AU2013263719B2

AU2013263719B2 - Method and system of operating a conveyor transfer station

Info

Publication number: AU2013263719B2
Application number: AU2013263719A
Authority: AU
Inventors: Aaron Leigh CARTER; Neal Schutte
Original assignee: SANDPIT INNOVATION Pty Ltd
Current assignee: SANDPIT INNOVATION Pty Ltd
Priority date: 2012-12-11
Filing date: 2013-11-26
Publication date: 2014-07-24
Anticipated expiration: 2033-11-26
Also published as: AU2013263719A1

Abstract

Abstract The invention generally provides for an automated conveyor transfer station 10 which is configured to direct material from an input conveyor 12 by means of a deflector plate 18 via a transfer chute 16 to an output conveyor or vessel 14. The transfer station 10 includes a sensor 20 which is configured to sense a characteristic of the material operatively conveyed on the input conveyor 12 and subsequently dumped into the transfer station 10. Also included is a controller 22 arranged in communication with the sensor 20, the controller 22 being configured to compare the sensed characteristic to known values of characteristics and to determine a position of the deflector plate 18 that is best suited to direct the material through the transfer chute 10. The known characteristics are generally indicative of such a best position for the deflector plate 18. Finally, an actuator 24 under control of the controller 22 is also included, the actuator 24 being arranged to adjust the deflector plate 18 to the best position prior to the sensed material impacting the deflector plate 18.

Description

P/00/011 (0311) Regulation 3.2 ORIGINAL AUSTRALIA Patents Act 1990 COMPLETE SPECIFICATION Invention Title: Method and System of Operating a Conveyor Transfer Station The following statement is a full description of this invention, including the best method of performing known to us: Method and System for Operating a Conveyor Transfer Station TECHNICAL FIELD [0001] This invention relates to a method and associated system for operating a conveyor transfer station, as well as a conveyor transfer station incorporating such a system. BACKGROUNDART [0002] The following discussion of the background art is intended to facilitate an understanding of the present invention only. This discussion is not an acknowledgement or admission that any of the material referred to herein is or was part of the common general knowledge as at the earliest priority date of the application. [0003] Conveyor belts are well-known in the art and are typically used to transfer material, such as particulate material, between locations. As such, it is not uncommon in certain applications to have conveyors transferring large volumes of material over long distances. One example of this may be found in mining applications, such as coal or iron ore mining, where conveyor belts may be used to transfer materials, such as ore, for kilometers. [0004] It is often a requirement to transfer material between conveyor belts or from a conveyor belt to another vessel or structure. Accordingly, so-called conveyor transfer stations are generally used to facilitate the transfer of material from one conveyor belt to a second conveyor belt or vessel. Such a transfer station typically comprises some manner of chute arrangement into which a first conveyor dumps material at an upper end and the chute arrangement being configured to funnel or direct the material under the flow of gravity to a second conveyor or structure at a lower end thereof. [0005] Existing transfer stations sometime include a deflector plate at the upper end thereof to aid in directing or guiding the material which is dumped into the transfer station from the first or upper conveyor towards the second or lower conveyor or vessel. However, a number of shortcomings have been identified with existing transfer stations. [0006] For example, certain transfer stations are required to handle different types of materials at different times. As such, these different materials typically have different material flow properties due to differences in material volume, internal cohesion forces, particle sizes, moisture content, material type, volume flow rate of material being dumped into the transfer station, etc. [0007] As such, the material flow characteristics of material through a transfer station are dependent on various different factors. If the configuration of the transfer station is not suitable to the flow characteristics of the material transferred there through, a build-up of material may result generally leading to inefficient transfer of such material due to material spillage or blockage of the transfer station. This can have serious impacts on an operation reliant on the transfer station, such as a mining operation. Should a transfer station experience adverse effects due to such blockages or spillage, it may require a shutdown of the operation resulting in significant financial impacts whilst the transfer station is unblocked or cleared of material blockages.

