AU2015230853B2 - Method and system of payload optimisation - Google Patents

Abstract

A payload optimisation method for topping-off open-topped rail wagons pre loaded with particulate material, the method including: measuring a bogie load at each bogie of a pre-loaded rail wagon; comparing the measured bogie load to a predetermined bogie load and, where the measured bogie load is less than the predetermined bogie load, calculating a weight of particulate material representative of the difference between the measured bogie load and the predetermined bogie load; scanning the open-top of the wagon to determine a loading profile thereof; identifying by reference to the scanned loading profile at least one position within the wagon having capacity to receive the calculated weight of particulate material; and delivering the calculated weight of particulate material to the wagon at the at least one identified position within the wagon. 3 0 0 S t a r t Receiving measured bogie load at each bogie of pre-loaded wagon Comparing measured bogie load to 304 predetermined bogie load and determining difference Receiving scanned loading profile for pre-loaded wagon Identifying a position and/or region within the wagon having capacity to receive additional particulate material 308 Controlling the flow control actuator to deliver particulate material to the dispenser bins [Controlling the flow control actuator to stop the flow of particulate material to the dispenser bins 312 Controlling the dispenser control actuator to deliver the particulate material to the identified position 314 and/or region in the wagon

Description

2015230853 28 Sep 2015 ι "Method and System of Payload Optimisation"

Technical Field [0001] The disclosure relates, generally, to a method and system of payload optimisation and, more particularly, to a particulate material top-off method and associated system for topping-off open-topped rail wagons.

Background [0002] 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.

[0003] 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.

[0004] Whereas under-loading ore wagons represents wasted rail capacity and poor network efficiency, overloading of ore wagons can place unwanted stress on critical components which can lead to failures and even train derailments. Given the potential for train derailment, overloading can be a serious offence. As a result, miners and associated rail operators generally err on the side of caution, and try to ensure that rail wagons are consistently under-loaded rather than overloaded in order to avoid any transgression of rail loading regulations. However, as mentioned above, such underloading typically leads to wasted rail capacity and poor network efficiency, which translates into production losses for a mining operation. 2015230853 28 Sep 2015 2 [0005] Due to the amount of particulate material loaded into rail wagons, each wagon on a rail consistently may be under-loaded by a number of tons. In a case where a rail consistently comprises hundreds of rail wagons, such under-loading may represent hundreds to thousands of tons of under-loading and unutilized capacity. As a result, it is not uncommon for such under-loading losses to run into the order of hundreds of thousands to millions of dollars on an annual basis.

[0006] In this specification where a document, act or item of knowledge is referred to or discussed, this reference or discussion is not an admission that the document, act or item of knowledge or any combination thereof was at the priority date, publicly available, known to the public, part of the common general knowledge; or known to be relevant to an attempt to solve any problem with which this specification is concerned.

[0007] Throughout this specification the word “comprise”, or variations such as “comprises” or “comprising”, will be understood to imply the inclusion of a stated element, integer or step, or group of elements, integers or steps, but not the exclusion of any other element, integer or step, or group of elements, integers or steps.

Summary [0008] In a first aspect, there is provided a payload optimisation method for topping-off open-topped rail wagons pre-loaded with particulate material, the method including: measuring a bogie load at each bogie of a pre-loaded rail wagon; comparing the measured bogie load to a predetermined bogie load and, where the measured bogie load is less than the predetermined bogie load, calculating a weight of particulate material representative of the difference between the measured bogie load and the predetermined bogie load; scanning the open-top of the wagon to determine a loading profile thereof; 2015230853 28 Sep 2015 3 identifying by reference to the scanned loading profile at least one position within the wagon having capacity to receive the calculated weight of particulate material; and delivering the calculated weight of particulate material to the wagon at the at least one identified position within the wagon.

[0009] The step of measuring the bogie load at each bogie may involve the use of an on-track weight sensor, or a load cell, or the like.

[0010] The step of scanning the open-top of the wagon may involve the use of a radar scanner, a laser scanner, and/or the like. In addition, the scanned loading profile of the wagon may include a three-dimensional profile of the particulate material within the wagon.

[0011] The step of identifying at least one position within the wagon having capacity to receive the calculated weight of particulate material may further include comparing the scanned loading profile to a predetermined loading profile. More specifically, the predetermined loading profile may include a set of spatial data points representative of a desired loading profile for the wagon.

[0012] The step of delivering the calculated weight of particulate material to the wagon may occur while the wagon is in motion and may involve the use of a filler configured to deliver the calculated weight of particulate material to the at least one identified position within the wagon. Further, the filler may be configured to distribute the calculated weight of particulate material across at least two identified positions within the wagon.

