巴西专利BR112015005665B1 3d volume coefficient control apparatus and method for a reclaimer

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专利摘要:
RECOVERY 3D VOLUME COEFFICIENT CONTROLLER. 3D volume coefficient control method and apparatus (10) for rotating stockpile bucket wheel reclaimer comprising four 3D image sensors (12) adjacent to the bucket wheel (14) (reclaimer 16) providing 3D face images of bench stockpile. Includes data processor (20): (i) processing 3D images produced by the 3D sensors (12) generating 3D profile of the bench stockpile face; (ii) calculate cut volume coefficient to be retrieved from the face of the stockpile pile based on the change in the volume of the 3D profile of the face of the bench stockpile; (iii) calculate volume of cut material to be taken up from the face of the stockpile by determining the profile of the cut volume coefficient; and (iv) calculate operating parameter for retaker based on the previous items. The methods and apparatus provide accurate measurement of reclaimed volume regardless of product characteristics, bench stockpile face shape, and bucket wheel cutting parameters.
公开号:BR112015005665B1
申请号:R112015005665-2
申请日:2013-09-13
公开日:2021-05-11
发明作者:Paul John Wighton
申请人:3D Image Automation Pty Ltd；
IPC主号:

专利说明:

Field of Invention
[001] The present invention relates to a 3D volume coefficient control method and apparatus for controlling the recovery coefficient of a stockpile reclaimer and relates in particular, though not exclusively, to said applied method and apparatus to the rotating bucket wheel reclaimer. Background of the Invention
[002] Spinning bucket wheel reclaimers are the most common types of reclaimers used in the iron ore and coal industries. Another common type of reclaimer is the bridge reclaimer.
[003] Bucket wheel reclaimers are high cost items in mining. The cost of individual machines can exceed $30M, with the stockyard support infrastructure adding a significant cost. A relatively small improvement in the productivity of the reclaimer will provide a significant economic benefit to the business. As an example of the economic benefit that can be achieved is given below:
[004] Ship loading time is 20 hours for 200 kt to 10,000 tph.
[005] A 2.5% recovery coefficient improvement (10,000 tph to 10,250 tph) reduces ship loading time by approximately 30 minutes.
[006] Based on 300 machine production days per year this equates to a 150 hour reduction in machine operating time.
[007] Sustained coefficient improvement will provide >5,000 t per day of increased machine output.
[008] Based on 300 days of machine utilization per year, this equates to a production opportunity of more than 1.5 Mt per year.
[009] Slewing bucket wheel reclaimers operate as follows. The stockpile is taken up in a series of 'Benches' where each bench defines a layer of the stockpile, as illustrated in Figure 2. The height of each layer depends on the size of the bucket wheel, with a typical bench height being equal to the radius of the bucket wheel (5.0 meters) and the maximum height of the bench being 0.65 in diameter (6.5 meters). The reclaimer starts at the top of the bench in a previously stacked stockpile and resumes the bench in a series of radial cuts by rotating (alternating) the bucket wheel across the face of the stockpile, as shown in Figure 2.
[010] At the end of each face cut, the reclaimer travels forward (Advance Step) a short distance (typically 1.0 m for a 5.0 m bucket wheel), and then starts the next cut. The retake coefficient is controlled during face cutting by adjusting the speed of the rotation movement. The general formula for retake coefficient when digging the full height of the bench face, in cubic meters per second, at any point along a face cut is:
[011] Face height (meters) x Face cut depth (meters) x Radial rotation speed (meters per second).
[012] Where: Face Cut Depth = Cosine (Angle of Rotation) x Feed Step Distance
[013] The actual coefficient will depend on the shape of the stockpile on the face of the bucket wheel.
[014] The vast majority of bucket wheel reclaimers are equipped with energy-based retake coefficient controllers. Energy-based retake coefficient controllers derive an implicit retake coefficient based on the bucket wheel's digging power.
[015] The retake is performed in order to move the product from a stockpile to a destination, whether on a train, ship or other stockpile by means of a transport system.
[016] In general terms, the minimum cost to move the product is achieved by transporting the product at a maximum coefficient supported by the transport equipment. The maximum coefficient supported by the transport equipment is determined by the maximum volume coefficient. For example: 1. The maximum transport coefficient for a conveyor belt is generally limited by the volume that can be handled without splashing over the belt edges. 2. The maximum transport coefficient for the transfer chute is limited by the volume that can pass through the chute without blocking.
[017] Although volume is usually the limiting factor, current retake coefficient controllers use an implicit retake weight coefficient controller (controls in tons per hour). One of the disadvantages of prior art retake ratio controllers is the inability to control the retake ratio in terms of volume. This is due to the inability to measure the volume coefficient on the bucket wheel. The inability to control the volume coefficient means that it cannot reach the maximum transport volume coefficient.
[018] Although the volume is in general the limiting factor for the transport equipment, there are cases where the weight is also a limiting factor. For example, a conveyor stand may have a weight limitation that overcomes the volume limitation of the conveyor belt itself. In these cases, maximum transport efficiency is achieved by maintaining a consistent transport coefficient. Current resume coefficient controllers perform poorly in terms of coefficient fluctuation. This is because of their inability to accurately measure the resumption coefficient based on implicit measurement techniques. This will be further explained in the next section.
[019] In the case where there is a need to revert to a low coefficient, the inaccurate coefficient measurement of the current coefficient controllers results in an incorrect coefficient and high coefficient fluctuations. Energy-based coefficient controllers are unable to determine the edges of the stockpile at low retake coefficients and often require operator intervention to adjust fixed retake rotation limits.
[020] Due to the low depth of cut in the region of external rotation of the face cut of the stockpile, it is advantageous to finish the cut early for several cuts before cleaning the rib with a single longer cut. This practice is known as the 'Waltz Step' of 'Cleaning Pass'. However, 'Waltz Step' resumption is rarely used with energy-based coefficient controllers, mainly due to their inability to adequately control the coefficient during step changes in depth of cut between the actual face. and the outer rib.