[0008] For example, the Applicant is aware of one iron ore mining operation having a transfer station which was originally designed to handle 13,500 tons-per-hour (tph) of iron ore. However, throughputs of 16,000 tph have been measured. The transfer station is generally able to successfully handle the design tonnage of 13,500 tph consistently, but flow problems are experienced through the transfer station at higher throughputs of a new grade of iron ore having different flow characteristics than that for which the station was initially designed. Similarly, the transfer station also experiences blockages at lower material flow rates than that for which it was designed when different types of material are passed through it. These blockages are typically due to changes in material types and characteristics not generally suitable for the transfer station. [0009] These flow problems have been ascribed to poor control of the conveying rate of the first conveyor dumping material into the transfer station. The first conveyor is fed via a bucket wheel reclaimer reclaiming iron ore from a stockpile. The conveying rate is controlled via a belt weigh scale system that controls the speed of the bucket wheel on the stockpile reclaimer depending on the measured rate by weight. Challenges are experienced as the reclaimer traverses from one toe of the longitudinal stockpile to the other that overloads the belt. Mostly, this occurs because the buckets are at times not filled completely because of flow rate limitations down the surface of the pile during the reclaim operation; that is, during digging, some material 'hangs up' on the face of the stockpile due to its cohesive shear strength. In this scenario, the conveyor is "starved" of material, often referred to as 'digging air', and the weigh scale instructs the bucket wheel to speed up in order to reach the target reclaim rate. [0010] As the reclaim operation progresses excavation of the stockpile, the bucket wheel eventually undermines the overhanging material causing the stockpile to release avalanches of ore suddenly down the face of the pile that fill the buckets completely. At this point, because the bucket wheel of the reclaimer is operating at higher speeds when the avalanches suddenly fill the buckets, it results in an instantaneous high reclaim rate that overloads the conveyor belt until the weigh scale detects the overload and reduces the bucket wheel speed. This generally results in material surges on the conveyor belt that cannot be accommodated by the transfer station, typically causing spillage and blocks when it reaches the transfer station. [0011] As such, the material characteristics of the material passing through the transfer station typically have a big effect on the operation thereof. Characteristics such as moisture content, particle size, friction coefficients, material volume, material flow rate, etc. typically determine the behaviour through the transfer station. Transfer stations known in the art are generally designed to handle material with known characteristics, making such stations only suitable to some materials. [0012] It is against this background, and the problems and difficulties associated therewith, that the present invention has been developed. [0013] It is an object of the present invention to overcome, or at least ameliorate, one or more of the deficiencies of the problems mentioned above, or to provide a useful or commercial option for operating a transfer station to reduce spillages and blockages. SUMMARY OF THE INVENTION [0014] According to a first aspect of the invention there is provided an automated method of operating a conveyor transfer station which is configured to direct material from an input conveyor by means of a deflector plate via a transfer chute to an output conveyor or vessel, said method comprising the steps of: sensing a characteristic of the material operatively conveyed on the input conveyor and subsequently dumped into the transfer station; comparing the sensed characteristic to known values of characteristics; determining a position of the deflector plate best suited to direct the material through the transfer chute, the known characteristics indicative of such a position; and automatically adjusting the deflector plate to such a position prior to the sensed material impacting the deflector plate. [0015] Typically, the sensed material characteristics may be selected from a group consisting of material particulate size, material flow rate, material volume, material moisture content, material chemical composition, material position, material temperature and material velocity. [0016] It is to be appreciated that the step of sensing is typically performed in a continuous and/or intermittent manner suitable to a conveying rate of the input conveyor, i.e. the rate of sensing may be continuous or have a variable sample rate. For example, sensing may occur at a frequency of 1 Hertz or more, once per minute, or the like. [0017] According to a second aspect of the invention there is provided an automated system for operating a conveyor transfer station which is configured to direct material from an input conveyor by means of a deflector plate via a transfer chute to an output conveyor or vessel, said system comprising: a sensor configured to sense a characteristic of the material operatively conveyed on the input conveyor and subsequently dumped into the transfer station; a controller arranged in communication with the sensor, said controller configured to compare the sensed characteristic to known values of characteristics, and to determine a position of the deflector plate best suited to direct the material through the transfer chute, the known characteristics indicative of such a position; and an actuator under control of the controller, said actuator arranged to adjust the deflector plate to such position prior to the sensed material impacting the deflector plate. [0018] Typically, the sensor may include a sensor adapted to sense the characteristics which is selected from a group consisting of material particulate size, material flow rate, material volume, material moisture content, material chemical composition, material position, material temperature and material velocity. [0019] Typically, the sensor may be positioned proximate the input conveyor and sufficiently distal from the deflector plate to accommodate for adjustment response times of the controller and actuator. [0020] Typically, the controller may include a storage arrangement for storing the known values of characteristics.