[0013] In a further aspect, there is provided a payload optimisation system for topping-off open-topped rail wagons pre-loaded with particulate material, the system including: 2015230853 28 Sep 2015 4 a first sensor configured to measure a bogie load at each bogie of a pre-loaded rail wagon; a scanner configured to scan the open-top of the wagon to determine a loading profile thereof; a filler configured to deliver a quantity of particulate material to the wagon; and a processor arranged in communication with the first sensor, scanner and filler, the processor being configured to: compare the measured bogie load to a predetermined bogie load and, where the measured bogie load is less than the predetermined bogie load, calculate a weight of particulate material representative of the difference between the measured bogie load and the predetermined bogie load; identify by reference to the scanned loading profile at least one position within the wagon having capacity to receive the calculated weight of particulate material; and control the filler to deliver the calculated weight of particulate material to the at least one identified position within the wagon.

[0014] The first sensor may include an on-track weight sensor, or a load cell, or the like.

[0015] The scanner may include a radar scanner, a laser scanner, and/or the like. In addition, the scanned loading profile of the wagon includes a three-dimensional profile of the particulate material within the wagon. 2015230853 28 Sep 2015 5 [0016] The processor may include a general purpose microprocessor, a programmable logic controller (PLC), a digital signal processor (DSP), a microcontroller, and/or the like.

[0017] The filler may be configured to deliver the calculated weight of particulate material to the at least one identified position within the wagon while the wagon is in motion. Alternatively, or in addition, the filler may be configured to distribute the calculated weight of particulate material across at least two identified positions within the wagon.

[0018] In the step of identifying at least one position within the wagon having capacity to receive the calculated weight of particulate material, the processor may be further configured to compare the scanned loading profile to a predetermined loading profile. In this regard, the predetermined loading profile may include a set of spatial data points representative of a desired loading profile for the wagon.

[0019] The filler may also include: a flow control system configured to measure and isolate the calculated weight of particulate material; and a delivery system configured to deliver the calculated weight of particulate material to the at least one identified position within the wagon.

[0020] The flow control system may include: a surge bin configured to receive a continuous supply of the particulate material; one or more dispenser bins configured to receive the calculated weight of particulate material from the surge bin; and 2015230853 28 Sep 2015 6 a flow control actuator operable by the processor and being configured to control the flow of particulate material from the surge bin to the one or more dispenser bins.

[0021] The flow control system may further include at least one second sensor configured to measure the weight of particulate material in the one or more dispenser bins.

[0022] The processor may be further configured to: receive from the second sensor real-time information indicative of the weight of particulate material in the one or more dispenser bins; and in response to the real-time information received from the second sensor, control the flow control actuator by either: placing the flow control actuator in an open position if the weight of particulate material in the one or more dispenser bins is less than the calculated weight of particulate material; or placing the flow control actuator in a closed position if the weight of particulate material in the one or more dispenser bins is equal to or greater than the calculated weight of particulate material.

[0023] The delivery system may include: a dispenser configured to dispense the calculated weight of particulate material to the wagon; and a dispenser control actuator operable by the processor and being configured to control the flow of the calculated weight of particulate material via the dispenser from the one or more dispenser bins to the at least one identified position within the wagon. 2015230853 28 Sep 2015 7 [0024] The processor may be further configured to: identify by reference to the scanned loading profile and/or wagon position data received from a third sensor, the at least one identified position within the wagon; and control the dispenser control actuator by placing the dispenser control actuator in an open position so as to deliver the calculated weight of particulate material or portion thereof via the dispenser to the at least one identified position within the wagon while the wagon is in motion.

[0025] In a further aspect, there is provided a filler including: a dispenser configured to receive a supply of particulate material and to dispense a calculated weight of particulate material to a moving wagon; and a dispenser control actuator configured to operatively feed the dispenser from the supply in order to apportion a specific weight of particulate material through the dispenser at one or more positions within the rail wagon.

Brief Description of Drawings [0026] An embodiment of the disclosure is now described by way of example with reference to the accompanying drawings in which: - [0027] Figure 1 shows a perspective view of an embodiment of a payload optimisation system; [0028] Figure 2 is a schematic block diagram illustrating an embodiment of a payload optimisation system; [0029] Figure 3 is a flowchart illustrating an embodiment of the payload optimisation system shown in Figure 1; 2015230853 28 Sep 2015 8 [0030] Figure 4 is a line drawing of a filler used in the payload optimisation system shown in Figure 1; [0031] Figure 5 is a line drawing of the filler shown in Figure 4 with partial surrounding structures removed; and [0032] Figure 6 is a perspective view of a wagon used in the payload optimisation system shown in Figure 1.