[021] Current rebound coefficient control systems use the implicit methods to measure rebound coefficient, including dig energy (actual bucket wheel) or dig force (bucket wheel torque). The rebound coefficient achieved depends on the bucket wheel's digging efficiency (cubic meters per unit of energy/force) which is affected by a range of parameters that include: • Product type (particularly bead size) • Composition product mineral (mine and ore body section) • Density of product (variation from product source) • Moisture content (from rain or dust suppression sprays) • Secondary processing (combinations of crushing, screening and mixing ) • Bucket wheel cutting efficiency for different products • Bucket wheel cutting efficiency for Clockwise vs. counterclockwise • Bucket wheel cutting efficiency due to wear • Product compaction (time since stacking) • Stacking pattern • No load current/torque deviation • No linear load to coefficient ratio
[022] As the state of the stockpile is unknown, it is not possible to provide a compensation for these factors. This results in less-than-optimal retake coefficients. Efforts to improve the productivity of the reclaimer are limited by the measurement error of the retake coefficient.
[023] Several systems have attempted to improve the accuracy of the implicit retake coefficient by using single-point or 2D radar sensors. Such systems may collectively be referred to as 'predictive coefficient controllers'. Predictive coefficient controllers use 2D radar readers to predict the approximate volume that will be taken up by the bucket wheel. Predictive volume based systems perform a vertically oriented 2D read of the face of the stockpile, with the third dimension being provided by the rotational movement. The 2D scanner is located in a position ahead of the bucket wheel.
[024] An example of a prior art predictive coefficient controller that uses a 2D radar reader is the system marketed by Indurad (Germany) as the 'Bucket Wheel Excavator Predictive Cut Control'. The control is described to provide the customer benefits of 'predictive volume flow information and operator assistance'.
[025] The radar scanners used in existing predictive systems are based on 77 GHz vehicle collision avoidance radar units. The combination of field-of-view (FOV) angle resolution (typically 4 degrees) and accuracy of target distance (typically ±150 mm) results in an inability to measure the face of the stockpile volume, particularly when the bucket wheel's cutting depth is less than one meter (1.0 m).
[026] During retake operations, the stockpile area around the bucket wheel will collapse and flow as the product is removed. Accurate measurement of the retake coefficient requires that the volume in the area that comes into contact with the bucket wheel is continuously measured. The 2D nature of the predictive volume reading system means that the actual volume being taken up by the bucket wheel cannot be measured. Instead, the resumed volume is predicted. The collapse and dynamic movement of the stockpile due to product flow is not measured.
[027] Predictive volume systems are typically used for operator assistance on manually operated retakers or as the theoretical speed (forward feed) of an implicit (current/torque) retake coefficient controller. Although predictive volume systems improve the performance of an implicit coefficient controller, the performance of the control is still affected by the same factors as the default implicit coefficient controller.
[028] The use of prior art 3D laser scanning for forklift trucks and reclaimers is described in European patent EP 1278918, also published as US 2005/0246133. Said prior art document is hereinafter referred to as P2.
[029] The system described in P2 reads the stockpile to finish the shape of the stockpile in order to control the movement of the reclaimer to the up-facing position and to determine the rotating range of the bucket wheel during retake .
[030] One of the problems that P2 seeks to overcome is the inaccuracies in the storage pile model that occur when using a 2D reader where the shape of the storage pile is initially determined through a measurement pass of the wheel device. bucket and scanner in 2D, and then after the removal or stacking process is started the controller calculates a provisional model of the stockpile.
[031] However, said 2D system cannot detect changes in the shape of the stockpile that occur during the operation of the bucket wheel device, for example, due to rain and natural sliding processes or the like, as well as slips or slips triggered by a removal process itself. P2 overcomes said problems by reading the stockpile which uses a 3D laser reader to determine the actual shape of the stockpile regardless of the operation of the bucket wheel device. The system described in P2 includes GPS receivers to provide accurate position information to the bucket wheel retrieval and/or the bucket wheel itself. A claimed benefit of the system described in P2 is that a stockpile shape can be captured without performing the measurement pass and that collision in the stockpile is avoided.
[032] The system described in P2 is not able to measure the retake volume on the bucket wheel as the area that comes in contact with the bucket wheel is not read. Additionally there is no description or suggestion in P2 to calculate a reclaimed volume of material that will be cut from the face of the stockpile, based on the shape of the excavation tool and the 3D shape of the stockpile, to determine a coefficient cutting the resumed volume. In fact there is no reference in P2 or volume measurement or resumption coefficient control. The control function described is to position a bucket wheel device in dependence on the measured shape of the stockpile, so as to optimize the initial up-facing positioning of the bucket wheel and to control the bucket wheel oscillation range with based on the shape of the stockpile.
[033] A commercial implementation of P2 was developed by iSAM AG (Germany) and is marketed by FL Smidt as the 'iSAM for Stacker Reclaimers' Automation system. The referred commercial implementation of P2 uses implicit rebound coefficient control based on bucket wheel energy.
[034] The present invention was developed with an intention to provide a 3D volume coefficient control method and apparatus that is less susceptible to the aforementioned problems and disadvantages of the prior art of implicit resume coefficient controllers and of the predictive coefficient.
[035] References to the prior art in the present specification are provided for illustrative purposes only and should not be taken as an admission that said prior art is part of common general knowledge in Australia or elsewhere. Invention Summary
[036] According to one aspect of the present invention there is provided a 3D volume coefficient control apparatus for the stockpile reclaimer, the apparatus comprising: a plurality of 3D image sensors mounted adjacent to a digging tool. reclaimer and adapted to provide 3D images of the face of the bench stockpile; and, a data processor to: (i) process the 3D images produced by the 3D image sensors to generate a 3D profile of the face of the bench stockpile, (ii) calculate a cut volume coefficient to resume in which the material is being cut from the face of the stockpile pile based on a measured change in the volume of the 3D profile of the face of the bench stockpile in the area that contacts the excavation tool, (iii) calculate a volume of cut material to be taken back that will be cut from the face of the stockpile pile based on the shape of the excavation tool and the 3D profile of the face of the bench stockpile to determine a profile of the cut volume coefficient to take back with the feed forward, and (iv) calculate an operating parameter for the reclaimer based on the desired cut volume retake coefficient compared to the measured cut volume reclaim coefficient and the cut volume coefficient profile a resume with forward feeding.