[0021] Typically, the controller may be configured to determine the position according to a look-up table of predetermined positions according to the known characteristics indicative of such positions. [0022] Typically, the actuator may include an electromechanical actuator. Typically, the actuator may include a hydraulic or pneumatic actuator. [0023] Typically, the actuator may be configured to adjust the deflector plate in a vertical plane, a horizontal plane, and/or an angle of the deflector plate. [0024] Typically, the sensor, controller and/or actuator may be arranged in respective wireless communication. [0025] According to a third aspect of the invention there is provided an automated conveyor transfer station which is configured to direct material from an input conveyor by means of a deflector plate via a transfer chute to an output conveyor or vessel, said transfer station comprising: a sensor configured to sense a characteristic of the material operatively conveyed on the input conveyor and subsequently dumped into the transfer station; a controller arranged in communication with the sensor, said controller configured to compare the sensed characteristic to known values of characteristics, and to determine a position of the deflector plate best suited to direct the material through the transfer chute, the known characteristics indicative of such a position; and an actuator under control of the controller, said actuator arranged to adjust the deflector plate to such position prior to the sensed material impacting the deflector plate. BRIEF DESCRIPTION OF THE DRAWINGS [0026] 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 diagrammatic side representation of a transfer station having a system for operating same, in accordance with an aspect of the invention; and Figure 2 is a schematic representation of a flow diagram for method steps for operating a conveyor transfer station, in accordance with an aspect of the invention. DESCRIPTION OF EMBODIMENTS [0027] The following description provides examples of different embodiments of a conveyor transfer station 10. In broad terms, the transfer station 10 is configured to direct material, such as ore or other particulate material (not shown), from an input conveyor 12 by means of a deflector plate 18 via a transfer chute 16 to an output conveyor or vessel 14. [0028] Figure 1 shows the transfer station 10, which is adapted to facilitate the transfer of material conveyed and subsequently dumped from the input conveyor 12 into the transfer chute 16. The material traverses the chute 16, in use, and exits the chute 16 onto the output conveyor or into the vessel 14. The movement of material is generally indicated by the directional arrows, as shown, and the flow of material via the chute is generally known in the art. [0029] The transfer station 10 also includes a deflector plate 18 which aids in directing the material towards the output conveyor or vessel 14, as shown. It is not uncommon for material to be transported at a considerable rate, for example, the input conveyor 12 may transport iron ore at a rate of 5,5 meters per second. In this example, a large volume of material enters the transfer station and any inefficiency in directing the material towards the output conveyor or vessel 14 can cause the transfer chute to choke or become blocked with material, as described above. [0030] For example, should a large influx of material impinge against the deflector plate 18 and the material characteristics are such that the material does not move away from the plate 18 quickly enough, the material could agglomerate on the plate 18 and block the inflow of material from the input conveyor 12. This often results in blockages and/or spillages which, in turn, result in lost production and shutdowns upstream and downstream of the transfer station 10. [0031] The Applicants have identified that by positioning the deflector plate 18 according to the material characteristics of the material entering the transfer station 10, it is possible to minimize material build-up as said material enters the transfer station 10 and to improve the transfer of material through the transfer station 10. This ability to dynamically adjust the position of the deflector plate 18 based on the characteristics of material entering the transfer station 10 is an important aspect of this invention, enabling varying material types to be efficiently transferred via the single station 10. [0032] Accordingly, the transfer station 10 includes a sensor 20 which is configured to sense a characteristic of the material operatively conveyed on the input conveyor 12 and subsequently dumped into the transfer station 10. It is to be appreciated that the characteristics of the material which the sensor 20 is configured to sense may include any characteristic which can indicate the behaviour of the material as it traverses the station 10. As such, the sensed characteristic may include material particulate size, material flow rate, material volume, material moisture content, material chemical composition, material position, material temperature, material velocity and/or the like. The sensor 20 may subsequently include any suitable sensor as is known in the art and able to sense at least one of these characteristics. Furthermore, the sensor 20 may be configured to sense more than one characteristic and may include a number of different sensors, each for sensing a different material characteristic. [0033] In addition, the transfer station 10 also includes a controller 22 arranged in communication with the sensor 20, the controller 