Apparatus and method for stockpile control system

A stockpile control system adapted for use on a stockpile conveyor comprising a sensor that is disposed on the stockpile conveyor, a limit switch that is disposed on the stockpile conveyor, a pile probe that is disposed on the stockpile conveyor, and a microprocessor that is in operative communication with the limit switch and the sensor. The stockpile conveyor is adapted to move, the sensor is adapted to measure the location of the stockpile conveyor, the limit switch is adapted to limit the movement of the stockpile conveyor, the pile probe is adapted to measure a distance between the stockpile conveyor and a stockpile, and the microprocessor is adapted to control the movement of the stockpile conveyor. A method for controlling the production of a stockpile comprising providing a stockpile control system, calculating one or more stockpile boundaries, and controlling the movement of the stockpile conveyor.

FIELD OF THE INVENTION

The present invention relates generally to systems and methods for controlling items of equipment, and particularly to systems and methods for controlling stockpile equipment.

BACKGROUND AND DESCRIPTION OF THE PRIOR ART

It is known to use equipment to produce stockpiles. Conventional systems and methods, however, suffer from one or more disadvantages. For example, conventional stockpile systems and methods are undesirably inaccurate and imprecise in terms of placing and locating a stockpile. Conventional stockpile systems and methods also do not permit the user to repeat previous stockpile patterns. Conventional stockpile systems and methods are also difficult to use. In addition, conventional stockpile systems and methods rely on a timed event within the program to determine equipment location and thus material placement. Conventional stockpile systems and methods also do not sufficiently calculate and control the boundaries of the stockpile and the movement of the stockpile conveyor. In addition, conventional stockpile systems and methods do not maximize stockpile capacity or stockpile desegregation.

It would be desirable, therefore, if an apparatus and method for a stockpile control system could be provided that would accurately and precisely place and locate a stockpile. It would also be desirable if such an apparatus and method for a stockpile control system could be provided that would allow the user to repeat previous stockpile patterns. It would be further desirable if such an apparatus and method for a stockpile control system could be provided that would be easy to use. It would be still further desirable if such an apparatus and method for a stockpile control system could be provided that would determine equipment location using one or more sensors and computer-based software. In addition, it would be desirable if such an apparatus and method for a stockpile control system could be provided that would substantially continuously calculate and control the boundaries of the stockpile and the movement of the stockpile conveyor. It would also be desirable if such an apparatus and method for a stockpile control system could be provided that would maximize stockpile capacity and stockpile desegregation.

ADVANTAGES OF THE PREFERRED EMBODIMENTS OF THE INVENTION

Accordingly, it is an advantage of the preferred embodiments of the invention claimed herein to provide an apparatus and method for a stockpile control system that accurately and precisely places and locates stockpiles. It is also an advantage of the preferred embodiments of the invention claimed herein to provide an apparatus and method for a stockpile control system that is allows the user to repeat stockpile patterns. It is another advantage of the preferred embodiments of the invention claimed herein to provide an apparatus and method for a stockpile control system that is easy to use. It is a further advantage of the preferred embodiments of the invention claimed herein to provide an apparatus and method for a stockpile control system that determines the equipment location using one or more sensors and computer-based software. It is a still further advantage of the preferred embodiments of the invention claimed herein to provide an apparatus and method for a stockpile control system that substantially continuously calculate and control the boundaries of the stockpile and the movement of the stockpile conveyor. It is yet another advantage of the preferred embodiments of the invention claimed herein to provide an apparatus and method for a stockpile control system that maximizes stockpile capacity and stockpile desegregation.

Additional advantages of the preferred embodiments of the invention will become apparent from an examination of the drawings and the ensuing description.

SUMMARY OF THE INVENTION

The apparatus of the invention comprises a stockpile control system adapted for use on a stockpile conveyor. The preferred stockpile control system comprises a sensor that is disposed on the stockpile conveyor, a limit switch that is disposed on the stockpile conveyor, a pile probe that is disposed on the stockpile conveyor, and a microprocessor that is in operative communication with the limit switch and the sensor. The stockpile conveyor is adapted to move, the sensor is adapted to measure the location of the stockpile conveyor, the limit switch is adapted to limit the movement of the stockpile conveyor, the pile probe is adapted to measure a distance between the stockpile conveyor and a stockpile, and the microprocessor is adapted to control the movement of the stockpile conveyor.