[037] Preferably respective 3D image sensors are mounted on each side and adjacent to the excavation tool to provide 3D images of a complete cutting arc of the excavation tool on the face of the stockpile. Preferably the 3D image sensors also provide 3D images that extend along the oscillating arc for a distance sufficient to cover areas of the face that may flow or collapse around the excavation tool.
[038] Typically four 3D image sensors are provided, two on each side of the excavation tool respectively, in order to avoid the occlusion of the image by the support and drive structures of the excavation. In one modality, 3D image sensors are time of flight type 3D cameras that measure the distance to an object in front of the camera by analyzing the time it takes for a pulse of light to travel from a light source to the object and come back.
[039] Typically the reclaimer is a bucket wheel reclaimer and the digging tool is the bucket wheel. In the preferred embodiment, the bucket wheel reclaimer is the rotating bucket wheel reclaimer. Advantageously the four 3D cameras are located immediately adjacent to the bucket wheel and oriented so that the full cutting arc of the bucket wheel is measured.
[040] By providing accurate measurement of the volume taken up, the coefficient of volume to take up becomes independent of the product characteristics, the shape of the face of the stockpile and the cutting characteristics of the bucket wheel.
[041] Although measuring and calculating the resumed volume is complex, the application of bucket wheel speed control is simplified as there is no longer any need to apply the custom correction parameters that are typically needed to improve the performance of power-based controllers.
[042] The measured shape of the stockpile face is also used to provide enhanced machine safety and bucket wheel position control which operates in unison with the 3D volume coefficient controller to provide reclaimer performance enhancements.
[043] According to another aspect of the present invention a 3D volume coefficient control method is provided for the stockpile reclaimer, the method comprising the steps of: obtaining 3D images of the face of the stockpile; processing the 3D images to generate a 3D profile of the face of the bench stockpile; calculate a cut volume coefficient to resume based on a measured change in the volume of the 3D profile of the face of the bench stockpile in the area that contacts the excavation tool; calculate a volume of cut material to be reclaimed that will be cut from the face of the stockpile based on the shape of the reclaimer digging tool and the 3D profile of the bench stockpile face to determine a volume coefficient profile from cut to feed forward; and, calculating an operating parameter for the reclaimer based on the desired cut volume retake coefficient compared to the measured cut volume reclaim coefficient and the cut volume reclaim coefficient profile with the feed forward.
[044] Preferably, the step of calculating the volume of cut material to be taken back is performed by producing a cutting height map of the excavation tool, which is a two-dimensional structure of distance values measured from a reference on the excavation tool. excavation to an edge of the tool where the tool cuts into the face of the stockpile.
[045] Typically the reclaimer is a bucket wheel reclaimer, the dig tool is the bucket wheel, and a dig tool height of cut map is a bucket wheel height of cut map. In the preferred embodiment, the bucket wheel reclaimer is the rotating bucket wheel reclaimer.
[046] Typically the reference on the excavation tool is an arc formed by a point in the center of the bucket wheel as the bucket wheel is rotated outward through the face of the stockpile (bench arc). Distance values are preferably defined as the distance (in meters) from a bench arc and are measured along a series of radii running perpendicular to the bucket wheel axis (cutting arc). The series of spokes typically extends from a spoke that points vertically down to a spoke that points forward to the center of the bucket wheel face. Advantageously the angular separation between the spokes is chosen to match the camera target spot size on the face of the bucket wheel.
[047] Typically the step of calculating a cutting volume coefficient to be taken back involves a step of calculating the volume of material on the face of the bench stockpile. Preferably the step of calculating the volume of material on the face of the bench stock pile is performed by calculating the sum of the volumes for each point of the face profile of the bench stock pile in the area that contacts the bucket wheel.
[048] Preferably the coefficient of volume to be taken up is calculated by comparing the volume of the face of the bench stockpile at the two points in time as the bucket wheel cuts the face of the bench stockpile.
[049] Preferably a profile map is created to store a face profile of the bench stockpile, with each point of the profile defined in terms of the distance from a bench arc, along a radius of the cutting arc .
[050] Preferably a bucket wheel face height map is calculated from the face profile of the bench stockpile, with each point representing the distance from a bench arc.
[051] Preferably a bucket wheel face height map is subsequently used to calculate the bucket wheel cut volume per meter of bench arc length at intervals along a bench arc of the bucket face pile. bench stock, based on the known cutting radius of the bucket wheel.
[052] Preferably the reclaim volume coefficient and the bucket wheel shear volume per meter are used in conjunction with the desired reclaim volume coefficient to calculate the rotation speed of the bucket wheel at all points along of a bench arch. Preferably the calculated rotation speed of the bucket wheel is reported to the reclaimer's rotation speed control system.
[053] Throughout the specification, unless the context otherwise requires, the term "comprises" or variations such as "comprises" or "comprises" will be understood to imply the inclusion of a particular integer or group of whole numbers, but not the exclusion of any other given whole number or group of whole numbers. Likewise the term "preferably" or variations such as "preferred", will be understood to imply the inclusion of a particular integer or group of integers being desirable, but not essential to the functioning of the present invention. Brief Description of Drawings
[054] The nature of the present invention will be better understood from the following detailed description of the various specific modalities of the 3D volume coefficient control method and apparatus, given as an example only, with reference to the attached drawings, in which:
[055] Figure 1 illustrates a typical prior art rotating bucket wheel reclaimer;
[056] Figure 2 illustrates a typical prior arrangement of prior art benches in the stockpile;
[057] Figures 3 and 4 are a side view and a plan view respectively illustrating the reading arc for each camera in the preferred embodiment of a 3D volume coefficient control apparatus according to the present invention;
[058] Figure 5 illustrates the camera locations on each side of the bucket wheel in the Figure 3 apparatus;
[059] Figure 6 illustrates the field of view of each camera on the face of the bucket wheel in the apparatus of Figure 3;
[060] Figure 7 illustrates the coordinates of the camera as used in the apparatus of Figure 3;
[061] Figure 8 illustrates the target coordinates of the camera as employed in the apparatus of Figure 3;
[062] Figure 9 is a schematic overview of the 3D volume coefficient controller apparatus and method according to the present invention;
[063] Figure 10 is a process diagram showing the preferred steps to process the 3D images in the preferred embodiment of the 3D volume coefficient control method according to the present invention;
[064] Figure 11 is a process diagram showing the preferred steps for processing the images of the face of the bench stockpile in the preferred embodiment of the 3D volume coefficient control method according to the present invention;
[065] Figure 12 is a process diagram showing the preferred steps to apply the measured reclaim volume coefficient to control the reclaimer in the preferred embodiment of the 3D volume coefficient control apparatus according to the present invention with limitation coefficient;
[066] Figure 13 is a block diagram showing the components of the 3D volume coefficient control apparatus 10 and machine controller; and,
[067] Figure 14 illustrates a series of guide radii that extend from a bench arch to produce the bench face height profile. Detailed Description of Preferred Modalities
[068] The preferred embodiment of the 3D volume coefficient control apparatus 10 according to the present invention, as illustrated in Figures 2 to 13, comprises a plurality of 3D image sensors 12 mounted adjacent to an excavation tool 14 of the reclaimer 16 and adapted to provide 3D images of the face of bench stockpile 18 (see Figure 2). Preferably the respective 3D image sensors 12 are mounted on each side and adjacent to the excavation tool 14 to provide 3D images of a complete cutting arc of the excavation tool on the face of the bench stockpile 18. 3D imaging also provide 3D imaging that extends along the oscillating arc for a distance sufficient to cover areas of the bench face 18 that may flow or collapse around the excavation tool. Typically the reclaimer is a bucket wheel reclaimer 16 and the digging tool is the bucket wheel 14. In said embodiment the bucket wheel reclaimer 16 is a rotating bucket wheel reclaimer of the type shown in Figures 1 and 2.
[069] Typically four 3D image sensors 12 are provided, two on each side of the bucket wheel 14 respectively. Advantageously the four 3D image sensors 12 are located immediately adjacent to the bucket wheel 14 and oriented so that the full cutting arc of the bucket wheel 14 is measured, as shown in Figures 3 to 6. In said embodiment the sensors 3D imaging cameras are time of flight 12 type 3D cameras that measure the distance to an object in front of the camera by analyzing the time it takes for a pulse of light to travel from a light source to the object and back.
[070] The 3D volume coefficient control apparatus 10 further comprises a data processor 20 (see Figure 13) to process the 3D images produced by the 3D cameras 12 to generate a 3D profile of the face of the stockpile. Data processor 20 calculates a volume of material that is removed from the face of bench stockpile 18 based on the change in the volume of the stockpile pile adjacent to the bucket wheel to determine the cutting volume coefficient to be taken up. The data processor 20 then calculates one of more operating parameters for the reclaimer 16, such as the bucket wheel speed control, based on the desired reclaim volume coefficient compared to the measured cut reclaim volume coefficient. Said operating parameters are sent to the machine controller of the reclaimer 22, to control not only the travel speed, but also the rotation speed of the bucket wheel 14.
[071] The 3D Volume Ratio Control Apparatus 10 provides improved retaker performance compared to existing "state of the art" implicit ratio systems. Said improved performance is achieved by accurate and dynamic retake volume measurement which uses the change in volume around bucket wheel 14 to control the retake volume coefficient. Accurate measurement of resumed volume is achieved by capturing a volume change of the area that contacts each side of the bucket wheel 14. High-speed 3D imaging sensors (12 cameras) are used to measure the volume that is in contact. being removed from the face of the stockpile area that contacts the bucket wheel 14.
[072] The face of the area of the stockpile that contacts the bucket wheel 14 is subject to profile changes due to product flow, face collapse and product being thrown off the bucket wheels. Flow and collapsing characteristics are unpredictable and product can also flow and collapsing from the face, even when the bucket wheel is not rotating. By providing accurate measurement of the reclaimed volume the reclaimed volume coefficient becomes independent of the product characteristics, the face shape characteristics of the stockpile and the cutter of the bucket wheel.
[073] Although measuring and calculating the resumed volume is complex, the application of bucket wheel speed control is simplified as there is no longer any need to apply the custom correction parameters that are typically needed to improve performance of power-based controllers.
[074] The measured shape of the stockpile face is also used to provide enhanced machine safety and bucket wheel position control which operates in unison with the 3D volume coefficient controller to provide reclaimer performance enhancements.
[075] A preferred 3D volume coefficient control method for the stockpile reclaimer 16, which uses the apparatus of Figure 13, will now be described in detail with reference to Figures 3 to 12. The process illustrated in the flow chart of Figure 10 is for four 3D cameras 12 (cameras 12a, 12b, 12c and 12d). The method can employ fewer 3D cameras, for example, in cases where the excavation tool's full cutting arc is within the field of view. The 3D volume coefficient control method typically comprises the first step 100 in Figure 10 of obtaining 3D images of the face of the bench stockpile. The method then comprises processing the 3D images to generate a 3D profile of the face of the bench stockpile, as will be described in more detail below.
[076] The area in which the stockpiles reside is called the stockyard. The area of the stockyard in which the pickup 16 is operating is defined as a horizontal plane that extends over the entire length and width of the stockyard and is parallel to the machine tracks. The north direction of the stockyard is defined as the positive travel direction along the machine tracks.
