AU2016200664B2 - System and method for loading particulate material - Google Patents
System and method for loading particulate material Download PDFInfo
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- AU2016200664B2 AU2016200664B2 AU2016200664A AU2016200664A AU2016200664B2 AU 2016200664 B2 AU2016200664 B2 AU 2016200664B2 AU 2016200664 A AU2016200664 A AU 2016200664A AU 2016200664 A AU2016200664 A AU 2016200664A AU 2016200664 B2 AU2016200664 B2 AU 2016200664B2
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- receptacle
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- profile
- sensing
- discharge chute
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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.
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Description
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[0001] This invention relates to a system and associated method for loading particulate material.
[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.
[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.
[0034] Further features of the present invention are more
fully described in the following description of several non
limiting 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.
[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 (24)
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 variable
position valve to such calculated preferred position to
dynamically regulate the flow of material.
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 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.
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 claim 10, 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 claims 10 to 12, 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 variable position valve to such calculated preferred position to dynamically regulate the flow of material.
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.
Priority Applications (1)
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AU2016200664A AU2016200664B2 (en) | 2015-02-03 | 2016-02-03 | System and method for loading particulate material |
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AU2015900319A AU2015900319A0 (en) | 2015-02-03 | System and method for loading particulate material | |
AU2015900319 | 2015-02-03 | ||
AU2016200664A AU2016200664B2 (en) | 2015-02-03 | 2016-02-03 | System and method for loading particulate material |
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AU2016200664B2 true AU2016200664B2 (en) | 2020-10-22 |
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Publication number | Priority date | Publication date | Assignee | Title |
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WO2018213869A1 (en) * | 2017-05-26 | 2018-11-29 | Der-Chang John Lee atf Ikhthus Trust | Train load-out arrangement |
Citations (4)
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US4460308A (en) * | 1982-02-08 | 1984-07-17 | Kerr-Mcgee Coal Corporation | Method for loading coal into railroad cars |
US4629392A (en) * | 1984-07-16 | 1986-12-16 | Kerr-Mcgee Coal Corporation | System for batch loading coal into railroad cars |
US6155767A (en) * | 2000-03-10 | 2000-12-05 | Walker; Harold A. | Three-batch coal loadout system and method |
WO2014197930A1 (en) * | 2013-06-11 | 2014-12-18 | Technological Resources Pty. Limited | A train loading system |
-
2016
- 2016-02-03 AU AU2016200664A patent/AU2016200664B2/en active Active
Patent Citations (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US4460308A (en) * | 1982-02-08 | 1984-07-17 | Kerr-Mcgee Coal Corporation | Method for loading coal into railroad cars |
US4629392A (en) * | 1984-07-16 | 1986-12-16 | Kerr-Mcgee Coal Corporation | System for batch loading coal into railroad cars |
US6155767A (en) * | 2000-03-10 | 2000-12-05 | Walker; Harold A. | Three-batch coal loadout system and method |
WO2014197930A1 (en) * | 2013-06-11 | 2014-12-18 | Technological Resources Pty. Limited | A train loading system |
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