The method of the invention comprises a method for controlling the production of a stockpile. The preferred method comprises providing a stockpile control system. The preferred stockpile control system comprises a sensor that is disposed on the stockpile conveyor, a limit switch that is disposed on the stockpile conveyor, a pile probe that is disposed on the stockpile conveyor, and a microprocessor that is in operative communication with the limit switch and the sensor. The stockpile conveyor is adapted to move, the sensor is adapted to measure the location of the stockpile conveyor, the limit switch is adapted to limit the movement of the stockpile conveyor, the pile probe is adapted to measure a distance between the stockpile conveyor and a stockpile, and the microprocessor is adapted to control the movement of the stockpile conveyor. The preferred method further comprises calculating one or more stockpile boundaries, and controlling the movement of the stockpile conveyor.

DESCRIPTION OF THE PREFERRED EMBODIMENTS OF THE INVENTION

Referring now to the drawings, the preferred embodiment of the apparatus and method for a stockpile control system in accordance with the present invention is illustrated byFIGS. 1 through 10. As shown inFIGS. 1-10, the preferred apparatus and method for a stockpile control system are adapted to accurately and precisely place and locate stockpiles. The preferred embodiments of the invention claimed herein also provide an apparatus and method for a stockpile control system that allows the user to repeat stockpile patterns. The preferred embodiments of the invention claimed herein further provide an apparatus and method for a stockpile control system that is easy to use. The preferred embodiments of the invention claimed herein still further provide an apparatus and method for a stockpile control system that determines the equipment location using one or more sensors and computer-based software. The preferred embodiments of the invention claimed herein also provide an apparatus and method for a stockpile control system that substantially continuously calculates and controls the boundaries of the stockpile and the movement of the stockpile conveyor. In addition, the preferred embodiments of the invention claimed herein provide an apparatus and method for a stockpile control system that maximizes stockpile capacity and stockpile desegregation.

Referring now toFIG. 1, a front perspective view of the preferred embodiment of the stockpile control system on an exemplary stockpile conveyor in accordance with the present invention is illustrated. As shown inFIG. 1, the preferred stockpile control system is designated generally by reference numeral20. Preferred stockpile control system20is disposed, in part, on exemplary stockpile conveyor22which is adapted to move in one or more directions. Preferably, stockpile conveyor22is adapted to move between a retracted position and an extended position along stockpile longitudinal axis24. Exemplary stockpile conveyor22is also adapted to move pivotally about vertical axis26and horizontal axis28. More particularly, preferred stockpile control system20comprises a sensor adapted to measure the location of stockpile conveyor22, a limit switch adapted to limit the movement of the stockpile conveyor, and a pile probe adapted to measure the distance between stockpile conveyor and a stockpile. Preferably, the sensor, the limit switch, and the pile probe are disposed on exemplary stockpile conveyor22. Preferably, the sensor comprises angle sensor30and rotation sensor32. Preferred angle sensor30is adapted to measure the pivotal movement of stockpile conveyor22about horizontal axis28so as to measure the angle of the stockpile conveyor relative to a horizontal plane. Preferred stockpile conveyor22includes one or more actuators36adapted to control the movement of the conveyor about horizontal axis28. Preferred rotation sensor32is adapted to measure the pivotal movement of stockpile conveyor22as the conveyor is pivotally moved about vertical axis26. Preferably, stockpile conveyor22is rotatably mounted to pivot plate40at proximal end42of the conveyor.

Still referring toFIG. 1, the preferred limit switch comprises stinger switches50and travel switches52. Preferred stinger switches50are adapted to limit the movement of stockpile conveyor22along longitudinal axis24and prevent stinger portion54of the stockpile conveyor from extending too far along the longitudinal axis. Preferred stinger switches50are also adapted to reset to a predetermined absolute value in the event the stinger switch is activated. Preferred stinger switches50comprise a hard-wired, redundant system. Preferably, stockpile control system20includes a winch and winch encoder56adapted to determine a length of stockpile conveyor22and control the movement of stinger portion54along longitudinal axis24. Preferred winch encoder is56is in operative communication with a microprocessor. Preferred travel switches52are adapted to limit the pivotal movement of stockpile conveyor22about vertical axis26and prevent the stockpile conveyor from rotating about the vertical axis too far to the left and too far to the right. Preferred travel switches52are also adapted to reset to a predetermined absolute value in the event the travel switch is activated. Preferred travel switches52comprise a hard-wired, redundant system. Preferably, stockpile control system20includes one or more wheel and motor assemblies58adapted to control the movement of stockpile conveyor22about vertical axis26. Preferred pile probe60is disposed at distal end62of stockpile conveyor22. Preferred pile probe60is adapted to measure the distance between conveyor22and the top of a stockpile. WhileFIG. 1illustrates the preferred configuration and arrangement of the stockpile conveyor, the sensors, the limit switches and the pile probe, it is contemplated that the stockpile conveyor, the sensors, the limit switches and the pile probe may be of any suitable configuration and arrangement.