[077] The preferred 3D volume coefficient control method uses a local (right) Cartesian coordinate system (x, y, and z, as shown in Figures 7 and 8) to define the points in 3D stockyard space with the axes defined as follows: • X axis: a horizontal axis aligned with the machine rails and in the north direction of the stockyard • Y axis: a horizontal axis perpendicular to, and in a counterclockwise direction (from east to west) from, the positive X-axis (right coordinate system) • Z-axis: a vertical axis perpendicular to the x- and y- axes
[078] The positions and orientations of the components in the reclaimer 16 are defined with reference to the reclaimer's location reference point and with all movements are their home positions. The local reference position of the reclaimer 16 is typically defined as the center of rotation and the height of the track. Forward kinematic methods are used to transform the location component coordinates into the area coordinates of the stockyard, based on current movement positions.
[079] The movement of the reclaimer pivots and the components (bucket wheel 14 and cameras 12) are modeled, (step 104 in Figure 11 and step 106 in Figure 10) to provide the basis for calculating the positions and orientation of the components within of a 3D space. The position and orientation of each camera with respect to bucket wheel 14 is fixed. The known position, orientation (relative to the reclaimer's local reference point), and dimensions of the bucket wheel 14 are measured in step 102 (in Figure 11), are transformed in step 108, to provide the parameters for calculating the face of the bench bow bucket wheel in step 112 (in Figure 11). The orientation of the bucket wheel 14 includes parameters that describe any inclination and displacement of the bucket wheel.
[080] In the case where the bucket wheel 14 is not tilted or offset, then the bucket wheel cut is described as a torus with a circular cross section. Where the bucket wheel 14 is tilted and/or offset, then the bucket wheel cut is a torus with an elliptical cross section.
[081] The method further comprises step 114 (in Figure 11) of calculating a cut volume profile of the material that will be cut from the face of the stockpile based on the shape of the reclaimer excavation tool and the profile from the 3D face of the stockpile to determine a cutoff coefficient of the reclaimed volume. The cut volume profile is calculated in increments of distances along an arc across the face of the bench stockpile by measuring the 3D profile of the face of the bench stockpile (using the merged images from the 3D cameras 12) in step 116 and then assess which position of the face profile of the bench stockpile will be cut by the pickup wheel retake arc. The bench face profile is continuously updated in step 118. The updated bench face images can be viewed on monitor 30.
[082] An accurate calculation of the cut volume is achieved, irrespective of bucket wheel tilt and/or displacement, by calculating the volume along the direction of the bucket wheel face cut. That is, the direction of cut is along the line that runs around the tilted/shifted bucket wheel 14.
[083] The target position data provided by each camera is mapped from the camera coordinates to the stockyard area coordinates. Time of filght 12 type 3D cameras return a target distance for each pixel in the field of view (FOV), as shown in Figures 7 and 8. For camera 12 with a pixel frame size of 160 (h) x 120 (v), there will be 19,200 target distance values returned in each frame. Angular resolution depends on the FOV camera. For a FOV of 40° (h) x 30° (v), the angular resolution will be 0.25°. The position of the target point for each pixel is defined in terms of the camera's coordinate system.
[084] The depth distance (Z) produced by each camera 12 is the perpendicular distance from the target point to the entrance pupil plane of the lens (the entrance pupil plane is behind the front glass of the camera). The depth distance is different from the range distance which is the straight line distance from the target point to the corresponding pixel in the lens input pupil plane. Note that for the target point located on the optical axis of camera 12, the depth and distance ranges are the same. The camera coordinate reference point (x = 0, y = 0, and z = 0) is located where the optical axis intersects the input pupil plane of the lens.
[085] The position of each target point is described by the target distance along the Z axis and the angular displacement along the camera x and Y axis. The target point data from multiple 12 3D cameras are combined to create a profile of the face of the bench stockpile expressed in terms of a stockyard coordinate system.
[086] Each camera is capable of providing target point data at a high frame rate (typically up to 30 frames per second). A high frame ratio is not essential to the stockpile face profile as the reclaimer moves relatively slowly. For bench stock stack face profile, a frame coefficient of 10Hz is adequate. For camera 12 with a pixel frame size of 160 x 120, the number of target values returned by each camera is 192,000 per second (160 x 120 x 10Hz).
[087] When creating a stockpile face profile from camera target values, it is important to: • Preserve the accuracy of the measured face position relative to the cutting arc of the take-up bucket wheel. • Store stockpile face data in a format that facilitates accurate calculation of bucket wheel cut volume. • Keep data storage space needs within manageable limits.
[088] As the objective is to calculate the cut volume resumed from the bucket wheel 14, the target points from all cameras 12 are mapped in a face points to resume map. The face point map to resume is the two-dimensional coordinate structure of points. One dimension of the frame extends along the length of the arc to be resumed (90 degrees) while the second dimension wraps around the arc. The number of elements in each dimension is selected to match the available resolution of the 12 cameras.
[089] A face profile of the bench stockpile is stored as a height map wrapped around a bench arch. Said format provides maximum resolution for coefficient control. A bench arch is defined as the center of bucket wheel 14. Bench base level and thus arch level may vary due to any east/west slope of the stockpile base level. The height distance is stored as the UINT ((unsigned hexadecimal integer) unsigned int16) with a scale factor of 0.5 mm. A bench arc length for a bench radius of 60 m is 94.75 m (π * 0.5 * 60.0). A height map wraps around a bench arch from the base to a point above the bench arch. The cutting arc length for a 5.0m radius of bucket wheel 14 is 7.85m. A 12 m height map is required for a profile that extends 2 m above a bench arch and 2 m behind a bench arch.
[090] The storage requirements for a bench height map with a horizontal scale of 200 mm and a vertical scale of 100 mm is 60,000 terms (500 x 120 x UINT). A height map above a bench arc level is referenced to a line that runs vertically up from a bench arc. A height map can be rolled back to the back of the bucket wheel base to provide a detected product behind the center of the bucket wheel. The level of a height map behind a bench arch is referenced to the line that runs horizontally to a bench arch.
