AU2016200664A1

AU2016200664A1 - System and method for loading particulate material

Info

Publication number: AU2016200664A1
Application number: AU2016200664A
Authority: AU
Inventors: Der-Chang John Lee
Original assignee: SANDPIT INNOVATION Pty Ltd
Current assignee: SANDPIT INNOVATION Pty Ltd
Priority date: 2015-02-03
Filing date: 2016-02-03
Publication date: 2016-08-18
Anticipated expiration: 2036-02-03
Also published as: AU2016200664B2

Abstract

A system for loading particulate material through a discharge chute into a receptacle, a variable position valve operatively regulating a flow of material through the discharge chute, the system comprising a speed sensor for sensing a relative speed between the receptacle and the discharge chute, a volumetric flow sensor for sensing a volumetric flow of particulate material through the discharge chute into the receptacle, a profile sensor for sensing a profile of material discharged into the receptacle, and a processor arranged in signal communication with the speed, volumetric flow and profile sensors and the valve, said processor configured to receive respective inputs from the sensors, to execute a predetermined algorithm to calculate a preferred valve position according to the sensed inputs in order to maximise material discharge into the receptacle whilst minimising material spillage, and to actuate the valve to such preferred position. Pr 4-b

Description

SYSTEM AND METHOD FOR LOADING PARTICULATE MATERIAL

TECHNICAL FIELD

[0001] This invention relates to a system and associated method for loading particulate material.

BACKGROUND ART

[0002] The following discussion of the background art is intended to facilitate an understanding of the present invention only. The discussion is not an acknowledgement or admission that any of the material referred to is or was part of the common general knowledge as at the priority date of the application.

[0003] Various production and industrial processes involve the loading of particulate or granular material into receptacles or containers. A typical requirement for such processes is accurate material flow control to ensure that the relevant receptacle or container is loaded according to process requirements.

[0004] For example, in the mining industry, mined ore is loaded into ore wagons for transport purposes. Correct loading of such ore wagons is generally necessary to ensure that ore wagons are not overloaded or material loss does not occur during subsequent rail transport. At the same time, proper loading is necessary to ensure that a maximum amount of ore is loaded into each wagon to allow for efficient transport thereof.

[0005] Overloading of ore wagons can place unwanted stress on critical components which can lead to failures and even train derailments. On the other hand, under-loaded ore wagons represent wasted rail capacity and poor network efficiency.

[0006] In order to enable correct loading of such ore wagons, control systems are known whereby weight sensors are used to measure the weight of each ore wagon during the loading process. The loading is typically performed by means of a train load-out (TLO) installation, generally comprising a conveyor system feeding a bin with material and a discharge chute via which the material is discharged into the ore wagons, typically under the influence of gravity.

[0007] The flow of material is typically controlled by means of a knife gate or a clamshell gate design to regulate the flow of material from the bin into the ore wagons. In practice, a train consist is made to pass underneath the TLO and the gate is controlled to open at an appropriate time so that material passes into each wagon via the discharge chute .

[0008] The known control systems weigh each ore wagon and control the clamshell gate so that material flow is slowed as a specified full-load weight is reached. Once an ore wagon is at the specified full-load weight, the flow of material into the wagon is stopped.

[0009] However, one shortcoming of the prior art control systems is that they are operated reactively, i.e. manual input is required when loading circumstances change. For example, the known control systems are generally unable to respond to changing material characteristics, such as moisture content, particle size, temperature, etc.

[0010] For example, weight is not an accurate representation of material volume, as the same type of material may have different volumes at various levels of moisture content for the same weight.

[0011] As a result, changes in material characteristics may easily lead to under-loading or overloading, where material spillage may occur, resulting in lost production or even damage to system components.

[0012] The following invention seeks to propose a possible solution to these shortcomings.

SUMMARY OF THE INVENTION

[0013] According to a first aspect of the invention there is provided a system for loading particulate material through a discharge chute into a receptacle, a variable position valve operatively regulating a flow of material through the discharge chute, the system broadly comprising: a speed sensor for sensing a relative speed between the receptacle and the discharge chute; a volumetric flow sensor for sensing a volumetric flow of particulate material through the discharge chute into the receptacle; a profile sensor for sensing a profile of material discharged into the receptacle; and a processor arranged in signal communication with the speed, volumetric flow and profile sensors and the valve, said processor configured to receive respective inputs from the sensors, to execute a predetermined algorithm to calculate a preferred valve position according to the sensed inputs in order to maximise material discharge into the receptacle whilst minimising material spillage, and to actuate the valve to such preferred position.