Description of Embodiments [0033] In the drawings, and particularly Figure 1, reference numeral 10 generally designates an embodiment of a payload optimisation system. The payload optimisation system 10 is particularly useful in relation to topping-off open-topped rail wagons and it will therefore be convenient to describe the system 10 in that environment. However, it should be understood that the system 10 is not limited to this embodiment, and may be utilised or implemented in other environments or application.

[0034] Figure 2 is a schematic diagram illustrating a system 10 within which embodiments of the present system 10 may be implemented.

[0035] The system 10 preferably uses a communications network 102, e.g. the Internet or a local wired network (e.g. LAN), to facilitate payload optimisation for topping-off open-topped rail wagons. In the exemplary embodiment 10, a server 104 executes a software application for provision of control and monitoring operations via client computing devices 106. Communication between the server 104 and the devices 106 may therefore be conveniently based upon standard hypertext transfer protocol (HTTP) and/or secure hypertext transfer protocol (HTTPS), although other communication protocols may also be employed by the system 10.

[0036] The devices 106 (i.e. control and monitoring stations) may be fixed devices such as desktop computers, and/or mobile devices such a smart phones, tablets, 2015230853 28 Sep 2015 9 notebook computers and so forth. As will be appreciated by persons skilled in the communication arts, various mechanisms and technologies are available to provide access to the Internet 102 from fixed and mobile devices 106, and all such technologies fall within the scope of the system 10 described herein.

[0037] The server 104 may generally comprise one or more computers, each of which includes at least one microprocessor 108. The number of computers and processors 108 generally depends upon the required processing capacity of the system, which in turn depends upon the number of concurrent client computing devices 106 which the system is designed to support. In order to provide a high-degree of scalability, the server 104 may utilise cloud-based computing resources, and/or may comprise multiple server sites located in different geographical regions. The use of a cloud computing platform, and/or multiple server sites, enables physical hardware resources to be allocated dynamically in response to service demand and or redundancy requirements. These and other variations, regarding the server computing resources, will be understood to be within the scope of the system 10 described herein, although for simplicity the exemplary embodiments described herein employ only a single server computer 104 with a single microprocessor 108.

[0038] The microprocessor 108 is interfaced to, or otherwise operably associated with, a non-volatile memory/storage device 110. The non-volatile storage 110 may be a hard-disk drive, and/or may include solid-state non-volatile memory such as readonly memory (ROM), flash memory, or the like. The microprocessor 108 is also interfaced to volatile storage 112, such as random access memory (RAM), which contains program instructions and transient data relating to the operation of the server 104.

[0039] In a conventional configuration, the storage device 110 maintains known program and data content relevant to the normal operation of the server system 104, including operating systems, programs and data, as well as other executable application software necessary to the intended functions of the server 104. In the embodiment shown, the storage device 110 also contains program instructions which, when ίο 2015230853 28 Sep 2015 executed by the processor 108, enable the server computer 104 to perform operations relating to the implementation of services and facilities embodying the present system 10, such as are described in greater detail below with reference to Figure 1 and Figures 3 to 5. In operation, instructions and data held on the storage device 110 are transferred to volatile memory 112 for execution on demand.

[0040] The microprocessor 108 is operably associated with a network interface 114 in a conventional manner. The network interface 114 facilitates access to one or more data communications networks, including the Internet 102, to enable communication between the server 104 and the client devices 106. In use, the volatile storage 112 includes a corresponding body of 116 of program instructions configured to perform processing and operations embodying features of the present system 10, for example as described below with reference to Figure 1 and Figures 3 to 5. In particular, it will be convenient to describe the program instructions performed by the processor 108 by referring to the flowchart 300 at Figure 3 of the drawings.

[0041] Various implementations of embodiments of the system 10 will be apparent to persons skilled in the art of software engineering, including various combinations of server-side and client-side executable program components.