[091] The arc to retake is the path from the center of the bucket wheel as the bucket wheel is rotated across the face of the stockpile. The center point of the arc to be taken back is nominally located at the X-Axis and Y-Axis positions of the take-up reference position (rotation pivot) and at the level of the bucket wheel center point. The arc reference point is held in one location for the duration of one full rotation cut and then moves forward (along the X axis) in unison with the retaker in consecutive bench cuts. At the completion of each bench face cut, the current map of face points to retake is processed to determine the reclaimer path target position for the next bench face cut, based on the required bucket wheel cut depth.
[092] Finally, the 3D volume coefficient control method comprises calculating a control parameter for the reclaimer 16 based on the desired reclaim volume coefficient 120 (see Figure 12) compared to the cut volume reclaim coefficient 119 In the illustrated process this involves calculating the rotational speed profile in step 122 and the rotational speed setpoint in step 124.
[093] Preferably the 3D volume coefficient control method of the reclaimer provides not only the target travel position but also the target travel speed in order to control the retake coefficient during the movement of the reclaimer advance step 16. The method provides retake coefficient control during forward motion (Advanced Step) by determining the volume for meter (cubic meters per meter), similar to the control strategy for rotational motion.
[094] On each occasion that the reclaimer goes forward, the current retake face points map is processed to create a new retake face points map where a bench arc pivot is located at a new pivot position of rotation of the reclaimer.
[095] The mapping of camera target points (expressed in terms of camera coordinates) to the area of the stockyard coordinate system is performed by rotating and translating the target points through the camera to the area transformation matrix . The transformation matrix is composed of a location transformation matrix and an area transformation matrix. The location transformation matrix provides for mapping the target points from camera coordinates to the take-up location coordinates based on the position and orientation of the camera in the location coordinate system. The area transformation matrix provides target point mapping from the reclaimer location coordinates to the stockyard area coordinates based on the position of each reclaimer's move.
[096] The location transformation matrix for mapping the camera target points to the machine location coordinate system is calculated as follows. The position and orientation of each camera 12 relative to the reclaimer's location coordinate system is known as accurate measurement. The camera position is described by the translation of the camera coordinate reference point with respect to the retaker coordinate system reference point. So for the camera mounted 50 m from the pivot point of rotation, 10 m to the left of the reclaimer's X axis and 15 m above the rail, the translation is x = 50.0, y = -10.0 and z = 15 .0.
[097] The camera orientation can be described by the direction (rotation) of the optical axis (Z axis) with reference to the X axis of the machine and the direction (rotation) of the camera Y axis with reference to the Y axis of the retriever. Camera orientation is expressed as a Quaternium but can also be expressed as Euler Angles or Rotation Matrix. A quaternium of position orientation and translation are combined to provide the location transformation matrix. The steps of composing the camera transformation matrix, and subsequently transforming the camera image to the stockyard coordinate system is shown in Figure 10 at steps 126 and 128. The transformed camera images are merged in step 130.
[098] The mapping of points expressed in terms of the reclaimer location coordinates to the area of the stockyard coordinate system is performed by transformation (rotation and translation) of the points using an area transformation matrix. The transformation is described by the translation of the points based on the position of the reclaimer's coordinate reference position within the stockyard area (x = south/north, y = east/west, z = level) and the rotation of the points with based on the linked axis positions between a retaker location reference point and the point to be transformed.
[099] The reclaimer volume coefficient control apparatus and method controls the reclaimed volume coefficient (cubic meters per second) based on the 3D profile directly measured from the face of the bench stockpile. A face profile of the bench stockpile is measured by the four 3D cameras 12 mounted on each side of the reclaimer bucket wheel 14. [100] The individual images from the 3D camera are combined to provide a high-resolution map of the reclaimer. face of the bench stockpile. The high-resolution map of the stockpile face depends on the pixel resolution of the camera and the distance from the camera to the stockpile. Typically, the target dot size of the stockpile face is less than 40mm in both the vertical and horizontal planes. [101] Parts of the bucket wheel 14 and boom structure of the pickup 24 can interfere with the camera's field of view. Image points that correspond to the structural elements of the reclaimer are ignored when mapping the composite image to a bench stock stack frame face profile. This is accomplished by providing 3D models of bucket wheel 14 and boom 24. Target points that fall within the 3D space model are ignored. The disposition of the bucket wheel image points is shown in step 132 in Figure 10. [102] A profile map is created to store a face profile of the bench stockpile, with each point of the profile defined in terms of the distance from a bench arc, along a radius of the cutting arc. A face profile of the bench stockpile taken at 118 is mapped to the bucket wheel height profile to provide a bucket wheel height of cut profile at 113. The step of calculating the cut volume profile 115 of material on the face of the bench stockpile is performed by calculating in step 114 the sum of the volumes for each point of the face profile of the bench stockpile in the area that contacts the bucket wheel. [103] The bucket wheel 113 height-of-cut profile is the two-dimensional structure of distance values. Distance values are defined as the distance (in meters) from an arc formed by the point in the center of the bucket wheel 14 as it is rotated outward across the face of the stockpile. Distances are measured along a series of spokes that travel perpendicular to the axis of the bucket wheel. A series of spokes extends from a spoke that points vertically down to a spoke that points forward to the center of the face of the bucket wheel 14. Where the spoke extends above the center of the bucket wheel 14, then the radius will be horizontal and the origin will be on a line that extends vertically upward from the center of the bucket wheel. Where the radius extends behind the center of the bucket wheel 14, then the radius will be vertical and the origin will meet on a line that extends