Referring now toFIG. 2, a front view of preferred stockpile control system20on exemplary stockpile conveyor22is illustrated with a first exemplary stockpile. As shown inFIG. 2, preferred stockpile control system20is disposed, in part, on exemplary stockpile conveyor22. More particularly, preferred stockpile control system20comprises angle sensor30, rotation sensor32, stinger switches50, travel switch52, pile probe60, and microprocessor70. Preferred microprocessor70operatively communicates with the sensors and the limit switches and is adapted to control the movement of stockpile conveyor22. Preferred microprocessor70also comprises graphical interface72. Preferably, microprocessor70allows stockpile control system20to substantially continuously calculate one or more stockpile boundaries and automatically adjust the movement of stockpile conveyor22in substantially real time. In addition, preferred microprocessor70allows stockpile control system20to substantially continuously calculate a material flow depth and automatically adjust the movement of the stockpile conveyor in substantially real time. Preferred microprocessor70further allows stockpile control system20to produce repeatable stockpiles.

Referring now toFIG. 3, a top view of preferred stockpile control system20on exemplary stockpile conveyor22is illustrated. As shown inFIG. 2, preferred stockpile control system20is disposed, in part, on exemplary stockpile conveyor22. More particularly, preferred stockpile control system20comprises angle sensor30, rotation sensor32, stinger switches50, travel switches52, pile probe60, and microprocessor70. Preferred stockpile control system20is adapted to produce a standard stockpile configuration. Preferably, standard stockpile configuration is defined by left boundary74, right boundary75, inner boundary76, and outer boundary77.

Referring now toFIG. 4, a top view of preferred stockpile control system20on exemplary stockpile conveyor22is illustrated with a second exemplary stockpile. As shown inFIG. 4, preferred stockpile control system20is disposed, in part, on exemplary stockpile conveyor22. More particularly, preferred stockpile control system20comprises angle sensor30, rotation sensor32, stinger switches50, travel switches52, pile probe60, and microprocessor70. Second exemplary stockpile80is produced when preferred control system20operates in the radial continuous mode (seeFIG. 8).

Referring now toFIG. 5, a top view of preferred stockpile control system20on exemplary stockpile conveyor22is illustrated with a third exemplary stockpile. As shown inFIG. 5, preferred stockpile control system20is disposed, in part, on exemplary stockpile conveyor22. More particularly, preferred stockpile control system20comprises angle sensor30, rotation sensor32, stinger switches50, travel switches52, pile probe60, and microprocessor70. Third exemplary stockpile90is produced when preferred control system20operated in the inline continuous mode (seeFIG. 9).

Referring now toFIG. 6, a top view of preferred stockpile control system20on exemplary stockpile conveyor22is illustrated with a fourth exemplary stockpile. As shown inFIG. 6, preferred stockpile control system20is disposed, in part, on exemplary stockpile conveyor22. More particularly, preferred stockpile control system20comprises angle sensor30, rotation sensor32, stinger switches50, travel switches52, pile probe60, and microprocessor70. Fourth exemplary stockpile100is produced when preferred control system20operates in the radial conical mode (seeFIG. 10).

Referring now toFIG. 7, a flow chart illustrating the preferred sequence for operation of preferred control system20is illustrated. As shown inFIG. 7, the flow chart illustrates the steps an operator would go through to select a stockpile pattern, a level of desegregation, and one or more stockpile boundaries. The preferred control system20then determines if the selections made by the operator constitute a valid stockpile. If they do, then preferred control system20loads the stockpile data and automatically builds the selected stockpile. If the selections made by the operator do not constitute a valid stockpile, then control system20requires the operator to change one or more of his selections and the validation process is repeated. After the selected stockpile is built, preferred control system20determines if one or more additional stockpiles are desired. If another stockpile is desired, then preferred control system20requires the operator to go through the stockpile selection process again and the validation process is repeated. If another stockpile is not desired, then preferred control system20automatically stops.