[0042] As illustrated at Figure 1 of the drawings, the system 10 preferably operates using certain existing infrastructure that would commonly be found at a mining or excavation site. For example, at such mining sites, mined ore is typically loaded into ore wagons for transport purposes via a rail network. As such, the system 10 relies upon the existence of a rail network for transportation of the mined ore, and an ore-loading facility 12 such as, for example, a ‘train load out’ (TLO), as it is commonly referred to in the mining industry. In accordance with existing TLO systems, the unloaded train wagons 22 are driven along a rail track 20 at a relatively low speed (e.g. 1.2kmph). The infrastructure of the TLO 12 generally consists of a large surge bin 14 that is continuously fed by a conveyor 16 with the mined and processed (e.g. crushed) ore. However, it should be appreciated that other TLO configurations are also possible and able to be utilised by the system 10. 11 2015230853 28 Sep 2015 [0043] The surge bin 14 of the TLO 12 is typically configured to be positioned above the rail track 20, so that the unloaded rail wagons 22 travel along the track 20 and pass directly beneath the surge bin 14. As each of the wagons 22 passes beneath the surge bin 14, a quantity of the mined ore is released into the wagon via a high-rate flow control mechanism. Due to the nature of the high-volume throughput, the accuracy of the flow control mechanism under the surge bin 14 is granular, and the final weight of mined ore delivered to each wagon 22 varies. However, the high-volume throughput is still seen as being necessary in order to rapidly load the wagons 22, particularly where the wagons 22 are constantly moving along the track 20.

[0044] In accordance with the system 10, a TLO 12 (or similar loading facility) is still preferably required in order to load the wagons 22 (i.e. deliver the bulk of the particulate material to the wagons 22). As with existing TLO systems, the aim of the TLO 12 is to deliver a full wagon capacity of mined ore in a single discharge from the surge bin 14. However, due to operational constraints, physical infrastructure limitations, and characteristics of the particulate material, a full load of particulate material may not always be delivered to the wagon 22 by the TLO 12 . For example, the TLO 12 (via the initial discharge from the surge bin 14) may, under certain conditions, deliver to the wagon 22 mined ore representing only about 95% of the capacity of the wagon 22. As a result, the capacity of the wagon 24 is underutilised by about 5%. It should be appreciated that greater or lesser amounts of mined ore could be delivered to the wagons 22 by the TLO 12 depending on the particular conditions and characteristics of the particulate material..

[0045] The system 10 also includes a first sensor 30 operatively coupled to the processor 108, and being configured to measure a bogie load at each bogie of a pre-loaded rail wagon 24. This first sensor 30 is preferably an on-track weight sensor (also known as a track scale), but could equally be any similar device capable of measuring the load at each bogie of the pre-loaded wagon 24 (such as, for example, a load cell). Following the initial pre-loading of the wagons 24 by the TLO 12, the wagons 24 pass over the first sensor 30, at which point the first sensor 30 is configured to measure the bogie load at each bogie 32 of the pre-loaded wagon 24. 12 2015230853 28 Sep 2015 [0046] As illustrated in the Figure 6 of the drawings, by way of illustrative example, each bogie 32 may comprise a bogie frame 34 that is suspended above the rail track 20 by one or more wheelsets 36. Each of the wheelsets 36 preferably comprises an axle 37 and a set of wheels 38. In the example shown in Figure 6, each of the wagons 22, 24 is supported by two bogies 34, one positioned near the front of the wagon 22, 24 and one positioned near the rear of the wagon 22, 24. However, it should be appreciated that additional bogies 32 may be used and positioned along the undercarriage of the wagon 22, 24 as required. Similarly, in the example shown in Figure 6, each of the bogies 32 is illustrated with two wheelsets 36 i.e. two axles 37, each axle 37 having a set of wheels 38. However, it should be appreciated that alternative configurations are also possible. For example, a particular bogie 32 may comprise more than two wheelsets 36, particularly if the wagon 22, 24 is intended to receive a particularly heavy load of particulate material. In addition, the bogie 32 may also include suspension (not shown) positioned between the bogie frame 34 and the wagon 22, 24.

[0047] Referring now to the flowchart 300 shown in Figure 3 of the drawings, at 302 the processor 108 is configured to receive from the first sensor 30 information representative of the bogie load at each bogie 32 of the wagon 24 and, preferably, to store this information in memory 110, 112. At 304, the processor 108 is then configured to compare the measured bogie load to a predetermined bogie load and, where the measured bogie load is less than the predetermined bogie load, calculate a weight of particulate material representative of the difference between the measured bogie load and the predetermined bogie load. In one embodiment, the predetermined bogie load is the maximum allowable (e.g. optimal) bogie load for a particular bogie 32 design. For example, if each of the two axles 37 that comprise the bogie 32 are rated at 40 tons, then the predetermined bogie load for that particular bogie 32 would be 80 tons. This predetermined bogie load is preferably represented as a value stored in memory 110, 112 prior to operation of the system 10. As a result, step 304 involves the retrieval by the processor 108 of the predetermined bogie load from memory 110, 112 and a comparison of that predetermined bogie load to the measured bogie load information received from the first sensor 30, in order to determine the difference between the predetermined bogie load and the measured bogie load. For example, the 13 2015230853 28 Sep 2015 predetermined bogie load for the wagon may be 80 tons and the measured bogie load for a particular wagon may be 78 tons. In relation to this example, the difference calculated by the processor 108 would be approximately 2 tons. This difference between the predetermined bogie load and the measured bogie load (i.e. the calculated weight of particulate material) is preferably stored in memory 110, 112 for later use. It should also be appreciated that the calculated weight of particulate material, representative of the difference between the measured bogie load and the predetermined bogie load, can be a combined difference between the measured bogie load and the predetermined bogie load for all bogies 32 of a particular wagon 24 (e.g. combining the difference between the measured bogie load and the predetermined bogie load for the front bogie with the difference between the measured bogie load and the predetermined bogie load for the rear bogie).