horizontally backwards from the center of the bucket wheel. This is illustrated in Figure 14. The angular separation between the spokes is chosen to match the camera's target spot size on the face of the bucket wheel. [104] The bench cut height profile 113 is used to calculate in step 117 the bench face cut volume in the area that contacts the bucket wheel excavation tool. The cut volume coefficient to be taken back 119 is then calculated in step 123 as the change in volume of the face of the bench stockpile between two points in time. The time interval between volume sampling is chosen to provide continuous updating of the volume coefficient to be resumed 119. [105] A bench cut height profile 113 is also used to calculate in step 114 the cut volume profile (115 in Figure 11) as the bucket wheel cut volume per meter of bench arch length at intervals along a bench arch. This is based on the known cutting radius of the bucket wheel. The cut volume profile 115 is used to calculate, at step 121 in Figure 12, a volume coefficient profile to be taken back from the feed forward. A control parameter for the reclaimer is then calculated in step 125 based on the desired reclaim volume coefficient compared to the measured cut reclaim volume coefficient and the feed forward volume coefficient profile. [106] The bucket wheel cut volume per meter (cut volume profile 115) is also used to calculate, in step 122 (in Figure 12), the rotation speed profile of the bucket wheel at all points along a bench arch. The calculated rotation speed profile of the bucket wheel is reported to the rotation speed control system in the machine controller 22. [107] Due to compaction, the bulk density of the stacked material will be higher than the density. of the volume of material taken back. Thin materials have a higher compaction factor than lump material. The material excavated by the bucket wheel 14 will consist of a mixture of compacted and loose material. Mixing depends on the flow characteristics of the product and the presence of collapsed material. Compensation for the change in volume density can be provided by a 'Material Volume Offset' factor which is defined as the ratio of 'Resumed Material Volume' to 'Stacked Material Volume'. Said factor can be provided in the observation table which contains a factor for each type of material, or optionally by measuring the take-back volume and subsequent calculation of the 'Material Volume Offset' for the current stockpile product. [108] The calculation of the 'Material Volume Offset' is achieved by the program routine which tracks the 'Material Stacked Volume' from the bucket wheel to a position on the reclaimer boom carrier where the 'Material Volume Resumed' is measured. Measurement of 'Reclaimed Material Volume' is typically provided by the belt profile reader, which uses a 2D laser line reader or a 3D image capture instrument. [109] It is normally necessary to ensure that the bucket wheel power (or torque) is kept within the operating drive power limits. Resume coefficient is limited in high energy scenarios to control not only the instantaneous peak energy but also the long-term thermal power limits of the bucket wheel drive. This is accomplished in step 124 (see Figure 12) by limiting the rotation speed if the bucket wheel energy exceeds preset limits. [110] The 3D volume coefficient control apparatus and method preferably also provides not only the travel target position but also the travel target speed in order to control the retake coefficient during the movement of the advance step. The apparatus and method provide control of the resumption coefficient during forward movement (Advanced Step) by determining the volume per meter (cubic meters per meter), similar to the control strategy for the rotational movement. [111] Now that the preferred embodiments of the 3D volume coefficient control method and apparatus have been described in detail, it will be apparent that the described embodiments provide a number of advantages over the prior art, including the following: (i) Provide accurate metering of reclaimed volume the reclaimed volume co-efficient becomes independent of product characteristics, stockpile face shape and bucket wheel cutting characteristics. (ii) Although measuring and calculating the resumed volume is complex, the application of the bucket wheel speed control is simplified as there is no longer any need to apply the custom correction parameters that are typically needed to improve performance of power-based controllers. (iii) Provide machine collision protection by detecting when the final bench target is below the face of the next highest bench to avoid undermining; detect the collapse of the stockpile face; and, continuously monitoring the space on each side of the boom and stopping machine movement to prevent the stockpile and machine from colliding. (iv) Provide improved production resumption coefficients: by using the highly accurate 3D bucket wheel for stockpile distance to provide automatic bench face control with optimal depth of cut in the first rotation; for using accurate edge detection and optimized depth of cut at all positions in the stockpile, including full compensation for the end cone shape to produce an optimal depth of cut every time; for optimizing the rotation around based on the correct determination of the position of the edge of the face; for maintaining precise volume based on rotation speed control across the entire bench arch to optimize around rotation; by avoiding the resumption conditions that lead to stockpile dragging based on accurate edge detection; for keeping the depth of cut at optimal values regardless of the internal rotation around the position, shape of the end cone and bench height and thus the resumption with the minimum number of rotation cuts; by removing the dependence of the product characteristics (density, moisture content etc...) to reach the maximum volume coefficient; by providing measured coefficient control in both cutting directions and therefore not being affected by changes in bucket wheel cutting efficiency caused by tilting or offsetting from the bench face; and by using the bench face profile read to detect face collapses the controller is able to respond to the collapse and prevent the bucket wheel from overloading, and the collapsed volume is measured so that the production coefficient is maintained . (v) Provide reduced maintenance and improved production without driving the machine harder. Greater retake control provides several maintenance benefits, including reduced bucket wheel wear (optimized bucket wheel depth of cut), improved core tracking (less fluctuation in retake coefficient), and reduced chute blocking (coefficient of controlled volume peak). [112] It will be readily apparent to those skilled in the art that various modifications and enhancements can be produced in the foregoing embodiments, in addition to those already described, without deviating from the inventive basics of the present invention. For example, other suitable types of 3D image sensors can be employed in addition to the "time-of-flight" type 3D cameras described. Therefore, it will be appreciated that the scope of the present invention is not limited to the specific embodiments described.