22 configured to compare the sensed characteristic to known values of characteristics, and then to determine a position of the deflector plate 18 which is best suited to direct the material through the transfer chute 16. [0034] The known characteristics are generally indicative of such a best position for the deflector plate 18 according material flow modelling which is typically able to show how different types of material behave under different positions for the deflector plate 18. For example, it is possible to model the operation of the transfer station according to Discrete Element Method (DEM) simulation techniques for different material characteristics. These DEM simulations can be used to determine a range of different deflector plate 18 positions according to different material characteristics to enable most efficient transfer of material through the transfer chute 16. Also, the best deflector plate position for a given material characteristic may be empirically determined, i.e. through trial-and-error or experiment. The best deflector plate position may also be determined according to a combination of DEM modelling in combination with empirical measurements. [0035] In addition, the controller 22 may also be integrated with some manner of overall plant operating system (not shown), of which the input conveyor and transfer station 10 form part. Such an overall plant operating system is typically responsible for overall control and operation of a larger plant incorporating the transfer station 10 and, as such, may supply additional material characteristic information to the controller 22. For example, the overall plant operating system may know material characteristics of the material on the input conveyor 12 from other sensors or processes, such as material type, particulate size, moisture content, etc. In this example, the sensor 20 may be configured to sense material volume on the input conveyor 12, this material characteristic being used by the controller 22 in conjunction with the other known characteristics supplied by the overall operating system to calculate the best position for the deflector plate 18. [0036] The controller 22 typically includes a storage arrangement for storing the known values of characteristics indicative of the best deflector plate position, such as a memory storage device, or the like. The controller 22 may determine the best position according to a look-up table of such modelled and predetermined deflector plate positions. As described above, the DEM modelling may be used to generate the known values of characteristics indicative of the best position for the deflector plate 18. [0037] The transfer station 10 also includes an actuator 24 which is under control of the controller 22 and which actuator 24 is arranged to adjust the deflector plate 18 to such best position prior to the sensed material impacting the deflector plate 18. The actuator 24 may include any suitable actuator, as is known in the art, such as an electromechanical, a hydraulic and/or pneumatic actuator. [0038] As shown by the directional arrows in Figure 1, the actuator 24 is generally configured to adjust the deflector plate 18 in a vertical plane, a horizontal plane, and/or adjust an angle of the deflector plate 18. [0039] It is to be appreciated that the sensor 20 is typically positioned proximate the input conveyor 12 but also sufficiently distal from the deflector plate 18 to accommodate for adjustment response times of the controller 22 and actuator 24, i.e. depending on the speed of the input conveyor 12, the controller 22 and actuator 24 may require some lead time to adjust the deflector plate 18 to the best position before the portion of the material which was sensed reaches the plate 18. As such, the sensor 20 may continuously sense the material, so the sensor 20 is typically removed from the deflector plate 18 a sufficient distance so that the speed of the conveyor 12 is compensated for. [0040] It is to be appreciated that the transfer station 10 may be used to transfer material to the output conveyor 14 or to another vessel or receptacle intended to receive the material. For example, the vessel 14 may include any container, such as a ship for carrying iron ore, a train carriage, or the like. [0041] In one example the sensor 20, controller 22 and actuator 24 is arranged in respective wireless communication with each other. However these components may be arranged in communication with each other in any suitable manner. [0042] Figure 2 shows an example of associated method steps 28 for operating the conveyor transfer station 10, as described above. The method generally includes a step of continuously sensing the characteristic of the material operatively conveyed on the input conveyor 12 and subsequently dumped into the transfer station 10, as shown by block 30. The method also includes the step of comparing the sensed characteristic to the known values of characteristics, shown by block 32, and then a step of determining a position of the deflector plate 18 best suited to direct the material through the transfer chute 16, the known characteristics being indicative of such a position. This step is indicated by block 34. [0043] The method also includes the final step of automatically adjusting the deflector plate to the best position prior to the sensed material impacting the deflector plate 18, as indicated by block 36. [0044] It is to be appreciated that these method steps 28 are performed by the corresponding system components described above, i.e. the sensor 20, the controller 22 and the actuator 24.