[0048] As shown in Figure 1 of the drawings, the system 10 further includes a scanner 40 configured to scan the open-top of the wagon in order to determine a loading profile (preferably a three-dimensional profile) of the particulate material within the wagon 24. The scanner 40 is configured to measure a cross-sectional profile of the particulate material within the wagon 24 and to compile a three-dimensional profile of the particulate material within the wagon 24. The measurement of the cross-sectional profile of the particulate material is preferably performed using known volumetric sensing technology (e.g. laser scanner) that would be understood to those skilled in the art. In addition, the compilation of the three-dimensional profile of the particulate material within the wagon 24 is preferably performed, for example, through the use of known sensor software that is executed by the processor 108.

[0049] At step 306 of the flowchart 300 shown in Figure 3 of the drawings, the processor 108 is configured to receive from the scanner 40 information representative of the loading profile of the wagon 24. This information about the loading profile of the wagon 24 preferably includes geospatial data points (such as, for example, geospatial data points using a Cartesian coordinate system wherein the x-axis placed on the centreline of the wagon 24 length, the y-axis indicating depth of material in wagon 24, and the z-axis indicating how far the particulate material is positioned left or right 14 2015230853 28 Sep 2015 of the wagon 24 centre line). This information representative of the loading profile of the wagon 24 is preferably stored in memory 110, 112 for later use.

[0050] It should be appreciated from step 304 that if the measured bogie load is greater than or equal to the predetermined bogie load, then the processor 108 may not proceed to step 306 since no further quantity of particulate material is required to be added to the wagon 24. However, in an alternate embodiment, if the measured bogie load is greater than the predetermined bogie load (by more than, for example, a predetermined threshold amount) the processor 108 may still proceed to step 306 in order to determine from the scanned loading profile the positioning of the excess particulate material (so that, for example, the excess particulate material can be removed from the wagon 24).

[0051] Having received from the scanner 40 the information representative of the loading profile of the wagon 24, at step 308 the processor is configured to identify a position and/or region within the wagon 24 where an additional quantity of particulate material can be delivered. In other words, the processor is configured to identify from the three-dimensional loading profile of the wagon 24 (in the case where the measured bogie load of a particular wagon 24 is less than the predetermined bogie load), whether there is volumetric capacity within the wagon to receive an additional quantity of particulate material (e.g. a weight of particulate material representative of the difference between the measured bogie load and the predetermined bogie load).

[0052] In identifying a position and/or region within the wagon 24 where an additional quantity of particulate material can be delivered, the processor 108 (at step 308) is configured to compare the scanned loading profile with a predetermined loading profile (stored in memory 110, 112). In one embodiment, the predetermined loading profile is a set of spatial data points representative of a desired loading profile for the wagon. For example, the predetermined loading profile may comprise a set of spatial data points representative (collectively) of the maximum allowable fill profile for a particular wagon 24. The comparison of the scanned loading profile with the predetermined profile involves a comparison of the spatial data points representative of 15 2015230853 28 Sep 2015 the loading profile of the wagon 24 (i.e. the actual loading of the wagon 24) with the spatial data points representative of the predetermined loading profile (e.g. the desired loading profile) and, where applicable, calculating the difference between the two sets of data points in order to identify one or more positions and/or regions within the wagon 24 where an additional quantity of particulate material can be delivered. This position and/or region within the wagon 24 is preferably stored in memory 110, 112 for later use.

[0053] It should be appreciated that based on the loading profile received from the scanner 40, the processor 108 may determine that the additional quantity of particulate material (e.g. a weight of particulate material representative of the difference between the measured bogie load and the predetermined bogie load) should be distributed across more than one position and/or region within a particular wagon 24. Extending upon the earlier example where the difference between the predetermined bogie load and the measured bogie load is 2 tons (for both the front bogie and the rear bogie), the processor 108 may determine (by reference to the scanned loading profile) that 2 tons of particulate material is to be distributed above the front bogie of the wagon 24, and 2 tons of particulate material is to be distributed above the rear bogie of the wagon 24. Alternatively, and also by way of example, the processor 108 may determine (by reference to the scanned loading profile) that 4 tons of particulate material (i.e. the combined difference between the predetermined bogie load and the measured bogie load for both front and rear bogies) is to be distributed at a position between (or central to) the front and rear bogies (e.g. a position central to the wagon). In other words, the calculated weight of particulate material is not necessarily required to be delivered at position and/or region above either of the front of rear bogies 32.

