance, the crushing plant 50 may be driven by a drive unit 12 via a drive shaft 55 connected to an eccentric 54.

[0042] The eccentric 54 moves the moving crushing jaw 52 towards and away from the stationary crushing jaw 51 in an elliptical motion. In the course of such a stroke, the distance between the crushing jaws 51, 52 in the area of the crushing gap 56 also changes. The motion of the moving crushing jaw 52 causes the material 73 to be crushed to be crushed further and further along the shaft until it reaches a grain size that allows it to exit the shaft through the crushing gap 56. The crushed material 74 falls onto the crusher discharge belt 40, which is used to convey it along. Provision can also be made, for instance, for it to pass a magnetic separator 41, which separates ferromagnetic components from the shredded material 74 and ejects them laterally.

[0043] As FIG. 1 further shows, the material processing device 10 may comprise a sensor 101. It is also conceivable that multiple sensors 101 are provided. As shown in the exemplary embodiment, the sensor 101 may be a camera. The camera may comprise a lens 102. A sensor holding device 110 may be used to hold the sensor 101 or sensors 101 to the material processing device 10. The sensor holding device 110 may be a pole, to which the sensor 101 or sensors 101 are attached.

[0044] The sensor 101 may be indirectly or directly attached to the material processing device 10 by a sensor adjustment device 111. Presently, the sensor 101 is indirectly attached to the material processing device 10 by a sensor adjustment device 111 via the sensor holding device 110. For instance, the sensor adjustment device 111 may enable an articulated connection to the sensor holding device 110 such that the sensor 101 or sensors 101 can be swiveled, for instance, to permit different orientations of the sensor 101 or sensors 101. It is also conceivable to attach the sensor 101 or sensors 101 to the material processing device 10 and/or the sensor holding device 110 in a height-adjustable manner.

[0045] The sensor 101 may have a detection volume 103. This can be provided, for instance, by an aperture angle of a lens 102 used. The sensor 101 may be configured to be stand-alone and/or to be used in combination with a lens 102 to sense a measurement range 104. The measurement range 104 of the sensor 101 may be in the area of the conveyor device 23.

[0046] In this case, the measurement range 104 is oriented such that the parts of the material to be processed that are located on the conveyor device 23 in the area of the prescreening area and in front thereof in the conveying direction lie in the detection area. The position of the measurement range 104 of the sensor 101 can also be chosen in a different manner, wherein preferably at least partially a range in the conveying direction upstream of the screening (30) and/or crushing (50) unit is chosen. It is also conceivable to provide multiple measurement ranges 104 with different positions, in particular when using multiple sensors 101.

[0047] As further shown in FIG. 1, a level sensor 61 may be assigned to the crushing plant 50. The latter can be designed as an ultra-sound sensor. However, it is also conceivable to use other types of sensors, such as optical sensors (for instance, a camera system), radar sensors, or mechanically acting sensors. The level sensor 61 may monitor the level of material 73 to be crushed in the crusher 50.

[0048] During operation of the material processing device 10, material to be processed is conveyed on the conveyor device 23 toward the crushing 50 and/or the screening plant 30. Here, the material being processed, which is within the measurement range 104 of one or more sensors 101, is monitored. For instance, a characteristic of the material to be processed is continuously determined.

[0049] The characteristic can be, for instance, the feed size and/or the type of material to be processed. The characteristic is determined, for instance, using a sensor 101 configured as a camera. However, it is also conceivable that the characteristic is also selected, for instance, by means of GPS data from values typical for the respective place of use of the material processing device.

[0050] Preferably, however, at least one sensor 101 captures images 106 that can be transmitted to data processing equipment 200 of the material processing device 10 schematically shown in FIG. 2. The data processing equipment 200 may be adapted to execute image recognition algorithms to determine the characteristic of the material from the images 106. The use of object recognition algorithms is conceivable here.

[0051] However, it is particularly preferred that ANNs 130, 131, 132, 133 are used for image recognition. ANNs 130, 131, 132, 133 may have been trained in advance using data sets of images 106 with known expression of a characteristic such as the feed size and/or the type of rock. For instance, ANN 132 may recognize different classes 132.1, 132.2, 132.3, 132.4 of feed sizes.

[0052] Thus, it is possible to determine the characteristic of the material that subsequently reaches the crushing 50 and/or the screening plant 30.

[0053] Furthermore, provision can be made for alternatively or additionally determining the volume flow of the material to be processed. Preferably, a speed measuring device 206, which may also be referred to as speed sensor 206 is provided for this purpose. This, for instance, can be used to determine a speed of the material to be processed located on the conveyor device 23. Speed sensor 206 may be mounted on the sensor holding device 110 adjacent the sensor 101.

[0054] To determine a volume flow, the layer thickness of the material to be processed on the conveyor device 23 can also be determined. The sensor 101 described above, which is used to determine the characteristic, for instance, or alternatively another sensor 101 may be used for this purpose. The layer thickness can also be divided into several classes 130.1, 130.2, 130.3, 130.4, etc., and evaluated by means of an ANN 130 as described above.

[0055] Preferably, the evaluation of the images 106 with respect to the various target variables is performed by means of separate ANNs 130, 131, 132, 133, wherein several ANNs 130, 131, 132, 133 preferably run in parallel each on a separate computing unit and/or CPU 202a, 202b, 202c and 202d as described below.