[0014] The receptacle may include an ore wagon forming part of an ore train consist operatively moving underneath the discharge chute.

[0015] The speed sensor may include a radar-based speed sensor, a laser-based speed sensor, a displacement-time-type speed sensor, or the like.

[0016] The profile sensor may include a radar-based profile sensor, a laser-based profile sensor, or the like. The profile sensor may be configured to continuously sense a profile of material as such material is discharged into the receptacle .

[0017] The profile sensor may comprise a pre-load profile scanner and a post-load profile scanner configured to scan a pre-load profile and a post-load profile, respectively, of the receptacle, the processor configured to compare said pre-load and post-load profiles to determine a volume of material discharged into the receptacle.

[0018] The volumetric flow sensor may include a torque-based sensor responsive to material movement through the discharge chute.

[0019] The processor may include any suitable central processing unit configured for executing the predetermined algorithm as well as performing the control aspects of receiving sensor inputs, calculating preferred valve positions and actuating the valve. The processor typically includes an arithmetic logic unit and processor registers.

The processor may also include accessible memory for storing instructions pertaining to the predetermined algorithm, look-up tables of preferred valve positions according to sensor inputs, valve control instructions, and/or the like.

[0020] The system may include a weight sensor arranged in communication with the processor, said weight sensor configured to weigh the receptacle after material has been discharged therein. The weight sensor may also be configured to weigh the receptacle prior to the material being discharged therein.

[0021] The system may include a storage silo or bin in which particulate material is storable prior to discharge via the discharge chute.

[0022] The system may include a material level sensor arranged in communication with the processor, said level sensor configured to sense a level of material within the storage silo or bin. The level sensor may include a load cell.

[0023] The processor may be configured to calculate a density of the particulate material discharged into the receptacle. The processor may calculate the material density by sensing the material volume discharged into the receptacle with the profile sensor and sensing the weight of the loaded receptacle and performing the necessary calculations .

[0024] The system may include an input conveyor configured to feed particulate material into the storage silo or bin. The input conveyor may include a conveyor weight sensor for sensing a weight of material transported via the conveyor, and a conveyor speed sensor configured to sense a speed at which the material is transported.

[0025] Accordingly, the processor may be configured to calculate the material density by receiving inputs from the conveyor weight sensor, the conveyor speed sensor and the storage silo level sensor and performing the necessary calculations .

[0026] According to a second aspect of the invention there is provided a method for loading particulate material through a discharge chute into a receptacle, a variable position valve operatively regulating a flow of material through the discharge chute, said method broadly comprising the steps of: sensing a relative speed between the receptacle and the discharge chute; sensing a volumetric flow of particulate material through the discharge chute into the receptacle; sensing a profile of material discharged into the receptacle; calculating a preferred valve position, according to the sensed inputs, for maximising material discharge into the receptacle whilst minimising material spillage; and actuating the valve to such calculated preferred position.

[0027] The receptacle may include an ore wagon forming part of an ore train consist operatively moving underneath the discharge chute.

[0028] The step of sensing may be performed by a radar- based speed sensor, a laser-based speed sensor, a displacement-time-type speed sensor, or the like.

[0029] The step of sensing a profile may be performed by a radar-based profile sensor, a laser-based profile sensor, or the like. The step of sensing a profile may be performed continuously as material is discharged into the receptacle.

[0030] The step of sensing a volumetric flow may be performed by a torque-based sensor responsive to material movement through the discharge chute.

[0031] The system may include a weight sensor arranged in communication with the processor, said weight sensor configured to weigh the receptacle after material has been discharged therein. The weight sensor may also be configured to weigh the receptacle prior to the material being discharged therein.

[0032] The method may include the step of sensing a level of material within a storage silo in which particulate material is storable prior to discharge via the discharge chute .

[0033] The method may include the step of calculating a density of the particulate material discharged into the receptacle .

BRIEF DESCRIPTION OF THE DRAWINGS

[0034] Further features of the present invention are more fully described in the following description of several nonlimiting embodiments thereof. This description is included solely for the purposes of exemplifying the present invention. It should not be understood as a restriction on the broad summary, disclosure or description of the invention as set out above. The description will be made with reference to the accompanying drawings in which:

Figure 1 is a perspective representation of a system for loading particulate material;

Figure 2 is a closer perspective view of the system of Figure 1; and

Figure 3 is a perspective front-view of the system of Figure 1.