[0054] As shown in Figure 1 of the drawings, the system 10 further includes a filler 50 configured to deliver a quantity of particulate material to the wagon 24. The filler 50 preferably includes a flow control system 52 (as shown in Figure 4 and Figure 5 (with partial surrounding structures removed) of the drawings), configured to measure and isolate the calculated weight of particulate material. The flow control system 52 includes a surge bin 54 having a feed source (for example, an infrastructure conveyor 16 2015230853 28 Sep 2015 (not shown), auger conveyor, or a temporary stacker-type conveyor) that is capable of supplying the surge bin 54 at the required top-up rate. Located directly beneath the surge bin 54 (and above the track 20, and moving wagons 24), the flow control system 52 further includes one or more dispenser bins 56 for receiving the calculated weight of particulate material from the surge bin 54. In addition, the flow control system 52 also includes a flow control actuator 58 operable by the processor 108 and being configured to control the flow of particulate material from the surge bin 54 to the one or more dispenser bins 56.

[0055] At step 310 of the flowchart 300 shown in Figure 3 of the drawings, and after having identified a weight of particulate material representative of the difference between the measured bogie load and the predetermined bogie load (at step 304) and a position and/or region within the wagon 24 where an additional quantity of particulate material can be delivered (at step 308), the processor 108 is configured to control the flow of particulate material from the surge bin 54 to the one or more dispenser bins 56. As an initial control condition, the processor 108 is configured to place the flow control actuator 58 in an open position in order to commence the delivery of the particulate material from the surge bin 54 to the one or more dispenser bins 56.

[0056] In one embodiment, the one or more dispenser bins 56 are positioned on load cells (not shown) operatively coupled to the processor 108 so as to provide real-time information about the weight of particulate material delivered to the dispenser bins 56. It should be appreciated that any similar sensors could be used to provide real-time information about the weight of particulate material delivered to the dispenser bins 56.

[0057] At step 312 of the flowchart 300 shown in Figure 3 of the drawings, the processor 108 is configured to continuously monitor the real-time information (provided by the load cells) about the weight of particulate material delivered to the dispenser bins 56, and to place the flow control actuator 58 in a closed position once the weight of particulate material delivered to the dispenser bins 56 equals or exceeds the calculated weight of particulate material (i.e. the difference between the predetermined bogie load and the measured bogie load). 17 2015230853 28 Sep 2015 [0058] The filler 50 also includes a delivery system 60 configured to deliver the calculated weight of particulate material to the at least one identified position and/or region within the wagon 24. The delivery system 60 preferably includes a dispenser 62 configured to dispense the calculated weight of particulate material to the wagon 24, and a dispenser control actuator (not shown) operable by the processor 108 and being configured to control the flow of the calculated weight of particulate material via the dispenser 62 from the one or more dispenser bins 56 to the at least one identified position and/or region within the wagon 24. In one embodiment, the delivery of the particulate material via the dispenser 62 to the identified position within the moving wagon 24 involves an identification of when the identified position will align with the dispenser 62 (in the case where the dispenser 62 is fixed). In other words, since the wagon 24 is constantly moving along the track 20, the system 10 is configured to deliver the calculated quantity of particulate material to the identified position when that identified position passes substantially beneath (and aligns with) the dispenser 62. In an alternate embodiment, where a greater degree of accuracy is required in the delivery of the particulate material to the wagon, the dispenser (or a portion thereof) may be moveable above the surface of the wagon 24 to allow for delivery of a quantity of the particulate material to a specific position and/or region of the wagon 24.

[0059] In an exemplary embodiment, the filler 50 (in the case where the dispenser 62 is fixed) includes two dispenser bins 56 positioned above the track 20 and above the moving wagons 24 (such as shown in Figures 4 and 5 of the drawings). In addition, the dispenser 62 of the delivery system 60 preferably comprises two corresponding dispenser chutes 62 positioned directly beneath the dispenser bins 56 and above the moving wagons 24. The dispenser chutes 62 (and preferably, but not necessarily, the dispenser bins 56) are positioned on either side of a central plane of motion of the wagons 24 (e.g. one dispenser bin 56 and corresponding dispenser chute 62 positioned over the left side of the moving wagons 24, and one dispenser bin 56 and corresponding dispenser chute 62 positioned over the right side of the moving wagons 24). Such a configuration allows the filler 50 to deliver particulate material to the wagon 24 in a more precise manner. For example, if the at least one identified position and/or region within the wagon 24 is located over the front bogie of the wagon 24, and 18 2015230853 28 Sep 2015 toward the left-hand side of the wagon 24, the configuration of the filler 50 described in this exemplary embodiment would allow for delivery of particulate material specifically to that position and/or region (e.g. by release of particulate material only through the dispenser bin 56 and corresponding dispenser chute 62 positioned over the left side of the wagon 24)..