Referring now toFIG. 8, a flow chart illustrating the preferred radial continuous mode process for producing a stockpile is provided. As shown inFIG. 8, preferred control system20automatically determines the location of the stockpile conveyor and whether the conveyor should be raised. If the conveyor does not need to be raised, then preferred control system20determines if the stinger should be extended or retracted, and again determines if a conveyor raise is required. If no conveyor raise is required, preferred control system20determines the travel direction. The conveyor is continuously moving in this mode until the stockpile is completed. When the stockpile is sensed with the pile probe, preferred control system20raises the conveyor up to the next tier, adjusts its limits, and resumes building the stockpile. Once the maximum pile height is achieved, preferred control system20sounds a horn, retracts the stockpile conveyor inwardly to the retracted position, and drives the conveyor slightly off to the side of the completed stockpile. The resulting stockpile pattern is a number of arcs that snake inward or outward at the left and right boundaries.

Referring now toFIG. 9, a flow chart illustrating the preferred inline continuous mode process for producing a stockpile is provided. As shown inFIG. 9, preferred control system20automatically determines the location of the stockpile conveyor and whether the conveyor should be raised. If the conveyor does not need to be raised, then preferred control system20determines if the travel direction should be left or right, and again determines if a conveyor raise is required. If no conveyor raise is required, preferred control system20determines the stinger direction. The conveyor is continuously moving in this mode until the stockpile is completed. When the stockpile is sensed with the pile probe, preferred control system20raises the conveyor up to the next tier, adjusts its limits, and resumes building the stockpile. Once the maximum pile height is achieved, preferred control system20sounds a horn, retracts the stockpile conveyor inwardly to the retracted position, and drives the conveyor slightly off to the side of the completed stockpile. The resulting stockpile pattern is a series of radial portions that snake from side to side at the inner and outer boundaries.

Referring now toFIG. 10, a flow chart illustrating the preferred radial conical mode process for producing a stockpile is illustrated. As shown inFIG. 10, preferred control system20automatically determines the location of the stockpile conveyor and whether the conveyor should be raised. If the conveyor does not need to be raised, then preferred control system20determines if the stinger should be extended or retracted, and whether the conveyor should be moved to the left or right using the pile probe. If a conveyor raise is required, preferred control system20raised the conveyor to a target elevation and repeats the process until the conveyor reaches its maximum angle. In this mode, the conveyor is not continuously moving. Also in this mode, an entire tier is built before the conveyor is raised up for the next tier. Preferably, the stockpile conveyor begins at a far corner of the stockpile pattern and moves from one side (left or right) to the other side and then retracts and moves from side to side again. When the entire tier is completed, preferred control system20raises the stockpile conveyor and the process is repeated until a maximum angle is reached. Once the maximum pile height is achieved, preferred control system20sounds a horn, retracts the stockpile conveyor inwardly to the retracted position, and drives the conveyor slightly off to the side of the completed stockpile. The resulting stockpile pattern is a plurality of conical piles in a plurality of arcuate rows.

The invention also comprises a method for controlling the production of a stockpile. The preferred method comprises providing a stockpile control system. The preferred stockpile control system comprises a sensor that is disposed on the stockpile conveyor, a limit switch that is disposed on the stockpile conveyor, a pile probe that is disposed on the stockpile conveyor, and a microprocessor that is in operative communication with the limit switch and the sensor. In the preferred stockpile control system, the stockpile conveyor is adapted to move, the sensor is adapted to measure the location of the stockpile conveyor, the limit switch is adapted to limit the movement of the stockpile conveyor, the pile probe is adapted to measure the vertical height of a stockpile, and the microprocessor is adapted to control the movement of the stockpile conveyor. The preferred method further comprises calculating one or more stockpile boundaries, and controlling the movement of the stockpile conveyor. Preferably, the stockpile control system substantially continuously calculates one or more stockpile boundaries and automatically adjusts the movement of the conveyor in substantially real time. Also preferably, the stockpile control system substantially continuously calculate a material flow depth and automatically adjust the movement of the conveyor in substantially real time.