权利要求:
Claims (23)
[0001]
1. 3D volume coefficient control apparatus for a stockpile reclaimer, the apparatus characterized in that it comprises: a plurality of 3D image sensors mounted adjacent to an excavation tool of the stockpile reclaimer and adapted to provide 3D images of the face of the bench stockpile; and, a data processor to: (i) process the 3D images produced by the 3D image sensors to generate a 3D profile of the face of the bench stockpile, (ii) calculate a cut volume coefficient to resume in which the material is being cut from the face of the stockpile pile based on a measured change in the volume of the 3D profile of the face of the bench stockpile in the area that contacts the excavation tool, (iii) calculate a volume of cut material to be taken back that will be cut from the face of the stockpile pile based on the shape of the excavation tool and the 3D profile of the face of the bench stockpile to determine a profile of the cut volume coefficient to take back with the feed forward, and (iv) calculate an operating parameter for the reclaimer based on the desired cut volume retake coefficient compared to the calculated cut volume reclaim coefficient and the cut volume coefficient profile. o to resume with feeding forward; a machine controller which is connected to the data processor and the excavation tool and which controls a path of movement of the excavation tool by controlling at least one of: an excavating tool travel speed or an excavating tool rotation speed .
[0002]
2. 3D volume coefficient control apparatus according to claim 1, characterized in that the respective 3D image sensors are mounted on each side and adjacent to the excavation tool to provide 3D images of a complete cutting arc of the excavation tool on the face of the bench stockpile.
[0003]
3. 3D volume coefficient control apparatus according to claim 2, characterized in that the 3D image sensors provide 3D images that extend along the oscillating arc of the complete cutting arc for a distance to cover areas of the bench stockpile face that can flow or collapse around the excavation tool.
[0004]
4. 3D volume coefficient control apparatus according to claim 2 or 3, characterized in that two of the 3D image sensors are located on each side of the excavation tool respectively.
[0005]
5. 3D volume coefficient control device, according to any one of claims 1 to 4, characterized in that the 3D image sensors are 3D cameras of the "time-of-flight" type that measure the distance at a object in front of the camera by analyzing the time it takes for a pulse of light to travel from a light source to the object and back again.
[0006]
6. 3D volume coefficient control device according to any one of claims 1 to 5, characterized in that the stockpile reclaimer is a bucket wheel reclaimer and the digging tool is the bucket wheel .
[0007]
7. 3D volume coefficient control device according to claim 6, characterized in that the bucket wheel reclaimer is the rotating bucket wheel reclaimer.
[0008]
8. 3D volume coefficient control method for stockpile reclaimer, the method characterized by the fact that it comprises the steps of: obtaining 3D images of the face of the bench stockpile; processing the 3D images to generate a 3D profile of the face of the bench stockpile; calculate a cut volume to reclaim coefficient based on a measured change in the volume of the 3D profile of the bench stockpile face in the area that contacts the stockpile reclaimer excavation tool; calculate a volume of cut material to be taken back that will be cut from the face of the bench stockpile based on the shape of the digging tool and the 3D profile of the face of the bench stockpile to determine a volume coefficient profile from cut to feed forward; calculating an operating parameter for the stockpile reclaimer based on a desired cut volume reclaim coefficient compared to the calculated cut volume reclaim coefficient and the cut volume reclaim coefficient profile with the feed forward; sending the operating parameter to a machine controller connected to the excavating tool, and controlling, based on the operating parameter, at least one of: a traveling speed of the excavating tool, or a rotating speed of the excavating tool.
[0009]
9. 3D volume coefficient control method, according to claim 8, characterized in that the calculation of the volume of cut material to be taken back is performed by producing a cutting height map of the excavation tool, in which the excavation tool cut height map is a two-dimensional structure of distance values measured from the reference on the excavation tool to an edge of the excavation tool where it cuts into the face of the bench stockpile.
[0010]
10. A 3D volume coefficient control method according to claim 9, characterized in that the stockpile reclaimer is a bucket wheel reclaimer, the digging tool is the bucket wheel, and a dig tool height-of-cut map is a bucket wheel's height-of-cut map.
[0011]
11. 3D volume coefficient control method, according to claim 10, characterized in that the bucket wheel reclaimer is the rotating bucket wheel reclaimer.
[0012]
12. 3D volume coefficient control method, according to claim 11, characterized in that the reference in the excavation tool is a bench arc formed by a point in the center of the bucket wheel as it is rotated out through the face of the bench stockpile.
[0013]
13. 3D volume coefficient control method according to claim 12, characterized in that the distance values are the distance from the bench arc and are measured along a series of cutting arc radii which run perpendicular to the axis of the bucket wheel.
[0014]
14. 3D volume coefficient control method according to claim 13, characterized in that the cutting arc radii extend from a radius that points vertically down to a radius that points to the center of the face of the bucket wheel.
[0015]
15. 3D volume coefficient control method according to claim 14, characterized in that the angular separation between the spokes corresponds to the size of the sensor target point on the central face of the bucket wheel.
[0016]
16. 3D volume coefficient control method, according to any one of claims 10 to 15, characterized in that the calculation of a cut volume coefficient to be resumed comprises the calculation of a volume of material on the face of the pile of bench storage.
[0017]
17. 3D volume coefficient control method, according to claim 16, characterized in that the step of calculating the volume of material on the face of the bench stockpile comprises calculating the sum of the volumes for each point of the profile from the face of the bench stockpile in the area that contacts the bucket wheel.
[0018]
18. 3D volume coefficient control method, according to any one of claims 10 to 15, characterized in that calculating the cutting volume coefficient to be resumed comprises comparing the volume of the face of the bench stockpile in the two points in time as the bucket wheel cuts the face of the bench stockpile.
[0019]
19. A 3D volume coefficient control method according to claim 15, characterized in that it comprises creating a 3D profile map and storing a 3D profile of the face of the bench stockpile in the profile map, where the 3D profile of the bench stockpile face includes a plurality of profile points, and each profile point is defined by a distance from the bench arc, along a radius of the cutting arc.
[0020]
20. 3D volume coefficient control method according to claim 19, characterized in that it comprises calculating a height map of the bucket wheel face from the 3D face profile of the bench stockpile.
[0021]
21. A 3D volume coefficient control method according to claim 20, characterized in that it comprises calculating a bucket wheel cut volume per meter of bench arch length at intervals along a bench arch of the bench stockpile face, based on the known bucket wheel cut radius and the bucket wheel face height map.
[0022]
22. A 3D volume coefficient control method according to claim 21, characterized in that it comprises calculating a bucket wheel rotation speed at all points along the bench arc of the storage pile face. bench based on the retake cut volume coefficient, the bucket wheel cut volume per meter and a desired retake volume coefficient.
[0023]
23. 3D volume coefficient control method, according to claim 22, characterized by the fact that the rotation speed of the bucket wheel is informed to the rotation speed control system of the reclaimer.

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WO2014040137A1|2014-03-20|

BR112015005665A2|2017-07-04|

AU2013315356B2|2014-12-18|

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AU2013101229A4|2013-10-10|

RU2015113605A|2016-11-10|

CN104838072B|2017-08-18|

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CN104838072A|2015-08-12|

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法律状态:
2018-11-21| B06F| Objections, documents and/or translations needed after an examination request according [chapter 6.6 patent gazette]|

2020-02-11| B06U| Preliminary requirement: requests with searches performed by other patent offices: procedure suspended [chapter 6.21 patent gazette]|

2021-04-20| B09A| Decision: intention to grant [chapter 9.1 patent gazette]|

2021-05-11| B16A| Patent or certificate of addition of invention granted|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 13/09/2013, OBSERVADAS AS CONDICOES LEGAIS. |

优先权:

申请号 | 申请日 | 专利标题

AU2012904024A|AU2012904024A0|2012-09-14|Reclaimer 3D Volume Rate Controller|

AU2012904024|2012-09-14|

PCT/AU2013/001049|WO2014040137A1|2012-09-14|2013-09-13|Reclaimer 3d volume rate controller|

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