DESCRIPTION OF EMBODIMENTS

[0035] The following description provides examples of different embodiments of a system 10 for loading particulate material into a receptacle.

[0036] The system 10 will be described with reference to an application where the particulate material is mined ore loaded into ore wagons of an ore train. However, this example is non-limiting and other embodiments are possible where different types of particulate material are loaded into different types of receptacles.

[0037] Referring now to Figure 1, there is shown one example of a system 10 for loading particulate material. In this example, a train load-out assembly comprises a storage silo or bin 14 positioned across a rail line 7. The storage silo 14 includes a discharge chute 12 at a bottom end thereof via which any particulate material stored in the silo 14, being iron ore in this example, can be transferred into the receptacles, being ore wagons 8 in this example.

[0038] Such ore wagons 8 are generally arranged as an ore train consist 6 having a locomotive 4 as a prime mover for locomotion. Such an arrangement is well known in the art and will not be described in further detail. In use, the locomotive 4 moves the ore consist 6 underneath the discharge chute 12 which includes some manner of variable position valve 20 that determines the volume of iron ore being discharged via the chute 12. The valve 20 is typically a clamshell or knife-gate design, as is well known in the art in such an application.

[0039] The valve 20 regulates the flow of material through the discharge chute 12 according to how far 'open' or 'closed' the valve is. Maximum material flow occurs when the valve 20 is 100% open, no material flow occurs when the valve 20 is 100% closed, etc. In such a manner, the rate of material discharge through the chute 12 is controllable.

[0040] The system 10 generally includes a control box 24 housing a suitably configured processor 26 for controlling the valve 20. In this example, the valve 20 includes an actuator 22 via which movement of the valve 20 can be controlled. Such an actuator 22 is typically a hydraulic or pneumatic actuator, but may include any suitable actuator, e.g. electromagnetic, electromechanical, etc.

[0041] The processor 26 is accordingly configured to control a position of the variable position valve 20 by issuing suitable instructions to the actuator 22, e.g. open the valve 30%, close the valve 100%, open the valve 100%, or the like. It is to be appreciated that the process of the processor 26 controlling the valve is generally dynamic and done in real-time, i.e. the valve's position can be controlled precisely, accurately and timely as material is discharged through the chute 12.

[0042] The system 10 also includes a speed sensor 28 which is configured to operatively sense a relative speed between the ore wagons 8 and the discharge chute 12. In this example, the speed sensor 28 is typically a radar-based speed sensor. However, in other examples, different speed sensing technologies can be employed, such as laser-based speed sensing, displacement-time-type speed sensing, or the like .

[0043] Also included in the system 10 is a volumetric flow sensing arrangement 30 which is configured for sensing a volumetric flow rate of the particulate material through the discharge chute 12. In the current embodiment, the volumetric flow sensor 30 is typically a torque-based sensor responsive to the material movement through the discharge chute 12.

[0044] The system 10 additionally includes a profile sensor arrangement 32,34 for sensing a profile of the material discharged into the ore wagons 8. In the exemplified embodiment, the profile sensor arrangement comprises a pre-load profile scanner 32 and a post-load profile scanner 34, configured to scan a pre-load profile and a post-load profile, respectively, of each ore wagon 8. In this manner, the processor 26 can compare both pre-load and post-load scanned profiles to determine a volume of material discharged into that particular ore wagon 8.

[0045] The processor 26 is generally arranged in signal communication with the speed 28, volumetric flow 30 and profile sensors 32,34, as well as the valve 20, as described above. As such, the processor 26 is configured to receive the respective inputs from these sensors, and in response to such inputs, to execute a predetermined algorithm to calculate a preferred valve position according to the sensed inputs. Such a preferred valve position is calculated in order to maximise the material discharge into the ore wagon 8 whilst at the same time minimising any material spillage, i.e. to load the ore wagon 8 with ore as quickly as possible, according to how much ore has already been loaded, without spilling ore. The processor 26 is further configured to actuate the valve 20 to the calculated position, as described above.

[0046] It is to be appreciated that the processor 26 generally performs its functions at a frequency of several cycles per second, or Hertz. For example, sensor inputs and preferred valve position calculations, along with controlling of the valve 20, is typically performed numerous times per second during operation. In such a manner, monitoring by the sensors and control of the valve 20 is performed on a highly dynamic basis in comparison to the movement of the ore wagons 8 past the discharge chute 12. This allows for real-time monitoring and control of the valve 20, according to the sensed inputs, without any appreciable operations delays.