In operation, several advantages of the preferred embodiments of the apparatus and method for a stockpile control system are achieved. For example, the preferred embodiments of the apparatus and method for a stockpile control system is adapted to measure and control the angle of a stockpile conveyor. Preferably, the conveyor angle is measured using an inclinometer that determines the angle of the conveyor relative to a horizontal plane. The preferred stockpile control system is also adapted to measure a stockpile and the distance between the stockpile and a stockpile conveyor. Preferably, a pile probe is used to measure the distance between the top of a stockpile and the stockpile conveyor such that the control system can determine when the stockpile conveyor should be raised or moved laterally. The preferred stockpile control system is also adapted to determine the maximum angle of the stockpile conveyor. Preferably, the maximum angle of the stockpile conveyor is automatically determined from the lowest of the following three settings: (1) the conveyor's physical maximum incline angle that it cannot physically raise beyond; (2) a maximum conveyor angle set by the user when trying to stay below a specific angle; and (3) calculations based off the pile settings to determine a peak angle to which the conveyor can build the pile. The third setting is determined by watching for the front and back edges of the pile converging or the left and right edges. Whichever edge converges at the lowest angle sets the maximum calculated pile angle.

The preferred embodiments of the apparatus and method for a stockpile control system are also constantly calculating the stockpile boundaries at the specified angle of incline. More particularly, the preferred stockpile control system continuously calculates the left edge or boundary of the pile, the right edge or boundary of the pile, the inner edge or boundary of the pile, the outer edge or boundary of the pile, and the maximum pile incline or elevation. The preferred stockpile control system is further adapted to continuously convert analog sensor signals into relevant positioning information. In some preferred embodiments, the stockpile control system includes a material flow sensor that continuously measures the depth of the stockpile material traveling over the conveyor belt.

The preferred embodiments of the apparatus and method for a stockpile control system are also adapted to control the incremental movement of the stockpile conveyor and prevent the stockpile from extending outside one or pre-determined boundaries. More particularly, in the preferred stockpile control system, if the stockpile conveyor reaches a stockpile boundary prior to the final incremental movement in a particular direction, the control system will automatically stop the conveyor from moving past the boundary. Preferably, the stockpile control system includes a stinger switch that is adapted to prevent the conveyor from extending and retracting too far such that the stockpile would extend outside its outer or inner boundary, respectively, and a travel switch that is adapted to prevent the conveyor from pivotally moving too far to the left and too far to the right such that the stockpile would extend outside its left or right boundary, respectively.

The preferred stinger switch is adapted to automatically re-set to a distance of 0.0 when the stinger portion of the stockpile conveyor is in the fully retracted position even if the calculated value based on winch encoder pulses is not 0.0. As the stinger portion of the stockpile conveyor extends along its longitudinal axis, pulses received from the winch encoder are used to calculate the distance the stinger has moved. In the event that the actual distance the stinger portion of the stockpile conveyor has moved is its maximum distance (or its absolute value), preferred stinger switch will stop the stinger from extending any farther by overriding the current extension calculation, even if the distance calculated from the winch encoder pulses is less than the maximum distance.

The preferred travel switch is also adapted to limit the movement of the stockpile conveyor so as to maintain the stockpile within the left and right boundaries of the stockpile. The preferred stockpile control system includes a rotary encoder that continuously measures the radial angle of the stockpile conveyor as it pivotally moves about the pivot plate. Stockpile boundaries are preferably selected from a range of 45 to 315 degrees. The preferred travel switches include a trigger that can be tripped when encountered by an object like a log or a rock placed at the left and right boundaries of the stockpile. In the event of an error in the calculation of the radial angle of the stockpile conveyor, e.g. the pivot plate unintentionally moves, then the travel switch would cause the conveyor to stop at the left and right boundary and change its direction of travel. Although this description contains many specifics, these should not be construed as limiting the scope of the invention but as merely providing illustrations of some of the presently preferred embodiments thereof, as well as the best mode contemplated by the inventors of carrying out the invention. The invention, as described herein, is susceptible to various modifications and adaptations, and the same are intended to be comprehended within the meaning and range of equivalents of the appended claims.