[0060] At step 314 of the flowchart 300 shown in Figure 3 of the drawings, the processor 108 is configured to control the dispenser control actuator (not shown) to deliver the particulate material to the identified position and/or region in the wagon 24. Part of this process may involve continuously monitoring the position of consecutive moving wagons 24 and, in particular, detecting the gap between consecutive wagons 24. Preferably, the identification of the gap between the wagons 24 is achieved through the use of a third sensor (such as, for example, an optical sensor or short-range radar sensor or the like). One purpose of identifying this gap between the wagons 24 is to ensure that no particulate material is delivered into this gap (i.e. directly onto the track 20, and not within one of the wagons 24). However, another purpose may be to determine the starting position of each moving wagon 24 in order to coordinate the timing of delivery of particulate material to the wagon 24 at the identified position.

Also at step 314, the processor 108 is configured to control the dispenser control actuator 62 by placing the dispenser control actuator (not shown) in an open position so as to deliver the calculated weight of particulate material or portion thereof via the dispenser 62 to the at least one identified position within the wagon 24.

[0061] Following the completion of step 314, the processor 108 is configured to repeat steps 310 to 314 for the next consecutive wagon 24 or for the next identified position within the wagon 24 (i.e. in the situation where particulate material has already been delivered to one position within the wagon 24 (e.g. over the front bogie of the wagon 24) it may still be the case that particulate material is required to be delivered to another position (e.g. over the rear bogie of the wagon 24). In this regard, the processor 108 would again access (for the next consecutive wagon 24, or in relation to another bogie of the same wagon 24) the identified weight of particulate material representative of the difference between the measured bogie load and the 2015230853 28 Sep 2015 19 predetermined bogie load (at step 304) and a position and/or region within the wagon 24 where an additional quantity of particulate material can be delivered (at step 308).

[0062] As shown in Figure 1 of the drawings, the system 10 may optionally include a second sensor 70 operatively coupled to the processor 108, and being configured to measure a bogie load at each bogie 32 of the fully-loaded rail wagons. As with the first sensor 30, the second sensor 70 is preferably an on-track weight sensor (also known as a track scale), but could equally be any similar device capable of measuring the load at each bogie of the fully-loaded wagon 24 (such as, for example, a load cell). The primary purpose of the second sensor 70 is to confirm that the measured bogie load (of the full-loaded wagon 24) and the predetermined bogie load are the same (or within acceptable tolerance limits).

[0063] It will be appreciated by persons skilled in the art that numerous variations and/or modifications may be made to the above-described embodiments, without departing from the broad general scope of the present disclosure. The present embodiments are, therefore, to be considered in all respects as illustrative and not restrictive.

Claims (24)