[0047] An important advantage of such real-time monitoring and control is that the system 10 is able to respond immediately to any changes in the flow of material through the discharge chute 12, movement of the ore wagons 8, capacity of the ore wagons 8, etc. For example, the system 10 is able to accommodate for material surges through the chute 12, changes in ore wagon speed, and/or the like.

[0048] In use, the wagon consist 6 is pulled by the locomotive 4 past the discharge chute 12, as exemplified. The respective sensors senses the speed of the ore wagons a level of material inside each ore wagon as it passes the chute 12. If an ore wagon is empty, the processor 26 is able to sense it. Similarly, if there is already some material inside a wagon, the processor 26 is able to determine a level of such material in that respective wagon.

[0049] Once the ore wagon is located underneath the chute, the processor 26 activates the valve 20 so that material is discharged into the ore wagon. The processor 26 is able to monitor the flow behaviour of the material via the flow sensor 30. In certain embodiment, the processor 26 may also monitor the level of material inside the ore wagon as it is being loaded, by means of the profile sensors 32, 34. In such a manner, each ore wagon 9 can be loaded quickly and without material spillage.

[0050] The system 10 may also include a level sensor 36 which is configured to sense a level of material stored within the silo 14. In general, the silo 14 is fed with particulate material or ore by means of an input conveyor 18, as shown.

[0051] The system may also include a weight sensor 38 configured to weigh each ore wagon 8, as required. It is to be appreciated that the weight sensor 38 may be configured to sense the weight of ore wagons along different positions on the track 7. In the shown example, the weight sensors 38 are configured to weigh each ore wagon once they have passed underneath the discharge chute 12 and have been loaded with ore .

[0052] In certain examples, the processor 26 may be configured to calculate a density of the particulate material discharged into an ore wagon. This is typically done by the processor 26 sensing the material volume discharged into the wagon with the profile sensors 32,34 and sensing the weight of the loaded wagon with the weight sensor 38 and performing the necessary calculations.

[0053] Alternatively, the system 10 may calculate the density of the particulate material by means of the input conveyor 18 including a weight sensor (not shown) for sensing a weight of material transported thereon, along with a profile scanner (not shown) to determine a volume of the material. Knowing the weight and volume of transported material, the processor 26 is able to calculate the material density.

[0054] The invention also comprises an associated method for loading particulate material through the discharge chute 12 into a receptacle 8, typically being an ore wagon 8 of a train consist 6. As described above, the variable position valve 20 operatively regulates the flow of material through the discharge chute 12.

[0055] In general, the associated method broadly includes the steps of sensing a relative speed between the receptacle 8 and the discharge chute 12; sensing a volumetric flow of particulate material through the discharge chute 12 into the receptacle 8; sensing a profile of the material discharged into the receptacle 8; calculating a preferred valve position, according to the sensed inputs, for maximising material discharge into the receptacle 8 whilst minimising material spillage; and actuating the valve 20 to such calculated preferred position.

[0056] In the above-described manner, the current invention allows for a system for loading particulate material which is able to operate dynamically taking into account material characteristics when loading circumstances change. In this manner, the system 10 is able to respond to changing material characteristics, such as moisture content, particle size, temperature, etc.

[0057] It should be appreciated that the scope of the invention is not limited to the scope of the embodiments described. Various modifications and improvements may be made to the embodiments described without departing from the scope of the invention.

[0058] Throughout this specification, unless the context requires otherwise, the word "comprise" or variations such as "comprises" or "comprising", will be understood to imply the inclusion of a stated integer or group of integers but not the exclusion of any other integer or group of integers .

[0059] It is to be appreciated that reference to "one example" or "an example" of the invention is not made in an exclusive sense. Accordingly, one example may exemplify certain aspects of the invention, whilst other aspects are exemplified in a different example. These examples are intended to assist the skilled person in performing the invention and are not intended to limit the overall scope of the invention in any way unless the context clearly indicates otherwise.