[0045] It should be appreciated that the scope of the invention is not limited to the scope of the embodiment described. Various modifications and improvements may be made to the embodiment described without departing from the scope of the invention. [0046] 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. [0047] 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

1. An automated method of operating a conveyor transfer station which is configured to direct material from an input conveyor by means of a deflector plate via a transfer chute to an output conveyor or vessel, the deflector plate located at an upper end of the station proximate the input conveyor and configured to direct the material, as it impacts said deflector plate, through the station towards an exit at a lower end of the station proximate the output conveyor or vessel, said method comprising the steps of: sensing a characteristic of the material operatively conveyed on the input conveyor and subsequently dumped into the transfer station, the sensed characteristic indicative of a behaviour of the material as it impacts the deflector plate, the sensed material characteristic selected from a group consisting of material particulate size, material flow rate, material volume, material moisture content, material chemical composition, material position, material temperature and material velocity; comparing the sensed characteristic to known values of characteristics; determining a position of the deflector plate best suited to direct the material downward through the transfer chute and away from the deflector plate according to the sensed behaviour, the known characteristics indicative of such a position; and automatically adjusting the deflector plate to such a position prior to the sensed material impacting the deflector plate, so that material build-up on the deflector plate and subsequent blockages at the input conveyor is minimised as the material enters the transfer station and impacts said deflector plate, thereby enabling varying types of materials to be dynamically transferrable through the station. 17

2. An automated system for operating a conveyor transfer station which is configured to direct material from an input conveyor by means of a deflector plate via a transfer chute to an output conveyor or vessel, the deflector plate located at an upper end of the station proximate the input conveyor and configured to direct the material, as it impacts said deflector plate, through the station towards an exit at a lower end of the station proximate the output conveyor or vessel, said system comprising: a sensor configured to sense a characteristic of the material operatively conveyed on the input conveyor and subsequently dumped into the transfer station, the sensed characteristic indicative of a behaviour of the material as it impacts the deflector plate, the sensor adapted to sense a material characteristic selected from a group consisting of material particulate size, material flow rate, material volume, material moisture content, material chemical composition, material position, material temperature and material velocity; a controller arranged in communication with the sensor, said controller configured to compare the sensed characteristic to known values of characteristics, and to determine a position of the deflector plate best suited to direct the material downward through the transfer chute and away from the deflector plate according to the sensed behaviour, the known characteristics indicative of such a position; and an actuator under control of the controller, said actuator arranged to adjust the deflector plate to such position prior to the sensed material impacting the deflector plate so that material build-up on the deflector plate and subsequent blockages at the input conveyor is minimised as the material enters the transfer station and impacts the deflector plate, thereby enabling varying types of materials to be dynamically transferrable through the station. 18

3. A system of claim 2, wherein the sensor is positioned proximate the input conveyor and sufficiently distal from the deflector plate to accommodate for adjustment response times of the controller and actuator.

4. A system of either one of claims 2 or 3, wherein the controller includes a storage arrangement for storing the known values of characteristics.

5. A system of any one of claims 2 to 5, wherein the controller is configured to determine the position according to a look-up table of predetermined positions according to the known characteristics indicative of such positions.

6. A system of any one of claims 2 to 5, wherein the actuator is configured to adjust the deflector plate in a vertical manner, a horizontal manner or an angular manner.

7. An automated conveyor transfer station which is configured to direct material from an input conveyor by means of a deflector plate via a transfer chute to an output conveyor or vessel, the deflector plate located at an upper end of the station proximate the input conveyor and configured to direct the material, as it impacts said deflector plate, through the station towards an exit at a lower end of the station proximate the output conveyor or vessel, said transfer station comprising: a sensor configured to sense a characteristic of the material operatively conveyed on the input conveyor and subsequently dumped into the transfer station, the sensed characteristic indicative of a behaviour of the material as it impacts the 19 deflector plate, the sensor adapted to sense a material characteristic selected from a group consisting of material particulate size, material flow rate, material volume, material moisture content, material chemical composition, material position, material temperature and material velocity; a controller arranged in communication with the sensor, said controller configured to compare the sensed characteristic to known values of characteristics, and to determine a position of the deflector plate best suited to direct the material downward through the transfer chute and away from the deflector plate according to the sensed behaviour, the known characteristics indicative of such a position; and an actuator under control of the controller, said actuator arranged to adjust the deflector plate to such position prior to the sensed material impacting the deflector plate so that material build-up on the deflector plate and subsequent blockages at the input conveyor is minimised as the material enters the transfer station and impacts the deflector plate, thereby enabling varying types of materials to be dynamically transferrable through the station.