1. CLAIMS:

   1. A payload optimisation method for topping-off open-topped rail wagons preloaded with particulate material, the method including: measuring a bogie load at each bogie of a pre-loaded rail wagon; comparing the measured bogie load to a predetermined bogie load and, where the measured bogie load is less than the predetermined bogie load, calculating a weight of particulate material representative of the difference between the measured bogie load and the predetermined bogie load; scanning the open-top of the wagon to determine a loading profile thereof; identifying by reference to the scanned loading profile at least one position within the wagon having capacity to receive the calculated weight of particulate material; and delivering the calculated weight of particulate material to the wagon at the at least one identified position within the wagon.
2. 2. The method according to claim 1, wherein the step of measuring the bogie load at each bogie involves the use of an on-track weight sensor, or a load cell, or the like.
3. 3. The method according to any one of the preceding claims, wherein the step of scanning the open-top of the wagon involves the use of a radar scanner, a laser scanner, and/or the like.
4. 4. The method according to any one of the preceding claims, wherein the scanned loading profile of the wagon includes a three-dimensional profile of the particulate material within the wagon.
5. 5. The method according to any one of the preceding claims, wherein the step of identifying at least one position within the wagon having capacity to receive the calculated weight of particulate material further includes comparing the scanned loading profile to a predetermined loading profile.
6. 6. The method according to claim 5, wherein the predetermined loading profile includes a set of spatial data points representative of a desired loading profile for the wagon.
7. 7. The method according to any one of the preceding claims, wherein the step of delivering the calculated weight of particulate material to the wagon is performed while the wagon is in motion and involves the use of a filler configured to deliver the calculated weight of particulate material to the at least one identified position within the wagon.
8. 8. The method according to claim 7, wherein the filler is configured to distribute the calculated weight of particulate material across at least two identified positions within the wagon.
9. 9. A payload optimisation system for topping-off open-topped rail wagons preloaded with particulate material, the system including: a first sensor configured to measure a bogie load at each bogie of a pre-loaded rail wagon; a scanner configured to scan the open-top of the wagon to determine a loading profile thereof; a filler configured to deliver a quantity of particulate material to the wagon; and a processor arranged in communication with the first sensor, scanner and filler, the processor being configured to: compare the measured bogie load to a predetermined bogie load and, where the measured bogie load is less than the predetermined bogie load, calculate a weight of particulate material representative of the difference between the measured bogie load and the predetermined bogie load; identify by reference to the scanned loading profile at least one position within the wagon having capacity to receive the calculated weight of particulate material; and control the filler to deliver the calculated weight of particulate material to the at least one identified position within the wagon.
10. 10. The system according to claim 9, wherein the first sensor includes an on-track weight sensor, or a load cell, or the like.
11. 11. The system according to either claim 9 or claim 10, wherein the scanner includes a radar scanner, a laser scanner, and/or the like.
12. 12. The system according to any one of claims 9 to 11, wherein the processor includes a general purpose microprocessor, a programmable logic controller (PLC), a digital signal processor (DSP), a microcontroller, and/or the like.
13. 13. The system according to any one of claims 9 to 12, wherein the scanned loading profile of the wagon includes a three-dimensional profile of the particulate material within the wagon.
14. 14. The system according to any one of claims 9 to 13, wherein in the step of identifying at least one position within the wagon having capacity to receive the calculated weight of particulate material, the processor is further configured to compare the scanned loading profile to a predetermined loading profile.
15. 15. The system according to any one of claims 9 to 14, wherein the predetermined loading profile includes a set of spatial data points representative of a desired loading profile for the wagon.
16. 16. The system according to any one of claims 9 to 15, wherein the filler is configured to deliver the calculated weight of particulate material to the at least one identified position within the wagon while the wagon is in motion.
17. 17. The system according to any one of claims 9 to 16, wherein the filler is configured to distribute the calculated weight of particulate material across at least two identified positions within the wagon.
18. 18. The system according to any one of claims 9 to 17, wherein the filler further includes: a flow control system configured to measure and isolate the calculated weight of particulate material; and a delivery system configured to deliver the calculated weight of particulate material to the at least one identified position within the wagon.
19. 19. The system according to claim 18, wherein the flow control system includes: a surge bin configured to receive a continuous supply of the particulate material; one or more dispenser bins configured to receive the calculated weight of particulate material from the surge bin; and a flow control actuator operable by the processor and being configured to control the flow of particulate material from the surge bin to the one or more dispenser bins.
20. 20. The system according to claim 19, wherein the flow control system further includes at least one second sensor configured to measure the weight of particulate material in the one or more dispenser bins.
21. 21. The system according to claim 20, wherein the processor is further configured to: receive from the second sensor real-time information indicative of the weight of particulate material in the one or more dispenser bins; and in response to the real-time information received from the second sensor, control the flow control actuator by either: placing the flow control actuator in an open position if the weight of particulate material in the one or more dispenser bins is less than the calculated weight of particulate material; or placing the flow control actuator in a closed position if the weight of particulate material in the one or more dispenser bins is equal to or greater than the calculated weight of particulate material.
22. 22. The system according to any one of claims 19 to 21, wherein the delivery system includes: a dispenser configured to dispense the calculated weight of particulate material to the wagon; and a dispenser control actuator operable by the processor and being configured to control the flow of the calculated weight of particulate material via the dispenser from the one or more dispenser bins to the at least one identified position within the wagon.
23. 23. The system according to claim 22, wherein the processor is further configured to: identify by reference to the scanned loading profile and/or wagon position data received from a third sensor, the at least one identified position within the wagon; and control the dispenser control actuator by placing the dispenser control actuator in an open position so as to deliver the calculated weight of particulate material or portion thereof via the dispenser to the at least one identified position within the wagon while the wagon is in motion.
24. 24. The system according to claim 23, wherein in the step of identifying the at least one identified position within the wagon, the processor is further configured to identify the gap between consecutive wagons.