Claims

CLAIMS :

1. A system for loading particulate material through a discharge chute into a receptacle, a variable position valve operatively regulating a flow of material through the discharge chute, the system comprising: a speed sensor for sensing a relative speed between the receptacle and the discharge chute; a volumetric flow sensor for sensing a volumetric flow of particulate material through the discharge chute into the receptacle; a profile sensor for sensing a profile of material discharged into the receptacle; and a processor arranged in signal communication with the speed, volumetric flow and profile sensors and the valve, said processor configured to receive respective inputs from the sensors, to execute a predetermined algorithm to calculate a preferred valve position according to the sensed inputs in order to maximise material discharge into the receptacle whilst minimising material spillage, and to actuate the valve to such preferred position.
2. The system according to claim 1, wherein the receptacle includes an ore wagon forming part of an ore train consist operatively moving underneath the discharge chute.
3. The system according to either claim 1 or claim 2, wherein the speed sensor includes a radar-based speed sensor, a laser-based speed sensor, a displacement-time-type speed sensor, or the like.
4. The system according to any one of the preceding claims, wherein the profile sensor includes a radar-based profile sensor, a laser-based profile sensor, or the like.
5. The system according to any one or the preceding claims, wherein the profile sensor is configured to continuously sense a profile of material as such material is discharged into the receptacle.
6. The system according to any one of the preceding claims, wherein the profile sensor further comprises a preload profile scanner and a post-load profile scanner configured to scan a pre-load profile and a post-load profile, respectively, of the receptacle, the processor configured to compare said pre-load and post-load profiles to determine a volume of material discharged into the receptacle .
7. The system according to any one of the preceding claims, wherein the volumetric flow sensor includes a torque-based sensor responsive to material movement through the discharge chute.
8. The system according to any one of the preceding claims, where the system further comprises a weight sensor arranged in communication with the processor, said weight sensor configured to weigh the receptacle after material has been discharged therein.
9. The system according to claim 8, wherein the weight sensor is configured to weigh the receptacle prior to the material being discharged therein.
10. The system according to any one of the preceding claims, wherein the system further comprises a storage silo or bin in which particulate material is storable prior to discharge via the discharge chute.
11. The system according to any one of the preceding claims, wherein the system further comprises a material level sensor arranged in communication with the processor, said level sensor configured to sense a level of material within the storage silo or bin.
12. The system according to claim 11, wherein the material level sensor includes a load cell.
13. The system according to any one of the preceding claims, wherein the processor is further configured to calculate a density of the particulate material discharged into the receptacle.
14. The system according to claim 13, wherein the processor is further configured to calculate the density of the particulate material by sensing the material volume discharged into the receptacle with the profile sensor and sensing the weight of the loaded receptacle and performing the necessary calculations.
15. The system according to any one of the preceding claims, wherein the system further comprises an input conveyor configured to feed particulate material into the storage silo or bin.
16. The system according to claim 15, wherein the input conveyor includes a conveyor weight sensor for sensing a weight of material transported via the conveyor, and a conveyor speed sensor configured to sense a speed at which the material is transported.
17. The system according to claim 16, wherein the processor is further configured to calculate the density of the particulate material by receiving inputs from the conveyor weight sensor, the conveyor speed sensor and the storage silo level sensor and performing the necessary calculations.
18. A method for loading particulate material through a discharge chute into a receptacle, a variable position valve operatively regulating a flow of material through the discharge chute, said method comprising the steps of: sensing a relative speed between the receptacle and the discharge chute; sensing a volumetric flow of particulate material through the discharge chute into the receptacle; sensing a profile of material discharged into the receptacle; calculating a preferred valve position, according to the sensed inputs, for maximising material discharge into the receptacle whilst minimising material spillage; and actuating the valve to such calculated preferred position.
19. The method according to claim 18, wherein the receptacle includes an ore wagon forming part of an ore train consist operatively moving underneath the discharge chute .
20. The method according to either claim 18 or claim 19, wherein the step of sensing a relative speed is performed by a radar-based speed sensor, a laser-based speed sensor, a displacement-time-type speed sensor, or the like.
21. The method according to any one of claims 18 to 20, wherein the step of sensing a profile is performed by a radar-based profile sensor, a laser-based profile sensor, or the like. The step of sensing a profile may be performed continuously as material is discharged into the receptacle.
22. The method according to any one of claims 18 to 21, wherein the step of sensing a volumetric flow is performed by a torque-based sensor responsive to material movement through the discharge chute.
23. The method according to any one of claims 18 to 22, wherein the method further includes the step of sensing a level of material within a storage silo in which particulate material is storable prior to discharge via the discharge chute .
24. The method according to any one of claims 18 to 23, wherein the method further includes the step of calculating a density of the particulate material discharged into the receptacle .