[0056] FIG. 2 shows an exemplary block diagram of a parallel evaluation of images 106 by ANN 130. As can be seen from the figure, the captured images 106 can be transferred to several ANNs 130, 131, 132, 133 wherein, for instance, ANN 130 can be provided for evaluating the layer thickness and/or ANN 131 can be provided for evaluating the type of rock and/or an ANN can be provided for evaluating the feed size 132 and/or a further ANN 133 can be provided for evaluating further target variables.

[0057] The target variables can be divided into classes 130.1, 130.2, 130.3, 130.4, 131.1, 131.2, 131.3, 132.4, etc., respectively, wherein the same or different numbers of classes 130.1, 130.2, etc. can be provided for the different target variables to be determined for the ANNs 130, 131, 132, 133.

[0058] The characteristic and/or volume flow of the material to be processed can now be transferred to the data processing equipment, for instance a computing and/or memory unit of the material processing device 10. Alternatively, the characteristic and/or the volumetric flow rate have been determined previously by means of the data processing equipment if, for instance, the image and/or object recognition algorithms and/or the ANNs 130, 131, 132, 133 are implemented thereon.

[0059] FIG. 2 schematically represents this alternative embodiment wherein the data processing equipment 200, which may also be referred to as a controller 200, has the ANNs implemented thereon. The data processing equipment 200 may include the separate parallel computing units and/or CPU's 202a, 202b, 202c and 202d on which the ANNs 130, 131, 132 and 133, respectively, are implemented. The data processing equipment 200 may include the memory unit 204 which may be any conventional means of data storage or computer memory. The data processing equipment 200 may receive input signals from the various sensors such as sensor 101, level sensor 61, and speed sensor 206, which input signals are indicated by arrows pointing toward the data processing equipment 200. The data processing equipment 200 may generate control signals, such as for example to control the conveying speed of conveyor 23, which control signals are indicated by arrows from the data processing equipment 200 to the controlled device.

[0060] The data processing equipment 200 can now be used to determine a target conveying speed, taking into account the transferred parameters. For instance, one or more tables, maps and/or functional relationships can be stored in computer memory 204 in the data processing equipment 200, which, taking into account the predictive parameters entered, enable a target conveying speed to be determined. The conveyor device 23 can be controlled or regulated to this target conveying speed.

[0061] Preferably, a dwell time of the material to be processed in the crushing 50 and/or screening plant 30 is predicted based on the determined characteristic and/or volume flow. In this regard, the dwell time may be a measure of how long it will take to process a volume or mass element of the material to be in the crushing 50 and/or screening plant 30 or in an area of the crushing 50 and/or screening plant 30, for instance, the dwell time in the crushing chamber in front of the crushing gap 56. Based on the predicted dwell time, the conveying speed can be predictively controlled and/or regulated accordingly preventing an overload or underload situation, such as in the case of the crushing chamber being overfilled or underfilled. In particular, a target conveying speed can be determined, which, in combination with the determined volume flow, allows sufficient processing time, in particular according to the predicted dwell time.

[0062] In other words, unlike the prior art, which reacts to underfilling or overfilling, according to the present invention, overfilling or underfilling of the crushing chamber is prevented or cannot even occur at all.

[0063] For instance, in one operating situation, it is determined that there is a hard material having a large feed size on the conveyor device 23. In particular, it is determined, for instance, that the material is to be assigned to a hardness class 131.4, which means a great hardness. Also, at the moment of detection, the material has, for instance, a high layer thickness and/or is assigned to a high layer thickness class 130.4. Based on these parameters, for instance, a comparatively long dwell time results. The dwell time can be determined from the parameters, for instance, by the data processing equipment 200. In particular, the data processing equipment 200 can determine a dwell time taking into account the parameters from one or more tables, maps and/or functional relationships stored in computer memory 204 of the data processing equipment 200, for instance. Preferably, provision can also be made for the dwell time to be determined from the determined parameters by means of an ANN.

[0064] The target conveying speed of the conveyor device 23 can be adjusted to properly process the fed material. Accordingly, then there is sufficient processing time for the material, which is equal, for instance, to the dwell time.

[0065] In this manner, the operation of the material processing device 10 can be ensured to allow an uninterrupted processing of material with optimum capacity utilization of the crushing 50 and/or screening plant 30.

[0066] For instance, to continuously improve the control and/or regulation of the conveying speed and/or the prediction of the dwell time, the fill level sensor 61 can be used to monitor the fill level of the crushing plant 50. The monitored level can be transferred to the data processing equipment 200. If then the level is detected to be too high or too low during operation despite the predictive control, the tables and/or maps and/or functional relationships can be adapted to better avoid such situations in the future.

[0067] For instance, in an operating situation where a dwell time was predicted, an excessively high crusher level is determined. In that case, for instance, the dwell time to be predicted for the parameters determined, such as the characteristic of the material to be processed, can be corrected. For instance, the recordings 106 used by the one or more ANNs 130, 131, 132, 133, 134 to determine a dwell time may be tagged (labeled) with the corrected dwell time and provided to the one or more ANNs 130, 131, 132, 133, 134 as training data.

[0068] In addition to the crusher filling level, other operating parameters such as the capacity utilization of the drive motor of the crushing 50 and/or screening plant 30 are of course also suitable for this purpose.